Baja WD250U Service Manual Download

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13. Remove

• Gasket of left crankcase cover (1)

• Location pin (2)

• Intermediate gear shaft (3)

• Washer (4)

• Duplex intermediate gear (5)

(starting motor)

14. Remove

• Magneto (1)

CAUTION:

Disassemble the magneto rotator with special

tool.

15. Remove

• Semicircle key (1)

• Electric starting gear assy (2)

• Washer (3)

16. Remove

• Upper guide plate (1) (air intake side)

• Timing chain (2)

17. Remove

• 4 screws (1) (rear cover)

148

Summary of Contents for WD250U

Page 1: ...WD250U Service Manual For any questions please contact Baja Motorsports at 888 863 2252 ...

Page 2: ...ring diagram of ATV 21 I Technical explanation and requirement details of relative component 21 II Wiring diagram 1 23 III Wiring diagram 2 24 IV Wiring diagram 3 25 Section 7 Requirements for torque of fastener 26 1 ATV body 26 2 Engine 28 3 General torque specification 30 Section 8 Lubrication 31 1 Lubrication oil way 31 2 Lubrication diagram 32 Section 9 Lubrication point and type of lubricants...

Page 3: ...appliance 54 I Inspection of battery 54 II Inspection of fuse 55 III Replacement of headlight lamp 56 Section 5 Maintenance and adjustment of engine 58 I Adjustment of clutch 58 II Cleaning of air filter 58 III Inspection of spark plug 60 IV Adjustment of idle speed 61 V Adjustment of free clearance of throttle grip 61 VI Adjustment of speed limiter 62 VII Adjustment of valve clearance 63 VIII Adj...

Page 4: ...6 I Inspect switch 116 II Inspect the switch circuit 117 Section 3 Check headlight lamp 118 Wire diagram 119 Section 4 Troubleshooting the ignition system failure 120 Section 5 Running starting circuit 124 Section 6 Troubleshooting electric starting system 125 Section 7 Starting motor 128 Section 8 Check starting motor 129 Section 9 Battery will not hold charge 131 Section 10 Troubleshooting 133 S...

Page 5: ...ankcase 183 II Assembly of right crankcase 187 III Assembly of left crankcase 196 IV Selection and installation of adjusting washer 207 V Assembly of cylinder head 209 VI Manual starting mechanism and others 209 VII Mount the engine on the finished vehicle 219 Chapter VI Vehicle Troubleshooting 220 I Starting trouble difficulty 227 5 ...

Page 6: ...st silencer 12 Cushion 13 Fuel tank cover 14 Rear brake pedal 15 Front luggage carrier 16 Left rear brake lever 17 Hand operated parking brake 18 Main switch lock 19 Throttle grip 20 Right front brake lever 21 Left switch unit 22 Left and right mirror CAUTION The ATV you purchased may be slightly different from the pictures in the manual due to improvements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 7: ...e 5 Stop rotating meter for rotator used for removing and assembling rotator of kick starter 6 Puller for crank for disassembling crank from crankcase 7 Puller for rocker shaft used for the removing rocker shaft 8 Compressing tools for spring of valve for fixing and compressing spring when assembling valve lock clamp 9 Assembling and disassembling tools for valve guide 10 Assembling buffer used fo...

Page 8: ... II Instruments and meters The following instruments and meters can be selected with reference to the same type of vehicle 8 ...

Page 9: ...ether When assembling or replacing these components they should be kept in pairs 1 5 When disassembling the engine clean all components and place in a tray in the order of dis assembly not only increasing the assembling speed but also ensuring the correct assembly 2 Replace the components When replacing components use only the products lubricants and grease recommened by manu facturer 3 Oil seal s...

Page 10: ...lace all locking washer shim and location pin a After bolt or nut is in the lock position bend and fix both ends of locking shim along head of bolt or direction of nut 6 Bearing and oil seal 6 1 When assembling bearing and oil seal put the mark specification of manufacturer outside When assembling oil seal apply a thin layer of lithium based grease on the lip of oil seal CAUTION Do not dry inside ...

Page 11: ...ole of battery see figure 7 1 When tightening or loosening bolt on terminal of battery do not let the wrench contact the engine or other metal parts of the vehicle body to avoid electric shock 7 4 When connecting the wire to battery first con nect the positive pole then connect the negative pole After wires are connected apply clean grease on the terminal to increase resistence of rust 7 5 Check t...

Page 12: ...ector make sure there are no defects on the housing of the joints When inserting the joint after defects are fixed put plastic coating on In general multi head connectors are plastic and designed to lock When disassembling the connector first open lock when connecting again make sure the joints are in good condition and there are no bends or twists After connecting align the lock device and lock 8...

Page 13: ... mm 06 214 0 6214 3 281 1 094 0 3937 0 03937 mph mi ft yd in in Volume capacity cc cm cc cm lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP lig cu in qt IMP lig gal IMP liq Others kg mm kg cm Centrigrade 55 997 14 2234 9 5 C 32 lb in psi lb in2 Fahrenheit F Unit Read Definition Measurement mm cm Millimeter Centimeter 10ֿ Meter 10ֿ Meter Length Length kg kilogram 10 Gram Weight N Newton 1 ...

Page 14: ...ic centrifugal type Output Primary reduction system Gear driving Reduction ratio 73 22 3 318 Secondary reduction system Axle driving Reduction ratio 19 18x46 11 4 414 Output type Non cycle 5 gear forward gear back Operation Left foot operation Item Specifications Shifting type 1st speed 34 12 2 833 2nd speed 34 19 1 789 3rd speed 29 22 1 318 4th speed 26 25 1 040 5th speed 23 28 0 821 Reverse gear...

Page 15: ...less tire Material of rim Steel plate Sixe of tire AT22x10 10 Size of rim AT 10x8 0 Radial runout of rim 2 0mm Lateral swing of rim 2 0mm Type Drum type Outside diameter of brake drum 160mm 161mm Thickness of friction piece 4 0mm 2 0mm Free length of back spring of brake shoe 71 0mm Free play of brake lever left 5 7mm Free play of brake lever right 5 7mm Free play of rear brake pedal 20 30mm Free ...

Page 16: ...not Adjustable Assembling free play left end 1 0mm Assembling free play right end 1 0mm Front suspension system Rear suspension system Rear wheel fork Item Standard Voltage of electric system 12V Type D7RTC Resistence 10Ω Clearance of spark plug 0 6 0 7mm Resistence of primary coil At 20 C 68 F 0 5 1 5Ω Resistence of secondary oil At 20 C 68 F 4 6 7 6Ω Clearance of min spark 6mm 0 24in Ignition ti...

Page 17: ...ge At 2000r min 14 15V Coil resistence color At 20 C 68 F 1 0 1 2 white white Specific gravity 1 28 Type capacity 12N14 BS 12V 14Ah Type Fuse Main fuse 20A Reserved fuse 20A Coil resistence At 20 C 68 F 72 88Ω Diode Yes Type Constant mesh type Output power 0 35KW Resistence of armature coils At 20 C 68 F 0 004 0 005Ω Ampere 100A coils resistence At 20 C 68 F 4 8 5 3Ω Magneto Rectifier Charging sys...

Page 18: ...cylinder head with ruler 0 10mm Timing chain Type of timing chain Tension type of timing chain Roller chain Free adjustment Pneumatic camshaft Driving method Roundness tolerance of camshaft Outside diameter of camshaft Cam size Exhaust A B C Intake A B C Chain driven 24 96 24 98mm 36 582 36 682mm 30 252 30 352mm 6 572 6 692mm 36 537 36 637mm 30 131 30 231mm 6 527 6 647mm 0 03mm 36 482 30 152 36 43...

Page 19: ...lve stem exhaust intake Inside diameter of valve guide intake exhaust Clearance between valve stem and guide exhaust intake Roundness of valve seem 0 05 0 09 0 11 0 15 28 4 28 6mm 33 9 34 1mm 1 7 2 8mm 0 9 1 1mm 0 8 1 2mm 5 960 5 975mm 5 975 5 990mm 6 000 6 012mm 0 025 0 052mm 0 10 0 037mm 1 6mm 0 10mm 0 08mm 0 03mm Piston ring First ring Type Size BxT Clearance of endface in assembling Clearance ...

Page 20: ... D Big end radial clearance of connecting rod E 55 95 56 00mm 0 8 1 0mm 0 35 0 65mm 0 010 0 025mm 0 03mm 0 06mm 2 0mm Automatic centrifugal clutch Clutch shoe quantity thickness Clutch messhing revolution Clutch stalled revolution Free length of back spring of brake shoe Clutch Action method of clutch Clutch piece quantity thickness Friction piece quantity thickness Spring of clutch quantity free ...

Page 21: ...ot put through the guide clip of holding seat of steering bar See figure E E I Technical explanation and requirements details of relative component W After putting the fuel tank vent tube though the hole of main switch lead it to the lower right side of steering bar then put it through the wire hook on the frame NOTE Hose must be unlocked see figure E E V The leading wire on the switch units of st...

Page 22: ... 29 JS150 00 039 Cable band 6 28 JS150 00 03 Steering bar band 2 27 C D I magneto wire 1 26 Vent tube carb 1 25 JS150 00 06 Cut ff relay 1 24 FG 802000 0 Starting relay 1 23 SSA5 320000 0 Cable 1 22 SSA0 000516 0 Vent tube rear brake 1 21 Wire of starting motor 1 20 High voltage coils and wire 1 19 Vent tube battery 1 18 SSA0 000515 0 Vent tube front brake 1 17 Wire of headlight 1 16 SSA4 230000 0...

Page 23: ... II Wiring diagram 1 23 ...

Page 24: ... III Wiring diagram 2 24 ...

Page 25: ... IV Wiring diagram 1 25 ...

Page 26: ... 2 3 17 Steering vertical post upper lower holding seat of steering bar Bolt M8x60 4 20 2 14 Front wheel fork frame Bolt M10x70 4 45 4 5 32 Front wheel fork brake Nut M12x1 25 2 25 2 5 18 Engine upper connecting plate frame upper Bolt M8x16 2 33 3 3 24 Engine assy engine upper connecting plate Bolt M8x55 1 33 3 3 24 Engine assy frame front Bolt M8x65 1 48 4 8 35 Engine assy frame rear upper Bolt M...

Page 27: ...ow rear axle housing Bolt M8x1 25 4 28 2 8 20 Rear wheel fork frame left Bolt M22x1 5 1 130 13 94 Rear wheel fork frame right Bolt M22x1 5 1 6 0 6 4 3 Rear arm ahst nut right Nut M22x1 5 1 130 13 94 Rear wheel fork unit rear driving gearbox Nut M10x1 25 4 55 5 5 40 Rear wheel axle bushing rear driving gearbox Bolt M10x1 25x25 4 55 5 5 40 Rear shock absorber upper frame Bolt M12x75 1 50 5 36 Lower ...

Page 28: ...5 36 Locking nut adjusting screw of valve clear nace Nut M6 2 14 1 4 10 Cam timing sprocket Bolt M10 1 60 6 43 Chain tensioner Bolt M6 2 10 1 7 2 Chain tensioner cover Bolt M6 1 7 0 7 5 1 Upper guide plate of chain Bolt M6 2 8 0 8 5 8 Oil pump Screw M6 3 7 0 7 5 1 Oil draining screw plug Plug M35 1 43 4 3 31 Fine filter cover of engine oil draining oil Bolt M6 1 10 1 7 2 Fine filter cover of engin...

Page 29: ...g agent Locking nut clutch releasing adjustable screw Nut M8 1 15 1 5 11 Starting surpassing clutch Bolt M8 3 30 3 22 Apply tighten ing agent rivet to prevent lossen Connecting plate of starting motor Screw M6 2 7 0 7 5 1 Output gear Nut M16 1 60 6 43 Left case bearing clamp of driving shaft Screw M8 3 25 2 5 18 apply tighten ing agent Rear cover bearing inner hex agonal screw sleeve 2 50 5 36 app...

Page 30: ...ving disc Screw pin M6 1 12 1 2 8 7 III General torque specification General torque specification standard screw This figure is a screw locking specification drawn by International Standard Association In order to avoid twisting or unbalancing when locking screw cross lock as stated below When measuring torque force standard torque force testing spanner must be used A Nut B Screw m kg 10mm 6mm 0 6...

Page 31: ...Section 8 Lubrication I Lubrication oil way 31 ...

Page 32: ... 1 Oil draining plug 8 Oil pump driving gear 2 O ring 9 Camshaft 3 Compressing spring 10 Crankcase 4 Rough filter 11 Crank 5 Oil pump washer 12 Spindle 6 Oil pump assy 13 Driving shaft 7 Oil pump driven gear 14 Fine filter 32 ...

Page 33: ... 1 Single direction valve 8 Single direction bearing 2 Engine oil fine filter automatic centrifugal clutch 3 Engine oil fillter cover 9 Crank pin 4 O ring 10 Crank pin 5 Clip 11 Spindle 6 Camshaft 12 Driving shaft 7 Rocker 33 ...

Page 34: ...Light lithium base grease Dust proof ring of brake Light lithium base grease Joint of front brake cable Light lithium base grease Front brake lever axle rear brake lever axle Light lithium base grease Adjusting nut pin of front brake cable Light lithium base grease Adjusting nut pin of rear brake cable Light lithium base grease Rear brake pedal pivot brake pedal axle hole Light lithium base grease...

Page 35: ... Shift gear shaft upper cam plate unit Lubricating oil Steel ball bracket unit Steel ball bracket unit upper lower cam plate Lubricating oil Surpassing clutch Surpassing clutch main clutch cover inner spline sleeve Lubricating oil Outside surface of reverse gear Reverse gear controlling rod rear transmission controlling rod Lubricating oil Outside surface of reverse gear Reverse gear fork shaft re...

Page 36: ...et if necessary Spark surpressor Clean Oil circuit Check for cracks damage in oil tube Replace gasket if necessary Engine oil Replace preheat engine before draining oil Oil filter Clean Oil filter screen Clean Gear case oil Check oil level and leakage Replace Brake Check the operation Adjust if necessary Clutch Check the operation Adjust if necessary Wheel Check the balance damage run out etc Repl...

Page 37: ...ion 1 Disassembly 1 Place the vehicle on level ground 2 Disassemble the cushion 1 Pull the cushion lock lever 2 up then raise the rear of cushion 2 Installation First insert the support lug on the front end of cushion into the plug of frame press the rear of seat down 1 2 37 ...

Page 38: ...hion 3 see cush ion disassembly in this section 4 Disconnect the negative wire 5 and positive wire 4 of battery CAUTION Disconnect the negative wire 5 first 5 Disassemble the clamp plate 9 of battery 6 Disassemble the starting relay 6 7 Disassemble the cut off realy 7 8 Take out the battery 8 9 Disassemble the rear fender 10 1 2 3 4 5 6 7 8 9 10 38 ...

Page 39: ...ll a Cut ff relay 3 b Starting relay 4 c Connect the positive wire 6 to battery d Connect the negative wire 5 to battery 4 Install the cushion 1 CAUTION Insert the support lug 2 of cushion into the plug seat 3 on the frame then press down on the seat 5 Install rear luggage carrier 1 Torque requirement for fasteners Bolt 2 fastening torque 3N m Bolt 3 fastening torque 9N m CAUTION Remember to insta...

Page 40: ...xpansion screw assy 3 all around c Fuel tank cover 4 6 Turn the fuel shut off valve to the OFF position 7 Remove the fuel inlet pipe 8 CAUTION Place a cloth on the engine to absorb the splashed gasoline WARNING The gasoline is flammable Avoid splashing it on the hot engine 8 Remove 4 Bolts 1 flat washers 30 rubber hood of fuel tank and installing bushing of fuel tank 9 Remove the air inlet pipe 2 ...

Page 41: ... of air pipe and air rub ber pipe 4 CAUTION The convext part on the ring should be facing forward when installing the supporting pad 3 of air pipe 4 Install a Fuel tank cover 4 b Plastic expansion screw assy 3 c Bolt 2 and related fasteners and connecting pieces The fastening torque of bolt is 10N m 5 Connect Air hose 6 Install Cushion see Cushion installation 1 2 3 4 2 3 4 41 ...

Page 42: ...ehicle on level ground 2 Disassemble the front luggage carrier 1 3 Disassemble the front guarding plate 2 4 Cut off the connecting wire 1 of head light from connecting point 5 Disassemble the bumper 2 6 Disassemble the front fender 1 1 2 1 1 2 42 ...

Page 43: ...ting plate The fastening torque is 7N m 2 Install the bumper 1 The fastening torque of bolt bumper and frame is 16N m 2 Install the front guard plate 1 4 Install the front luggage carrier 1 Bolt 2 front luggage carrier and frame The fastening torque is 34N m Bolt 3 front luggage carrier and bumper The fastening torque is 11N m 2 1 1 2 3 1 1 43 ...

Page 44: ... mark 2 replace the brake shoe assy Refer to Rear wheel and rear brake section in Chapter VII II Adjustment of front brake CAUTION Before adjusting check the degree of wear on the front brake according to the above procedures CAUTION In order to avoid too large or too small brake force when braking make sure there is prop er free clearance of left right brake lever and rear brake pedal 1 Check If ...

Page 45: ...tate the adjusting screw 2 clockwise or counterclocksiwe to gain proper free clear ance Clockwise wear free clearance Counterclockwise decrease free clearance Tighten the lock nut III Adjustment of free clearance of left lever and rear brake pedal CAUTION Before adjusting check the wear condition of rear brake CAUTION In order to avoid too large or too small brake force of rear brake WARNING When ...

Page 46: ... clearance rear brake pedal 20 30mm Rotate adjusting nut 3 of rear brake cable until correct clearance is met 0 1mm 5 Rear brake arm assy 6 Pin Screw out the adjusting screw 2 of rear brake cable untl gaining correct free clearance b Free clearance b left lever 5 7mm Screw up the locking nut 1 Check the free clearance of left lever and rear brake pedal If is does not meet the standard value repeat...

Page 47: ...il level inspection of rear driving gear case Check the lubricating oil level of the gear case CAUTION The engine must be in a cold state Checking procedure Place the vehicle on level ground Placce oil catcher under the gear case Remove the oil filling screw plug 1 and sealing washer Observe the oil level the correct amount should be on the bottom of oil filling hole If the oil level is too low re...

Page 48: ...ng washer oil drain screw plug position If damaged replace it 5 Install Oil drain screw plug rear driving gear case Torsion of oil drain screw plug 23N m 6 Oil fill screw plug CAUTION Avoid any forgein matter from entering the driving gear case Recommended oil SAE80API GL 4 engine oil of hypoid gear If needed you may use SAE80W90 engine oil of hypoid gear Period replacement 0 12L Total capacity 0 ...

Page 49: ...nit of steering tension rod Rotate the steering bar leftward and or rightward then rotate from left to right If the ball pin unit 1 of steering tension rod has too much vertical clearance replace it Refer to Chapter 3 section 4 Steering system 4 Lift the front end of vehicle to make the front wheel not bear any load 5 Check Left right front seat assy on front brake position and or bearing 6005 2Z ...

Page 50: ...djust 3 Adjustment Adjustment steps of toe in Mark determination marks at the end of t left right tension rod 1 Loosen the locking nuts at the end of left right tension rod 2 Left right tension rods 3 should turn the same turns left or right up to obtain the specified toe in and make the lrft right tension rods are the same in strength Tighten up the locking nuts 2 at the end of left right tension...

Page 51: ...sorber and front wheel fork and Rear shock absorber and rear wheel fork 3 Inspection Operation Move the front rear shock absorbers up and down If it is not operating correctly replacce the compo nent Refer to Chapter 3 section 5 and 6 Front shock absorber and front wheel fork and Rear shock absorber and rear wheel fork XI Adjustment of rear shock absorber Adjustment of spring preload Turn the adju...

Page 52: ...xin Wuxi AT22x7 10 Rear Zhengxin Wuxi AT22x10 10 Tire pressure 1 Recommended tire pressure Front 20Kpa 0 20kg f cm Rear 25 Kpa 0 22kg f cm 2 Low tire pressure will cause the tire to dislodge from the rim in bad driving condition The Minimum tire pressure Front 17Kpa 0 17kg f cm Rear 22Kpa 0 22kg f cm 3 When installing the tire to the rim the tire pres sure should be no more than Front 250Kpa 2 50k...

Page 53: ...roper tire pressure The tire pressure of both the front and rear tires should be the same Normal Temp Front Rear Tire Pressure Standard 20kpa 0 20kgf cm 25kpa 0 25kgf cm Min 17kpa 0 17kgf cm 25kpa 0 22kgf cm Max 23kpa 0 23kgf cm 28kpa 0 28kgf cm 2 Inspection If wear or damage is found on the durface of the tire replace WARNING Using overworn tires is extremely dangerous If the tire is worn to the ...

Page 54: ...ures below a When changing the battery be in a well ventilated area b Keep away from flame or spark such as welding equipment burning cigarettes etc c Smoking is strictly prohibited when charging or operating the battery d Keep away from children 1 Removal refer to Section 2 of this chapter Cut off refer to Removal of cushion of this chapter Battery electrode negative electrode 1 positive electrod...

Page 55: ...ction of fuse CAUTION Close the main switch when checking or replacing the fuse otherwise it will cause a short circuit 1 Inspection steps Remove the fuse 1 Connect the small size test instrument to measure if the fuse is connected well CAUTION Set the test instrument at the position of 52x1 Small sixe test instrument 9 N YU 3112 90890 03112 If the indicating needle points toward the fuse is broke...

Page 56: ...nce of chapter 4 3 Installment of fuse cover III Replacement of headlight lamp 1 Cut off engine Connecting wire terminal of headlight 1 2 Removal Unit of headlight 2 3 Take out the lens 1 4 Remove the lens seat 2 Rotate countereclockwise when taking out the lens 1 CAUTION When removing the light head hold the front side of the headlight with hand 5 Removal Lamp 1 WARNING The lamp is very hot never...

Page 57: ... value If there are some oils on it clean off with cloth mixed with alcohol 7 Connect Light seat 1 CAUTION Be sure that the projective part of the lamp is engaged with the convex groove on the light seat 8 Install the lens to the light seat 9 Installment Headlight CAUTION Install the rubber hole guard ring of the headlight connecting wire to the headlight 10 Connect Connecting wire terminal of hea...

Page 58: ... screw rod 2 counterclock wise to decrease the clearance of clutch Turn the adjusting screw rod 2 clockwise to increase the clearance of clutch II Clean the air filter CAUTION There is an inspection cup 1 on the bottom of the air filter if there is dust or water deposits in the cap clean the filter core and filter box of air filter 1 Remove the cushion Refer to Cushion Remov al of this chapter 2 R...

Page 59: ...e foam filter core a Clean with water completely and slightly b Squeeze the surplus water of the foam and dry it NOTE When squeezing the water on the foam 7 Installament a Install the foam filter core to the foam supporting cylinder to combine an air filter assy b Install the air filter assy c Install the air filter cover CAUTION Make sure that the close fit surface of air filter is engaged with t...

Page 60: ...wn or light brown is normal condition If the color is clearly different check the engine 4 Clean the spark plug Clean the spark plug with spark plug cleaner 5 Measure the spark plug clearance 1 Measure with feeler gauge If out of specification adjust Spark plug standard clearance 0 6 0 7mm 6 Installment of spark plug a Clean the washer surface and spark plug surface before installing the spark plu...

Page 61: ...e throttle grip is within 3 5mm otherwise readjust the idle speed V Adjustment of free clearance of throttle grip CAUTION First adjust the engine idle speed when adjusting throttle grip 1 Rest the vehicle on level ground 2 Inspection Free clearance of throttle grip a If out of specifications adjust free clearance of throttle grip 3 5mm 3 Adjustment Adjustment steps of free clearance of throttle gr...

Page 62: ...locking nut 1 b Adjust the adjusting screw 2 clockwise or counter clockwise to make a obtain the specified length of 12mm c Lock the locking nut 1 WARNING a For the beginner driver pay extra attention to screw the limiter inward and screw out with im provement of driving skills Never remove the adjusting screw of speed limitor b For the correct throttle grip operation never screw out the adjuster ...

Page 63: ...he vehicle on level ground 2 Remove a Cushion Refer to section 2 Cushion removal of this chapter b Fuel tank Refer to section 2 Fuel tank remov al of this chapter 3 Remove a Timing observation hole scsrew 1 b Manual operation start mechanism 2 4 Remove a Valve cap 1 the side of exhaust valve b Valve cap 2 the side of intake valve 2 Adjustment 1 Measure the valve clearance a Turn the crankshaft cou...

Page 64: ...ce if it is out of specifica tion Intake valve clearance 0 05 0 09mm normal temp Exhaust valve clearancee 0 11 0 15mm normal temp 2 Adjustment of valve clearance a Loosen lock nut 1 b Insert the plug gauge spanner 2 between adjusting screw 3 and valve rod c Turn the adjusting screw 3 clockwise with valve adjusting spanner until the right clearance has been met Size of valve adjusting spanner 3mm C...

Page 65: ... up 3 ii Check if the o ring 4 is damaged if so re place immediately Torque of valve cap 10N m 2 Mount a Oil tank see oil tank installation in this section b Upper cover of oil tank c Seat see installation of seat in section 2 VIII Adjustment of timing chain tension The engine has an automatic adjusting tensioner on the chain so manual adjustment is not neccessary 1 2 65 ...

Page 66: ...f the spark plug cap 90890 003141 5 Inspection of ignition timing Inspection steps a Remove the plug 1 b Start the engine run engine at 1450r min 1550r min idle speed WARNING When the engine is running the mcahines oil may splash out be careful c Check if the the mark 2 on the crankcase is in range 3 of ignition under the magneto rotor indication If it is out of range check if the rotor or pulse c...

Page 67: ...ff 3 The following are steps for measuring compres sive force a Install pressure gauge 1 and change connec tor b Turn the throttle lever to max position Start engine with power battery has been charged fully until there is no increase on the pressure gauge WARNING When starting the engine the spark plug must be connected to ground to avoid sparks c Reading the pressure gauge Compressive foce on se...

Page 68: ...der head washer may be damage Read is over max value Check if cylinder head throttle surface or piston top end are carbon laydown 4 Remove pressure gauge 5 Mount spark plug torque of mount equals 17 5N m XI Inspection of oil quantity of engine CAUTION No foreign matter in crankcase 1 Place vehicle on flat ground 2 Check engine oil quantity and fill it if it is inadequate Inspection steps a Pre hea...

Page 69: ... of oil flow and replacement of engine oil CAUTION The clutch can be lubricated with engine oil but do not use any chemical additive in machine oil because it can cause the clutch to breakdown Foreign matter should not be permitted in the crankcase 1 Put vehicle on flat ground 2 Pre heat the engine and stop after several min utes 3 Place a container under the engine 4 Remove oil dipstick and drain...

Page 70: ...er 1 fire filter cap with O ring 2 rough filter 3 and draining plug 4 should be installed WARNING Be definite that th draining plug mount O ring 5 compressor spring 6 and fine filter are in the correct mounting order prior to installation Mounting torque fine filter cap 10N m Draining plug 43N m 10 Fill the crankcase with machine oil Refer to Inspection of Engine Oil Quantity Appendix Total 2 2 L ...

Page 71: ...loosen bolt 1 of cylinder head b start engine for racing until oil runs from the oil tunnel Stop the engine immediately if no machine oil comes out to avoid damaging the engine c Start the engine again after fixing step b and check the oil pressure d The oil tunnel bolt should be fastened ac cording to standard Fasten the torque of oil tunnel bolt 7N m 1 70 ...

Page 72: ...ans shaft 19 Circlip 20 Rear joint 21 Bearing 22 Oil seal 23 Bearing 13 Bearing 14 Bearing gasket 15 O ring 16 Bearing 17 Bushing 8 Bearing 9 Oil seal 10 Bearing 11 Main driving gear 12 Thrust pad Chapter III Repair and Maintenance of Vehicle Body Section 1 Rear driving gearcase and driving shaft 71 ...

Page 73: ...it s difficult to distinguish them from normal operating noise Remove these parts for special inspection if you think they may have been damaged II Inspection 1 Check abnormal noise The following noises may indicate mechanism trouble a Boom when vehicle is sliding accelerating or decelerating The noise is not direct ratio with higher engine and transmission case speed but is direct ratio with rear...

Page 74: ... of oil seal causes oil leakage in new vehicles 2 To avoid unnecessary disassembly check and confirm the oil leakage carefully III Trouble shooting table Check following points if there is basic trouble condition To check if the wheel bear ings are damaged lift the front end of vehicle and rotate the front wheels Check the rear wheel shaft to see if the bearings are damaged To check if the bearing...

Page 75: ...ear fender Refer to rear fender 3 Disassemble 1 Rear wheel left 2 Connecting plate of rear wheel 3 Rear wheel right 4 Rear brake and rear brake hub 5 Rear wheel shaft Refer to Rear wheel rear brake rear wheel shaft 4 Disconnect Air pipe 1 rear driving gear case 5 Disassemble Rear driving gear case body 2 CAUTION 1 The transmission shaft 3 could possibly drop out while driving gear case is removed ...

Page 76: ... Rear driving gear case body 1 2 Annular gear pad 3 Shift gear 4 Thrust plain pad c Disassemble Bearing gasket transmission shaft last grade CAUTION On the bearing there is left handed thread The bearing gasket may be loosened if rotated clockwise CAUTION Use special wrench when reinstalling the bear ing gasket 1 1 2 1 75 ...

Page 77: ...Oil seal 1 2 Bearing 2 shift gear Properly support rear driving gear case and use proper pressure assemble tool 3 f Disassemble Bearing 1 main driving gear Procedures for disassembly 1 Heat up the rear driving gear case to 150 C 2 With a proper punching pin 2 remove the outer circle of bearing 3 On the main driving gear remove the inner circle of bearing CAUTION Removing the inner circle of the ma...

Page 78: ...t be replaced The oil seal should not be used repeat edly b Be sure to adjust the main driving gear and or shift gear when replacing them Turn to Choice of Main Driving and Shift Gear Pad 5 If the transmission shaft 5 spline has any wear or damage replace it 6 If there are any cracks or damage on the driv ing gear case body 6 and cover 7 replace them CAUTION Be sure to adjust the pad of main drivi...

Page 79: ...Example 1 If 01 is engraved on the main driving gear then a is 84 0 01 84 01 2 If 10 is engraved on the main driving gear then b is 83 5 0 10 83 60 3 A 0 41 4 Chose the proper pad and correct the percent digit The resulted value in the example is 0 41 but the meter specifies to change 1 of the per centage digit to 0 The pad thickness will then be 0 40mm Number on Amending percent digit value 0 1 2...

Page 80: ... the shift gear f bearing thickness regarding unchange able 11 00mm For example 1 The number engraved on the driving gear case body is 07 c 45 5 0 07 45 57 2 The number engraved on the driving gear case cover is 06 d 1 0 06 1 06mm 3 The number engraved on the shift gear is 05 e 35 0 05 34 95 4 f 11 00 5 Pad thickness B 45 57 1 06 34 95 11 0 68 Number on Amending Percent value value 0 1 2 0 3 4 5 6...

Page 81: ...to the shift gear 2 Install oil seal 1 3 Install the outer circle of the needle bearing bigger 2 of shift gear onto the driving gear case body Warning Must use new oil seal 4 Install main driving gear 1 pad 2 and bearing 3 and install bearing gasket 4 Calculate the size of the pad CAUTION a The bearing gasket is left handed so tighten it by rotating counter clockwise b Before installing the bearin...

Page 82: ...AT22x10 10 2 Rim Dimension 8 5x10 3 Tire air pressure Normal Temperature Standard value Min value Max value 25KPa 22KPa 28KPa 4 Runout Radial runout End face runout 2mm 2mm 5 Wear limit of tire 2mm 6 Wear limit of friction disk 2mm 7 Rear brake hub wear limit 161mm Technical Parameter 81 ...

Page 83: ... Right end of rear wheel 1 Rear brake hub 2 Brake shoe 3 Bearing block 4 Dust proof seal 5 Air pipe 6 Rear brake cover assembly 7 Rear brake cam shaft 8 Brake indicating plate 9 Rear brake arm assembly 82 ...

Page 84: ...e parts falling which will cause danger during the removal process rest the vehicle firmly 4 Removal the Ser No is corresponding to the Ser No on the drawing 1 Connecting nut of front and rear wheels 2 Left rear wheel 3 Split pin 4 Rear wheel axle nut 5 Washer 6 Rear wheel connecting plate 5 Removal the Ser No is corresponding to the Ser No on the drawing 1 Connecting nut if front and rear wheels ...

Page 85: ...rake arm 3 Brake indicating plate 4 Rear brake cam shaft 12 Removal 1 O ring 30x1 8G 2 Plain pad of rear brake cover 13 Removal 1 Rear wheel axle Beat the right end of the rear wheel axle slightly pull the rear wheel axle from left end CAUTION Take out the rear wheel axle from the end of rear wheel axle bushing and gear box with soft hammer WARNING While taking out the rear wheel axle in order to ...

Page 86: ...onnecting plate 2 If worn or damaged replace it 4 Inspection Friction plate of rear brake 5 Measurement Thickness of brake friction plate See the Front wheel and Front brake inspec tion section of this chapter Attached The thickness of brake friction plate is 4 0mm 0 16in Wear limit 2 0mm 0 08in 6 Inspection Tension spring of brake shoe See the Front wheel and Front brake Inspec tion section of th...

Page 87: ...maged replace it 9 Inspection 1 If there are any cracks bends or damage on the brake cover replace it 2 If the dust proof seal is worn or damaged replace it 10 Inspection 1 If there is worn scraped marking or dam age on the cam shaft of rear brake replace it 2 If the air pipe of rear brake is clogged remove this pipe and clean the dirt if damaged replace it 11 Clean the air hole on the rear brake ...

Page 88: ...rn or damaged replace it Replacement steps of bearing and oil seal a Clean around the bearing of gear case end b Remove the oil seal 1 with plain screw driver CAUTION In order to protect the oil seal out edge from damage during the removal process place a wood block 2 under the screwdriver Remove the bearing 3 with corresponding tool The installment of new bearing and oil seal is in reverse Cautio...

Page 89: ...nstallment of rear wheel axle 1 CAUTION Before installing the rear wheel axle loosen all bolts on the driving gear case 2 hold the rear wheel axle with hand to make it enter the gear groove of gear case apply on the left end of the axle slightly with soft hummer WARNING In order to protect the axle thread and splint tooth of axle never beat the end face of axle directly with hummer 3 Installment P...

Page 90: ... brake cam shaft 1 At the same time align the punch mark c on the rear brake cam shaft with that d of the rear brake arm assy 3 The torque of rear arm assy 9Nm 6 Application Sealing agent Be suitable for the rear brake cover assy and rear wheel axle bushing sur face Attached Sealing agent P N ACC QUICK GS KT 7 Installment Rear brake cover assy 1 Bearing block of rear brake 2 CAUTION Install the re...

Page 91: ...or splint on the right end of rear wheel axle other wise during the work the surplus lubri cation oil will leave on the brake shoe affect ing the brake performance 10 Installment Rear brake hub 11 Installment The Ser No as shown on the drawing 1 Air pipe 1 of rear brake 2 Rear brake tension rod assy 3 Rear brake cable 12 Installment Spring Pin Adjusting nuts 4 of rear brake tension rod assy and re...

Page 92: ... is the arrow marking direction on the tire For this refer to Front wheel and Front Brake section of this chapter WARNING When installing the core nut to the rear wheel be sure to face its core edge to the wheel 18 Installment Connecting plate of rear wheel 1 Washer 16 2 Rear wheel axle nut M16 3 Split pin 4x30 4 Left rear wheel 5 Connecting nut of front and rear wheels 6 Refer to Rear wheel secti...

Page 93: ...Lower holder of steering bar 3 Steering vertical column welding 4 Steering vertical column holder 5 Seal ring 6 Bushing 7 Clip assy 8 Locking pad 9 Steering tension rod ball pin assy 10 Tension rod Section 4 Steering Operation system 92 ...

Page 94: ...2 Removal Main switch lock wire Neutral indicating light wire Reverse indicating light wire High beam indicating light wire Clutch switch wire 3 Removal 1 Front brake cable 4 Removal 2 Throttle grip assy 5 Removal After stopping the vehicle remove the rear brake cable 1 6 Removal Handlebar Handlebar bracket 1 1 93 ...

Page 95: ...plit pin 3 2x24 Nut M12x1 25 Tension rod 1 CAUTION When removing the tension rod end and steering ball pin from the steering vertical column weld ing assy and front seat assy of front brake with common bearing tension tool and other tools pay attention not to damage the relevant parts 5 Removal Remove the steering vertical column weld ing assy together with steering vertical column holder 6 Remova...

Page 96: ...umn do not straighten it forcefully if it is bent 3 Inspection Check the steering vertical column holder 1 and seal ring 2 If they are worn or damaged replace them 4 Inspection If the tension rod 1 is bent or damaged re place them 5 Correcting If the free clearance is found on the ball pin head replace the ball pin If the part around the ball pin head is uneven replace the ball pin If there is con...

Page 97: ...ssy the front brake CAUTION The connection nut A B can be tightened up only when the revealed thread length b of two ends of tension rod are the same Attached Connecting nut torque of tension rod 30Nm 7 Inspection If the bearing 1 and O seal 2 under the steering vertical welding are worn or damaged replace them IV Installment steps The reversal steps of Removal steps are the Installment steps Pay ...

Page 98: ...ION Never damage the seal ring when installing 4 Installment When installing the steering vertical column holder and steering vertical column welding take them as a unit WARNING In order to ensure that the correct circuit of brake cable and wire never damage and wind the cables and wires 5 Installment of left and right tension rod 2 CAUTION Make sure that the ball pin 1 at the side of scraped mark...

Page 99: ... Tightening After mounting the washer nut split pin under the steering vertical column Nut torque 30Nm 9 Install Clip 1 locking washer 2 bolt 3 Attached bolt torque 23Nm WARNING Always use new locking washer 10 Bent showing supporting lug of locking washer to lock lightly the bolt 11 Fill the lubrication oil at the oil cup to lubricate the bearing under the steering vertical column Lubrication oil...

Page 100: ...must cor respond with the sunken part 2 on the right lever seat when installed WARNING Correct installation of cable and wire is very necessary to ensure the safe operation of ve hicle Refer to chapter 1 Wiring diagram of vehicle 3 Adjusting the free clearance of brake cable Refer to Adjustment of Front Brake and Adjustment of free clearance about left handle lever and rear brake pedal in chapter ...

Page 101: ... 1 Front shock absorber 2 Left right front seat assy 3 Left right front wheel fork welding 4 Bushing unit Section 5 Front shock absorber and Front wheel fork 100 ...

Page 102: ...brake of this chapter 2 Take off split pin 1 nut 2 and steer ing rod ball pin assembly 3 3 Take off the bolt 3 under the front shock absorber nut of front shock absorber 2 and front shock absorber 4 4 Loosen the front shock absorber nut 2 5 Take off the bolt 3 under the front shock absorber nut of front shock absorber 2 and front shock absorber 4 6 Take off split pin 5 nut 6 on the left right fron...

Page 103: ... Nut torque 45Nm c Move the left right front wheel fork from one side to another to check it s side clearance If the side clearance is very obvious replace bushing sub assembly or a set of front wheel fork d Move the left right front wheel fork up and down to check its vertical clearance If the vertical moving is tight limited or uneven re place the bushing sub assembly or whole front wheel fork 8...

Page 104: ...ont seat assy of front brake if it is cracked sunk or damaged replace it WARNING If the front axle is bent don t straighten it This is to avoid reducing the performance of the front axle on the front brake 3 Check the left right front wheel fork weld ing If it is cracked bent or damaged replace it WARNING If the left right front wheel fork welding is bent don t straighten it sedulously in order to...

Page 105: ...ubrication oil is lithium base grease 2 Fix nut 2 Nut torque 45Nm CAUTION Must ensure that the correction of bolt mount ing of left right front wheel fork bolt head position showing on the drawing 1 front behind 2 that make the bolt head is out ward A means the vehicle is forward 3 Mount left right front seat assy 1 4 Fix the nut 2 of left right front seat assy Attached Nut torque 25Nm 104 ...

Page 106: ...k absorber CAUTION Before fixing the front shock absorber nut 5 you must ensure that the side plane 8 of universal joint 7 is limited by frame limited block The head of bolt should be forward The cor rection of bolt mounting direction 6 under the front shock absorber should be guaranteed 7 Tighten the nut 5 bolt of front shock absorber 6 Attached Nut torque of front shock absorber 5Nm Bolt torque ...

Page 107: ...e nut WARNING Must use new split pin 3 10 Mount front brake cap assy brake shoe assy front brake hub and front wheel Refer to Installation of front wheel and front brake of this chapter 11 Adjust front wheel toe in Refer to Adjustment of front wheel toe in in chapter 12 Mount front fender safety lever and front carrier Refer to the second section of chapter 2 106 ...

Page 108: ...sher assy of rear shock absorber 3 Rear arm nut M22 4 Rear arm joint bolt 5 Axle bushing 6 Oil sealing 7 Bearing 30203 8 Rear wheel fork Assy 9 Rubber tube 10 Lower cap of gear case Section 6 Rear shock absorber and Rear wheel fork 107 ...

Page 109: ... this chapter 2 Take off lower cap 2 of gear case 3 Take off the rear driving gear case sub as sembly 1 Refer to Dischargment of rear driving gear case sub assembly and driving shaft section of this chapter 4 Take off split pin 3 2x24 1 washer 12 2 and rear shock absorber pin shaft 3 CAUTION When taking off rear shock absorber pin shaft 3 hold rear wheel fork so that rear wheel fork does not drop ...

Page 110: ...t of rear wheel fork right side Attached Torque of rear arm joint bolt and nut is 130N m Torque of rear arm joint nut 2 is 6N m b Move the rear wheel fork across to check the side clearance A If the clearance is big check the relevant parts of bush bearing 30203 and frame Attached Free clearance value is less than 1 00mm c Move the rear wheel fork up and down to check the vertical clearance If the...

Page 111: ...m joint bolt 11 Take off rear wheel fork assy 1 II Checking steps 1 Check a If rear shock absorber is leakage if any replace it b If rear shock absorber is bent or damaged if any replace it c Pull the spring up and down to check if spring is fatigued or damaged if it is replace rear shock absorber 1 110 ...

Page 112: ... joint bolt 2 and bush 3 If one of these parts are worn or damaged replace it 5 Check the bearing 30203 1 of rear wheel fork assy if there is free clearance during the bearing match with the rear wheel fork or un even swirl replace the bearing Check the oil sealing 2 If it is worn or damaged replace it Replacing steps of bearing 30203 and oil seal ing a Clean the bearing round b Take off the oil s...

Page 113: ...g WARNING Don t strike the bearing inner race 5 and roller The pressure tooling 4 is only in contact with outer race 7 III Mounting steps The reverse step of disassembly is the mounting step but the following points must be paid attention to during the installation 1 Lubricate the bearing 10 oil sealing 2 bush 3 and rear arm joint bolt 4 Lubrication oil is Lithium base grease 2 Mount the real whee...

Page 114: ... makes contact with its bush 3 Attached Bolt torque value 6Nm c Fix right rear arm nut 4 by standard torque Attached Rear arm nut torque 130Nm 4 Check rear wheel fork free clearance Refer to step 8 in disassembly 5 Lubricate the upper and lower end surface of rear shock absorber see figure Use Lithium base grease as lubrication oil 6 Mount rear shock absorber Upper nut torque of rear shock absorbe...

Page 115: ...f rear driving gear case sub assembly and driving shaft section of this chapter 9 Mount the rear wheel axle rear brake hub right rear wheel rear wheel joint plate and left rear wheel Refer to Installation of rear wheel rear brake rear wheel axle section of this chapter 1 114 ...

Page 116: ... CDI assembly 15 Battery 2 Rectifier 22 Main switch lock 5 Safety starting relay 24 Neutral indicating assembly 6 Power off relay 26 Reverse indicator assembly 7 High voltage coil 28 High beam indicator assembly 11 Reverse switch 32 Cable 13 Neutral switch 115 ...

Page 117: ...1 when inspecct ing the circuit Turn the switch on and off many times while inspecting The left figure indicates the wire position of switch The vertical line indicates switch posi tion The first row indicates color of wire O O indicates the circuit between the wire ends 1 When the switch is turned to OFF the black and black white wire are on 2 When the switch is turned to ON the red and brown wir...

Page 118: ...pect if the circuit between wire and wire end is on If the contact is poor or the circuit is off repair or replace 1 Light switch 6 Reverse switch 2 Engine stop switch 7 Neutral switch 3 Starting switch 8 Protecting device 4 Main switch 5 Rear brake switch 117 ...

Page 119: ...d First connect the multimeter pen to wire end 1 and pen to wire end 2 to check the circuit between 1 and 2 Then connect the multimeter pen to wire end 1 pen to wire end 3 to check the circuit be tween 1 and 3 If it displays one time replace the lamp 3 Mount a checked lamp to check the lamp seat The same as checking the lamp connect the multimeter pen to related lamp seat wire and check the circui...

Page 120: ...119 ...

Page 121: ...t frame 3 Front fender Check and repair with the following tools 1 Spark plug Check the spark plug condition Check the spark plug type Check the spark plug clearance Refer to chapter 3 Check the spark plug Spark plug clearance 0 6 0 7mm 0 024 0 028in Correct 6 Main switch 7 Resistence value of triggering coil 8 Resistence value of charge coil 9 Circuit connection entire ignition system Power spark...

Page 122: ... Min spark clearance 6 0mm 0 24in No spark 3 Resistence of spark plug cap Remove the spark cap Connect the pocket multitester to spark plug cap Inspect if resistence of spark plug conform to specification Resistence of spark plug cap 20 C 68 F 4 7KΩ Conforming to specification 4 Resistence of ignition coil Remove the ignition coil connector from cable Connect the pocket multimeter Ωx1 to igni tion...

Page 123: ...efer to Check switch Normal 6 Main switch Refer to Check switch Normal 7 Resistence value of triggering coil Remove CDI magneto connector from cable Connect the multitester Ωx100 to wire end of triggering coil Multitester pen blue wire end 1 Multitester pen black wire end 2 Inspect if the resistence of triggering coil con forms to specification Resistence value of triggering coil At 20 C 68 F 180 ...

Page 124: ...r pen yellow green wire end 1 Multiteser pen red wire end 2 Inspect if the resistence value is not at the specification Coil resistence value At 20 C 68 F 450 550Ω PASS 9 Wire connection Check the connection of entire igntion sys tem Refer to Electric diagram PASS Replace CDI assembly FAIL Replace charge coil Poor contact Connect the ignitionsystem correcly 123 ...

Page 125: ...is closed OR Rear brake switch rear switch is closed When the vehicle is in drive or reverse and the rear brake is in idle then the cut off relay will prevent starting device from running In this state the cut off relay is closed When drive device is in neutral When rear brake is tensioned 1 Battery 2 Start motor 3 Start relay 4 Cut off relay 5 Start switch 6 Rear brake switch 7 Neutral switch A T...

Page 126: ...the condition of the battery Refer to Check battery chapter 3 Voltage of open circuit At 20 C 68 F 12 8V or much more PASS 3 Starting motor Connect the positive terminal 1 of the battery to cable 2 of starting motor by wire 3 Inspect the running condition of starting motor Pocket multimeter No electricty Replace the safety FAIL Clean the battery terminal Recharge or replace the battery WARNING Jum...

Page 127: ...lay is on The circuit is on 5 Starting relay Remove the connector of the starting relay from cable Connect the multimeter Ωx1 and battery 12V to end of wire on relay Battery end blue white wire end 1 Battery end black wire direction 2 Mutlitester pen red wire end 3 Multitester pen black wire end 4 Inspect if the starting relay is on The circuit is on No rotation Repair or replace starting motor Th...

Page 128: ...stem PASS 9 Starting switch Refer to Check system PASS 10 Circuit connection Check the circuit connetion of entire starting sytem Refer to Electric diagram FAIL Replace main switch FAIL Replace neutral switch FAIL Replace rear brake switch FAIL Replace left handlebar switch FAIL Connect entire starting system correctly 127 ...

Page 129: ...connecting wire Starting motor o ring 1 1 1 1 Remove the components according to sequence 1 2 3 4 5 6 7 Same disassembly as above Bracket 1 Washer pad Bracket 2 Pad Electrice brush spring Armature winding Magnet steel 1 1 1 1 2 2 1 1 Refer to Starting motor installation Installing sequence in re versed of disassembly 128 ...

Page 130: ...crape the mica with square scraper to get proper dimension to fit the reverser 4 Check Armature winding insulation power on Fail replace starting motor Check procedure of armature winding Connect the multitester to check power on 1 and insulation 2 condition Measure the armature resistence Inner resistence of armature winding Power on condition check 1 At 20 C 68 F 0 004 0 005Ω Insulation check At...

Page 131: ... Brushing spring force Fatigue out of specifications replace entire device Brushing spring force 326 970g 3 2 3 8N 7 Check Oil sealing Bushing O ring Worn or damaged replace Installation of starting motor 1 Mount Magnetic steel Bracket Make the matching mark a on the magnetic steel is in align to that on the bracket 130 ...

Page 132: ...y Refer to Inspection of battery in chapter 3 Voltage 12 8V or more at 20 C 68 F PASS 3 Charging voltage Connect engine tachometer to the wire to spark plug Connect pocket tester DC 20V to the battery Pocket multimeter white terminal Pocket multimeter white terminal Section 9 Battery will not hold charge Coil techometer Engine tachometer Pocket multimeter No electricity Replace the safety FAIL Cle...

Page 133: ...1 Pocket multimeter white terminal 2 Pocket multimeter white terminal 3 Pocket multimeter white terminal 4 Measure the resistence value of stator coil At 20 C 68 F 1 10 1 50Ω Specification met 5 Coupling of circuit Circuit the whole coupling of charging wire Refer to Electric diagram Correct Replace rectified adjuster Specification met No failure on charging circuit Out of specification Replace pa...

Page 134: ...rier 3 Front covering parts Use special tools for troubleshooting 1 Safety Refer to Inspection of switch PASS 2 Battery Check the condition of battery Refer to Inspection of battery in chapter 3 Voltage of open circuit 12 8V or more at 20 C 68 F PASS 3 Main switch Refer to Inspection of switch PASS Pocket multimeter P N YU 03112 90890 03112 No electricity Replace fuse FAIL Clean terminal of batter...

Page 135: ...e wire coupling for entire lighting system Refer to Diagram PASS Check the returning condition of each lighting system Refer to Inspection of lighting system FAIL If the lamp switch fails replace the switch on left handle Poor coupling Connect whole lighting system correctly 134 ...

Page 136: ...low terminal 2 Multimeter black terminal 3 A When switch is in LOW position B When switch is in HI position Turn main switch to ON position Turn lamp switch to LOW or HI position Check the voltage of green and yellow wires in coupler of bulb socket PASS No failure on this circuit No electricity Replace bulb and socket Out of specification If there is failure on the cicuit from main switch to bulb ...

Page 137: ...imeter blue terminal 1 Multimeter black terminal 2 Turn main switch to ON position Turn lamp switch to LOW or HI position Check the voltage of blue wire in coupler of bulb socket 12V PASS No failure on this circuit No electricity Replace bulb and socket Out of specification If there is failure on the cicuit from main switch to bulb socket coupler repair it 136 ...

Page 138: ...oting 1 Cushion 2 Front frame 3 Front pedal Use specific tools for troublshooting 1 Safety Refer to Inspection of switch PASS 2 Battery Check the condition of the battery Refer to Inspection of battery in chapter 3 Voltage of open circuit 12 8V or more at 20 C 68 F PASS Picket multimeter No electricity Replace fuse FAIL Clean battery terminal Recharge or replace the battery 137 ...

Page 139: ...ASS 4 Coupling of wires Check the coupling of whole signal system wires Refer to Diagram of wires PASS Check the condition of each signal system Refer to Inspection of signal system FAIL Replace main switch Poor connection Connect it correctly 138 ...

Page 140: ...ltage Connect pocket tester DC 20V to the tail lamp terminal Pocket tester brown terminal 2 Pcoket tester sky blue terminal 1 Adjust main switch to ON position Check voltage 12V Meet specification No failure on this circuit No electricity Replace bulb and socket No electricity Replace neutral switch Out of specification If there is failure on the circuit from the main switch to the bulb socket rep...

Page 141: ...et multimeter DC 20V to the taillight terminal Multimeter brown terminal 2 Multimeter green blue terminal 1 Adjust main switch ON position Check the volts 12V Meet specification No failure on this circuit No electricity Replace bulb and socket No electricity Replace reverse switch Out of specification If there is failure on the circuit from the main switch to the bulb socket repair it 140 ...

Page 142: ...t tester DC 20V to the tail lamp terminal Pocket tester brown terminal 1 Pcoket tester yellow terminal 2 Adjust main switch to ON position Check voltage 12V Meet specification No failure on this circuit No electricity Replace bulb and socket No electricity Replace handlerbar switch left Out of specification If there is failure on the circuit from the main switch to the bulb socket repair it 141 ...

Page 143: ...1 Remove Exhaust pipe 1 2 Remove Silencer 2 4 Carburetor and air intake pipe Place the throttle cock grip on OFF position and remove Throttle cable 1 Oil pipe 2 Hoop 3 Carburetor carburetor seat and hook hitch assy 4 CAUTION Before disassembling drain off the gasoline of the carburetor float cabinet firstly Wrap the overflow pipe with cloth to absorb the splashed gasoline The gasoline is inflammab...

Page 144: ...ing nut 1 Pin 2 Spring 3 Rear brake cable and tension rod 4 Remove from rear brake arm 2 Remove Left footrest 1 Shift pedal 2 Supporting rod of front fender 3 3 Remove Right footrest 1 Spring 2 7 Wire and hose 1 Remove Spark plug cap CDI magneto wire 1 Reverse switch wire 2 Neutral switch wire 3 Air pipe 4 143 ...

Page 145: ... nut 3 right Connecting screw column of rear arm 4 right Connecting bolt of rear arm 5 left 4 Remove Rear wheel driving unit rocker assy CAUTION When disassembling the rocker assy support the shock absorber to avoid dropping down When removing the rocker from the rubber hood the driving shaft may drop down Pay attention not to lose components 9 Disassembly of engine 1 Remove Bolt 1 top supporting ...

Page 146: ...e Hand starting unit 1 2 Remove Screw 1 2 3 Reverse controlling bar unit 4 Washer Pay attention not to lose washer 3 Remove Sprocket cabinet cover 1 4 Remove Spark plug 1 Upper valve cap intake 2 Lower valve cap exhaust 3 1 1 1 2 3 145 ...

Page 147: ...atchet 4 Use a wire to hold chain so the timing chain does not drop into crankcase 7 Remove All the bolts and nut on the cylinder cover CAUTION Loosen every bolt and nut by circle then disassemble Loosen them from big to small according to the numbers marked on the cylinder cover 8 Remove Cylinder cover unit 1 Cylinder cover pad 2 Location pin 3 Oil seal 4 Lower guide plate 5 exhaust side 1 2 1 2 ...

Page 148: ...avoid the circlip suddenly dropping into the case Before disassembling the piston pin remove the burr of circlip groove and piston pin If it is still difficult to remove the piston pin remove it with drawing aid Do not remove the piston pin with wood hammer 11 Remove Starting ratchet 1 CAUTION Fix the starting ratchet with special tool and loosen the bolt on the starting ratchet 12 Remove Left cra...

Page 149: ... intermediate gear 5 starting motor 14 Remove Magneto 1 CAUTION Disassemble the magneto rotator with special tool 15 Remove Semicircle key 1 Electric starting gear assy 2 Washer 3 16 Remove Upper guide plate 1 air intake side Timing chain 2 17 Remove 4 screws 1 rear cover 1 2 2 3 4 5 1 2 3 1 2 1 148 ...

Page 150: ...t assy 1 Bearing 2 Washer 3 Forward gear 4 21 Remove Fine filter cover of engine oil 1 Fine filter of engine oil 2 O ring 3 Right crankcase cover 4 Location pin 5 Gasket of right crankcase cover 6 22 Remove Compressing spring 1 Upper cam plate assy 2 Steel ball bracket assy 3 Lower cam plate 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 149 ...

Page 151: ... clutch when installing the main drive gear 2 So when removing the main clutch unit you must aim any one of the two grooves at the main driving gear firstly 25 Remove Nut 1 Output gear 2 CAUTION Slap flat the self locking part of the nut Place the engine to 1st gear to operate When loosening the nut output gear must fix the auxiliary hub assy 4 with special tool 26 Remove Clutch post rod 1 Bearing...

Page 152: ...lutch hub assy 3 with special tool when screwing the nut 28 Remove Locking washer 1 Clutch hub assy 2 Friction washer 3 Clutch piece 4 Compressing plate 5 Spline washer 6 Clutch gear assy 7 29 Remove Right connecting case 1 Gasket of right connecting case 3 30 Remove Oil pump unit 1 Pad 1 2 3 4 5 6 7 1 3 1 151 ...

Page 153: ...aped gear 32 Remove Star shaped gear 1 on shift cam CAUTION The location pin is easy to drop down Pay attention not to lose it 33 Remove Nut 2 balance shaft gear CAUTION Slap the locking washer 1 flat before removing the nut Put a cloth 3 folded thickly between the balance gear 4 and balance shaft driving gear 5 for seizing to prevent the rotation of the two gears when removing the nut 1 1 2 3 4 5...

Page 154: ...arator and must keep the separator body parallel with crankcase face If necessary screw the screw in reverse direction to adjust the separator body level When applying force to case body separator knock the front supporter of engine shift shaft and balance shaft alternately and continually 37 Remove Long fork shaft 1 Short fork shaft 2 Shift cam shaft 3 Fork 3 4 Fork 2 5 Fork 1 6 CAUTION Pay atten...

Page 155: ... Semicircle key 4 CAUTION Press out the crankshaft with pressure device 40 Remove Stop plate 2 Pressing plate 3 CAUTION Knock the locking part 1 of stop plate flat 1 before removing the stop plate 41 Remove Distribution cam shaft 1 CAUTION Screw in the bolt 2 10mm to cam shaft screw hole to draw out the distribution cam shaft 1 2 1 2 3 154 ...

Page 156: ... 1 Valve outer spring 2 Valve inner spring 3 Valve 4 Oil seal of valve rod 5 Spring seat of valve 6 CAUTION Pay attention to position of each component for installation to original position 45 Remove Starting lever cap 1 Starting lever 2 CAUTION Before untying the knot 3 pull out the rope long enough to tie a knot to avoid to be pulled into the cap 46 Remove Screw pin 1 Guide plate 2 Compressing s...

Page 157: ... Remove Bearing 1 Washer 2 50 Remove Circlip 1 Rear joint 2 CAUTION The disassembling method of rear joint is as follows Pull and press the driving fork downward Use a sleeve with the proper diameter below the front joint and press the bearing into the sleeve as shown in figure Repeat the procedure to corresponding bearing Remove the driving fork and rear joint 2 1 2 3 4 156 ...

Page 158: ...Connecting jaw 2 53 Remove Inner hexagon screw bushing 1 Bearing 3 Washer CAUTION Use inner hexagon screw bushing wrench 54 Remove Irregular left handed nut Reverse gear Washer CAUTION The irregular left handed nut is left handed screw thread Rotate the nut clockwise when loosening it Use irregular nut wrench 1 2 1 3 157 ...

Page 159: ...ork shaft 1 Reverse fork 2 Steel ball 3 Compressing spring 4 CAUTION When disassembling the reverse fork shaft the steel ball is easy to roll out Make sure not to lose it 57 Remove Circlip 1 Reverse controlling rod 2 Reverse controlling rod 3 Reverse controlling shaft 4 1 2 3 4 1 2 3 4 158 ...

Page 160: ...04in 2 Intake and exhaust valve 1 Check Valve surface Valve rod end Replace it if it is worn exfoliation corroded or unqualified Min thickness working limit a 0 8mm 0 031in Slope b 0 5mm 0 020in Min length working limit c 4 0mm 0 157in 2 Check Valve rod end 1 Replace the valve valve guide pipe and valve rod oil seal if it is mushroom shaped or its diameter is bigger than other rod diameter CAUTION...

Page 161: ... valve Guide pipe Intake 0 010 0 037mm 0 08mm valve 0 0004 0 0015in 0 0031in Exhaust 0 025 0 052mm 0 10mm valve 0 0010 0 0020in 0 0039in CAUTION When replacing the valve replace the valve guide pipe and valve rod oil seal together 3 Valve guide pipe 1 Check Valve guide pipe Replace it if it is worn or the oil leaks into the cylinder 2 Disassemble Valve guide pipe Use valve guide pipe disassembling...

Page 162: ...grind the valve race after installing valve guide pipe 4 Valve race 1 Clean Carbon deposit valve race and valve face 2 Check Valve seat ring Regrind the valve race if it is exfoliation corroded 3 Measure Contacting width of valve and valve race Regrind the valve race if unqualified Paint red lead powder on the valve fit pyramidal force of valve race Place the valve into the cylinder cove 161 ...

Page 163: ...043mm 063in If the contacting width is too wide too narrow or not in the middle it is necessary to recorrect valve race 4 Correct Valve race Use reamers of 30 45 and 60 CAUTION Rotate the reamer with even force to avoid cutting mark And remove surplus part to get ideal valve race Reamer used on each part Part Reamer A 30 B 45 C 60 Valve race correcting procedure The contacting part A is in the mid...

Page 164: ...r 45 contacting width 1 0mm 0 04in D The contacting part is too narrow and on bottom of valve Reamer assy of valve rale Result USE Use reamer of 60 first Make the contracting part in Reamer of 45 the middle and increase the width 5 Grind Valve face Valve race CAUTION Should grind the valve face and valve race after correcting the valve race or replacing valve and valve guide pipe Grinding procedur...

Page 165: ... to clean all the dirt on the valve face and valve race after every grinding 6 Measure the contacting width again after correcting and grinding Measure the contacting width and position of valve and valve race again according to method explained in 3 If the contacting width and position do not conform to specification yet recorrect and grind the valve race 5 Valve spring 1 Measure If the free leng...

Page 166: ...Valve rod oil seal 2 Install Valve spring seat 1 lower part Oil seal of valve rod 2 Valve 3 Inner spring 4 of valve Outer spring 5 of valve Spring cover 6 of valve Locking clip 7 of valve Inner spring intake exhaust When it is 30 5mm 1 2 in the pressure 8 4 10 2kg 18 5 22 5 lbs Outer spring intake exhaust When it is 32 0mm 1 26 in the pres sure is 16 6 20 4kg 36 6 45 0lbs 165 ...

Page 167: ...exhaust way respectively Check the valve seal There should be no leakage on valve race 2 3 Regrinding procedure Remove components of the cylinder cover again Grind repeatedly with fine grinding powder Clean totally Reassemble and check the leakage with solvent Repeat above procedures until getting ideal seal 7 Distribution cam 1 Check Distribution cam Replace if there is cave scratch or discolorat...

Page 168: ...face with distribution cam If ever worn replace it 2 Check Rocker shaft surface Replace or check lubrication if there are dents scratches or discoloration 3 Measure Measure inner diameter of valve rocker hole Replace it if unqualified Inner diameter of rocker hole 12 000 12 018mm 0 4724 0 4731 in Measure the outer diameter b of rocker shaft Replace it if unqualified Outer diameter of rocker 11 985...

Page 169: ...1 in Limit 0 037mm 0 0015 in 9 Timing chain Check Timing chain Replace it if the chain is stretched or not flexible or broken 10 Timing sprocket and crankshaft sprocket Check Timing chain Crankshaft sprocket on crankshaft If there is wear and damage replace the sprocket and chain totally 11 Guide plate 1 Check Lower guide plate 1 exhaust side Upper guide plate 2 intake side Replace it if it is wor...

Page 170: ...e is cracks and damage 14 Cylinder and piston 1 Check Carbon deposit from piston top to ring slot 2 Check Surface of cylinder and piston Rebore cylinder or replace cylinder and piston if there is vertical scratch 3 Measure Clearance between cylinder and piston Measuring method is as follows Measure the inner diameter C of cylinder with inner diameter gauge a is the measuring position a is 40mm 1 6...

Page 171: ...formulas Mating cylinder clearance C P Inner diameter of cylinder C Piston lower part diameter P Mating cylinder clearance 0 04 0 06mm 0 0016 0 0024 in Limit 0 15mm 0 0059 in If out of specification rebore or replace the cylinder and replace the piston and piston ring as a set at the same time 15 Piston ring and piston pin Piston ring 1 Measure Clearance between piston ring and ring groove Use fee...

Page 172: ...8in then pull the pis ton ring with piston top to make it vertical with cylinder wall Use feeler gauge 1 If out of specification replace a set of ring Closed clearance Standard Limit Piston 0 15 0 30mm 0 4mm ring 1 0 006 0 012in 0 016in Piston 0 15 0 30mm 0 4mm ring 2 0 006 0 012in 0 016in Oil ring 0 2 0 7mm 0 008 0 028in CAUTON You cannot measure the closed clearance of scraping plate of oil ring...

Page 173: ...96 0 6299 in 3 Measurement Inner diameter b of piston pin Out of specification replace it Inner Diameter of piston pin hole 16 002 16 013mm 0 63 0 6304in 4 Measurement Clearance between piston pin and piston pin hole Clearance between piston pin and piston pin hole b a Inner diameter of piston pin hole b Outer diameter of piston pin a Clearance between piston pin and piston pin hole 0 002 0 022mm ...

Page 174: ...If out of specification replace it or repair it Max side clearance 0 35mm 0 65mm 0 014 0 026 in Runout E of big head of connecting rod If out of specification replace it or repair it Runout amount of big head of connecting rod 0 010 0 025mm 0 0004 0 0010 in Clearance F of small end If out of specification replace it or repair it Clearance of small end 0 8mm 1 0mm 0 032 0 040 in Limit 2 0mm 0 08 in...

Page 175: ...ermediate gear axle 2 If scraped worn or damaged replace it Electric starting gear assy 3 Contact surface of overrunning clutch 4 Bimetallic bushing 5 If scraped worn or damaged replace duplex intermediate gear intermediate gear axle electric starting gear assy as a set 3 Inspection of overrunning Install the electric starting big gear to the run ning clutch and fasten the running clutch Turn the ...

Page 176: ...ration of single direction clutch Make sure that the inner spline cover 1 can only rotate clockwise in direction A if the inner spline cover functions unsmoothly or rotates Counterclockwise replace the inner spline cover 1 and main clutch case assy 2 at the same time Main clutch shoe 1 Inspection Clutch shoe If abrasion is found replace it Wear limit of main clutch shoe a 1 5mm 0 06 in 2 Measureme...

Page 177: ...plates 2 Measurement Friction plate thickness Measure four positions If out of specification replace a set of friction plate Wear Limit 2 8mm 0 110 in Clutch plate Measurement Planeness of clutch plate Use flat plate and feeler gauge 1 If out of specification replace it Planeness Limit 0 2mm 0 008 in Clutch post rod and earing Inspection Bearing 1 Post rod If rough in surface or jammed in rotation...

Page 178: ... 2 O ring 3 If cracks wear or damage replace it 21 Oil Pump 1 Measurement Clearance a between oil pump and outer rotor 2 with feeler gauge If out of specification replace oil pump Clearance Limit 0 09mm 0 004 in 2 Measurement Side clearance between outer rotor 1 and inner rotor 2 If out of specification replace oil pump Side clearance limit 0 2mm 0 008 in 3 Inspection Gear of driving oil pump on d...

Page 179: ...ovement of fork on the fork shaft 1 If not smooth in operation replace fork or fork shaft 23 Shift cam Inspection Groove of shift cam 1 If worn damaged or scraped replace it Start wheel 2 If damaged or worn replace it Needle bearing 3 If rough on surface or not active in operation replace it 24 Main vice shaft and gear 1 Measurement Runout of shaft 1 Main vice shaft Measure with bracket and runout...

Page 180: ...n Movement of gear shift mechanism If not smooth in operation replace 25 Shift shaft and limit lever 1 Inspection Shift shaft 1 Hook plate 2 If bent worn damaged replace it 2 Inspection Limit lever 3 If not smooth in operation replace it If bent or damaged replace it 3 Inspection Shift torsion spring 4 on the shift shaft Tension spring 5 Hook plate Limit torsion spring 6 On Limit Lever If worn or ...

Page 181: ...p and washer Inspection Circlip Washer If damaged loose or bent replace it 29 Crankcase 1 Clean crankcase with soft agent completely 2 Clean all sealing surfaces and closing surfaces completely 3 Inspection Crankcase Cracks damage replace it Oil trace If jammed blow with compressed air CAUTION When replacing the crankcase be sure to readjust the output gear washer 180 ...

Page 182: ...Cracks damage replace it 31 Output Mechanism 1 Inspection All gears 1 If pressing mark abrasion wear is found replace it Connecting jaw 2 If pressing mark abrasion wear is found replace it Driving shaft 3 Output shaft 4 If damaged or bent replace it CAUTION When replacing any gear or output shaft be sure to readjust core gear washer refer to Selection of adjusting washer section 2 Inspection Beari...

Page 183: ...t shaft and reuse it 6 Inspection Flexibility of fork movement Install the reverse fork 1 to fork shaft if not active or smooth in operation replace fork and fork shaft 7 Inspection Reverse control lever 1 Operating plate 2 Reverse operating shaft 3 If bends cracks or damage is found replace it 8 Inspection Rear cover 1 If cracks or damage on the position connecting with left crankcase rear drivin...

Page 184: ...ankcase Crank balance shaft 1 Crank sprocket 2 Bearing 6305 3 Left crank 4 Crank pin Section 3 Assembly and Adjustment of Engine 5 Needle bearing 6 Connecting lever 7 Right crank assy 8 Bearing 6306 C4 9 Bearing 6304 10 Balance shaft 183 ...

Page 185: ...ear 9 Circlip 26 10 Inner spline washer 11 2nd gear of driven gear 12 Driving shaft assy 13 Fork 2 14 Fork 1 15 Long fork shaft 16 Needle bearing 17 Shift cam shaft assy 18 Fork 3 19 Short fork shaft 20 Bearing 6204 21 Spindle assy 22 5th gear of driving gear 23 Spline pad 24 Circlip 25 3rd gear of driving gear 26 4th gear of driving gear 27 2nd gear of driving gear 28 Oil seal 184 ...

Page 186: ...ing hole of cylinder with hand 2 Installment Spindle assy and driving shaft assy 1 3 Installment Balance shaft 1 Fork 1 2 Fork 2 3 Fork 3 4 Shift cam 5 Short fork shaft 6 Long fork shaft 7 CAUTION Lubricate each gear and bearing Before closing be sure to set the shift mechanism at neutral and active in operation 1 1 1 2 3 4 5 6 7 185 ...

Page 187: ...y CAUTION Before installing the closing screw be sure to rotate shaft at random direction so as to check if the function of shifting mechanism is normal 7 Tighten up Screw crankcase CAUTION Tighten up the screw as the order shown on the drawing 8 Applying oil 4 stroke engine oil Applying to the bearing and oil hole 9 Inspection Operation of crankshaft and shift mechanism Not active then replace 1 ...

Page 188: ...drain plug 10 Woodruff key 11 Driving gear of balance shaft 12 Circlip 26 13 Screw M6x18 14 Pressure plate spring 15 Bearing 6203 16 Oil seal 17 Right connecting case 18 Pin 99530 12016 19 Right connecting case 20 Woodruff key 21 Balance shaft gear 22 Locking washer 23 Nut 24 Right crankcase cover gasket 25 Right crankcase cover 26 O ring 27 Oil dipstick 28 Oil fine filter 29 O ring 30 Oil fine fi...

Page 189: ...od 21 Locking washer 22 Nut 23 Guide rod 24 Lower cam plate 25 Steel ball stand assy 26 Upper cam plate assy 27 Operating swing arm assy 28 Compressing spring 29 Connecting pin 30 Bracket seat 31 Washer 8 32 Splint pin 1 2x4 33 Adjusting screw 34 O ring 35 Washer 8 36 Locking nut 37 Shift shaft assy 38 Torsion spring pin 39 Torsion spring 40 Shift lever assy 41 Shift torsion spring 42 Washer 43 Li...

Page 190: ...e mark 4 of driven gear 3 Installment Locking washer 1 Nut 2 Driven gear CAUTION Be sure to use new locking washer Install the locking washer locating plate 3 inside the key groove of balance shaft 4 4 Tighten up Nut 1 Driven gear CAUTION Place a fold cloth 2 between the balance shaft gear 3 and the gear of driving gear 4 so as to avoid turning of shaft then tighten up the nut 5 Bend the locking p...

Page 191: ... Tighten up Screw 1 star gear Apply the thread fastening agent on the screw 1 4 Installment Shift torsion spring 1 install to shift shaft Washer 2 Limit lever 3 and limit torsion spring assy 4 Washer 5 5 Installment Shift shaft 1 CAUTION Before installing the shift shaft apply the grease to the oil seal lip left crankcase Pull the hook plate 2 in arrow direction and limit lever 3 and press and ins...

Page 192: ...TION 4 stroke engine oil should be applied to lubrication oil trace of crankcase otherwise the engine would be damaged 9 Applying engine oil 4 stroke engine oil Apply on the lubrication oil trace of oil pump 10 Installment Oil pump pad Oil pump to crankcase Tighten 3 screws 7 Nm CAUTION Be sure to use new pad 3 Right connecting case 1 Installment Right connecting case gasket 1 new Locating pin Rig...

Page 193: ...3 Installment Clutch hub Install to pressure plate CAUTION The arrow mark 3 of clutch hub should align with the arrow mark 4 on the pressure plate 4 Installment Clutch hub pressure plate clutch plate and friction plate assy 1 to main shaft 2 Locking washer 3 Nut 4 CAUTION Be sure to use new locking Be sure to install the locking washer inside the indent of clutch hub 5 Tighten up Nut 4 Clutch hub ...

Page 194: ...ch spring 1 Pressure cover 2 Bearing 3 Clutch post rod 4 8 Installment Output gear 1 Nut 2 60 Nm CAUTION Be sure to use new nut 9 Tighten up Nut 2 CAUTION Fasten the clutch hub of vice clutch and tighten up the nut 10 Lock the nut 2 with screwdriver 1 2 3 4 1 2 193 ...

Page 195: ...dents should align with the main clutch gear 2 12 Installment Locking washer 1 Nut 2 main clutch CAUTION Be sure to use new locking washer The locating plate of locking washer should be installed n the indent of clutch shoe assy 13 Tighten up Nut 2 main clutch CAUTION Fasten the clutch shoe assy then tighten up nut 14 Bend the locking plate 3 of locking washer 1 2 3 4 1 2 1 2 3 194 ...

Page 196: ...vex block of shift shaft The locating notch of upper cam plate should align with guide rod 2 Installment Locating pin 1 Right crankcase gasket 2 Right crankcase gasket 3 Oil fine filter 5 O ring 6 Oil fine filter cover 7 Clutch operating rocker assy CAUTION Be sure to use new gasket The hole of clutch operating rocker assy should align with shift shaft 3 Tighten up Screw right crankshaft cover 1 2...

Page 197: ...ing 18 Nut 19 Rear cover 20 O ring 21 Bolt M8x15 22 Reverse fork 23 Compressing spring 24 Steel ball 6 35G100b 25 Reverse fork shaft 26 Reverse control lever assy 27 Reverse operating shaft 28 Circlip 14 10 Screw bushing 11 Irregular left hand nut 12 Output shaft 13 Washer 14 Bearing 15 Inner hexagonal screw bushing 16 Front connecting fork 17 Washer 196 ...

Page 198: ...4 Double wheel 5 Woodruff key 6 Washer 7 Electric starting gear assy 8 Electric starting clutch 9 Roller 10 Spring cover 11 Spring 12 Timing chain 13 Up guide plate assembly 14 Magneto rotor 15 Magneto starter 16 Left crankcase cover 17 Starting ratchet assy 197 ...

Page 199: ...rst for fixing the steel ball and spring that is easy to mount the fork pin into fork 3 Lubrication Apply lubrication oil SAE20W 40 in the inner diameter of fork and pin 4 Mount Reverse gear fork shaft 1 With O ring Mount the reverse gear fork pin 1 into the hole of rear driving cover 3 Reverse gear fork 2 CAUTION Mount the reverse fork shaft into the hole of the reverse fork and then pull out the...

Page 200: ... turning nut by counterclockwise direction because it is left turning thread Use special shaped nut spanner 4 Fasten Special shaped left handed nut 5 Mount Washer Bearing 2 Nut collar 3 CAUTION Use allen wrench Coat 518 anaerobic sealing gun or equal substitute on outer end surface of bearing 2 which side is near to washer Coat thread fastening agent on allen nut col lar 3 6 Fasten Allen nut colla...

Page 201: ...riving fork into the splice Coat grease on the needle bearing Press every needle bearing 1 into the front splice with proper tube to ensure that the driving fork is inserted into the needle bearing hole Fix the hog ring into every bearing groove CAUTION Check every needle because the needle may drop out from bearing cone to lose If it is like this the universal joint can t be turned flexibly Inser...

Page 202: ...r Brand of sealing agent is 518 anaerobic seal ing gum or equal substitute 5 Mount Rear driving cover 1 Tighten bolt 2 Caution Before running the rear driving cover on the crank make the gear on the forward shaft position 6 Tighten 4 Bolts 23Nm 1 rear cover CAUTION When mounting rear cover to the crankcase the arrow must be upward 7 Electric starting system Apply sealing gum 2 3 4 5 6 1 201 ...

Page 203: ...the conical part of crank and magneto When installing the magneto key must be in the key groove of crank for avoiding it Mount the magneto 4 drops out on the crank and then fix the electric starting gear assy 2 turn the magneto by counterclock wise to make it into the electric starting big gear 3 Mount Double wheel 1 Washer Wheel axle 3 Locating pin 4 Sealing washer 5 of left crankcase cover CAUTI...

Page 204: ...ng the crankcase output gear and output shaft the applied washer thickness is determined by the actual machining dimension of the following parts Adjust the correct break in of he level gear and the clearance of every moving parts by washer thickness Crankcase Output gear Reverse gear Rear cover Forward gear Output shaft When replacing above parts must select the ad justing washer again 1 Mounting...

Page 205: ...heory installing distance42 of output gear adds the value engraved on the output gear b is the value engraved on crankcase CAUTION All the units about the value is mm 2 For example If 0 02 is engraved on the output gear that is a 42 0 02 42 02 If 41 45 is engraved on the left crankcase So the washer thickness is A 42 02 41 45 0 57mm 3_ The following is prepared thickness of washer mm 0 2 0 4 0 3 0...

Page 206: ... are the value engraved on the left crankcase e at the forward gear bearing thickness no change 13 00mm f Theory installing distance 37 5 of for ward gear adds value engraved on forward gear 2 For example If d 110 08 is engraved on left crankcase c 59 02 If 0 02 is engraved on the forward gear f 37 5 0 02 37 52 So the washer thickness is B 110 08 59 02 13 00 37 52 0 54mm 3 The following is the pre...

Page 207: ...ng thickness 12 00 at the reverse gear i means that the theroy installing distance 39 of reverse gear adds value engraved on reverse gear 2 For example c 58 98 is engraved on left crankcase g 7 49 is engraved on rear cover If 0 02 is engraved on reverse gear i 39 0 02 38 98 So washer C thickness is the prepared thickness of washer mm 0 2 0 4 0 3 0 5 The way selected washer C is same with the way o...

Page 208: ...on output shaft 2 For example If 0 97 is engraved on rear cover 110 05 is engraved on left crankcase 14 4 is engraved on forward gear 80 45 is engraved on output shaft So the washer thickness is D 110 05 0 97 13 00 0 50 14 4 80 45 0 25 2 42mm 3 The following us the prepared washer thick ness mm 1 0 1 3 1 7 1 1 1 5 Washer selection table The washer thickness is 2 42mm by calculation So the washer t...

Page 209: ...her A Mount Washer A 1 Bearing 2 CAUTION This step is carried out before assembly with closing case Mount Clamp plate 1 CAUTION This step is carried out before assembly with case 2 Washer B Mount Forward gear 1 Washer B 2 Bearing 3 3 2 1 207 ...

Page 210: ...ed nut left handed thread so tighten it in counter clockwise direction Use special shaped nut wrench 4 Washer D Mount Washer Bearing 2 Bushing 3 CAUTION Use inner allen bushing wrench Coat 518 anaerobic sealing gum or equal substitute on outer end surface of bearing 2 which side is near to washer 2 3 208 ...

Page 211: ...Valve locking 6 Valve spring cover 7 Valve recoil sealing 8 Valve spring 9 Valve outer spring 10 Valve spring seal 11 Inlet valve 12 Bolt M6x12 13 Locking plate 14 Clamp plate 15 Rolling bearing 6005 RS C3 16 Driving pin 17 Valve cam shaft 18 Rolling bearing 6202 Z 19 Rocker axle 2 20 O ring 21 Exhaust valve 209 ...

Page 212: ...2 Washer 25 O ring 26 Screw M6x18 06025 29 Chain tensioner 30 Tensioner washer 31 Upper guide plate assembly 32 Bolt 95026 06014 33 Bolt M10V1 25x25 34 Washer 35 Timing sprocket wheel 36 Lower guide plate 37 Timing chain 13 Screw M8x45 10 9 14 Washer 8 15 Sprocket wheel cover assy 16 Oil shield assy 17 Breather tube 18 Work carrier 19 O ring 20 Screw 98512 06012 21 O ring 22 Screw 98512 06012 23 U...

Page 213: ... 2 1 Cylinder body assy 2 Screw M6 x 25 10 9 3 Cylinder body washer 4 Locating pin 99530 14016 5 O ring 6 Piston ring 1 7 Piston ring 2 8 Oil ring subassembly 9 Circlip 10 Piston 11 Piston Pin 12 Double end bolt 211 ...

Page 214: ...n pin piston ring groove and piston edge 4 Installation of piston ring Assemble the piston ring split clearance stag geringly according to showing figure 1 Top ring 2 Oil Ring lower ring 3 The second ring 4 Oil ring upper ring 5 Install Cylinder body washer Locating pin 2 O ring 3 CAUTION Be sure to use new sealing washer and o ring CAUTION Be sure to check the standard of manufac ture and engrave...

Page 215: ...ber 7 Lubricate Valve rocker Rocker shaft Lubrication oil SAE 10W30 machine oil 8 Install Valve rocker Rocker shaft CAUTION Thread hole on the rocker shaft is toward out Mount rocker shaft With O ring at the side of outlet and the long rocker shaft with slot at the side of inlet The slot direction needs to be adjusted when mounting inlet rocker shaft to make the slot align with hole of cylinder co...

Page 216: ...r cover 9 Mount Bearing 1 to valve cam Bearing 2 to valve cam CAUTION The bearing 1 with oil sealing is toward out when assembling it and the bearing 2 with dust cap is toward inside when assembling it 11 Mount Clamp plate 1 Bearing Locking plate 2 new 12 Fasten Bolt 1 13 Bend locking plate end 2 1 2 1 2 2 1 214 ...

Page 217: ...ut 6 Washer 8 Screw 9 CAUTION Apply 4 stroke engine oil on the washer 7 15 Fasten the bolt and nut according to the order in the figure 16 Mount Timing sprocket pulley Mounting step of timing sprocket pulley Turn the camshaft to make sure the cam pin 1 is correspondence with the matching mark 2 of cylinder head 1 2 3 4 5 6 215 ...

Page 218: ...ming sprocket pulley Insert the special tooling into the tension hole of timing chain and pull the tensioner timing chain toward inside The matching mark 5 of timing sprocket is sure to correspond to the matching mark 2 of cylinder head when pulling the timing chain tensioner Change the matching position between sprocket pulley chain if the marks are not aligned After the marks are aligned fasten ...

Page 219: ...ioner sub assembly Take off the screw drive from the tensioner and then tighten the locking bolt of tensioner assy Mount tension bolt 1 with washer 10Nm CAUTION Always use new washer 18 Adjust The valve clearance There is a valve clearance between two rocker when the mark 3 of timing sprocket is align with the mark 4 of cylinder cover Inlet valve clearance cool 0 05 0 09mm Outlet clearance cool 0 ...

Page 220: ...ing in the sealing groove of sprocket chamber cover first CAUTION Check the o ring If it is deformed or damaged replace it 22 Mount O ring Carburetor seat Washer Carburetor Mount o ring in sealing groove first CAUTION Check the o ring If it is damaged replace it 23 Mount Carburetor seat and carburetor on cylinder cover Wire clamp CAUTION The carburetor seat and the o ring in the sealing groove of ...

Page 221: ...s Starting system manual 1 Left side cover assy 2 Guy 3 Starting lever 4 Starting lever cover 5 Washer 6 Coil spring backboard assy 7 Driver disc assy 8 Torsion spring 9 Drive jaw 10 Circlip 11 Screw pin 12 Guide plate 13 Pressure spring 219 ...

Page 222: ...rd assy 2 CAUTION End of the coil spring is hung on the inner race of left side cover coil spring 3 Wind the rope in the drive disc groove 4 circles by clockwise 4 Lubricate Coil spring backboard assy Drive disc 5 Mount Drive disc 1 CAUTION The projection need to be mounted into two hole groove 2 and the coil spring hook hang er also need to be mounted into the hole groove 4 1 2 1 2 3 4 1 2 4 220 ...

Page 223: ...starting ratchet pawl make the end 7 of torsion spring align to groove A on the drive disc 7 Turn the drive disc 3 circles by clockwise and pre tighten the coil spring 8 Mount Starting lever 1 Cover 2 CAUTION Make the rope across the hole of left side and knit it so that the rope is not pulled into left side cover After knitting 4 and untie 1 2 3 4 5 6 1 2 4 221 ...

Page 224: ... over 1 Mount Engine Mount the engine from right side of frame 2 Mount Bolt 1 Installation position of engine rear lower Bolt 2 Installation position of engine rear upper Bolt 3 Installation position of engine front Bolt 4 Installation position of engine top CAUTION Mount all the installing bolts from right side of motorcycle Turn the nut and bolt temporarily but don t fasten them at this time 1 7...

Page 225: ...heel fork forward and mount drive shaft 7 on the rear joint of direction knot 8 4 Connect Rubber bushing etc 1 5 Mount Coupling bolt 2 of rear arm Rear arm nut 3 Coupling bolt 4 of rear arm CAUTION Turn the rear shaft bolt and rear arm shaft nut temporarily and don t fasten them at this time 6 Check Operation of drive shaft Checking steps Hold the front wheel and put the proper bracket on the fram...

Page 226: ...3 3m bg 24ft lb Bolt Installation position of engine rear lower 33Nm 3 3m bg 24ft lb Bolt Installation position of engine front 48Nm 4 8m bg 35ft lb Bolt Installation position of engine top 33Nm 3 3m bg 24ft lb Coupling bolt of rear arm rear arm shaft left 130Nm 13m bg 94ft lb Coupling bolt of rear arm rear arm shaft right 0 6Nm 0 6m bg 4 3ft lb Rear arm nut 130Nm 13m bg 94ft lb Bolt rear shock ab...

Page 227: ...re of starting motor 3 CAUTION Lubricate o ring before mounting the starting motor 12 Mount Spring 1 Foot rest 2 right Bolt foot rest 65Nm 6 5m 47ft lb Bolt Shifting Pedal 10Nm 1m 7 2ft lb Bolt foot rest 65Nm 6 5m 47ft lb Bolt foot rest 30Nm 3 0m 22ft lb 13 Mount Bracing 1 of front fender Shifting pedal 2 Foot rest 3 left 14 Connect Rear brake cable 1 Rear brake rod 2 15 Adjust Rear brake Refer to...

Page 228: ...nce of plunger clutch 19 Adjust Position of drive selection lever Refer to relevant part in section 5 of chapter 2 20 Adjust Idle speed Refer to relevant part in section 5 of chapter 2 Idle speed 1400 1500r min 21 Adjust Idle stroke of throttle cable Refer to relevant part in section 5 of chapter 2 Idle stroke of throttle cable 3 5mm 226 ...

Page 229: ...ad washer is damaged Cylinder body is worn or damaged Trouble CAUTION Please refer to relevant contents for the in spection adjustment and replacement of parts I Starting trouble difficulty 1 Fuel system 1 Fuel tank No oil Fuel filter is clogged Fuel filter net is clogged Breather tube is clogged Fuel is deteriorated or polluted 2 Fuel cock Intel tube is clogged Fuel cock is not opened 3 Carbureto...

Page 230: ...ork is worn 3 Shifting cam Recess of shifting cam is worn 2 Piston and piston ring Improper piston ring installation Piston ring is worn and out of elasticity Piston ring is broken Piston is damaged or cracked 3 Valve camshaft and crank shaft Valve didn t close entirely Improper match between valve and valve seat Wrong port timing Valve spring is damaged Valve camshaft is damaged Crank shaft is da...

Page 231: ...ation or handlebar is bent 2 Steering system Wrong toe in Steering pillar is bent 4 Driving system Claw of gear end is down V Clutch slips 1 Clutch Improper adjustment of clamp plate release rod clearance of clutch Clutch spring is loosen primary clutch and secondary clutch Clutch spring is fatigue primary clutch and secondary clutch Friction disc is worn Clamp plate is worn or deformed Main clutc...

Page 232: ...ear wheel is too big 5 Frame Bend Damaged frame 6 Rear wheel fork Bearing is bushing or worn Rear wheel fork is bent or damaged X Lighting System 1 Head light is out of work Bulb is trouble Too big load Charging difficulty Lighting coiler rectifier is failure Wrong connection of wire Wrong connection of ground Poor connection Main switch or lighting switch Use life of belt is end 2 Bulb is off Bul...

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Baja WD250U, Service Manual

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