GTS 250 JOYMAX 250 SERVICE MANUAL FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER
Homepage Contents Forward This service manual contains the technical data of each component inspection and repair for the SANYANG LM25W series scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the scooter, LM25W series scooter, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Homepage Contents How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG LM25W series scooter. 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 and special tools manual.
Homepage Contents Page Content Index 1-1 ~ 1-16 General Information 1 2-1 ~ 2-18 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~ 4-14 Fuel System 4 5-1 ~ 5-10 Engine Removal 5 6-1 ~ 6-16 Cylinder Head / Valve 6 7-1 ~ 7-8 Cylinder / Piston 7 8-1 ~ 8-14 “V” Type Belt Driving System / Kick-Starter 8 9-1 ~ 9-8 Final Driving Mechanism 9 10-1 ~ 10-10 Alternator 10 11-1 ~ 11-8 Crankshaft / Crankcase 11 12-1 ~ 12-14 Cooling System 12 13-1 ~ 13-14 Body
Home page Serial Number Contents
Homepage Contents 1.
To this chapter contents 1. General Information General Safety Carbon monoxide 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.
To this chapter contents 1. General Information Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG ATV may damage the ATV. y 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. y When servicing this ATV, use only metric tools.
To this chapter contents 1. General Information y 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.
To this chapter contents 1. General Information y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly. y And the two posts of battery have to be greased after connected the cables. y Check if positions and operation for installed parts is in correct and properly. y Make sure service safety each other when conducting by two persons.
To this chapter contents 1. General Information y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not pull the wires as removing a connector or wires. Hold the connector body. y Insert the terminal completely. Check if the terminal is covered by the boot. Do not let boot open facing up. y Secure wires and wire harnesses to the frame with respective wire bands at the designated locations.
To this chapter contents 1. General Information y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied. y Keep wire harnesses far away from the hot parts. y Secure the rubber boot firmly as applying it on wire harness.
To this chapter contents 1. General Information y Do not let the wire harness been twisted as installation. y With sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later. Clean rust y Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.
To this chapter contents 1.
To this chapter contents 1. General Information Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type 5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut Tighten Torque Type 0.45~0.6kgf-m 0.8~1.2kgf-m 1.8~2.5kgf-m 3.0~4.0kgf-m 5.0~6.0kgf-m Tighten Torque 5 mm screw 6 mm screw、SH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 0.35~0.
To this chapter contents 1. General Information Frame Torque Values Item Mounting bolt for steering handle post Lock nut for steering stem Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks 1 10 4.0~5.0 1 BC1 1.0~2.0 Steering top cone race 1 BC1 2.0~3.0 Front wheel axle nut 1 12 5.0~7.0 Rear wheel axle nut 1 16 11.0~13.0 Front cushion mounting bolt 4 10 3.5~4.5 Rear cushion upper connection bolt 1 10 3.5~4.5 Rear cushion under connection bolt 1 8 2.4~3.
To this chapter contents 1. General Information Troubles Diagnosis 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 tom 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. Check if sparks Weak sparks, no spark at all Perform cylinder compression pressure test.
To this chapter contents 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. Check ignition timing (Using ignition lamp) Ignition timing correct Incorrect ignition timing 1. Air cleaner clogged 1. Poor fuel supply 2. Lines in fuel tank evaporation system clogged 3. Exhaust pipe clogged 4.
To this chapter contents 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 alternator) 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 No air sucked Air sucked 1. Poor heat insulation gasket 2.
To this chapter contents 1. General Information E. Clutch, Driving And Driving Pulley FAULT CONDITIONS Engine can be started but motorcycle can not be moved. Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running) Poor initial driving (Poor climbing performance) PROBABLE CAUSES 1. 2. 3. 4. 5. 6.
To this chapter contents 1.
Home page Contents 2.
To this chapter contents 2.
To this chapter contents 2. Maintenance Information 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 Caution ● Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely. Place an oil pan under the motorcycle, and remove oil drain bolt.
To this chapter contents 2. Maintenance Information Gear Oil Oil inspection bolt Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine. Gear Oil Change Remove oil inspection bolt. Remove drain plug and drain oil out. Install the drain plug after drained. Torque value: 0.8~1.2kgf-m Add gear oil to specified quantity from the inspection hole. Install the inspection bolt. Torque value: 1.0~1.4kgf-m Gear Oil Quantity: 170 c.c.
To this chapter contents 2. Maintenance Information Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Adjustment nut Air Cleaner Air Cleaner Element Remove 8 screws from the air cleaner cover and then remove the cover. 8 screws Remove the body cover. Loosen bolt from the air cleaner air hose. Remove 6 screws, and then remove the air cleaner element.
To this chapter contents 2. Maintenance Information P.C.V. system Draws out the plug from lower of the breather chamber hose. Releases the dry internal deposit.
To this chapter contents 2. Maintenance Information Carburetor Idle Speed Adjustment Ignition coil cable 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.) Park the motorcycle with main stand and warm up engine.
To this chapter contents 2. Maintenance Information Ignition System Caution ● ● C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is in normal or not. Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover. Connect tachometer and ignition lamp. Start engine. As engine in idle speed: 2,500 rpm, aim at the “F” mark with the ignition lamp.
To this chapter contents 2. Maintenance Information Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove luggage box and 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. y Usually, the highest pressure reading will be obtained in 4~7 seconds.
To this chapter contents 2. Maintenance Information Steering Handle Top Bearing Caution ● Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing. Cushion Caution y Do not ride the motorcycle with poor cushion.
To this chapter contents 2. Maintenance Information Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. 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 Caution y In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle stop.
To this chapter contents 2. Maintenance Information Brake Lining Wear Lining The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc. Caution It is not necessary to remove brake hose when replacing the brake lining. Brake disk Brake caliper Remove the brake clipper bolt, and take out the clipper. 2 bolts Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.
To this chapter contents 2. Maintenance Information Brake Light Switch/Starting Inhibitor Switch Stop switch 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. Headlight Beam Distance Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high. Caution y To adjust the headlight beam follows related regulations.
To this chapter contents 2. Maintenance Information Battery Open the inner box lid. Loosen screw & remove the battery cover Battery cable remove： 1. Disconnect the cable negative terminal (-), 2. then the cable positive terminal (+) 3. Remove the battery from the motorcycle.。 If there is some rust on battery posts, clean it with steel brush Install the battery in the reverse procedures of removal Caution y If there is rust on the posts very serious, spray some hot water on the posts.
To this chapter contents 2. Maintenance Information Special Tools List NAME NO NAME NO NAME NO Left crank bearing puller SYM-9100100 NAME NO L. Crank shaft puller SYM-1130000-HMA H9A R. crank case bearing 6201 assembles tool SYM-9614000-HMA 6201 NAME NO R/L. crank case disassemble tool SYM-1120000-HMA H9A Tappet adjusting wrench SYM-9001200 NO Left crankshaft & oil seal assembly socket.
To this chapter contents 2. Maintenance Information NAME NO NAME NO NAME NO NAME NO 2-16 Inner bearing puller SYM-6204022 Clutch nut wrench SYM-9020200 Steering head top thread wrench SYM-5320010 Air operated bearing puller SYM-9100410-400 A6205 NAME NO NAME NO NAME NO NAME NO Outer bearing puller SYM-6204001 Universal holder SYM-2210100 Bearing driver HK1516 SYM-9100200-HMA RB1 HK1516 Oil seal driver 34*52*5 SYM-9125500-HMA NAME NO NAME Handle stand nut wrench SYM-5321100 AC.G.
To this chapter contents 2.
To this chapter contents 2.
Home page Contents 3.
To this chapter contents 3. Lubrication System Precautions in Operation General Information: z This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Change: 1200c.c. SAE 10W-30 (Recommended King serial oils) Oil viscosity Gear oil Disassembly: 1400 c.c. Disassembly: Change: 180c.c. 170c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) Unit: mm Items Standard (mm) Limit (mm) 0.15 0.
To this chapter contents 3. Lubrication System Engine Oil Turn off engine, and park the scooter 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 makes sure oil can be drained smoothly and completely. Place an oil pan under the scooter, and remove oil drain bolt.
To this chapter contents 3. Lubrication System Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Clip Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump. 2 screws Oil Pump Disassembly 1 screw Remove the screws on oil pump cover and remove the cover. Remove oil pump shaft roller and shaft.
To this chapter contents 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 Pins Install inner and outer rotors into the pump body. Align the indent on driving shaft with that of inner rotor. Install the oil pump shaft and roller. Install the oil pump cover and fixing pins properly.
To this chapter contents 3. Lubrication System Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0.1~0.3kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft. Install starting gear and generator.
To this chapter contents 3. Lubrication System Gear Oil Gear oil join bolt Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m Make sure that the drain bolt washer can be re-used. Add oil to specified quantity from the join hole. Gear Oil Quantity: 170c.c. when replacing Make sure that the join bolt washer can be re-used, and install the bolt. Torque value: 1.0~1.
To this chapter contents 3.
Home page Contents 4. Fuel System Mechanism Diagram ...........................4-1 Automatic by-starter............................4-7 Precautions in Operation....................4-2 Float Chamber......................................4-8 Trouble Diagnosis...............................4-3 Adjustment of Idle Speed....................4-10 Carburetor Remove / Install ...............4-4 Fuel Tank ..............................................4-11 Vacuum Chamber................................
To this chapter contents 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 y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
To this chapter contents 4.
To this chapter contents 4. Fuel System Carburetor Remove / Install Removal Remove luggage box. Drain out fuel in the float chamber. Throttle cable Fuel pipe Disconnect the fuel hose, vacuum hose. Disconnect the auto by-start and heater couplers. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Release the clamp strip of carburetor, and then remove the carburetor. Installation Clamp Install in reverse order of removal procedures.
To this chapter contents 4. Fuel System Remove fuel needle seat, spring, and injector needle. Piston Needle seat Needle Inspection Check if the vacuum piston and needle for wear out, crack or other damage. Check if the diaphragm for damage or crack. Caution ● Do not damage vacuum diaphragm. Spring Installation Install in reverse order of removal procedures.
To this chapter contents 4. Fuel System Air Cut-off Valve 2 screws Removal Removal the throttle cable seat (2 screws) Remove the screws (2 screws) of the air cut-off valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack. Installation Install the valve as reverse order of removal. Caution z Do not damage the vacuum diaphragm or in opposite installation direction.
To this chapter contents 4. Fuel System Automatic by-starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter. Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the automatic by-starter with a new one if resistance value exceeds standard. Remove the carburetor, allow it to cool off for 30 minutes. Connect a pressure tester form air pump. Connect fuel rich circuit.
To this chapter contents 4. Fuel System Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. 3 screws Remove the fuel level plate, float pin, float and float valve. Float 1 screw Main jet Inspection Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
To this chapter contents 4. Fuel System Assembly Air adjustment screw Install main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution Set the air adjustment screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Float 1 screw Main jet Slow jet Checking fuel level Caution y Check again to ensure float valve, float for proper installation.
To this chapter contents 4. Fuel System Adjustment of Idle Speed Throttle cable adjustment nuts Caution y Air 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. y The parking brake must be used to stop the scooter to perform the adjustments. Use a tachometer when adjusting engine RPM. Screw in air adjustment screw gently, then back up to standard turns.
To this chapter contents 4. Fuel System Fuel Tank Fuel unit coupler Fuel unit removal Remove the left and right side covers. Open seat and remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the foot pedal (please refer to chapter 13 for these components above.) 4 bolts Remove fuel unit coupler, and then remove fuel unit (4 screws). Caution ˙Do not bend the float arm of fuel unit ˙Do not fill out too much fuel to fuel tank.
To this chapter contents 4. Fuel System Remove fuel tank upper bolts (2 bolts). 2 bolts Remove fuel tank under bolt (1 bolt). 1 bolt Remove fuel tank. Installation Install the fuel tank in the reverse order of removal.
To this chapter contents 4. Fuel System Fuel Pump Clamp Inspection Remove the left side cover and floor panel side cover. Warm up the engine and adjust idle speed. Remove fuel hose from carburetor and then wait for 5 minutes. Measure the output of fuel pump. Its output time is 10 seconds. Output quantity: Min. 20 c.c. If the output quantity is lower than 20 c.c., check fuel hose, vacuum hose and fuel filter. Removal / Installation 2 nuts Outlet tube Remove floor plate.
To this chapter contents 4. Fuel System Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Remove the air cleaner (3 bolts). Installation Install the tank in the reverse order of removal. 2 bolts Cleaning air cleaner element 8 screws Remove the air cleaner cover (8 screws). Remove element mounting screws (6 screws). Remove the air cleaner element. With compressed air to cleaning dirty around the element. Replace it if it is too dirty to clean.
Home page Contents 5. Removal & Installation of Engine Operational Precautions····················· 5-1 Rear Fork ·············································· 5-7 Engine Removal ·································· 5-2 Removal of Engine Bush····················· 5-9 Engine Hanger ····································· 5-6 Installation of Engine··························· 5-10 Operational Precautions General Information y Engine must be supported by a bracket or adjustable tool in height.
To this chapter contents 5. Removal & Installation of Engine Engine Removal Open inner box cover. Remove battery cover (1 screw). Remove the battery negative (-) cable. Remove the battery positive (+) cable. Positive Negative Open the seat. Remove the luggage box (6 bolts, 2 screws). (Refer to chapter 13) Remove right and left side covers (4 screws on each side.). Remove rear carrier (4 bolts). Remove body cover (4 screws & 1 coupler).
To this chapter contents 5. Removal & Installation of Engine Remove the generator power wire and pulse generator connector. Remove the starter motor wire. Couplers of the generator and pulse generator Starter motor wire Remove engine blow-by pipe. Engine blow-by pipe Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor. Loosen the clamp strip of air cleaner and carburetor, and then remove the air cleaner hose.
To this chapter contents 5. Removal & Installation of Engine Remove the air cleaner connection bolts (2 bolts). Remove the air cleaner. 2 bolts Remove the exhaust muffler (3 bolts, 2 nuts). 3 bolts 2 nuts Drain out coolant, and remove coolant inlet hose. Drain bolt Remove the coolant inlet hose and thermo-sensor wire.
To this chapter contents 5. Removal & Installation of Engine Remove rear brake hose clamp and rear brake caliper. 2 bolts Remove the right rear cushion lower bolt (1 bolt). Remove the rear fork bolts (2 bolts). Remove the rear wheel axle nut (1 nut). Rear axle nut Brake hose clamp 2 bolts 1 bolt Remove the rear fork and rear axle collars. Remove left rear cushion lower bolt (1 bolt).
To this chapter contents 5. Removal & Installation of Engine With a bracket to support the engine to prevent from it damage by falling down as removing the engine. Remove frame side engine hanger bolts (each side 1 bolt), and then remove engine. Frame side bolt Engine side bolt Engine Hanger Removal Remove the engine side bolts of engine hanger. (1 bolt on each side) Remove the engine hanger. Check if the engine hanger bush and cushion rubber for damage. If so, replace with new ones.
To this chapter contents 5. Removal & Installation of Engine Rear Fork Cir clip Bearing Inspection Check bearings on rear fork. Rotate bearing inner ring with fingers. Check if bearing can be turned in smooth and silent, and also check if bearing outer ring is mounted on rear fork tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Bearing removal Remove bearing mounting cir clip. Drive the bearing out of the rear fork.
To this chapter contents 5. Removal & Installation of Engine Install assembly directs puller bearing puller. Special Service Tools: SYM-2341110 Assembly directs puller Bearing puller Use screw driver holder bearing puller lower part, and turn the bearing puller upper part to install the rear fork bearing. Install bearing mounting cir clip.
To this chapter contents 5. Removal & Installation of Engine Removal of Engine Bush If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then, with the bush remover / presser, ø28mm & ø20mm, to press the bush out, and replace it with new one. Engine hanger bush: ø 28mm Rear cushion bush: ø 20mm Pressing out Place the detent section of the bush remover toward the bush, and drive both the pressing ring and bolt in to press the bush out.
To this chapter contents 5. Removal & Installation of Engine Installation of Engine Install the engine according to the reversing order of removal. Caution z z z Note both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose. Route all cables and wires in accordance with the routine layout. Engine hanger nut: Torque Value: 7.5~9.5kgf-m Rear cushion bolt: Torque Value: upper: 3.5~4.5kgf-m Under: 2.4~3.0kgf-m Rear wheel axle nut: Torque Value: 11.0~13.
Home page Contents 6.
To this chapter contents 6. Cylinder Head / Valve Precautions in Operation General Information y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. y Cylinder head service can be carried out when engine is in frame. Specification Item Standard Limit 12±2 kg/cm2 --- Intake 34.880 34.860 Exhaust 34.740 34.725 ID of valve rocker arm 11.982~12.000 12.080 OD of valve rocker arm shaft 11.966~11.984 11.936 Intake 4.975~4.990 4.
To this chapter contents 6. Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve y Improper valve adjustment y Burnt or bent valve y Improper valve timing y Valve spring damage y Valve carbon deposit. 2. Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts). Tensioner bolts Thermostat bolts Remove Air Injection system (AI) pipe mounting bolts. Remove spark plug. Remove cylinder head cover (4 bolts).
To this chapter contents 6. Cylinder Head / Valve Remove the side cover mounting blots of cylinder head, and then take out the side cover. 3 bolts Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Disassembly Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.
To this chapter contents 6. Cylinder Head / Valve Remove valve cotters, spring retainers, springs and valves. Inlet valve Exhaust valve Inner spring Outer spring Spring retainer Cotter Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.05 mm Camshaft Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm Inspect the camshaft bearing for looseness or wear out. If any damage, replace whole set of camshaft and bearing.
To this chapter contents 6. Cylinder Head / Valve Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: Inner spring 35.20 mm Outer spring 36.90 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: 4.90 mm Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.
To this chapter contents 6. Cylinder Head / Valve Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated plate or toaster. Valve guide driver 5.0mm Caution y Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. y Wear on a pair of glove to protect your hands when operating. Hold the cylinder head, and then press out old valve guide from combustion chamber side. Tool: Valve guide driver: 5.
To this chapter contents 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 y Do not let emery enter into between valve stem and valve guide. y 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.
To this chapter contents 6. Cylinder Head / Valve Use 60° cutter to cut a quarter lower parts 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 Caution 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.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Disassembly Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.
To this chapter contents 6. Cylinder Head / Valve Install camshaft into cylinder head. Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Cam shaft setting plate 2 bolts Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
To this chapter contents 6. Cylinder Head / Valve Install cylinder head side cover (3 bolts). 3 bolts Tensioner bolts Install thermostat (2 bolts). Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt. Thermostat bolts Install cylinder cover (4 bolts). Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder head. Install and tighten spark plug. Torque value: 1.0~2.
To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment 4 bolts Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover. Remove the cylinder head side cover. Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position. Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge.
Home page Contents 7. Cylinder / Piston Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7 Trouble Diagnosis································ 7-2 Cylinder Installation ························· 7-7 Cylinder and Piston Removal ············· 7-3 Mechanism Diagram 0.8~1.2kgf-m 7 1.0~1.
To this chapter contents 7. Cylinder / Piston Precautions in Operation General Information y Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit：mm Item Cylinder Limit 70.995~71.015 71.100 - 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 - 70.430~70.480 70.380 0.010~0.040 0.100 17.002~17.008 17.020 16.994~17.000 16.960 0.002~0.014 0.
To this chapter contents 7. Cylinder / Piston Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston. Remove cylinder gasket and dowel pin. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
To this chapter contents 7. Cylinder / Piston Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm 2nd ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. Caution Pay attention to remove piston rings because they are fragile. Place piston rings respective into cylinder below 20 mm of cylinder top.
To this chapter contents 7. Cylinder / Piston Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole. Service Limit: 0.02 mm Measure piston outer diameter. Caution The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin. Service limit：70.
To this chapter contents 7. Cylinder / Piston 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. Caution y Do not damage piston and piston rings as installation. y All marks on the piston rings must be forwarded to up side. y Make sure that all piston rings can be rotated freely after installed.
To this chapter contents 7. Cylinder / Piston Piston Installation IN mark Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve. Install new piston pin clip. Clip end gap Caution y Do not let the opening of piston pin clip align with the piston cutout. y Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation.
To this chapter contents 7. Cylinder / Piston Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。 Install coolant hose onto cylinder. Install cylinder head (refer to Chapter 6).
Home page Contents 8. V-Belt Driving System Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-5 Maintenance Description ···················· 8-2 Drive Face·············································8-7 Trouble Diagnosis ······························· 8-2 Clutch Outer / Driven Pulley················8-10 Left Crankcase Cover ························· 8-3 Mechanism Diagram 8 5.0~6.0kgf-m 8.5~10.5kgf-m 5.0~6.
To this chapter contents 8. V-Belt Driving System Maintenance Description Precautions in Operation General Information y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. y Drive belt and drive pulley must be free of grease. Specification Item Driving belt width Standard value Limit 24.000 mm 22.500 mm OD of movable drive face boss 29.946~29.980 mm 29.926 mm ID of movable drive face 30.000~30.040 mm 30.060 mm OD of weight roller 19.500~20.000 mm 19.
To this chapter contents 8. V-Belt Driving System Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (8 bolts) Remove 2 dowel pin and gasket. 8 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
To this chapter contents 8. V-Belt Driving System Left crankcase cover inspection Remove 2 bolts to remove left crankcase cover bearing setting plate. Check bearing on left crankcase cover. Rotate 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 cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
To this chapter contents 8. V-Belt Driving System Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool：universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer. Universal holder Bearing stay collar Caution y Using special service tools for tightening or loosening the nut. y Fixed rear wheel or rear brake will damage reduction gear system.
To this chapter contents 8. V-Belt Driving System Installation Caution ● ● Pull out driven face to avoid it closing. Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Driven face Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face. Install the clutch outer and bearing stay collar.
To this chapter contents 8. V-Belt Driving System Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Movable drive face Remove movable drive face comp and drive face boss from crankshaft. Crankshaft Remove ramp plate. Ramp plate Remove weight rollers from movable drive face.
To this chapter contents 8. V-Belt Driving System 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 affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter. Replace it if exceed the service limit. Service limit: 19.0 mm Weight: 17.
To this chapter contents 8. V-Belt Driving System With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution y The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Install movable drive face comp. onto crankshaft. Drive face boss Movable drive face Crank shaft Driven pulley installation Press down Press drive belt into pulley groove, and then pull the belt onto drive shaft.
To this chapter contents 8. V-Belt Driving System Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution y Do not press the compressor too much. Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool.
To this chapter contents 8. V-Belt Driving System Clutch lining Measure each clutch weight thickness. it if exceeds service limit. Service limit: 3.0 mm Replace Clutch lining Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.400 mm Free length Driven pulley Check following items: y If both surfaces are damaged or worn. y If guide pin groove is damaged or worn. Replace damaged or worn components.
To this chapter contents 8. V-Belt Driving System Clutch weight Replacement Remove snap ring and washer, and then remove clutch weight and spring from driving plate. Spring Driving plate Caution y Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity. Snap ring Clutch weight Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins.
To this chapter contents 8. V-Belt Driving System Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clipper Caution y If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. y If the pulley equipped with ball bearing, it has to remove snap ring and then the bearing.
To this chapter contents 8. V-Belt Driving System 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 Guide pin Oil seal Guide pin O-ring Guide pin roller Install the collar.
Home page Contents 9.
To this chapter contents 9. Final Driving Mechanism Precautions in Operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 180 c.c. (170 c.c. when replacing) Torque value Gear box cover 2.6~3.
To this chapter contents 9. Final Driving Mechanism Disassembly of Final Driving Mechanism Remove the rear wheel. Remove the clutch. Drain out gear oil from gear box. Loosen 7 bolts and remove gear box cover bolts. 7 bolts Remove the gear box cover. Remove the gasket & dowel pin. Remove final gear. Remove counter shaft, gear and 2 washers. Remove final shaft. Final shaft Counter shaft Remove the drive shaft.
To this chapter contents 9. Final Driving Mechanism Inspection of Final Driving Mechanism Check if the drive shaft are burn, wear or damage and replace it if necessary. Caution y If remove the drive shaft from the gear box upper side, then its bearing has to be replaced. Check if the countershaft is wear or damage and replace it if necessary. Check if the final shaft and gear are burn, wear or damage and replace it if necessary. Check bearings on gear box cover.
To this chapter contents 9. Final Driving Mechanism Bearing Replacement Outer bearing puller Left crankcase side If the drive shaft is pulled out with its bearing, then remove the bearing with bearing puller and shaft protector. Special tool: Multi-functional bearing puller or Outer bearing puller SYM-6204001 Shaft protector SYM-6204010 Remove final shaft bearing and counter shaft bearing from left crankcase using following tools.
To this chapter contents 9. Final Driving Mechanism Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Use screw driver hold bearing puller lower part, and turn the bearing puller upper part to install the drive shaft bearing. Assembly directs puller Gear box cover side Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools.
To this chapter contents 9. Final Driving Mechanism Install new final shaft bearing and bearing puller onto left crankcase. Special tool: Bearing puller 6205 SYM-9100400-6205 Install assembly directs puller bearing puller. Special Service Tools: Assembly directs puller SYM-2341110 Assembly directs puller Bearing puller 6205 Use screw driver holder bearing puller lower part, and turn the bearing puller upper part to install the final shaft bearing.
To this chapter contents 9. Final Driving Mechanism Re-Assembly of Final Driving Mechanism Clutch nut wrench Drive shaft and seal install socket Install drive shaft. Special tool: Drive shaft puller SYM-2341110- HMA RB1 Drive shaft socket & oil seal driver (25*40*8) SYM-9120200-HMA Clutch nut wrench SYM-9020200 Drive shaft puller Apply with grease onto drive shaft oil seal. Install the oil seal to left crankcase.
Home page Contents 10. Alternator / Starting Clutch Mechanism Diagram ···························10-1 Flywheel Removal ······························ 10-5 Precautions in Operation ···················10-2 Starting Clutch···································· 10-6 Right Crankcase Cover Removal ······10-3 AC.G. Flywheel Installation ··············· 10-8 AC.G. Set Removal ·····························10-4 AC.G.
To this chapter contents 10. Alternator / Starting Clutch Precautions in Operation General information y Refer to chapter 17: The troubleshooting and inspection of alternator. y Refer to chapter 17: The service procedures and precaution items of starter motor. Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear 25.026~25.045 25.050 OD of starting clutch gear 42.192~42.208 42.100 Torque value Flywheel nut Starting clutch hexagon bolt 8 mm bolts 12 mm bolts 5.0~6.0kgf-m 1.
To this chapter contents 10. Alternator / Starting Clutch Right Crankcase Cover Removal Remove left side cover. Remove seat and luggage box. (Refer chapter 13) Remove the exhaust muffler (3 bolts, 2 nuts). 3 bolts 2 nuts Drain out the engine oil and coolant (refer chapter 5). Remove coolant hoses. Coolant hoses Disconnect the couplers of the Power source output line Remove water pump cover (4 bolts). Remove 10 bolts from the right crankcase cover. Remove the right crankcase cover.
To this chapter contents 10. Alternator / Starting Clutch AC.G. Set Removal 3 screws Remove 2 mounting screws from pulse generator. Remove 3 screws from right crankcase cover and then remove generator coil set. Pulse generator screws Right Cover Bearing Cir clip Rotate the bearing with finger to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary. Remove the bearing 6201with inner bearing puller.
To this chapter contents 10. Alternator / Starting Clutch Flywheel Removal Remove right crankcase cover and generator coil. Remove flywheel nut. Flywheel nut Installs shaft protector onto the crank shaft. Special tool: Shaft protector Shaft protector Reduction gear Remove starter reduction gear and shaft. Pull out flywheel with AC.G. flywheel puller. Special tool: AC.G. Flywheel puller SYM-3110000-HMA Flywheel puller Remove flywheel and starting driven gear.
To this chapter contents 10. Alternator / Starting Clutch Starting Clutch Starting Clutch Inspection ID Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 25.050 mm OD: 42.100 mm OD Check the starting reduction gear and shaft for wear or damage. Check each roller for wear or damage. Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear.
To this chapter contents 10. Alternator / Starting Clutch Remove the starting gear Loosen 3 starting clutch socket bolts from one way clutch and remove one way clutch. 3 bolts Push out the roller set and check each roller for wear or damage. One way clutch Installation One way clutch Install the components in the reverse procedures of removal. Torque value: 1.0~1.4kgf-m Caution Cannot lock the thread of socket bolt.
To this chapter contents 10. Alternator / Starting Clutch AC.G. Flywheel Installation Starting driven gear Install starting driven gear onto one way clutch. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Torque value: 5.0~6.
To this chapter contents 10. Alternator / Starting Clutch AC.G. Set Installation 3 screws Install the AC.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator. Pulse generator screws Right Crankcase Cover Installation Dowel pins Install dowel pins and new gasket. Remove water pump cover. Install right crankcase cover onto the crankcase.
To this chapter contents 10.
Home page Contents 11. Crankcase / Crank Mechanism Diagram ··························11-1 Disassembly of Crankcase················ 11-3 General Information ···························11-2 Crankshaft Inspection ······················· 11-4 Trouble Diagnosis ······························11-2 Assembly of Crankcase····················· 11-6 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 11 0.8~1.
To this chapter contents 11. Crankcase / Crank General Information Operational precautions y This Section concerns disassembly of the crankcase for repair purpose. y Remove following components before disassembling crankcase.
To this chapter contents 11. Crankcase / Crank Disassembly of Crankcase Tensioner Setting plate Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Loosen 2 bolts on the right crankcase. 2 bolts Loosen 8 bolts on the left crankcase. 8 bolts Place right crankcase downward and left crankcase upward. Install crank disassemble tool onto left crankcase. Caution Care should be taken not to damage the contact surfaces.
To this chapter contents 11. Crankcase / Crank Remove crankshaft and wave washer 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. Drive out left crankcase oil seal. Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.
To this chapter contents 11. Crankcase / Crank 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 50 mm 50 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely, smoothly and noiseless. Check the inner ring to see it links firmly on the bearing.
To this chapter contents 11. Crankcase / Crank Assembly of Crankcase Install new bearing and bearing puller onto left crankcase bearing hole. Special tool: L. crank shaft bearing puller SYM-9100100 Crank shaft bearing puller Install crank disassemble tool onto left crankcase. Install left crank shaft puller into crank case disassemble. Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft bearing into left crankcase.
To this chapter contents 11. Crankcase / Crank Hold left crank shaft puller, and turn the shaft puller nut by clutch nut wrench to pull in crank shaft into left crankcase. Crank shaft puller Put wave washer onto right crank bearing. Caution Right flank the wave washer piece certainly must install. Cannot install the wrong position or leak the attire. Otherwise can cause the motorcycle to have the fierce vibration Install 2 dowel pins and new gasket.
To this chapter contents 11. Crankcase / Crank Apply a layer of grease on the lip of oil seal Clean the crankshaft with clean solvent. Install the oil seal in the left crankcase with special tool. Special tool: Crank shaft install socket & oil seal driver Oil seal driver SYM-2341110- HMA RB1 Tensioner Setting plate Install the cam chain tensioner & and tighten the bolts. Torque value: 1.2~1.6kgf-m Install the cam chain. Install the cam chain setting plate.
Home page Contents 12.
To this chapter contents 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. y y y y y y Refill the radiator with distilled water or specified additives. Add coolant to the reservoir. The cooling system can be serviced on the motorcycle.
To this chapter contents 12. Cooling System Trouble Diagnosis for Cooling System The temperature indicated is too high Y A. Stop and waiting for the engine is completely cooled down, open cap to check the capacity of coolant in radiator. A1.Refill the radiator with coolant then check for any leakage? N Water leaking problem N Y B. Turn on main switch and check the water temperature indicator back to zero? Y N B-1. Measure thermo unit to confirm voltage 6V↑? N Replace thermo unit Y Y B-2.
To this chapter contents 12. Cooling System Preceding page E. Keep eng. 3000~4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks? N E-1. Measure thermal switch to confirm voltage be changed (12→0V)? N Replace thermal switch Y Y F. Confirm the cooling fan was convulsion? E-2.
To this chapter contents 12. Cooling System Change of coolant Warning y Never attempt to carry out service work on the cooling system unless the engine is completely cooled down, otherwise, you may get scalded. Remove the reserve tank cap cover, and then remove tank cap. Reserve tank cap Place a water pan under the water pump; loosen the drain bolt to drain out the coolant. Reinstall the drain bolt. Drain bolt Refilling system with coolant and bleeding the air bubbles.
To this chapter contents 12. Cooling System Check reserve tank y Open the inner box lid. y Check the liquid level in the reservoir. y Add coolant to proper level if too low. Caution y The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in the cooling system the refrigerant backflow floods. Viewing window Radiator Check Check for any leakage from weld seam. Blow radiator clean using compressed air.
To this chapter contents 12. Cooling System Disconnect the couplers for the thermo switch and fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Thermo switch coupler Cooling fan coupler Engine coolant inlet pipe Remove reserve tank coolant inlet pipe. Remove the radiator and the cooling fun. Coolant inlet pipe Loosen the cooling fun mounting bolts (3 bolts). Remove thermo switch.
To this chapter contents 12. Cooling System Water Pump Check water pump seal / cooling system divulges inspection y Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. y Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
To this chapter contents 12. Cooling System Check any wear and damage of the mechanical seal and inside seal. Mechanical seal Caution The mechanical seal and inside seal must be replaced as a unit. Water pump mechanical seal driver Replacement of Mechanical Seal Remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase. Special tools: Inner bearing puller Water pump bearing drive Caution Replace a new mechanical seal after removing it.
To this chapter contents 12. Cooling System Install the new inner seal onto the right crankcase. Special tools: Water pump oil seal driver (inner) Install a new outside bearing to the right crankcase cover. Special tools: Water pump bearing driver (6901) Water pump oil seal driver (inner) Water pump bearing driver (6901) Caution y Do not reuse old bearing. It must be replaced with a new one once it has been removed. Mount the water pump shaft and the inner bearing to the right crankcase cover.
To this chapter contents 12. Cooling System Install the seal washer into the rotor. Caution y Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m Water pump rotor Caution y The rotor is left thread. Install the dowel pin and right cover gasket. The rotation water pump rotor, causes the water pump drive shaft scoop channel, aligns the oil pump drive shaft flange, install the right crank case.
To this chapter contents 12. Cooling System Thermostat Thermo sensor Please refer to chapter 17 for inspection of thermo unit. Removal Remove the luggage box and body cover. Drain out the coolant. Remove the thermostat cover. (2 bolts) 2 bolts Remove the thermostat. Inspection Visually inspect thermostat for any damage.
To this chapter contents 12. Cooling System Place the thermostat into heated water to check its operation. Caution y Whenever the thermostat and the thermometer are in contact to the wall of heated water container, the reading displayed is incorrect. If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change, then it must be replaced. Technical Data Valve begins to open Valve stroke 82~95℃ 0.
To this chapter contents 12.
Home page Contents 13.
To this chapter contents 13. Body Cover Maintenance Body covers disassemble sequence: R/L. Handle covers Wind screen garnish Luggage box & seat Handle upper cover Wind screen Rear carrier Front fender Meter visor R/L body cover Front cover Rear fender R/L. side cover Meter panel Rear mudguard Under cover R/L. side cover Front under spoiler Inner box Floor panel y y y y y Be careful not to damage various covers in assembly or disassembly operation.
To this chapter contents 13. Body Cover Handle Cover Remove Loosen the 2 screws from handle upper cover front end. 2 screws Loosen the 2 screws from handle upper cover rear end. Remove right and left handle side cover. 2 screws Remove the handle upper cover cap. Upper cover cap Loosen the 3 screws from the handle upper cover, and then remove handle upper cover. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Each side 2 screws Loosen 8 screws from the wind screen and remove the wind screen. 8 screws Loosen 4 screws from the meter visor and remove the meter visor. 4 screws Loosen 8 screws from the inner box.
To this chapter contents 13. Body Cover Loosen 2 bolts from the front cover under side. 2 bolts Loosen 2 screws and 2 bolts from the front cover upper side. Each side 1 screw Disconnect the headlight, foggy light and winker light couplers. Remove the front cover. Each side 1 bolt Headlight coupler Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Meter Panel Left side Right side Remove Remove wind screen garnish, wind screen, meter visor and front cover. Remove reserve tank cap. Loosen 4screws from right & left side of the meter panel. 4 screws Loosen 2 screws from in side of meter panel. 2 screws Loosen the meter cord coupler. Meter coupler Remove the meter panel. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Inner Box Reserve tank Remove Remove wind screen garnish, wind screen, meter visor, front cover, meter panel, R/L side cover and front under spoiler. Loosen 1 screw from reserve tank stay. 1 screw Loosen 1 screw from fuse box and remove it. Loosen 1 screw from main switch cap and remove the cap. Loosen DC power outlet mounting nut, and remove DC power outlet. 1 screw 1 screw DC power outlet Loosen 1 screw from battery cover and remove it.
To this chapter contents 13. Body Cover Remove the filler pipe cover. Loosen 3 screws of the filler pipe. 3 screws Loosen 2 bolts from inner box under side. Each side 1 bolt Loosen 2 bolts from inside of the inner box. Disconnect the hazard light and foggy light switch couplers. Remove inner box. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Side Cover Remove Loosen 2 screws from the side cover side end. 2 screws Loosen 2 screws from the side cover upper end. 2 screws Remove the side cover. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Front under Spoiler Each side 1 bolt Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover and R/L side cover. Loosen 2 screw and 2 bolts from the front under spoiler upper end. Remove the front spoiler. Installation Install in reverse order of removal procedures. Rear Carrier Remove Loosen 4 bolts from the rear carrier and remove it. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Luggage Box 2 screws Remove Open the seat. Loosen 2 screws from the luggage box rear cover. Disconnect the luggage box light and switch coupler. Remove the luggage box rear cover. Loosen 2 bolts from luggage box front side 2 bolts Loosen 4bolts from luggage box rear side. 4 bolts Remove the luggage box. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel. Each side 1 screw Loosen right and left side screws from rear side of the body cover. Each side 1 screw Disconnect the tail light coupler. Tail light coupler Remove the body cover. Installation Install in reverse order of removal procedures.
To this chapter contents 13. Body Cover Floor Panel Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover, R/L side cover, front under spoiler, inner box, luggage box and body cover. Loosen 4 bolts and 2 screws from floor panel. Each side 2 bolts Remove floor panel. Installation Install in reverse order of removal procedures. Front Fender Remove Loosen 4 screws from front cushion. Each side 2 screws Remove the front fender.
To this chapter contents 13. Body Cover Rear Fender Loosen 4 bolts from rear fender. 2 bolts Remove the rear fender. Installation Install in reverse order of removal procedures.
Home page Contents 14.
To this chapter contents 14. Brake System 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. y The brake caliper can be removed without removing the hydraulic system. y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
To this chapter contents 14. Brake System Trouble Diagnosis Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8. Blocked brake hose 9. Warp/bent brake disk 10. Bent brake lever Hard operation of brake lever 1. 2. 3. 4. 5. Blocked brake system Poor brake caliper Blocked brake pipe Seized/worn master cylinder piston Bent brake lever Uneven brake 1. 2. 3. 4. 5.
To this chapter contents 14. Brake System Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of. Remove the front brake pad cap. Check the brake from behind the brake caliper.
To this chapter contents 14. Brake System Adding Brake Fluid Front brake master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
To this chapter contents 14. Brake System Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay valve the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder. Recommended brake fluid: WELLRUN DOT 3 brake fluid Connect one end of transparent hose to the drain valve, and put the other end into a container.
To this chapter contents 14. Brake System Front Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper. Installation Caliper mounting bolts Install the brake caliper and tighten the mounting bolts. Pad caps Torque: 2.9~3.5kgf-m Caution y Use M8 x 35 mm flange bolt only.
To this chapter contents 14. Brake System Rear Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper. Installation Caliper mounting bolts Install the brake caliper and tighten the mounting bolts. Torque: 2.9~3.5kgf-m Caution y Use M8 x 35 mm flange bolt only.
To this chapter contents 14. Brake System Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: Front brake disk 2.5 mm Rear brake disk 3.5 mm Micrometer Remove the brake disk from wheel. Check the disk for deformation and bend. Allowable limit: 0.30 mm Caution y The dirty brake lining or disk will reduce the brake performance.
To this chapter contents 14. Brake System Remove the rubber pad. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Cir clip Rubber boot Piston Piston Spring 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.
To this chapter contents 14. Brake System Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. 2 bolts Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified torque value. Make sure the hose is installed correctly. Install all wires, hoses, and components carefully so avoid to twisting them together.
To this chapter contents 14.
Contents Home page 15. Steering / Front Wheel / Front Cushion Mechanism Diagram ···························· 15-1 Front Wheel ·········································· 15-5 Operational Precautions ····················· 15-2 Front Cushion ······································ 15-8 Trouble Diagnosis ······························· 15-2 Steering Stem······································· 15-9 Steering Handle ··································· 15-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 2.
To this chapter contents 15. Steering / Front Wheel / 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 5.0 ~ 7.0kgf-m Nut for the steering handle 4.0 ~ 5.0kgf-m Lock nut for the steering handle stem 1.0 ~ 2.0kgf-m Top crown for the steering handle stem 0.2 ~ 0.3kgf-m Locating screw for the speedometer cable 0.15 ~0.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Steering Handle Master cylinder Remove Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake. Holder Loosen the deceleration throttle cable fixing nut. Loosen 1 screw from the acceleration throttle fixing plate. 2 bolts Fixing nut 1 screw Loosen 2 screws from the throttle holder.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Loosen 2 bolts from the master cylinder of the rear brake. Remove holder and master cylinder. Master cylinder Holder 2 bolts Loosen left handle switch connecter. Loosen 2 screws from left side handle switch holder. Remove the right handle switch. 2 screws Switch connecter Loosen handle mounting nut. Remove handle mounting bolt, and then remove the handle. Installation Install handle and align with bolt hole.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Wheel 2 screws Loosen 2 bolts from the front brake caliper and remove it Caution y 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. Loosen screw & remove speedometer cable. Turn loose the axle nut. Speedometer cable Axle nut Pull out the front wheel axle.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Inspection Wheel axle Place the wheel axle on a V block, measure its run out. Service limit: 0.2 mm Bearing Use finger to move the inner ring of each bearing, it shall move smoothly and quietly. Check the outer ring is securely attached on the wheel hub. If the motion of the inner ring of the bearing is not smooth, or noisy and loose when being moved, remove and discard it.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Assembly Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist. collar. Install the right side bearing. Dust seal Dist collar Bearing 6201U Caution y Carefully install the bearing in correct and evenly. y Bearing outer face should be faced up as bearing installation. Dust seal Bearing 6201U Install the brake disk and then tighten the bolts. Torque value: 4.0~4.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Front Cushion 2 bolts Remove Remove front cover, front under spoiler and front fender. Remove front wheel. Remove front brake caliper. Remove speedometer cable. Speedometer cable Loosen 4 bolts from steering stem. Remove the front cushions. 4 bolts Installation Align the cover flange with upper level of the cushion clamp, and then tighten bolts. Torque value: 2.4~3.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Steering Stem Stem mounting nut Steering stem top thread wrench Remove Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Top cone race Top cone race Remove top cone race and steering stem. Caution y Place the steel ball onto a parts container to prevent from missing.
To this chapter contents 15. Steering / Front Wheel / Front Cushion Lubricate the top cone race seat with grease. Screw the cone race in to top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turns. Torque value: 0.25kgf-m Steering lock nut Return 1/2 turns Caution y Check the steering stem that should be rotated freely and no clearance in vertical direction.
Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram ···························16-1 Rear Wheel ········································· 16-3 Operational Precaution ······················16-2 Rear Fork ············································ 16-5 Trouble Diagnosis ······························16-2 Rear Cushion······································ 16-6 Muffler··················································16-3 Mechanism Diagram 11.0~13.0kgf-m 3.5~4.5kgf-m 2.
To this chapter contents 16. Rear Wheel / Rear Fork / 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.
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Muffler Removal Loosen the 2 nuts from exhaust muffler front side. 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler. Installation Install in reverse order of removal procedures. Caution y Replace the front side muffler pipe gasket if worn or deformed. Torque Value: Muffler mounting bolt Muffler mounting nut 3.2 ~ 3.8kgf-m 1.0 ~ 1.
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Remove rear wheel axle nut. 1 nut Remove rear fork and both side collars. Remove the rear wheel. Inspection rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm Installation Install in reverse order of removal procedures. Torque Value: Rear wheel axle nut 11.0~13.0kgf-m Rear cushion under bolt 2.4~3.0kgf-m Rear fork mounting bolt 4.0~5.
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Rear Fork Free play Inspection rear fork bearing Rotate the inner ring of the bearing with a finger. The bearing should move smoothly and quietly. Check the fit of the bearing and rim. Replace the bearing if its motion is not smooth or noisy. Replacement of rear fork bearing Free play Cir clip Remove the bearing lock cir clip. Uses the bearing driver; drive out the bearing.
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Install the bearing lock cir clip. Cir clip Outside collar Bearing (6303UU) Inside collar Rear Cushion Left Upper bolt Removal Remove the luggage box, rear carrier and body covers. Loosen the mounting bolts of the air cleaner (2 bolts). Remove the exhaust muffler (3 bolts, 2 nuts). Remove the under bolts by left and right rear cushions. Remove the upper bolts by left and right rear cushions, and then remove the cushion.
Home page Contents 17.
To this chapter contents 17. Electrical System Maintenance Data Operational precaution y 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.) y The model of the spark plug and the tightening torque. y The ignition timing. y Adjustment of headlight. y Removal and installation of AC generator.
To this chapter contents 17. Electrical System Trouble Diagnosis No voltage y y y y y y y y y Battery discharged The cable disconnected The fuse is blown Improper operation of the main switch Low voltage The battery is not fully charged Poor contact Poor charging system Poor voltage regulator No spark produced by spark plug y The spark plug is out of work y The cable is poorly connected, open or short-circuited y Between AC.G. and C.D.I. y Poor connection between C.D.I.
To this chapter contents 17. Electrical System Battery Removal Loosen 1 screw and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery. Voltage Check Use the digital voltmeter to check the voltage of the battery. Voltage: Fully charged: 12.8V ↑ at 20℃ Undercharged: Below 12.0 V at 20℃ Warning y Keep flames away while recharging. y Charging is completely controlled by the ON/OFF switch on the charger, not by battery cables.
To this chapter contents 17. Electrical System Fuse Fuse circuit diagram Fuse box (Headlight) Fuse 20A Headlight (Hi & Lo-beam) Transistor ignition Auto by-starter Meter Carburetor heater (Ignition) Fuse 15A Winker & hazard control unit (Meter & Operate) Fuse 20A Main switch Meter Horn (Luggage box & Outlet) Fuse 20A Luggage box light Switch Power outlet Open seat motor (Foggy & Fan) Fuse 15A Foggy light Cooling fan (Charge) Fuse 30A Regulator rectifier AC.
To this chapter contents 17. Electrical System Charging System Charging circuit R R Main switch Reg. Rec. Fuse 20A Y R Y B R Y G Y/L Battery R B G Y Red Black Green Yellow AC. G.
To this chapter contents 17. Electrical System Inspection on AC. Generator coil Y1 Remove the luggage box, rear carrier and body covers. Disconnect 3 pin couplers of the generator coil. Connect an ohmmeter to the each terminal end. Check the continuity of the each terminal end, and engine ground with short circuit? If there is no continuity or short circuit, replace the AC. Generator. V Ω Y1 70~80 0.2~0.4 Y2 70~80 0.2~0.4 Y3 70~80 0.2~0.4 And you can check voltage by engine is running.
To this chapter contents 17. Electrical System Inspection on Charging Voltage Voltmeter Ammeter Connect a tachometer. Turn on the headlight to high beam and start the engine. Accelerate the engine to the specified revolution per minute and measure the charging voltage. Specified Charging Current: 1.2 A / 6000 rpm Control Charging Voltage: 14.5 V/1500 rpm Caution y To replace the old battery, use a new battery with the same current and voltage.
To this chapter contents 17. Electrical System Ignition System Ignition circuit diagram Main switch B/G R Side stand switch W/R B Fuse 20A Power relay G L/W R/Y Engine stop switch Resistor R Fuse 15A Ignition coil R Thermo switch G/B W/Y B/Y L/Y G/W Battery Transistor ignition Red Black Green Yellow W L P G R/G R/G AC. G.
To this chapter contents 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: 0.17±10% Ω Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding. Standard resistance: Without cap 9 ± 20% KΩ With cap 14.
To this chapter contents 17. Electrical System Starting System Starting circuit diagram Main switch Front brake switch Fuse 20A Brake light G/Y B R Rear brake switch R Fuse 20A Start relay Y/R G Battery Start switch Side stand switch W/R B/G R B G Y Red Black Green Yellow W L SB O White Blue Sky blue Orange L/W Start motor SB/O Engine stop relay Engine stop switch Side stand lamp Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch.
To this chapter contents 17. Electrical System Disconnect the positive cable of the starter motor. Disconnect the coupler of the relay. Connect an ohmmeter to the large terminal end. Connect the yellow/red cable to the battery positive terminal and the green/yellow cable to the battery negative terminal. Check the continuity of the large terminal end. If there is no continuity, replace the relay. Removal of Starter motor Turns off the main switch Remove the luggage box.
To this chapter contents 17. Electrical System Meters Meter circuit diagram Meter (Ignition) Fuse 15A R O Turn right indicator SB Turn left indicator L High beam indicator L/W Side stand warning light W/B Foggy right indicator Main switch Fuse 20A B Charge indicator REG. REC. R Y/L Eng.
To this chapter contents 17. Electrical System Removal of meter Remove wind screen garnish, wind screen, meter visor, front cover, meter visor. (Refer chapter 13) Disconnect the coupler of the speedometer, and take off the meter panel and meter. Meter coupler Loosen 4 screws from meter panel. Remove the speedometer.
To this chapter contents 17.
To this chapter contents 17. Electrical System Replacement headlight bulbs Remove wind screen garnish, wind screen, meter visor, front cover. (Refer chapter 13) Disconnect the rubber sleeve and the terminal coupler from the headlight. Loosen 1 screw from the headlight bulb setting stay. Remove setting stay and take out the headlight bulb. Replace with new bulb if necessary.
To this chapter contents 17. Electrical System Replacement the front winker light and foggy light bulb Front winker light Remove wind screen garnish, wind screen, meter visor, front cover. (Refer chapter 13) Foggy light Disconnect the rubber sleeve and turn the foggy light bulb seat in C.C.W. direction to remove the bulb seat and bulb. Turn the winker light bulb seat in C.C.W. direction to remove the bulb seat and bulb. Replace with new bulb if necessary.
To this chapter contents 17. Electrical System Replacement the meter bulbs Remove the meter board waterproofing rubber. Indicator bulb Uses the “-“ screw driver turn the indicator bulb seat in C.C.W. direction, and take out the indicator bulb. Uses the round nose pliers turn the illumination bulb seat in C.C.W. direction, and take out the illumination bulb. Specification: Indicator bulb 12V 1.7W Illumination bulb 12V 1.
To this chapter contents 17. Electrical System Switch / Horn 2 blots Main switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below Pin BAT BAT1 BAT2 Position LOCK Main switch coupler OFF ON Wire Color Red Black Blake Replacement of main switch Remove main switch cap. Disconnect the coupler of the main switch and loosen the mounting bolts (3 bolts). Remove the main switch.
To this chapter contents 17. Electrical System High and low beam switch Left handle switch Remove the handle cover and front cover. Disconnect the coupler of left handle switch.
To this chapter contents 17. Electrical System Fuel Unit Fuel unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove right & left side cover. Remove the body cover Remove the floor panel. Disconnect the coupler of the fuel unit. Loosen 4 bolts from fuel unit and remove it. Caution y Great care shall be taken not to damage or bend the float arm of the gauge.
To this chapter contents 17. Electrical System Cooling Fan Thermo Switch The thermo 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 main switch, the fan motor should operate. If the fan motor still fails to run, measure battery voltage between the green and black / blue leads.
To this chapter contents 17. Electrical System Thermo Sensor Thermo sensor Remove the thermo unit. Hang the thermo unit 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 Caution y Wear gloves and goggles when performing this test. Caution y Engine oil should be used as a heating medium as the test temperature must be higher than 100℃.
To this chapter contents 17.
Home page Contents 18. Emission Control System Names of Mechanisms in the Emission Control System······································ 18-1 Function of Mechanisms in the Emission Control System······································ 18-1 Secondary Air Introduction System ··· 18-5 Positive Crankcase Ventilation System (P.C.V.
To this chapter contents 18. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) 1. Construction: y Reduce HC to pollute air. y To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Automatic control fuel cup Vapor hose Vapor purge control solenoid Blow-by hose Air cleaner Active carbon canister Flesh air inlet Engine Flesh air Fuel Fuel vapor Vacuum 2.
To this chapter contents 18. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge Pressure source Active carbon canister Plugged 2) Plug canister vent. 3) Apply 100mmAq into pressure source inlet then plug it.
To this chapter contents 18. Emission Control System Catalytic Converting System (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO2, H2O, N2 gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.
To this chapter contents 18. Emission Control System Secondary Air Introduction System 4. Construction Secondary air filter Carburetor Intake valve Flesh air Vacuum hose Engine Cylinder head Reed valve Flesh air Mixture gas First burn exhaust Purged exhaust gas Vacuum Exhaust valve Air injection cut valve Exhaust pipe This system contained AICV (air Injection Cut Valve), R/V (Reed Valve) and other intake components. 2.
To this chapter contents 18. Emission Control System 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject cut valve (AICV). b. System hose leakage. c. abnormal ignition timing. d. lean mixture gas. e. abnormal fuel supply. Rich Exhaust Gas: a. plugged air-jet by dirty carburetor. b. poor adjustment of air adjustment screw. c. poor reed valve. d. System hose leakage or plugged. Noise: a. System hose leakage. b. Loosen secondary air injection filter. c.
To this chapter contents 18. Emission Control System 1. Warm-up test: y Start engine. y Remove the air injection filter. y Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet Reed valve Air filter Secondary air inject filter Exhaust muffler Cylinder head Engine y If no sound is heard, remove air cut-off valve, and connect a vacuum meter to air pipe to check for leakage.
To this chapter contents 18. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Exhaust pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: y Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.
To this chapter contents 18. Emission Control System Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1. Visual inspect the carbon canister and hoses for damage. 2. Leaking check. 3. Function test of the purge control solenoid. Catalytic converter 1. Check if exhaust gas content is within standard. 2.
To this chapter contents 18. Emission Control System Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2) Clean the carburetor (SJ, MJ, SAJ, MAJ) Replace the carburetor Keep the CO value in 1.5~4.5% (note 3) by adjusting the carburetor. Clean the carbon deposit in cylinder and combustion chamber.
Home page Contents 19.
Home page 19.
