DAELIM B-BONE Service Manual Download Page 240

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19-6

LIGHTS/SWITCHES/HORN

FUEL TANK

UNIT SET CAP

FUEL GAUGE

BASE PACKING

FUEL GAUGE

●

Remove the floor panel.

●

Remove the unit set cap, and remove the fuel gauge.

●

Take precaution not to damage the wire.

●

Check the base packing for damage.

●

Inspect the fuel gauge.

OFF

FUEL CHECK

COLOR

FUEL GAUGE

FUEL

YELLOW / WHITE

GREEN

1.2 L

ETC

THERMISTER

Summary of Contents for B-BONE

Page 1: ......

Page 2: ......

Page 3: ...information and troubleshooting guide Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be reprod...

Page 4: ......

Page 5: ...OCATION 1 1 SPECIFICATIONS 1 2 TORQUE VALUES 1 4 STANDARD TORQUE VALUES 1 5 SYMBOLS ABBREVIATIONS 1 5 WIRINGDIAGRAM 1 6 GENERALSAFETY 1 10 SERVICERULES 1 10 CAUTION WHEN WIRING 1 14 SERIAL NUMBER LOCA...

Page 6: ...1 2 SERVICE INFORMATION 7 1 1 2 stroke SOHC ATDC 1 910mm 750mm 1 090mm 1 360mm 755mm 126mm 130kg 277kg 60 2 00 2 25 25 80 90 70 13 8 380 6 8 1 0 1 05 MARKED CONTENTS APPLY TO EURO 2 ONLY 90mm...

Page 7: ...55W 12V 55W 12V 5W 12V 10W 4 12V 21 5W LED LED LED 12V 5W TYPE VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY R...

Page 8: ...1 4 SERVICE INFORMATION...

Page 9: ...SERVICE INFORMATION 1 5...

Page 10: ...1 6 SERVICE INFORMATION...

Page 11: ...1 7 SERVICE INFORMATION...

Page 12: ...1 8 SERVICE INFORMATION...

Page 13: ...1 9 SERVICE INFORMATION...

Page 14: ...person are working always pay attention to other worker s action and alway have safety in mind 6 The skin exposed to used engine oil can be a major reason of the skin cancer Pay attention not to expos...

Page 15: ...nuts and pieces must be tightened from the bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test a...

Page 16: ...may damage the bearing Prior to installation apply oil or grease to the bearing 16 Install the snap ring so that chamfered side directs to the load applied side After installation check the proper in...

Page 17: ...ntact surface of each case of the engine while removing gasket material completely Remove damaged contact surface by wiping with the oil stone equally 23 Pay attention not to bend the cable excessivel...

Page 18: ...tion of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After connecting the terminal apply the grease to the termi...

Page 19: ...following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting t...

Page 20: ...the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start from the frame replace...

Page 21: ...ness not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please rea...

Page 22: ...MEMO...

Page 23: ...10 2 11 SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDERCOMPRESSION RESSURE CARBURETOR IDLE SPEED TRANSMISSION OIL ENGINE OIL...

Page 24: ...2 2 INSPECTIONS ADJUSTMENTS...

Page 25: ...2 3 INSPECTIONS ADJUSTMENTS...

Page 26: ...UT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT L...

Page 27: ...IALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPARKPLUGCAP SPARKPLUGCAP SPARKPLUGC...

Page 28: ...JUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST...

Page 29: ...TGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER U...

Page 30: ...E HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE R...

Page 31: ...STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREA...

Page 32: ...URE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESS...

Page 33: ...ng surfaces not shown here CONTROL CABLE LUBRICATION Periodically disconnect the upper end of the throttle cable and that of clutch cable then apply oil after cleaning Change it when the cable lengthe...

Page 34: ...MEMO...

Page 35: ...3 FRONT COVER 3 3 FRONTFENDER 3 4 FRONT UNDER COVER 3 4 SEAT 3 5 REAR FENDER 3 5 REAR UPPER COVER 3 5 REAR UNDER COVER 3 5 SEAT SUPPORT PIPE 3 6 CENTER COVER 3 6 TRUSS PIPE 3 7 FLOOR SIDE COVER 3 7 F...

Page 36: ...chart shows arrows connected in the order of disassembling covers INNER BOX FR COVER FR FENDER FR WHEEL FR UNDERCOVER SEAT RR FENDER RR UPPERCOVER RR UNDERCOVER SEATSUPPORTPIPE CENTERCOVER UNDERCOVER...

Page 37: ...CREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD...

Page 38: ...EW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW S...

Page 39: ...WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FE...

Page 40: ...AT SEAT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPO...

Page 41: ...APPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW BATTERY COVER BATTE...

Page 42: ...AL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHE...

Page 43: ...FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOM...

Page 44: ...MEMO...

Page 45: ...4 1 LUBRICATION SYSTEM 4 1 4 2 4 3 4 3 4 4 4 7 4 8 4 4 4...

Page 46: ...Inclusion of water Low or no oil pressure Close oil valve relief Clogged oil strainer Worn and faulty oil pump Internal oil leaks Inadequate oil viscosity Shout of oil quantity Oil pump drivegear or s...

Page 47: ...APPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOL...

Page 48: ...FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL...

Page 49: ...DY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE...

Page 50: ...SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILP...

Page 51: ...OVER RADIATOR COVER RADIATOR COVER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIA...

Page 52: ...T OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL...

Page 53: ...ode table 5 9 How to remove the fault code 5 10 EMS trouble shooting 5 10 6 ECU Electronic Control Unit 5 11 7 THROTTLE BODY 5 12 8 INJECTOR 5 16 9 MAPAT Manifold Air pressure Sensor temperature senso...

Page 54: ...ause these parts may be damaged by the impact of the drop Do not touch the ECU terminal because it may be damaged by the static The ignition key off when assembly and disassembly of the ECU coupler ot...

Page 55: ...ipe and injector The fuel in tank being high pressed by fuel pump moves to the division pipe through fuel filter Next the fuel is supplied to injector being highly maintained as regulated pressure abo...

Page 56: ...5 4 EMS Engine Management System 3 TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO 6 7 8 11 13 14 15 16 21 29 32 36 38 were not connected 4 WIRING DIAGRAM OF THE ECU...

Page 57: ...n the main key is turned on Remarks 1 If the EMS has some problem and the MIL on and off engine starting and driving are temporary by the EMS s fail safe function But the EMS is not normal condition s...

Page 58: ...inimum driving of vehicle MILon off INTAKE MIL INTAKE MILon on INTAKE INTAKE The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order intake in...

Page 59: ...r to check the malfunction of vehicle is placed in the rh side cover Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool The...

Page 60: ...ect information to driver If the MILon when engine is working engine is able to be operated by fail safe However in the event that Injector Fuel pump Ignition coil has something wrong vehicle may not...

Page 61: ...e speed actuator failure ISA 22 3 Electrical fuel pump failure EFP 23 4 Intake Manifold absolute pressure signal failure IMP 12 5 Throttle position signal failure TPS 13 6 O2 sensor heater output fail...

Page 62: ...e ignition key on off If many problems happened in the EMS parts at the same time only one defect code will is displayed by the priority order Even thought repair a fault and remove the memorized faul...

Page 63: ...PPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE CENTER COVER CENTER COVER CENTER COVER CENTER...

Page 64: ...dy ass y Remove the each component parts securing throttle body and check 5 12 EMS Engine Management System CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER C...

Page 65: ...T SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SEN...

Page 66: ...h new one INSTALLATION OF INSULATOR AND THROTTLE BODY Installation of insulator and throttle body in the reverse order of removal Check the o ring when the insulator assembly Assemble the insulator ga...

Page 67: ...diagnostic tool The vehicle is warms up enough to adjust the idling speed The vehicle is warms up enough to adjust the idling speed ENGINE TEMPERATURE OVER 100 IDLE SPEED ACTUATOR APROXIMATELY 20 INSP...

Page 68: ...R CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTO...

Page 69: ...e resistance is normal turns on the ignition key If the fuel pump operated for 3 seconds the power supply relay of injector is normal 6 Measure between the voltage of coupler Measuring terminal BLACK...

Page 70: ...SOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR M...

Page 71: ...4 Measure the input voltage of MAPAT intake pressure sensor intake temperature sensor s coupler Input voltage 4 5 5 5 V Measuring terminal MAPAT 3 terminal MAPAT 1 terminal Remarks Measuring unit of...

Page 72: ...294 V 5 If the measured voltage is not normal Check the P electric wire P G electric wire P L electric wire to see if they have been broken or have short circuited Replace the MAPAT sensor with the ne...

Page 73: ...no problem ECU is broken Replace the ECU with the new one it rechecks 4 Turn on the ignition key Start the engine and idling 5 Measure the voltage of intake pressure sensor for ECU check Measuring the...

Page 74: ...TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAP...

Page 75: ...isassemble the TPS coupler 4 Turn on the IGNITION KEY Measuring terminal ECU NO 18 Gr B GRAY BLACK ECU NO 4 W R WHITE RED Measure the terminal voltage of TPS s coupler Measuring voltage 4 5 V 5 5 V Re...

Page 76: ...9 If resistance and continuty are normal connect the TPS coupler 10 Turn on the ignition key 11 Measure the TPS voltage of wire harness to check the ECU Rotate the throttle lever measure the voltage...

Page 77: ...the key is off ASSEMBLY Assembly is the reverse order of removal Disconnect the ETS RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHR...

Page 78: ...LUE ECU No 4 W R WHITE RED Measure the terminal voltage of ETS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit for voltage voltage V If the voltage value is not normal Check to see if t...

Page 79: ...e ETS Engine Temperature Sensor Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil Read the temperature of thermometer depending upon oil temperatu...

Page 80: ...COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA...

Page 81: ...r of ISA measure the resistance between ISA terminals ISA resistance 31 5 38 5 20 remarks Measuring unit of resistance Resistance R 4 If there is not problem check about the level of electricity flow...

Page 82: ...ge measuring unit Voltage V If the measured voltage is normal Checkthe B R electricwire L G electricwire W R electricwireto see if they have been broken or have short circuited if there is a bad conta...

Page 83: ...PLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPL...

Page 84: ...ition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 Disassemble the coupler of oxygen O2 sensor and turn on ignition key 4 Measure in...

Page 85: ...BY OXYGEN O2 SENSOR LAMBDA SIGNAL 1 Turn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 The wire harness to check the...

Page 86: ...e Measuring terminal B Y electric wire G electric wire output voltage 9V 15V Remarks measuring unit of voltage voltage V If the measured voltage is normal Checkthe R Y electricwire B electricwire G el...

Page 87: ...RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SH...

Page 88: ...r Assembly is the reverse order of removal MEASUREMENT RESISTANCE Remove the seat Remove the LH side cover Disconnect the ACG coupler and L G connector Measure the resistance between G and L STANDARD...

Page 89: ...e ENGINE SINK ON change OFF to ON it s okay Check if ENGINE SINK ON is OFF while start up Remove the A C generator If there are over 10 spots on the flywheel protrusion replace it Check the CKP is wor...

Page 90: ...Measure terminal No 30 pin of wire harness for inspection Red wire of coupler of CKP Measuring resistance 0 1 Check the wiring of crank signal B Measure terminal No 22 pin of wire harness for inspecti...

Page 91: ...PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SE...

Page 92: ...ystem CONNECTOR WIRING LOCATION FUNCTION COLOR C D B A FUEL UNIT FUEL UNIT2 PUMP GROUND YELLOW GREEN RED BLACK The terminal arrangement of the fuel pump The following color chart is the internal color...

Page 93: ...red resistance value is out of standard at float position replace the fuel unit The FLOAT position F 140 5 mm 1 2 83 5 mm E 28 5 mm Terminals resistance 40 5 220 5 400 3 CHECK THE BLOW PRESSURE OF FUE...

Page 94: ...rnthelgnitionkeyon Pressthepowerbuttonofthe diagnostictool Presstheenterbuttonintheinitial screen Presstheenterinthe vehicle diagnosisscreen Presstheenterbuttononthe resettingECUvalues Presstherestbut...

Page 95: ...5 43 EMS Engine Management System Press theenterbuttonwhenitis ready WhentheECUwas initialized turnoffthelgnition keyandthenturnontheignitionkey...

Page 96: ...erbuttonofthediagnosistool Press theenterbuttonontheinitial screen Press thebuttonatthevehicle diagnostic screen Press theenterbuttononthecurrentdata By looking the displayed figure on the ISA PWM adj...

Page 97: ...diagnostic tool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Pressthe enterbuttonontheinitial screen Pressthe enterbuttononthevehiclediagnosisscreen Presstheenterbuttononthe...

Page 98: ...tool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Press the enterbuttonontheinitial screen Presstheenterbuttononthe vehiclediagnosisscreen Press the enterbuttononthecurrentd...

Page 99: ...MEMO...

Page 100: ...MEMO...

Page 101: ...desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogge...

Page 102: ...or is blocked Compression pressure is low Air Fuel mixture is extremely lean Fuel jet is blocked Bad ventilation of air in tank cap Fuel strainer screen is blocked Fuel tank is bent creased or blocked...

Page 103: ...TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL...

Page 104: ...AL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL...

Page 105: ...ER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET ARM PIN ARM PIN ARM PIN ARM PIN...

Page 106: ...the compressed air CARBURETORBODY TOP SET COMPRESSION SPRING FLOATCHAMBERSET SCREWSET AUTOBYSTARTERSET NEEDLEJETHOLDER MAINJET 95 SLOWJET NEDDLEJETCOMP VACUUMPISTONCOMP FLOAT VALVESET FLOATCOMP DIAPHR...

Page 107: ...n screws SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SC...

Page 108: ...ATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT...

Page 109: ...MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCRE...

Page 110: ...CCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELE...

Page 111: ...NGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FUELP...

Page 112: ...UELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP After install the fuel pump check the blowing quantity of fuel in the outlet tube NOTE Check the gaske...

Page 113: ...l or installation The following works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 12 STARTING CLUTCH SECTION 9 OIL PUMP SECTION 4 A C GENERATOR SECTION 9...

Page 114: ...MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD...

Page 115: ...ECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARC...

Page 116: ...8 0 LH CRANKCASECOVER CONTINUOUSL YV ARIABLETRANSMISSION LH CRANK CASE COVER...

Page 117: ...ELT WIDTH 22mm 20 5mm WEIGHT ROLLER OUTER DIAMETER 19 95 20 02mm 19 50mm CLUTCH OUTER AND INNER DIAMETER 125 0 125 2mm 125 5mm DRIVEN FACE SPRING PLAY 140mm 135mm DRIVEN FACE OUTER DIAMETER 33 965 33...

Page 118: ...EN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN P...

Page 119: ...FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVE...

Page 120: ...LLEYSUBASS Y DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT...

Page 121: ...PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABL...

Page 122: ...TE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE G...

Page 123: ...REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR R...

Page 124: ...SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE...

Page 125: ...nd guide pin rollers and the movable driven face Remove the O ring from movable driven face Remove the oil seal from the movable driven face Remove the movable driven face SEAL COLLAR MOVABLE DRIVEN F...

Page 126: ...aring with your finger Check that the bearing turns smoothly and quietly and that the bearing outer race fits securely Replace the bearing 8 11 MOVABLE DRIVEN FACE SPRING INSPECTION Measure the free l...

Page 127: ...34 060mm Check the driven face for damage or excessive wear replace as necessary Measure the O D of the driven face replace if the service limit is exceeded SERVICE LIMIT 33 785mm Install in a new inn...

Page 128: ...face Install the movable face on the driven pulley face Install the guide rollers and guide pins Install the seal collar DRIVENPULLEYSUBASS Y Install the spring guide driven face drive plate ass y Com...

Page 129: ...i fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi DRIVEN PULLEY D...

Page 130: ...9 0 A C GENERATOR STARTER CLUTCH sai COOLING FAN FLY WHEEL STARTER COMP SAI LID VALVE...

Page 131: ...9 9 9 9 9 9 9 9 1 A C GENERATOR STARTER CLUTCH 9 16...

Page 132: ...SHROUD RH SHROUD RH SHROUD RH SHROUD SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE S...

Page 133: ...A C G ROTOR PULLER A C G ROTOR PULLER A C G ROTOR PULLER DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE...

Page 134: ...K CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER SAI REED VALVE SAI REED VALVE SAI REED VALVE SA...

Page 135: ...CASE COVER RH CRANK CASE COVER OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SE...

Page 136: ...ET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTI...

Page 137: ...EAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER ONEWAY CLUTCH SET STARTER ON...

Page 138: ...HER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER...

Page 139: ...MEMO...

Page 140: ...10 0 CYLINDER HEAD VALVES FLANGE NUT INVALVEROCKERARM CAM SHAFT HORDER CAM SHAFT COMP INLET VALVE CYLINDERHEADCOMP CYLINDER HEAD GASKET EX VALVE ROCKER ARM EX VALVE CARBURETORINSULATOR SAI PIPE...

Page 141: ...T BOLT 1 0 kgf m SPARK PLUG 1 2 kgf m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m CYLINDER HEAD COVER BOLT 0 9kgf m CYLIND...

Page 142: ...urned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 11 Excessiv...

Page 143: ...CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL...

Page 144: ...ETER MICROMETER MICROMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNER...

Page 145: ...ADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET C...

Page 146: ...SSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRING VALVESPRING VALVESPRING VALVE...

Page 147: ...AMER VALVEGUIDEREAMER VALVEGUIDEREAMER VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGU...

Page 148: ...ER HEAD VALVES Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and...

Page 149: ...ng a 37 degree cutter remove of the existing valve seat material 10 9 CYLINDER HEAD VALVES Valve faces and stem tips cannot be ground If a valve face or stem tip is rough worn unevenly or contacts the...

Page 150: ...e seat must be lowered using a 37 degree flat cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too low on the valve the seat must be raised using a 55...

Page 151: ...CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE V...

Page 152: ...YLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLIN...

Page 153: ...N ROCKERARMSHAFT IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN...

Page 154: ...CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMI...

Page 155: ...LIP TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENS...

Page 156: ...11 0 CYLINDER PISTON CYLINDER CYLINDER GASKET PISTON TOPRING SECONDRING OILRING...

Page 157: ...ing Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston 11 SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 1 CYLINDER 11 2 PISTON PISTON RING 11 3 CYLINDER INSTALLATION...

Page 158: ...the cylinder measurements exceed the service limits replace the cylinder SERVICE LIMIT OUT OF ROUND 0 005 mm TAPER 0 05 mm CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAI...

Page 159: ...UGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE Any...

Page 160: ...11 4 CYLINDER PISTON...

Page 161: ...K SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CON...

Page 162: ...PISTON PISTON PISTON PISTON PISTON PISTON DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWE...

Page 163: ...MEMO...

Page 164: ...12 0 TRANSMISSION CRANKSHAFT CRANK CASE...

Page 165: ...12 12 1 12 2 12 3 12 6 12 7 12 8 12 9 12 10 12 1 TRANSMISSION CRANKSHAFT CRANKCASE 12 SECTION 4 4 SECTION 7 SECTION 9 SECTION 8 SECTION 8 SECTION 12 SECTION 10 AND 11...

Page 166: ...SSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission damage Transmission seized Noise during op...

Page 167: ...COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT...

Page 168: ...NAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUN...

Page 169: ...LOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT CRANK ASSEMBLY COLLAR CRANK ASSEMBLY COLLAR CRANK ASS...

Page 170: ...NE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE MISSION COVER MISSION COVER MISSION COVER MISSION...

Page 171: ...HAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET...

Page 172: ...E LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE BE...

Page 173: ...RIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT...

Page 174: ...NK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT...

Page 175: ...MEMO...

Page 176: ...13 0 FRONT WHEEL FRONT FORK STEERING STEERINGHANDLE STEERING STEM FRONT FORK FRONT TIRE FRONTWHEEL FRONTDISK...

Page 177: ...EERING TOP CONE RACE 0 49 1 27 f m FRONT CUSHION BOLT 1 98 2 45 f m FRONT AXLE NUT 4 41 4 9 f m BRAKE CALIPER BOLT 2 45 3 43 f m 13 SERVICE INFORMATION 13 1 TROUBLESHOOTING 13 2 STEERING HANDLE 13 3 F...

Page 178: ...e race Insufficient tire pressure Tire is worn Steers to one side or does not track straight Bent front fork Bent front axle Bent frame Tire is worn or modification Worn wheel bearing Front wheel wobb...

Page 179: ...OLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYL...

Page 180: ...FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE...

Page 181: ...EAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARIN...

Page 182: ...SHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASH...

Page 183: ...ETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER...

Page 184: ...ONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTF...

Page 185: ...PRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOL...

Page 186: ...face If the slider bush is extensively damaged replace the bottom case FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING...

Page 187: ...bottom case Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed TOOLS FORK S...

Page 188: ...LT FLANGEBOLT FLANGEBOLT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT SETTING HANDLE COLLAR SETTING HANDLE COLLAR...

Page 189: ...PTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT...

Page 190: ...14 0 REAR WHEEL SUSPENSION REAR SWING ARM...

Page 191: ...ALUES REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION UNDER BOLT 3 5 4 5 f m REAR CUSHION ROD LOCK NUT 3 0 4 5 f m REAR AXLE NUT 6 0 8 0 f m 14 SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 2 REAR WHEE...

Page 192: ...tened properly Insufficient air in tire Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorbe...

Page 193: ...R REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR...

Page 194: ...ALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWI...

Page 195: ...PRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPR...

Page 196: ...COMPRESSOR ATTACHMENT REAR CHUSION COMPRESSOR Install the spring with the smaller pitch side facing downward NOTE REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWI...

Page 197: ...REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARS...

Page 198: ...MEMO...

Page 199: ...MEMO...

Page 200: ...15 0 BRAKE SYSTEM...

Page 201: ...d brake disk and pad reduces the braking performance if contaminated replace the pad with a new one and clean the disk SPECIFICATIONS 15 SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 2 BRAKE FLUID 15 3...

Page 202: ...aminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn c...

Page 203: ...REEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDE...

Page 204: ...KEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELE...

Page 205: ...ANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEB...

Page 206: ...AD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER F...

Page 207: ...R GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN CALIPER BODY CALIPER BODY...

Page 208: ...BOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIP...

Page 209: ...BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY DISASSEMBLY Remove the rear brake caliper Check the...

Page 210: ...C RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC PISTON PISTON PISTON PISTON PISTON PISTON PISTON...

Page 211: ...BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE...

Page 212: ...ry for scores scratches or nicks replace if necessary Check the primary and secondary cups for wear Check the master cylinder for scores scratches or nicks and replace if necessary Apply the recommend...

Page 213: ...ISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK...

Page 214: ...16 0 CHARGING SYSTEM 15A...

Page 215: ...s charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to note here that the...

Page 216: ...e broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Battery is...

Page 217: ...BLE BATTERY REMOVAL Loosen the screws securing the battery cover and remove the battery cover Remove the battery Disconnect the negative battery cable first and then disconnect the positive cable The...

Page 218: ...s fully charged before performing this test The amount of current flow may change abruptly if not sufficiently charged Use a battery whose voltage between its terminals is 13 0 13 2V NOTE Take precaut...

Page 219: ...ULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REG...

Page 220: ..._ AC GENERATOR B Y PULSE GENERATOR BATTERY 12V10AH UNIT SIDESTAND SWITCH IGNITION COIL SPARK PLUG G R MAIN SW FUSE 15A G G B W P B G B B Y G B Y HEADLIGHT RELAY IGNITION SYSYTEM 17 0 IGNITION SYSTEM...

Page 221: ...ty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive peak voltage As inspections for co...

Page 222: ...side stand switch 6 Faulty peak voltage adaptor 7 Faulty CDI unit in case when above No 1 6 are normal 1 Faulty spark plug or leaking ignition coil secondary current ampere 2 Faulty ignition coil 1 Th...

Page 223: ...V TOOL PVA MULTI TESTER Installinthereverseorderofremoval ITEM GROUNDWIRE IGNITION COIL PRIMARYCOIL PULSE GENERATOR MAIN SWITCH Check that there is battery voltage between main switch wire black and g...

Page 224: ...SCREW FAN SCREW FAN SCREW FAN SCREW FAN SCREW IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL...

Page 225: ...TCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND...

Page 226: ...18 0 STARTER SYSTEM M CABLE CABLE STARTER RELAY STARTER MOTOR BATTERY 12V10AH FUSE Y R STARTER SWITCH REAR STOP SWITCH G Y STOP LAMP G Y FRONT STOP SWITCH B MAIN SWITCH G STARTER SYSTEM...

Page 227: ...le to turn the starter motor quickly enough or supply adequate ignition current The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over The engine may not...

Page 228: ...switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 6 Connect the starter magnetic switch coupler Measur...

Page 229: ...TOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MO...

Page 230: ...COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR OI...

Page 231: ...T RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK...

Page 232: ...TIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWIT...

Page 233: ...Apply battery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there is continuity betwee...

Page 234: ...MEMO...

Page 235: ...d Remove these locks prior to disassembling and insert these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity te...

Page 236: ...KER BULB WINKER BULB WINKER BULB WINKER BULB WINKER BULB HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET...

Page 237: ...DOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER...

Page 238: ...ITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH...

Page 239: ...SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADL...

Page 240: ...GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GA...

Page 241: ...MEMO...

Page 242: ...MEMO...

Page 243: ...0 1 WIRING DIAGRAM EURO 2 WIRING DIAGRAM...

Page 244: ...0 2 WIRING DIAGRAM EURO 3 WIRING DIAGRAM...

Page 245: ...SERVICEMANUAL 2009 02 PRINTED 2009 02 PUBLICATION C CO OP PY Y P PR RO OH HI IB BI IT T...

Page 246: ......

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