1. DL manuals
  2. E-TON
  3. Offroad Vehicle
  4. ATV3U 150
  5. Service Manual

E-TON ATV3U 150 Service Manual

Summary of ATV3U 150

  • Page 1

    Service manual atv3u 150 yukon ii (u.S.) challenger 150 (eur) e-ton power.

  • Page 2

    Yukon ii & challenger 150 service manual 2009 by e-ton power tech co., ltd. First edition, october 2009 all rights reserved. Any reproduction or unauthorized use without the written permission of e-ton power tech co., ltd. Is expressly prohibited..

  • Page 3: Important

    Important this manual was produced by the e-ton power tech co primarily for use by e-ton dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on e-ton m...

  • Page 4: How to Use This Manual

    How to use this manual manual organization this manual consists of chapters for the main categories of subjects. (see “symbols”) 1st title : this is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : this title indicates the section of the chapter and only a...

  • Page 5: Spec

    Symbols the following symbols are not relevant to every machine. Symbols to indicate the subject of each chapter. General information specifications periodic checks and adjustments engine carburetor chassis electrical troubleshooting symbols to indicate the following. Serviceable with engine mounted...

  • Page 6: Table of Contents

    Table of contents specifications periodic checks and adjustments engine carburetor chassis electrical general information 1 2 – + 7 6 5 4 3 troubleshooting 8.

  • Page 7: Chapter  1

    Chapter 1 general information machine identification........................................................................... 1-1 vehicle identification number ..................................................... 1-1 engine serial number...............................................................

  • Page 8: Chapter  2

    General specifications ...................................................................... 2-1 engine specifications .......................................................................... 2-4 chassis specifications ........................................................................ 2-11 ...

  • Page 9: Chapter  3

    Introduction ........................................................................................... 3-1 periodic maintenance chart for the ................................................................... 3-1 emission control system general maintenance and lubrication chart......................

  • Page 10: Chapter  4

    Engine ..........................................................................................................4-1 exhaust pipe/muffler, cables and leads................................ 4-1 engine mounting bolts ................................................................. 4-2 removing the eng...

  • Page 11

    Disassembling the secondary sheave.................................... 4-32 removing the primary sheave.................................................... 4-33 removing the secondary sheave and v-belt........................ 4-33 disassembling the secondary sheave......................................

  • Page 12: Chapter  5

    Carburetor................................................................................................ 5-1 disassembling the carburetor................................................... 5-4 checking the carburetor ............................................................. 5-4 assembling the ...

  • Page 13: Chapter  6

    Front and rear wheels ...................................................................... Front wheels .................................................................................... Rear wheels ...................................................................................... Checking t...

  • Page 14

    Steering system ..................................................................................... 6-23 handlebar........................................................................................... 6-23 removing the handlebar grips.................................................. 6-25 rem...

  • Page 15: Chapter  7

    Electrical components........................................................................ 7-1 checking the switches ........................................................................ 7-4 wiring diagram ...........................................................................................

  • Page 16: Chapter  8

    Starting failure/hard starting ....................................................... 8-1 fuel system.......................................................................................... 8-1 electrical system............................................................................. 8-1 comp...

  • Page 17: Gen

    1 1 - 1 gen info machine identification general information machine identification vehicle identification number the vehicle identification number is stamped into the front side of the frame. The engine serial number is stamped on the engine. Engine serial number 1 1 1 1.

  • Page 18: Gen

    1 - 2 gen info important information important information preparation for removal and disa- ssembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. 3. When disassembling always keep mated parts together. This i...

  • Page 19: Gen

    1 - 3 gen info important information lock washers/plates and cotter pins after removal, replace all lock washers/plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Bearings and oil seals install bearings and oil seal...

  • Page 20: Gen

    1 - 4 gen info important information checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- era...

  • Page 21: Spec

    2 2 - 1 spec general specifications general specifications item standard model code dimensions overall length 1730 mm (68.1 in) overall width 980 mm (38.6 in) overall height 1070 mm (42.1 in) seat height 760 mm (29.9 in) wheelbase 1115 mm (43.9 in) minimum ground clearance 160 mm (6.3 in) minimum tu...

  • Page 22: Spec

    2 - 2 spec general specifications item standard fuel type unleaded gasoline only fuel tank capacity plastic 6.5 l (1.43 lmp gal, 1.71 us gal) fuel reserve amount plastic 1.0 l (0.22 imp gal, 0.26 us gal) carburetor type/quantity cvek-019 x 1/usa Ǵcvek-008 x 1/eur manufacturer kei hin spark plug type...

  • Page 23: Spec

    2 - 3 spec general specifications item standard brake front brake type operation right hand operation rear brake type operation left hand operation suspension front suspension leading arm rear suspension swing arm shock absorber front shock absorber coil spring/oil damper rear shock absorber coil sp...

  • Page 24: Spec

    2 - 4 spec engine specifications engine specifications item standard limit cylinder head warp limit 0.05 mm (0.002 in) cylinder bore size 57.400 ~ 57.410 mm (2.2598 ~ 2.2602 in) taper limit ---- 57.50 mm 13.7 ~14.1 cm 0.10 mm (0.0039 in) (2.2638 in) maximum out-of-round ---- 0.10 mm (0.0039 in) cams...

  • Page 25: Spec

    2 - 5 spec engine specifications rocker arm/rocker arm shaft rocker arm inside diameter 10.000 ~ 10.018 mm (0.3937 ~ 0.3944 in) rocker arm shaft outside diameter 9.972 ~ 9.987 mm (0.3926 ~ 0.3932 in) rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.046 mm (0.0005 ~ 0.0018 in) valve, valve seat, va...

  • Page 26: Spec

    2 - 6 spec engine specifications stem-to-guide clearance in 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) ex 0.030 ~ 0.057 mm (0.0012 ~ 0.0022 in) 0.10 mm (0.0039 in) stem runout limit ---- 0.02 mm (0.0008 in) valve seat width in 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) ex 0....

  • Page 27: Spec

    2 - 7 spec engine specifications 0.10 mm (0.0039 in) (0.0002 ~ 0.0013 in) 57.375 ~ 57.395 mm (2.2589 ~ 2.2596 in) (0.5906 ~ 0.5909 in) 15.040 mm (0.5921 in) (0.5903 ~ 0.5906 in) 14.960 mm (0.5890 in) limit standard item direction of winding ---- clockwise clockwise in (top view) ---- ex 2.0 2.0 2.0 ...

  • Page 28: Spec

    2 - 8 spec engine specifications ---- barrel 1.00 × 2.30 mm (0.0394 × 0.0906 in) ---- 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in) 0.45 mm (0.0177in) 0.015 ~ 0.055 mm (0.0006 ~ 0.0022 in) 0.09 mm (0.0035in) ---- taper 1.00 × 2.40 mm (0.0394 × 0.0945in) ---- 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in) 0.60mm (0.0236 ...

  • Page 29: Spec

    2 - 9 spec engine specifications automatic centrifugal clutch type 4.0 mm clutch shoe thickness clutch shoe spring free length clutch housing inside diameter compression spring free length 168.9 mm (6.6496 in) weight outside diameter 1360 ~ 1540 r/min clutch-in revolution 1760 ~ 2040 r/min clutch-st...

  • Page 30: Spec

    Spec engine specifications oil pump ---- trochoid oil pump type inner-rotor-to-outer-rotor-tip clearance (0.0000 ~ 0.0059 in) 0.15 mm (0.0059 in) outer-rotor-to-oil-pump-housing clearance (0.0059 ~ 0.0083 in) 0.25 mm (0.0098 in) 0.15 ~ 0.21 mm 0.00 ~ 0.15mm lubrication chart : pressure feed : splash...

  • Page 31: Spec

    Spec chassis specifications chassis specifications item standard limit front suspension shock absorber travel 50 mm (1.97 in) ---- rear suspension shock absorber travel 85 mm (3.35 in) ---- front wheel type panel wheel ---- ---- ---- ---- ---- rim size 10 x 5.5 at ---- rim material steel ---- rim ru...

  • Page 32: Spec

    Spec brake lever brake lever free play (pivot) rear ---- ---- ---- throttle lever free play 1 ~ 3 mm (0.04 ~ 0.12 in) rear disc brake type disc outside diameter × thickness brake disk maximum deflection 0.25 mm (0.009 in) 3.00 mm (0.120 in) pad thickness inner 6.2 mm (0.24 in) dot 4 25.4 mm (1.00 in...

  • Page 33: Spec

    Spec electrical specifications item standard limit voltage 12 v ---- ignition system ignition timing (b.T.D.C.) 13.0 ° /1,700 r/min ---- advanced timing (b.T.D.C.) 29.0 ° /4,000 r/min ---- advancer type electrical (digital) ---- c.D.I. Magneto model/manufacturer c1120-v30-9000/shingyih ---- pickup c...

  • Page 34: Spec

    Spec electric starter system ---- constant mesh type starter motor ---- c1200-v30-0000/shingyih model/manufacturer ---- ---- 0.50 kw output armature coil resistance 0.005 ~ 0.007 at 20 °c (68 ° ---- f) 5.5 mm 11.5 mm (0.45 in) 6.67 ~ 9.03 n brush overall length (0.22 in) spring force (680 ~ 920 gf, ...

  • Page 35: Spec

    Spec tightening torques tightening torques engine tightening torques part to be tightened part name thread size q’ty tightening torque remarks nm m · kg ft · lb 2 - 15 cover head cylinder m6 bolt 4 12 1.2 m8 holder cam shaft nut 4 20 2.0 spark plug — m10 1 11 1.1 cylinder head (pipe assy, inlet) m6 ...

  • Page 36: Spec

    Spec tightening torques chassis tightening torques part to be tightened thread size tightening torque nm m · kg ft · lb m10 rear shock absorber and frame m10 rear shock absorber and swingarm m10 front shock absorber and frame m10 steering stem and frame m10 steering stem and tie-rod ball joint m10 t...

  • Page 37: Spec

    Spec general tightening torque specifications how to use the conversion table / how to use the conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Conversion table general tightening torque specif...

  • Page 38: Spec

    Spec lubrication points and lubricant types lubrication point lubricant ls ls e m ls e ls ls e e e e e e e m m m e e e ls ls oil seal lips o-ring (except v-belt drive unit) cylinder head tightening nut mounting surface cylinder head stud bolt thread cylinder head gasket dowel pin crankshaft pin outs...

  • Page 39: Spec

    Spec lubrication points and lubricant types bel-ray assembly lube bel-ray assembly lube sealant sealant sealant sealant sealant lubrication point lubricant ls primary sheave inside, collar, solid bush, secondary fixed inner surface secondary sheave torque cam ditch gasket (cylinder head cover) stopp...

  • Page 40: Spec

    Oil flow diagrams oil flow diagrams camshaft crankshaft oil pump oil filter 1 2 3 4 3 4 1 2 spec 2 - 20

  • Page 41: Spec

    Spec cable routing cable routing 1 6 5 4 3 2 rear brake hose choke cable (usa/can) fuel tank breather hose 9 10 11 8 oil catch hose crankcase breather hose oil cooler hoses bear tube 12 rubber tube fuel filter hose 7 vacuum tube 2 - 21 a a a a 1 6 5 4 3 2 front brake cable (right) front brake cable ...

  • Page 42: Spec

    A a a a 1 6 5 4 3 2 9 7 10 11 8 12 13 2 9 spec cable routing 2 - 22 a b fasten the rear brake switch lead and handlebar switch lead with a plastic band. Insert the fuel tank breather hose into the hole in the handlebar cover. C f d fasten the wire harness with a plastic band and a clamper pulser cor...

  • Page 43: Spec

    Spec cable routing starter relay lead battery c.D.I. Unit ignition coil head light lead choke cable (usa/can) throttle cable 1 2 1 2 main fuse (on wire harness) 2 - 23 horn meter lead ptc controller light controller 2 3 4 5 wire harness main switch lead 0 1 6 7 16 17 13 14 15 generator lead negative...

  • Page 44: Spec

    1 2 spec cable routing 2 - 24 a pass these leads through rear fender. B fasten the power supply lead on the wire harness with a plastic band. 8 9 10 11 12 13 14 15 1 0 2 3 4 5 6 7 0 12 11 10 16 17 a b.

  • Page 45: Spec

    Spec rear brake switch lead handlebar switch lead rear brake hose front brake cable (right) front brake cable (left) fuel tank breather hose choke cable (usa/can) throttle cable 1 6 5 4 3 2 cable routing 7 8 9 neutral switch lead 2 - 25 battery c.D.I. Unit main fuse (on wire harness) wire harness 0 ...

  • Page 46: Spec

    Spec cable routing 2 - 26 connect the negative battery lead to the battery so that the lead is routed to the side of the battery. Connect the positive battery lead to the battery so that the lead contacts the battery case. Fasten the handlebar switch lead, rear brake switch lead with a plastic band....

  • Page 47: Spec

    Spec cable routing rear brake hose choke cable (usa/can) throttle cable crankcase breather hose oil cooler hoses oil catch hose fasten the handlebar switch lead and rear brake switch lead with a plastic band. A fasten the haed light leads with plastic bands. B front brake cable (right) front brake c...

  • Page 48: Chk

    3 3 - 1 chk adj periodic maintenance/lubrication introduction periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation ...

  • Page 49: Chk

    3 - 2 chk adj periodic maintenance/lubrication introduction 10 * shock absorber assemblies check operation and correct if necessary. Check for oil leakage and replace if necessary. 11 * front knuckle piv- ots lubricate with lithium-soap-based grease. 12 * steering shaft lubricate with lithium-soap-b...

  • Page 50: Chk

    3 - 3 chk adj racks, seat, fenders and fuel tank racks, seat, fenders and fuel tank racks, seat and front panel order job/part q’ty remarks removing the racks, seat and front panel remove the parts in the order listed. 3 seat 1 front rack 2 rear rack 1 tip pull back the seat lock lever, than pull up...

  • Page 51: Chk

    3 - 4 chk adj front fender order job/part q’ty remarks removing the front fender remove the parts in the order listed. Racks, seat and front panel refer to “racks, seat and front panel”. 1 fuel tank top panel 1 2 cvt inlet tube 1 remove. 3 front fender 1 for installation, reverse the removal pro- ce...

  • Page 52: Chk

    Racks, seat and front panel refer to “racks, seat and front panel”. Order job/part q’ty remarks removing the rear fender , footrest boards bettery and c.D.I unit remove the parts in the order listed. Front fender refer to “front fender”. 1 battery band 1 2 negative battery lead 1 disconnect. Notice ...

  • Page 53: Chk

    3 - 6 chk adj 2 fuel filter assy 1 3 fuel tank 1 (fuel tank with the fuel cock) (usa) (1) 4 footrest bar 2 order job/part q’ty remarks removing the fuel tank and footrest bars remove the parts in the order listed. Front fender refer to “front fender”. 1 vacuum tube comp 1 for installation, reverse t...

  • Page 54: Chk

    3 - 7 chk adj 1. Remove: valve clearance (cold) intake valve 0.07 mm (0.003 in) 0.07 mm (0.003 in) exhaust valve • • • c.D.I. Magneto cover • cylinder head cover refer to “cylinder head” in chapter 4 . Engine adjusting the valve clearance the following procedure applies to all of the valves. Valve c...

  • Page 55: Chk

    3 - 8 chk adj c. Measure the valve clearance using a thick- ness gauge . Out of specification → adjust. 3. Adjust: • valve clearance a. Loosen the locknut . B. Insert a thickness gauge between the adjuster end and the valve end. C. Turn the adjuster clockwise or counter- clockwise with the tappet ad...

  • Page 56: Chk

    3 - 9 chk adj 4. Adjust: • engine idling speed a. Turn the throttle stop screw in or out until the specified idling speed is obtained. 5. Detach: • engine tachometer turning right idling speed becomes higher. Turning left idling speed becomes lower. 6. Adjust: • throttle lever free play refer to “ad...

  • Page 57: Chk

    Chk adj 2. Adjust: • throttle lever free play a. Pull back the adjuster cover . B. Loosen the locknut on the carburetor side. C. Turn the adjuster in or out until the cor- rect free play is obtained. D. Tighten the locknut . E. Push in the adjuster cover . After adjusting the free play, turn the han...

  • Page 58: Chk

    2. Adjust: • speed limiter length a. Loosen the locknut . B. Turn the adjuster in or out until the speci- fied speed limiter length is obtained. C. Tighten the locknut. • particularly for a beginner rider, the speed limiter should be screwed in com- pletely. Screw it out little by little as their ri...

  • Page 59: Chk

    4. Clean: • spark plug (with a spark plug cleaner or wire brush) 5. Measure: • spark plug gap use a wire gauge or thickness gauge. Out of specification → regap. 6. Tighten: • spark plug spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) t r . . 11 nm (1.1 m · kg, 8.0 ft · lb) a checking the spark plug/ ...

  • Page 60: Chk

    4. Detach: • timing light • engine tachometer 5. Install: • shroud cap the ignition timing is not adjustable. Checking the ignition timing/ measuring the compression pressure insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance out of specification → ...

  • Page 61: Chk

    A. Set the main switch to “on”. B. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. To prevent sparking, ground the spark plug lead before cranking the engine. C. If the compression pressure is above the maximum specification, check the cylinder he...

  • Page 62: Chk

    A. Warm up the engine for several minutes, and stop it, then wait at least several min- utes for the oil to drain back into the crank- case. Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick. B...

  • Page 63: Chk

    Changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • dipstick • engine oil drain bolt (along with the o-ring, spring and oil filter 4. Drain: • engine oil (completely from the crankcase...

  • Page 64: Chk

    Cleaning the air filter elements • air filter case cover 1. Loosen: • bolts / screws 2. Remove: • • air filter element • air filter element the engine should never be run without the air filter; excessive piston and/or cylinder wear may result. 3. Check: damaged → replace. Cleaning the air filter el...

  • Page 65: Chk

    Cleaning the spark arrester chk adj 3 - 18 cleaning the spark arrester 1. Clean: • spark arrester • select a well-ventilated area free of com- bustible materials. • always let the exhaust system cool before performing this operation. • do not start the engine when removing the tailpipe from muffler....

  • Page 66: Chk

    Chassis before adjusting the front brake, the front brake linings should be checked. Proper lever free play is essential to avoid excessive brake drag. 1. Measure: • front brake lever free play out of specification wear indicators reaches the wear limit line adjust the front and rear brake lever fre...

  • Page 67: Chk

    2. Check: • brake fluid level below the minimum level mark → add the recommended brake fluid to the proper level. • use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • refill with the same type of brake flui...

  • Page 68: Chk

    • rear brake hose cracks/wear/damage → replace. 3. Check: • brake hose clamps loosen → tighten. 4. Hold the machine in an upright position and apply the rear brake. 5. Check: • brake hose apply the brake lever times. Fluid leakage → replace the hose or pipe. Refer to “rear brake” in chapter 6. 6. In...

  • Page 69: Chk

    • be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • when bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre- caution could allow air to enter the hyd...

  • Page 70: Chk

    Changing the final transmission oil 1. Place the machine on a level surface. 2. Place a receptacle under the final transmission case. 3. Remove: • final transmission oil drain plug • final transmission oil filler cap • final transmission oil filler cap 4. Drain: • final transmission oil 5. Install: ...

  • Page 71: Chk

    1. Measure: • drive chain slack out of specification → adjust. 2. Adjust: • drive chain slack the drive chain slack is adjusted by the rota- tion of the rear axle hub. A. Loosen the rear axle pinch bolts . B. Loosen the locknut . C. To tighten the drive chain, turn the drive chain adjusting nut in d...

  • Page 72: Chk

    3. Check: • tie-rod ends turn the handlebar to the left and/or right until it stops completely, then slightly move the handlebar slightly in the opposite direction. Tie-rod end (s) have vertical play → replace the tie-rod end(s). Refer to “steering system” in chapter 6. 4. Raise the front end of the...

  • Page 73: Chk

    3. Adjust: • toe-in • be sure that both tie-rods are turned the same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mis- handling and an accident. • after setting the toe-in to specification, run the machine slowly for some dis...

  • Page 74: Chk

    Checking the front and rear shock absorbers 1. Place the machine on a level surface. 2. Check: • damper rod bends/damage → replace the front/rear shock absorber assembly. • oil leakage excessive oil leakage → replace the front/ rear shock absorber assembly. • cylinder damage → the front/rear shock a...

  • Page 75: Chk

    Adjusting the shock absorbers always adjust the spring preload of both front shock absorbers to the same setting. Uneven adjustment can result in poor han- dling and loss of stability. 1. Adjust: • spring preload a. Turn the adjusting ring in direction or with the spanner wrench . Direction spring p...

  • Page 76: Chk

    • tire pressure 1) recommended tire pressure front 25 kpa (0.25 kgf/cm 2 , 3.6 psi) rear 25 kpa (0.25 kgf/cm 2 , 3.6 psi) 2) tire pressure below the minimum speci- fication could cause the tire to dislodge from the rim under severe riding condi- tions. The following are minimums: front 23 kpa (0.23 ...

  • Page 77: Chk

    Uneven or improper tire pressure may ad- versely affect the handling of this machine and may cause loss of control. • maintain proper tire pressures. • set tire pressures when the tires are cold. • tire pressures must be equal in both front tires and equal in both rear tires. 2. Check: • tire surfac...

  • Page 78: Chk

    Checking and lubricating the cables a damaged cable sheath may cause corro- sion and interfere with the cable move- ment. An unsafe condition may result so replace a damaged cable as soon as possi- ble. 1. Check: • cable sheath damage → replace. 2. Check: • cable operation unsmooth operation → lubri...

  • Page 79: Chk

    Electrical system checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear when handling or working near batteries. •...

  • Page 80: Chk

    Since vrla (valve regulated lead acid) batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • seat •...

  • Page 81: Chk

    Example c. Open-circuit voltage = 12.0 v d. Charging time e. Charge of the battery = 20 ~ 30% 5. Charge: • battery (refer to the appropriate charging method illustration) • never remove the vrla (valve regulated lead acid) battery sealing caps. • do not use a high-rate battery charger since it force...

  • Page 82: Chk

    • as shown in the following illustration, the open-circuit voltage of an vrla (valve regulated lead acid) battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. Checking and charging the...

  • Page 83: Chk

    Checking and charging the battery chk adj charging method using a variable-current (voltage) charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charg- ing amperage written on the batter...

  • Page 84: Chk

    Charging method using a constant voltage charger measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Charge the battery until the charging voltage reaches 15 v. Leave the battery unused for more than 30 minutes before measuring its ope...

  • Page 85: Chk

    6. Install: • battery 7. Connect: • battery leads (to the battery terminals) first, connect the positive battery lead , and then the negative battery lead . 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery terminals 10.Install...

  • Page 86: Chk

    B.If the pocket tester indicates “•”, replace the fuse. 3.Replace: • blown fuse a.Set the main switch to “off”. B.Install a new fuse of the correct amperage. C.Set on the switches to verify if the electrical circuit is operational. D.If the fuse immediately blows again, check the electrical circuit....

  • Page 87: Eng

    4 4 - 1 eng engine engine engine exhaust pipe/muffler, cables and leads order job/part q’ty remarks removing the exhaust pipe/muffler, cables and leads remove the parts in the order listed. Racks, seat, fenders and fuel tank refer to “racks, seat, fenders and fuel tank” in chapter 3. 1 exhaust pipe/...

  • Page 88: Eng

    4 - 2 eng engine refer to “removing the engine”. Engine mounting bolts order job/part q’ty remarks removing the engine mounting bolts remove the parts in the order listed. Exhaust pipe/muffler refer to “exhaust pipe/muffler, cable and leads” . 1 drive chain 1 1 2 inlet tube, c.V.T comp 3/3 1 3 catch...

  • Page 89: Eng

    4 - 3 removing the engine installing the engine 1. Install: • flange bolts/ nuts do not fully tighten the bolts and nuts. The master link clip must be installed with the rounded end facing the direction of travel. 2. Tighten: 1. Remove: • drive chain • master link 3. Install: • drive chain • master ...

  • Page 90: Eng

    4 - 4 cylinder head order job/part q’ty remarks removing the cylinder head remove the parts in the order listed. Carburetor assembly refer to “carburetor” in chapter 5. Exhaust pipe/muffler refer to “engine”. 2 spark plug 1 8 gasket exhaust pipe 1 7 insulator carb 1 6 gasket, carb insulator 1 5 pipe...

  • Page 91: Eng

    4 - 5 (x4) (x4) (x4) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 11 nm (1.1 m • kg, 8.0 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t r . . 9 nm (0.9 m • kg, 6.5 ft • ib) t...

  • Page 92: Eng

    4 - 6 removing the cylinder head 1. Align: • “t” mark on the rotor (with the stationary pointer on the crank- case) a. Turn the crankshaft clockwise with a wrench. B. Align the “t” mark on the rotor with the stationary pointer on the crankcase. When the “t” mark is aligned with the sta- tionary poin...

  • Page 93: Eng

    4 - 7 checking the timing chain tensioner assembly 1. Check: • lifter comp tensioned wear/damage → replace. 3. Remove: cam shaft comp head comp cylinder fasten a safety wire to the timing chain to prevent it from falling into crankcase. Checking the camshaft sprocket 1. Check: • camshaft sprocket mo...

  • Page 94: Eng

    4 - 8 checking the cylinder head 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: • cylinder head damage/scratches → replace. 3. Measure: • cylinder head warp...

  • Page 95: Eng

    4 - 9 2. Install: • cam shaft comp a. Rotate the camshaft to align the round h- ole in camshaft sprocket away from t- he cylinder head. B.Turn the crankshaft clockwise with a wrench. C. Align the “t” mark on the rotor with the stationary pointer on the crankcase. When the “t” mark is aligned with th...

  • Page 96: Eng

    I. If the marks are aligned, temporarily tighten the camshaft sprocket bolt. If the marks are not aligned, change the meshing position of the camshaft sprocket and timing chain. 3. Install: bolt, flg. (small head) lifter comp tensioner always use a new gasket. 4. Adjust: • timing chain tensioner 5. ...

  • Page 97: Eng

    Camshaft, rocker arms and valves refer to “removing the rocker arms and camshaft” and “installing the camshaft and rocker arms”. Refer to “removing the valves and valve springs” and “install- ing the valves and valve springs”. For installation, reverse the removal pro- cedure. 1 4 4 5 5 2 3 12 12 13...

  • Page 98: Eng

    Removing the rocker arms and camshaft 1. Loosen: • locknuts • screw, valve adjusting 2. Remove: • shaft in rocker arm • shaft ex rocker arm • intake rocker arm • exhaust rocker arm remove the rocker arm shafts with the slide hammer bolt and weight . 3. Remove: • camshaft comp removing the valves and...

  • Page 99: Eng

    2. Remove: • valve cotters attach a valve spring compressor and attach- ment between the valve spring retainer and the cylinder head to remove the valve cotters. Checking the camshaft 1. Check: • cam lobes pitting/scratches/blue discoloration → replace. 2. Measure: • cam lobe dimensions and out of s...

  • Page 100: Eng

    4. Measure: • rocker arm inside diameter out of specification → replace. Rocker arm inside diameter 10.000 ~ 10.018 mm (0.3937 ~ 0.3944 in) (0.3926 ~ 0.3932 in) 5. Measure: • rocker arm shaft outside diameter out of specification → replace. 6. Calculate: • rocker-arm-to-rocker-arm-shaft clearance ca...

  • Page 101: Eng

    Checking the valves and valve springs 1. Measure: • stem-to-guide clearance • out of specification → replace the cylinder head ass'y. Stem-to-guide clearance = valve guide inside diameter – valve stem diameter stem-to-guide clearance intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.08 mm (0.0031 in)...

  • Page 102: Eng

    • when installing a new valve always replace the guide. • if the valve is removed or replaced always replace the oil seal. 5. Eliminate: • carbon deposits (from the valve face and valve seat) 6. Check: • valve seats pitting/wear → reface the valve seat. 7. Measure: • valve seat width out of specific...

  • Page 103: Eng

    A. Apply a coarse lapping compound to the valve face. Do not let the compound enter the gap between the valve stem and the guide. B. Apply molybdenum disulfide oil to the valve stem. C. Install the valve into the cylinder head. D. Turn the valve until the valve face and valve seat are evenly polishe...

  • Page 104: Eng

    10.Measure: • compressed spring force out of specification → replace. Installed length inner spring 33.55 ~ 41.00 n at 26.00 mm (3.42 ~ 4.18 kg, 7.54 ~ 9.21 lb at 1.0236 in) outer spring 82.10 ~ 100.40 n at 29.00 mm (8.37 ~ 10.23 kg, 18.45 ~ 22.56 lb at 1.1417 in) compressed spring force a a b a b a...

  • Page 105: Eng

    4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Hitting the valve tip with excessive force could damage the valve. Installing the camshaft and rocker arms 1. Install: • camshaft comp be sure to align the round hole in camshaft 2. Apply: • engine oi...

  • Page 106: Eng

    Cylinder and piston order job/part q’ty remarks removing the cylinder and piston remove the parts in the order listed. Refer to cylinder head “cylinder head”. Refer to 1 cylinder “installing the cylinder”. 1 2 cylinder gasket 2 3 dowel pin 2 4 piston pin clip refer to “removing the piston” and “inst...

  • Page 107: Eng

    Removing the piston 1. Remove: • piston pin clips • piston pin • piston • before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • before removing each piston pin, deburr the clip groove and pin hole area. If ...

  • Page 108: Eng

    B. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter “p” with the micrometer. 5 mm (0.20 in) from the bottom edge of the pis- ton d. If out of specification, replace the piston and piston rings as a set. E. Cal...

  • Page 109: Eng

    Checking the piston rings 1. Measure: • piston ring side clearance out of specification → replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. 2. Install: • piston ring (into the cy...

  • Page 110: Eng

    Checking the piston pin 1. Check: • piston pin blue discoloration/grooves → replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter out of specification → replace the piston pin. Piston pin outside diameter 14.994 ~ 15.000 mm (0.5903 ~ 0.5904 in) : 14....

  • Page 111: Eng

    New 2. Position: • top ring • 2nd ring • oil ring offset the piston ring end gaps as shown. Top ring end 2nd ring end side rail spacer side rail 20 mm (0.79 in) or more 3. Install: • piston • piston pin • piston pin clips • apply engine oil onto the piston pin, piston rings and piston. • be sure tha...

  • Page 112: Eng

    For installation, reverse the removal pro- cedure. Removing the c.D.I. Magneto duct inlet assy fan c.D.I. Magneto rotor stator coil assembly c.D.I. Magneto remarks order job/part q’ty 1 2 3 1 1 1 disassemble the parts in the order listed. Refer to “cylinder head”. Disconnect the c.D.I. Magneto lead ...

  • Page 113: Eng

    Removing the c.D.I. Magneto rotor 1. Remove: checking the pickup coil/stator assembly 1. Check: • pickup coil/stator assembly damage → replace. • while holding the c.D.I. Magneto rotor with the holding tool , loosen the c.D.I. Magneto nut . • do not allow the sheave holder to touch the pro- • clean ...

  • Page 114: Eng

    Remarks order job/part q’ty 1 2 3 1 1 2 belt drive crankcase cover removing the belt drive arm comp kick starter cover, crank case left knock pin 4 5 6 1 2 1 plate crank case (l) o-ring o-ring 7 1 oil seal (l) remove the parts in the order listed. For installation, reverse the removal pro- cedure. T...

  • Page 115: Eng

    Remarks order job/part q’ty 4 5 2 1 3 6 7 9 8 1 1 1 1 1 1 1 1 1 remove the parts in the order listed. Refer to “crankcase cover “. Refer to “installing the kickstarter“. For installation, reverse the removal pro- cedure. Kickstarter removing the kickstarter crankcase, cover circlip washer gear comp ...

  • Page 116: Eng

    Installing the kickstarter 1. Install: 2. Hook: hook the spring end on the spindle comp kick start as shown, and hook the other end on the projection . 3. Install: 4. Install: install the clip at the position shown. • boss kick spindle • spindle comp kick start • spring kick starter • spring kick st...

  • Page 117: Eng

    Remarks order job/part q’ty 1 2 3 4 5 6 8 9 10 11 12 13 1/1 1 1 1 1 1 1 1 2 1 1 1/6 1 remove the parts in the order listed. Refer to “ removing the face assy, movable drive “. Refer to “ removing the plate sub assy driven and v-belt “. For installation, reverse the removal pro- cedure. Removing the ...

  • Page 118: Eng

    Remarks order job/part q’ty 1 1 3 3 3 1 1 1 1 3 3 1 2 2 disassemble the parts in the order listed. Refer to “ plate sub assy driven and v-belt “. For assembly, reverse the disassembly procedure. Disassembling the plate sub assy drive nut lock plate comp drive roller clutch weight set clutch spring c...

  • Page 119: Eng

    Removing the primary sheave 1. Remove: while holding the primary fixed sheave with the rotor holding tool , loosen the primary fixed sheave nut. Removing the secondary sheave and v-belt 1. Remove: while holding the clutch housing with the sheave holder , loosen the secondary sheave nut. 2. Loosen: d...

  • Page 120: Eng

    Disassembling the secondary sheave 1. Remove: install the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown. Then, compress the spring, and re- move the nut lock . Checking the clutch shoe 1. Measure: scratches → glaze using coarse sandpaper. Damage/wear → replace ...

  • Page 121: Eng

    Checking the drive pulley 1. Check: cracks/damage/wear → replace the face movable drive, face driver and v-belt. Checking the primary roller weights the following procedure applies to all of the roller weights. 1. Check: cracks/damage/wear → replace. 2. Measure: out of specification → replace. Rolle...

  • Page 122: Eng

    2. Check: damage/wear → replace the face comp, driven and face comp, movable drive as a 3. Check: 4. Measure: out of specification → replace. Spring driven face free length 168.9 mm (6.65 in) : 164.0 mm (6.46 in) : 125.5 mm (4.94 in) 5. Measure: out of specification → replace. Outer clutch internal ...

  • Page 123: Eng

    3. Install: assembling the secondary sheave 1. Lubricate: (with the recommended lubricant) 2. Install: install the face comp, movable driven onto the face comp, driven with the oil seal guide . • piece slide • face movable drive • plate ramp • face comp, movable driven’s inner surface • face comp, d...

  • Page 124: Eng

    Installing the belt drive 1. Install: do not allow grease to contact the v-belt, secondary sheave assembly. Install the v-belt onto the face comp, driven. 2. Install: while holding the clutch carrier with the rotor holding tool , tighten the clutch carrier nut with the locknut wrench . T r . . 55 nm...

  • Page 125: Eng

    Starter clutch and starter motor remarks order job/part q’ty 1 2 3 4 1 (x3) 1 1 1 1 1 1 1 1 3 3 disassemble the parts in the order listed. Refer to “ removing the primary sheave “ for installation, reverse the removal pro- cedure. Removing the starter clutch and starter motor primary sheave 5 6 8 9 ...

  • Page 126: Eng

    Checking the starter wheel gear 1. Check: 2. Check: a b a. Install the starter wheel gear onto the idle gear and hold the starter clutch. B. When turning the starter wheel gear clock- wise , the starter clutch and the starter wheel gear should engage, otherwise the starter clutch is faulty and must ...

  • Page 127: Eng

    Oil pump e remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 2 1 1 1 1 1 1 1 1 1 1 disassembling the oil pump c.D.I. Magneto cover oil seal knock pin separator oil oil pump chain nut oil pump driven sprocket oil pump shaft oil pump body knock pin outer ro...

  • Page 128: Eng

    Oil pump eng • fan cover assy • cooling fan composition removing the oil pump 1. Remove: 1 1 2 2 • a.C.G generator assy • the right crankcase cover 3 4 4 3 • gear comp starting clutch and flange 5 6 5 6 starting clutch 4 - 42.

  • Page 129: Eng

    Oil pump eng • flange bolts and separator oil • oil pump chain and oil pump driven • oil pump assy • disassemble the oil pump assy 8 7 8 9 10 9 10 11 12 12 11 7 sprocket checking the oil pump 1. Check: cracks/damage/wear → replace the defective part(s). • sprocket oil pump driven 1 4 - 43.

  • Page 130: Eng

    Oil pump eng out of specification → replace the oil pump. Rotor clearance 2. Measure: inner rotor outer rotor inner-rotor-to-outer-rotor-tip clear- ance : 0.15mm (0.0059 in) outer-rotor-to-oil-pump-housing clearance 0.15 ~ 0.21 mm (0.0059~0.0083in) 0.00 ~ 0.15 mm (0.0000~0.0059in) : 0.25 mm (0.0098 ...

  • Page 131: Eng

    Crankcase and crankshaft remarks order job/part q’ty 1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 1 1 1 1 1 1 1 remove the parts in the order listed. Refer to “ engine “ and “cylinder head “. Refer to “cylinder and piston “. Refer to “v-belt, clutch, drive and driven pulley “. Refer to “starter clutch and starter ...

  • Page 132: Eng

    Crankcase and crankshaft eng separating the crankcase 1. Remove: • crankcase bolt • crankshaft assembly • timing chain • timing chain • timing chain guide 1 1 removing the crankshaft assembly 1. Remove: sprocket. Moved if the timing chain is attached onto the crankshaft sprocket. Checking the timing...

  • Page 133: Eng

    Eng checking the crankshaft and con- necting rod 1. Measure: bearing or both. Turn the crankshaft slowly. Maximum crankshaft runout 0.04 mm (0.0016 in) 2. Measure: bearing, crankshaft pin, or connecting rod. Big end side clearance 0.10~0.30 mm (0.0039~0.0118 in) 3. Measure: crankshaft width 45.00~45...

  • Page 134: Eng

    Crankcase and crankshaft eng installing the crankshaft 1. Install: to avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Put the timing chain in parallel into the crank case, then use ha...

  • Page 135: Eng

    Transmission remarks order job/part q’ty 1 2 3 4 5 7 1 1 2 1 1 1 removing the lock washer, drive sprocket, and circlip transmission oil crankcase cover belt drive driven pulley plate fixing sprocket drive cover mission gasket, mission cover knock pin 6 1 spindle assy shift shaft gear shift 8 9 1 1 f...

  • Page 136: Eng

    3 (x2) t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) t r . . 12 nm (1.2 m • kg, 8.7 ft • ib) 4 remarks order job/part q’ty removing the shaft comp rod and back position sw shift shaft 1 2 5 7 7 6 8 9 10 11 1 2 3 4 5 7 1 1 1 1 1 2 fixing support catch shaft comp rod f...

  • Page 137: Eng

    Checking the shift fork 2. Check: • shift fork cam follower • shift fork pawl • shaft gear shift 3. Check: do not attempt to straighten a bent shaft gear shift. Checking the drum comp gear shift 1. Check: • shift drum groove • shift drum segment • shift drum bearing 1 2 bends/damage/scoring/wear → r...

  • Page 138: Eng

    (with a centering device and dial gauge ) out of specification → replace the drive shaft. Out of specification → replace the final shaft. Bluediscoloration/pitting/wear → replace the incorrect → reassemble the transmission rough movement → replace the defective 2. Measure: dirve shaft runout limit 0...

  • Page 139: Eng

    • remove the knock pins and gasket • remove final shaft comp and counter shaft • relax the bolts and remove the mission • remove the plate fixing and sprocket drive cover • pull the shaft gear shifts out and remove the fork shift • remove the shaft gear shift comp from the final shaft comp comp 3 3 ...

  • Page 140: Eng

    Installing the gear set • check the sprocket drive and plate fixing • install counter shaft comp • install shaft gear shift comp • install drum comp gear shift and spindle • install the mission cover and final shaft comp together with circlip for wear or damage 1 2 1 2 • install the shaft gear shift...

  • Page 141: Carb

    5 5 - 1 carb carburetor order job/part q’ty remarks removing the carburetor remove the parts in the order listed. 1 tube clip (b) 2 2 tube, rubber (a) 1 3 tube clip (a) 2 4 pipe, bypass 6 bear tube comp 1 5 tube, rubber 1 7 three through tube comp 1 only europe. 2 9 a.C.V spring 1 10 a.C.V diaphragm...

  • Page 142: Carb

    Order job/part q’ty remarks disassembling the carburetor remove the parts in the order listed. Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. Plate fixed piston cover (b) 1 1 plate fixed piston co...

  • Page 143: Carb

    5 - 3 order job/part q’ty remarks pilot jet carb chamber float pin 1 1 main jet 1 1 needle jet holder 1 needle jet 1 needle valve assy 1 1 float for assembly, reverse the disassembly procedure. 10 11 12 16 17 14 13 15 carb carburetor 6 8 9 7 10 11 12 (x4) 1 2 4 5 3 new (x4) 17 13 14 15 16.

  • Page 144: Carb

    5 - 4 disassembling the carburetor before disassembling the carburetor, make sure to note the number of times the air adjusting screw is turned out from the seated position to its set position. Checking the carburetor 1. Check: cracks/damage → replace. Damage → replace. Damage/obstruction/wear → rep...

  • Page 145: Carb

    5 - 5 4. Check: 5. Check: 6. Check: 8. Check: insert the piston valve into the carburetor body and move it up and down. 7. Check: • piston valve • piston valve diaphragm • plate fixed piston cover (b) • plate fixed piston cover (a) • vacuum piston cover • piston spring • pilot jet • jet needle • fue...

  • Page 146: Carb

    5 - 6 assembling the carburetor before assembling the carburetor, make sure to turn out the pilot air screw the same number of times, as noted before disassembly, from the seated position to the set position. 1. Install: • before assembling the carburetor, wash all • always use a new gasket. • needl...

  • Page 147: Carb

    5 - 7 2. Adjust: throttle cable free play (at the flange of the throttle grip) 5 ~ 10 mm (0.20 ~ 0.39 in) 18.8 mm (0.74 in) refer to “adjusting the throttle cable free play” in chapter 3. • throttle cable free play measuring and adjusting the fuel 1. Measure: • fuel level out of specification → adju...

  • Page 148: Chas

    6 6 - 1 front and rear wheels chas chassis order job/part q’ty remarks removing the front wheels remove the parts in the order listed. Place the machine on a level surface. Securely support the machine so there is no danger of it falling over. The following procedure applies to both of the front whe...

  • Page 149: Chas

    6 - 2 rear wheels order job/part q’ty remarks removing the rear wheels remove the parts in the order listed. Place the machine on a level surface. Securely support the machine so there is no danger of it falling over. The following procedure applies to both of the rear wheels. Refer to “installing t...

  • Page 150: Chas

    6 - 3 front and rear wheels chas checking the wheels the following procedure applies to both of the front and rear wheels. 1. Check: • wheel 2. Measure: • wheel runout over the specified limit → replace the wheel or check the wheel bearing play . 3. Check: • wheel balance out of balance → adjust. Af...

  • Page 151: Chas

    6 - 4 eye protection is recommended when using striking tools. C. To install the wheel bearings, reverse the above sequence. Use a socket that matches outside diameter of bearing outer race to drive in bearing. Do not strike the center race or balls of the bearing. Contact should be made only with t...

  • Page 152: Chas

    6 - 5 installing the front wheels the following procedure applies to both of the front wheels. 1. Install: • wheel the arrow mark on the tire must point in the direction of rotation of the wheel. 2. Tighten: • nuts a installing the rear wheels the following procedure applies to both of the rear whee...

  • Page 153: Chas

    6 - 6 front brakes order job/part q’ty remarks removing the front brakes remove the parts in the order listed. Refer to “front and rear wheels”. The following procedure applies to both of the front brakes. 1 brake shoe 2 refer to “installing the front brakes”. 2 front brake cable (drum side) 1 3 bra...

  • Page 154: Chas

    6 - 7 removing the front brakes the following procedure applies to each brake. 1. Remove: • brake camshaft lever • brake camshaft when removing the brake camshaft lever, mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft. Checking the front br...

  • Page 155: Chas

    6 - 8 3. Measure: • brake shoe lining thickness out of specification → replace. Measuring points replace the brake shoes as a set if either is found to be worn to the wear limit. Brake lining thickness 4.0 mm (0.16 in) : 1.5 mm (0.06 in) checking the front brake drums the following procedure applies...

  • Page 156: Chas

    6 - 9 during installation, lightly grease the brake camshaft and the pivot pin. Wipe off the excess grease. 2. Install: • brake camshaft • brake camshaft lever • install the brake camshaft so its punch mark is positioned as shown. • align the punch mark in the brake camshaft with the mark on the bra...

  • Page 157: Chas

    Rear axle and rear axle hub order job/part q’ty remarks removing the rear axle and rear axle hub remove the parts in the order listed. Rear wheels/rear wheel hubs refer to “front and rear wheels”. 1 nut 2 2 brake caliper 1 do not apply the brake lever and do not use the parking brake when the brake ...

  • Page 158: Chas

    Order job/part q’ty remarks 4 rear axle 1 refer to “removing the rear axle”. 6 driven sprocket/sprocket bracket 1/1 ket”. 7 chain puller 1 9 bearing/oil seal 10 bearing spacer 1 11 bearing/oil seal 1/1 for installation, reverse the removal procedure. 8 rear axle hub 1 1/1 5 axle plate fixed 1 rear a...

  • Page 159: Chas

    Removing the rear axle 1. Place the machine on a level surface. • nuts • apply the brake lever so that the rear axle does not turn, when loosening the nut. • use the axle nut wrench (36 mm) . 3. Elevate the rear wheels by placing the suit- able stand under the frame. 4. Remove: • rear wheels • wheel...

  • Page 160: Chas

    Installing the driven sprocket 1. Install: • driven sprocket make sure that the blunt-edged corner of the driven sprocket is facing outward. Checking the brake disc 1. Check: • brake disc galling/damage → replace. 2. Measure: • brake disc deflection out of specification → replace. • brake disc thick...

  • Page 161: Chas

    Order job/part q’ty remarks removing the rear brake caliper remove the parts in the order listed. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapter 3. 1 union bolt 1 2 copper washer 2 3 brake hose 1 disconnect. 4 brake caliper assembly 1 for installation, reverse the remov...

  • Page 162: Chas

    Checking the rear brake caliper recommended brake component replacement schedule brake pads as required caliper ass'y every two years brake hoses every four years brake fluid replace when brakes are disassembled. 1. Check: • brake caliper body cracks/damage → replace. • brake fluid delivery passage ...

  • Page 163: Chas

    Proper brake hose routing is essential to insure safe machine operation. Refer to “cable routing” in chapter 2. 2. Fill: • brake reservoir brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. Recommended brake fluid dot 4 • use only the designate...

  • Page 164: Chas

    Disc brake components rarely require dis- assembly. Do not: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; • use spent brake fluid for cleaning; (use only clean brake fluid) • allow brake fluid to come in contact with the eyes, as this may caus...

  • Page 165: Chas

    6. Check: • brake lever or brake pedal operation soft or spongy feeling → bleed the brake system. Refer to “bleeding the hydraulic brake system” in chapter 3. C. Tighten the brake caliper bleed screw. D. Install a new brake pad spring and new brake pads. 4. Install: • brake caliper • brake caliper m...

  • Page 166: Chas

    Rear brake master cylinder order job/part q’ty remarks removing the rear brake master cylinder remove the parts in the order listed. Brake fluid drain. Refer to “bleeding the hydraulic brake system” in chapter 3. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm 1 3 front brake light s...

  • Page 167: Chas

    Checking the master cylinder 1. Check: • brake master cylinder wear/scratches → replace the brake mas- ter cylinder assembly. • brake master cylinder body cracks/damage → replace. • brake fluid delivery passage (brake master cylinder body) blockage → blow out with compressed air. 2. Check: • rear br...

  • Page 168: Chas

    2. Install: • copper washers • brake hose • union bolt • tighten the union bolt while holding the brake hose as shown. • turn the handlebar to the left and to the right to check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.). Correct if necessary. Proper b...

  • Page 169: Chas

    4. Air bleed: • brake system refer to “bleeding the hydraulic brake system” in chapter 3. 5. Check: • brake fluid level brake fluid level is under the “lower” level line → add the recommended brake fluid to the proper level. Refer to “checking the rear brake fluid level” in chapter 3. Rear brake cha...

  • Page 170: Chas

    Steering system handlebar order job/part q’ty remarks removing the handlebar remove the parts in the order listed. Handlebar cover refer to “seat, fenders and fuel tank” in chapter 3. 1 handlebar grip 2 grips” and “installing the handlebar grips”. 2 front brake cable 2 3 throttle cable 1 4 front bra...

  • Page 171: Chas

    6 - 24 order job/part q’ty remarks 11 upper handlebar holder 2 refer to “installing the handlebar”. 12 handlebar 1 for installation, reverse the removal procedure. Steering system chas 10 plastic band 1 (x4) t r . . 14 nm (1.4 m • kg, 10.1 ft • ib) 1 2 4 10 11 1 6 8 (x2) t r . . 14 nm (1.4 m • kg, 1...

  • Page 172: Chas

    Removing the handlebar grips 1. Remove: • handlebar grips blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. Removing the rear brake switch 1. Remove: • rear brake switch push the fastener when removing the rear brake switch out of the rear b...

  • Page 173: Chas

    Installing the handlebar 1. Install: • handlebar • upper handlebar holders • install the handlebar, please align the punch mark and the gap at handlebar holder . • the upper handlebar holders should be installed with the flange forward . First tighten the bolt on the rear side of the handlebar holde...

  • Page 174: Chas

    Installing the rear brake master cylinder 1. Install: • handlebar switch • installing the rear brake master cylinder , make sure the handlebar switch , handlebar grip , and brake master cylinder are in the positions shown in the illustration. Installing the front brake lever assembly 1. Install: • f...

  • Page 175: Chas

    Order job/part q’ty remarks removing the steering stem remove the parts in the order listed. Front fender refer to “seat, fenders and fuel tank” in chapter 3. Handlebar refer to “handlebar”. 1 bolts 2 2 fix plate 1 3 steering shaft pressed holder 1 4 collar 2 5 steering stem bushing 1 6 oil seal 2 2...

  • Page 176: Chas

    Removing the steering stem 1. Remove: • steering stem when loosening each tie-rod end nut , hold the tie-rod ball joint with a 14-mm wrench . Checking the steering stem 1. Check: • steering stem bends → replace. Do not attempt to straighten a bent stem; this may dangerously weaken the stem. 2. Check...

  • Page 177: Chas

    Installing the steering stem 1. Tighten: • steering stem nut • tie-rod end nut when tightening each tie-rod end nut , hold the tie-rod ball joint with a 14-mm wrench . Installing the lock washer 1. Install: • lock washer • bolts 2. Bend the lock washer tab along a flat side of the bolt. 1 3 3 2 2 2 ...

  • Page 178: Chas

    Tie-rods and steering knuckles order job/part q’ty remarks removing the tie-rods and steering knuckles remove the parts in the order listed. The following procedure applies to both of the tie-rods and steering knuckles. Refer to “front brakes”. 1 tie-rod refer to “installing the tie-rods”. 1 2 suspe...

  • Page 179: Chas

    Removing the tie-rods the following procedure applies to both of the tie-rods. The following procedure applies to both of the steering knuckles . 1. Remove: • tie-rod when removing the tie-rod, hold each tie-rod ball joint with a 14-mm wrench and then loosen the tie-rod end nut. Checking the tie-rod...

  • Page 180: Chas

    Installing the tie-rods the following procedure applies to both of the tie-rods. 1. Install: • tie-rod • the tie-rod side which must be installed on the outside has grooves . • when installing the tie-rod, hold each tie-rod ball joint with a 14-mm wrench and then tighten the tie-rod end nut. 2. Adju...

  • Page 181: Chas

    Front arms and front shock absorber assemblies order job/part q’ty remarks removing the tie-rods and steering knuckles remove the parts in the order listed. The following procedure applies to both of the tie-rods and steering knuckles. Refer to “front brakes”. 1 tie-rod 1 1 1 1 front brakes refer to...

  • Page 182: Chas

    Removing the front arms 1. Check: • front arm free play a. Check the front arm side play by moving it from side to side. If side play is noticeable, check the bush- ings. B. Check the front arm vertical movement by moving it up and down. If the vertical movement is tight or rough, or if there is bin...

  • Page 183: Chas

    Checking the ball joints the following procedure applies to both of the front arm ball joints. 1. Check: • ball joint damage/pitting → replace the front arm. Free play → replace the front arm. Turns roughly → replace the front arm. Installing the front arms the following procedure applies to both of...

  • Page 184: Chas

    Rear shock absorber, swingarm and drive chain order job/part q’ty remarks removing the rear shock absorber, swingarm and drive chain remove the parts in the order listed. Seat/rear fender/air filter case refer to “seat, fenders and fuel tank” in chapter 3. Rear axle hub refer to “rear axle and rear ...

  • Page 185: Chas

    T r . . 35 nm (3.5 m • kg, 25.3 ft • ib) 6 8 3 7 4 t r . . 75 nm (7.5 m • kg, 54.2 ft • ib) (x2) 2 5 9 10 7 8 t r . . 10 nm (1.0 m • kg, 7.2 ft • ib) t r . . 35 nm (3.5 m • kg, 25.3 ft • ib) t r . . 25 nm (2.5 m • kg, 18.1 ft • ib) 1 t r . . 25 nm (2.5 m • kg, 18.1 ft • ib) order job/part q’ty remar...

  • Page 186: Chas

    Checking the rear shock absorber 1. Check: • shock absorber oil leaks → replace the rear shock absorber assembly. • shock absorber rod bends/damage → replace the rear shock absorber assembly. • spring fatigue → replace the rear shock absorber assembly. Move the spring up and down. Removing the rear ...

  • Page 187: Chas

    2. Remove: • flange nut • flange bolt • swingarm checking the swingarm 1. Check: • swingarm bends/cracks/damage → replace. 2. Check: • flange bolt roll the axle on a flat surface. Bends → replace. Do not attempt to straighten a bent plange bolt. 3. Clean: • plange bolt • spacer recommended cleaning ...

  • Page 188: Chas

    3. Check: • drive chain rollers damage/wear → replace the drive chain. • drive chain side plates cracks/damage/wear → replace the drive chain. 4. Lubricate: • drive chain 5. Check: • drive sprocket • driven sprocket morethan1/4tooth wear → replace the drive chain sprockets as a set. Bent teeth → rep...

  • Page 189: Elec

    7 electrical components elec electricalcomponents ignition coil horn fuel sender buzzer light control unit neutral switch reverse switch ptc controller main switch battery rectifier/regulator starter relay pickup coil/stator assembly starter motor head light c.D.I. Unit rear brake switch handlebar s...

  • Page 190: Elec

    Wiring diagram elec 7 - 2 main s witch c .D .I. Magneto rectifier/regulator batter y main fuse batter y (+) lead batter y (-) lead wire lead star ter rela y star ter motor c .D .I. Unit ignition coil b rak e light s witch star t s witch engine stop s witch hor n hor n s witch t ail/br a k e light di...

  • Page 191: Elec

    Checking switch continuty elec 7 - 3 off on br r/w a b checking switch continuity check each switch for continuity with the poc- ket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Notice: never insert the tester probes into the cou-...

  • Page 192: Elec

    7 - 4 checking the switches elec checking the switches check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “checking switch continuity”. Damage/wear → repair or replace. Improperly connected → properly connect. Incorrect continuity readin...

  • Page 193: Elec

    Elec 7 - 5 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear repair or replace the bulb, bulb socket or both. Improperly connected properly connect. No continuity repair or replace ...

  • Page 194: Elec

    Elec 7 - 6 2. Check: • bulb (for continuity) (with the pocket tester) no continuity replace. Tip: before checking for continuity, set the pocket tester to “0” and to the “ Ω x 1” range. A. Connect the positive tester probe to termi- nal and the negative tester probe to ter- minal , and check the con...

  • Page 195: Elec

    Elec 7 - 7 ignition system ignition system circuit diagram main switch c.D.I. Magneto battery main fuse 5 1 2 4 c.D.I. Unit ignition coil engine stop switch 12 11 15 neutral switch reverse switch 25 24 w/r b l/y l/y w b w b b l/b b l/b r/w r/w br off on off st ar t main st ar t sw (natural) 12v2w (r...

  • Page 196: Elec

    Elec 7 - 8 2. Spark plug • check the condition of the spark plug. • check the spark plug type. • measure the spark plug gap. Refer to “checking the spark plug” in chapter 3. Standard spark plug cr7hsa (ngk) spark plug gap 0.6 ~ 0.7 mm • is the spark plug in good condition, is it of the correct type,...

  • Page 197: Elec

    Elec 7 - 9 ignition system 4. Spark plug cap resistance • remove the spark plug cap from the spark plug lead. • connect the pocket tester (“ Ω x 1k” range) to the spark plug cap as shown. • measure the spark plug cap resistance. Spark plug cap resistance at 20°c 3.75~6.25 kΩ • is the spark plug cap ...

  • Page 198: Elec

    Elec 7 - 10 ignition system 9. Pickup coil resistance • disconnect the pickup coil coupler from the wire harness. • connect the pocket tester ( Ω x 100) to the pickup coil terminal as shown. Positive tester probe blue/yellow negative tester probe black(ground) • measure the pickup coil resistance. P...

  • Page 199: Elec

    Elec 7 - 11 electric starting system electric starting system circuit diagram main switch battery main fuse 5 1 4 starter relay starter motor brake light switch starter switch 9 13 10 14 eng stop switch 15 w/r b l/y l/y w b w b b l/b b l/b r/w r/w br off on off st ar t main st ar t sw (natural) 12v2...

  • Page 200: Elec

    Elec 7 - 12 electric starting system off on r r r b r g/y l/w b/r br m starting circuit cut-off system operation if the main switch is set to “on” the starter motor can only operate if at least one of the following conditions is met: • the engine stop switch is on. • the brake switch is on. When at ...

  • Page 201: Elec

    Elec 7 - 13 electric starting system troubleshooting check: 1. Main fuse 2. Battery 3. Starter motor 4. Starter relay 5. Main switch 7. Brake light switch 6. Start switch 9. Wiring connections 8. Eng stop switch (of the entire starting system) tip: • before troubleshooting, remove the follo- wing pa...

  • Page 202: Elec

    Elec 7 - 14 electric starting system 4. Starter relay • disconnect the starter relay coupler from the coupler. • connect the pocket tester ( Ω x 1) and bat- tery (12 v) to the starter relay coupler as shown. Positive battery terminal blue/white negative battery terminal black positive tester probe r...

  • Page 203: Elec

    Elec 7 - 15 electric starting system starter motor o-ring starter motor front cover brush brush spring armature assembly starter motor rear cover brush wear limit : 6.5 mm commutator wear limit : 20.5 mm.

  • Page 204: Elec

    Elec 7 - 16 electric starting system removing the starter motor 1. Remove: • seat assy. • helmet box • starter motor checking the starter motor 1. Check: • commutator dirt clean with 600-grit sandpaper. 2. Measure: • commutator diameter a out of specification replace the starter motor. 3. Measure: •...

  • Page 205: Elec

    Elec 7 - 17 electric starting system assembling the starter motor 1. Install: • brush set • rubber seal • starter motor front cover 2. Install: • starter motor rear cover 3. Install: • starter motor bolts note: when install the starter motor the ground ter- minal a is installed with upper side bolt....

  • Page 206: Elec

    Elec 7 - 18 charging system charging system circuit diagram c.D.I. Magneto rectifier/regulator battery main fuse 5 2 3 4 w/r b l/y l/y w b w b b l/b b l/b r/w r/w br off on off st ar t main st ar t sw (natural) 12v2w (reverse) 12v2w 12v 21w/5w 10a br br br br br r/w r/w r r r l/ w l/ w r b br br y y...

  • Page 207: Elec

    Elec 7 - 19 charging system troubleshooting check: 1. Charging voltage 2. Main fuse 3. Battery 4. Charging coil resistance 5. Wiring connections (of the entire charging system) tip: • before troubleshooting, remove the follo- wing part(s): 1.Seat 2. Front fender • troubleshoot with the engine tachom...

  • Page 208: Elec

    Elec 7 - 20 charging system positive tester probe white negative tester probe white/red • measure the charging coil resistance. Charging coil resistance 0.72 ~ 0.97 Ω at 20°c • is the charging coil ok? 5. Wiring • check the wiring connections of the entire charging system. Refer to “circuit diagram”...

  • Page 209: Elec

    Checking switch continuty elec 7 - 21 lighting system lighting system circuit diagram main switch c.D.I. Magneto rectifier/regulator battery main fuse 5 1 2 3 4 tail/brake light dimmer switch light control unit headlight 17 19 21 20 w/r b l/y l/y w b w b b l/b b l/b r/w r/w br off on off st ar t mai...

  • Page 210: Elec

    Elec 7 - 22 lighting system troubleshooting check: 1. Main fuse 2. Battery 3. Main switch tip: • before troubleshooting, remove the follo- wing part(s): • troubleshoot with the pocket testerl. Any of the following fail to light: head- light, taillight. 4. Dimmer switch 5. Wiring connections (of the ...

  • Page 211: Elec

    Elec 7 - 23 lighting system checking the lighting system 1. The headlight fail to come on. 1. Headlight bulb and socket • check the headlight bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” • are the headlight bulb and socket ok? 2. Voltage • connect the pocket tester ...

  • Page 212: Elec

    Elec 7 - 24 lighting system 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” • are the tail/brake light bulb and socket ok? 2. Voltage • connect the pocket tester ...

  • Page 213: Elec

    Elec 7 - 25 signaling system signaling system circuit diagram fuel lever meter fuel sender 24 25 27 26 23 main switch battery main fuse brake light switch eng stop switch horn horn switch light control unit t ail/brake light 5 1 4 13 15 16 22 18 21 20 neutral switch reverse switch shift indicator li...

  • Page 214: Elec

    Elec 7 - 26 signaling system troubleshooting •any of the following fail to light: buzzer, brake light or an shift indicator light. •the horn fails to sound. Check: 1. Main fuse 2. Battery 3. Main switch 4. Wiring connections (of the entire signaling system) tip: • before troubleshooting, remove the ...

  • Page 215: Elec

    Elec 7 - 27 signaling system checking the signaling system 1. The horn fails to sound. 1. Horn switch • check the horn switch for continuity. Refer to “checking the switches”. • is the horn switch ok? 2. Voltage • connect the pocket tester (dc 20 v) to the horn connector at the horn terminal as show...

  • Page 216: Elec

    Elec 7 - 28 signaling system 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • check the tail/brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets” • are the tail/brake light bulb and socket ok? 2. Brake light switches • check the br...

  • Page 217: Elec

    Elec 7 - 29 signaling system 4. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket • check the neutral indicator light bulb and socket for continuity. Refer to “checking the bulbs and • are the neutral indicator light bulb and replace the neutral indicator light...

  • Page 218: Elec

    Elec 7 - 30 signaling system 5. The forward indicator light fails to come on. 1. Forward indicator light bulb and socket • check the forward indicator light bulb and socket for continuity. • are the forward indicator light bulb and replace the forward indicator light bulb socket or both. Yes no sock...

  • Page 219: Elec

    Elec 7 - 31 signaling system 4. Wiring check the entire signaling system’s wiring. 7. The bizzer fails to sound. 2. Voltage • connect the pocket tester (dc 20 v) to the bizzer connector at the bizzer terminal as shown. Positive tester probe blue/black negative tester probe ground • set the main swit...

  • Page 220: Elec

    Elec 7 - 32 auto choke system auto choke system circuit diagram ptc control unit auto choke unit 30 11 31 c.D.I. Magneto rectifier/regulator c.D.I. Unit 2 3 14 start switch w/r b l/y l/y w b w b b l/b b l/b r/w r/w br off on off st ar t main st ar t sw (natural) 12v2w (reverse) 12v2w 12v 21w/5w 10a ...

  • Page 221: Elec

    Elec 7 - 33 troubleshooting the auto choke system fails to operate. Check: 1. Auto choke unit resistance 2. Wiring connections (of the entire auto choke system) auto choke system 1. Auto choke unit resistance • disconnect the auto choke unit coupler from wire harness. • connect the pocket tester(Ω ×...

  • Page 222: Trbl

    8 8 - 1 trbl shtg starting failure/hard starting troubleshooting tip the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of ...

  • Page 223: Trbl

    8 - 2 trbl shtg starting failure/hard starting/poor idle speed performance/poor medium and high-speed performance compression system cylinder and cylinder head • loose spark plug • loose cylinder head or cylinder • broken cylinder head gasket • broken cylinder gasket • worn, damaged or seized cylind...

  • Page 224: Trbl

    8 - 3 trbl shtg faulty gear shifting/clutch slipping/ dragging/overheating faulty clutch engine operates but vehicle will not move v-belt • bent, damaged or worn v-belt • slipping v-belt plate ramp and piece slide • damaged or worn plate ramp • damaged or worn piece slide clutch spring(s) • damaged ...

  • Page 225: Trbl

    8 - 4 trbl shtg faulty brake/shock absorber malfunction/ unstable handling faulty brake poor braking effect front drum brake • worn brake shoe lining • worn brake drum • oily or greasy brake shoe lining • oily or greasy brake drum • improperly adjusted brake lever free play • improper brake cam leve...