FORWARD HOW TO USE THIS MANUAL CONTENTS SERVICE MANUAL
Homepage Contents FORWARD This service manual contains the technical data of each component inspection and repair for the Sanyang JOYRIDE 125/150/200 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.
How to Use This Manual Homepage Contents This service manual describes basic information of different system parts and system inspection & service for Sanyang JOYRIDE 125/150/200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information. Th third to the tenth chapters cover engine and driving systems.
Homepage Page Contents CONTENTS Content Index 1-1 ~ 1-16 GENERAL INFORMATION 1 2-1 ~ 2-12 MAINTENANCE INFORMATION 2 3-1 ~ 3-6 LUBRICATION SYSTEM 3 4-1 ~ 4-9 FUEL SYSTEM 4 5-1 ~ 5-6 ENGINE REMOVAL 5 6-1 ~ 6-14 CYLINDER HEAD/VALVE 6 7-1 ~ 7-8 CYLINDER/PISTON 7 8-1 ~ 8-14 V-BELT DRIVING SYSTEM/FOOT STARTER 8 9-1 ~ 9-8 FINAL DRIVING MECHANISM 9 10-1 ~ 10-6 ALTERNATOR/STARTING CLUTCH 10 11-1 ~ 11-8 CRANKSHAFT/CRANKCASE 11 12-1 ~ 12-11 COOLING SYSTEM 12 13-1 ~ 13-13 BODY
MODEL ILLUSTRATION Homepage Contents Fuel pump Winker relay REG/REC. Start MAG. switch Battery IG. coil Radiator Fuses / C.D.I. Horn Spark plug Fuel tank Fuel tank cap Seat catch A Seat catch B Frame number Engine number ENG.
Homepage Contents 1. GENERAL INFORMATION 1 Symbols and marks………………….1-1 Torque values……………………….1-8 General safety…………………………1-2 Cables and harness routing………1-10 Service precautions………………….1-3 Troubleshooting…………………….1-11 Specifications…………………………1-5 Lubrication points…………………..
1. GENERAL INFORMATION General safety Carbon monoxide Battery If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor. Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death. Gasoline Gasoline is a low ignition point and explosive material.
1. GENERAL INFORMATION Service Precautions z Always use with Sanyang genuine parts and recommended oils. Using non-designed parts for Sanyang motorcycle may damage the motorcycle. z Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged. z When servicing this motorcycle, use only metric tools.
1. GENERAL INFORMATION z The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.
1. GENERAL INFORMATION Specifications Overall Width 760 mm Overall Height 1155 mm Wheel Base 1440 mm Curb Weight 2010 mm Front 55 kg Rear 89 kg Total 144 kg Passengers/ MODEL LA12W Suspension System Front Tire Specifications Front 110 / 80-12 61L Rear 130 / 70-12 64L Rear Brake System Two /110 kg TELESCOPIC FORK UnlT SWING Front DlSK (ψ273mm) Rear DlSK (ψ200mm) Max.
1. GENERAL INFORMATION Specifications Overall Width 760 mm Overall Height 1155 mm Wheel Base 1440 mm Net Weight 2010 mm Front 55 kg Rear 89 kg Total 144 kg Passengers/ MODEL Suspension System Front Tire Specifications Front 110 / 80-12 61L Rear 130 / 70-12 64L Rear Two /110 kg TELESCOPIC FORK UNlT SWING Front DlSK (ψ273mm) Rear DlSK (ψ200mm) Brake System Max.
1. GENERAL INFORMATION Specifications Overall Width 760 mm Overall Height 1155 mm Wheel Base 1440 mm Curb Weight 2010 mm Front 55 kg Rear 89 kg Total 144 kg Passengers/ MODEL LA18W Suspension System Front TELESCOPIC FORK Rear UNlT SWING Tire Specifications Front 110 / 80-12 61L Rear 130 / 70-12 64L Brake System Two /110 kg Front DlSK (ψ273mm) Rear DlSK (ψ200mm) Max.
1. GENERAL INFORMATION Torque values Item Q’ty Thread Dia. Torque Value (mm) (Kgf-m) Cylinder head bolt 4 8 2.0-2.4 Valve clearance adjust nut 4 5 0.7-1.1 Spark plug 1 10 1.0-1.4 L. Crankcase cover bolts 7 6 1.1-1.5 Crankcase bolts 7 6 0.8-1.2 Oil drain bolt 1 8 1.1-1.5 Oil strainer cap 1 30 1.3-1.7 Gear oil drain bolt 1 6 1.0-1.4 Gear oil inspection bolt 1 6 1.0-1.4 Transmission cover bolt 7 6 1.0-1.4 Flywheel bolt 1 14 5.0-6.
1. GENERAL INFORMATION Standard Torque Values for Reference Type Torque value kgf-m 5 mm Bolt, Nut 0.45 - 0.6 6 mm Bolt, Nut 0.8 - 1.2 8 mm Bolt, Nut 1.8 - 2.5 10 mm Bolt, Nut 3.0 - 4.0 12 mm Bolt, Nut 5.0 - 6.0 5 mm Screw 0.35 - 0.5 6 mm Screw & 6mm bolt with 8mm head 0.7 - 1.1 6 mm Flange bolt, nut 1.0 - 1.4 8 mm Flange bolt, nut 2.4 - 3.0 10 mm Flange bolt, nut 3.5 - 4.
1. GENERAL INFORMATION Cables and harness routing Note the following when routing cables and wire harnesses: • • • • • • • • • • • • • • A loose wire, cable or harness may cause safety hazard. After clamping, check each wire to make sure it is secured. Do not squeeze wires against the weld or its clamp. Secure wires and wire harnesses to the frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.
1. GENERAL INFORMATION Troubleshooting A. Engine hard to start or can not be started Check and adjustment Fault condition Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied from carburetor sufficient No fuel is supplied to carburetor Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. Probable causes 1. No fuel in fuel tank 2. Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged. 3.
1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Engine speed can be increased. Engine speed can not be increased. 1. Air cleaner clogged 2. Poor fuel supply 3. Lines in fuel tank evaporation system clogged 4. Exhaust pipe clogged Check ignition timing (Using ignition lamp) Ignition timing correct Incorrect ignition timing 1. Malfunction of CDI 2.
1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal 1. Incorrect ignition timing (malfunction of CDI or AC generator) Adjust the air screw of carburetor Good Poor 1. Rich mixture (loosen the screw) 2. Lean mixture (tighten the screw) Air sucked through carburetor gasket 1. Poor heat insulation gasket No air sucked Air sucked 2.
1. GENERAL INFORMATION E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged 3. Driving pulley spring broken Engine can be started but motorcycle can not be driving 4. Clutch lining broken 5. Driving shaft groove broken 6. Transmission gear damage 7. Transmission gear worn out or burned Engine running and misfire as motorcycle initial forward moving or jumping sudden (rear wheel rotating as engine in running) 1.
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Homepage Contents 2. MAINTENANCE INFORMATION Precautions in operation .............. 2-1 Brake system hose........................ 2-8 Periodical maintenance schedule......................................... 2-2 Brake fluid...................................... 2-8 Fuel Lines....................................... 2-3 Air bleed operation........................ 2-9 Acceleration operation.................. 2-3 Added brake fluid .......................... 2-9 Air cleaner............................
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2. MAINTENANCE INFORMATION FUEL LINES Fuel pump Remove trunk. Remove side cover. Remove central cover. Remove body frame cover. Remove pedal. Remove front glove box. Check all lines, and replace it when they are deterioration, damage or leaking. Warning Filler hole Fuel hose Fuel tank Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
2. MAINTENANCE INFORMATION AIR CLEANER Remove trunk. Remove side cover. Remove 8 screws from the air cleaner cover and then remove the cover. Caution Air cleaner element contains a paper made filter so do not try to clean it. CRANKCASE VENTILATION Pull out the plug from draining hose to clean deposit. Separato Separator Caution When always riding in rainy area or full throttle position, maintenance travel must be shorted. The deposits can be seen in the transparent section of draining hose.
2. MAINTENANCE INFORMATION VALVE CLEARANCE Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke. Caution Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.
2. MAINTENANCE INFORMATION CARBURETOR IDLING SPEED ADJUSTMENT Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Idle adjustment Park the motorcycle with main stand and warm up engine.
2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor. Caution Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.
2. MAINTENANCE INFORMATION BRAKE SYSTEM (FRONT/REAR DISK BRAKE) 10〜 〜20mm (3/8〜 〜3/4 in) Free play of front/rear brake: 10~20 mm BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil. Brake hose BRAKE FLUID Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found.
2. MAINTENANCE INFORMATION AIR BLEED OPERATION Drain valve Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses. Air bubble Caution Before closing the air bleed valve, do not release the brake lever. Transparent hose ADDED BRAKE FLUID LOWER Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.
2. MAINTENANCE INFORMATION Remove brake lining bolt. Take out the lining. Lining Caution In order to maintain brake power balance, the brake lining must be replaced with one set. Lining bolt BRAKE LAMP SWITCH/STARTING INHIBITOR SWITCH Master cylinder The brake lamp switch is to light up brake lamp as brake applied. Make sure that electrical starter can be operated only under brake applying. HEADLAMP BEAM DISTANCE Brake switch Turn on main switch Headlamp beam adjustment.
2. MAINTENANCE INFORMATION SIDE STAND Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly. Make sure that side stand is no bending or deformation. Side stand SHOCK ABSORBER Warning Do not ride the motorcycle with poor shock absorber. Looseness, wear or damage shock absorber will make poor stability and drive-ability.
2. MAINTENANCE INFORMATION WHEEL/TIRE Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails, stones or other materials. Appointed tire pressure Tire size Tire pressure as cold engine (Kg/cm²) Load for under 90 Kg Full loaded Front tire Rear tire 1.5 2.0 1.5 2.5 Check if front and rear tires’ pressure is in normal. Measure tire thread depth from tire central surface.
Homepage 3. LUBRICATION SYSTEM Contents Precautions in operation .............. 3-2 Oil pump disassembly .................. 3-4 Troubleshooting ............................ 3-2 Oil pump inspection...................... 3-5 Engine oil ....................................... 3-3 Oil pump re-assembly................... 3-5 Engine oil strainer clean ............... 3-3 Oil pump installation..................... 3-6 Oil pump removal .......................... 3-4 Gear oil.............................
3. LUBRICATION SYSTEM PRECAUTIONS IN OPERATION General Information: • This chapter contains maintenance operation for the engine oil pump and gear oil replacement. SAE Specifications Engine oil quantity Disassembly: Change: 1000 c.c. 800 c.c. Gear oil Disassembly: Change: 110 c.c. 100 c.c.
3. LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. Oil Change Drain bolt Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely. Place a oil pan under the motorcycle, and remove oil drain bolt. After drained, make sure washer can be re-used.
3. LUBRICATION SYSTEM Oil Pump Removal Remove generator and starting gear. Remove snap ring and take out oil pump driving chain and sprocket. Torque value: 0.8~1.2 Kg-m Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump. Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pump as illustration shown.
3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor.
3. LUBRICATION SYSTEM Install the oil pump cover and fixing pin properly SCREW× × 1 Tighten screw Make sure that oil pump shaft can be rotated freely. Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value: 0.8~1.2 Kg-m Make sure that oil pump shaft can be rotated freely. Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft. Install starting gear and generator.
3. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil. Recommended using King serial oils. Install oil inspection bolt. Torque value: 1.0~1.4 Kgf-m Gear oil drain plug Gear Oil Change Remove oil level inspection bolt. Remove drain plug and drain oil out.
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Homepage Contents 4. FUEL SYSTEM Precautions in operation .............. 4-2 Float chamber................................ 4-7 Trouble diagnosis ......................... 4-3 Installation of carburetor .............. 4-8 Air cut-off valve ............................. 4-4 Adjustment of pilot screw............. 4-8 Auto by-starter............................... 4-4 Fuel tank ....................................... 4-9 Carburetor removal ....................... 4-5 Air cleaner.....................
4. FUEL SYSTEM PRECAUTIONS IN OPERATION General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions ˙Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. ˙When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly ˙There is a drain screw in the float chamber for draining residual gasoline.
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4. FUEL SYSTEM AIR CUT-OFF VALVE Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve. Vacuum value: 420~500 mm-Hg Pump compressed air from air pump to air vent hose. Caution The vacuum can not be over 600 mm-Hg. Or the air cut-off will be damaged. If the valve is in normal, it will restrict air-flow.
4. FUEL SYSTEM AUTO BY-STARTER Screw ×1 Auto by– starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter. Resistance value: Max. 10Ω Ω (Measured after engine stopped for more than 10 minutes) Replace the auto starter with a new one if resistance value exceeds standard. Remove carburetor, allow it to cool off for 30 minutes. Connect a pressure tester from air pump. Connect by-starter circuit.
4. FUEL SYSTEM Carburetor removal Throttle cable Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove air cut-off valve hose. Remove fuel pipe, vacuum hose. Disconnect automatic by-starter connectors. Release the clamp strip of carburetor isolation. Release the clamp strip of air cleaner.
4. FUEL SYSTEM Installation Install needle, spring and needle seat to vacuum piston. Piston Needle seat Spring Needle Install vacuum piston to carburetor body and align the indent on the diaphragm. Install compress spring. Install vacuum chamber cover and tighten 2 screws. Screw ×2 Caution ˙Do not damage vacuum diaphragm. ˙When tightening the vacuum chamber screw, hold down vacuum piston.
4. FUEL SYSTEM FLOAT CHAMBER Float Screw ×3 Disassembly Remove 4 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt. Caution Float Pin Screw ×1 In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding.
4. FUEL SYSTEM Assembly Pilot screw Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking fuel level Caution • Check again to ensure float valve, float for proper installation. • To ensure correct measurement, position the float meter in such a way so that float chamber face is vertical to the main jet. Fuel level: 20.
4. FUEL SYSTEM Adjustment of pilot screw Throttle cable adjust nut Caution ˙Pilot screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. ˙The main stand must be used to support the motorcycle to perform the adjustments. Use a tachometer when adjusting engine RPM. Screw in adjustment screw gently, then back up to standard turns.
4. FUEL SYSTEM FUEL TANK Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear bracket (2 bolts). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 bolts). Remove the central cover (6 screws). Remove the left & right body covers and the central upper cover (4 screws and 2 bolts). Remove pedal (4 bolts and 4 screws). Disconnect fuel unit connector.
4. FUEL SYSTEM AIR CLEANER Open the seat. Loosen the clamp strip of air cleaner. Remove left cover (2 screws). Remove mounting bolts for crankcase and gear box (2 bolts). Remove air cleaner cap (8 screws). Remove air cleaner set (4 screws). Caution Screw ×8 The air cleaner element is made of paper so do not soap it into water or wash it with water.
Homepage 5. ENGINE REMOVAL Contents Precautions in Operation.............. 5-1 Removal of Engine ........................ 5-2 Removal of Engine Mounting Bracket ........................................... 5-5 Engine Mounting Bracket Installation ..................................... 5-6 Engine Installation ........................ 5-6 PRECAUTIONS IN OPERATION General Information z The engine has to be supported with special service tools that can be lifted or adjustable.
5. ENGINE REMOVAL Removal of Engine Open seat cushion. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (3 bolts). Remove rear bracket (2 bolts). Remove the rear central cover (4 screws). Remove the left and right pedals (1 bolt). Remove the left and right covers (4 screws). Remove the central cover (6 screws). Remove the left & right body covers and the central upper cover (4 screws and 2 bolts). Remove battery negative (-) post. Remove battery positive (+) post.
5. ENGINE REMOVAL Remove fuel pipe, vacuum tube and throttle valve wire from carburetor. Loosen the screw of air cleaner duct strip, and then remove the duct. Remove water hose from water pump. Remove the thermo-sensor wires. Water hose Water pump Remove the muffler (3 bolts, 2 nuts).
5. ENGINE REMOVAL Remove brake hose bracket (1 bolt). Remove rear brake callipper (2 bolts). Bolt × 1 Caution Do not operate brake lever after the clipper removed to avoid clipping the brake lining. Bolt × 2 Remove the mounting bolt of right-rear shock absorber and the shock absorber. Cushion Remove rear wheel mounting nut. Bolt × 1 Remove swing arm. Remove rear wheel.
5. ENGINE REMOVAL Loosen the mounting screw of left crankcase duct, and then remove the duct. Screw . Remove the mounting bolts (2 bolts) of air cleaner. Bolt × 2 Bolt × 1 Remove the lower mounting bolt of left shock absorber. Removal of Engine Mounting Bracket Remove coil wire from engine mounting bracket. Remove the bolts and nuts of engine mounting bracket. Remove engine mounting bracket bolts. Caution ˙Support engine with special engine supporter to prevent from engine falling down.
5. ENGINE REMOVAL Check if engine mounting bracket bushing and cushion rubber for damage. Bush Engine Mounting Bracket Installation Install engine onto engine mounting bracket. Install engine mounting bracket bolts & nuts and then tighten the nuts. Bolt × 1 Engine Installation Check if the bushings of engine suspension parts and shock absorber for damage. Install engine in the reverse procedures of removal. Caution ˙Pay attention of foot & hand safety as engine installation to avoid hurting.
Homepage Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ....................... 6-1 Valve stem replacement ..................6-8 Precautions in Operation................ 6-2 Valve seat inspection and service ..6-9 Cylinder Head Removal .................. 6-4 Cylinder head reassembly...............6-11 Cylinder Head Disassembly ........... 6-6 Cylinder head Installation ...............6-12 6 1.0~1.4 kgf-m 2.0~2.4 kgf-m 0.7~1.
6. CYLINDER HEAD/VALVE PRECAUTIONS IN OPERATION General Information z This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. z Cylinder head service can be carried out when engine is in frame. Specification Item Standard Limit 12+/2 kg/cm2 --- Intake 30.800~30.920 3.075 Exhaust 30.411~30.531 30.26 ID of valve rocker arm 12.000~12.018 12.10 OD of valve rocker arm shaft 11.966~11.984 11.910 Intake 4.975~4.990 4.900 Exhaust 4.955~4.
6. CYLINDER HEAD/VALVE TOOLS Special service tools Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor Troubleshooting Engine performance will be effected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated.
6. CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Vacuum tube Clamp strip Remove cushion and body center cover. Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator. Remove 1 bolt of thermostat and then remove the thermostat. Thermostat bolt Hole cap of adjustment bolt Remove the side cover mounting blot of cylinder head, and then take out the side cover.
6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from cylinder head side cover, and then remove 4 nuts and washers from cylinder head upper side. Insulator bolt Nuts Cylinder head mounting bolts Remove the cylinder head. Remove 2 bolts of carburetor insulator and then take the insulator out. Carburetor insulator Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.
6. CYLINDER HEAD/VALVE CYLINDER HEAD DISASSEMBLY Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts. Then, remove the cap. Remove the rocker arm pin stopper plate, and then screw a 5mm bolt into the rocker arm pin. Finally, remove the pin and the rocker arm. Screw a 6 mm bolt into cam sprocket mounting bolt hole, and then pull the camshaft out. Stopper plate bolt Use a valve compressor to press the valve spring.
6. CYLINDER HEAD/VALVE INSPECTION CYLINDER HEAD Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.5 mm Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: 31.5 mm Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter. Service Limit: IN: 4.90 mm EX: 4.
6. CYLINDER HEAD/VALVE Caution z If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too. Caution It has to correct valve seat when replacing valve guide. VALVE STEM REPLACEMENT Valve guide driver 5.
6. CYLINDER HEAD/VALVE VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution z Do not let emery enter into between valve stem and valve guide. z Clean up the emery after corrected, and apply with engine oil onto contact faces of valve and valve seat. Remove the valve and check its contact face.
6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm (0.04 in) Caution z Make sure that all roughness and uneven faces had been ground. Grind valve seat again if necessary. 45° Coat the valve seat surface with red paint.
6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. CYLINDER HEAD REASSEMBLY Intake valve Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Install valve springs and retainers. Caution Valve spring retainer z The closed coils of valve spring should face down to combustion chamber.
6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts. Carburetor insulator Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole. Then, insert the rocker arm pin. Install rocker arm pin mounting plate. Stopper plate Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with thickness gauge.
6. CYLINDER HEAD/VALVE Install cylinder head. Tighten 4 nuts and washers on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover. Torque value: 2.0~2.4 kgf-m Insulator mounting bolt Nuts Install and tighten spark plug Torque value: 2.0~2.
6. CYLINDER HEAD/VALVE Vacuum hose Install carburetor insulator onto carburetor and tighten clamp strip bolt. Install the vacuum hose of carburetor insulator. Remove the intake valve adjustment hole cap Start engine, and make sure that lubricant flows to cylinder head. Turn off engine after confirmed, and install the intake valve adjustment hole cap. Install seat cushion and body center cover. Caution z z If lubricant does not flow to cylinder head, engine components will be worn out seriously.
Homepage Contents 7. CYLINDER/PISTON Mechanism Diagram ..................... 7-1 Piston Removal ..............................7-4 Precautions in Operation.............. 7-2 Piston Ring Installation .................7-6 Trouble Diagnosis ......................... 7-2 Piston Installation ..........................7-7 Cylinder Removal .......................... 7-3 Cylinder Installation.......................
7. CYLINDER/PISTON PRECAUTIONS IN OPERATION General Information z Both cylinder and piston service can be carried out when engine mounted on frame. Specification LA12W & LA15W & LA18W Item Cylinder Limit 56.995~57.015 57.016 - 0.050 0.015~0.050 0.090 2 ring 0.015~0.050 0.090 Top ring 0.150~0.300 0.500 2 ring 0.300~0.450 0.650 Oil ring side rail 0.200~0.700 - 56.985~57.005 56.900 0.010~0.040 0.100 15.002~15.008 15.040 14.960~15.000 14.930 0.002~0.014 0.020 15.016~15.034 15.
7. CYLINDER/PISTON CYLINDER REMOVAL Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder head. Remove cylinder. Coolant hose Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily.
7. CYLINDER/PISTON Check cylinder if warp. Service limit: 0.05 mm PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring. Inspection Measure clearance between piston ring and its grooves. Service Limit: Top ring: 0.09 mm 2nd ring: 0.
7. CYLINDER/PISTON Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston. Service Limit: Top ring: 0.50 mm 2nd ring: 0.65 mm Measure the outer diameter of piston pin. Service Limit: 14.93 mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06 mm Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.
7. CYLINDER/PISTON Measure piston outer diameter. Caution z The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin. Service limit: LA12W & LA15W: 56.9 mm LA18W: 60.9 mm Compare measured value with service limit to calculate the clearance between piston and cylinder. PISTON RING INSTALLATION Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.
7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution z z Do not let the opening of piston pin snap ring align with the opening piston ring. Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation. CYLINDER INSTALLATION Clean up all residues and foreign materials on the matching surface of crankcase.
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Homepage Contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Mechanism Diagram ..................... 8-1 Kick starter .....................................8-3 Maintenance Description.............. 8-2 Driving belt .....................................8-5 Trouble Diagnosis ......................... 8-2 Drive face........................................8-6 Left crankcase cover..................... 8-3 Clutch outer/Driven pulley.............8-10 3.5~4.5 kgf-m 5.0~6.0 kgf-m 8 5.0~6.
8. V-BELT DRIVING SYSTEM/KICK STARTER MAINTENANCE DESCRIPTION Precautions in Operation General Information z z Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Driving belt and driving pulley must be free of grease. Item Standard value (mm) Limit (mm) 19.000 17.500 ID of drive face boss 27.000~27.021 27.060 OD of drive face 26.970~26.990 26.940 OD of roller 19.950~20.100 19.500 130.000~130.200 130.500 4.000~4.100 2.000 88.300 83.
8. V-BELT DRIVING SYSTEM/KICK STARTER Left crankcase cover LEFT CRANKCASE COVER Left crankcase cover removal Remove body cover. Remove air cleaner (2 bolts). Remove kick starter (1 bolt). Remove L crankcase cover (9 bolts). Kick starter Disassembly of Kick Starter Remove snap ring and thrust washer from L crankcase cover. Install kick starter arm, rotate the arm slightly and then remove driven gear and washer. Remove the kick starter arm, starter spindle, and return spring as well as socket.
8. V-BELT DRIVING SYSTEM/KICK STARTER Starter spindle Reassembly of Kick Starter Install socket, return spring and starter spindle as diagram shown. Install thrust washer and snap ring onto starter spindle. Install kick starter arm temporary. Rotate the arm and then align driven gear with width-tooth on the starter spindle. Install the friction of driving gear onto convex part of the cover.
8. V-BELT DRIVING SYSTEM/KICK STARTER DRIVING BELT Nut Removal Remove left crankcase cover Hold clutch outer with universal holder, and remove nut and clutch outer. Caution z z Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake will damage reduction gear system. Universal holder Driven pulley/driving belt Push the driving belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley.
8. V-BELT DRIVING SYSTEM/KICK STARTER Drive face Driving belt Driven pulley Install the clutch with universal holder, and then tighten nut to specified torque value. Torque value: 5.0~6.0 kgf-m Drive shaft Clutch outer Nut Universal holder DRIVE FACE Removal Remove left crankcase cover. Universal holder Hold generator flywheel with universal holder, and then remove drive face nut. Remove drive face.
8. V-BELT DRIVING SYSTEM/KICK STARTER Movable drive face Removal Drive face boss Remove movable drive face comp. and driving belt from crankshaft. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable drive face. Movable drive face Weight roller Inspection The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be effected.
8. V-BELT DRIVING SYSTEM/KICK STARTER Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face, and replace it if it exceed service limit. Service limit: 26.94 mm Measure the inner diameter of movable drive face, and replace it if it exceed service limit. Service limit: 27.06 mm Movable drive face Drive face boss Reassembly/installation Install weight rollers. Weight roller Install ramp plate.
8. V-BELT DRIVING SYSTEM/KICK STARTER Install movable drive face comp. onto crankshaft. Movable drive face Drive face boss Crankshaft Driven pulley installation Press down Press driving belt into pulley groove, and then pull the belt onto drive shaft. Driving belt Install driven pulley, washer and nut. Caution Make sure that two sides of pulley surfaces have to be free of grease. Clean it with cleaning solvent. Hold crankshaft with universal holder.
8. V-BELT DRIVING SYSTEM/KICK STARTER CLUTCH OUTER/DRIVEN PULLEY Clutch nut wrench Disassembly Remove driving belt and clutch outer/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool.
8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Clutch lining Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 83.2 mm Free length Driven pulley Check following items: z If both surfaces are damaged or worn. z If guide pin groove is damaged or worn. Replace damaged or worn components.
8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch weight Replacement Spring Driving plate Remove snap and washer, and then remove clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity. Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins.
8. V-BELT DRIVING SYSTEM/KICK STARTER Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Clipper Remove inner bearing. Caution z z Outer bearing If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. If the pulley equipped with ball bearing, it has to remove snap ring and then the bearing.
8. V-BELT DRIVING SYSTEM/KICK STARTER Installation of Clutch OUTER/Driven Pulley Assembly Oil seal Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face.. Specified grease O-ring Install the movable driven face onto driven face. Install the guide pin and guide pin roller. Movable driven face Oil seal Guide pin Or Guide pin O-ring Collar Install the collar. Install driving belt, spring and clutch weight COMP.
Homepage Contents Mechanism Diagram ..................... 9-1 Precautions in operation .............. 9-2 9. FINAL DRIVING MECHANISM Inspection of Final Driving Mechanism .....................................9-3 Trouble Diagnosis ......................... 9-2 Bearing Replacement ....................9-4 Disassembly of Final Driving Mechanism..................................... 9-3 Re-assembly of Final Driving Mechanism .....................................
9. FINAL DRIVING MECHANISM Precautions in operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4 kg-m Tools Special tools Bearing (6203/6004UZ) driver Bearing (6204) driver Bearing (6301) driver Oil seal (27*42*7) driver Oil seal (20*32*6) driver Inner bearing puller Outer bearing puller Trouble Diagnosis Engine can be started but motorcycle can not be moved.
9. FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover. Remove gasket and dowel pin. 7 bolts Remove drive shaft. Remove final driving gear and shaft. Remove countershaft and gear. Inspection of Final Driving Mechanism Check if the countershaft is wear or damage. Check if the final shaft and gear are burn, wear or damage.
9. FINAL DRIVING MECHANISM Check bearings on gear box. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Check oil seal for wear or damage, and replace it if necessary. Check gear box cover bearing as the same way above, and replace it if necessary.
9. FINAL DRIVING MECHANISM Remove oil seal, and then remove final shaft bearing from left crankcase. Install new final shaft bearing. Press the bearing in with hydraulic presser. Tool: Bearing (6203/6004UZ) driver Oil seal (27*42*7) driver Press out the driving shaft from gear box cover. Using bearing protector as operation. Remove oil seal from gear box cover and discard the seal. Use bearing puller to remove the final shaft bearing from the cover.
9. FINAL DRIVING MECHANISM Install a new final shaft bearing onto gear box cover. Tool: Bearing (6203/6004UZ) driver Press the bearing in with hydraulic presser. Install the driving shaft onto gear box cover and then place it to proper position. Apply with grease onto new oil seal lip, and then install the oil seal. Tool: Oil seal (20*32*6) driver Re-assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft.
9. FINAL DRIVING MECHANISM Install dowel pin and new gasket. dowel pin Gasket Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4 kgf-m Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase. Install rear wheel. Add gear oil.
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Homepage Contents 10. ALTERNATOR/STARTING CLUTCH Precautions in Operation.............. 10-2 Starting Clutch ...............................10-4 Right Crankcase Cover Removal . 10-3 Flywheel Installation ......................10-7 A.C.G. Set Removal ....................... 10-3 A.C.G. Set Installation....................10-7 Flywheel Removal ......................... 10-3 Right Crankcase Installation.........10-7 1.0~1.4 kgf-m 10 5.0~6.0 kgf-m 0.8~1.
10. ALTERNATOR/STARTING CLUTCH Precautions in Operation General information • Refer to chapter 5: Engine removal and installation • Refer to chapter 16: The troubleshooting and inspection of alternator • Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear 20.026~20.045 20.100 OD of starting clutch gear 42.175~42.200 42.100 Torque value Flywheel nut 5.0~6.
10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 7 bolts Remove 7 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. A.C.G. Set Removal 2 bolts Remove 2 mounted bolts from pulse generator and then remove it. Remove 3 screws from right crankcase cover and A.C.G. set. 3 screws Flywheel Removal Remove oil through from crankshaft. Remove the pin from crankshaft.
10. ALTERNATOR/STARTING CLUTCH Hold flywheel with flywheel holder, and then remove flywheel nut. Tool: Multi-functional holder Pull out flywheel with A.C.G. flywheel puller. Tool: A.C.G. Flywheel puller Starting Clutch Removal Remove starting driven gear. Remove mounting plate, starter reduction gear, and the shaft.
10. ALTERNATOR/STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the starting clutch gear. Service Limit: ID: 20.1 mm OD: 42.10 mm Check the starting reduction gear and shaft for wear or damage. Install one way clutch onto starting clutch gear. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely, but not C.W direction. (View as shown in this figure.
10. ALTERNATOR/STARTING CLUTCH Remove the rollers, spring caps, and springs of clutch on the one way clutch that located on the back of flywheel. Check each roller and plug for wear or damage. Install rollers, plugs and springs. Springs Rollers Spring cap Installation Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4 kg-m Installation Install reduction gear shaft and reduction gear.
10. ALTERNATOR/STARTING CLUTCH Flywheel Installation Insert the pin onto crankshaft. Make sure that there is no other material stock on it. If so, clean it up. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 5.0~6.0 kg-m Tool: Flywheel holder Install spring and oil through. A.C.G. Set Installation 2 bolts Install the A.C.G. set onto right crankcase cover (3 screws).
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Homepage Contents 11. CRANKSHAFT/CRANKCASE General information .............................11-2 Crankshaft..............................................11-5 Trouble diagnosis ................................11-2 Assembly of crankcase.........................11-6 Disassembly of crankcase...................11-3 1.2~1.6 kgf-m 11 1.0~1.5 kgf-m 0.8~1.2 kgf-m To this chapter contents 1.5~3.
11. CRANKSHAFT/CRANKCASE General information Operational precautions • This Section concerns disassembly of the crankcase for repair purpose. • Remove following components before disassembling crankcase.
11. CRANKSHAFT/CRANKCASE Tensioner Disassembly of crankcase Remove the cam chain. Loosen the bolt and remove the tensioner. Cam chain Loosen seven bolts on the crankcase. Bolt× × 7 Place right crankshaft case downward and lift up crankcase. Caution •Care should be taken not to damage the contact surfaces. R/L. crank disassemble tool Refer to chapter 18: Special tools Special tool : R/L. crank case disassemble/install tool SYM-1120000-H9A R/L.
11. CRANKSHAFT/CRANKCASE Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution •Do not damage contact surface of the gasket. •It is better to moisten the gasket residue for easy scrapping. Check any damage in oil seal. Replace with new one if damaged.
11. CRANKSHAFT/CRANKCASE Crankshaft Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measuring point for the big end of the connecting rod. Measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm Place the crankshaft on a V-block, measure run-out of the crankshaft. Service limit: 0.10 mm 90 mm 60 mm Checking crankshaft bearing. Use hand to crank the bearing to see it moves freely, smoothly and noiseless.
11. CRANKSHAFT/CRANKCASE Assembly of crankcase Install a new bearing onto the left crankcase. Special tool : left crank shaft bearing driver SYM-9100200-H9A R/L. crank case disassemble/install tool SYM-1120000-H9A Crank shaft puller SYM-11130000-H9A Clutch nut wrench SYM-9020200 Left crank shaft bearing driver Clutch nut wrench Crank shaft puller R/L. crank case disas. / install tool Install crank shaft onto the left crankcase. Special tool : R/L.
11. CRANKSHAFT/CRANKCASE Crank shaft puller R/L. crank case disas. / install tool Clutch nut wrench Crank shaft puller R/L. crank case disas. / install tool Install new dowel pin and new gasket. Install the right crankcase onto the left crankcase. Tighten seven bolts on the crankcase. Torque value: 0.8~1.
11. CRANKSHAFT/CRANKCASE Install the new oil seal. Apply a layer of grease on the lip of oil seal. Clean the crankshaft with clean solvent. Special tool : Oil seal driver (25*40*8) SYM-9121600 Oil seal driver Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. Install the tensioner and tighten the bolts. Tensioner Torque value: 1.2 ~1.6 kgf-m Install the cam chain.
Homepage 12. COOLING SYSTEM Contents General Information ...................... 12-2 Radiator .......................................... 12-5 Trouble Diagnosis ......................... 12-3 Water Pump.................................... 12-6 System Test ................................... 12-4 Temperature sensor ...................... 12-10 Change of coolant ......................... 12-4 Thermostat .....................................
12. COOLING SYSTEM General Information General Warning: ˙While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. z z z z z z Refill the radiator with distilled water or specified additives. Add coolant to the reservoir. The cooling system can be serviced on the motorcycle.
12. COOLING SYSTEM Trouble Diagnosis The engine temperature is too high z z z z z z The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to closed. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The filler cap of the radiator malfunction. The engine temperature is too low z The water thermometer and the temperature sensor malfunction. z The thermostat is stuck to open.
12. COOLING SYSTEM System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low. The specified pressure shall be maintained at least for 6 seconds in the test Relief pressure for the filler cap: 0.75-1.
12. COOLING SYSTEM Removing the reserve tank filler cap. ˙Check the liquid level in the reservoir. Add coolant to proper level if too low. ˙Reinstall the reserve tank filler cap. Reserve tank filler cap Radiator Removal Remove the front guard, check for any leakage from weld seam. Blow cooling fan clean using compressed air. If the cooling fan is blocked by dirt, use low pressure water jet to clean it. Care shall be taken when straightening the sink fan. Coolant leakage Loosen 2 nuts and 4 screws.
12. COOLING SYSTEM Loosen the hose clamp and remove the upper water hose. Disconnect the connectors for the thermostat and fan motor. Loosen the hose clamp and remove the lower water hose. Disconnect the horn. Loosen four screws and air duct. Remove radiator and the fan motor. Bolt × 1 Disassembly Upper water hose Loosen the lock bolt from the fan and remove the fan. Loosen three screws from the fan motor, and take off the fan motor.
12. COOLING SYSTEM Removal of water pump Remove the water hose. Loosen three bolts and remove the pump cover. Loosen 9 bolts and remove the right cover. Take off the gasket and dowel pin. Turn pump rotor clockwise and remove. Caution The rotor is provided with left turn thread. Removal of Water Pump Shaft Circlip Remove the circlip from the right crankcase cover. Remove the water pump shaft and the inner bearing. Remove the outside bearing by inner bearing puller.
12. COOLING SYSTEM Replacement of Mechanical Seal Drive the mechanical seal and inner seal out of the right crankcase. Tools required Water pump bearing driver Caution Replace a new mechanical seal after removing it. bearing driver Install the new inner seal onto the right crankcase. Tools required Water pump mechanical seal driver Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new oil seal. Install the mechanical seal onto the right crankcase.
12. COOLING SYSTEM Mount the water pump shaft and the inner bearing to the right crankcase cover. Install the circlip to hold the inner bearing. Bearing Water pump shaft Install water pump rotor Install the seal washer into the rotor. Washer Caution Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and tighten. Water pump rotor Torque Value:1.0~1.4 kgf-m Caution The rotor is left thread.
12. COOLING SYSTEM Install the right crankcase cover.(bolt × 9) Install the dowel pin and new gasket. Install the water pump cover with three bolts. Temperature sensor Please refer to chapter 17 for inspection of temperature sensor. Removal Remove the body cover. Drain out the coolant. Disconnect the cable of temperature sensor. Remove the temperature sensor. Installation Apply a coat of 3 Bond No. 1212 sealant or equivalent to the thread of temperature sensor and install it on the holder.
12. COOLING SYSTEM Thermostat Temperature sensor Removal Remove the rear cover. Drain out the coolant. Disconnect the cable from the thermostat. Remove the water hose from the thermostat holder. Remove the air vent hose from the holder. Remove the holder and lock bolt from the cylinder head. Remove the temperature sensor and O ring from the holder. O-ring Bolt × 2 Remove two bolts and separate the holder from the cover. Remove the thermostat. Inspection Visually inspect thermostat for any damage.
12. COOLING SYSTEM Technical Data Valve begins to open 71 ~ 80℃ Valve stroke 3.5 ~ 4.5 mm at 80℃ Installation Install in reverse order of removal. Caution Always use a new oil ring and apply a coat of grease on it before installing. Refill the specified coolant as necessary.
Homepage Contents 13. BODY COVERS Mechanical Illustration.................. 13-1 Side Cover ......................................13-7 Maintenance................................... 13-2 Body Cover.....................................13-8 Steering Handlebar Guard ............ 13-3 Central Cover .................................13-9 Front Guard.................................... 13-4 Foot Rest ........................................13-10 Front Lower Spoiler ......................
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13. BODY COVERS Steering Handle Cover Screw x 4 Disassembly Loosen 5 screws from both sides and rear. Screw x 1 Disengage the buckle from the slot, take off the front cover of the handlebar and loosen two screws. Screw x 2 Dismount the rear cover of the handlebar. Assembly In reverse order of the disassembly. Caution The tail of each cover is held with buckles and slot, never pull them with force, or it would crack the buckles.
13. BODY COVERS Front Cover Disassembly Loosen two lock bolts. Bolt Loosen four screws on the lower part of the front cover. Screw x 4 Take off four screws that hold the front luggage carrier (Screw x 4). Disconnect the connectors for the head lamp and the direction lamps. Disassemble the front guard. Assembly In reverse order of the disassembly.
13. BODY COVERS Front Under Spoiler Disassembly Loosen six screws that hold the front inner box. Screw x 6 Loosen two screws that lock up the front under spoiler. (Screw x 2) Screw x 2 Loosen one screw at the back of the under spoiler. (Screw x 2) Remove the front under spoiler. Screw Assembly In reverse order of the disassembly.
13. BODY COVERS Luggage Box Bolt x 6 Disassembly Lift up the seat saddle Loosen six bolts inside the luggage box. (Bolt x 6) Loosen one hook screw on the center cover (Screw x 1) Screw x 1 Hold the front end of the luggage box and lift it upward to take off from the frame Assembly In reverse order of the disassembly.
13. BODY COVERS Side Covers Disassembly Loosen four screws and take of the rear center cover. (Screw x 4). Screw x 4 Loosen six screws and remove two side covers from the frame (Screw x 3 for each cover). Screw x 1 Screw x 1 Screw x 2 Assembly In reverse order of the disassembly.
13. BODY COVERS Body Cover Disassembly Loosen three bolts and remove the rear grip. (Bolt x 3). Bolt x 3 Loosen two bolts from the rear frame. (Bolt x 2) Bolt x 2 Loosen two screws that link the central guard and the body cover (Screw x 2). Screw x 2 Loosen two bolts from the tail lamp (Bolt x 2). Disconnect the tail lamp connector. Hold the body cover with two hands, lift it upward to take off from the frame. Assembly In reverse order of the disassembly described above.
13. BODY COVERS Center Cover Disassembly Remove the hook and screw from the center cover (Screw x 1). Screw x 1 Loosen four screws and take off the center cover from the frame (Screw x 4). Screw x 4 Assembly In reverse order of the disassembly as described above.
13. BODY COVERS Floor Panel Screw x 4 Disassembly Loosen four screws (Screw x 4). Loosen four front bolts (Bolt x 4). Bolt x 4 Loosen two bolts under the saddle (Bolt x 2). Loosen four screws under the saddle (Screw x 4). Bolt x 2 Screw x 4 Remove the floor panel. Assembly In reverse order of the disassembly as described above.
13. BODY COVERS Inner cover Disassembly Take off four screws from the speedometer cover (Screw x 4). Disconnect the cable and connector of the speedometer. Loosen two bolts from under speedometer (Screw x 2). Remove the speedometer and speedometer cover. Bolt x 2 Screw x 4 Bolt x 1 Loosen one bolt that holds the inlet cap of radiator (Bolt x 1). Loosen two bolts that hold the fuel filler (Screw x 2). Bolt x 2 Remove the fuel filler cap and bushing. Disassemble the main switch cap.
13. BODY COVERS Front Fender Screw x 4 Disassembly Loosen four screws from the front fender (Screw x 4). Lift the front fender upward and disengage the front shock absorber to remove the front fender. Assembly In reverse order of the disassembly as described above.
Homepage Contents Illustration - Front Disc Brake System ....................................................14-1 Illustration - Rear Disc Brake System ....................................................14-2 Maintenance Description .......................14-3 Trouble Diagnosis ..................................14-4 14. BRAKE Hydraulic Disc brake ................................. 14-5 Air Bleed .................................................... 14-6 Brake Calliper ......................................
14. BRAKE Rear Disk Brake System 3.5 kgf-m 0.55 kgf-m 4.
14. BRAKE Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. z z z z z The brake calliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
14. BRAKE Trouble Diagnosis Master cylinder Soft brake lever 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Holder Alignment point Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining/disc Low brake fluid Blocked brake hose Warp/bent brake disc Bent brake lever UP mark Retaining Seat Hard operation of brake lever 1. 2. 3. 4. 5.
14. BRAKE Hydraulic Disc Brake z z Close the drain valve of the hydraulic disc brake. Replace the brake fluid. Lower level Master cylinder Cap Plate Diaphragm Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, then remove the brake fluid reservoir. Cover the painted surfaces, plastic or rubber components with a rag when servicing brake system.
14. BRAKE Air bubble Air Bleed Drain valve 1. Tightly hold the brake lever and open the drain valve around 1/4 turns, and then close the valve. CAUTION • Do not release the brake lever before the drain valve is closed. • Always check the brake fluid level when carrying out the air bleeding procedure to avoid air enter into the system. 2. Slowly release the brake lever, and wait for a few seconds until it reaches its top position. 3.
14. BRAKE Brake Disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Brake disc Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel. Check the disc for deformation and bend. Allowable limit: 0.30 mm Brake Master Cylinder Removal Master cylinder CAUTION Do not let foreign materials enter into the cylinder.
14. BRAKE Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Allowable limit: 11.055 mm Cylinder gauge Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Piston Allowable limit: 10.
14. BRAKE Install the rubber cap into the groove correctly. Place the master cylinder onto handlebar, and install the master cylinder seat and its bolts. The “UP” mark on the seat should face upward. Align the master cylinder seat with the alignment point on the handlebar. Tighten the upper bolt of the seat to specified torque value, and then tighten lower bolt to the same specified torque value. Install the brake lever, and connect wires to brake lamp switch. Connect brake hoses with 2 new washes.
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Homepage Contents 15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Mechanical Illustration.................. 15-1 Front Wheel ....................................15-6 Operational Precautions ............... 15-2 Front Brake.....................................15-9 Trouble Diagnosis ......................... 15-2 Front Shock Absorber ...................15-10 Steering Handlebar ....................... 15-3 Front Fork/Steering .......................15-11 2.4~3.0 kgf-m 4.0~5.0 kgf-m 1.0~2.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Operational Precautions General Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of the tire. Torque Values Nut for the front wheel axle Nut for the steering shaft Lock nut for the steering shaft Top crown for the steering shaft Locating screw for the speedometer cable Front shock absorber: Upper lock bolt 10.0 ~ 12.0 kgf-m 4.0 ~ 5.0 kgf-m 1.0 ~ 2.0 kgf-m 0.2 ~ 0.3 kgf-m 0.15 ~0.3 kgf-m 2.4 ~ 3.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Steering Handlebar Removal Remove the front handle cover. (Screw ×4) Screw× × 1 Screw× × 4 Remove the rear handle cover. (Screw ×3) Remove the right switch assembly by loosening two screws. Remove the acceleration cable and take off the handlebar. Screw× × 2 Loosen the lock bolt for the master cylinder of the front brake. Bolt× × 2 Remove the master cylinder of the front brake.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Remove the left switch assembly by loosening two screws. Screw × 2 Loosen the lock bolt for the master cylinder of the rear brake. Bolt× × 2 Remove the master cylinder of the rear brake. Loosen the lock bolt for the handle fix bolts. (Bolt ×4) Bolt× × 2 Loosen the lock bolts for the handle holder of the handlebar.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Loosen nuts and locating sleeve from the handlebar. Remove the handlebar. Bolt× × 1 Installation In reverse order of the disassembly. Caution Apply grease to the throttle cable end and connect it to the throttle holder. After the steering handlebar is installed, check the throttle cable for free movement. Carry out the following inspection and adjustment: - Operation of the throttle. - Brake level free travel. - Operation of all meters.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Bolt× × 2 Front Wheel Removal Loosen two screws from the front brake calliper. Remove the front brake calliper. Caution Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out. In case that the brake pad is accidentally squeezed out, use a screwdriver to force it back to the place. Remove the speedometer cable. Turn loose the nuts and pull out the wheel axle. Remove the front wheel.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Wheel rim Place the wheel rim on a rotary rack. Rotate the wheel rim and measure the runout. Service limit: Radial: Axial: 2.0 mm 2.0 mm Disassembly Remove the bushes and dust-proofing oil seal. Insert the bearing puller into the bearing and pull out the bearing. Remove the spacer and take off the bearing itself. Tools Bearing puller (Inner) Assembly Fill the bearing cap with grease Place the left bearing into the bracket.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Assembly Assemble in reverse order of disassembly. Apply a coat of grease on the inner side of the dust-proofing oil seal. Install the dust proofing oil seal and the left and right bushes. Installation Insert the wheel axle through the front shock absorber and wheel. Tighten the nut for the wheel axle. Torque value: 10.0 ~ 12.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Install the speedometer cable. Press the brake pad to open. Install the brake caliper and tighten the lock screw. Torque value: 3.3 kgf-m Front Brake Remove the front wheel. Loosen the lock screws and remove the brake disk. Inspection Check the brake disk for smoothness, damage and deformation. Measure the thickness of the disk. Allowable minimum thickness: 2.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Front Shock Absorber Removal of front shock absorber Loosen two bolts from the front brake calliper. Remove the front brake calliper and hose. Calliper Bolt× × 2 Loosen the bolts and remove the front shock absorber. Installation Install the front fork and front shock absorber. Tighten the bolts. Align the top of the cushion with the steering and tighten the bolt.( Note not to interference the cushion oil installing bolt.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Front Fork/Steering Removal of the front fork Remove the following parts: - The instrument panel assembly - The Steering handlebar - The front wheel Use the steering nut wrench to loosen the lock nut from the steering. Steering lock nut Steering cone Tools Steering head top thread wrench Remove the top crown and front fork. Caution Place balls in a container to avoid missing. Check the top crown to see any wear and damage. If affirmative, replace it.
15. STEERING/FRONT WHEEL/FRONT BRAKE/FRONT CUSHION Use the punch and the drive to press the ball race into the steering shaft end. Tools Driver Punch Use the punch and the driver to press the bottom ball race into the steering shaft end. Tools Driver Punch Installation of front fork Fill the upper and lower ball race with grease, and load each carrier with balls. Install the front fork into the steering shaft. Care shall be exercised not to lose the balls.
Homepage Contents 16. REAR WHEEL/REAR BRAKE/REAR CUSHION Mechanical Illustration.................. 16-1 Muffler ............................................ 16-3 Operational Precaution ................. 16-2 Rear Wheel..................................... 16-3 Trouble Diagnosis ......................... 16-2 Rear Cushion................................. 16-5 3.5~4.5 kgf-m 2.4~3.0 kgf-m 0.55 kgf-m 3.5 kgf-m 1.8 kgf-m 16 4.
16. REAR WHEEL/REAR BRAKE/REAR CUSHION Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Run-out of rear rim Standard Allowable Limit Radial - 2.0 Axial - 2.0 4.0 2.0 238.6 233.6 Thickness of rear brake lining Free length of rear shock absorber Torque Value Rear shaft nut 10.0-12.0 kgf-m Rear cushion bolt 2.4-3.
16. REAR WHEEL/REAR BRAKE/REAR CUSHION Muffler Removal Loosen the front lock nuts of the muffler (nut x2). Loosen the lock bolts (bolt x 3). Remove the exhaust pipe. Installation In reverse order of the removal. Caution Replace the front gasket if worn or deformed. Torque Value For lock bolt: For lock nut: 3.2 ~ 3.8 kgf-m 2.7 ~ 3.3 kgf-m Rear Wheel Removal Remove the rear cover (screw x 4). Remove the right side cover (screw x 3). Remove the muffler (bolt x 3, nut x 2).
16. REAR WHEEL/REAR BRAKE/REAR CUSHION Check any deformation and warping of the brake disc. Allowable limit: 0.3 mm Warning Never contaminate the brake disc with grease. The contaminated brake disc will reduce it performance. z The brake disc contains asbestos. Never use air jet to clean it. Preferably, the operator shall wear respirator and gloves, and use the vacuum cleaner to clean the brake disc. z Inspection of Rear Wheel Wheel Rim Place the wheel rim on a rotational support.
16. REAR WHEEL/REAR BRAKE/REAR CUSHION Align the rear shock absorber with the rocker arms hole; tighten the cushion with bolts. Install the brake calliper and tighten the lock bolts. Install the muffler and tighten the lock bolts. Install the guards and cover in reverse order of removal. Torque Value Cushion bolt: 2.4 ~ 3.0 kgf-m Nuts of rear wheel shaft: 10.0 ~ 12.0 kgf-m Bolts for the brake calliper: 2.9 ~ 3.5 kgf-m Bolts for the muffler: 3.2 ~ 3.8 kgf-m Nuts for the muffler: 2.7 ~ 3.
16. REAR WHEEL/REAR BRAKE/REAR CUSHION Remove an upper bolt from the shock absorber (bolt x 1). Remove the rear shock absorber. Installation In reverse order of removal. Caution The shock absorber must be replaced as a unit. Never disassemble the shock absorber as that would damage the structure. Torque Value Absorbing bolt: Lock nut: 16-6 2.4 ~ 3.0 kgf-m 3.5 ~ 4.
Homepage Contents 17. ELECTRICAL SYSTEM Mechanical Illustration.................. 17-1 Lamp/Bulb ......................................17-12 Maintenance Data.......................... 17-2 Switch/Horn ....................................17-13 Trouble Diagnosis ......................... 17-3 Fuel Gauge .....................................17-16 Battery ............................................ 17-4 Thermal Switch...............................17-17 Charging System ...........................
17. ELECTRICAL SYSTEM Maintenance Data Operational Precaution z When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) z The model of the spark plug and the tightening torque. z The ignition timing. z Adjustment of headlamp. z Removal and installation of AC generator. z The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.
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17.ELECTRICAL SYSTEM Battery Removal Loosen four screws and remove the rear cover (screw x 4). Loosen three screws and remove the right body cover (screw x 3). Loosen two nuts and remove the battery guard cover (nut x 2). Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the motorcycle. Voltage Check Use the digital voltmeter to check the voltage of the battery. Voltage: Fully charged: Undercharged: 13.0 – 13.2 V at 20℃ Below 12.
17.ELECTRICAL SYSTEM Charging System Charging Circuit Main Switch Green Black Red Fuse 20A Yellow Yellow Yellow Battery Yellow Regulator rectifier Auto by-pass starter Generator Current Leakage Test Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal.
17.ELECTRICAL SYSTEM Inspection on Charging Voltage Caution z Before conducting the inspection, be sure that the battery is fully charged. If undercharged, the current changes dramatically. z Use a fully charged battery having a voltage larger than 13.0 V z While starting the engine, the starter motor draws large amount of current from the battery. After the engine is warmed up, replace original battery with a fully charged battery. Connect a digital voltmeter to the battery terminals.
17.ELECTRICAL SYSTEM Inspection on SCR Remove the bumper by loosening four screws (screw x 4). Remove the right side cover by loosening three screws (screw x 3). Disconnect 3P and 4P connectors to remove the SCR. Item Check Points Standard Value Main switch R–B Battery voltage connection (ON) Battery R–G Battery voltage connection Charging coil Y–Y 0.4 – 0.8Ω Ω If the readings measured are not normal, check parts in the circuit. If the parts are normal, then trouble is in the wiring.
17.ELECTRICAL SYSTEM Ignition System Ignition circuit diagram CDI assembly Green Main switch Black/white Black/red Green/ white Black/yellow Blue/ yellow Green Spark plug Pulse generator Ignition coil Exciting coil C.D.I Assembly Disconnect connectors of the C.D.I assembly. Check the following connectors as indicated in the table at the harness side.
17.ELECTRICAL SYSTEM Inspection on Ignition Coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Standard resistance: 0.17Ω Ω ± 10% Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding. Standard resistance: With no cap: 3.6Ω Ω ± 10% With cap: 7.
17.ELECTRICAL SYSTEM Starting System Starting Circuit Diagram Main switch Main fuse 20A Red Main fuse 10A Rear brake switch Starter switch Starter relay Yellow/red Starter motor Green/yellow Inspection on Starter Relay Remove the luggage box assembly. Open the main switch Press the brake Push down the starter switch If a sound of “Looh Looh” is heard, it indicates the relay function normally. Disconnect the cable positive terminal from the relay. Disconnect the positive cable of the starter motor.
17.ELECTRICAL SYSTEM Removal of Starter motor bolt× 2 Remove the rear cover (screw x 4). Remove the right body cover (screw x 3). Remove the battery cover (nut x 2). Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove the luggage box. Loosen the lock bolt and remove the starter motor. Installation of Starter motor In reverse order of the removal of the starter motor.
17.ELECTRICAL SYSTEM Lamp/Bulb Replacing Bulb for Headlamp Loosen the front cover (bolt x 2, screw x 8). Headlamp assembly Front cover Disconnect the terminal connector and the rubber sleeve from the headlamp. Remove the bulb spring holder and the bulb. Replace with new bulb if necessary. screw× 4 Headlamp terminal Caution z Never touch the bulb with finger, which will create a heat point. z Clean the fingerprint left on the bulb with alcohol.
17.ELECTRICAL SYSTEM Replacing Bulb of Number Plate Lamp Screw× × 2 Remove the rear cover (screw x 4). Remove the lamp lens (screw x 2). Winker light screw Replacing bulbs of Tail light, Brake light, and Rear winker light Remove the rear cover (screw x 4). Remove the lamp lens for tail light and rear winker light (screw x 4). screw× 2 Tail / brake bulb Winker bulb Switch/Horn Main Switch Inspection Remove the front cover (bolt x 2, screw x 8). Disconnect the main switch.
17.ELECTRICAL SYSTEM Replacement of Main Switch Bolt×2 Disconnect the connector of the main switch and loosen the lock bolts (bolt x 2). Remove the main switch. Install the new main switch and tighten the lock bolts (bolt x 2). Steering Handlebar Switch Remove the front handlebar guard (bolt x 2, screw x 8). Disconnect the connector of steering handlebar switch. Check the continuity between two points as indicated in the table below. ENG. Stop switch ENG.
17.ELECTRICAL SYSTEM Winker light R R WR ● ● L Seat open switch(LA18W) B1 B2 SEAT OPEN ● ● Wire Color Black Purple FREE N PUSH OFF L Light blue Wire Color ● ● Gray Orange Passing switch(LA12W & LA15W) Horn switch BAT3 HO BAT4 HI ● ● FREE FREE ● Wire Color White/ Green PASSING ● Light green Wire Color White/ Green Blue Brake Switch While grasp the brake lever firmly, the terminals of white/green and green/yellow of the brake should have continuity.
17.ELECTRICAL SYSTEM Fuel Gauge Fuel gauge connector Open the seat. Remove the luggage box (bolt x 6, screw x 1). Remove the rear carrier (bolt x 3). Remove the rear carrier seat (bolt x 2). Remove the rear center cover (screw x 4). Remove the left and right rear foot rest (bolt x1). Remove the left and right side cover (screw x 4). Remove the central cover (screw x 6). Remove the left and right body cover, the center cover (screw x 4, bolt x 4). Remove the foot rest (bolt x 4, screw x 4).
17.ELECTRICAL SYSTEM Thermal Switch The thermal switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the switch, the fan motor should operate. If the fan motor still fails to run, measure battery voltage between the green and black/blue leads. If there is no voltage, check for blown fuse, loose connection or short-circuit.
17.ELECTRICAL SYSTEM Sensor Remove the sensor. Hang the sensor in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2 Sensor Sensor Caution Wear gloves and goggles when performing this test. Sensor Caution z z Engine oil should be used as a heating medium as the test temperature must be higher than 100℃.
17.ELECTRICAL SYSTEM Gauges Fuel Indicator Speedometer Water temperature Fuel Warning Indicator Turn Signal Indicator Turn Signal Indicator High Beam Indicator Alarm set button Odometer set b tt Fuel Gauge Water temperature gauge Odometer Digital meters trouble diagnosis 1. The meter doesn’t indicate Check if the main switch is ON Check the White/Green wire for loosening Check the Red wire for loosening 2.
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Homepage Contents 18. SPECIAL TOOLS Special tools list ............................. 18-1 Crank case / transmission oil seal driver.....................................................18-7 How to use special tools................ 18-4 R/L. Crank case disassemble / install tools...................................... 18-4 AC.G. flywheel puller ...........................18-8 Bearing driver ................................. 18-5 Outer / inner bearing puller .................
18. SPECIAL TOOLS 10 11 12 (27*42*7) WATER PUMP MECHANICL SEAL NAME DRIVER NO. SYM-1721700-H9A PRICE USD 3.72 NAME AC.G. FLYWHEEL PULLER NO. SYM-3110A00 PRICE USD 7.82 13 NAME OIL SEAL DRIVER SYM-9121600 PRICE USD 7.82 NAME CLUTCH NUT WRENCH SYM-9020200 PRICE USD 7.45 18-2 SYM-9125500 PRICE USD 7.82 15 (20*32*6) NAME OIL SEAL DRIVER NO. SYM-9120200 PRICE USD 6.70 16 NO. NO. 14 (25*40*8) NO. NAME OIL SEAL DRIVER NAME UNIVERSAL HOLDER NO. SYM-2210100 PRICE USD 11.
18. SPECIAL TOOLS 19 NAME VALVE SPRING COMPRESSOR NO. SYM-1471100 PRICE USD 16.02 20 21 VALVE COTTER REMOVE & NAME ASSEMBLY TOOL NO. SYM-1471110/20 PRICE USD 8.19 22 NAME UNIVERSAL HOLDER NO. SYM-9001210 PRICE USD 17.88 23 24 (ψ ψ30mm) RR CUSHION ADJUSTING NAME WRENCH NO. SYM-5320000 PRICE USD 4.47 NAME CRANK CASE BUSH PULLER NO. PRICE USD 5.59 25 NAME OUTER BEARING PULLER NO. SYM-6204010 PRICE USD 40.97 SYM-1120310 (ψ ψ22mm) NAME CRANK CASE BUSH PULLER NO.
18. SPECIAL TOOLS How to use special tools: R/L.
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18. SPECIAL TOOLS AC.G.
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Contents 19.
LA18W SERIER WIRING DIAGRAM 19.
