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BODY / SUSPENSION / STEERING

CHAPTER 7

BODY / SUSPENSION / STEERING

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

FRONT CAB REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

REAR CAB REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

FRONT BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

CAB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

SHOCKS EXPLODED VIEW. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

FRONT SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

REAR SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

FRONT A-ARM. . . . . . . . . . . . . . . . . . . . . . . . ... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

A-ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . … . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . … . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

SWING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

SWING ARM EXPLODED VIEW. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .7.11

SWING ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

STEERING . . . . . . . . . . . . …………... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

STEERING/FRONT SUSPENSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

STEERING POST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16

HANDLEBAR BLOCK INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 7.16

EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16

DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17

7.1

Summary of Contents for 2007 GOES 300 S

Page 1: ...t side of the vehicle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service procedures before starting the work Certain procedures require the use of ...

Page 2: ...he operator bystander or person s inspecting or servicing the vehicle SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during di...

Page 3: ...1 GENERAL INFORMATION 1 MAINTENANCE 2 CVT 3 ENGINE 4 TRANSMISSION 5 FUEL SYSTEM 6 BODY SUSPENSION STEERING 7 BRAKES 8 ELECTRICAL 9 2 4 ...

Page 4: ...ION 1 2 GENERAL SPECIFICATIONS 1 3 GENERAL SPECIFICATIONSMODEL GOES 300 S 1 3 GENERAL VEHICLE INSPECTIONAND MAINTENANCE 1 4 VEHICLE COMPONENT INSPECTION LOCATIONS 1 4 GENERAL SPECIFICATIONSMODEL TREETRENTAR 330 ON ROAD 1 5 GENERAL VEHICLE INSPECTIONAND MAINTENANCE 1 6 VEHICLE COMPONENT INSPECTION LOCATIONS 1 6 GLOSSARY OF TERMS 1 7 1 1 ...

Page 5: ...ut an engine be sure to refer to the engine serial number This information can be found stamped on the top LH side of the crankcase as shown below Vehicle Identification Number Location The vehicle identification number VIN and engine serial number are important for identification purposes See the illustrations 1 2 ...

Page 6: ...system Electric start and coil start Front brake Duel disc with single bore caliper Max power 14kw 6500rpm Rear brake Single Disc with single bore caliper Max torque 22Nm 5500rpm Combined brake Foot pedal CARBURATOR Parking device Cable controlled parking through rear caliper Type Keihin PTG ACV Front tire 21 7 10 Slide valve B34 Rear tire 20 10 9 Main jet 108 DIMENSIONS Pilot jet 38S Overall leng...

Page 7: ...rfill All brakes check operation Throttle check for free operation Headlight Taillight Brake light check operation of all indicator lights and switches Engine stop switch check for proper function Wheels check for loose wheel nuts Air cleaner element check for dirt or water clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehi...

Page 8: ...Starting system Electric start and coil start Front brake Duel disc with single bore caliper Max power 14kw 6500rpm Rear brake Single Disc with single bore caliper Max torque 22Nm 5500rpm Combined brake Foot pedal CARBURATOR Parking device Cable controlled parking through rear caliper Type Keihin PTG ACV Front tire 21 7 10 Slide valve B34 Rear tire 20 10 9 Main jet 108 DIMENSIONS Pilot jet 38S Ove...

Page 9: ...GENERAL INFORMATION Vehicle Component Inspection Location 1 6 ...

Page 10: ...oltage Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis End Seals Rubber seals at each...

Page 11: ...cal sense ohms resulting in energy conversion to heat RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywheel supporting the battery cha...

Page 12: ...E 2 7 FUEL SYSTEM SAFETY 2 7 THROTTLE STOP SPEED CONTROL SYSTEM 2 7 CHOKE CABLE ADJUSTMENT 2 8 IDLE SPEED ADJUSTMENT 2 8 FUEL LINES 2 8 AIR SCREW ADJUSTMENT 2 9 FUEL FILTER 2 9 FUEL VALVE LOCATION 2 10 CARBURETOR DRAINING 2 10 AIR FILTER SERVICE 2 11 ENGINE 2 12 ENGINE OIL LEVEL 2 12 ENGINE OIL AND FILTER CHANGE 2 12 COMPRESSION LEAKDOWN TEST 2 13 VALVE CLEARANCE ADJUSTMENT 2 13 ENGINE MOUNTS 2 14...

Page 13: ...ND STEERING INSPECTION 2 19 LUBRICATION GREASE POINTS 2 20 WHEEL ALIGNMENT 2 20 WHEEL ALIGNMENT 2 20 TOE ADJUSTMENT 2 21 FRONT SUSPENSION INSPECTION 2 21 REAR SUSPENSION INSPECTION 2 22 SUSPENSION SPRING ADJUSTMENT 2 22 BRAKE SYSTEM 2 22 BRAKE SYSTEM INSPECTION 2 22 BRAKE LEVER TRAVEL 2 22 PARKING BRAKE ADJUSTMENT 2 23 WHEELS AND TIRES 2 23 WHEELS 2 23 WHEEL HUB AND SPINDLE TORQUE TABLE 2 23 WHEEL...

Page 14: ...iced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in oil sump or crankcase Change oil immediately if the oil level begins to ris...

Page 15: ...x sediment tube Daily Drain deposits when visible Head lamp tail lamp Daily Check operation apply dielectric grease if replacing CVT housing Weekly Drain water as needed check often if operating in wet conditions Brake lever travel 10H Monthly 150 Inspect regularly Brake freeplay 10H Monthly 150 Inspect regularly Spark plug 10H Monthly 150 Clean check condition adjust gap replace as needed Idle sp...

Page 16: ...e tighten fasteners Rear suspension 50H 6M 800 Inspect lubricate tighten fasteners Fuel system 100H 12M 1500 Check for leaks at tank cap lines fuel valve filter carburetor replace lines every two years Fuel filter 100H 12M 1500 Replace yearly Engine mounts 100H 12M 1500 Inspect Exhaust muffler pipe 100H 12M 1500 Inspect Ignition timing 100H 12M 1500 Inspect Wring 100H 12M 1500 Inspect for wear rou...

Page 17: ...mm bolts and nuts 36 43 ft lbs 50 60 Nm 4 mm screws 22 30 in lbs 2 5 3 4 Nm 5 mm screws 30 43 in lbs 3 5 5 Nm 6 mm Hex bolts 87 121 in lbs 10 14 Nm 8 mm Hex bolts 17 22 ft lbs 24 30 Nm 10 mm Hex bolts 25 32 ft lbs 35 45 Nm Maintenance Quick Reference Item Lube Rec Method Frequency 1 Engine oil OW 50 Synthetic Check level or change oil Check during pre ride inspection change oil every 30 hours or 6...

Page 18: ...oline is stored Do not overfill the tank Fill the tank to the bottom of the filler neck This will allow for thermal expansion If you get gasoline in your eyes or swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or run it in an enclosed area Gasoline powered engine exhau...

Page 19: ...e freeplay Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Adjustments to the freeplay can be made by loosening the choke cable adjustment in or out to gain the desired freeplay If smooth choke operation is not obtainable inspect choke cable for kinks or sharp bends in routing Fuel Lines 1 Check fuel lines for signs of wear deterioration damage or leakage Re...

Page 20: ...egins to drop Stop turning at this point 4 Center the mixture screw between points in Step 2 and 3 5 Readjust idle speed if not within specification Fuel Filter The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter Fuel Filter Location Located in line between fuel valve and carburetor inlet To service the fuel filter 1 Sh...

Page 21: ...flammable and explosive under certain conditions Do not smoke or allow sparks in near the area when inspecting fuel valve 1 Remove vacuum impulse hose and carburetor fuel hose 2 Install a vacuum gauge into vacuum impulse hose 3 Inspect gauge keeping pressure ability if not must replace diaphragm in fuel valve 4 The gauge is keeping pressure but no fuel from carburetor hose Inspect fuel filter jam ...

Page 22: ...he foam air filter Wash the foam filter in warm soapy water then rinse and let it dry If the filter is damaged install a new foam filter 4 Apply a commercially available foam filter oil to the foam filter 5 Inspect the filter support screen and clean away any oil or sediments in the air box NOTE The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at...

Page 23: ... contact with skin 5 Place a drain pan beneath the engine crankcase 6 Remove the drain plug and pre filter screen Allow the oil to drain completely 7 Wash the oil pre filter screen with solvent to remove any debris Allow the screen to air dry NOTE Do not fill the over the normal oil operating range Filling over the normal operating range could cause a mist of oil to enter the air box NOTE Rising o...

Page 24: ...PORTANT Use of a compression tester adaptor that is too long WILL CAUSE DAMAGE to the cylinder head The adaptor length should be no longer than the length of the spark plug threads 19mm 2 Remove spark plug and rotate engine to TDC on the compression stroke 3 Insert a 0 1 mm feeler gauge between end of intake valve stem and adjuster screw 4 If adjustment is required loosen the locknut and turn adju...

Page 25: ... TRANSMISSION AND FINAL DRIVE Transmission Lubrication The transmission lubricant level should be checked and changed in accordance with the maintenance schedule Remember to Verify the vehicle is level before proceeding Verify the vent hose is routed properly and is not obstructed Follow instructions to check change transmission fluid Transmission Lubricant Level The gear case fill plug is located...

Page 26: ... 1 Loosen the four rear axle hub mount bolts 6 Add the recommended lubricant Maintain the lubricant level at the bottom of the fill plug hole threads 7 Reinstall the fill plug Check for leaks ATV Gearcase Lubricant AGL 900 ml 11 8 oz Drive Chain Inspection 1 Check the amount of chain slack by moving the vehicle slightly forward to gain deflection at the top of the chain 3 Turn the chain adjuster c...

Page 27: ... Removal Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive g...

Page 28: ...ith dielectric grease or petroleum jelly Battery Installation 1 Place the fully charged battery in its holder 2 Attach the hold down strap s 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Torque the battery terminal bolts to 4 7 Nm 3 5 ft lbs 6 Verify that the cables are properly routed Battery Storage Whenever the vehicle is not used for a...

Page 29: ...ssary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 7 Apply a small amount of anti seize compound to the spark plug threads 8 Install spark plug and torque to 12 14 Nm 9 11 ft lbs Spark Plug Inspection 1 Remove spark plug high tension lead Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark ...

Page 30: ...s outlined in this chapter The steering component repair and adjustment be performed by an authorized Goes Dealer Only a qualified technician should replace worn or damaged steering parts Use only genuine Goes replacement parts Tie Rod End Steering Inspection 1 Elevate front end of ATV so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firml...

Page 31: ...ease until it is visible on the ends of the pivot points Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 0 6 mm toe out 1 Set the handlebars in a straight ahead position NOTE The steering arm can be used as an indicator of whether the handlebars are straight The arm should always point straight back from the steering post 2 Place the stands in...

Page 32: ...recommended in the Periodic Maintenance Chart Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table below Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting Inspect the rear shock and spring to ensure proper function If the shock is leaking oil replace it Inspect the swing arm and w...

Page 33: ...ie rod needs adjusting NOTE Be sure the handlebars are straight ahead before determining which tie rod s need adjustment Front Suspension Inspection Compress and release front suspension Damping should be smooth throughout the range of travel Inspect the front shocks and springs to ensure proper function If the shock is leaking oil replace it Check all front suspension components for wear or damag...

Page 34: ...65Nm 48ft lbs Rear hub retaining nut 65Nm 48ft lbs Wheel Inspection Inspect the front and rear wheel bolts for tightness Re torque the wheel bolts periodically and check before each ride 6 When fully tight the cable adjusting nut but functions that must adjust rear caliper parking swing arm 7 Tight back the cable adjusting nut then Loosen the fasten nut at rear caliper 8 Adjust the bolt when you f...

Page 35: ...d install all wheel nuts Tire Pressure Tire Pressure Inspection PSI Cold Front Rear 5 psi 34 5 kPa 5 psi 34 5 kPa Tire Inspection Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 0 3 cm 1 8 or less Maintain proper tire pressure Refer to the tire pre...

Page 36: ...ER EXPLODED 3 4 DRIVE CLUTCH EXPLODED VIEW 3 4 DRIVEN CLUTCH EXPLODED VIEW 3 4 CVT OVERHEATING DIAGNOSIS 3 5 CLUTCH COVER REMOVAL 3 6 SPIKE LOAD SYSTEM REMOVE 3 7 DRIVEN CLUTCH SERVICE 3 9 DRIVEN CLUTCH DISASSEMBLY AND INSPECTION 3 9 CVT BELT INSPECTION 3 9 DRIVEN CLUTCH ASSEMBLY 3 8 DRIVE CLUTCH SERVICE 3 5 DRIVE CLUTCH DISASSEMBLY AND INSPECTION 3 5 DRIVE CLUTCH ASSEMBLY 3 6 3 1 ...

Page 37: ...s to push against the cam plate and force the moveable sheave toward the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch If belt speed is sufficient centrifugal friction shoes on the driven clutch overcome their return spring pressure and swing outward against the transmission drive hub and the vehicle if in...

Page 38: ...in plug and O ring located on the bottom of the crankcase and let the water drain out The CVT drain plug is shown at right 2 To further expel water from the CVT area cover and to dry out the CVT system shift the transmission to neutral and rev the engine slightly to expel the moisture This will also air dry the belt and clutches 3 Allow engine RPM to settle to idle speed shift transmission to lowe...

Page 39: ...CVT SYSTEM CVT EXPLODED VIEW 3 4 ...

Page 40: ...emperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases CVT temperatures and co...

Page 41: ...VT case and case 1 Remove the left foot rest 2 Loosen the duct clamps and slide ducts upward off cover 3 Remove all screws and cover with re coil start attached 7 Use two hands to hold the cam plate and the primary sliding sheave together when removing the primary sliding sheave and the cam plate assembly This prevents the roller weights from falling out of the assembly 3 6 ...

Page 42: ...olts must with loctite when recombination Spike load system Removal NOTE This assembly utilizes a torque limiting system to prevent transmission damage Use care removing the clutch assembly as the torque limiting components become free and could fall apart Mark or note parts during disassembly 1 Remove the driven clutch assembly by releasing the set screw and removing the nut from the shaft 3 7 ...

Page 43: ...excessive wear or damage Replace components as required Spring Washer Orientation Additional 1mm washer can be added here to increase spring preload 3 Remove the ball bearings Use a snap ring pliers to remove the retainer on the hold cam Remove the washer Inspect the hold cam for excessive spline wear or damage Replace the component if required 3 8 ...

Page 44: ...pect the condition and diameter of the drum lining If either the measurements or the lining indicates excessive wear replace the clutch cover Spring pressure can cause components to eject suddenly Use care during removal 5 Inspect the condition of the clutch drum Measure the inside diameter of the cover at 90 degree intervals using a caliper Inspect the condition and diameter of the drum lining If...

Page 45: ... onto the threaded shaft and apply Loctite 272 to the threads 12 Have an assistant available for final assembly Install the compression spring Place the friction pad assembly over the spring and compress the driven assembly together with both hands With the assembly compressed and the threads exposed have an assistant thread a new retaining nut onto the shaft Secure the assembly in a clamping devi...

Page 46: ...rive clutch and install driven clutch on transmission shaft 5 Install driven clutch hub then the retaining nut and O ring Torque retaining nut to specification 2 Have an assistant available for final assembly Install the compression spring Place the friction pad assembly over the spring and compress the driven assembly together with both hands With the assembly compressed and the threads exposed h...

Page 47: ...the assembly 6 Inspect sheave faces E for grooves or wear Check bushings F and seals in the moveable sheave The sleeve should be a close smooth fit in the bushings and seals should fit tightly on the sleeve 3 Remove cam plate 4 Inspect surface of sleeve for wear pitting or damage 7 Remove and inspect each roller Replace as a set if any have flat spots or if worn they should be cylindrical 5 Inspec...

Page 48: ...n the middle and install the outer drive clutch sheave as far as possible Hold outer sheave in place 3 Install the cam plate 4 Install the bushing primary sliding sheave and cam plate assembly NOTE When installing the primary sliding sheave and the cam plate assembly hold the assembly together to prevent the rollers from dislodging 8 Install the claw washer engaging the inner spline of the washer ...

Page 49: ...EAD INSPECTION 4 12 CYLINDER HEAD WARP INSPECTION 4 13 COMBUSTION CHAMBER INSPECTION 4 13 CYLINDER HEAD DISASSEMBLY 4 13 VALVE INSPECTION 4 14 VALVE SEAT RECONDITIONING 4 15 VALVE SEAT INSPECTION 4 15 CYLINDER HEAD RECONDITIONING 4 15 CYLINDER HEAD ASSEMBLY 4 17 VALVE SEALING TEST 4 18 BOTTOM END DISASSEMBLY 4 18 CYLINDRE REMOVAL 4 19 CAM CHAIN FOLLOWER TENSIONER BLADES 4 19 CYLINDER INSPECTION 4 ...

Page 50: ...ION 4 33 CYLINDER HEAD AND CAMSHAFT INSTALLATION 4 33 CAMSHAFT TIMING 4 34 CAMSHAFT INSTALLATION TIMING METHOD 1 4 34 CAMSHAFT INSTALLATION TIMING METHOD 2 4 35 ROCKER SHAFT ARM INSTALLATION 4 36 CAM CHAIN TENSIONER INSTALLATION 4 36 INTAKE VALVE CLEARANCE ADJUSTMENT 4 39 EXHAUST VALVE CLEARANCE ADJUSTMENT 4 39 FLYWHEEL INSTALLATION 4 39 STATER DRIVE ASSEMBLY 4 39 STATOR HOUSING INSTALLTION 4 40 T...

Page 51: ...ENGINE ENGINE EXPLODED VIEW 4 3 ...

Page 52: ...ENGINE 4 4 ...

Page 53: ...ENGINE OIL FLOW DIAGRAM 4 5 ...

Page 54: ...ly ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame 1 Flywheel 2 Alternator Stator 3 Starter Motor Starter Drive 4 Oil pump 5 Rocker Arms 6 Carburetor 7 Transmission ENGINE REMOVAL 1 Clean work area 2 Thoroughly clean the ATV engine and chassis 3 Disconnect battery cables 4 Drain engine oil 5 Drain radiator water 6 Disconnect spark pl...

Page 55: ...t clutch rollers shoes and springs before reassembly Transmission Inspect transmission operation and adjust linkage if necessary Exhaust Replace exhaust gaskets Seal connections if desired with high temp sealant After running the engine verify all bolted exhaust connections are tight and in good condition Engine Mount Torque Front Mount 80Nm Rear Mounts 80Nm Engine Break In Period 4 Cycle Engine B...

Page 56: ...he stator housing on the crankcase 2 Insert a M6x8 1 00 oil pressure gauge adaptor into the crankcase and attach a low pressure gauge 0 10psi 0 70kpa 3 Start engine and allow it to reach operating temperature while monitoring gauge indicator Any pressure above zero is an indication of good oil flow TOP END DISASSEMBLY CAM CHAIN TENSIONER REMOVAL 1 Remove oil fill cap from the stator housing and va...

Page 57: ...r cylinder head bolts evenly 1 4 turn each time in a cross pattern until loose 2 Remove bolts and tap the cam support tower with a plastic hammer until loose 3 Remove the rocker shaft locking plate 5 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged 6 Remove each rocker arm ...

Page 58: ...mm Rocker Arm OD 9 91mm 9 Inspect rocker adjuster screws for wear pitting or damage to threads of the adjuster or locknut Replace all worn or damaged parts NOTE The end of the adjuster is hardened and cannot be ground or re faced CAMSHAFT REMOVAL AND INSPECTION NOTE Cam chain tensioner must be removed before performing this procedure 1 Remove the 4 cylinder head bolts evenly by loosening each one ...

Page 59: ...t from falling into the crankcase 4 Inspect cam sprocket teeth for wear or damage Replace if necessary 2 Thoroughly clean the cam shaft 3 Measure height of each cam lobe using a micrometer Replace cam if worn below minimum height Replace camshaft if damaged or if any part is worn excessively CAMSHAFT INSPECTION 1 Visually inspect each cam lobe and bearing for wear chafing or damage 4 11 ...

Page 60: ... time in a cross pattern until loose 2 Remove the cylinder bolts and tap the cam support tower with a plastic hammer until loose Remove 3 After removing the the camshaft and securing the cam chain tap cylinder head lightly with a plastic hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging casting 4 Remove the thermostatic 4 Remove in...

Page 61: ...ustion chamber it is recommended the component be replaced CYLINDER HEAD WARP INSPECTION 1 Lay a straight edge across the surface of the head at several different points and measure warp age by inserting a feeler gauge between the straight edge and the cylinder head surface If warp age exceeds the service limit replace the cylinder head Cylinder Head Warp Limit 0 05mm COMBUSTION CHAMBER INSPECTION...

Page 62: ...ll or use V blocks and a dial indicator 5 Check spring for squareness as shown Replace spring if measurements are out of specification 3 Check end of valve stem for flaring pitting wear or damage A NOTE Replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup 4 Inspect split keeper groove for wear or flari...

Page 63: ...e Seat Reconditioning for procedure Cylinder Head Reconditioning NOTE Servicing the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the Valve Seat Reconditioning Kit Wear eye protection when performing cylinder head service Valve guide replacement will require heating of the cylinder head Wear gloves to p...

Page 64: ...at check the pilot Look for burrs nicks or run out If the pilot is bent it must be replaced If the contact area of the cutter is in the same place the valve guide is distorted from improper installation and must be replaced Be sure the cylinder head is at the proper temperature and replace the guide If the contact area of the initial cut is greater than 75 continue to cut the seat until all pits a...

Page 65: ...angle 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem 11 Rotate the valve rapidly back and forth until the cut sounds smooth Lift the valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do this four to five times until the valve is fully seated and repeat process for the other valve 12 Clean ...

Page 66: ...epers VALVE SEALING TEST 1 Clean and dry the combustion chamber area 2 Pour a smallamount of cleaning solvent into each port and check for leakage around each valve The valve seats should hold fluid with no seepage ENGINE BOTTOM END DISASSEMBLY Cylinder Removal Follow engine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 1 Remove cam chain guide at front of...

Page 67: ... 3 Remove the compression rings starting with the top ring Using a piston ring pliers Carefully expand ring and lift it off the piston Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Use care to not scratch the ring lands 4 Repeat procedure for second ...

Page 68: ...ntion of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines Use a motor speed of approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 3 cm above and below t...

Page 69: ...iston to Cylinder Clearance Std 0 02 0 05 mm Limit 0 1 mm 3 Measure piston pin bore Replace piston if out of round 4 Measure piston pin O D Replace piston pin if out of round 5 Measure connecting rod small end ID Replace crankshaft if out of round 6 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to ...

Page 70: ...cylinder A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the installed gap measurement exceeds the limit replace the rings If using new rings and the measurement is too small file the ring ends to achieve the proper gap NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re ...

Page 71: ...ENGINE ALTERATOR STATER OIL PUMP EXPLODED VIEW NOTE The CVT system starter motor starter drive flywheel stator oil pump and transmission can be serviced with the engine in the frame 4 23 ...

Page 72: ...in two directions 90 apart to determine if out of round Calculate clearance Replace components if clearance is excessive 5 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL REMOVAL INSPECTION The crankshaft end contains an oil passage plunge joint A as shown below The plunger must be able to move in and out freely Avoid damage to the cranks...

Page 73: ...eel 2 Inspect the bearing surfaces and drive teeth for signs of wear or gouging Replace the one way clutch as an assembly if it is not working properly NOTE One way clutch components are not serviceable Replace the component as an assembly 3 To reattach the one way assembly apply Loctitet 272 to the retaining screw threads Torque to specification One Way Clutch Screw Torque 10 Nm 3 Remove pump cha...

Page 74: ...mp and transmission can be serviced with the engine in the frame CRANKCASE SEPARATION AND CAM CHAIN REMOVAL NOTE Stator housing flywheel and gears have are previously removed for this procedure Use care during the removal process to avoid damage to the cam chain NOTE Valve train and cylinder removal must be performed prior to this procedure NOTE Always replace the pto crankshaft seal after perform...

Page 75: ...he crankshaft out Use care not to damage the crankshaft oil passage on the right end crankshaft end NOTE Use care not to damage the crankshaft end NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smoothly and quietly The inner ra...

Page 76: ...he outer race should fit tightly in the crankcase The inner race should be firm with minimal side to side movement and no detectable up and down movement 2 To remove crankcase bearings use a blind hole bearing puller NOTE Bearings are stressed during the removal procedure and should not be re used 3 Remove all traces of gasket sealer from the crankcase mating surfaces Inspect the surfaces closely ...

Page 77: ...PTO end of the crankshaft NOTE Use care not to damage the crankshaft end The balance shaft flat must square with crankshaft PTO end 3 Install a new gasket onto the right hand crankcase half Applying a thin amount of crankcase sealer to the gasket will help hold it in place 4 Install 4 flange bolts circled from the right side crankcase NOTE Use care not to damage the crankshaft end Crankcase Bolt T...

Page 78: ...pump is not a servicable assembly Do not disassemble pump Replace entire component 1 Inspect the oil pump sealing surface on the crankcase Apply a liberal amount of engine oil to the surfaces and pump 2 Install oil pump as shown Torque screws to specified torque Oil Pump Cover Screw Torque 8 Nm 5 Install the circlip into oil pump shaft 6 Install oil pump shield NOTE Do not use gasket sealer on the...

Page 79: ...or deformed during installation 1 Install a new circlip on one side of the piston with the end gap facing up or down 2 Apply clean engine oil to the piston rings ring lands piston pin bore piston pin and piston skirt Lubricate the connecting rod both ends and crankshaft main bearing area 3 IMPORTANT Install the piston on the connecting rod with the IN casting mark facing the intake side of engine ...

Page 80: ...ylinder down This will help push the piston past the ring taper into the cylinder 8 Up side down cylinder then place the blunt edge tool on cylinder Align it with cylinder 9 Place piston into blunt edge tool 9 Use non metallic rod to push piston until piston through the tool to cylinder 4 32 ...

Page 81: ...crankcase and cylinder Remove all traces of old gasket material and apply a new base gasket 1 Install the dowel pin s Install an new base gasket onto the mating surface and install the piston into cylinder NOTE Route cam chain through the cylinder chain room and secure it holding it up while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade 2 Apply clean engi...

Page 82: ... links are not used to time the camshaft When the stator housing is installed use Method 2 This method establishes accurate Top Dead Center TDC by aligning the single mark on the flywheel with the notch in the timing inspection hole see Method 2 The camshaft sprocket alignment marks are parallel to the gasket surface and camshaft lobes are pointing down The cam chain plate links are not used to ti...

Page 83: ...e any advance marks if evident 2 Align the cam chain onto the teeth of the cam chain drive sprocket Use a wire to pull the chain up through the cylinder and cylinder head and to hold it in place Secure the chain 3 Apply grease or molybdenum disulfide grease to the camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil 4 Orientate the camshaft w...

Page 84: ... to specification 3 Apply engine assembly lube to the cam lobes and cam follower surfaces 4 Verify the cam lobes are pointing downward before installing rocker assembly 5 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 6 Install cylinder head nuts and torque to specification 2 With the plunger retracted install the tensioner assembly with a new gasket and t...

Page 85: ...ENGINE CAMSHAFT TIMING METHOD 1 Method 1 Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward 4 37 ...

Page 86: ...D 2 Method 2 Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward Cam Timing View through timing inspection hole Position crankshaft at TDC 4 38 ...

Page 87: ...screw 3 Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge 4 When clearance is correct hold adjuster screw and tighten locknut securely 5 Re check the valve clearance 6 Repeat adjustment procedure if necessary until clearance is correct with locknut secured VALVE CLEARANCE 0 1 mm FLYWHEEL INSTALLATION 1 Install flywheel key flywheel washer and nut Torque flywheel n...

Page 88: ...n choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle and or needle jet worn or improperly adjusted Excessive carburetor vibration loose or missing needle jet locating pins Loose jets in carburetor or calibration incorrect for altitude temperature Incorrect float level setting CVT system calibrated incorrectly or components worn or ...

Page 89: ...r piston ring or valve wear or damage check compression CVT not operating properly Restricted exhaust muffler Dirty carburetor Cam lobe worn Piston Failure Scoring Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Worn rings piston or cylinder Excessive piston to cylinder clearance Worn valves guides o...

Page 90: ...N DISASSEMBLY 5 3 TRANSMISSION INSPECTION 5 4 DRIVE SHAFT REMOVAL AND INSPECTION 5 4 SHIFT FORK INSPECTION 5 5 MIAN SHAFT REMOVAL AND INSPECTION 5 5 COUNT SHAFT INSPECTION 5 6 OUTPUT SHAFT REMOVAL AND INSPECTION 5 6 SHIFT DRUM REMOVAL AND INSPECTION 5 7 TRANSMISSION REASSEMBLY 5 7 TROUBLE SHOOTING 5 9 GEAR WILL NOT ENGAGE 5 9 POPS OUT OF GEAR 5 9 NOIS 5 9 5 1 ...

Page 91: ...ot required to service transmission components Process shown below is with engine removed for clarity 1 Drain the transmission oil from the gear case A and engine oil from crankcase B Shift System Removal 1 Remove right footwell 2 Remove sprocket cover and drive sprocket 3 Remove shift cables from the bracket 5 2 ...

Page 92: ...t screws 5 Remove shift cover and the bracket 6 Remove gasket and discard 7 Note timing of shift shaft before removing The center tooth on shift shaft is positioned between the two dots on the drum teeth Transmission Disassembly 1 Remove the cover screws 2 Remove cover or with output shaft Push or tap on shift shaft to keep it in the case 3 Remove gasket and discard 5 3 ...

Page 93: ...wear the appropriate protective gear and use caution when operating a press Drive shaft removal and inspection 1 With transmission components removed inspect all shaft bearings visually and by feel Bearings should roll smoothly without excessive movement or noise Replace any bearing that is removed as the removal process destroys the bearing 2 Bearings can be removed using a standard blind bearing...

Page 94: ...red due to axial movement if radial movement shown in Step 6 passes inspection Shift fork inspection 1 Inspect the shift fork B for scoring or signs of wear Area C should not show contact 3 Radial movement should not exceed 0 05 mm Main shaft removal and inspection 1 Inspect sliding gear dogs E and dog slots in the mating gears F for wear or damage The edges of dogs and slots should be square and ...

Page 95: ...d components 8 Assemble the reverse gear washer a new snap ring and the sliding gear on the shaft 9 Assemble the forward gear washer bush and a new snap ring on the shaft 5 Remove second snap ring from main shaft Counter shaft inspection 1 Inspect the shaft and gears visually without excessive wear or crack Replace any damaged components 6 Remove reverse gear components Output shaft removal and in...

Page 96: ...ective gear 1 Remove shift sensor from drum shaft NOTE Drum shaft components are not serviceable Replace Drum shaft as an assembly Transmission Reasssembly NOTE Lubricate all bearings with clean transmission oil before assembly Clean the gasket surfaces on the crankcase and transmission cover Remove all traces of old gasket material and apply a new base gasket 1 Place the counter shaft into case 2...

Page 97: ... install fork shaft 9 Install the drum detent and shift teeth Ensure all dots must on center position 10 Install detent bolt and fasten to 10Nm 6 Place flat washer on output shaft bearing 7 Install the output shaft 8 Install the transmission cover then fasten all bolts to 12Nm Transmission cover Bolt Torque 12 Nm 8 8 ft lbs 11 Check transmission operation before final assembly and after installing...

Page 98: ...bles loosened Shift cables broken CVT Belt broken Internal trans gear damage Shift fork broken or bent Shift shaft broken Pops Out Of Gear Shift arm indexed incorrectly Shift cables loosened Detent spring or ball missing worn or broken Gear engagement dogs worn rounded or broken Shift fork bent Noise Incorrect transmission lubricant Lubricant level too low Lubricant level too high Bearings worn or...

Page 99: ...3 8 THROTTLE 6 8 JET NEEDLE NEEDLE JET 3 8 3 4 THROTTLE 6 9 MAIN SYSTEM 3 4 TO FULL THROTTLE 6 9 FUEL DELIVERY 6 10 VENT SYSTEM 6 10 CARBURETOR CLEANING 6 10 CARBURETOR REMOVAL 6 11 CARBURETOR REMOVAL GENERAL 6 11 CARBURETOR DISASSEMBLY 6 12 THROTTLE VALVE AND CHOKE DISASSEMBLY 6 13 AIR CUTTING VALVE DISASSEMBLY 6 13 CARBURETOR INSPECTION 6 14 FLOAT HEIGHT ADJUSTMENT 6 15 CARBURETOR ASSEMBLY 6 15 ...

Page 100: ...with soap and water and change clothing Carburetor Function Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control Inlet Pipe Needle and Seat Float and Float Pin Maintains specified fuel level in float chamber carburetor float bowl All systems all throttle ranges Venting Passages in carburetor and vent lines Supplies atmospheric pressure to float ...

Page 101: ... speed fuel system or pilot system and a main fuel system are provided in these type of carburetors The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an ideal air fuel mixture which can burn without leaving an exc...

Page 102: ...and fine tuning the carburetor with optional jetting may provide a slight improvement in high altitude performance but generally is not needed CARBURETOR JETTING IMPORTANT The following guidelines must be followed when establishing a main jet setting 1 Select the lowest anticipated temperature at which the machine will be operated 2 Determine the lowest approximate altitude at which the machine wi...

Page 103: ...fuel level should not be changed arbitrarily Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute interval under a given set of conditions Air Mixture...

Page 104: ...ay be significantly affected A carburetor with a slide type throttle valve is also called a variable venturi type carburetor In this type of carburetor the needle jet and jet needle serve to control proper air fuel mixture ratio at the medium throttle valve opening between 1 4 and 3 4 opening Having the proper needle jet and jet needle has a major impact on engine performance at partial load The j...

Page 105: ...of fuel CCs which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer mixture Throttle slide The throttle slide controls the rate of engine air intake by moving up and down inside the main bore At small throttle openings air flow control is performed chiefly by the cutaway By controlling air flow the negative pressure over the nee...

Page 106: ...When the air screw is opened the mixture is made more lean as the amount of air is Increased Slide Cutaway 1 8 3 8 Throttle Throttle valve cutaway effect is most noticeable at 1 4 throttle opening The amount of cutaway is pre determined for a given engine to maintain a 14 1 air fuel ratio at part throttle A steep angle would indicate a fairly lean mixture because there is less resistance to air fl...

Page 107: ...is made up of the jet needle needle jet and main jet The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly This system works in conjunction with the needle jet system During low speed driving there is very little clearance between the jet needle and the needle jet therefore very little fuel...

Page 108: ...el delivery at 1 4 throttle and consistently increases to full throttle opening VENT SYSTEM The fuel tank vent supplies atmospheric pressure to the fuel in the tank The vent must be free of debris and restrictions to prevent lean mixture and possible engine damage All vent linesmust be properly routed to prevent damage to the line and to prevent contaminants from entering the tank Protect eyes fro...

Page 109: ...s as the orifice size may be altered 5 Use low pressure air to dry carburetor body and all components Carburetor Removal General The following procedure is provided to use as a reference when removing the carburetor from vehicle Some steps may differ slightly between models 1 Remove the seat 2 Loosen air cleaner box bolts 3 Bend and tie up fuel intake hose then drain the fuel from the carb through...

Page 110: ...1 Remove the 3 float bowl screws and float bowl 2 Remove fuel retainer 3 Remove the float pin A float B and inlet needle C 4 Remove the pilot jet main jet and from the carb body 5 Note the position of both the air mixture screw and idle speed adjustment screw and remove both from the carb body 6 12 ...

Page 111: ...rom the carb body 3 disconnect throttle cable from slide valve 4 Remove choke screw and bracket 5 Remove the choke arm Spring pressure can cause components to eject suddenly Use care during removal 6 Remove the choke spring Air Cutting Valve disassembly 1 Remove air cutting valve cover and diaphragm 6 13 ...

Page 112: ... the needle jet and hold it to a light source Light will be visible between the needle and needle jet if it is worn 2 Inspect the inlet needle tapered surface for any sign of wear or damage Be sure the spring loaded pin is free moving and returns freely when pushed The inlet needle and seat should be pressure tested after assembly 3 Inspect the idle speed adjust screw tip for flat spots and the pi...

Page 113: ...llel to each other Themeasurement should bemade at the mid point on top of the float using Float Adjustment Tool or a caliper When measuring the height verify the inlet needle valve spring is not compressed Float Height Parallel to Gasket Surface 1mm Needle and Seat Leak Test 1 Install the float bowl 2 Invert the carburetor and install a Mity Vac to the fuel inlet fitting 3 Apply 5 PSI pressure to...

Page 114: ...running or shut off however engine must run briefly to allow fuel level to stabilize 1 Attach a clear line to drain fitting Be sure line fits tightly on fitting Position hose along side of carburetor as shown 2 Open bowl drain screw by turning counterclockwise approximately two turns Start and run engine for 3 to 5 seconds to allow fuel level to stabilize in the line If level is out of specificati...

Page 115: ...FUEL CARBURATOR Fuel tank location 6 17 ...

Page 116: ... the fuel tank 4 Remove fuel valve from frame 5 Disconnect the fuel lever gauge harness 6 Place a shop rag or towel underneath the tank and remove fuel line fuel valve and filter from the tank 7 Disconnect the fuel tube from tank 8 To reinstall the tank reverse the removal procedure Be sure to torque the tank mounting bolts Fuel Tank Mounting Bolt Torque 8 Nm 72 in lbs 6 18 ...

Page 117: ...OR Air Cleaner Removal 1 Release the screw and remove the cover 2 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let it dry If the filter is damaged install a new foam filter 6 19 ...

Page 118: ...tor and air cleaner 4 Loosen oil separator hoses then remove air cleaner box 5 Apply commercially available foam filter oil to the foam filter 6 Reinstall the foam filter foam and air box cover Secure the clips The air intake on cover must toward front of vehicle 6 20 ...

Page 119: ...le binding or improperly routed Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets Weak or damaged choke plate return spring Fouled spark plug Poor Idle Idle Too High Idle adjusted improperly ...

Page 120: ... 7 5 CAB EXPLODED VIEW 7 6 SUSPENSION 7 7 SHOCKS EXPLODED VIEW 7 7 FRONT SHOCK REMOVAL 7 7 REAR SHOCK REMOVAL 7 8 FRONT A ARM 7 9 A ARM EXPLODED VIEW 7 9 A ARM REPLACEMENT 7 9 SWING ARM 7 11 SWING ARM EXPLODED VIEW 7 11 SWING ARM REMOVAL 7 11 STEERING 7 14 STEERING FRONT SUSPENSION EXPLODED VIEW 7 14 STEERING POST ASSEMBLY 7 15 HANDLEBAR 7 16 HANDLEBAR BLOCK INSTALLATION PROCEDURE 7 16 EXPLODED VI...

Page 121: ...m 14 ft lbs Steering Post Mount Nuts 22 Nm 16 ft lbs Steering Post Nut 55 Nm 40 ft lbs Final Drive Fasteners Front Wheel Spindle Nut 60 Nm 44 ft lbs Rear Wheel Hub Nut 80 Nm 58 ft lbs Front Rear Wheel Bolts 30 Nm 22 ft lbs Sprocket Bolts Front 9 8 Nm 87 in lbs Rear 22 Nm 16 ft lbs Chain Tensioner Bolt 10 Nm 84 in lbs Bearing Carrier Mounting Bolts 55 Nm 40 ft lbs Chain Guard Bolts 22 Nm 16 ft lbs ...

Page 122: ...or wind shield bolts on each side 7 Remove the 8 screws attaching front and rear cabs to the footwells on each side 8 Remove the 2 bolts attaching the body to the front cab on each side 9 Disconnect the main switch ignition harness 10 Disconnect power supplier wires 11 Disconnect both front indicator plugs 7 3 ...

Page 123: ... 13 Remove shift lever grip 14 Completely remove the front cab from body Rear Cab Removal 1 Remove 2 footwells from body 2 Remove the 4 bolts of rear cab 3 Disconnect the taillight harness 4 Remove the 2 bolts attaching the rear cabs then take off taillight 7 4 ...

Page 124: ...e bumper from the ATV Treetrentar 330 Headlight housing Removal 1 The front cab removal procedure same as Goes 300 S except headlight housing 2 Remove the 2 upper bolts attaching on front cab 2 Reverse the previous procedure to reinstall the bumper 3 Torque mounting bolts to 87 in lbs 9 8 Nm Front Bumper Mount Bolt Torque 10 Nm 90 in lbs 3 Remove the 2 bottom bolts attaching under front cab 4 Comp...

Page 125: ...BODY SUSPENSION STEERING 7 6 ...

Page 126: ...ould occur if machine tips or falls 2 Remove the upper shock mounting bolts from the frame and the lower shock mounting bolts from the front suspension arm A arm 3 Replace the shock or spring as required 4 Install shock as shown above Exploded Figure 5 Torque shock mounting bolts to specification Front Shock Mounting Bolt Torque 44 Nm 32 ft lbs 7 7 ...

Page 127: ...occur if machine tips or falls 2 Remove the upper shock mounting bolt from the frame and the lower shock mounting bolt from the swing arm 3 Replace the shock spring or adjuster cam as required 4 Install the shock as shown above Exploded Figure 5 Torque shock mounting bolts to specification Rear Shock Mounting Bolt Torque 50 Nm 37 ft lbs 7 8 ...

Page 128: ...acement 1 Elevate front end of ATV off the ground far enough to remove the wheel Severe injury could occur if machine tips or falls 2 Remove wheel nuts and remove wheels 3 Remove brake caliper bolts and caliper 4 Remove wheel hub and brake disc 7 9 ...

Page 129: ...ce if worn Discard hardware 10 Insert A arm shaft E into the new A arm C H 11 Install new A arm assembly onto vehicle frame upper and lower Torque bolts to 42Nm 30 ft lbs 12 Attach upper A arm C and lower A arm H to steering knuckle J Tighten both ball joint nuts to 50 Nm 37 ft lbs If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends toward rear...

Page 130: ...ate rear end of ATV off the ground far enough to remove the rear wheels Severe injury could occur if machine tips or falls 2 Remove the dust cap and cotter pin from 2 rear wheels 3 Remove 2 rear wheels nut and remove wheel and hub as an assembly 7 11 ...

Page 131: ...washers 5 Remove chain protector bolts then chain protector 8 Bend the lock bracket back the remove bolts and sprocket 6 Take off the master link from chain by pliers then remove chain from sprocket 9 Pull the axle with disc toward left way some time need to use soft hammer on right of rear axle Ensure do not damaged axle thread 7 12 ...

Page 132: ...e the hub if the component fail inspection 14 Inspect the axle hub main bearings for worn or damaged The bearing must be inspected visually and by turning feel The bearing should turn smoothly and quietly 12 Loosen 4 bolts then remove axle hub toward right hand away 15 Remove the rear shock upper blot 16 Remove brake tube clamp 17 Remove swing arm shaft then swing arm 7 13 ...

Page 133: ...BODY SUSPENSION STEERING 7 14 ...

Page 134: ... cotter pin hole 3 Install the cotter pin B and bend both ends of the cotter pin around the nut in opposite directions 4 Check the steering The handlebars must move freely and easily from full left to full right without binding Check all cables and electrical wires for binding and route as needed 7 15 ...

Page 135: ... the bolts down Evenly torque the 2 front bolts to 15 18 Nm 11 13 ft lbs 3 Install the rear bolts B and tighten evenly Evenly torque the 2 rear bolts to 15 18 Nm 11 13 ft lbs 4 Install the four handlebar bolts and pod bracket C loosely into the blocks 5 Install the handlebar pod E and screws F NOTE There will be a slight gap on the backside of the blocks after the procedure is performed 7 16 ...

Page 136: ...al to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To flame treat the decal area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should occur...

Page 137: ...TER CYLINDER INSTALLATION 8 11 FRONT PADS REMOVAL 8 11 FRONT PADS ASSEMBLY 8 12 FRONT DISC INSPECTION 8 13 FRONT BRAKE DISC REMOVAL REOLACEMENT 8 13 REAR FOOT PARKING BRAKE 8 14 REAR FOOT PARKING BRAKE EXPLODED VIEW TORQUE 8 14 REAR CALIPER FLUID REPLACEMENT AND AIR BLEEDING 8 15 BRAKE FLUID DRAINING 8 15 REAR CALIPER FLUID FILLING BLEEDING 8 15 FOOT BRAKE REMOVAL 8 16 FOOT BRAKE FLUID FILLING BLE...

Page 138: ...ke Disc Thickness Variance Between Measurements 0 05mm 0 002 Brake Disc Runout 0 25mm 0 01 Torque Specifications Item Torque Nm Torque ft lbs except where noted Front Caliper Mounting Bolts 25 18 Rear Caliper Mounting Bolts 42 31 Master Cylinder Reservoir Cover Bolts 0 6 5 in lbs Brake Line Banjo Bolt 20 15 Brake Disc Mounting Bolts 29 21 4 Caliper Bleed Screws 3 27 in lbs Foot Brake Master Cylind...

Page 139: ...LESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise check the backing of each pad for worn spots allowing metal to metal contact See table below Brake Noise Troubleshooting Possible Cause Remedy Dirt dust or imbedded material on pads or disc Spray disc and pads with a...

Page 140: ...ted When the right foot brake lever master cylinder is applied the two front brake calipers and a rear caliper are active and under pressure The rear brake system is hydraulically actuated When the right front brake lever master cylinder is applied the rear brake caliper is active and under pressure The parking brake system operates using mechanical brake cables The left front parking brake lever ...

Page 141: ... to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid During system service be sur...

Page 142: ...BRAKES FRONT BRAKE EXPLODED VIEW 8 6 ...

Page 143: ...r cylinder Always wear safety glasses during these procedures Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces Severe injury could occur if machine tips or falls 1 Elevate front end of ATV off the ground far enough to remove the wheel 2 Remove the dust cap and cotter pin 3 Remove wheel nuts and remove wheel and rim as an assembly 6 Ensure...

Page 144: ...e lever master cylinder is applied the rear brake caliper is active and under pressure 8 Remove the disc blots then disc 9 Remove the speedometer sensor 10 The front left hand brake use same procedure Shunt Removal 1 Remove two mounting bolts under frame 2 Remove all banjo bolts then shunt 3 Inspect two piston s o ring and rubber cups surface for wear or other damage Replace an assembly if necessa...

Page 145: ... on fitting NOTE When brake lever is pumped Place diaphragm in reservoir to prevent spills Do not install cover 7 Slowly pump brake lever until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight or air may be drawn into caliper 9 Repeat procedure until clean fluid appear...

Page 146: ...ir bubbles do not appear in the plastic hose 3 If air is entering the bleeder from around the bleed valve threads seal the threads with Teflon tape 4 Close the bleed valve and operate brake lever If it still feels spongy bleed the system again 5 If a brake bleeder is not available use the following procedure Pump up the system pressure with the brake lever until lever resistance is felt MASTER CYL...

Page 147: ...ter cylinder Torque the banjo bolt to 20 Nm 15 ft lbs Master Cylinder Mounting Clamp Bolt Torque 3 Nm 25 in lbs Banjo Bolt Torque 20 Nm 15 ft lbs 3 Fill reservoir with DOT4 Brake Fluid 4 Follow bleeding procedure on Pages 8 8 Check all connections for leaks and repair if necessary FRONT PADS REMOVAL 1 Follow front caliper remove procedure on page 8 6 Severe injury could occur if machine tips or fa...

Page 148: ...lts If previously removed Front Caliper Mounting Bolts Torque 25 Nm 18 ft lbs 3 Slowly pump the brake lever until pressure has been built up Maintain at least 20 mm of brake fluid in the reservoir to prevent air from entering the brake system 4 Be sure fluid level in reservoir is between MIN and MAX lines and install reservoir cap 5 Install wheels and torque wheel nuts Front Wheel Nut Torque 40 Nm...

Page 149: ...sure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 0 25 mm 0 01 FRONT BRAKE DISC REMOVAL REPLACEMENT 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install disc on h...

Page 150: ...int where the rear brake disc housing can be accessed on Chapter 7 NOTE You do not need to fully disassemble the rear axle swing arm to service the rear brakes 2 Inspect the brake pads contact disc surface and the axle housing seal surface for excessive wear pitting or damage Replace if necessary 3 Remove the brake pads from the rear caliper assembly Follow Front pads remove procedure on page 8 11...

Page 151: ... Bleeding Procedure on page 8 8 to 8 10 NOTE 1 Check the fluid lever often while bleeding the brake to prevent air from being pumped into the system 2 Repeat the above procedure until air bubbles do not appear in the plastic hose 3 If air is entering the bleeder from around the bleed screw threads seal the threads with Teflon tape 4 Close the bleed screw and operate brake lever If it still feels s...

Page 152: ...er is applied the brake oil output to shunt The two front brake calipers and a rear caliper are active and under pressure 1 Remove right hand foot well from body 2 Remove the cotter pin from foot brake lever and foot brake master cylinder 3 Loosen foot brake lever and brake sensor return spring with long nose pliers 4 Remove the brake lever fastener bolt 8 16 ...

Page 153: ...er when reservoir fluid level is low 3 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a wrench on the top caliper bleeder screw 4 Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting 5 Slowly pump foot brake lever until pressure builds and holds 6 While maintaining lever pressure open...

Page 154: ...er resistance is felt Ensure the vent slot ring must face with cover when install oil tank diaphragm vent slot ring and cover Parking brake removal The parking brake system operates using mechanical brake cables The left front parking brake lever operates the rear brake caliper swing arm to push caliper piston assembly When removing and installing the parking braking system The spring may cause se...

Page 155: ...loosen about 5mm back 2 Replace rubber dust proof if worn or cracked 3 Install the both spring and swing to caliper 4 Ensure the upper return spring 50 60mm with cable adapter 5 Install the adjusting bolt and fastener nut an assembly 6 Fully turn the adjusting bolt to end then loosen it 3 4 circuit Fasten the nut present and security 7 Inspect the parking lever cable and rubber pad replace them if...

Page 156: ...or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch Lever Vibration Disc damaged Disc worn run out or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Auxiliary brake peda...

Page 157: ...AMP REPLACEMENT 9 8 SINGNAL 9 9 FRONT SIGNAL REPLACEMENT 9 9 REAR SIGNAL REPLACEMENT 9 9 SPEEDOMETER AND INDICATOR 9 10 SPEEDOMETEER SIGNAL DESCRIPTION 9 10 SPEEDOMETER DIGITAL DISPLAY FUCTIONAL 9 11 SPEED HOUR 9 11 ODOMETER 9 11 FUEL LEVER SCALE 9 11 RADIATOR TEMPERATURE SCALE 9 12 TIRE WHEEL DIAMETER SETTING 9 12 IGNITION SYSTEM 9 13 RPM LIMITER SPECIFICATION 9 13 IGNITION COIL TEST 9 13 ALTERNA...

Page 158: ...AINTENANCE BATTERY OFF SEASON STORAGE 9 22 SEALED LOW MAINTENANCE BATTERY CHARGING PROCEDURE 9 23 CONVENTIONAL BATTERY ACTIVATION SVC 9 23 BATTERY TERMINALS TERMINAL BOLTS 9 24 CONVENTIONAL BATTERY INSPECTION REMOVAL 9 24 CONVENTIONAL BATTERY INSTALLATION 9 24 CONVENTIONAL BATTERY TESTING 9 24 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 9 25 CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST 9 25 C...

Page 159: ...onent to be tested Disconnect it from the wiring harness or power supply Wires color letter list Letter Color Letter Color B Black L Y Blue Yellow B L Black Blue O Orange Br Brown O B Orange Black B R Black Red P Pink Br L Brown Blue Pu Purple Br W Brown White R Red B Y Black Yellow R B Red Black C Cyan R W Red White DB Deep Brown W White DG Deep Green WB Water Blue G Green W B White Black Gr Gray...

Page 160: ...Nm 45 in lbs SWITCH SERVICE Brake Lever Switches Each brake lever utilizes an electrical brake switch that sends voltage to activate the brake light 1 Locate the brake switches on each of the brake levers 2 Disconnect wire harness from brake switch and connect an ohmmeter across the two switch wires The reading should be infinite 3 Apply brake the brake lever s and check for continuity between swi...

Page 161: ...ECTRICAL Left Hand Switch Assembly The following illustration shows the internal operation of the LH switch assembly If any part of the switch is faulty the entire LH switch assembly must be replaced 9 5 ...

Page 162: ...owing 1 Disconnect the harness from the faulty light 2 Using a Volt Ohm Meter measure the AC voltage between the yellow red YE RD and black BK wires Voltage above 5 VAC should be present when unit is running If voltage is present 1 Replace the faulty bulb If voltage is not present 1 The black wire should have continuity to ground If no continuity is present check for an open in the wiring harness ...

Page 163: ...tart the engine to make sure the lights come on If the lights do not operate check the charging system and related wiring for possible malfunction Headlight Adjustment The headlight beam can be adjusted up and down and side to side 1 Place the vehicle on a level surface with the headlight approximately 7 6 m 25 from a wall 2 Measure the distance from the floor to the center of the headlight and ma...

Page 164: ...hould be 20 3 cm 8 in 25 5 Adjust beam to desired position by moving headlight Taillight Taillight Lamp Replacement If the tail light lamp does not work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the LED lamp and replace it with a new recommended LED lamp Apply Dielectric Grease to the lamp terminals 3 Test the light for proper o...

Page 165: ...ss 2 Remove front signal and bracket from cab as picture 3 Remove rubber waterproof cap 4 Remove socket fastener screw and lamp socket 5 Remove and replace lamp 6 Reinstall all front signal components Rear Signal Replacement 1 Remove rear signal and bracket from cab as picture 2 Use small blade drive screw to remove lens 3 Remove all components and replace lamp 4 Reinstall all rear signal componen...

Page 166: ...ELECTRICAL Speedometer and Indicator Speedometer Replacement 1 Remove the handlebar pod to access the speedometer 2 Disconnect the speedometer wire connections from the harness 9 10 ...

Page 167: ...ice to finish selection 2 Odometer It sum up total mileage that can t zero or delete anymore But will change following KM H and MILE H selection 3 Odometer mode there are three modes ODO TRIP and TRIP B 3 1 As item 2 in ODO you can t change anymore 3 2 In TRIP A press zero button after two seconds to clear the mileage 3 3 In TRIP B press zero button after two seconds to clear the mileage 4 Fuel le...

Page 168: ...thermostatic sensor locates at right hand of the radiator If the sensor is faulty replace the entire assembly Do not open the radiator cap or remove sensor hose bimetal valve and water pump when the engine is still hot The Bimetal valve locates at right hand of cylinder If the valve is faulty replace the entire assembly The water pump locates at right hand of crank cover The Remove and reinstall p...

Page 169: ... 23x8 11 11 inch 588 mm 1842 mm d 23 0 IGNITION SYSTEM RPM LIMITER SPECIFICATIONS NOTE The ATV is limited through the CDI box located on the bulkhead under the front cab In forward gear the CDI reads the RPM s from the stator The CDI acts as a limiter when the peak RPM is met In Reverse Gear the CDI also limits RPM taking a signal from the shift drum switch that the vehicle is in reverse IGNITION ...

Page 170: ... by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 Alternator Current Output Reading should be no less than 30 40V AC above 2000 RPM on each leg NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced CDI OUTPUT TEST USING PEAK READING ADAPTOR OR A VOLT METER Re connect ...

Page 171: ...th the adaptor All measurements are indicated in Volts Readings obtained without a peak reading adaptor will be significantly different Disconnect the stator connectors from the CDI module Test output from the detection and pulse trigger coil and compare to the chart The following measurements were obtained when cranking the engine with the electric starter spark plug installed The starter system ...

Page 172: ...atic for connections and specifications Compare results to the specifications on the exploded views Are all within specifications NO Inspect battery condition connectors wiring and grounds to the component in question Replace the component if a wiring problem cannot be found YES Check coil ground connection between engine and coil mount using an ohmmeter The coil mount should have good continuity ...

Page 173: ...ings Sheared flywheel key Flywheel loose or damaged Excessive crankshaft runout on magneto RH end should not exceed 005 Faulty CDI module CHARGING SYSTEM MAIN FUSE ASSEMBLY The main fuse assembly is located under the seat and has a 15 amp capacity NOTE Use only the recommended fuse capacity as use of a higher amperage fuse to correct blown fuse situations could lead to electrical component damage ...

Page 174: ...y discharge if operated below the Break Even RPM Continued problems would call for battery inspection NO Disconnect the wires leading from the regulator rectifier Using a multitester perform an Alternator Output AC amp test See test procedure on Page 9 18 for procedure Is output above 5 amps NO Inspect the wiring harness between the panel and the stator for damage If no damage is found remove the ...

Page 175: ...eter leads if a positive reading is indicated Shift transmission into neutral and start the engine If using an ammeter in series start engine with kick start only Turn headlight on high beam and apply the brake light Increase engine RPM while observing ammeter and tachometer Note RPM at which the battery starts to charge ammeter indication is positive With lights and other electrical load off this...

Page 176: ... the battery condition and charge accordingly Battery Check 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 2 Check the voltage with a voltmeter or multimeter A fully charged battery should be 12 8 V or higher 3 If the voltage is below 12 8 V the battery will need to be recharged New Batteries Batteries must be fully...

Page 177: ...dition before and 1 2 hours after the end of charging WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Reference Table State of Charge VOLTAGE ACTION CHARGE TIME 100 12 8 13 0V None FULL None Required 75 12 5 12 8V Sl...

Page 178: ...ormed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whene...

Page 179: ...attery type in the vehicle Use the section that applies to the battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes ...

Page 180: ...ning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps CONVENTIONAL BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positi...

Page 181: ...harged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 8V Less than 12 70V 12 50V 12 20V 12 0V Less than 11 9V SPECIFIC GRAVITY State of charge Conventional lead acid Low Maintenance Type 100 75 Charged 50 Charged 25 Charged 0 Charged 1 265 1 210 1 160 1 120 Less than 1 100 1 275 1 225 1 175 1 135 Less than 1 115 At 28 NOTE Subtract 01 from the specific gravity reading at 0 CONVENTIONAL BATTERY LOAD ...

Page 182: ...rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease 4 Connect battery cables To avoid the possibility of explosion connect positive red cable first and negative black cable last 5 After connecting the battery cables install the cover o...

Page 183: ...tions should not exceed 0 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on next page to perform voltage drop tests on the starter system Voltage Drop should not exceed 0 1 DC volts per connection Use the illustration below when troubleshooting a No Start condition Starter Motor Servi...

Page 184: ...ease the brush coil spring away 2 Push the armature out of case 3 Using an Ohmmeter measure the resistance between the cable terminal and the insulated brush The reading should be 3 ohms or less Measure the resistance between the cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite no reading 4 Remove the brush plate and brushes Measure the b...

Page 185: ...e lengthwise 3mm 1 8 above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced 6 Inspect the permanent magnets in starter housing Make sure they are not cracked or separated from housing CAUTION Use care when handling the starter housing Do not drop or strike the housing as magnet damage is possible If the magne...

Page 186: ...ton and brake depressed Replace the defective component YES Test starter relay coil by connecting an ohmmeter between the coil leads Resistance should be 3 4 1 Check relay ground path by measuring resistance between the G Y harness wire and battery negative terminal Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the relay end of the battery to rela...

Page 187: ... function Faulty starter relay starter motor Engine problem seized or binding Can engine be rotated easily with recoil starter Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test below Engine problem seized or binding Can engine be rotated easily with recoil starter Faulty or worn brushes in starter motor Autom...

Page 188: ...ELECTRICAL 9 32 ...

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