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Dinli DL702, Service Manual

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Dinli DL702 Service Manual Download Page 23

 

 

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BRAKE 

BRAKE 

Table of Contents 

Brake Fluid-----------------------------------------------------------------------------------------------------3-2 
    Brake Fluid Recommendation----------------------------------------------------------------------3-2 
    Brake Fluid Level Inspection------------------------------------------------------------------------3-3 
    Brake Fluid Change------------------------------------------------------------------------------------3-3 
    Brake Line Air Bleeding------------------------------------------------------------------------------3-4 
Master Cylinder----------------------------------------------------------------------------------------------3-5 
    Master Cylinder Removal----------------------------------------------------------------------------3-5 
    Master Cylinder Installation-------------------------------------------------------------------------3-5 
Calipers---------------------------------------------------------------------------------------------------------3-5 
    Front Caliper Removal--------------------------------------------------------------------------------3-5 
    Rear Caliper Removal---------------------------------------------------------------------------------3-6 
    Caliper Installation------------------------------------------------------------------------------------3-6 
Brake Pads-----------------------------------------------------------------------------------------------------3-7 
    Brake Pads Removal-----------------------------------------------------------------------------------3-7 
    Brake Pads Installation--------------------------------------------------------------------------------3-7 
        Brake Pads Wear Inspection-------------------------------------------------------------------------3-7 
Brake Discs-----------------------------------------------------------------------------------------------------3-7 
    Disc Cleaning--------------------------------------------------------------------------------------------3-7 
        Front  Brake  Disc  Removal---------------------------------------------------------------------------3-8 
        Rear Brake Disc Removal-----------------------------------------------------------------------------3-8 
    Front Disc Installation---------------------------------------------------------------------------------3-8 
    Rear 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 
Foot Brake----------------------------------------------------------------------------------------------------3-10 
    Brake Pedal Position Inspection-------------------------------------------------------------------3-10 
    Brake Pedal Position Adjustment-----------------------------------------------------------------3-10 
    Brake Pedal Free Play Inspection-----------------------------------------------------------------3-10 
    Brake Pedal Removal-------------------------------------------------------------------------------3-10 
    Brake Pedal Installation-----------------------------------------------------------------------------3-10 
    Master Cylinder Removal--------------------------------------------------------------------------3-11 
    Master Cylinder Installation-----------------------------------------------------------------------3-11 

Summary of Contents for DL702

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

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 manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest prod...

Page 3: ...ms 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 t take shortcuts Remember to keep complete records of maintenance and repair with dates and any replaced parts How to Use This Manual In preparing this manual we divided the product into its major ...

Page 4: ...ould 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 symbol indicates points of particular interest for more efficient and convenient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of ...

Page 5: ... 0 4 FOREWORD INDEX CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 WHEELS TIRES CHAPTER 3 BRAKE CHAPTER 4 SUSPENSION CHAPTER 5 FRAME CHAPTER 6 ENGINE CHAPTER 7 ELECTRICAL CHAPTER 8 APPENDIX ...

Page 6: ... 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 7: ...e battery 3 Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if installation or 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 It is preferable to mark and record the locations and routing when...

Page 8: ...sed Apply them sparingly Excessive amount may block engine oil passages and cause serious damage 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where 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 Replac...

Page 9: ...t Parts When there is a replacement instruction replace these parts with new ones every time 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 cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires ...

Page 10: ...rial 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 serial number are important for vehicle identification ...

Page 11: ...diators Quantity 3 liter Starting system Electric Carburetor Mikuni BSR42 Transmission L H N R P Final drive 2WD 4WD 4WD LOCK Shaft Clutch type Automatic CVT wet drum Engine idle speed 1300 100 rpm Spark plug standard CR6E NGK Spark plug gap 0 8 0 9 mm Lubrication system Forced pressure and wet sump Lubricant 4 cycle motorcycle engine oil 10W 40 Grade SF or higher Ignition system CDI Gasoline Unle...

Page 12: ... 0psi 4 4psi Turning radius 6 5m Fuse 5A 10A 15A 30A Loading limit Incl rider cargo etc 250kg Voltage 12V Battery GS GTX20L BS Ground clearance unloaded 295 mm Water crossing maximum depth 520 mm Front suspension travel 170mm Rear suspension travel 170mm Dry weight approx KGs 298 Fuel tank capacity 20L Throttle lever free play 3 8 mm Air filter Foam Brake fluid DOT 4 Brake pad thickness MIN 3 5 mm...

Page 13: ...IL FILTER s C R R DIFFERENTIAL GEAR OIL I Replace every two years FINAL GEAR OIL I Replace every year COOLANT I I I Replace every two years SWITCHES engine stop start tether ignition I I BRAKE FLUID I I I Replace every two years BRAKE SYSTEM cables discs pads hosed etc I I I I I BRAKE DISCS I I I I Replace every 10000 km LIGHTING headlight tail light turning lights I I BATTERY terminals I C EXHAUS...

Page 14: ...2 4 Toe in Adjustment 2 4 Wheels Rims 2 5 Wheel Removal 2 5 Wheel Installation 2 5 Wheel Rim Inspection 2 5 Wheel Rim Replacement 2 6 Tires 2 6 Tires Removal 2 6 Tires Installation 2 7 Tires Inspection 2 8 Front Hub 2 8 Front Hub Removal 2 8 Front Hub Installation 2 9 Front Hub Disassembly Assembly 2 9 Rear Hub 2 9 Real Hub Installation 2 9 Rear Hub Disassembly Assembly 2 9 ...

Page 15: ... Alignment Toe in 11 40 mm Tires Standard tire Front Rear Tire air pressure when cold 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 0 psi 30 kPa 0 31 kgf cm2 4 4 psi 250 KG ...

Page 16: ...spection Test ride the vehicle If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure Otherwise go on to the Steering Centering Adjustment procedure Steering Centering Adjustment Support the vehicle so that the front wheels are off the ground and the front axles about the same height as the rear axle Hold a straight edge A against the...

Page 17: ... 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 not in the specified range go on to the Toe in adjustment procedure Toe in of Front Wheels Standard Standard 0 2 mm Toe in Adjustment Loosen the locknuts A B and turn the adjusting sleeves C the same number of turns on both sides to achieve the specified toe ...

Page 18: ...the wheel so that the air valve A is toward the outside of the vehicle Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 52 N m 5 3 kgf m 38 ft lb Wheel Rim Inspection Examine both sides of the rim for dents A If the rim is dented replace it If the tire is removed inspect the air sealing surfaces A of the rim for scratches or nicks Smooth the sealing surfaces with fine emery cloth ...

Page 19: ...eflate the tire Use a paper valve core tool Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water This helps the tire beads slip off the rim flanges Remove the tire from the rim using a suitable commercially available tire changer CAUTION Replace the air valve whenever the tire is replaced Do not reuse the air valve CAUTION Do not use engine oi...

Page 20: ...n the rim Check to see that rim lines A on both sides of the tire are parallel with the rim flanges B If the rim lines and the rim flanges are not paralleled deflate the tire lubricate the sealing surfaces again and re inflate the tire After the beads are properly seated check for air leaks Apply a soap and water solution around the tire bead and check for bubbles Deflate the tire to the specified...

Page 21: ... with a soap and water solution Check the shape of the tread knobs If no vertical side is left on the drive side of the knobs replace the tire Front Hub Front Hub Removal Remove the wheel see Wheel Removal Remove the cotter pin Remove the caliper by taking off the mounting bolts A and let the caliper hang free Remove the axle nut and pull off the front hub brake disc Separate the brake disc from t...

Page 22: ...a unit Rear Hub Rear Hub Installation Grease the axle spindle Apply non permanent locking agent Rear Axle Nuts Tighten Torque Rear Axle Nut 109 N m 11 0 kgf m 80ft lb Insert a new cotter pin and bend it over the nut Rear Hub Disassembly Assembly Do not press the hub bolts out If any hub bolt is damaged replace the hub and bolts as a unit A B ...

Page 23: ...val 3 7 Brake Pads Installation 3 7 Brake Pads Wear Inspection 3 7 Brake Discs 3 7 Disc Cleaning 3 7 Front Brake Disc Removal 3 8 Rear Brake Disc Removal 3 8 Front Disc Installation 3 8 Rear 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 Foot Brake 3 10 Brake Pedal Position Inspection 3 10 Brake Pedal Position Adj...

Page 24: ... distillate 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 disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Replace the...

Page 25: ...ainer Fill the reservoir with new brake fluid Change the brake fluid as follows Open the bleed valve D Squeeze the brake lever and hold it B Close the bleed valve C Release the brake level A Check the fluid level in the reservoir often replenishing it as necessary Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid change WARNING Change the fluid...

Page 26: ... level must be checked several times during the bleeding operation and replenished as necessary Tighten Torque Bleed Valves 5 4 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 fittings A B NOTE Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir NOTE If the fluid in the reser...

Page 27: ...nstallation see Brake Line Air Bleeding Check the brake for good braking power and no fluid leakage Caliper Front Caliper Removal Remove the front wheel see Wheels Tires chapter Loosen the banjo bolt A at the brake hose lower end and tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper CAU...

Page 28: ... Bolts 25N m 2 5kg m 18 0ft lb Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft lb Check the fluid level in the brake reservoir Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage NOTE If the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is removed see...

Page 29: ...er pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 4 5mm Service Limit 2mm Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc Oil on a disc must be cleaned off with an oil cleaning fluid such as trichloroethylene or acetone WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged...

Page 30: ... Mounting Bolts 37N m 3 8kg m 27ft lb After installing the discs check the disc runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Brake Disc Installation The disc must be installed with the marked side A facing toward front Tighten Non permanent Locking Agent Disc Mounting Bolts Torque Disc Mounting Bolts 37N m 3 8kg m 27ft lb After i...

Page 31: ...line can cause fluid to leak or the hose to burst if the line 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 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 brak...

Page 32: ...l 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 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 Pedal Free Play Standard 2 2 0 5 mm Brake Pedal Removal Remove Cir clip B Pin C Master Cylinder Joint A Pulling d...

Page 33: ...se Banjo 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 power and no fluid leakage A D C B CAUTION Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately WARNING Do not attempt to drive the vehicle until...

Page 34: ...ion Arm Assembly 4 3 Steering 4 4 Steering Stem Removal 4 4 Steering Stem Installation 4 4 Steering Knuckle Removal 4 5 Steering Knuckle Installation 4 5 Tie Rod Removal 4 5 Tie Rod Installation 4 6 Tie Rod End Removal 4 6 Tie Rod End Installation 4 6 Steering Maintenance 4 6 Steering Inspection 4 6 Steering Stem Warp 4 7 Steering Lubrication 4 7 Steering Stem Clamp Inspection 4 7 Tie Rod End and ...

Page 35: ...ver 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 different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following photograph Turn the adjusting sleeve on shock absorber to the desired position with the wrench Rear Shock Ab...

Page 36: ...Bolts Caps Bushings Spacer Holding the suspension arm with a vise remove the cotter pin A and unscrew the castle nut B and then remove the knuckle joint and circlip Suspension Arm Assembly When installing the rubber bushing into the arm lubricate the outer surface of the bushings with a soap and water solution Position the bushings in the suspension arm as shown using a suitable bearing driver in ...

Page 37: ...and Nut F To remove the steering stem bearing G remove the cotter pin and nut from the bottom end of the steering stem Pull the steering stem out of the frame Steering Stem Installation Lubricate the steering stem clamp grease seals See Steering Lubrication Install the grease seals B facing the end A rearward to prevent the entry of dirt Install the steering stem clamps on both grease seals fit in...

Page 38: ...nuckle Installation Clean the sealing surface A and the hole B Grease the sealing surface 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 kgf m 35 ft lb Front Shock Absorber Clamp Nut 52 N m 5 3 kgf m 38 ft lb Tie Rod End Nut 47 N m 4 8 kgf m 35 ft lb Tie Rod Removal Remove Tie Rod End Nuts A Tie Rod B CAUTION Do not loosen the locknuts at ...

Page 39: ...ect length A and the both visible thread length B make equal Tie Rod Length Standard 398 mm Tighten Torque Tie Rod adjusting Sleeve Locknut 27 N m 2 8 kgf m 20 ft lb Steering Maintenance Steering Inspection Turn the handlebar left and right and check the steering action If the steering is not smooth or if the steering binds or catches before the stop lubricate the steering Check the steering actio...

Page 40: ...eering stem for straightness Use a straightedge rule along the stem If the steering stem is bent replace the steering stem Steering Lubrication Lubricate the steering stem clamps Remove the steering stem see Steering Stem Removal Wipe all the old grease off the steering stem and clamps and out of the grease seals Apply grease to the steering stem A grease seal lips and mating surface B of the clam...

Page 41: ...en the holder rear bolts first and then the front bolts Torque Handlebar Holder Bolts 27 N m 2 8 kgf m 20 ft lb If the holder is correctly installed there will be no gap at the rear and an even gap at the front after tightening Transmission Differential Gear Oil Inspection Place the vehicle on level ground Remove the oil level plug 1 and oil filler plug 2 and inspect the oil level If the oil level...

Page 42: ...tial Gear Oil Specification Hypoid gear oil SAE 80 API grade GL 5 Torque Front differential gear oil level plug 9 N m 0 9 kgf m 6 5 ft lb Front differential gear oil drain plug 32 N m 3 2 kgf m 23 0 ft lb Front differential gear oil filler plug 35 N m 3 5 kgf m 25 5 ft lb Rear Driver Gear Oil Inspection Place the vehicle on level ground Remove the oil level plug 1 and oil filler plug 2 and inspect...

Page 43: ... 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 filter plug 2 to the specified torque Install the front under protector Rear Driver Gear Oil Specification Hypoid gear oil SAE 80 API grade GL 5 ...

Page 44: ... 2 Seat Installation 5 2 Front and Rear Fenders 5 2 Front Fender Removal 5 2 Front Fender Installation 5 4 Rear Fender Removal 5 4 Rear Fender Installation 5 4 Radiator Removal 5 4 Radiator Installation 5 5 Foot Board Removal 5 5 Headlight Assembly Removal 5 5 ...

Page 45: ...ard 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 the seat hook C under seat into lock D Push the front of the seat until you hear the click sound to lock the seat Front and Rear Fenders Front Fender Removal Remove Seat Handlebar holder cover Disconnect Instrument Panel Fuel tank decoration Front rack A B A B C D ...

Page 46: ...erting the opening stick into the hole A to open it Remove the maintenance compartment Remove headlight by unscrewing the screws C 6 Remove headlight shade by unscrew the screws D 6 Remove under cover of front fender by unscrew the screws E 4 A B C D E ...

Page 47: ...moval Remove Seat Rear rack Remove Pan head Screw A 6 attach to luggage compartment Pan head Screw B 3 attach to luggage compartment Machine Screw C 6 right 3 left 3 attach to footboard Rear Fender Installation Please reverse the Removal steps to install Radiator Removal Remove Front fender decoration Headlight shade A C B E ...

Page 48: ...er hose C Reservoir tank bolt 2 Reservoir tank Radiator Installation Please reverse the Removal steps to install Foot Board Removal Remove Machine Screw 6 attach to front rear fender Hex Washer Face Bolt 2 attach to body decoration Foot Board Bracket Bolts A 4 Foot Board Headlight Assy Removal Remove Headlight Screws A 3 Headlight Wire Headlight A B A A C A ...

Page 49: ...mbly 6 5 Engine Top Side 6 5 Engine Bottom Side 6 9 Inspection 6 15 Camshaft and Cylinder Head 6 15 Cam Chain Tensioner 6 19 Cam Chain Guide 6 19 Cylinder 6 19 Timing Gear 6 19 Piston 6 20 Connecting Rod 6 21 Clutch 6 22 Movable Drive Face and Driven Face 6 23 Drive Belt 6 25 Oil Pump 6 25 Transmission 6 26 Reassembly 6 26 ...

Page 50: ...emove the seat Remove the side fenders Remove the rear propeller shaft Disconnect the battery lead wires Remove front and rear rack and fender Remove the water hoses Remove Subharness assembly coupler 1 and Coolant Temperature sensor coupler 2 CAUTION When disconnecting the battery lead wires be sure to disconnect the battery lead wire first ...

Page 51: ...or coupler 2 Remove Tie rod end of lever assembly rod Remove Shift lever assembly 3 Remove air tube 4 Remove Starter Motor assembly coupler 1 and Gear shift indicator coupler 2 Remove fuel feeding hoses Remove Regulator Remove the CVT ducts Breather and outlet ...

Page 52: ...GINE Remove the Intake duct Remove the Ignition coil 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 ...

Page 53: ...ne mounting nuts to the specified torque Tightening Torque 60N m Tighten the front differential gear mounting nuts to the specified torque Tightening Torque 50N m Apply thread lock to the nuts When installing the shift lever rod align the both serrations Apply thread lock to the foot board bracket bolts and tighten them to the specified torque Tightening Torque 55N m Install the new gasket and tig...

Page 54: ... 6 6 ENGINE Remove the start motor Remove water hoses 1 and 2 Remove the recoil starter Remove Timing screen cover Remove cylinder head cover ...

Page 55: ...Remove the cam chain tensioner bolt 1 Remove the cam chain tensioner 2 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 cover CAUTION Be sure to loosen the camshaft cover bolts evenly by shifting the wrench diagonally NOTE Be careful not to drop the pins into the crankcase...

Page 56: ... bolts M10 and washers Remove the cylinder head 6 Remove the dowel pins 1 and cylinder head gasket 2 Remove the cam chain guide 3 Remove the cylinder nuts 4 Remove the cylinder 5 NOTE Be careful not to drop the spacer 4 into the crankcase NOTE Loosen the cylinder nuts NOTE When loosening the cylinder head bolts loosen each bolt little by little diagonally ...

Page 57: ...e the oil filter with the special tool Remove the water pump 1 Remove the start cup nut with a suitable bar 1 Remove the starter cup Remove the left crankcase cover 3 NOTE Be careful not to drop the dowel pins into the crankcase NOTE Place a clean rag under the piston so as not to drop the piston pin circlip into the crankcase ...

Page 58: ...Remove the dowel pins 4 and gasket 5 Remove the generator rotor bolt Install the special tool to the crankshaft end Remove the generator rotor with the special tool Remove the key 2 Remove the starter driven gear 3 ...

Page 59: ...p driven gear 3 Remove the oil pump bolts and the oil pump Remove the balancer shaft driven gear bolts with the special tool Remove the water pump drive gear 1 and oil pump driven gear 2 Remove the balancer shaft driven gears 3 Remove the clutch cover 1 and gasket Remove the movable drive face cover 1 NOTE Be careful not to drop the snap ring 1 into the crankcase ...

Page 60: ... removing the bolt Remove the movable driven face assembly by removing the bolt Remove the drive belt Remove the fixed drive face Remove the front and rear output connectors Remove the plate 1 clutch inner cover 2 with the clutch housing and gasket ...

Page 61: ... 6 13 ENGINE Remove the gear shift indicator 1 Remove the clutch housing 1 Remove the O ring Remove the clutch shoe nut Remove the one clutch shoe with the special tool ...

Page 62: ...ol Remove the collar 1 Remove the drive bevel gear 2 Remove the dowel pins 2 Remove the oil sump filter 3 NOTE Loosen the crankcase bolts diagonally with the smaller sizes first NOTE The crankcase separator plate is parallel with the end face of the crankcase The crankshaft must remain in the left crankcase half ...

Page 63: ...Check for ware and damage on decompression related parts Check if decompression would be operated smoothly If any parts would be damaged or worn replace with new Camshaft Assy Camheight Check for damage and ware on cam profile portion Measure the height of cam profile Service Limit of cam profile height IN 36 150 mm EX 35 100 mm NOTE Identify the original position of disassembled parts with markin...

Page 64: ... ID of cam journal portion Standard IN EX 23 000 23 021 mm OD of Camshaft journal portion Standard IN EX 22 980 to 22 959 mm Clinder head Remove tappets 1 and shim 2 Use special tools Valve spring compressor compress the Valve Spring and remove the valve keeper Remove the spring retainer and valve spring Pull out the valve 3 from the combustion chamber side Remove oil seal and valve guide NOTE Do ...

Page 65: ...ngles 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 Valve face wear Inspect each valve for wear of its seating face Replace any valve with an abnormally worn face Measure the thickness and if it measures less than the limit replace the valve Service Limit of Valve head thi...

Page 66: ... OD IN 5 450 to 5 465 mm EX 5 430 to 5 445 mm Valve Spring Measure the free length of Valve Spring Check the force required to compress the spring If the result is not correct replace the spring Service Limit of Valve spring free length IN EX 46 1 mm Service Limit of Valve spring free length IN EX 19 0 21 4kgf 36 50mm Water bypass union and oil pressure gauge Remove the oil pressure gauge 1 and wa...

Page 67: ...ylinder distortion Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at every position of the straightedge exceeds the limit replace the cylinder Cylinder Distortion Service Limit 0 05 mm Cylinder bore Check for damage or ware on bore surface Measure the cylinder bore at...

Page 68: ...o align the TDC line A with the index mark B of the crankcase to make the piston to the highest position Make the mark C on the Timing chain driver gear to the highest position Meanwhile the mark on the opposite side the Timing chain driver gear is also aligned with the mark position D Assemble the camshafts by aligning the engraved marks E with the mating surface of the cylinder head cover ...

Page 69: ...ards in the groove with thickness gauge If any of the clearances exceeds the limit replace both piston and piston rings Service Limit of clearance Top 0 180 mm Second 0 150 mm Piton ring groove width Standard Top 1 21 1 23 mm Second 1 21 1 23 mm Oil 2 01 2 03 mm Piton ring thickness Standard Top 1 17 1 19 mm Second 1 17 1 19 mm Piston Ring gap Opening Insert Piston Ring into the lower portion of C...

Page 70: ... for ware and damage on the sliding surface Measure ID in the X and Y direction with caliper dial gauge Small end ID Service limit 23 040 mm Connecting rod deflection Wear of the big end of the rod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the rod s big end Connecting Rod deflection Service Limit 3 0 mm Side clearance at ...

Page 71: ...tch Tighten the bolts to the specified torque Torque Starter clutch bolts 26 N m Install the starter driven gear to the starter clutch Check that the starter driven gear turns in the opposite direction of the arrow mark on the rotor while holding the generator motor The gear never turns in the direction of the arrow If there is anything unusual replace the one way clutch Check the starter driven g...

Page 72: ...aused by burning If any damages are found replace the drive faces with new ones Install the oil seal with the special tool Reassembly Reassemble the movable and fixed drive face in the reverse order of disassembly Apply a small amount of grease to the bore and oil seal lip Position the eight rollers on the movable drive face Mount on the dampers on the movable drive face plate Position the movable...

Page 73: ...al with a new one Remove the oil seal Install the oil seal with the special tool Movable driven face spring Measure the spring free length with the vernier caliper If the length is shorter than the service limit replace the spring with a new one Movable driven face spring free length Service Limit 155 mm Movable and fixed driven face Inspect the driven faces for any abnormal conditions such as ste...

Page 74: ... DRIVE BELT Inspection Check that the drive belt is free from any greasy substance Inspect the contact surface of the drive belt for cracks or damage and measure the width of the drive belt using the vernier calipers If any damages are found or the measurement exceeds the service limit replace the drive belt with a new one Drive belt width Service Limit 33 3 mm Oil Pump Rotate the oil pump by hand...

Page 75: ...ns If any 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 Standard Reverse 5 60 to 5 67 mm High 5 60 to 5 67 mm Thickness of Shift Fork craw Measure the thickness of Shift Fork craw with micrometer Thickness of Shift Fork craw Standard Reverse 5 40 to 5...

Page 76: ...t Test 7 10 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 12 Ignition Timing Test 7 13 CDI Unit Inspection 7 13 Lighting System 7 14 Headlight Bulb Replacement 7 14 Taillight Bulb Replacement 7 14 Indicator Bulb Replacement 7 14 Rear View Mirror ...

Page 77: ...Regulator rectifier output 14 15 V Alternator output voltage DC14V 23A 3000 rpm Stator Charge Coil Y1 Y2 0 52 Ω Y2 Y R 0 49 Ω Y R Y1 0 49 Ω Y Ground Pulser Coil W R W 110 Ω W Grnd Ignition Coil Primary 0 3 Ω Secondary 6 3 kΩ Spark plug Gap 0 8 0 9 mm Cap resistance 5 kΩ Starter motor Nominal Output 0 7 kW Reduction Ratio 28 235 ...

Page 78: ...itch A Hazard Lights Switch B Horn Switch C Indicator Switch D Ignition Switch E Starter Button F Battery A Starter Circuit Relay B CDI Unit C Indicator Relay D Position Light Relay E Ignition Coil F Spark Plug G A B C D E F A B C E D Cylinder head Cover G ...

Page 79: ... 7 4 ELECTRICAL SYSTEM Regulator Rectifier H Magneto CP A Starter Motor B Horn C Temperature Sensor D D A B H C ...

Page 80: ...ay 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 radiated from the bulb Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or it...

Page 81: ...and then the positive cable red Take out the battery Battery Installation Connect the positive cable first and then the negative cable Battery Charging The battery is a maintenance 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 of the battery can cause an ex...

Page 82: ...ly determined Turn the charger off or unplug it then disconnect it from the battery Check battery condition If the battery condition indicates that is not fully charged additional charging time is necessary CAUTION NEVER attempt to add electrolyte or water to the maintenance free design and construction Doing so will damage the case and shorten the life of the battery CAUTION Always remove the bat...

Page 83: ...battery is defective The self discharge rate of a good battery is only about 1 per day Regulator Rectifier Output Voltage Inspection Check the battery condition see Battery section Warm up the engine to obtain actual alternator operating conditions Check that the ignition switch is turned off and connect the hand tester to the battery terminal Start the engine and note the voltage readings at vari...

Page 84: ... measurements Alternator Output Voltage Minimum of 5 AC Amps at Idle CDI Output Test Using Peak Reading Adaptor Connect all CDI wires to stator wires Disconnect CDI module wire from ignition coil primary terminal Connect one lead to engine ground and the other to the ignition coil primary wire leading from the CDI module Set meter to read DC Volts Crank engine and check output of CDI wire to coil ...

Page 85: ...lator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Measure the gap A with a wire type thickness gauge If the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 8 0 9 mm Ignition Coil Removal Pull out the coil off cylinder Remove the bolt A 2 Ignition Coil Installation Connect the primary w...

Page 86: ...ame chapter Starter Relay B Connect the hand tester and 12V battery to the starter relay as shown If the relay does not work as specified the relay is defective replace the relay Testing Relay Hand Tester Range x 1Ω range Criteria When battery is connected 0Ω When battery is disconnected Ω Lighting System Headlight Bulb Replacement Remove Headlight Unit See Frame Removal Chapter Bulb Holder Slide ...

Page 87: ...placement Please refer 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 If it is blown out replace 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 ...

Page 88: ... 7 13 ELECTRICAL SYSTEM Wiring Diagram ...

Page 89: ... 7 14 ELECTRICAL SYSTEM Wiring Diagram ...

Page 90: ... 7 15 ELECTRICAL SYSTEM NOTE ...

Page 91: ... 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 92: ...aller or larger one A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture Carburetor Pilot Screw Adjustment Start engine and warm it up to operating temperature about 10 minutes With engine off turn pilot screw in clockwise until lightly seated Connect an accurate tachometer that will read in increments of or 50 RPM Start engine Set idle speed to 1600 RPM Slowly ...

Page 93: ...diately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Never drain the float bowl when the engine is hot Severe burns may result Fuel Lines Check fuel lines for signs of wear deterioration damage or leakage Replace if necessary Be sure fuel ...

Page 94: ...may be needed for severe conditions such as continuous high speed riding or towing heavy loads Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a colder plug If a spark plug with a heat range is used that is a cold plug that cools itself too well the plug will stay too cool to burn off the carbon and the carbon will collect on the electrod...

Page 95: ...causing overheating and marking it very difficult to insert the correct spark plug later If the reach is too long carbon will build up on the exposed spark plug threads causing overheating pre ignition and possibly burning a hole in the piston top In addition it may be impossible to remove the plug without damaging the cylinder head CAUTION The heat range of the spark plug functions like a thermos...

Page 96: ...age low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent ...

Page 97: ...heating 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 cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high D...

Page 98: ...r final gear case noise 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 universal joint damaged Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other n...

Page 99: ... 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 plates sulfated shorted through Sedimentation electrolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble ...

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