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Dinli DL-702 2008, Service Manual

The Dinli DL-702 2008 Service Manual is a must-have for all owners of this powerful ATV. This comprehensive manual covers everything you need to know to keep your vehicle running smoothly. Download your free manual from manualshive.com today and ensure you're always prepared for any maintenance or repairs.

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3-1

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BRAKE 

 

BRAKE 

Table of Contents 

Construction---------------------------------------------------------------------------------------------------3-2 
Brake Fluid-----------------------------------------------------------------------------------------------------3-3 
        Brake  Fluid  Recommendation----------------------------------------------------------------------3-3 
        Brake Fluid Level Inspection------------------------------------------------------------------------3-4 
        Brake Fluid Change------------------------------------------------------------------------------------3-4 
        Brake Line Air Bleeding------------------------------------------------------------------------------3-5 
Master  Cylinder----------------------------------------------------------------------------------------------3-6 
        Removal--------------------------------------------------------------------------------------------------3-6 
        Installation-----------------------------------------------------------------------------------------------3-7 
Caliper----------------------------------------------------------------------------------------------------------3-8 
        Front Caliper Removal--------------------------------------------------------------------------------3-8 
        Rear Caliper Removal---------------------------------------------------------------------------------3-8 
        Parking Brake Caliper Removal--------------------------------------------------------------------3-8 
        Caliper Installation-------------------------------------------------------------------------------------3-9 
        Caliper  Inspection------------------------------------------------------------------------------------3-10 
Brake  Pad-----------------------------------------------------------------------------------------------------3-12 
        Removal-------------------------------------------------------------------------------------------------3-12 
        Installation----------------------------------------------------------------------------------------------3-13 
        Inspection-----------------------------------------------------------------------------------------------3-13 
Brake  Disc----------------------------------------------------------------------------------------------------3-14 
        Disc  Cleaning------------------------------------------------------------------------------------------3-14 
        Front  Disc  Removal----------------------------------------------------------------------------------3-14 
        Rear  Disc  Removal-----------------------------------------------------------------------------------3-15 
        Front Disc Installation-------------------------------------------------------------------------------3-15 
        Rear Disc Installation--------------------------------------------------------------------------------3-16 
        Inspection-----------------------------------------------------------------------------------------------3-16 
Brake Hose and Pressure Valve-------------------------------------------------------------------------3-17 
        Inspection-----------------------------------------------------------------------------------------------3-17 
        Replacement-------------------------------------------------------------------------------------------3-17 
Foot  Brake----------------------------------------------------------------------------------------------------3-19 
        Brake Pedal Inspection------------------------------------------------------------------------------3-19 
        Brake Pedal Position Adjustment-----------------------------------------------------------------3-19 
        Brake  Pedal  Removal-------------------------------------------------------------------------------3-20 
        Brake Pedal Installation-----------------------------------------------------------------------------3-20 
        Master  Cylinder  Removal--------------------------------------------------------------------------3-20 
        Master Cylinder Installation-----------------------------------------------------------------------3-21 

 

 
 

Summary of Contents for DL-702 2008

Page 1: ...FOREWORD INDEX 0 0...

Page 2: ...been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products m...

Page 3: ...and non scheduled maintenance Use proper tools and genuine DINLI vehicle parts Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don...

Page 4: ...result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE This note...

Page 5: ...RAL INFORMATION CHAPTER 2 WHEELS TIRES CHAPTER 3 BRAKE CHAPTER 4 SUSPENSION STEERING DRIVE SHAFT CHAPTER 5 BODY CHAPTER 6 ENGINE CHAPTER 7 COOLING AND LUBRICATION SYSTEM CHAPTER 8 ELECTRICAL SYSTEM CH...

Page 6: ...tion 1 8 Fuel For USA and Canada 1 8 Fuel For Other Countries 1 8 Engine Oil For USA 1 8 Engine Oil For Other Countries 1 8 Front Differential Gear Oil 1 8 Rear Gear Final Box Oil 1 8 Brake Fluid 1 9...

Page 7: ...t the positive wire to the positive terminal of the battery 3 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if installation or assembly sequ...

Page 8: ...revent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may bloc...

Page 9: ...thermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are...

Page 10: ...isconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive...

Page 11: ...1 6 GENERAL INFORMATION DINLI DL 702 Right Side Left Side Difference between photograph and actual vehicle may exist depending on the markets...

Page 12: ...ial number Vehicle identification number ENGINE SERIAL NUMBER Ex 15M18XXXXX VEHICLE IDENTIFICATION ex RFWAK85CX6Txxxxxx Whenever corresponding with DINLI about a particular issue the engine number and...

Page 13: ...or SG under the API American Petroleum Institute service classification The recommended viscosity is SAE 10W 40 If SAE 10W 40 oil is not available select an alternative according to the following char...

Page 14: ...an distilled water can corrode and clog the aluminum radiator Anti Freeze Engine Coolant The engine coolant performs as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coola...

Page 15: ...before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follow...

Page 16: ...re or during operating the ATV Maximum Vehicle Load 250kg 551 lbs Includes weight of operator cargo and accessories Never load over 250kg or may cause loss of control Always wear protective clothing w...

Page 17: ...tem Liquid cooled 85 Cooling device operating temperature 1 2 water anti freeze ethylene glycol containing corrosion inhibitors for aluminum engines and radiators Coolant Starter system Electrical and...

Page 18: ...n Transfer L H N R P Automatic transmission ratio Variable change 2 670 0 787 Secondary reduction ratio 2 158 40 21 17 15 Final reduction ratio Front Rear 3 600 36 10 Low 2 294 39 17 Transmission gear...

Page 19: ...t DC 14V 23A 3000 rpm Battery GS GTX20L BS 12 V 20Ah Main fuse 30 A Fuse 5A 7 5A 10A 15A 30A Headlight 12V 35 35W Main 3W Position Taillight P21 5W RY 10W Indicator Speedometer LCD High beam indicator...

Page 20: ...Wheel Rim 2 4 Removal 2 4 Installation 2 4 Inspection 2 5 Replacement 2 5 Tire 2 6 Removal 2 6 Installation 2 6 Inspection 2 8 Hub 2 9 Front Hub Removal 2 9 Front Hub Inspection 2 9 Front Hub Installa...

Page 21: ...pressure when cold Front Rear Maximum tire bead seat pressure Front Rear Vehicle Maximum load capacity AT 25 8 12 MAXXIS M915 Tubeless AT 25 10 12 MAXXIS M916 Tubeless 35 kPa 0 35 kgf cm2 5 1 psi 35...

Page 22: ...cs 11 Tire 2 Front Wheel Hub 7 Castle Nut 4pcs 12 Rim 3 Rear Wheel Hub 8 Cotter Pin 4pcs 13 Rim 4 FHSC 8pcs 9 Spring Washer 4pcs 14 Name Plate 4pcs 5 Insert Bolt 16pcs 10 Tire 15 Rim Valve 4pcs Item N...

Page 23: ...he wheel Installation A A A Check the tire rotation mark A on the tire and install the wheel accordingly NOTE The direction of the tire rotation is shown by an arrow on the tire sidewall B Position th...

Page 24: ...im see Tire Removal Remove the air valve and discard it CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve 2 5 Install a new air valve in the new rim Remove the val...

Page 25: ...allation Inspect the rim see Wheel Rim Inspection Replace the air valve with a new one Check the tire for wear and damage see Tire Inspection CAUTION When using the tire bead breaker do not scratch or...

Page 26: ...the tire until the tire beads seat on the rim WARNING Do not inflate the tire to more than the maximum tire air pressure Over inflation can explode the tire with possibility of injury and loss of line...

Page 27: ...ore operation Tire Inspection Examine the tire for damage and wear If the tire is cut or cracked replace it Lumps or high spots on the tread or sidewalls indicate internal damage requiring tire replac...

Page 28: ...the caliper hang free Remove the axle nut and pull off the front hub with brake disc CAUTION Replace the removed cotter pin with a new one A B Separate the brake disc by removing the brake disc mount...

Page 29: ...hten the axle nut to the specified torque Tightening Torque 110 N m 11 0 kgf m 79 5 lb ft Insert the new cotter pin and bent it over the nut Rear Hub Removal Remove the wheel See wheel Removal Remove...

Page 30: ...ar hub in the reverse order of removal Pay attention to the following points Apply GREASE to the hub spline Tighten the axle nut 1 to the specified torque Tightening Torque 110 N m 11 0 kgf m 79 5 lb...

Page 31: ...liper Installation 3 9 Caliper Inspection 3 10 Brake Pad 3 12 Removal 3 12 Installation 3 13 Inspection 3 13 Brake Disc 3 14 Disc Cleaning 3 14 Front Disc Removal 3 14 Rear Disc Removal 3 15 Front Dis...

Page 32: ...ter Cylinder Assy 19 Pin 32 Braking Hose 7 Protector 20 Spring Washer 2pcs 33 Braking Hose 8 Hex Socket Bolt 4pcs 21 Washer 17pcs 34 Braking Hose 9 Hexagonal Flange Bolt 7pcs 22 Spring Washer 4pcs 35...

Page 33: ...te will cause deterioration of the rubber parts Oil spilled on any parts will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handing the d...

Page 34: ...container Fill the reservoir with new brake fluid Change the brake fluid as follows Open the bleed valve in counterclockwise Squeeze the brake lever B Release the brake lever A Check the fluid level...

Page 35: ...out the brake fluid reservoir The fluid level must be checked several times during the bleeding operation and replenished as necessary Tighten the bleed valve to the specified torque Tightening Torque...

Page 36: ...linder to catch any split fluid Remove the brake hose union bolt and disconnect the brake hose B Remove the master cylinder by taking off its clamp bolts A Remove the brake lever 1 CAUTION Brake fluid...

Page 37: ...rque 9 N m 0 90 kg m 6 5 lb ft Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Tightening Torque 25N m 2 5kg m 18 0 lb ft Bleed the brake line after master cyli...

Page 38: ...moval Remove the rear wheel see Wheels Tires chapter Loosen the banjo bolt at the brake hose lower end and tighten it loosely Remove the caliper mounting bolts and detach the caliper from the disc Rem...

Page 39: ...he reverse order of removal Pay attention to the following points Replace the washers 1 that are on each side of hose fitting with new ones Tighten the caliper mounting bolts 2 and the brake hose banj...

Page 40: ...o the rear hub and tighten them to the specified torque Tightening Torque 25 N m 2 5 kgf m 18 0 lb ft Replace the circlips 1 with new ones Tighten the wire rope bolt 2 Caliper Inspection Inspect the b...

Page 41: ...3 11 BRAKE...

Page 42: ...e B remove the pads C Remove the anti rattle spring Rear Brake Remove the rear caliper See Caliper Removal Push the plate A remove the pads B Remove the anti rattle spring Parking Brake Remove the rea...

Page 43: ...thickness A of the pads in each caliper If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set WARNING Do not attempt to drive the vehicle un...

Page 44: ...ront Brake Disc Removal Remove the front wheel see Wheel Removal Remove the front brake caliper Remove the front hub by removing its cotter pin and axle nut Remove the brake disc mounting bolts A Remo...

Page 45: ...x bolts and slide the gear box backward Remove the disc Front Disc Installation The disc must be installed with the marked side A facing toward the steering knuckle Apply non permanent locking agent D...

Page 46: ...point solvent Inspection Disc Wear Measure the thickness of each disc at the point A where it has worn the most Replace the disc if has worn past the service limit B Measuring Area Micrometer 0 25 mm...

Page 47: ...Brake Hose Pump the brake fluid out of the line as explained in the Brake Fluid Change Remove the banjo bolts at both ends of the brake hose and pull the hose off the vehicle Immediately wipe up any...

Page 48: ...sure valve by installing the brake hose banjo bolts and pressure valve mounting bolts Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid...

Page 49: ...the brake pedal free play A Depress the brake pedal lightly by hand until the brake is applied If the free play is incorrect adjust it Brake Pedal Position Adjustment Remove the brake pedal see Brake...

Page 50: ...he Removal steps to install the brake pedal Master Cylinder Removal Remove the master cylinder joint A and the banjo bolt B at the brake hose lower end and tighten it loosely Remove the brake hose C L...

Page 51: ...d level A in the brake reservoir Bleed the brake line after master cylinder installation see Brake Line Air Bleeding Check the brake for good braking power and no fluid leakage WARNING Do not attempt...

Page 52: ...izer Removal 4 18 Rear Stabilizer Installation 4 19 Front Propeller Shaft 4 20 Removal and Disassembly 4 20 Inspection and Reassembly 4 21 Installation 4 23 Rear Propeller Shaft 4 24 Removal 4 24 Insp...

Page 53: ...3 Spring washer 2pcs 4 Driver shaft protector 14 Cap 2pcs 24 Spacer 2pcs 5 Front shock absorber 15 Hex socket bolt 2pcs 25 Spacer 6 Lower A arm 16 Hex washer face bolt 5pcs 26 C type circlip 7 Upper A...

Page 54: ...nt wheel hubs with brake discs See brake chapter Remove the front brake calipers and hang it free Remove the driver shaft protector Remove the cotter pins and tie rod end nuts Remove the front brake d...

Page 55: ...sorber lower mounting bolts nuts and the upper A arm washer face bolts nuts Remove the upper A arms 1 Remove the lower A arm washer face bolts nuts Remove the lower A arms 2 Remove the shock absorber...

Page 56: ...s for wear or damage If any damages are found replace it with a new one Remove the snap ring 1 Remove the knuckle ends with the special tools Bearing Installer Set Front Fork Installer Hammer A arm In...

Page 57: ...w one Bushing Inspect the rubber bushings A arm for wear or other damage If any damages are found replace them with new ones Oil Seal Inspect the Oil seal lips for wear or damage If any damages are fo...

Page 58: ...y are in the steering knuckles Rotate the inner races by hand to inspect for abnormal noise and smooth rotation If there is anything unusual replace the bearing with a new one Remove the circlip Remov...

Page 59: ...and disassembly Pay attention to the following points Install the hub bearings with the special tool Install the steering knuckle oil seal with the special tool The oil seal which has faces to the fr...

Page 60: ...lb ft Lower 60 N m 6 0 kgf m 43 5 lb ft Tighten the shock absorber mounting lower bolt nut 1 to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 lb ft Tighten the shock absorber mounting u...

Page 61: ...ll the front brake calipers Install the front wheels tires Spring Pre Load Adjustment After installing the front shock absorbers adjust the spring pre load The spring adjusting sleeve on shock absorbe...

Page 62: ...x washer face bolt 21 Spacer 2pcs 4 Driver shaft protector 13 Hex washer face bolt 2pcs 22 Spacer 5 Rear shock absorber 14 Hex washer face bolt 23 C type circlip 6 Double row angular bearing 15 Hex wa...

Page 63: ...the driver shaft protector Remove the cotter pin and rear hub nut Remove the rear wheel hub Remove the rear stabilizer joint lower bolt nut Remove the rear shock absorber Remove the rear knuckle moun...

Page 64: ...her face bolt nuts Inspection and Disassembly Rear Shock Absorber Inspect the shock absorber for oil leakage or damage If any damages are found replace the rear shock absorber with a new one Bushing I...

Page 65: ...nuckle oil seal with a suitable bar Hub Bearing Inspect the inner race play of the hub bearing by hand while it is in the rear knuckle Rotate the inner race by hand to inspect for abnormal noise and s...

Page 66: ...ion Reassemble and install the rear suspension in the reverse order of removal and disassembly Pay attention to the following points Apply GREASE to the hub bearings and the lips of the oil seals befo...

Page 67: ...ghten rear knuckle bolt nut to the specified torque Tightening Torque 60 N m 6 0 kgf m 43 5 lb ft Apply THREAD LOCK to the rear shock absorber mounting bolts and then tighten the nut to the specified...

Page 68: ...bsorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following phot...

Page 69: ...ge If any damages are found replace the rear stabilizer bar with a new one Stabilizer Bracket Bushing Inspect the stabilizer bracket for damage If any damage are found replace the stabilizer bracket w...

Page 70: ...SION STEERING DRIVE SHAFT Rear Stabilizer Installation Install the stabilizer bar Tighten the rear stabilizer bracket bolts Tighten the rear stabilizer joint bolt nut Tightening Torque 34 N m 3 4 kgf...

Page 71: ...emove the boot bands of the differential side joint double offset joint Slide the boot toward the center of the front propeller shaft and remove the stopper ring from the outer race Separate the outer...

Page 72: ...all the cage 1 on the shaft A Large Diameter B Small Diameter NOTE Wash the disassembled parts except for the boots After washing completely dry the parts using compressed air Clean the boots with a c...

Page 73: ...iver into the boot on the outer race side and allow air to enter the boots so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustrat...

Page 74: ...4 23 SUSPENSION STEERING DRIVE SHAFT Installation Install the front propeller shaft in the reverse order of removal...

Page 75: ...ands for wear or damage If any damages are found replace them with new ones Inspect the axle play by using a push and pull motion given to the axle shaft and wheel spindle as shown NOTE Wash the disas...

Page 76: ...he shaft A Large Diameter B Small Diameter Install the new snap ring Apply GREASE to the entire surface of the cage and the inside of the outer race NOTE The tube of joint grease is included in the wh...

Page 77: ...the boot on the outer race side and allow air to enter the boot so that the air pressure in the boot becomes the same as the atmospheric pressure at the positions indicated in the illustration A 188 1...

Page 78: ...ate 13 Cotter pin 2 Steering Tie rod assy 2sets 8 Bush bearing 14 Cotter pin 4pcs 3 Steering shaft bracket 2pcs 9 Oil seal 2pcs 15 Spring washer 4pcs 4 Pin 10 Hexagonal flange bolt 16 Washer 4pcs 5 Se...

Page 79: ...ar clamp bolts Remove the wire rope that from the handlebar assembly See Handlebar Removal Remove the handlebar upper clamps A Remove the handlebar Remove the cotter pins and tie rod end nuts Separate...

Page 80: ...et bolts Remove the steering shaft brackets spacers oil seals and plate Remove the steering shaft Remove the seal cover 1 pin 2 bush bearing 3 and washer 4 CAUTION Replace the removed oil seals with n...

Page 81: ...m with new ones Tie Rod Inspect the tie rod for distortion or damage If any damages are found replace it with a new one Tie Rod End Inspect the tie rod ends and boots for smooth movement If there are...

Page 82: ...ge If any damages are found replace it with new one Inspect the steering shaft seal cover for any scratches or other damage If any damages are found replace the shaft seal cover with new ones Inspect...

Page 83: ...torque Tightening Torque 23 N m 2 3 kgf m 16 5 lb ft Install the steering shaft lower nut with the washer Tighten the steering shaft lower nut to the specified torque Tightening Torque 120 N m 12 0kgf...

Page 84: ...clamp align the brake reservoir on the horizontal direction of the handlebar Install the handlebar upper clamps as shown First tighten the bolts 1 to the specified torque and then tighten the bolts 2...

Page 85: ...t until the toe out is within the specified range B A Tie out Temporarily tighten the four locknuts Check that the distance C and D are equal as shown If the distances are not equal adjust the tie rod...

Page 86: ...ndlebar 6 Handle grip 2pcs 11 Right lever assy 2 Throttle wire 7 Hex socket bolt 4pcs 12 Left lever assy 3 Choke cable 8 Rear View mirror L 13 Right switch 4 Upper handlebar clamp L 9 Rear View mirror...

Page 87: ...ove the brake hose Remove the brake master cylinder assembly See Brake chapter Remove the throttle wire Remove the right switch assembly Remove the choke cable by removing its cap 1 Remove the parking...

Page 88: ...hat the angle of the handlebar matches the angle of the steering stem as shown Install the handlebar upper clamps as shown First tighten the bolts 1 to the specified torque and then tighten the bolts...

Page 89: ...ator T M level 18 Level assy rod 3 Indicator T M level 11 Indicator T M level bracket 19 Tie rod end 2pcs 4 T M level cover 12 Spacer 2pcs 20 Level rod 5 Tapping screw 4pcs 13 Washer 3pcs 21 Nut 6 Hex...

Page 90: ...SION STEERING DRIVE SHAFT Removal Remove the indicator T M lever knob 1 indicator level tapping screws 2 and mounting bolts 3 Loosen the bolt 1 and remove the tie rod end 2 Remove the T M lever assemb...

Page 91: ...eplace it with a new one Installation Install the indicator T M lever in the reverse order of removal Pay attention to the following points Apply GREASE to level shaft Install the T M lever assembly t...

Page 92: ...ly keep the tie rod end 1 in the N position Install the tie rod end 1 on its shaft Tighten the bolt 2 securely NOTE When installing the tie rod end align the tie rod end s grooves with the spline of t...

Page 93: ...If the lever can not move successfully measure the tie rod length and adjust the tie rod to the proper position Adjust the tie rod in two positions as shown in the figure CAUTION Adjust the tie rod le...

Page 94: ...tion 5 4 Front and Rear Fenders 5 5 Front Fender Construction 5 5 Front Fender Removal 5 6 Front Fender Installation 5 10 Rear Fender Construction 5 11 Rear Fender Removal 5 12 Rear Fender Installatio...

Page 95: ...se to seat open position B Lift the seat front slightly pull it toward the front and remove the seat Seat Installation Align the catch A at the back of the seat with the receiver B on the frame Slip t...

Page 96: ...Front and Rear Racks Front and Rear Racks Removal Remove the front rack by removing its bolts A 4 left right B 2 left right Remove the rear rack by removing its bolts C 2 left right D 2 E 2 left right...

Page 97: ...5 4 BODY Front and Rear Racks Installation Install the front and rear rack in the reverse order of removal NOTE When installing the racks notice that the difference between front and rear rack...

Page 98: ...partment 12 Hook cover 21 Plug 4 Front fender L 13 Clip nut 10pcs 22 Fixed plate 4pcs 5 Front fender R 14 Hex washer face bolt 23 Fixed plate 2pcs 6 Front fender under cover 15 Hex washer face bolt 2p...

Page 99: ...fender decoration B by inserting the opening stick into the hole A to open it Remove the maintenance compartment C by removing its screws and bolts D 4 left right attach to the front fender E 2 left...

Page 100: ...move the front fender decoration See 5 6 Remove the headlight lead wire coupler A Remove headlight shade by unscrew the screws B 5 C 6 left right attach to the front fender Front Fender Under Cover Re...

Page 101: ...B 4 Front Fender Left Right Remove the front rack See 5 3 Remove the maintenance compartment See 5 6 Remove the headlight shade See 5 7 Remove Left and Right Fender by removing A 6 left right attach...

Page 102: ...the fuel tank cap B Remove the fuel tank decoration by removing its bolts attach to the luggage compartment Fuel Tank Remove the fuel tank decoration See 5 9 Disconnect the Fuel level indicator lead w...

Page 103: ...5 10 BODY Remove the fuel tank by removing its bolts Front Fender Installation Please reverse the Removal steps to install...

Page 104: ...2pcs 3 Left body decoration 11 Screw 6pcs 19 Heat insulation pad 4 Right body decoration 12 Pan head bolt 4pcs 20 Hex washer face bolt 2pcs 5 Rear fender 13 Machine screw 16pcs 21 Tapping screw 2pcs 6...

Page 105: ...Remove the seat See 5 2 and rear rack See 5 3 Remove the taillight lead wire coupler left right Remove the rear fender by removing A 6 attach to luggage compartment B 3 attach to luggage compartment C...

Page 106: ...fender See 5 8 Remove the body decoration screws A 6 left right Remove the body decoration by removing screws B 4 left right attach to the foot board Foot Board Remove the foot board by removing Foot...

Page 107: ...ee 5 13 Footrest Remove the footboard See 5 13 Remove the footrest mounting bolts When installing the footrest by its mounting bolts tighten them to the specified torque Tightening Torque 55 N m 5 5 k...

Page 108: ...olts Remove the battery Remove the electrical relays and units Remove the fuel tank decoration See 5 9 Remove the seat hook wire rope See 5 9 Remove the rear fender See 5 12 Remove the intake pipe cla...

Page 109: ...5 16 BODY Drainage Plug Inspection Check the drainage plug and the compartments for accumulating water If the water had been accumulated drain the water and clean the compartments...

Page 110: ...5 17 BODY Protector Protector Removal Installation Remove the front 1 engine 2 and rear protector 3 by removing its bolts Install the protector by installing their bolts 1 1 2 3...

Page 111: ...ction 6 23 Camshaft and Cylinder Head 6 23 Cam Chain Tensioner 6 32 Cam Chain Guide 6 32 Cylinder 6 32 Timing Gear 6 34 Piston 6 35 Connecting Rod 6 37 Clutch 6 38 Oil Gallery Copper Plug 6 39 Movable...

Page 112: ...rk area Drain coolant and engine oil Remove the seat Remove the side fenders Remove the rear propeller shaft Disconnect the battery lead wires CAUTION When disconnecting the battery lead wires be sure...

Page 113: ...ENGINE 6 3 Remove Oil pressure gauge coupler 1 and Coolant Temperature sensor coupler 2 Remove the air cleaner box Remove the carburetor Remove fuel feeding hoses...

Page 114: ...embly rod Remove Shift lever assembly 3 Remove PCV Positive Crankcase Ventilation tube 4 Remove Starter Motor assembly coupler 1 and Gear shift indicator coupler 2 Remove Regulator Rectifier coupler 1...

Page 115: ...move the high voltage cable Remove the Exhaust pipe bolts Remove the muffler Remove the right foot board Remove the right foot board bracket bolts 1 Remove the right foot board bracket Remove the foot...

Page 116: ...NGINE Remove the front differential mounting bolts nuts Slide the front differential assy forward Remove the front propeller shaft spring Remove the front propeller shaft Remove the rear gear box bolt...

Page 117: ...ENGINE 6 7 Slide the rear gear box assy backward Remove the rear propeller shaft spring Remove the rear propeller shaft Remove the engine mounting bolts nuts Remove the engine from the right side...

Page 118: ...60N m 6 0 kgf m 43 5 lb ft When installing the shift lever rod adjust the tie rod length to the properly position Tighten the rear gear box mounting nuts to the specified torque Tightening Torque 50N...

Page 119: ...bracket bolts 1 and tighten them to the specified torque Tightening Torque 55N m 5 5 kgf m 40 0 lb ft Install the new gasket and tighten the muffler bolts and exhaust pipe nuts to the specified torqu...

Page 120: ...6 10 ENGINE Engine Disassembly Engine Top Side Remove the spark plug Remove the start motor Remove water hoses 1 and 2 Remove the water union Remove the recoil starter...

Page 121: ...the crankcase B A A B NOTE At the above condition the piston is at TDC of compression stroke and also the engraved marks C on the camshafts are parallel with the mating surface of the cylinder head c...

Page 122: ...e the cam driver gear 1 by removing the shaft cover 2 shaft 3 and the spacer 4 3 2 1 NOTE Be careful not to drop the spacer 4 into the crankcase Remove the cylinder head bolts M6 1 Remove the cylinder...

Page 123: ...the cylinder nuts 4 Remove the cylinder 5 Remove the dowel pins 1 and the gasket 2 NOTE Be careful not to drop the dowel pins into the crankcase Remove the piston by removing the piston pin circlip 1...

Page 124: ...m Side Remove the oil filter with the special tool Remove the water pump cover 1 Remove the starter cup nut with a suitable bar 1 Remove the starter cup 2 Remove the left crankcase cover 3 Remove the...

Page 125: ...Remove the gearshift shaft 1 Remove the gearshift cam driven gear 2 by removing its bolts Remove the generator rotor bolt Rotor Mounting Socket Wrench Install the special tool to the crankshaft end D0...

Page 126: ...the balancer shaft driven gear bolts with the special tool Stopper Plate Remove the oil pump driven gear CAUTION The oil pump drive gear and the oil pump driven gear must removed at the same time Rem...

Page 127: ...and the oil pump Remove the balancer shaft driven gears 1 1 2 Remove the water pump drive gear 2 Remove the keys 1 1 Remove the cam chain drive gear with the special tools Bearing Remover Set Remove...

Page 128: ...he CVT cover 1 and gasket Remove the movable drive face cover 1 Remove the dowel pins Remove the movable drive face 2 by removing the bolt Remove the movable driven face assembly by removing the bolt...

Page 129: ...rear output connectors Remove the plate 1 CVT inner cover 2 and gasket Remove the gear position indicator 1 Remove the pin Remove the clutch housing shaft 1 NOTE Be careful about the size of the bolts...

Page 130: ...6 20 ENGINE Remove the output shaft 2 Remove the collar 1 Remove the drive bevel gear 2 Remove the dowel pins 1 Remove the O ring Remove the one way clutch...

Page 131: ...right crankcase bolts M6 M8 NOTE Loosen the crankcase bolts diagonally with the smaller sizes first Separate the right crankcase with the special tool Remove the dowel pins 2 There have two more bolt...

Page 132: ...cam drum 5 Remove the seminal gear 6 Remove the countershaft assembly 7 Remove the input main shaft 8 Remove the final shaft T M assembly 9 CAUTION Do not attempt to disassemble the output driven gear...

Page 133: ...rating smoothly If it does not operate smoothly or the spring occur elastic fatigue replace the camshaft automatic decompression assembly with a new one Camheight Check for damage and wear on cam prof...

Page 134: ...he limit measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the specific...

Page 135: ...he valve 3 from the combustion chamber side Remove oil seals 1 and spring seats 2 NOTE Do not reuse the removed oil seals Cylinder head distortion Clean and remove carbon deposits from the surface Nev...

Page 136: ...al gauge at right angles to the valve head face and measure the valve head radial runout If it measures more than the limit replace the valve Service Limit Of Valve head radial runout IN EX 0 03 mm Di...

Page 137: ...e the guide Measure OD of Valve Stem sliding portion at total 6 points upper middle and lower positions and X and Y directions by means of micrometer Service Limit of Valve Guide OD IN 5 450 5 465 mm...

Page 138: ...prevent the possibility of the tappet shim replacement If the contact area is too high on the valve or if it is too wide use the 30 60 cutters to lower and narrow the contact area If the contact area...

Page 139: ...assemble the head and valve components Use the vacuum pump gauge to cover intake and exhaust ports and check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that...

Page 140: ...e lip of the oil seal Install the valve spring with the small pitch portion 1 facing cylinder head 2 Large pitch portion 3 Upward 3 1 2 Install the valve spring and spring retainer with special tool C...

Page 141: ...the camshaft If the value is not correct use the tappets 1 to adjust the valve clearance Valve Clearance IN 0 1 0 2 mm EX 0 2 0 3 mm Thickness Gauge 1 Intake Pipe Remove the intake pipe 1 Apply GREAS...

Page 142: ...READ LOCK to the thread part of water bypass union and tighten it to the specified torque Tightening Torque 14 N m 1 4 kgf m 10 0 lb ft Thermostat Remove the thermostat cover 1 Remove the thermostat C...

Page 143: ...g at every position of the straightedge exceeds the limit replace the cylinder Cylinder Distortion Service Limit 0 05 mm Thickness Gauge Recognize Cylinder Different color on the cover of outside cyli...

Page 144: ...the TDC line A with the index mark B of the crankcase to make the piston to the highest position A B B A Make the mark C on the Timing chain driver gear to the highest position Meanwhile the mark on t...

Page 145: ...linder B Piston has to be matched with B cylinder Piston Rings Clearance between Piston Ring and groove Measure the clearance between Piston Ring and groove by holding the Ring upwards in the groove w...

Page 146: ...ervice Limit of Piston Ring end gap Top ring 0 50 mm Second ring 0 50 mm Thickness Gauge Piston pin and pin bore ID of Piston hole for Pin Clean Piston hole for Pin Measure ID in the up and down direc...

Page 147: ...e rod This method can also check the extent of wear on the rod s big end Connecting Rod deflection Service Limit 0 3 mm Magnetic Stand Dial Gauge 1 100 mm V block Set 100 mm Side clearance at large en...

Page 148: ...wear If any damages are found replace the clutch wheel with a new one Starter Clutch Remove the starter clutch securing bolts Install the starter clutch in the proper direction Apply the engine oil to...

Page 149: ...turns in the direction of the arrow If there is anything unusual replace the one way clutch Check the starter driven gear bearing If there is anything unusual replacing the bearing Remove the bearing...

Page 150: ...l seal 2pcs 13 Movable drive plate 23 Spring 4 Hexagonal flange bolt 14 Movable drive face 24 Pin 4pcs 5 Hexagonal flange bolt 15 Roller set 8pcs 25 Ring 4pcs 6 Hexagonal flange bolt 16 Slide piece 4p...

Page 151: ...and sliding surface Inspect each roller and their sliding surface for wear or damage If any damages are found replace the rollers as a set Front Side NOTE The rollers must always be changed as a set O...

Page 152: ...ed drive face in the reverse order of disassembly Apply a small amount of GREASE to the bore and oil seal lip CAUTION Wipe off any excess grease thoroughly Take care not to apply grease to the contact...

Page 153: ...ING Do not remove the movable driven face ring nut before attaching the clutch spring compressor Ring Nut Socket Wrench Attach the special tool to the movable driven face assembly and compress the mov...

Page 154: ...ove the movable driven face O ring and Oil seal Inspect the lip of the oil seal and O ring for wear or damage If any damages are found replace the oil seal or O ring with a new one Remove the oil seal...

Page 155: ...fixed driven face Inspect the driven faces for any abnormal conditions such as stepped wear or discoloration caused by burning If any damages are found replace the movable driven face with a new one...

Page 156: ...ith the holes Compress the spring with the special tool Tighten the movable driven face ring nut temporarily Remove the special tool from the movable driven face assembly Tighten the movable driven fa...

Page 157: ...surement exceeds the service limit replace the drive belt with a new one Drive belt width Service Limit 33 3 mm CAUTION If grease or oil is present on the surface of the drive belt degrease the belt t...

Page 158: ...er shaft 05 Hex washer bolt 17 Indicator switch 29 Fork 41 Low driven gear 06 Flange hex nut 18 Dowel pin 30 Pin 2pcs 42 Reverse driven gear 07 Spacer 19 Output shaft 31 Fork 2pcs 43 High T M gear 08...

Page 159: ...g After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring do not expand the end gap larger than required to slip th...

Page 160: ...to groove clearance by using the thickness gauge If the clearance exceeds the limits replace the fork or its gear or both Shift for to groove clearance Standard 0 10 0 27 mm Service Limit 0 50 mm Thic...

Page 161: ...ll the water pump and its cover See Water Pump Reassembly and Installation Reassembly Install the oil seals with the special tool necessary CAUTION It is necessary to put the oil seals and needle bear...

Page 162: ...6 52 ENGINE Install the bearings with the special tool Install the generator stator assy CAUTION The harness of the sensor must be fastened to prevent for hitting the stator...

Page 163: ...face and driven face away from any greasy matter Engine Bottom Side Install the crankshaft into crankcase CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic mallet Inst...

Page 164: ...se NOTE Fit the thinner side of the oil sump filter in the bottom as shown Tighten the crankcase bolts a little at a time to equalize the pressure until the specified torque Tightening torque M6 10 N...

Page 165: ...o the specified torque Tightening Torque 150 N m 15 0 kgf m 108 5 lb ft NOTE The clutch shoe nut has left hand threads Apply MOLYBDENUM OIL to the inside of the one way clutch Install the one way clut...

Page 166: ...cleaning solvent to wipe off oily or greasy matter and make its surfaces completely dry CAUTION Movable Driven Face Spring Compressor The other way is using the same size bolts which at least 70 mm l...

Page 167: ...ve face assembly Use nonflammable cleaning solvent to wipe off oily and greasy matter and make its surfaces completely dry NOTE Be careful about the direction of the collar Tighten the movable drive f...

Page 168: ...n the clutch cover bolts to the specified torque Tightening Torque 9 N m 0 9 kgf m 6 5 lb ft Install the pin Install the balancer shaft drive gear Install the cam chain drive gear with the special too...

Page 169: ...to the direction of the water pump drive gear and oil pump drive gear Apply THREAD LOCK to the oil pump mounting bolts Install the pin 1 Install the oil pump drive gear 1 and oil pump driven gear with...

Page 170: ...am chain guide Tighten the cam chain guide bolt to the specified torque Tightening Torque 23 N m 2 3 kgf m 16 5 lb ft Install the starter driven gear 1 Install the key 2 NOTE Degrease the tapered port...

Page 171: ...ightening Torque 160 N m 16 0 kgf m 115 lb ft Install the gearshift cam stopper the stopper 1 bolts 2 and return spring 3 Install the gearshift cam stopper 1 and cam driven gear 2 NOTE Hook the return...

Page 172: ...starter reduction gear and gearshift shaft Install the dowel pins 1 and new gasket 2 2 1 Install the copper plug and its O ring Install the generator cover 1 Install the starter cup NOTE Fit the pin...

Page 173: ...oil filter with the special tool D003 Oil Filter Wrench Engine Top Side Install the piston rings in the order of oil ring second ring and first ring The first member to go into the oil ring groove is...

Page 174: ...Install the piston and piston pin Place a clean rag over the crankcase Install the circlip Fit the dowel pins 1 and the new gasket 2 Piston 3 has to be matched with same level cylinder see 6 35 and 6...

Page 175: ...nd cam drive sprocket Install the cam chain guide 1 Fit the dowel pins 2 and new cylinder head gasket 3 2 1 CAUTION Use a new gasket to prevent gas leakage 3 Install the cylinder head Tighten the cyli...

Page 176: ...Install the cam drive idle gear sprocket with cam drive chain onto the cylinder head Align the punched mark on the cam drive idle gear sprocket with the embossed line on the cylinder head Install the...

Page 177: ...ied torque Tightening Torque 10 N m 1 0 kgf m 7 0 lb ft Install the new O ring Install the cam chain tensioner cap bolt Tighten the cam chain tensioner cap bolt to the specified torque Tightening Torq...

Page 178: ...M OIL SOLUTION to the camshaft journal holders NOTE Before installing the camshaft check that the tappets are installed correctly Tighten the camshaft journal holder bolts to the specified torque Tigh...

Page 179: ...lb ft Final 14 N m 1 4 kgf m 10 0 lb ft NOTE Apply engine oil to the both side of head cover washer before installing the head cover bolts Tighten the valve timing inspection plug to the specified tor...

Page 180: ...6 70 ENGINE Install the starter motor...

Page 181: ...r Hose Inspection 7 7 Cooling Fan 7 8 Inspection 7 8 Removal 7 8 Remounting 7 8 Cooling Fan Thermo Switch 7 9 Removal 7 9 Inspection 7 9 Installation 7 9 ECT Sensor 7 10 Removal 7 10 Inspection 7 10 I...

Page 182: ...er Do not mix an alcohol base anti freeze and different brands of anti freeze Do not use a radiator anti leak additive Anti freeze 1334 ml Water 666 ml WARNING You can be injured by scalding fluid or...

Page 183: ...ds this pressure for 10 seconds If the pressure should fall during this 10 second interval it means that there is a leaking point in the system In such a case inspect the entire system and replace the...

Page 184: ...lant by removing the drain plug Remove the right headlight Disconnect the cooling fan motor lead wire coupler 1 and cooling fan thermo switch leas wire coupler 2 Remove the front grill upper cover Dis...

Page 185: ...his cleaning Remove the radiator fin guard net Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver Radiator Remounting Install the radiator in the reve...

Page 186: ...adiator Cap Inspection Remove the radiator cap lid Fit the cap 1 to the radiator cap tester 2 Build up pressure slowly by operating the tester Make sure that the pressure build up stops at 110 140 kPa...

Page 187: ...e the left headlight Remove the left inner fender Remove the left side cover Any radiator hose found in a cracked condition or flattened must be replaced Any leakage from the connecting section should...

Page 188: ...electric motor fan running at full speed the ammeter 4 should be indicating not more than 5 3 amperes If the fan motor does not turn replace the cooling fan assembly with a new one Removal Remove the...

Page 189: ...ater to raise its temperature slowly and read the column thermometer 2 when the switch closes or opens Multi circuit tester set Tester knob indication Continuity test Installation Install the new O ri...

Page 190: ...its temperature slowly and read the column thermometer 3 and the ohmmeter If the ECT sensor ohmic value does not change in the proportion indicated replace it with a new one If the resistance is noted...

Page 191: ...e ECT sensor in the reverse order of removal Tighten the ECT sensor to the specified torque Tightening Torque 20 N m 2 0 kgf m 14 44 lb ft Pour engine coolant CAUTION Take special care when handling t...

Page 192: ...g manner Pass a string between flange immerse the thermostat in the water contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat the water 1 by plac...

Page 193: ...to open temperature and valve lift must be replaced Installation Install the thermostat in the reverse order of removal Apply engine coolant to the rubber seal on the thermostat After installing the...

Page 194: ...the impeller shaft pin 3 and washer 4 NOTE Before draining engine coolant inspect engine coolant leakage between the water pump and crankcase If engine oil is leaking visually inspect the oil seal and...

Page 195: ...remover set Place a rag over the water pump Remove the oil seal using a suitable bar Remove the needle bearing from the front side as shown Visually inspect the oil seal for damage with particular at...

Page 196: ...he water pump in the reverse order of removal and disassembly Pay attention to the following points Install the needle bearing from the other side and make sure the mark is face to the engine Apply a...

Page 197: ...Apply GREASE to the impeller shaft Install the impeller shaft and the impeller to the water pump body Install the washer 1 and impeller shaft pin 2 to the impeller shaft Install the water pump driven...

Page 198: ...O ring 1 Install the water pump cover 1 and tighten its mounting bolts to the specified torque Tightening Torque 10 N m 1 0 kgf m 7 0 lb ft Connect the radiator hoses Pour engine coolant CAUTION Use...

Page 199: ...oil to the gasket of the new oil filter before installation Install the new oil filter to the engine Turn it by hand until you feel that the oil filter gasket has contacted the oil filter mounting sur...

Page 200: ...it moves smoothly If it does not move smoothly replace the oil pump assembly NOTE When installing the oil sump filter always use the new one to keep oil clean And the thinner side is face to the CVT C...

Page 201: ...7 21 COOLING AND LUBRICATION SYSTEM Engine Lubrication System Chart...

Page 202: ...7 22 COOLING AND LUBRICATION SYSTEM Engine Lubrication System 1 2 3 1 2 3 1 2 3...

Page 203: ...7 23 COOLING AND LUBRICATION SYSTEM 1 2 3...

Page 204: ...Spark Plug Removal Installation 7 17 Spark Plug Cleaning Inspection 7 17 Spark Plug Gap 7 18 Ignition Coil Removal 7 18 Ignition Coil Installation 7 18 Ignition Coil Inspection 7 18 CDI Output Test 7...

Page 205: ...7 2 ELECTRICAL SYSTEM Fuses 7 30 Main Fuse Removal 7 30 Fuse Inspection 7 30 Switches 7 31 Wiring Diagram 7 32...

Page 206: ...egulator rectifier output DC 14 15 V Alternator no load output voltage AC 65 V and more at 5000 rpm Y1 Y2 0 49 Charge Coil Stator Y2 Y3 0 49 Y3 Y1 0 49 Y Ground Pulser Coil Bu Y G W 110 15 Ignition Co...

Page 207: ...E D A Battery G Ignition Coil B Starter Circuit Relay H Regulator Rectifier C CDI Unit I Gear Position Indicator D Flash Relay J Starter Motor E Position Light Relay K 2WD 4WD Diff 4WD Actuator F Tra...

Page 208: ...H D A B H C A High Low Beam Switch G Ignition Switch B Hazard Lights Switch H Spark Plug C Horn Switch I Cooling Fan D Indicator Switch J Temperature Sensor E Diff 4WD Confirm Button K Speed Sensor F...

Page 209: ...d wire first If the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush After connecting the battery apply a light coat of grease to the battery terminals Al...

Page 210: ...to drop the part with a semi conductor built in such as a CDI unit Properly use the multi circuit tester and probes Improper use can cause damage to the vehicle and tester If the voltage and current...

Page 211: ...f the connector is corroded or dirty clean it carefully If it is damaged replace it Check the wiring for continuity Use the wiring diagram to find the ends of the lead which is suspected of being a pr...

Page 212: ...intenance free design and construction Use of conventional lead acid batteries is not recommended No electrolyte or refilling water is required Because this battery is a completely sealed type abuse o...

Page 213: ...ecified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active mat...

Page 214: ...fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity If a fully charged battery doesn t...

Page 215: ...akage OK Step3 Measure the regulated voltage between the battery terminals Is the regulated voltage OK Step4 Measure the resistance of the alternator coil Is the resistance of alternator coil OK YES R...

Page 216: ...on Battery Current Leakage Remove the seat Turn the ignition switch to the OFF position Disconnect the battery lead wire 1 Measure the current between battery terminal and the battery lead wire with t...

Page 217: ...Battery 14 15 V Turn off the ignition switch to stop the engine and remove the seat Remove the battery stay 1 1 Measure the DC voltage between the and terminals with the multi circuit tester If the r...

Page 218: ...on Resistance Alternator coil resistance 0 1 1 0 Y Y Y Grnd NOTE When making above test it is not necessary to remove the alternator Alternator no load performance Disconnect the alternator coupler 1...

Page 219: ...ere electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent CDI unit damage Do...

Page 220: ...lug wrench from the vehicle right side When installing the spark plug make sure to tighten the spark plug to the specified torque Tightening Torque 14 N m 1 4 kgf m 10 0 lb ft Spark Plug Cleaning Insp...

Page 221: ...ition coil Measure the primary winding resistance as follows Connect the tester between the coil terminals Set the tester to the 1 range and read the tester Measure the secondary winding resistance as...

Page 222: ...lay coil resistance between the terminals with the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one Multi Circuit Tester Set Tester kno...

Page 223: ...main relay 1 1 First check the insulation between 1 and 4 terminals with the tester Then apply 12 V to terminals 2 and 3 and check the continuity between 1 and 4 If there is no continuity replace the...

Page 224: ...ng the transfer selecting switch The voltage must maintain at 12 V if the voltage does not conform to the standard check the continuity of each lead wire or replace the actuator assembly with a new on...

Page 225: ...se compared to those currently in use because of this composition 1 5 2 6 3 4 7 8 13 9 10 11 14 12 Mode Button 1 8 Engine Oil Indicator Coolant Temperature Indicator 4WD Differential Lock Indicator 2...

Page 226: ...sly 4 Setting Button Press button to switch the display of Clock Hour Tacho Temp Meter 5 Indicator Light When the indicator switch is operated this indicator light will blink and the buzzer will sound...

Page 227: ...ur Tacho Temp Meter This display has four functions Clock Hour Tacho and Temp meter To change the display press Set button shortly Clock Display the time in 12 hour To set the clock change to Clock mo...

Page 228: ...ING To avoid riding with only one hand do not operate the buttons while riding Odometer Displays the total distance travelled Trip meter Displays the distance travelled since the trip meter was last r...

Page 229: ...turning the ignition switch ON Also check them for lighting in accordance with their switch positions If the LCD fails in operation replace the combination meter unit with a new one after checking its...

Page 230: ...is adjusted to the specified values If either one or all indications are abnormal replace the combination meter with a new one Fuel Meter Remove the rear fender Connect each resistor between the termi...

Page 231: ...ft mud guard Disconnect speed sensor coupler 1 Remove the speed sensor 2 by removing its mounting bolt Connect the 12 V battery 10k resistor and the multi circuit tester as shown in the right illustra...

Page 232: ...ly Taillight Bulb and Assembly Replacement Remove Taillight Bracket Screw 3 A Taillight Unit Insert the new bulb Indicator Bulb and Assembly Replacement Remove Indicator Screw B Insert the new bulb B...

Page 233: ...lace the fuse Before replacing a blow fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a s...

Page 234: ...s Multi Circuit Tester Set Wire Color B Black W B White with Black tracer Br Brown W Bu White with Blue tracer Bu Blue W R White with Red tracer G Green Y B Yellow with Black tracer Gr Gray Y R Yellow...

Page 235: ...7 32 ELECTRICAL SYSTEM Wiring Diagram...

Page 236: ...7 33 ELECTRICAL SYSTEM Wiring Diagram...

Page 237: ...7 34 7 34 ELECTRICAL SYSTEM ELECTRICAL SYSTEM...

Page 238: ...7 35 ELECTRICAL SYSTEM NOTE...

Page 239: ...9 14 Differential Gear Oil Replacement 9 14 Rear Driver Gear Oil 9 15 Engine Coolant 9 16 Radiator 9 17 Radiator Hoses 9 17 CVT Water Draining Inspection 9 18 Drive Belt 9 18 Brakes 9 22 Brake Fluid...

Page 240: ...9 2 PERIODIC MAINTENANCE...

Page 241: ...ic service work necessary to keep the vehicle operating at peak performance and economy Maintenance intervals are expressed in terms of kilometers miles and months and are dependent on whichever comes...

Page 242: ...k Rear rack Front fender Rear fender Left footboard Right footboard Air cleaner If the air cleaner element is clogged with dust intake resistance will be increased which results decrease in power outp...

Page 243: ...ected bolt 3 to the specified torque Tightening Torque Exhaust Pipe Nut 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler assembly connected bolt 23 N m 2 3 kgf m 1...

Page 244: ...e valve clearances to specification if necessary Remove the front fender Remove the cylinder head cover Remove the recoil starter 1 Remove the valve timing inspection plug 2 Turn the crankshaft to bri...

Page 245: ...able for details in the following pages After replacing the tappet shim and camshafts rotate the engine so that the tappet is depressed fully This will squeeze out oil trapped between the shim and the...

Page 246: ...9 8 PERIODIC MAINTENANCE Intake Side...

Page 247: ...9 9 PERIODIC MAINTENANCE Exhaust Side Side...

Page 248: ...trode is extremely worn or burnt replace the spark plug with a new one Also replace the spark plug if it has a broken insulator damaged threads etc Insert the spark plug and tighten it to the cylinder...

Page 249: ...pe 2 by non synthetic brush If necessary blow debris from the arrester with compressed air Reinstall the spark arrester pipe 2 Fuel Line Inspect the fuel feed hose for damage and fuel leakage If any d...

Page 250: ...spect the carburetor for dirt or mud If any dirt or mud is found clean it Idle Adjustment To adjust the idle allow the engine to reach operating temperature 70 158 Adjust the idle speed to maintain at...

Page 251: ...m 1 9 kgf m 14 0 lb ft When performing an oil change the engine will hold about 3 3 L of oil Use engine oil that meets the API service classifications SF or SG and that has a viscosity rating of SAE 1...

Page 252: ...ns with the special tool D003 Oil Filter Wrench Pour the new engine oil through the oil filler hole When performing the oil filter change the engine will hold about 3 3 L of oil Check the oil level Ad...

Page 253: ...plug 1 Tighten the oil drain plug 3 to the specified torque and pour fresh oil through the oil filter hole until it overflows from the oil level hole Tighten the oil level plug 1 and oil filler plug 2...

Page 254: ...l pan below the rear driver gear case Drain oil by removing the oil drain plug 3 oil filler plug 2 and oil level plug 1 Tighten the oil drain plug 3 to the specified torque and pour fresh oil through...

Page 255: ...Tighten the drain plug 5 to the specified torque Tightening Torque 13 N m 1 3 kgf m 9 5 lb ft Pour the specified engine coolant into the reservoir tank Inspect every 1000 km 50 hours 3 months Replace...

Page 256: ...or Inspect the radiator for damage and engine coolant leakage If any damages are found replace it with a new one Radiator Hoses Inspect the radiator hoses for damage and engine coolant leakage If any...

Page 257: ...CVT from damage or danger is necessary Remove the CVT drainage bolt to drain the water that from the CVT Drive Belt Removal Remove the right body decoration See Body chapter Remove the right footboar...

Page 258: ...he movable drive face by removing its bolt 2 Remove the movable driven face with belt by removing movable driven face bolt 3 Remove the drive belt 4 from the movable driven face Inspection Inspect the...

Page 259: ...ive belt Install the movable driven face assembly Tighten the movable driven face bolt to the specified torque with the special tool Tightening Torque 110 N m 11 0 kgf m 79 5 lb ft Install the movable...

Page 260: ...d torque with the special tool Tightening Torque 85 N m 8 5 kgf m 62 0 lb ft Install the dowel pins Install the movable drive face cover 1 NOTE Be careful about the direction of the collar NOTE Turn t...

Page 261: ...ith new ones Foot Brake Pedal Check that the brake pedal A is in the correct position as shown If it is incorrect adjust the brake pedal position Loosen the nut A and turn the bracket B until pedal is...

Page 262: ...uld be between 6 8 mm when the lever is lightly pulled in towards the grip If adjustment is necessary slacken the cable by loosening the locknut 2 and screwing the adjusters 3 on the brake lever holde...

Page 263: ...n the brake fluid circuit be purged of air in the following manner Remove the reservoir cap and fill the reservoir with new brake fluid Slowly pump the brake lever several times until no air bubbles c...

Page 264: ...d as necessary Tighten the bleed valve to the specified torque Tightening Torque 5 5 N m 0 55 kg m 48 in lb Apply the brake lever forcefully for a few seconds and check for fluid leakage around the fi...

Page 265: ...ehicle Load Capacity Limit 250 kg 551 lb Inspect every 1000 km 50 hours 3 months Tire Tread Depth Service Limit Front 3 0 mm Service Limit Rear 3 0 mm Inflation Tire Pressure kPa Kgf cm2 psi Front 35...

Page 266: ...raight position Place a load of 75 kg 165 lbs on the seat Measure the distances A and B between the front wheels Subtract the measurement of B from that of A to find the toe out If the toe out is not...

Page 267: ...age If any damages are found replace them with new ones See Suspension chapter Shift Rod Check the position of the gearshift lever shift the lever to the N position and check if the lever moves smooth...

Page 268: ...ifting to the R or P position is not available Apply the foot brake The cable will pull the stopper to allow the transmissions gear shifting to the R or P position due to foot brake applied CAUTION Ad...

Page 269: ...and rear 110 11 0 79 5 8 Wheel set nut 60 6 0 43 5 9 Steering knuckle end nut upper and lower 29 2 9 21 0 10 Front shock absorber mounting bolt nut lower 60 6 0 43 5 11 Front shock absorber mounting...

Page 270: ...9 32 PERIODIC MAINTENANCE 1 2 3 4 18 19 12 16 17 21 13 14 15 22 23 5 6 7 8 9 12 10 11 20...

Page 271: ...y rust and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the vehicle has been operated under wet or rainy c...

Page 272: ...ted parts and test the compression pressure in the following manner Remove the spark plug Install the compression gauge in the spark plug hole Make sure that the connection is tight Keep the throttle...

Page 273: ...ressure Engine oil viscosity is too high Clogged oil Passage Combination of the above items Oil Pressure Test Procedure Remove the front fender See Body chapter Remove the fuel tank See Body chapter C...

Page 274: ...up the engine Initial Engagement Inspection Connect the tachometer or the multi circuit tester onto the spark plug high voltage cable Start the engine Shift the range lever to the HIGH position Slowly...

Page 275: ...s as firmly as possible Fully open the throttle for a brief period and note the maximum engine speed sustained during the test cycle Lock Up Speed 3800 4200 rpm If the lock up speed rpm does not coinc...

Page 276: ...2 Engine 10 2 Radiator Cooling System 10 9 Transmission 10 10 Drive Train 10 11 Chassis 10 13 Electrical 10 17 Battery 10 18 Special Tools 10 20 Tightening Torque 10 21 Engine 10 21 Chassis 10 22 Coo...

Page 277: ...cting Wiring open or shorted Ignition switch trouble Fuse blown 2 Starter motor rotating but engine doesn t turn over Starter one way clutch trouble 3 Recoil starter not operating Recoil starter sprin...

Page 278: ...djusted Spark plug cap or spark plug cable trouble Spark plug cap not in good contact Spark plug incorrect Pickup coil trouble CDI unit trouble Ignition coil trouble Battery voltage low Wiring shorted...

Page 279: ...led or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose 3 Compression low Spark plug loose Cylinder head not sufficiently tightened d...

Page 280: ...clogged Fuel level too high or too low Air cleaner clogged poorly sealed or missing Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Return...

Page 281: ...level too high Engine oil viscosity too high Balancer mechanism malfunctioning Overheating 1 Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect CDI unit trouble 2 Compressio...

Page 282: ...level too high Abnormal Engine Noise 1 Knocking CDI unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating 2 Piston noise Cylinder piston cl...

Page 283: ...cessive Connecting rod big end clearance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runou...

Page 284: ...ogged with dirt Faulty cooling fan Defective cooling fan thermo switch Clogged water passage Air trapped in the cooling circuit Defective water pump Use of incorrect engine coolant Defective thermosta...

Page 285: ...ve worn Shift cam worn Shift stopper positioning bolt spring weak or broken Shift tie rod maladjusted Drive shaft output shaft and or gear worn Distorted or worn gearshift forks 3 Over shifts Shift ar...

Page 286: ...ble sheave bush worn Drive pulley roller worn 4 Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly installed too loose 5 Shifting too slowly Belt dirty or worn Driv...

Page 287: ...oil Front final gear case Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted 3 Front axle or propeller shaft noise Front propeller shaft Constant velocity universal joint dam...

Page 288: ...ed Pressure valve trouble Brake pedal not properly adjusted 2 Rear Brake Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched i...

Page 289: ...ient tightening of connection joints Cracked hose Worn piston and or cup Brake Drags Rusty part Insufficient brake lever or brake pedal pivot lubrication Shock absorption unsatisfactory 1 Too hard Tir...

Page 290: ...loose tie rod ends Damaged or worn A arms and related bushings Wheel rim warped Front axle runout excessive Wheel bearing worn Handlebar clamp loose Loose chassis nuts and bolts 3 Handlebar pulls to o...

Page 291: ...Loose nuts or bolts on rear suspensions Loose rear wheel hub nuts Improper rear brake adjustment Rear shock absorber leaks oil Loosen rear stabilizer mounting bolts Other Noise Shock absorber damaged...

Page 292: ...Overheat or Burn Too hot spark plug Overheated the engine Loose spark plug Too lean mixture Start Button Is Not Effective Run down battery Defective switch contacts Brushes not seating properly on st...

Page 293: ...oil Wiring faulty Battery Over charged Regulator rectifier trouble Poorly grounded regulator rectifier Battery trouble e g internal short circuit in the battery Alternator Dose Charge But Charging Rat...

Page 294: ...vercharging Internal short circuit in the battery Too low battery voltage Too old battery The option accessories had been installed so the load excessive Battery Sulfation Incorrect charging rate When...

Page 295: ...pression Gauge Set D001 Rotor Holding Tool D005_02 Valve Lifter D005_01 Valve Lifter Attachment D006 Rotor Remover Vernier Calipers Piston Ring Clamp Micrometer Oil Pressure Gauge Bearing Remover Set...

Page 296: ...1 0 7 0 Crankcase bolt M6 10 1 0 7 0 M8 26 2 6 19 0 Valve timing inspection plug 23 2 3 16 5 Clutch shoe nut 150 15 0 108 5 Movable drive face bolt 85 8 5 62 0 Movable driven face bolt 110 11 0 79 5...

Page 297: ...olt 25 2 5 18 0 Front brake air bleeder valve 5 5 0 55 4 0 Front brake pad mounting bolt 18 1 8 13 0 Front brake caliper mounting bolt 25 2 5 18 0 Front brake disc bolt 25 2 5 18 0 Front brake master...

Page 298: ...stem Item N m kgf m lb ft Water pump cover bolt 10 1 0 7 0 Cooling fan thermo switch 25 2 5 18 0 ECT sensor 20 2 0 14 44 Thermostat cover bolt 10 1 0 7 0 Cooling fan mounting bolt 5 0 5 3 6 Water hose...

Page 299: ...bolt 7 marked bolt A mm N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32...

Page 300: ...445 Valve seat width IN EX 0 9 1 1 Valve head radial runout IN EX 0 03 Valve spring free length IN EX 48 0 190 214 N 19 0 21 4 kgf 41 8 47 2 lbs at length 36 5 mm Valve spring tension IN EX Camshaft...

Page 301: ...2nd RN Approx 11 70 8 7 1st 1R 0 15 0 30 0 50 Piston ring end gap 2nd RN 0 15 0 30 0 50 1st 0 180 Piston ring to groove clearance 2nd 0 150 1 21 1 23 1st 1 30 1 32 Piston ring groove width 2nd 1 21 1...

Page 302: ...uction ratio Rear 3 600 36 10 Low 2 294 39 17 Transfer gear ratio High 1 133 30 26 Reverse 1 882 32 17 Drive belt width 34 3 33 3 Movable driven face spring free length 158 0 150 0 Shift fork to groov...

Page 303: ...ening pressure 110 140 kPa 1 1 1 4 kgf cm2 15 6 19 9 psi Cooling fan thermo switch operating temperature OFF to ON Approx 96 205 ON to OFF Approx 86 187 Use an antifreeze coolant compatible with alumi...

Page 304: ...1 0 Alternator no load voltage When engine is cold 65 V AC and more at 5000 rpm Starter relay resistance 3 5 Type designation GS GTX20L BS Battery Capacity 12 V 20Ah Headlight HI LO 10 A Power source...

Page 305: ...pe DOT 4 30 Right Left Steering angle Turning radius 3 25 m Toe out With 75 kg 10 4 Tire Unit mm Item Standard Limit Front 35 kPa 0 35 kgf cm Suspension Cold inflation tire pressure Solo riding 2 5 0...

Page 306: ...aining MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Fuel type Gasoline used should be graded 95 octa...

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