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2-6

INSPECTIONS/ADJUSTMENTS

Summary of Contents for S2-125

Page 1: ...rvice 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...

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Page 3: ...SERVICE INFORMATION 1 1 1...

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Page 12: ...1 10 SERVICE INFORMATION 145kg 11 5 2 2 stroke SOHC 306 9kg ATDC...

Page 13: ...1 11 SERVICE INFORMATION 30A LED LED LED...

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Page 19: ...FUEL PUMP TO CARBULATOR TUBE CLIP START MOTOR CABLE START MAGNET SW ASS Y BATTERY CABLE START MAG SW CORD BATTERY EARTH CABLE WIRE CLIP ACG WIRE TO FUEL TANK ACG CORD TUBE CLIP TUBE CLIP TO INSULATOR...

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Page 21: ...2 1 INSPECTIONS ADJUSTMENTS 2...

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Page 31: ...3 1 EXTERNAL PARTS 3...

Page 32: ...3 2 EXTERNAL PARTS...

Page 33: ...3 3 EXTERNAL PARTS...

Page 34: ...3 4 EXTERNAL PARTS...

Page 35: ...R UNDER UNDER UNDER UNDER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDL...

Page 36: ...R COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDER COVER A FRONT UNDE...

Page 37: ...3 7 EXTERNAL PARTS...

Page 38: ...EXTERNAL PARTS 3 8...

Page 39: ...4 1 LUBRICATION SYSTEM 4 1 4 2 4 3 4 3 4 4 4 7 4 8 4 9 4 4 4...

Page 40: ...4 2 LUBRICATION SYSTEM...

Page 41: ...4 3 LUBRICATION SYSTEM...

Page 42: ...4 4 LUBRICATION SYSTEM...

Page 43: ...4 5 SERVICE LUBRICATION SYSTEM...

Page 44: ...4 6 LUBRICATION SYSTEM...

Page 45: ...4 7 LUBRICATION SYSTEM...

Page 46: ...4 8 LUBRICATION SYSTEM...

Page 47: ...4 9 LUBRICATION SYSTEM...

Page 48: ...MEMO...

Page 49: ...How to read the fault code 5 8 Fault code table 5 9 How to remove the fault code 5 10 EMS trouble shooting 5 10 6 INJECTOR 5 11 7 MAPAT 5 14 8 TPS 5 17 9 ETS 5 20 10 ISA 5 23 11 O2 Oxygen SENSOR 5 26...

Page 50: ...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 51: ...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 52: ...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 53: ...y temporary when that happen Normally the MIL illuminates for 3 seconds when 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 temp...

Page 54: ...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 55: ...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 56: ...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 57: ...re ISA Electrical fuel pump failure EFP Intake Manifold absolute pressure signal failure IMP Throttle position signal failure TPS O2 sensor heater output failure LSH Lambda signal failure VLS Engine t...

Page 58: ...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 59: ...nagement System Remove Connector Connector bolt Injector and injector cap Replace the injector 6 INJECTOR NOTICE Before disassemble the key is off CAUTION Make sure that dust does not enter the thrott...

Page 60: ...stance of injector 14 5 0 7 20 Remarks measuring unit for resistance resistance R 4 If there is no problem check the continuity between each terminal and ground The resistance between each terminal an...

Page 61: ...ECU coupler are a bad contact ECU terminal No 40 If there is no problem in the electric wires ECU is broken Replace the ECU with new one it rechecks 8 If the measured voltage is not normal Check the...

Page 62: ...the coupler is toward to insulator CAUTION Located on the left side of the throttle body Before disassembly the key is off CAUTION 5 14 EMS Engine Management System ISA ISA ISA ISA ISA ISA ISA ISA IS...

Page 63: ...ey 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 o...

Page 64: ...electricwire P G electricwire P L electricwireto see if they have been broken orhave short circuited if there is a bad contact badnessofterminalNo 3 No 26 No 27ofECUcoupler If the electric wire is no...

Page 65: ...easuring voltage 0 1 V 4 9 V Remarks Measuring unit of voltage Voltage V 6 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...

Page 66: ...N KEY Input voltage 4 5 5 5 V 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 Remarks Measuring unit of...

Page 67: ...heck 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 check the ECU Rotate the throttle lever measure the voltage...

Page 68: ...rder of removal Situated on the Right hand side of cylinder head Before disassembly the key is off CAUTION 5 20 EMS Engine Management System ETS torque 3 0 3 kgf m CAUTION PUSH PUSH PUSH PUSH PUSH PUS...

Page 69: ...GREEN BLUE 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...

Page 70: ...the 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 temper...

Page 71: ...Maintenance cover ISA connector It is located upwards on the throttle body Before disassembly the key is off CAUTION O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Rin...

Page 72: ...f 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 bet...

Page 73: ...easuring 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 contact o...

Page 74: ...re disassembly the key is off CAUTION Beware of muffler after driving as it is still hot to be burnt Warning 11 O2 Oxygen SENSOR 5 26 EMS Engine Management System O2 Sensor O2 Sensor O2 Sensor O2 Sens...

Page 75: ...urn 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 Disassemble the coupler of oxygen O2 sensor and turn on ignition k...

Page 76: ...CODE 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 che...

Page 77: ...voltage Measuring terminal ECU No 24 L B BLUE BLACK EARTH output voltage battery voltage Remarks measuring unit of voltage voltage V If the measured voltage is normal Checkthe L B electricwire B elect...

Page 78: ...e the LH side cover CAUTION Be sure to assemble the ECU ground wire The color is green CAUTION 13 ECU ELECTRONIC CONTROL UNIT Make sure that the key is off before disassembly ECU ground wire ECU groun...

Page 79: ...N Be sure to assemble the IG coil Ground wire Be sure to check the high tension cord is assembly like a picture Install in the reverse order of removal CAUTION 14 IGNITION COIL IG coil ground wire IG...

Page 80: ...Cooling fan Flywheel Stator CPS screw Replace the CPS ENG RH crankcase cover Before disassembly the key is off CAUTION Install in the reverse order of removal 15 CRANK POSITION SENSOR CPS CPS wire CPS...

Page 81: ...is stored Always replace the packing when the fuel pump is removed Before disconnecting the fuel hose release the fuel pressure by loosing the fuel hose banjo bolt at the fuel tank Always replace the...

Page 82: ...EMS Engine Management System 5 34 The terminal arrangement of the fuel pump The following color chart is the internal color of the fuel pump 16 FUEL PUMP...

Page 83: ...r assemble Measure the resistance between Y W YELLOW WHITE wire and G GROUND wire of fuel unit terminal Remark measuring unit of resistance resistance If the measured resistance value is out of standa...

Page 84: ...TLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY ISA ISA I...

Page 85: ...speed actuator Disconnect theMAPAT Do not disconnect the throttle valve CAUTION Check Throttle shaft Throttle valve MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT...

Page 86: ...e o ring to insulator CAUTION INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INJECTOR INJECTOR INJECTOR INJ...

Page 87: ...the insulator gasket ADJUSTMENT OF THROTTLE CABLE INSPECTION OF SENSOR AND ACTUATOR Assemble the throttle cable Adjust the free play of the throttle grip 4 Connecteachsensorandtheactuator scoupler Che...

Page 88: ...eignitionkey Pressthepower buttonofdiagnostictool SUPPLEMENT TheECUisalwaysinitialized beforetheengine isstarting Thevehicleiswarmsupenoughtoadjustthe idlingspeed CAUTION If the ETS temperature is 90...

Page 89: ...owerbuttonofthediagnostictool Presstheenterbuttonintheinitialscreen Presstheenterinthevehiclediagnosisscreen PresstheenterbuttonontheresettingECUvalues Presstherestbuttononthefollowingscreen If the en...

Page 90: ...Presstheenterbuttonwhenitisready WhentheECUwasinitialized turnoffthelgnition keyandthenturnontheignitionkey EMS Engine Management System 5 42...

Page 91: ...werbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Pressthebuttonatthevehiclediagnosticscreen Presstheenterbuttononthecurrentdata By looking the displayed figure on the ISA PWM adjust t...

Page 92: ...gnostictool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbuttononthecurrent...

Page 93: ...tictool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbuttononthecurrentdata...

Page 94: ...MEMO...

Page 95: ...6 1 FUEL SYSTEM ENGINE 6 4 6 6 6 6...

Page 96: ...6 2 FUEL SYSTEM ENGINE...

Page 97: ...6 3 FUEL SYSTEM ENGINE...

Page 98: ...MEMO...

Page 99: ...7 1 ENGINE REMOVAL INSTALLATION 7 7 7 1 7 2...

Page 100: ...7 2 ENGINE REMOVAL INSTALLATION...

Page 101: ...7 3 ENGINE REMOVAL INSTALLATION...

Page 102: ...8 0 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 103: ...8 1 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION 8 8 8 8 8 8 8 8...

Page 104: ...8 2 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 105: ...8 3 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 106: ...8 4 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 107: ...8 5 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 108: ...8 6 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 109: ...8 7 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 110: ...8 8 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 111: ...8 9 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 112: ...8 10 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 113: ...8 11 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 114: ...8 12 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 115: ...8 13 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 116: ...9 0 A C GENERATOR STARTER CLUTCH...

Page 117: ...9 9 9 9 9 9 9 9 1 A C GENERATOR STARTER CLUTCH 9...

Page 118: ...9 2 A C GENERATOR STARTER CLUTCH...

Page 119: ...9 3 A C GENERATOR STARTER CLUTCH...

Page 120: ...9 4 A C GENERATOR STARTER CLUTCH...

Page 121: ...9 5 A C GENERATOR STARTER CLUTCH...

Page 122: ...9 6 A C GENERATOR STARTER CLUTCH...

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Page 125: ...MEMO...

Page 126: ...INJECTOR ASSY ENGINE TEMP SENSOR 10 0 CYLINDER HEAD VALVE...

Page 127: ...10 10 1 10 2 10 3 10 5 10 6 10 6 10 7 10 8 10 11 10 13 10 1 CYLINDER HEAD VALVE 10...

Page 128: ...10 2 CYLINDER HEAD VALVE...

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Page 139: ...10 13 CYLINDER HEAD VALVE...

Page 140: ...10 14 CYLINDER HEAD VALVE...

Page 141: ...throttle body 10 15 CYLINDER HEAD VALVE...

Page 142: ...CYLINDER PISTON 11 0...

Page 143: ...11 1 11 11 11 1 11 1 11 2 11 3 11 5...

Page 144: ...11 2 CYLINDER PISTON...

Page 145: ...11 3 CYLINDER PISTON...

Page 146: ...11 4 CYLINDER PISTON...

Page 147: ...11 5 CYLINDER PISTON...

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Page 149: ...MEMO...

Page 150: ...12 0 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 151: ...12 12 1 12 2 12 3 12 6 12 7 12 8 12 9 12 10 12 1 TRANSMISSION CRANKSHAFT CRANKCASE 12...

Page 152: ...12 2 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 153: ...12 3 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 154: ...12 4 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 155: ...12 5 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 156: ...12 6 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 157: ...12 7 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 158: ...12 8 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 159: ...12 9 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 160: ...12 10 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 161: ...MEMO...

Page 162: ...13 0 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 163: ...14 24 935mm 25 25 039mm 25 27mm 25 07mm 25 278 25 328mm 25 44 25 41mm 25 27mm 25 42mm 33 914 33 935mm 34 34 039mm 33 87mm 34 01mm FRONT COMBI BRAKE CALIPER CYLINDER I D REAR REAR 13 13 1 13 2 13 3 13...

Page 164: ...13 2 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 165: ...13 3 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 166: ...13 4 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 167: ...13 5 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 168: ...13 6 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 169: ...13 7 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 170: ...13 8 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 171: ...13 9 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 172: ...13 10 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 173: ...13 11 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 174: ...ng and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outwar...

Page 175: ...ase to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper to the shock absorber and tighten the two bolts Torque 24 5 34 3N m Check the...

Page 176: ...13 14 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 177: ...13 15 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 178: ...13 16 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 179: ...13 17 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 180: ...13 18 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 181: ...13 19 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 182: ...13 20 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 183: ...MEMO...

Page 184: ...REAR WHEEL BRAKE SUSPENSION REAR SWING ARM 14 0...

Page 185: ...14 1 14 14 14 1 14 2 14 3 14 5 14 7 14 7...

Page 186: ...14 2 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 187: ...14 3 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 188: ...14 4 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 189: ...14 5 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 190: ...14 6 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 191: ...14 7 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 192: ...14 8 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 193: ...MEMO...

Page 194: ...30A 15 0 CHARGING SYSTEM...

Page 195: ...15 15 1 15 2 15 2 15 3 15 4 15 5 15 1 15...

Page 196: ...13 5 15 5V 13 5V 15 2 CHARGING SYSTEM...

Page 197: ...15 3 CHARGING SYSTEM...

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Page 200: ...MEMO...

Page 201: ...0 73 0 08 23 5 80 150 15K 16 16 1 16 3 16 4 16 5 16 6 16 6 16 1 16...

Page 202: ...16 2 IGNITION SYSTEM...

Page 203: ...pulser pulser 16 3 IGNITION SYSTEM...

Page 204: ...Thesecondarycoilresistancemightnotmeasurecause bythehighvoltagediodeinsidetheignitioncoil 16 4 IGNITION SYSTEM...

Page 205: ...GREEN AND BLACK WHITE GREEN AND BLACK WHITE 16 5 IGNITION SYSTEM...

Page 206: ...RE D 3 0 17 0 STARTER SYSTEM...

Page 207: ...17 17 1 17 4 17 7 17 2 17 3 17 1 17...

Page 208: ...17 2 STARTER SYSTEM...

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Page 214: ...MEMO...

Page 215: ...18 18 1 18 1 18 4 18 2 18 2 18 3 18 3 18 4 18 4 18 1 18...

Page 216: ...COLOR BAT 1 2 P GRAY BAT 2 18 2 LIGHTS SWITCH HORN...

Page 217: ...3 18 3 LIGHTS SWITCH HORN...

Page 218: ...18 4 LIGHTS SWITCH HORN...

Page 219: ...MEMO...

Page 220: ...MEMO...

Page 221: ...19 CIRCUIT DIAGRAM...

Page 222: ...19 1 19...

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