Dinli DL-901 Service Manual Download | Manualshive

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APPENDIX

Appendix

Table of Contents

Considerations for Various Riding Conditions-------------------------------------------------------------8-2
Carburetor----------------------------------------------------------------------------------------------------8-2
Fuel System--------------------------------------------------------------------------------------------------8-3
Spark Plug----------------------------------------------------------------------------------------------------8-4
Clutch Adjustment------------------------------------------------------------------------------------------8-6
Troubleshooting Guide----------------------------------------------------------------------------------------8-7

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Summary of Contents for DL-901

Page 1: ......

Page 2: ...0 0 FOREWORD INDEX...

Page 3: ...very possible care has 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 suc...

Page 4: ...I vehicle parts Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts Remember to keep complete records of maintenan...

Page 5: ...ontains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE This note symbol indicates points of particular interest for more effic...

Page 6: ...0 4 FOREWORD INDEX CHAPTER INDEX CHAPTER1 GENERAL CHAPTER2 WHEELS TIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTER5 FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTER8 APPENDIX...

Page 7: ...0 5 FOREWORD INDEX...

Page 8: ...1 1 GENERAL INFORMATION GENERAL INFORMATION Table of Contents Before Servicing 1 2 Model Identifications 1 5 General Specifications 1 6 Periodic Maintenance Chart 1 8...

Page 9: ...r assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assembled in the same way I...

Page 10: ...the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle be...

Page 11: ...ime they are removed Always replace these parts with new ones every time they are removed Although the previously mentioned gasket O ring ball bearing needle bearing grease seal oil seal cir clip and...

Page 12: ...number Vehicle identification number ENGINE SERIAL NUMBER Ex EW450SR00100000xxx VEHICLE IDENTIFICATION ex RFWAK85CX6Txxxxxx Whenever corresponding with DINLI about a particular issues the engine numbe...

Page 13: ...ators Starting system Electric Carburetor Mikuni BSR42 Transmission 5 speed with reverse Final drive 2WD chain Clutch type Manual Release Multi Plate 8 plates wet Engine idle speed 1600 rpm Spark plug...

Page 14: ...Loading limit Incl rider cargo etc 200kg Voltage 12V Battery GS GTX14 BS Ground clearance unloaded 200 mm Water crossing maximum depth 575 mm Front suspension travel 11 Rear suspension travel 10 Dry...

Page 15: ...r ignition I I LIGHTING headlight tail light turning lights I I ENGINE OIL I R R R R ENGINE OIL FILTER s C R R R R DRIVE CHAIN sag stretch buffer guide sprockets condition tightness guards I I I I BRA...

Page 16: ...in Inspection 2 4 Toe in Adjustment 2 4 Wheels Rims 2 5 Wheel Removal 2 5 Wheel Installation 2 5 Wheel Rim Inspection 2 6 Wheel Rim Replacement 2 6 Tires 2 6 Tires Removal 2 6 Tires Installation 2 7...

Page 17: ...0 mm Tires Standard tire Front Rear Tire air pressure when cold Front Rear Maximum tire air pressure to seat beads when cold AT 21 7 10 KENDA K300F 002 Tubeless AT 20 11 9 KENDA K300 004 Tubeless 35 k...

Page 18: ...e tie rod adjustment it is very important that the precautions be taken when tightening tie rod end jam nuts Steering Centering Inspection Test ride the vehicle If the handlebar is straight when the v...

Page 19: ...ght measure the distance between the scribed lines for both front and rear of the front tires Subtract the measurement of the front from the measurement of the rear to get the toe in If the toe in is...

Page 20: ...hat the wheels are off the ground Take off the wheel nuts and remove the wheel Wheel Installation Check the tire rotation mark A on the tire and install the wheel accordingly NOTE The direction of the...

Page 21: ...the air valve Install a new air valve in the new rim Remove the valve cap lubricate the stem with a soap and water solution and pull the stem A through the rim from the inside out until it snaps into...

Page 22: ...air valve Check the tire for wear and damage see Tire Inspection Lubricate the tire beads and rim flanges with a soap and water WARNING Do not use the lubricant other than a water and soap solution o...

Page 23: ...er solution around the tire bead and check for bubbles Deflate the tire to the specified pressure Check the tire pressure using an air pressure gauge Tire Air Pressure when cold Front 50 kPa 7 0 psi R...

Page 24: ...free Remove the axle nut and pull off the front hub brake disc Separate the brake disc from the front hub Front Hub Installation Grease Seal Front Spindle Tighten Torque Front Spindle Nut 145 N m 15 0...

Page 25: ...non permanent locking agent Rear Axle Nuts A Tighten Torque Rear Axle Nut 265 N m 27 0 kgf m 195ft lb Insert a new cotter pin B and bend it over the nut Rear Hub Disassembly Assembly Do not press the...

Page 26: ...n 3 7 Brake Discs 3 8 Disc Cleaning 3 8 Disc Removal 3 8 Disc Installation 3 8 Disc Wear Inspection 3 8 Disc Runout 3 9 Brake Hoses 3 9 Brake Hose Inspection 3 9 Brake Hose Replacement 3 9 Rear Brake...

Page 27: ...er fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any parts will be difficult to wash off completely a...

Page 28: ...t is already in the reservoir are unidentified Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kg m 13 in lb Brake Fluid Change Removal the reservoir cap and the rubber cap on the bleed valve Attach...

Page 29: ...Line Air Bleeding Bleed the air whenever brake parts are replaced or reassembled Remove the reservoir cap and fill the reservoir with new brake fluid Slowly pump the brake lever several times until no...

Page 30: ...e Hose Banjo Bolt B Master Cylinder Clamp Bolts A Master Cylinder CAUTION Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Master Cylinder Insta...

Page 31: ...is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see Caliper Disassembly Caliper Installation Install the caliper an...

Page 32: ...Pad Mounting Bolts 18N m 1 8kg m 13 0ft lb WARNING Do not attempt to drive the vehicle until a full brake level is obtained by pumping the brake level until the pads are against each disc The brakes w...

Page 33: ...olts A Brake Disc B Disc Installation The disc must be installed with the marked side A facing toward the steering knuckle Tighten Non permanent Locking Agent Disc Mounting Bolts Torque Disc Mounting...

Page 34: ...e is not properly maintained Bend and twist the brake hose while examining it Replace it if any cracks or bulges are noticed Brake Hose Replacement Pump the brake fluid out of the line as explained in...

Page 35: ...he nut A and turn the bracket B until pedal is correctly positioned Tighten the nut A Check the brake pedal free play see Brake Pedal Free Play Inspection Brake Pedal Free Play Inspection Check the br...

Page 36: ...ot available disassemble the caliper before the brake hose is removed Caliper Installation Install the caliper and brake hose lower end Replace the washers that are on each side of hose fitting with n...

Page 37: ...far as it will go Be sure that the anti rattle spring is in place Install the pads Be careful not mix it up inboard pads with the out board pad Tighten Torque Pad Mounting Bolts 18N m 1 8kg m 13 0ft l...

Page 38: ...njo Bolt 25N m 2 5kg m 18 0ft lb Check the fluid 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 pow...

Page 39: ...ove the disc Brake Disc Installation The disc must be installed with the marked side A facing toward the steering knuckle Tighten Non permanent Locking Agent Disc Mounting Bolts Torque Disc Mounting B...

Page 40: ...Swingarm 4 4 Swingarm Removal 4 4 Swingarm Installation 4 4 Swingarm Bearing Removal 4 4 Swingarm Bearing Installation 4 5 Swingarm Bearing Inspection 4 5 Swingarm Bearing Lubrication 4 5 Steering 4...

Page 41: ...e vehicle at high speed may endanger driver s safety Front Shock Absorber Preload Adjustment The spring adjusting sleeve on rear shock absorber has 5 positions so that the spring can be adjusted for d...

Page 42: ...ont Shock Absorber Mounting Bolts C Suspension Arm Pivot Bolts D Suspension Arm Installation Tighten Torque Suspension Arm Pivot Bolts 88 N m 9 0 kgf m 65 ft lb Steering Knuckle Joint Nut 42 N m 4 3 k...

Page 43: ...in the bearing driver set Swingarm Removal Support the vehicle on a stand or the jack so that the rear wheels are off the ground Remove Rear Wheels Rear Brake Disc see Caliper Removal Rear shock Absor...

Page 44: ...the bearings are damaged Replace the grease seals and both left and right bearing The play developed during use may indicated bearing damage In this case remove the swingarm and inspect the bearings R...

Page 45: ...Bolts A Steering Clamp Support Plate B Steering Clamp C Tie Rod End Nuts D Steering Stem Cotter Pin E and Nut F CAUTION Do not loosen the locknut at the ends of the tie rod adjusting sleeve or the to...

Page 46: ...m 3 0 kgf m 22 ft lb Bearing Housing Bolts 20 N m 2 0 kgf m 14 5 ft lb Clamp Allen Bolts 25 N m 2 5 kgf m 18 0 ft lb Tie Rod End Nuts 47 N m 4 8 kgf m 35 ft lb Inspect the toe in if necessary Steerin...

Page 47: ...the tie rod be careful not to bend it Do not loosen the locknut C at the end of the tie rod adjusting sleeve or the toe in of the front wheel will be changed Tie Rod Installation The right and left ti...

Page 48: ...ction which must be taken into account Check the steering action again If the steering lubrication does not remedy the problem inspect the steering stem warp steering stem clamps and tie rod bearings...

Page 49: ...ips and mating surface B of the clamp and pack the grooves C in the clamp with grease Steering Stem Clamp Inspection Inspect the steering stem clamps A If roughness excessive play or seizure is found...

Page 50: ...der Bolts A Handlebar Holders B Handlebar C Handlebar Installation Install the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown Tighten the holder rear bolt...

Page 51: ...4 12 SUSPENSION STEERING NOTE...

Page 52: ...emoval 5 2 Seat Installation 5 2 Front and Rear Fenders 5 3 Front Cover Removal 5 3 Front Fender Removal 5 3 Front Fender Installation 5 3 Rear Fender Removal 5 4 Rear Fender Installation 5 4 Radiator...

Page 53: ...A by pulling the seat latch lever B up and then pulling the seat up to the rear Seat Installation Slip the seat hook B under seat and put the stoppers C into the holes on the rear fender Push down th...

Page 54: ...lts A 2 B 2 Front Fender Removal Remove Front Left Fender Bracket Screws A 4 Front Left Fender Bracket Front Left Fender Screw B 4 Front Left Fender Remove Front Right Fender Bracket Screw C 4 Front R...

Page 55: ...5 4 FRAME Rear Fender Removal Remove Air Intake Duct C Rear Fender Bracket Bolts A 6 Rear Fender Bracket Screw B 4 Rear Fender Installation Please reverse the Removal steps to install...

Page 56: ...Removal Remove Side Cover Screw A Side Cover B Water Tube C D E Connector F G Cooler Bolts 2 H Cooler I Remove Radiator Cover Bolts A Radiator Protector B Radiator Installation Please reverse the Remo...

Page 57: ...ve Step Bracket Bolts A B Step Screw 4 C and Bolts 2 D Step Bracket E Step F Headlight Assy Removal Remove Handlebar see Handlebar Removal Front Cover see Front Cover Removal Headlight Holder Bolts A...

Page 58: ...6 7 Reassembly 6 15 Attachment 1 Special Tool 6 32 2 Timing Chain 6 33 3 Matrix Table 6 34 4 Tightening Torque table 6 35 5 Tightening Torque chart 6 40 6 Service Data 6 45 7 Adhesive Sealant and Oil...

Page 59: ...out Cover CP Drive Chain and Plate Drive Chain Operate Shift Pedal to engage the transmission gears Remove bolts and take out Fixing Plate and then remove Sprocket 14T Remove Shift Pedal Remove Revers...

Page 60: ...and Spring Filter Note Adopt tray or clothes waste to prevent oil pollution Remove Clutch Cover CP Note Adopt tray or clothes waste to prevent oil pollution Clutch Remove bolts and take out Spring and...

Page 61: ...er Pin and then pull out Shifter Cam Remove Stopper Arm and Spring Stopper Take out Point Neutral along with Spring Point and then remove Switch Position Remove nut and take out washer and Primary Gea...

Page 62: ...Adopt tray to prevent coolant pollution Make sure the original one position of a cupper washer Take out Impeller Take out Sealing Washer Note When reassembling replace with new Sealing Washer CYLINDE...

Page 63: ...the Fork Shaft on the counter shaft side Take out Shift Fork Main Shift Fork Right and Shift Fork Left Note Make sure their original positions for reassembling Take out Shift Drum CP with the Reverse...

Page 64: ...ake out Valve Seal Cylinder Head warpage Clean and remove carbon deposits from the surface Never damage the surface when cleaning Place the measuring block diagonally on the surface and check with thi...

Page 65: ...e 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 5 950 to 5 965 mm EX 5 945 to 5 9...

Page 66: ...ure the height of cam profile Service Limit of cam profile height IN 42 05 mm EX 42 05 mm Oil clearance at cam journal portion Measure the ID of cam journal portion with Cam Support fixed to the speci...

Page 67: ...e the measuring block diagonally on the surface and check with thickness gauge Cylinder warpage Service Limit 0 05 mm Cylinder bore Check for damage or ware on bore surface Measure the cylinder bore a...

Page 68: ...3 001 to 23 007 mm Piston Pin OD Check for ware and damage on the sliding surface Measure OD at total 3 positions both ends and middle position in the X and Y direction Piston Pin OD Standard 22 996 t...

Page 69: ...on Ring into the lower portion of Cylinder horizontally by using Piston Measure the Piston Ring gap opening with thickness gauge Service Limit of Piston Ring gap Opening Top ring 0 7 mm Second ring 0...

Page 70: ...essure disk Check for ware and damage Check for movement of bearing If any fault would be found replace with new one Visual checking Plate and Disk Check for ware and deformation on Plate Check for wa...

Page 71: ...ware and damage replace with new one Width of Shift Fork groove Check for ware and scratch in the Fork groove Measure the width of Shift Fork groove with caliper gauge Width of Shift Fork groove Stan...

Page 72: ...ng Torque 9 15 N m Attach Reverse Arm CP onto Crankcase 1 Retain the Reverse Arm CP with washer and snap ring from the outside of Crankcase 1 Note Be sure not to damage oil seal Make sure the snap rin...

Page 73: ...o the upper groove of Counter Shaft Install Shifter Fork left facing the ID marking L upwards into the lower groove of Counter Shaft Install Shift Drum CP in the pin side upright condition Set each pi...

Page 74: ...Torque 7 9 N m Fastener M6 Hex bolt 1 pcs Apply TB 1316 to threads Install Drain Plug Tightening Torque 7 9 N m Fastener M16 Bolt 1 pcs Fit Oil Strainer UN On plastic containers place Crankcase 2 with...

Page 75: ...7 pcs M6X75L 7 pcs M6X50L 1 pc Case 2 M6X75L 1 pc Note After tightening all bolts securely make sure Crankshaft is smoothly rotated Install Position Switch Caution Install Position Switch after assem...

Page 76: ...12L 1 pc Note Make sure the Reverse Arm Spring orientation Apply TB 1316 to Stopper Pin threads and tighten to the specified tightening torque Tightening Torque 20 26 N m Align the locator pin of Shi...

Page 77: ...Rotor Scavenge 7 Oil Pump Shaft 8 Dowel Pin 2 pcs Insert shorter pin 3 X 15L into the hole of Oil Pump Shaft and then assemble with Inner Rotor Scavenge Set Pump Case 1 into Oil Pump Shaft Insert anot...

Page 78: ...L 2 pcs Fit Oil Pump Gear and adopt snap ring into the groove on Oil Pump Shaft end Insert Shift Shaft CP with Special Tool Oil Seal Guide adopted Apply oil to Special Tool Oil Seal Guide in advance E...

Page 79: ...ls Fit new clip into the groove on one side and make sure of the clip fitting properly in the groove Place Special Tool Piston Support Plate Insert Piston with the marking on the top surface faced to...

Page 80: ...et Valve Spring Inner facing the green paint marking upwards Set Valve Spring Outer facing the yellow paint marking upwards Apply oil onto the shaft ends of IN and EX Valve Valve Guide and Seal Valve...

Page 81: ...M11 X 198L 4 pcs Tighten M6 bolts Tightening Torque 9 11 N m Fastener M6 X 40L 2 pcs Install Chain Lever with pivot bolt Tightening Torque 13 5 16 5 N m Fastener M8 X 22 5L Pivot bolt 1 pc Put Timing...

Page 82: ...of Timing Chain aligned Note Decompression is furnished on Camshaft EX Do not mixed up Fit Bearing Stopper onto Ball Bearing Apply oil to Cam Support and install in position Tightening Torque 9 11 N m...

Page 83: ...nship between checking results and listed figures 3 digits Select applicable Adjusting Pad and fit it in place with original one Check again valve clearance and make sure it is within the specificatio...

Page 84: ...sure of smooth counterclockwise rotation Apply TB 1306 and remove oil from taper hole of Flywheel Fit Flywheel apply oil to threads and retaining surface of M14 nut Tighten the nut to the specified ti...

Page 85: ...nut Caulk the lock nut with Special Tool Caulking Tool Apply oil onto Push Rod and insert into Main Shaft and then fit Pusher Fit Disk Clutch and Plate Clutch Note Make sure the widest friction plate...

Page 86: ...urface Fit Clutch Cover and tighten bolts Tightening Torque 9 11 N m Fastener M6 X 25L 11 pcs M6 X 65L 1 pc Commonly tighten Filter Cover Tighten Filter Cover plug to the specified tightening torque I...

Page 87: ...2 5 3 5 N m Fastener M5 X 12L 2 pcs Fit Plug 1 and 2 MAG Cover Tightening Torque Plug 1 10 12 N m Plug 2 3 5 N m Note Make sure O ring is attached onto Plug MAG Cover Set the harness grommet into the...

Page 88: ...20L 2 pcs Install carburetor onto Adapter Set Adapter band screw with the screw head upwards on MAG side Fastener M4 X 30L 1 pc Fit Shift Pedal with the markings aligned Tightening Torque 9 11 N m Fa...

Page 89: ...6 32 ENGINE Attachment 1 Special Tool...

Page 90: ...6 33 ENGINE...

Page 91: ...ve Clearance Before Adjusting mm 0 96 1 00 230 Exhaust Adjusting Pad Selection Matrix Existing Adjusting Pad Marking numeral mark w 3 digits on Adjusting Pad 145 150 155 160 162 165 167 170 172 175 18...

Page 92: ...lastics Hex bolt M14 1 3 5 Plastics Main Shaft Hex bolt M6 1 12 14 Bearing retaining Neutral Switch Screw M5 2 3 5 Oil Delivery Pipe Banjo bolt M12 3 15 21 Oil fittings Oil Drain Plug Bolt M16 1 20 23...

Page 93: ...6 36 ENGINE...

Page 94: ...6 37 ENGINE...

Page 95: ...6 38 ENGINE...

Page 96: ...6 39 ENGINE...

Page 97: ...6 40 ENGINE...

Page 98: ...6 41 ENGINE...

Page 99: ...6 42 ENGINE...

Page 100: ...6 43 ENGINE...

Page 101: ...6 44 ENGINE...

Page 102: ...t bearing PTO 21 99 22 00 mm MAG 24 946 24 963 mm Outer diameter of Camshaft bearing PTO 21 976 21 985 mm MAG 0 037 0 075 mm 0 10 mm Camshaft Oil clearance of camshaft bearing PTO 0 005 0 024 mm 0 10...

Page 103: ...Piston and Piston Pin 0 001 0 011 mm Clearance between Piston Pin and Connecting Rod small end hole 0 007 0 024 mm 0 050 mm Top ring 0 20 0 35 mm 0 7 mm Second ring 0 35 0 50 mm 0 8 mm Gap Opening en...

Page 104: ...ver At press fitting of Pipe CP TB 1377N Crankcase AT press fitting of Pipe CP TB Three Bond Oil or Grease Application Oil or Grease Application Oil Pump Rotor Transmission Gears and Crank Shaft IN an...

Page 105: ...week Every month Every 6 months Every year Every two years Check ENGINE OIL level X Check COOLANT level X Clean AIR CLEANER X Replace ENGINE OIL X Replace ENGINE OIL FILTER X Clean SPARK PLUG and adju...

Page 106: ...3 6 kW 8250 rpm 45 HP 8250 rpm MAXIMUM TORQUE SAE 41 2 N m 7500 rpm 4 2 Kg m 7500 rpm MAXIMUM ENGINE SPEED 9100 rpm IGNITION CUT AT MORE THAN 9100 rpm IDLE ENGINE SPEED 1600 rpm COOLING SYSTEM LIQUID...

Page 107: ...ANKSHAFT VS OUTPUTSHAFT 2 429 34 14 6 994 1 611 29 18 4 640 1 286 27 21 3 703 1 087 25 23 3 130 0 920 23 25 2 650 2 071 29 14 5 966 FINAL DRIVE SYSTEM TYPE REDUCTION RATIO ROLLER CHAIN SPROCKET OUTPUT...

Page 108: ...Ignition System 7 11 Spark Plug Removal Installation 7 11 Spark Plug Cleaning Inspection 7 11 Spark Plug Gap 7 11 Ignition Coil Removal 7 11 Ignition Coil Installation 7 12 Ignition Coil Inspection 7...

Page 109: ...ltage Regulator rectifier output 14 15 V Alternator output voltage DC14V 13 7A 3000 rpm Y1 Y2 0 52 Y2 Y R 0 49 Y R Y1 0 49 Charge Coil Y Ground W R W 190 Stator Pulser Coil W Grnd Primary 0 3 Ignition...

Page 110: ...Parts Location High Low Beam Switch A Hazard Lights Switch B Horn Switch F Indicator Switch D Ignition Switch E Starter Button C Battery A Starter Circuit Relay B CDI Unit C Ignition Coil D Spark Plu...

Page 111: ...7 4 ELECTRICAL SYSTEM Regulator Rectifier G Magneto CP A Starter Motor B Horn B Temperature Sensor C...

Page 112: ...burn out the starter motor windings Do not use a illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the handle cover could be warped by excessive heat ra...

Page 113: ...k the wiring for continuity Use the wiring diagram to find the ends of the lead which is suspected of being a problem Connect the hand tester between the ends of the leads Set the tester to the x 1 ra...

Page 114: ...explosion Please adhere to the following points 1 Follow the instructions shown on battery package for preparation and filling with battery electrolyte 2 Never interfere with the sealed state of the b...

Page 115: ...ates that is not fully charged additional charging time is necessary Battery Test Charging If the battery is suspected of being defective sulfated or unable to take a charge consult the table To test...

Page 116: ...specified voltage Regulator Rectifier Output Voltage Connections Tester Range Tester to Tester to Reading 25 V DC Battery Battery 14 15 V Turn off the ignition switch to stop the engine and disconnec...

Page 117: ...ng procedures Disconnect the alternator connector Connect the hand tester to red white to white Start the engine Run it at the rpm Note the voltage readings total 3 measurements Alternator Output Volt...

Page 118: ...ve or install the spark plug A using the spark plug wrench from the vehicle right side Torque Spark Plug 14 N m 1 4 kgf m 10 0 ft lb Spark Plug Cleaning Inspection Clean the spark plug preferably in a...

Page 119: ...Connect the tester between the coil terminals Set the tester to the 1 range and read the tester Measure the secondary winding resistance as follows Remove the plug cap by turning it counterclockwise C...

Page 120: ...owing to avoid damage to the CDI unit Do not disconnect the CDI unit with the ignition switch on This may damage the CDI unit Do not disconnect the battery leads while the engine is running This may d...

Page 121: ...sure the socket is clean Insert the new bulb by aligning the tang with the notch in the headlight unit Push the holder in turn it clockwise and release it it should lock in position Fit the dust cove...

Page 122: ...fer the Headlight Bulb Replacement Fuses Main Fuse Removal Remove the seat see Frame chapter Remove the fuse case cap A and take out the fuse B Fuse Inspection Inspect the fuse element A If it is blow...

Page 123: ...LGn R W W R Gy Y B Left Right High Low ON OFF ON OFF OFF ON B Br R B R P R W LBu DIRECTIONAL SIGNAL RIGHT FRONT SIGNAL DIRECTIONAL LEFT HANDLEBAR SWITCH ASSEMBLY MAIN SWITCH HEADLIGHT SWITCH BRAKE HA...

Page 124: ...RECTIFIER WINKER RELAY RELAY STARTER BATTERY 12V BRAKE SWITCH CDI UNIT DIRECTIONAL SIGNAL RIGHT REAR LEFT REAR SIGNAL DIRECTIONAL TAIL LIGHT COIL HOT LAMP SWITCH FOOT IGNITION FAN MOTOR FAN SWITCH SW...

Page 125: ...7 18 ELECTRICAL SYSTEM NOTE...

Page 126: ...8 1 APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions 8 2 Carburetor 8 2 Fuel System 8 3 Spark Plug 8 4 Clutch Adjustment 8 6 Troubleshooting Guide 8 7...

Page 127: ...replaced with a smaller or larger one A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture Carburetor Pilot Screw Adjustment Note Pilot screw is covered by a welsh...

Page 128: ...e area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes of if you swallow gasoline seek medical attention im...

Page 129: ...e electrodes will stay hot enough to keep all the carbon burned off but cool enough to keep from damaging the engine and the plug itself This temperature is about 400 800 o C 750 1 450 o F and can be...

Page 130: ...white the plug is operating at too high a temperature and it should be replaced with the next colder type CAUTION If the spark plug is replaced with a type other than the standard plug make certain th...

Page 131: ...nt screw B and lock ring C Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring Squeeze the...

Page 132: ...ark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Pickup coil trouble CDI unit trouble Ignition co...

Page 133: ...Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect CDI unit trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cl...

Page 134: ...e Insufficient lubricant Incorrect oil Front final gear case Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Front axle or propeller shaft noise Constant velocity universa...

Page 135: ...properly adjusted Linings over worn or worn unevenly Drum worn unevenly or scored Oil grease on lining and drum Dirt water between lining and drum Overheated Battery Discharged Battery faulty e g plat...

Page 136: ......

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