FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Quad Lander 250 SERVICE MANUAL
Homepage Contents FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG Quad Lander 250 ATV. 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 ATV, Quad Lander 250, 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 Quad Lander 250 ATV. 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 ~ 1-18 GENERAL INFORMATION 1 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2 3-1 ~ 3-8 LUBRICATION SYSTEM 3 4-1 ~ 4-12 FUEL SYSTEM 4 5-1 ~ 5-6 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 ~ 9-12 FINAL DRIVING MECHANISM 9 10-1 ~ 10-10 ALTERNATOR 10 11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11 12-1 ~ 12-12 COOLING SYSTEM 12 13-1 ~ 13-14 BODY COVER
Home page SERIAL NUMBER Frame number Engine number Contents
Homepage Contents 1. GENERAL INFORMATION Symbols and Marks............................. 1-1 Specifications..................................... 1-10 General Safety ..................................... 1-2 Torque Values .................................... 1-11 Service Precautions ............................ 1-3 Troubles Diagnosis............................ 1-13 Specifications ...................................... 1-9 Lubrication Points .............................
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.
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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 5 mm screw 6 mm screw、SH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut Tighten Torque 0.35~0.
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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.
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To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS Engine can be started but motorcycle can not be moved.
To this chapter contents 1. GENERAL INFORMATION G.
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To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines Fuel tank Remove seat.and 2 bolts Loosen 2the screws Remove the tank cover Check all lines, and replace it when they are deterioration, damage or leaking Fuel hose Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it. Vacuum hose Fuel filter Acceleration Operation Have a wide open of throttle valve as handle in any position and release it to let back original (full closed) position.
To this chapter contents 2. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. 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.
To this chapter contents 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition cable Caution y Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. y 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 ATV with main stand and warm up engine.
To this chapter contents 2. MAINTENANCE INFORMATION Ignition System Caution y C.D.I ignition system is set by manufacturer so it can not be adjusted. y Ignition timing check procedure is for checking whether CDI function is in normal or not. Connect tachometer and ignition light. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition light. Then, it is means that ignition timing is correct. Increase engine speed to 6000 rpm to check ignition advance degree.
To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Clamp strips Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Remove 9 bolts of the engine left side cover and the cover. 9 bolts Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it. Width limit: 22.
To this chapter contents 2. MAINTENANCE INFORMATION Brake System (Disk Brake) 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 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. Front brake Lining Caution y To check front brake lining must be remove front wheel first. y It is not necessary to remove brake hose when replacing the brake lining. Brake lining wear limitation groove Brake disk Brake Lining Replacement (refer chapter 14) Make sure the brake lining condition.
To this chapter contents 2. MAINTENANCE INFORMATION 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. y Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting. Adjust screw Clutch Disc Wear Clutch weight Run the ATV and increase throttle valve opening gradually to check clutch operation.
To this chapter contents 2. MAINTENANCE INFORMATION Steering Handle 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 check the handle top bearing. Wheel/Tire Caution Tire pressure check should be done as cold engine.
To this chapter contents 2. MAINTENANCE INFORMATION Special Tools List NAME Rocker arm pin puller NAME NO SYM-1445100 NO NAME Tappet adjuster NAME NO SYM-9001209 NO NAME Left crank seal driver NAME NO SYM-1332100-HMA NO NAME Bearing driver 6205LLU NAME NO 2-12 SYM-9100410/440 NO Tappet adjusting wrench SYM-9001200 NO Valve cotter remove & assembly tool SYM-1471110/20 SYM-2341110-HMA Rear axle bearing driver RA1 Tappet adjusting wrench SYM-1472100 NAME AC.G.
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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: 750c.c. 650c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) 單位:mm Items Standard (mm) Limit (mm) 0.15 0.
To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the ATV 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 ATV, 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: 650c.c. when replacing Make sure that the join bolt washer can be re-used, and install the bolt. Torque value: 3.5~4.
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Home page Contents 4. FUEL SYSTEM Mechanism Diagram ............................ 4-1 Throttle Valve .......................................4-6 Precautions in Operation..................... 4-2 Float Chamber......................................4-7 Trouble Diagnosis................................ 4-3 Adjustment of Idle Speed....................4-9 Carburetor Remove / Install ................ 4-4 Fuel Tank ..............................................4-10 Air Cut-Off Valve ........................
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.
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To this chapter contents 4. FUEL SYSTEM Carburetor Remove / Install Removal Drain out fuel in the float chamber. Drain bolt Loosen the choke cable fixed iron sheet screw from plate. Remove the choke cable. 1 screw Choke cable Vacuum pipe Fuel pipe Disconnect the fuel hose. Release the clamp strip of air cleaner. Clamp Remove the carburetor upper parts from the carburetor. Release the 2 nuts of carburetor insulator, and then remove the carburetor.
To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. O-ring Spring Air cut-off valve Cover Inspection Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly. Check the vacuum pipe o-ring is in normal. Assembly Install in reverse order of removal procedures.
To this chapter contents 4. FUEL SYSTEM Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Throttle valve Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Spring Assembly Place the fuel needle onto the throttle valve and clip it with needle clamp. Install the sealed cap, carburetor upper part, and throttle valve spring.
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 Float valve Fuel level plate Pin Inspection Pin 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 Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw. y Before removing adjustment screw, turn it all the way down and note the number of turns. y Does not turn adjust screw forcefully to avoid damaging valve seat face. Needle jet Clean jets with cleaning fluid. Then use compressed air to blow the dirt off.
To this chapter contents 4. FUEL SYSTEM Adjustment of Idle Speed Parking brake 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 ATV 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 4 bolts Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter 13) Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Caution ˙Do not bend the float arm of fuel unit ˙Do not fill out too much fuel to fuel tank. Coupler Fuel unit inspection (Refer to electrical equipment chapter 17).
To this chapter contents 4. FUEL SYSTEM Air Cleaner Clamp Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts). Installation Install the tank in the reverse order of removal. Clamp 4 bolts 4 hooks Cleaning air cleaner element Remove the air cleaner cover (4 catch hooks). Remove element mounting screw.
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Home page Contents 5. ENGINE REMOVAL Precautions in Operation ..................... 5-1 Removal of Engine ............................... 5-2 Engine Installation ................................ 5-6 Precautions in Operation General Information y The engine has to be supported with special service tools that can be lifted or adjustable. y Engine shall be removal in the conditions of necessary repair or adjustment to the only. y The following parts can be serviced as engine mounted on frame: Carburetor.
To this chapter contents 5. ENGINE REMOVAL Removal of Engine Negative Remove the seat. Remove battery negative post (-). Remove battery positive (+) post. Remove front fender and the footrest (refer chapter 13). Positive Remove starter motor wire. Starter motor wire Remove the spark plug cap. Spark plug cap Disconnect A.C. Generator wire couplers. A.C.
To this chapter contents 5. ENGINE REMOVAL Remove muffler protect (2 bolts). 2 bolts Loosen muffler front side bolt. 2 bolts Remove 2 bolts, and then remove the exhaust muffler. 2 bolts Remove 2 nuts, and then remove exhaust pipe.
To this chapter contents 5. ENGINE REMOVAL Loosen 1 screw and disconnect the choke cable. 1 screw Choke cable Remove fuel pipe and vacuum pipe. Release the clamp strip of air cleaner duct. Vacuum pipe Fuel pipe Clamp Disconnect the carburetor upper parts and cable. Release the 2 nuts of carburetor insulator, and then remove the carburetor. 2 nuts Release the clamp strips of left crankcase cover ducts, and then remove the ducts.
To this chapter contents 5. ENGINE REMOVAL Remove coolant drain bolt, and drain out coolant. Remove coolant inlet hoses from water pump. Water hoses clamp Drain bolt Remove the thermo-sensor wire, by-pass pipe and coolant outlet hose. By-pass pipe Outlet hose Thermo-sensor wire Remove gear change lever (1 bolt). 1 bolt Remove change switch couplers.
To this chapter contents 5. ENGINE REMOVAL Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box. Speedometer cable 3 bolts Caution The socket bolt is provided with left turn thread. Socket bolt Remove 2 bolts, and then remove the drive sprocket fixing plate, drive chain and drive sprocket. 2 bolts Remove the rear side engine hanger mounting nuts and bolts.
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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 2 nuts Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt 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). Thermostat bolts Tensioner bolts Remove Air Injection system (AI) pipe mounting bolts. Remove spark plug.
To this chapter contents 6. CYLINDER HEAD/VALVE 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. Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms.
To this chapter contents 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. 4 Nuts 2 bolts Gasket Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution y Do not damage the matching surfaces of cylinder and cylinder head.
To this chapter contents 6. CYLINDER HEAD/VALVE 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. 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.
To this chapter contents 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm. Service Limit: Replace when it is less than 11.936 mm. Calculate the clearance between the rocker arm shaft and the rocker arm. Service Limit: Replace when it is less than 0.10 mm.
To this chapter contents 6. CYLINDER HEAD/VALVE Valve guide Caution 5.0 mm valve guide reamer Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide. Service Limit: IN→0.08 mm EX→0.
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 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 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.
To this chapter contents 6. CYLINDER HEAD/VALVE 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. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.
To this chapter contents 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution Timing mark 2 bolts Make sure timing marks are matched. Install cylinder head side cover (3 bolts). Install thermostat (2 bolts). 3 bolts Thermostat bolts Loosen auto tensioner adjustment bolt and remove bolt and spring.
To this chapter contents 6. CYLINDER HEAD/VALVE Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder Install and tighten spark plug Torque value: 1.0~2.0kgf-m 4 bolts Spark plug Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected. Install the engine onto frame (refer chapter 5).
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 1.0~1.4kgf-m 7 0.8~1.
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. UA25A 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 Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily. 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.
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 Clamp strips Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket. 9 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 2 bolts Remove 2 bolts to remove left crankcase cover bearing setting plate. 9 bolts 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. Install drive belt onto driven pulley. z Driven face z 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. Remove movable drive face comp and drive face Movable drive face boss from crankshaft. Crankshaft Remove 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 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. Movable drive face Drive face boss Crank shaft Press down Driven pulley installation 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 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.
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: 97.4 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 Spring Driving plate 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. Snap ring Clutch weight Check if shock absorption rubber is damage or deformation. Replace it if necessary.
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 Oil seal O-ring Guide pin Install the collar.
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To this chapter contents 9. TRANSMISSION Precautions in operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 750c.c. (650c.c. when replacing) Item Standard value Limit (mm) OD of shift fork shaft 11.982~12.000 mm 11.970 mm ID of shift fork 12.016~12.043 mm 12.010 mm 5.930~6.000 mm 5.730 mm Shift fork claw thickness Torque value Gear box cover Gear oil drain bolt Gear oil fill bolt 2.6~3.0kgf-m 1.1~1.5kgf-m 3.5~4.
To this chapter contents 9. FINAL DRIVING MECHANISM Disassembly of Transmission Remove gear change lever (1 bolt). 1 bolt Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box. Speedometer cable 3 bolts Caution The socket bolt is provided with left turn thread. Socket bolt Remove 2 bolts, and then remove the drive sprocket fixing plate, drive chain and drive sprocket.
To this chapter contents 9. TRANSMISSION Remove gear box cover bolts (9 bolts) and then remove the cover. 9 bolts Remove shift drum catch ball, spring and bolt. Shift drum fixed catch bolt Shift drum Remove shift spindle, shift fork shaft, shift fork and shift drum. Shift fork shaft and fork Remove final shaft, counter shaft and reverse shaft.
To this chapter contents 9. FINAL DRIVING MECHANISM Remove drive shaft bearing setting plate (1 bolt). Bearing setting plate Remove the drive shaft. Special tool: Shaft protector Remove gasket and dowel pin. Caution y If non- essential do not remove the drive shaft from the case upper side. y If remove the drive shaft from the gear box, then its bearing and oil seal has to be replaced.
To this chapter contents 9. TRANSMISSION Inspection of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Measure the outer diameter of shift fork shaft, and replace it if it exceed service limit. Service limit: 11.970 mm Measure the inner diameter of shift fork, and replace it if it exceed service limit. Service limit: 12.
To this chapter contents 9. FINAL DRIVING MECHANISM Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. 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.
To this chapter contents 9. TRANSMISSION Bearing Replacement Inner bearing puller Caution y Never install used bearings. Once bearing removed, it has to be replaced with new one. Crankcase side Remove drive shaft bearing setting plate, and then remove drive shaft bearing from left crankcase using following tools. Remove reverse shaft bearing and counter shaft bearing from left crankcase using following tools. Remove drive shaft oil seal.
To this chapter contents 9. FINAL DRIVING MECHANISM Install drive shaft. Special tool: Drive shaft puller Drive shaft and oil seal install bush Clutch nut wrench Clutch nut wrench Drive shaft and seal install bush Drive shaft puller Apply with grease onto new drive shaft oil seal lip, and then install the oil seal. Special tool: Drive shaft and oil seal install bush Install drive shaft bearing setting plate (1 bolt).
To this chapter contents 9. TRANSMISSION Remove final shat out side bearing. Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearing and bearing driver into gear box cover outer side. Install the universal bearing puller and bearing driver. Inner bearing puller Universal bearing puller Bearing driver Turn the universal bearing puller to install drive shaft bearing.
To this chapter contents 9. FINAL DRIVING MECHANISM Re-assembly of Final Driving Mechanism Oil seal Apply with grease onto the oil seal lip of final driving shaft. Install counter shaft, reverse shaft and final shaft onto gear box. Reverse shaft Final shaft Drive shaft Counter shaft Shift drum Install shift drum, shift fork and fork shaft onto gear box. Shift fork shaft and fork Shift spindle Install shift drum fixed catch ball, spring and bolt onto gear box.
To this chapter contents 9. TRANSMISSION Align the position mark on the shift spindle sprocket with that of shift drum, and then install shift spindle. Install dowel pins and new gasket. Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4kgf-m Install the shift spindle bracket, drive chain protector, speedometer gear box and gear change lever. Add gear oil. Gear oil quantity: 750c.c.
Home page Contents 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram ··························· 10-1 Flywheel Removal ································ 10-4 Precautions in Operation···················· 10-2 Starting Clutch ····································· 10-5 Right Crankcase Cover Removal ······· 10-3 Flywheel Installation···························· 10-7 A.C.G. Set Removal····························· 10-3 A.C.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 5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 11 bolts Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. Water pump cover bolts 2 screws A.C.G. Set Removal Remove 2 mounted screws from pulse generator and then remove it.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Check the oil seal for wear or damage. it if necessary. Replace Oil seal Install a new one bearing (6201LU) by bearing driver. Special tool: Bearing driver Bearing driver Flywheel Removal Remove right crankcase cover. Remove left crankcase cover. Hold the flywheel by drive face with universal holder. Remove flywheel nut.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Remove starter reduction gear and shaft. Pull out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Flywheel puller Remove flywheel and starting driven gear. flywheel puller 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.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install starting clutch driven gear onto one way clutch. 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.) One way clutch removal Starting driven gear Remove starting driven gear. 3 socket bolts Remove 3 socket bolts, and then remove one way clutch.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH One way clutch Installation 3 socket bolts Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Starting driven gear Install starting driven gear. Flywheel Installation Groove 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.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install reduction gear shaft and reduction gear. Reduction gear A.C.G. Set Installation Wire 2 bolts Install the A.C.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. 3 screws Right Crankcase Cover Installation Install dowel pin and new gasket.
To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install right crankcase cover (11 screws). Install the dowel pin, new gasket and water pump cover onto crankcase cover. 11 bolts Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover.
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Home page Contents 11. CRANKCASE / CRANK Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3 General information ···························11-2 Crankshaft Inspection ······················· 11-5 Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m 11 0.8~1.2kgf-m Eng. Oil drain bolt 3.5~4.
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 Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Cam chain setting plate Loosen 2 bolts on the right crankcase. 2 bolts Loosen 11 bolts on the left crankcase. 11 bolts Place right crankcase downward and left crankcase up. Tap the left crankcase with a plastic hammer to remove it. Caution Care should be taken not to damage the contact surfaces.
To this chapter contents 11. CRANKCASE / CRANK Remove balance shaft from right 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. Drive out left crankcase oil seal.
To this chapter contents 11. CRANKCASE / CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank 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.
To this chapter contents 11. CRANKCASE / CRANK Check balance shaft bearing Balance shaft bearings Check bearings on right and left crankcase. Rotate each bearings 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.
To this chapter contents 11. CRANKCASE / CRANK Install 2 dowel pins and new gasket. Dowel pins Install the left crankcase onto the right crankcase. Tighten 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m 11 bolts Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.
To this chapter contents 11. CRANKCASE / CRANK Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. By oil seal driver (27×42×7), oil seal will knock into located. Special tool: Oil seal driver (27×42×7) Install the tensioner and tighten the pivot bolt. Torque value: 0.8 ~1.2kgf-m Install the cam chain. Install the cam chain setting plate.
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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 ATV.
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 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: 0.9-0.
To this chapter contents 12. COOLING SYSTEM Check reserve tank y Remove the front center cover, and then remove reserve tank filler cap. y Check the liquid level in the front fender right side. Add coolant to proper level if too low. y Reinstall the reserve tank filler cap. Upper Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in the cooling system the refrigerant backflow floods.
To this chapter contents 12. COOLING SYSTEM Loosen the radiator 4 bolts. Remove coolant upper side pipes. Coolant inlet pipe 4 bolts Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. Coolant outlet pipe Thermo switch coupler Disassembly Loosen the 3 bolts from the fan duct, and then remove the fan duct. Loosen 3 screws from the fan motor, and take off the fan motor. Remove nut to remove the fan from fan motor.
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. Replacement of Mechanical Seal Water pump bearing driver 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 driver 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 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 impeller. Caution Washer must be replaced together with the mechanical seal. Install the impeller onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m Water pump rotor Caution The impeller is left thread. Install the dowel pin and right cover gasket. The rotation water pump impeller, 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 Temperature sensor By-pass pipe Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) 2 Bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation. Caution Whenever the thermostat and the thermometer are in contact to the wall of heated water container, the reading displayed is incorrect.
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To this chapter contents 13. BODY COVER Maintenance Body covers disassemble sequence: Handle cover R/L Lower side covers Rear carrier Handle protect cover R/L Side covers R/L Lower side covers Front center cover Front center cover R/L Side covers R/L Footrests Front fender Rear fender R/L Side grilles Rear bumper Tail cover y y y y y Be careful not to damage various covers in assembly or disassembly operation. Never injure hooks molded on the body covers.
To this chapter contents 13. BODY COVER Handle front cover / Meter cover Remove Loosen 4 bolts from handle cover right and left side. 4 bolts Meter couplers Remove couplers of meter. Remove speedometer cable, and then remove handle cover, meter cover and meter. Speedometer cable Disassembly Remove 4 screws of meter stay and meters.
To this chapter contents 13. BODY COVER Remove meter stay and meters. Remove 3 screws and disassembly handle cover and meter. Installation Install in reverse order of removal procedures. 3 Screws Handle protect cover Loosen 2 bolts from handle protect cover, and then remove handle protect cover. Installation Install in reverse order of removal procedures. 2 bolts Front center cover Remove Loosen 2 screws from the front center cover.
To this chapter contents 13. BODY COVER Fuel tank cover Remove Remove front center cover. 2 screws Remove seat. Remove fuel tank cap. Fuel tank cap Remove 1 bolt, and then remove fuel tank cover. Installation Install in reverse order of removal procedures.
To this chapter contents 13. BODY COVER Front fender Remove Remove seat. Remove fuel tank cap and fuel tank cover. Loosen the two bolts of front fender rear side. 2 bolts Remove 1 screw, and then remove fixed support catch. 1 screw Loosen the 6 screws, which connect the front fender and side lower covers, these 6 screws just be twin the front fender two side. 6 screws Remove right and left side lower covers rear side screws (each side 3 screws), and then remove side lower covers.
To this chapter contents 13. BODY COVER Remove right and left side covers (each side 1 screw). 1 screw Loosen the front fender two side bolts (each side 1 bolt). 1 Bolt Headlight coupler Remove headlight, front winker light and power outlet couplers. Winker coupler Remove front fender under side bolts (each side 1 bolt).
To this chapter contents 13. BODY COVER Remove front fender front side bolts (2 bolts). 2 Bolts Remove the left crankcase cover duct. Duct Remove front fender upper bolt, and then remove front fender and headlight. 1 Bolt Disassembly Remove 3 screws to remove front emblem.
To this chapter contents 13. BODY COVER Remove headlights inner side 4 screws. Each side 2 screws Remove headlights front side 4 screws, and then remove headlights. 4 screws Remove winker lights 4 screws, and then remove winker lights. Each side 2 screws Remove 8 screws, and then remove right and left grille.
To this chapter contents 13. BODY COVER Remove power outlet setting nut, and then remove power outlet. Installation Install in reverse order of removal procedures. Setting nut Rear carrier Remove Loosen 4 bolts from the rear carrier. Remove the rear carrier. Installation Install in reverse order of removal procedures.
To this chapter contents 13. BODY COVER Rear fender Remove rear carrier. Pull the “Seat Release Bar” up in order to remove the seat. This seat release bar is under the rear side of the rear fender. Seat release bar Loosen the 6 screws, which connect the front fender and side lower covers, these 6 screws just be twin the front fender two side. 6 screws Remove right and left side lower covers rear side screws (each side 3 screws), and then remove side lower covers.
To this chapter contents 13. BODY COVER Remove rear fender front side bolts and screws (each side 1 screw and 1 bolt). Each side 1 bolt Each side 1 screw Remove battery, CDI unit, start relay and fuse box. Remove rear fender upper side 5 bolts. 5 bolts Loosen the 2 bolts, which connect the rear tender and frame, these 2 bolts just below the rear fender light coupler side. Each side 1 bolt Loosen the 2 bolts, which connect the rear tender and frame, these 2 bolts just below the rear fender rear side.
To this chapter contents 13. BODY COVER Disassembly 2 screws Remove rear fender and rear bumper upper side 2 screws. Remove rear fender and rear bumper inner screws (each side 2 screws). Remove rear bumper and taillights. Each side 2 screws Remove tail cover and rear bumper 6 screws, and then remove tail cover. Remove license light 2 screws, and then remove license light. 6 screws 2 screws Loosen the 10 screws, and then remove taillights (each side 5 screws).
To this chapter contents 13. BODY COVER Footrest Remove Loosen the 6 bolts, which connect the footrest and frame, these 6 bolts just be twin under the footrests. 2 bolts 1 bolt Loosen the 4 bolts, and then remove footrest bars and footrests. These 4 bolts just are the right and left footrests. Installation Install in reverse order of removal procedures.
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To this chapter contents 14. FRONT BRAKE & FRONT WHEEL 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. FRONT BRAKE & FRONT WHEEL Trouble Diagnosis Soft brake lever 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining/disk Low brake fluid Blocked brake hose Warp/bent brake disk 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 Hard steering 1.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel axle cover (4 screws). 4 screws Remove the front wheel nuts, and then remove front wheels. Installation Install the front wheel and tighten the nuts. Torque: 2.4kgf-m 4 nuts Front Wheel Hub Removal Remove front brake caliper (2 bolts). 2 bolts Remove cotter pin, wheel hub nut and washer.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Inspection Wheel hub Check bearings on wheel hub. 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 wheel hub. 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. Brake disk Disassembly Collar Inner bearing puller Caution y Never install used bearings.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove 4 socket bolts, and then remove the brake disk from wheel hub. 4 bolts Assembly Bearing driver Install brake disk. Install new inner side bearing and seal into front wheel hub. Install front wheel hub bearing inner spacer. Install new out side bearing and seal into front wheel hub. Special tool: Bearing driver (6203) Oil seal drive (24×35×7) Installation Wheel hub nut Install the front brake disk to the wheel hub.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL 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. Check the brake from behind the brake caliper.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid 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. FRONT BRAKE & FRONT WHEEL Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate 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 Pressure control valve Air-bleed must from pressure control valve fist.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Brake Caliper Brake hose bolt 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 bolts and the caliper. 2 bolts Inspection Make sure the brake linings condition. Replace the linings if the brake linings wear limitation groove close to the brake disk. Brake lining replacement Remove two guide pins.
To this chapter contents 14. FRONT BRAKE & FRONT WHEEL 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: 2.5 mm Micrometer Remove the brake disk from wheel hub. 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. FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Cir clip Rubber boot Piston Piston cup 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. FRONT BRAKE & FRONT WHEEL Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. 2 socket bolts Install the brake lever, and connect leads to brake light switch. Connect brake hoses with 2 new washers. Tighten the brake hose bolt to the specified torque value. Torque: 3.5kgf-m Make sure the hose is installed correctly.
To this chapter contents 14.
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To this chapter contents 15. STEERING / FRONT SUSPENSION Operational Precautions Torque Values Handlebar upper holder bolt Handlebar under holder nut Steering shaft holder bolt Steering shaft nut Steering tie-rod nut Knuckle nut Tie rod lock nut Suspension arm nut Front cushion mounting nut 2.4kgf-m 4.0kgf-m 3.4kgf-m 5.0kgf-m 5.0kgf-m 5.0kgf-m 3.6kgf-m 5.0kgf-m 4.6kgf-m Trouble Diagnosis Hard to steer Front suspension noise y y y y y y Loose front suspension fasteners. y Binding suspension link.
To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter 13) Loosen the socket bolts for the front brake master cylinder, and remove front brake master cylinder. Handle protect cover brocket bolts Caution Do not let foreign materials enter into the cylinder. Master cylinder bolts Remove 2 screws, and then remove throttle hosing holder and throttle hosing.
To this chapter contents 15. STEERING / FRONT SUSPENSION Loosen 2 screws, and then remove handle left switch and choke hosing. 2 screws Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. 4 socket bolts Remove 2 nuts to remove handle under holder and meter bracket. 2 Nuts Installation Install in reverse order of removal procedures. Torque value: Handlebar under holder nut Handlebar upper holder bolt 15-4 4.0kgf-m 2.
To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Shaft Tie-rod nuts Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod. Cotter pin Remove the cotter pin below steering shaft, and remove steering shaft nut and washer. Steering shaft nut Cotter pin Bend out the steering shaft holder nut fixed plate. Loosen 2 bolts, and then remove steering shaft holder, nut fixed plate, pressed plate and steering shaft.
To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Tie-Rod Tie-rod nuts Remove Remove cotter pin and tie-rod nut from steering shaft side. Cotter pin Remove cotter pin and tie-rod nut from wheel side. Tie-rod nuts Cotter pin Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly.
To this chapter contents 15. STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Remove cotter pin and tie-rod nut, remove tie rod. Tie-rod Nut Cotter pin Universal holder Remove cotter pin and ball joint nut. Remove upper and under ball joints by ball joint driver. Remove the knuckle. Special Tool：ball joint driver Ball joint Ball joint Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking.
To this chapter contents 15. STEERING / FRONT SUSPENSION Front Cushion Nut Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion upper bolt nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque value: Front cushion nut 4.
To this chapter contents 15. STEERING / FRONT SUSPENSION Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Suspension arm nuts and bolts Loosen upper suspension arm nuts, remove swing arm bolts. Remove upper suspension arm. Suspension arm nuts and bolts Loosen under suspension arm nuts, remove swing arm bolts. Remove under suspension arm. Inspection Inspect the suspension arm, ball joint and bush for damage or bending.
To this chapter contents 15. STEERING / FRONT SUSPENSION Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully to move the vehicle back, let the wheels turn 180 degree, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks.
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To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION 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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Trouble Diagnosis Soft brake lever 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining/disk Low brake fluid Blocked brake hose Warp/bent brake disk Bent brake lever Vibration or Wobble 1. Axle is not tightened well 2. Bent rim 3. Axle bearings are worn 4. Faulty tires 5. Rear axle bearing holder is faulty Hard Suspension 1.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Removal Raise the rear wheels off the ground by placing a jack or other support under the frame. Remove rear axle cover (4 screws). 4 screws Remove the rear wheel nuts, and then remove rear wheels. Installation Install the rear wheel and tighten the nuts. Torque: 2.4kgf-m 4 nuts Rear Wheel Axle Connecter Wheel hub nut Removal Remove cotter pin, rear wheel axle connecter nut and washer.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Axle Remove right and left rear wheel, wheel connecter. Remove 2 bolts, and then remove rear brake caliper. 2 bolts Remove 2 bolts and 1 nut, and remove drive chain cover. 2 bolts 1 nut Remove 4 bolts to remove rear under protect. Front side 2 bolts Rear side 2 bolts Remove drive chain lock clip, master link, and then remove drive chain.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove 4 nuts, and remove driven sprocket. Bend out the rear axle nut fixed plate. 4 nuts Bend out the rear wheel axle holder nut fixed plate. Fixed plate Remove rear wheel axle nuts. Special tool: Rear axle nut wrench (55mm) Remove rear brake disk bracket and disk.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove rear wheel axle and driven sprocket holder. Driven sprocket holder Inspection Check bearings on rear wheel axle bearing seat. 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 bearing seat. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Installation Install rear wheel axle and driven sprocket holder. Driven sprocket holder Install rear brake disk bracket and disk. Brake disk bracket Install rear wheel axle nuts, rear axle nut fixed plate and tighten the nuts. Torque: 9.2kgf-m Special tool: Rear axle nut wrench (55mm) Rear axle nut torque wrench Torque wrench After tightened the axle nut, bend the rear axle nut fixed plate.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Install driven sprocket, drive chain, drive chain cover and brake caliper. Moving direction Master link Caution y Note the chain lock clip direction. Install rear wheel shaft connecter, rear wheel. Lock clip Driven sprocket inspection Check the condition of the driven sprocket teeth. Replace the sprocket if it worn. { X Caution y The drive chain, drive sprocket and driven sprocket must be also inspected for wear.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION 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. Check the brake from behind the brake caliper.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Adding Brake Fluid Fluid cup 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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate 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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Brake Caliper Brake hose bolt 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 bolts and the caliper. 2 bolts Inspection Make sure the brake linings condition. Replace the linings if the brake linings wear limitation groove close to the brake disk.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION 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: 2.5 mm Micrometer Remove the brake disk from rear wheel axle. 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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder B Place a container under the brake master cylinder, remove fluid hose clamp, and drain out the brake fluid. Loosen the brake hose bolt and finally remove the brake hose. 2 bolts Hose clamp Remove the E type clip, and remove brake push rod pin. Remove the master cylinder socket bolts and the master cylinder. E type clip Disassembly Remove the rubber boot. Remove the cir clip.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 13.954 mm Foot brake 15.850 mm Master Cylinder Assembly Caution y It is necessary to replace the whole set comprising piston, spring, piston cup, and cir clip. y Make sure there is no dust on all components before assembling.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder B Install the master cylinder bolts and the master cylinder. 2 bolts Hose clamp Install brake push rod to the brake pedal, and install pin and E type clip. Lock nut Adjustment nut Caution To adjustment brake pedal, you must be removed push rod pin fist. Loosen lock nut, and turn adjustment nut and push rod bracket to adjustment brake free play.
To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Cushion Nut Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Rear cushion under bolt Remove rear cushion upper bolt, and then remove rear cushion. Installation Install rear cushion, and install rear cushion upper bolt. Install rear cushion under bolt, and install nut. Tighten the rear cushion upper bolt and under nut to the specified torque value. Torque: 4.
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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.
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To this chapter contents 17. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery... Clamp Voltage Check Use the digital voltmeter to check the voltage of the battery. Voltage: Fully charged: 13.0~13.2 V at 20℃ Undercharged: Below 12.3 V at 20℃ Charging Connect the positive terminal (+) of the charger to the battery positive terminal (+).
To this chapter contents 17. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Fuse 20A Red Black Yellow Yellow Yellow Battery Regulator rectifier AC. Generator 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.
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 + 0.5 V / 2000 rpm Caution Fuse connector Caution y Before conducting the inspection, be sure that the battery is fully charged.
To this chapter contents 17. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Main switch connection Battery connection Charging coil Check Points Standard Value R–B Battery voltage (ON) R–G Battery voltage Y–Y 0.17 ~ 0.8Ω 2 couplers If the readings measured are not normal, check parts in the circuit.
To this chapter contents 17. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram Shift gear control unit B R G W Y L CDI. Unit B/W G G/W Black Red Green White Yellow Blue B/Y G W/B Fuse 15A Ignition coil B L/Y Main fuse 30A Spark plug Battery Main switch G Pulse generator C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side.
To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Ignition Coil 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 ± 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 ± 10% With cap: 7.
To this chapter contents 17. ELECTRICAL SYSTEM Starting System Starting circuit diagram Shift gear control unit Fuse 15A W/B B R BR/Y Main switch G/W G Main fuse 30A G/R Brake switch F N R Battery G/Y Change switch Y/B B R G W Y BR Black Red Green White Yellow Brown Starter relay Y/R Starter motor G Starter switch G/Y Brake light Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch.
To this chapter contents 17. ELECTRICAL SYSTEM Removal of Starter motor Negative Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. Loosen the lock bolts and remove the starter motor. 2 Bolts Installation of Starter motor Install in reverse order of removal procedures.
To this chapter contents 17. ELECTRICAL SYSTEM Meters Removal Loosen 4 bolts of the meter stay. Each side 2 bolts Remove the front center cover, and then remove meter couplers and main switch coupler. Remove speedometer cable. Meter set couplers Main switch coupler Remove speedometer cable, and then remove meter set, main switch and handle cover Speedometer cable Remove 4 nuts and meter wire, and then remove speedometer and fuel meter.
To this chapter contents 17. ELECTRICAL SYSTEM Light / Bulb Replacing Bulb for Headlight Remove 4 screws for the headlight cover, and remove the cover. Adjustment screw 4 screws Loosen headlight bulb setting plate screw. 1 screw Remove bulb setting hook. Take out the bulb connector and the bulb. Replace with new bulb if necessary. (H7 12V 55W) Hook 1 screw Caution y Never touch the bulb with finger, which will create a heat point. y Clean the fingerprint left on the bulb with alcohol.
To this chapter contents 17. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Front winker bulb Pull out the front winker light bulb seat. Replace with new front winker light bulb. (12V 21W) Position light bulb Replacing Bulb of Position Light Pull out the position light bulb seat. Replace with new position light bulb.
To this chapter contents 17. ELECTRICAL SYSTEM Replacing Bulb of Taillight and Rear Winker Light Taillight bulb Turn the taillight and rear winker light bulb connectors by CCW. Rear winker bulb Replace with new taillight bulb. (12V 5W/21W) Replace with new rear winker light bulb. (12V 21W) Replacing Bulb of License Light Taillight Rear winker light License light Turn the license light bulb connectors by CCW. Replace with new license light bulb.
To this chapter contents 17. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: Pin Position BAT1 BAT2 OFF Main switch coupler ON Wire Color Red Black Replacement of main switch Disconnect the coupler of the main switch. Push out the main switch. Align the main switch stopper with the meter cover groove, and install main switch. Install the main switch coupler.
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To this chapter contents 17. ELECTRICAL SYSTEM Front Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake light switch Horn Remove the horn from front fender left side.
To this chapter contents 17. ELECTRICAL SYSTEM Fuel Unit 4 bolts Remove the seat. Remove the fuel tank cap. Remove the fuel tank cover and front fender (refer chapter 13). Disconnect the coupler of the fuel unit. Remove the fuel unit (4 bolts). Caution y Great care shall be taken not to damage or bend the float arm of the gauge. Fuel unit coupler When the float arm shifts to the F position or the E position, the resistance measured shall be as follows: Position Resistance E (Empty) 97.5~107.
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 unit Thermo unit 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℃.
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