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E-TON ATV3U 150 Service Manual Download Page 66

CHASSIS

Before adjusting the front brake, the front
brake linings should be checked. 

Proper lever free play is essential to avoid
excessive brake drag. 

1. Measure: 

• front brake lever free play 

Out of specification 

Wear indicators reaches the wear limit line

Adjust the front and rear brake lever free play
after replace the brake shoes.

→ Replace the brake shoes as a set.

→

 Adjust.

2. Adjust: 

• front brake lever free play

Front brake lever free play 

a. Loosen the locknuts 

.

b. Turn the adjusters 

 in or out until the

specified front brake lever free play is obtained.

Make sure that the difference between clear-
ances 

 and 

 is less than 4 mm when the

front brake lever is squeezed.

c. Tighten the locknuts.

CHECKING THE FRONT BRAKE SHOES 

1. Operate the brake:

2. Check: 

3. Adjust: 

Refer to “FRONT BRAKES” in chapter 6.

ADJUSTING THE FRONT BRAKE 

ADJUSTING THE FRONT BRAKE

CHECKING THE FRONT BRAKE SHOES/

•

wear indicator

a

a

b

c

b

c

1

2

4 ~ 7 mm (0.16 ~ 0.28 in)

1

2

2

1

1

2

CHK

ADJ

TIP

TIP

რ

NOTICE

3 - 19

Summary of Contents for ATV3U 150

Page 1: ...SERVICE MANUAL ATV3U 150 YUKON II U S CHALLENGER 150 EUR E TON POWER...

Page 2: ...r 150 SERVICE MANUAL 2009 by E TON POWER TECH CO LTD First edition October 2009 All rights reserved Any reproduction or unauthorized use without the written permission of E TON POWER TECH CO LTD is ex...

Page 3: ...res will be forwarded to all authorized E TON dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFOR...

Page 4: ...on the next page 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the step by step format s...

Page 5: ...l Torque Wear limit clearance Engine speed Electrical data V A Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybde...

Page 6: ...TABLE OF CONTENTS SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL GENERAL INFORMATION 1 2 7 6 5 4 3 TROUBLESHOOTING 8...

Page 7: ...TION NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PI...

Page 8: ...IONS 2 13 TIGHTENING TORQUES 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 16 HOW TO USE THE CONVERSION TABLE 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 LUBRICATION POINTS A...

Page 9: ...CLEANING THE AIR FILTER ELEMENTS 3 17 CLEANING THE SPARK ARRESTER 3 18 CHASSIS 3 19 CHECKING THE FRONT BRAKE SHOES 3 19 ADJUSTING THE FRONT BRAKE 3 19 CHECKING THE REAR BRAKE FLUID LEVEL 3 20 CHECKING...

Page 10: ...NGS 4 12 CHECKING THE CAMSHAFT 4 13 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 13 CHECKING THE VALVES AND VALVE SPRINGS 4 15 INSTALLING THE VALVES AND VALVE SPRINGS 4 18 INSTALLING THE CAMSHAFT...

Page 11: ...SION 4 49 TRANSMISSION 4 49 SHIFT SHAFT 4 50 CHECKING THE TRANSMISSION 4 51 CHECKING THE SHIFT FORK 4 51 REMOVING THE GEAR SET 4 52 CHECKING THE GEAR SET 4 53 INSTALLING THE GEAR SET 4 54 CHECKING THE...

Page 12: ...CARBURETOR 5 1 DISASSEMBLING THE CARBURETOR 5 4 CHECKING THE CARBURETOR 5 4 ASSEMBLING THE CARBURETOR 5 6 INSTALLING THE CARBURETOR 5 6 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHAPTER 5 CARBURETOR...

Page 13: ...EAR AXLE AND REAR AXLE HUB REMOVING THE REAR AXLE CHECKING THE REAR AXLE CHECKING THE DRIVEN SPROCKET CHECKING THE BRAKE DISC INSTALLING THE DRIVEN SPROCKET INSTALLING THE REAR AXLE REAR BRAKE REAR BR...

Page 14: ...E STEERING KNUCKLES 6 32 REMOVING THE TIE RODS 6 32 CHECKING THE TIE RODS 6 32 CHECKING THE STEERING KNUCKLES 6 32 INSTALLING THE TIE RODS 6 33 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6 34 REMO...

Page 15: ...ION OF THE BULBS SOCKETS 7 6 ELECTRIC STARTING SYSTEM 7 11 CIRCUIT DIAGRAM 7 11 STARTING CIRCUIT OUT OFF SYSTEM OPERATION 7 12 TROUBLESHOOTING 7 13 STARTER MOTOR 7 15 CHECKING THE STARTER MOTOR 7 16 R...

Page 16: ...ERFORMANCE 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY CLUTCH 8 3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 8 3 CLUTCH SLIPPING 8 3 POOR STARTING PERFORMANCE 8 3 POOR SPEED PERFORMANCE 8 3 O...

Page 17: ...ION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the front side of the frame The engine serial number is stamped on the en...

Page 18: ...s be reused or replaced as an assembly 4 During disassembly clean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installati...

Page 19: ...stalling oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate Oil seal Do not spin the bearing with compressed ai...

Page 20: ...nect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure all connectio...

Page 21: ...7 1 Standard compression pressure at sea level 1250 kPa 12 5 kg cm2 181 3 psi at 1 000r min Electric starter kick starter Starting system Lubrication system Wet sump Oil type or grade Engine oil SAE5W...

Page 22: ...mary reduction system V belt Primary reduction ratio 2 50 1 0 1 Secondary reduction system Spur gear Secondary reduction ratio 36 14 40 15 6 857 Transmission type V belt automatic Chassis Frame type S...

Page 23: ...ont shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Electrical Ignition system DC CDI Generator system AC magneto Battery type Lead Acid Battery capacity 12 V 8 0 Ah D...

Page 24: ...mm 0 0039 in Camshaft Drive method Chain drive Left Cam dimensions Intake A 29 745 29 845 mm 1 1711 1 1750 in 29 645 mm 1 1671 in B 25 185 25 215 mm 0 9915 0 9927 in 25 076 mm 0 9872 in Exhaust A 29...

Page 25: ...Stem outside diameter Guide inside diameter Item Standard Limit B C D A Head Diameter Face Width Seat Width Margin Thickness IN 27 4 27 6 mm 1 0787 1 0866 in EX 23 4 23 6 mm 0 9213 0 9291 in IN 1 00...

Page 26: ...pring Free length IN 32 3 mm 1 27 in 29 3 mm 1 15 in EX 32 3 mm 1 27 in 29 3 mm 1 15 in Compressed pressure installed IN 33 55 41 00 N at 26 00 mm 3 42 4 18 kg 7 54 9 21 lb at 1 0236 in EX 33 55 41 00...

Page 27: ...n 2 0 1 2 mm 0 05 in Compressed pressure installed 82 10 100 40 N at 29 00 mm 8 37 10 23 kg 18 45 22 56 lb at 1 1417 in 82 10 100 40 N at 29 00 mm 8 37 10 23 kg 18 45 22 56 lb at 1 1417 in IN Tilt lim...

Page 28: ...0 0866 in 0 20 0 80 mm 0 0079 0 0315 in Limit Standard Item Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed 2nd ring Type Dimensions B T End gap installed Side cle...

Page 29: ...0 in 32 0 mm 1 2598 in 20 0 mm 0 7874 in 124 9 125 1 mm 0 7047 0 7126 in 17 9 18 1 mm Transmission V belt automatic Transmission type Primary reduction system Primary reduction ratio Secondary reducti...

Page 30: ...housing clearance 0 0059 0 0083 in 0 25 mm 0 0098 in 0 15 0 21 mm 0 00 0 15mm Lubrication chart Pressure feed Splashed scavenge Crankshaft pin Camshaft Rocker arm Valve Timing chain area Oil strainer...

Page 31: ...wheel Rim size Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Drive chain Type manufacturer 520 KMC Link quantity 78 Front drum brake Type Brake drum inside diameter...

Page 32: ...25 mm 0 009 in 3 00 mm 0 120 in Pad thickness inner 6 2 mm 0 24 in DOT 4 25 4 mm 1 00 in 12 7 mm 0 50 in Dual cylinder 190 0 mm 3 5 mm Pad thickness outer 6 2 mm 0 24 in Master cylinder inside diamet...

Page 33: ...C D I unit model manufacturer C0410 V30 9001 E YANG Ignition coil Model manufacturer C051A FIA0 0010 SHIHLIN Minimum spark gap 6 0 mm 0 24 in Primary winding resistance 0 19 0 25 at 20 C 68 F Secondar...

Page 34: ...rush overall length 0 22 in Spring force 680 920 gf 23 99 32 45 oz 19 4 mm 22 0 mm 0 87 in Commutator diameter 0 76 in 7 mm 0 07 in 1 Mica undercut Starter relay C5850 A04 0000 SHINGYIH Model manufact...

Page 35: ...assy movable drive Nut 1 55 5 5 Outer clutch Nut M12 1 55 5 5 Plate comp drive Nut M28 1 55 5 5 Bolt Motor start comp M6 2 12 1 2 Bolt Gear comp starting clutch M22 1 95 9 5 M6 Nut Oil pump driven spr...

Page 36: ...caliper bracket Brake hose and union bolt M10 M10 M14 M10 M10 M10 M8 35 3 5 25 3 35 3 5 25 3 35 3 5 25 3 35 3 5 25 3 55 5 5 39 8 35 3 5 25 3 25 2 5 18 1 35 3 5 25 3 35 3 5 23 5 35 3 5 25 3 80 8 0 57...

Page 37: ...pecified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm x 0 03...

Page 38: ...e Connecting rod Piston outside and ring groove Piston pin outside surface Crankshaft journal Camshaft profile journal Valve stem IN EX Valve stem seal Valve stem end IN EX Valve lifter Oil pump assem...

Page 39: ...Sealant Sealant Sealant Sealant Lubrication Point Lubricant LS Primary sheave inside Collar Solid bush Secondary fixed inner surface Secondary sheave torque cam ditch Gasket Cylinder head cover Stopp...

Page 40: ...OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 1 2 3 4 3 4 1 2 SPEC 2 20...

Page 41: ...Bear tube 12 Rubber tube Fuel filter hose 7 Vacuum tube 2 21 A A A A 1 6 5 4 3 2 Front brake cable right Front brake cable left Throttle cable 9 7 10 11 8 12 13 0 Wire harness 1 Handlebar switch lead...

Page 42: ...D Fasten the wire harness with a plastic band and a clamper pulser cord Fasten the wire harness and Generator lead with a plastic band E Fasten the wire harness and Starter relay lead with a clamper...

Page 43: ...fuse on wire harness 2 23 Horn Meter lead PTC controller Light controller 2 3 4 5 Wire harness Main switch lead 0 1 6 7 16 17 13 14 15 Generator lead Negative starter motor lead Neutral switch lead 8...

Page 44: ...1 2 SPEC CABLE ROUTING 2 24 A Pass these leads through rear fender B Fasten the power supply lead on the wire harness with a plastic band 8 9 10 11 12 13 14 15 1 0 2 3 4 5 6 7 0 12 11 10 16 17 A B...

Page 45: ...able left Fuel tank breather hose Choke cable USA CAN Throttle cable 1 6 5 4 3 2 CABLE ROUTING 7 8 9 Neutral switch lead 2 25 Battery C D I unit Main fuse on wire harness Wire harness 0 6 5 2 3 4 1 Ne...

Page 46: ...d is routed to the side of the battery Connect the positive battery lead to the battery so that the lead contacts the battery case Fasten the handlebar switch lead rear brake switch lead with a plasti...

Page 47: ...ear brake switch lead with a plastic band A Fasten the Haed light leads with plastic bands B Front brake cable right Front brake cable left 0 Wire harness 1 Head light lead left 2 Head light lead righ...

Page 48: ...ct if necessary Check engine idling speed and adjust if neces sary 5 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 6 Exhaust system Check for leakag...

Page 49: ...operly tightened 14 15 Engine oil strainer Clean Final transmission oil 18 Lubricate Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjus...

Page 50: ...back the seat lock lever than pull up on the rear of the seat 4 Front panel 1 5 Fuel tank breather hose 1 1 1 6 Front plate of handlebar cover 1 7 Handlebar cover 1 TIP When installing the handlebar...

Page 51: ...emove the parts in the order listed Racks seat and front panel Refer to RACKS SEAT AND FRONT PANEL 1 Fuel tank top panel 1 2 CVT inlet tube 1 Remove 3 Front fender 1 For installation reverse the remov...

Page 52: ...1 2 Negative battery lead 1 Disconnect NOTICE First disconnect the negative lead then disconnect the positive lead 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Rear fender 1 6 Footrest board 2...

Page 53: ...d Front fender Refer to FRONT FENDER 1 Vacuum tube comp 1 For installation reverse the removal pro cedure FUEL TANK AND FOOTREST BARS Except for USA RACKS SEAT FENDERS AND FUEL TANK TIP Before disconn...

Page 54: ...op dead center TDC on the compression stroke 2 Measure valve clearance Out of specification Adjust a Turn the crankshaft clockwise with a wrench b Align the T mark on the rotor with the stationary poi...

Page 55: ...hten the locknut e Measure the valve clearance f If the clearance is incorrect repeat the above steps until the proper clearance is obtained T R Locknut 9 Nm 0 9 m kg 6 5 ft lb 4 Install C D I magneto...

Page 56: ...tle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY Throttle lever free play 1 0 3 0 mm 0 0 4 0 12 in ADJUSTING THE ENGINE IDLING SPEED 1 ADJUSTING THE THROTTLE LEVER FREE PLAY Engine...

Page 57: ...sed Turning out Free play is decreased ADJUSTING THE THROTTLE LEVER FREE PLAY TIP 1 2 3 2 1 Disconnect the throttle cable at the upper end Lubricate the cable with commercially lubricant to prevent pr...

Page 58: ...n out the adjuster more than 11 0 mm 0 43 in Also always adjust the throttle lever free play to 1 0 3 0 mm 0 04 0 12 in Turning in Speed limiter length is decreased Turning out Speed limiter length is...

Page 59: ...ed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Remove Shroud cap 2 Attach engine tachometer timing light to spark plug lead TIP 1 a 1 a 3 Check ignit...

Page 60: ...d then turn it off 3 Disconnect spark plug cap 4 Remove spark plug Before removing as park plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling i...

Page 61: ...again Refer to the following table 7 Install spark plug 8 Connect spark plug cap Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Pistonring s wear or...

Page 62: ...ipstick and check the oil level whether or not it is between maximum and minimum level d If the level is lower add the oil up to the proper level Recommended oil classification API service SG type or...

Page 63: ...ain bolt 7 Fill crankcase with the specified amount of the recom mended engine oil 8 Install dipstick 9 Start the engine warm it up for several min utes and then turn it off 10 Check engine for engine...

Page 64: ...eck Damaged Replace CLEANING THE AIR FILTER ELEMENTS 1 2 1 2 3 4 5 5 3 4 seals Place the air filter element in the original position and then install the screw CHK ADJ NOTICE NOTICE 4 Install air filt...

Page 65: ...ulling it out of Only U S c Tap the tailpipe lightly with a soft face hammer or suitable tool then use a wire brush to remove any Remove the screw Only U S carbon deposits from the spark arrester port...

Page 66: ...front brake lever free play Front brake lever free play a Loosen the locknuts b Turn the adjusters in or out until the specified front brake lever free play is obtained Make sure that the difference b...

Page 67: ...Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid...

Page 68: ...1 Remove seat front fender Refer to SEAT FENDERS AND FUEL TANK 2 Check CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicators almost touch the brake disc Replace the brake pads as a set Refer...

Page 69: ...nect a clear plastic hose tightly to the bleed screw d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully squeeze the brake lever or...

Page 70: ...75 L 0 66 Imp qt 0 79 US qt Recommended oil SAE80W 90 gear oil ADJUSTING THE DRIVE CHAIN SLACK Measure the drive chain slack halfway between the drive axle and the rear axle When checking and adjustin...

Page 71: ...e chain slack will overload the engine and other vital parts keep the slack within the specified limits The chain should be cleaned and lubricated after every use of the vehicle a Drive chain slack 15...

Page 72: ...front arms upper and lower and or wheel bearings CHECKING THE STEERING SYSTEM 1 ADJUSTING THE TOE IN 1 Place the machine on a level surface 2 Measure toe in Out of specification Adjust Toe in 10 15 mm...

Page 73: ...onds correctly If not turn either the right or left tie rod within the toe in speci fication ADJUSTING THE TOE IN a Mark both tie rods ends This reference point will be needed during adjustment b Loos...

Page 74: ...hock absorber assembly spring Fatigue the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBERASSEMBLIES and REARSHOCK ABSORBER SWINGARM AND DRIVE CHAIN in chapter 6 3 Check...

Page 75: ...ront shock absorbers ADJUSTING THE SHOCK ABSORBERS 1 1 2 2 a b a b a b a b 1 2 CHECKING THE TIRES This model is equipped with low pressure tires It is important that they be inflated correctly and mai...

Page 76: ...fully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT Vehicle load limits 75 0 kg 165 35 lb Total weight of the cargo trailer hitch vertical load rider and accessories CHECKING THE...

Page 77: ...is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Tire wear limit Front and rear 3 mm 0 12 in a a CHECKING THE WHEELS 1 Check wheel Damage...

Page 78: ...ubricate or replace Hold the cable end up and apply several drops of lubricant to the cable Recommended lubricant Lithium soap base grease LUBRICATING THE LEVERS STEERING SHAFT AND STEERING KNUCKLES L...

Page 79: ...tact External Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg...

Page 80: ...attery ter minals The charge state of an VRLA Valve Regulated Lead Acid battery can be checked by measur ing its open circuit voltage i e the voltage when the positive terminal is disconnected No char...

Page 81: ...attery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are no...

Page 82: ...voltage of an VRLA Valve Regulated Lead Acid battery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circu...

Page 83: ...timer to the charging time determined by the open circuit voltage Refer to CHECKING AND CHARGING THE BATTERY If the required charging time exceeds 5 hours it is advisable to check the charging amperag...

Page 84: ...charge an VRLA battery A variable voltage charger is recommended Set the charging time to a maxi mum of 20 hours Leave the battery unused for more than 30 minutes before measuring its open circuit vol...

Page 85: ...to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease CHECKING AND CHARGING THE BATTERY 1 2 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circ...

Page 86: ...again check the electrical circuit CHECKING THE FUSES Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive...

Page 87: ...S SEAT FENDERS AND FUEL TANK in chapter 3 1 Exhaust pipe muffler 1 2 Exhaust pipe gasket 1 3 Throttle cable 1 4 5 Choke cable 1 6 Spark plug lead 1 7 Reverse switch lead 1 8 Neutral switch lead 1 Gene...

Page 88: ...T PIPE MUFFLER CABLE AND LEADS 1 Drive chain 1 1 2 Inlet tube c v t comp 3 3 1 3 Catch tank 1 4 Cooler comp oil assy 1 6 Engine assembly 5 Flange bolt nut Refer to INSTALLING THE ENGINE Install all of...

Page 89: ...lly tighten the bolts and nuts The master link clip must be installed with the rounded end facing the direction of travel 2 Tighten 1 Remove drive chain master link 3 Install drive chain master link T...

Page 90: ...assy head cylinder 1 3 Lifter comp tensioner 1 4 Gasket lifter tensioner 1 1 Spark plug lead 1 CYLINDER HEAD Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD x4 x4 x4 T R 12 Nm 1...

Page 91: ...3 ft Ib T R 20 Nm 2 0 m kg 14 5 ft Ib 1 2 10 9 8 7 6 5 11 12 14 15 16 17 13 M E LS LS 3 4 New New Order Job Part Q ty Remarks 11 2 10 1 For installation reverse the removal procedure 12 1 13 1 14 1 1...

Page 92: ...rms must have a valve clear ance when the camshaft sprocket alignment mark is aligned with the cylinder head alignment mark If not give the crankshaft one counterclock wise turn to meet the above cond...

Page 93: ...HE CAMSHAFT SPROCKET 1 Check camshaft sprocket More than 1 4 tooth wear Replace the cam shaft comp and timing chain as a set 1 4 of a tooth correct roller sprocket CHECKING THE CYL HEAD COVER ASSY 1 C...

Page 94: ...gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cyl...

Page 95: ...p onto the camshaft comp and finger tighten the nut with wa When the camshaft sprocket alignment ma rk is aligned with the cylinder head alig hole in camshaft sprocket away from the f Force the camsha...

Page 96: ...procket and timing chain 3 Install bolt flg small head lifter comp tensioner Always use a new gasket 4 Adjust timing chain tensioner 5 Check camshaft sprocket alignment mark rotor T mark Out of alignm...

Page 97: ...t Q ty Remarks Removing the camshaft rocker arms and valves Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Cam shaft comp 1 1 1 2 Shaft in rocker arm 2 3 Shaft ex rocker a...

Page 98: ...d weight 3 Remove camshaft comp REMOVING THE VALVES AND VALVE SPRINGS 1 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVES...

Page 99: ...5 mm 25 185 25 215 mm Exhaust 29 510 29 610 mm 25 185 25 215 mm CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check r...

Page 100: ...tion Replace 6 Calculate rocker arm to rocker arm shaft clearance Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Out of specification...

Page 101: ...Exhaust 0 030 0 057 mm 0 0012 0 0022 in Limit 0 10 mm 0 0039 in a a b a b a 2 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the stem R...

Page 102: ...through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve se...

Page 103: ...d repeat the above steps After every lapping operation be sure to clean off all of the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Install the...

Page 104: ...e Spring tilt limit Inner 2 0 1 1 mm 2 0 0 04 in INSTALLING THE VALVES AND VALVE SPRINGS 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valve spring seats valve ste...

Page 105: ...lve INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install camshaft comp Be sure to align the round hole in camshaft 2 Apply engine oil onto the rocker arm shafts 3 Install rocker arms rocker arm shafts Us...

Page 106: ...to 1 Cylinder INSTALLING THE CYLINDER 1 2 Cylinder gasket 2 3 Dowel pin 2 4 Piston pin clip Refer to REMOVING THE PISTON and INSTALLING THE PISTON 1 5 Piston pin 1 6 Piston 2 7 Piston ring set 1 8 Pi...

Page 107: ...rive the piston pin out 2 Remove piston rings Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown CHECKING THE CYLINDER AND PISTON 1 Check piston...

Page 108: ...specification rebore or replace the cylinder and replace the piston and piston rings as a set Cylinder bore C 57 000 57 010 mm 2 2441 2 2 4 4 5 in Taper limit T Out of round R C maximum of D1 D2 T max...

Page 109: ...p Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring side cleara...

Page 110: ...bore clearance Out of specification Replace the piston pin and piston as a set Piston pin bore diameter 15 002 15 008 mm 0 5906 0 5909 in Limit 15 040 mm 0 5921 in Piston pin to piston pin bore cleara...

Page 111: ...ton pin clips cover the crankcase with a clean rag to prevent the piston pin clips from falling into the crank case 4 Lubricate piston piston rings cylinder Apply a liberal coating of engine oil New g...

Page 112: ...assembly C D I MAGNETO Remarks Order Job Part Q ty 1 2 3 1 1 1 Disassemble the parts in the order listed Refer to CYLINDER HEAD Disconnect the C D I magneto lead coupler 2 1 3 x2 T R 12 Nm 1 2 m kg 8...

Page 113: ...make sure While holding the C D I magneto with the hold Do not allow the sheave holder to touch the pro jection on the C D I magneto rotor the magneto rotor hub of the crankshaft ing tool tighten the...

Page 114: ...tarter Cover crank case left Knock pin 4 5 6 1 2 1 Plate crank case L O ring O ring 7 1 Oil seal L Remove the parts in the order listed For installation reverse the removal pro cedure T R 12 Nm 1 2 m...

Page 115: ...STALLING THE KICKSTARTER For installation reverse the removal pro cedure KICKSTARTER Removing the kickstarter Crankcase cover Circlip Washer Gear comp starter idle Spring friction start gear Washer Sp...

Page 116: ...her end on the projection 3 Install 4 Install Install the clip at the position shown boss kick spindle spindle comp kick start spring kick starter spring kick starter plain washer kgear comp starter i...

Page 117: ...re Removing the V belt clutch primary and secondary sheave Nut flange Washer Ratchet kick starter Boss drive face Face drive Outer clutch Plate comp drive V belt Gasket Clip Boss face movable drive Fa...

Page 118: ...plate sub assy drive Nut lock Plate comp drive Roller clutch Weight set clutch Spring clutch Plate clutch Collar spring Spring driven face Collar seal Pin guide Roller Face comp movable drive Oil sea...

Page 119: ...r loosen the secondary sheave nut 2 Loosen Do not remove the nut lock nut at this stage While holding the clutch carrier with the rotor with the socket wrench holding tool loosen the nut lock one full...

Page 120: ...787 in Limit 19 0 mm 0 7480 in not use them again 3 Remove Remove the V belt and clutch assembly from the primary sheave side 2 1 econdary sheave assembly V belt V belt V belt width nut lock clutch sh...

Page 121: ...asure Out of specification Replace roller weight outside diameter 17 9 18 1 mm 0 7047 0 7126 in 1 2 face movable drive face driver roller weight piece slide face comp movable drive face comp driven ro...

Page 122: ...er clutch internal diameter 125 mm 4 92 in set Damage wear Replace the face comp driven and face comp movable drive as a set torque cam groove guide pin spring driven face out clutch internal diameter...

Page 123: ...ace torque cam groove oil seals bearings face comp movable drive guide pin o ring spring clutch comp face comp driven guide pin groove 1 2 3 1 2 3 2 3 2 3 3 1 2 1 2 1 1 3 Install 4 Lubricate with the...

Page 124: ...Nm 5 5 m kg 39 8 ft Ib T R 55 Nm 5 5 m kg 39 8 ft Ib 3 Install 4 Position Tighten the secondary sheave nut with the sheave holder V belt clutch nut hex outer clutch nut V belt plate sub assy drive 1...

Page 125: ...edure Removing the starter clutch and starter motor Primary sheave 5 6 8 9 11 10 12 STARTER CLUTCH AND STARTER MOTOR T R 12 Nm 1 2 m kg 8 7 ft Ib T R 95 Nm 9 5 m kg 68 7 ft Ib O ring Starter motor Sha...

Page 126: ...the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise it should turn freely otherwise the starter cl...

Page 127: ...eal Knock pin Separator oil Oil pump chain Nut Oil pump driven sprocket Oil pump shaft Oil pump body Knock pin Outer rotor Inner rotor Plate oil pump 14 1 Knock pin Remove the parts in the order liste...

Page 128: ...MP ENG fan cover assy cooling fan composition REMOVING THE OIL PUMP 1 Remove 1 1 2 2 A C G generator assy the right crankcase cover 3 4 4 3 Gear comp starting clutch and flange 5 6 5 6 starting clutch...

Page 129: ...tor oil oil pump chain and oil pump driven oil pump assy Disassemble the oil pump assy 8 7 8 9 10 9 10 11 12 12 11 7 sprocket CHECKING THE OIL PUMP 1 Check Cracks damage wear Replace the defective par...

Page 130: ...in inner rotor to outer rotor tip clearance outer rotor to oil pump housing clearance oil pump housing to inner rotor and outer oil pump assembly oil pump driven sprocket flange nut oil pump chain se...

Page 131: ...sembly Engine Cylinder head Cylinder piston V belt clutch drive driven pulley Starter clutch C D I magneto Oil pump Right crankcase Knock pin Crankshaft Shaft drive Bearing ball radial Bearing ball ra...

Page 132: ...1 Remove sprocket moved if the timing chain is attached onto the crankshaft sprocket CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1 Check 2 Check Before removing the crankshaft assembly The cran...

Page 133: ...ig end side clearance 0 10 0 30 mm 0 0039 0 0118 in 3 Measure Crankshaft width 45 00 45 05 mm 1 7717 1 7736 in big end side clearance crankshaft width crankshaft journal crankshaft runout Out of speci...

Page 134: ...e crank shaft to check whether it is tightly engaged with the timing chain if not install again 3 2 3 1 crankshaft timing chain crankshaft gasket crankshaft crankshaft crankcase right timing chain kno...

Page 135: ...ver Knock pin 6 1 Spindle assy shift Shaft gear shift 8 9 1 1 Fork shift Drum comp gear shift 10 1 Shaft gear shift comp 11 12 1 1 Counter shaft comp Final shaft comp Remove the parts in the order lis...

Page 136: ...sw SHIFT SHAFT 1 2 5 7 7 6 8 9 10 11 1 2 3 4 5 7 1 1 1 1 1 2 Fixing support catch Shaft comp rod Fixed support rod shift Boss Pin rod shift 6 1 Split pin Washer 8 9 1 1 Plate transmission Spring rod...

Page 137: ...ge scoring wear Replace Damage scratches wear Replace the shift Damage wear Replace the shift drum as sembly Damage pitting Replace the shift drum as Bends Replace Roll the shaft gear shift on a flat...

Page 138: ...nout limit 0 08 mm 0 0031 in 3 Measure with a centering device and dial gauge Final shaft runout limit 0 08 mm 0 0031 in 4 Check 5 Check each pinion gear to its respective wheel gear 6 Check shaft gea...

Page 139: ...e the fork shift remove the shaft gear shift comp from the final shaft comp comp 3 3 4 3 6 5 5 6 8 7 7 10 11 11 10 9 9 8 4 3 CHECKING THE GEAR SET 1 Check the bearings should turn smoothly and quietly...

Page 140: ...nstall the mission cover and final shaft comp together with circlip for wear or damage 1 2 1 2 install the shaft gear shifts and the fork install a new gasket and the knock pins shift assy shift 2 3 4...

Page 141: ...ss 6 Bear tube comp 1 5 Tube rubber 1 7 Three through tube comp 1 Only Europe 2 9 A C V spring 1 10 A C V diaphragm assy 11 Oil seal 12 Air cut cable 1 8 A C V cover 1 1 Only Manual choke 13 M Manual...

Page 142: ...s the pilot screw is turned out from the seated position to its set position Plate fixed piston cover B 1 1 Plate fixed piston cover A 1 Vacuum piston cover assy 1 Piston spring 1 1 1 1 Jet needle Thr...

Page 143: ...Carb chamber Float pin 1 1 Main jet 1 1 Needle jet holder 1 Needle jet 1 Needle valve assy 1 1 Float For assembly reverse the disassembly procedure 10 11 12 16 17 14 13 15 CARB CARBURETOR 6 8 9 7 10...

Page 144: ...ks damage Replace Damage Replace Damage obstruction wear Replace Dirt Clean Obstruction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b B...

Page 145: ...e movement main jet needle jet holder needle jet Damage scratches wear Replace Cracks tears Replace Cracks damage Replace Bends damage wear Replace Cracks damage wear Replace Tightness Replace Obstruc...

Page 146: ...he carburetor wash all Always use a new gasket needle jet holder float pin needle valve float main jet pilot jet of the parts in a petroleum based solvent 1 1 2 2 3 1 2 3 3 2 Install 3 Install piston...

Page 147: ...Loosen the fuel drain screw d Hold the fuel level gauge vertically next to the line on the float chamber e Measure the fuel level Fuel level above the float chamber mating surface 1 2 3 a a 2 Adjust...

Page 148: ...it falling over The following procedure applies to both of the front wheels 2 Cotter pin 1 1 Rubber cap 1 Refer to INSTALLING THE WHEEL HUBS 3 Axle nut 1 4 Front wheel 1 5 Front brake drum 1 For inst...

Page 149: ...ng over The following procedure applies to both of the rear wheels Refer to INSTALLING THE WHEEL HUBS 1 For installation reverse the removal pro cedure 4 5 x4 2 3 1 New 2 Cotter pin 1 1 Rubber cap 1 3...

Page 150: ...se an accident resulting in machine damage and possible operator injury Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE FRONT WHEEL HUBS The following procedure applies to...

Page 151: ...g procedure applies to both of the rear wheel hubs 1 Check wheel hub splines Wear damage Replace INSTALLING THE WHEEL HUBS The following procedure applies to both of the front and rear wheel hubs 1 In...

Page 152: ...The arrow mark on the tire must point in the direction of rotation of the wheel 2 Tighten nuts a INSTALLING THE REAR WHEELS The following procedure applies to both of the rear wheels 1 Install wheel 2...

Page 153: ...to INSTALLING THE FRONT BRAKES 2 Front brake cable drum side 1 3 Brake shoe plate 1 Refer to REMOVING THE FRONT BRAKES and INSTALLING THE FRONT BRAKES 4 Brake camshaft lever 1 5 Brake camshaft 1 1 1...

Page 154: ...to each brake 1 Check brake shoe plate pivot pin brake camshaft Bends cracks damage Replace dust seal Wear damage Replace CHECKING THE FRONT BRAKE SHOES The following procedure applies to each brake...

Page 155: ...um inside diameter Out of specification Replace Front brake drum inside diameter Front 110 5 mm 4 35 in Limit 111 5 mm 4 39 in TIP FRONT BRAKES CHAS a a a a 2 Check brake drum inner surface Oil scratc...

Page 156: ...r Left side Right side A B A B T R 14 Nm 1 4 m kg 10 1 ft Ib FRONT BRAKES CHAS NOTICE TIP a a a 1 2 3 Install brake shoe plate When installing the brake shoe plate align the groove of the brake shoe p...

Page 157: ...ot use the parking brake when the brake cal iper is off of the brake disc as the brake pad will be force shut 3 Brake disc brake disc bracket 1 1 Refer to REMOVING THE REAR AXLE and INSTALLING THE REA...

Page 158: ...oil seal 1 1 For installation reverse the removal procedure 8 Rear axle hub 1 1 1 5 Axle plate fixed 1 REAR AXLE AND REAR AXLE HUB CHAS 6 11 Refer to INSTALLING THE DRIVEN SPROC 5 LS 6 7 8 x4 x4 x4 9...

Page 159: ...nd with a ham mer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the right 2 Remov...

Page 160: ...brake disc deflection Out of specification Replace brake disc thickness Out of specification Replace Brake disc maximum deflection 0 25 mm 0 009 in Brake disc minimum thickness 3 0 mm 0 12 in INSTALL...

Page 161: ...in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper assembly 1 For installation reverse the removal procedure REAR BRAKE CALIPER Refer to INSTALLING THE REAR BRAKE...

Page 162: ...t with compressed air Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled 1 1 INSTALLING THE REAR BRAKE CALIPER 1 Install brake caliper assembly brake caliper mou...

Page 163: ...ll with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when ref...

Page 164: ...eaned properly filled and bled after reassembly REPLACING THE REAR BRAKE PADS It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove 2 Measure bolts bra...

Page 165: ...hapter 3 c Tighten the brake caliper bleed screw d Install a new brake pad spring and new brake pads 4 Install brake caliper brake caliper mounting bolts 5 Check brake fluid level Refer to CHECKING TH...

Page 166: ...ap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch 1 4 Brake lever 1 5 Union bolt 1 6 Copper washer 2 7 Brake hose 1 Disconnect 8 Brake master cylinder bracket 1 9 Brake master cylind...

Page 167: ...YLINDER All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals...

Page 168: ...inted surfaces or plastic parts Always clean up spilled brake fluid immediately Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor...

Page 169: ...HE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE REAR BRAKE FL...

Page 170: ...e cable 2 3 Throttle cable 1 4 Front brake lever assembly 1 LEVER ASSEMBLY 6 Handlebar switch 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 7 Rear brake hose 1 8 Rear brake switch 1 9 Rear brak...

Page 171: ...R 12 Handlebar 1 For installation reverse the removal procedure STEERING SYSTEM CHAS 10 Plastic band 1 x4 T R 14 Nm 1 4 m kg 10 1 ft Ib 1 2 4 10 11 1 6 8 x2 T R 14 Nm 1 4 m kg 10 1 ft Ib 5 7 12 3 9 T...

Page 172: ...REMOVING THE REAR BRAKE SWITCH 1 Remove rear brake switch Push the fastener when removing the rear brake switch out of the rear brake lever holder CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks...

Page 173: ...ar side of the handlebar holder and then tighten the bolt on the front side 14 Nm 1 4 m kg 10 1 ft lb INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips Before installing the handlebar grips tem...

Page 174: ...the front brake lever assembly and handlebar grip 2 Adjust front brake Refer to ADJUSTING THE FRONT BRAKE in chapter 3 brake master cylinder Install the brake master cylinder please align the punch ma...

Page 175: ...Fix plate 1 3 Steering shaft pressed holder 1 4 Collar 2 5 Steering stem bushing 1 6 Oil seal 2 2 7 Lower handlebar holder 1 8 For installation reverse the removal pro cedure Steering stem STEERING S...

Page 176: ...may dangerously weaken the stem 2 Check fix plate steering shaft pressed holder oil seal steering stem bushings Bends damage Replace Bends damage Replace Wear damage Replace The lower handlebar holder...

Page 177: ...nut hold the tie rod ball joint with a 14 mm wrench INSTALLING THE LOCK WASHER 1 Install lock washer bolts 2 Bend the lock washer tab along a flat side of the bolt 1 3 3 2 2 2 T R 35 Nm 3 5 m kg 25 3...

Page 178: ...ods and steering knuckles Refer to FRONT BRAKES 1 Tie rod Refer to INSTALLING THE TIE RODS 1 2 Suspension of arm 1 3 Steering knuckle 2 4 Sleeve 1 5 Cap Refer to REMOVING THE STEERING KNUCK LES For in...

Page 179: ...e rods 1 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rod Bends damage Replace CHECKING THE STEERING KNUCKLES The following...

Page 180: ...e rod side which must be installed on the outside has grooves When installing the tie rod hold each tie rod ball joint with a 14 mm wrench and then tighten the tie rod end nut 2 Adjust toe in Refer to...

Page 181: ...kles Refer to FRONT BRAKES 1 Tie rod 1 1 1 1 Front brakes Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS 4 For installation reverse the removal procedure ASSEMBLIES FRONT ARMS AND FRON...

Page 182: ...heck front arms seal covers CHECKING THE FRONT SHOCK ABSORBERS The following procedure applies to both of the front shock absorber assemblies 1 Check shock absorber shock absorber rod spring Move the...

Page 183: ...Damage pitting Replace the front arm Free play Replace the front arm Turns roughly Replace the front arm INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install...

Page 184: ...axle hub Refer to REAR AXLE AND REAR AXLE HUB 1 Protect cover 1 2 Drive chain cover 1 3 Rear shock absorber 1 4 Flange nut 5 Flange bolt 1 6 Swingarm 1 7 Seal cover 8 Oil liner 2 1 REAR SHOCK ABSORBE...

Page 185: ...25 3 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib 1 T R 25 Nm 2 5 m kg 18 1 ft Ib Order Job Part Q ty Remarks 9 Spacer 10 ubber sleeve 1 1 11 Lock washer 12 Drive sprocket 13 Drive chain 1 1 1 For installation...

Page 186: ...ing the drive chain and the sprockets measure the drive chain slack and a 15 link section of the drive chain REMOVING THE SWINGARM 1 Check swingarm free play a Check the tightening torque of the pivot...

Page 187: ...nge bolt 3 Clean plange bolt spacer Recommended cleaning solvent Kerosene CHECKING THE DRIVE CHAIN 1 Check drive chain Stiffness Clean and lubricate or replace 2 Clean drive chain a Wipe the drive cha...

Page 188: ...kets as a set Bent teeth Replace the drive chain sprockets as a set Correct Drive chain roller Drive chain sprocket INSTALLING THE DRIVE SPROCKET 1 Install drive sprocket lock washer bolts 2 Bend the...

Page 189: ...se switch PTC controller Main switch Battery Rectifier regulator Starter relay Pickup coil stator assembly Starter motor Head light C D I unit Rear brake switch Handlebar switch Main fuse Tail light W...

Page 190: ...hite R B Red Black W L White Blue W B White Black W G White Green Y B Yellow Black Y W Yellow White W R B L Y L Y W B W B B L B B L B R W R W Br OFF ON OFF START MAIN START SW Natural 12V2W Reverse 12...

Page 191: ...poc ket tester to 0 and to the x1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop s...

Page 192: ...SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch B G W R W R W OFF ON MAIN SW Br Br OFF START START SW Br L W G Y...

Page 193: ...the socket by pushing and turning the bulb counterclockwise Bulbs d and e are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out CHECKING...

Page 194: ...ngs indicate no conti nuity replace the bulb CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket te...

Page 195: ...r L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5...

Page 196: ...ccurs Minimum ignition spark gap 6 0 mm Is there a spark and is the spark gap within specification IGNITION SYSTEM TROUBLESHOOTING Check 1 Main fuse 2 Spark plug 3 Ignition spark gap 4 Spark plug cap...

Page 197: ...e primary coil resistance Primary coil resistance 0 19 0 25 at 20 C Connect the pocket tester x 1k to the ignition coil as shown Negative tester probe spark plug lead Positive tester probe ground Meas...

Page 198: ...m s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects Replace the pickup coil Properly connect or repair the ignition system s wiring Replace the...

Page 199: ...B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8...

Page 200: ...ly operate if at least one of the following conditions is met The engine stop switch is ON The brake switch is ON When at least one of the above conditions has been met the starter relay is closed and...

Page 201: ...2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C Is the battery OK 3 Starter motor Connect the...

Page 202: ...Refer to CHECKING THE SWITCHES Is the start switch OK 9 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defect...

Page 203: ...ELEC 7 15 ELECTRIC STARTING SYSTEM STARTER MOTOR O ring Starter motor front cover Brush Brush spring Armature assembly Starter motor rear cover Brush wear limit 6 5 mm Commutator wear limit 20 5 mm...

Page 204: ...rmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of...

Page 205: ...E STARTER MOTOR 1 Install brush set rubber seal starter motor front cover 2 Install starter motor rear cover 3 Install Starter motor bolts NOTE When install the starter motor the ground ter minal a is...

Page 206: ...R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11...

Page 207: ...3000 r min Measure the charging voltage Charging voltage 12 V or more at 3000 r min 15 V or less at 8000 r min NOTE Make sure the battery is fully charged Is the charging voltage within specification...

Page 208: ...e 0 72 0 97 at 20 C Is the charging coil OK 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly connected and without...

Page 209: ...R B L B Or L B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 1...

Page 210: ...tch OK 5 Wiring Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM Is the lighting system s wiring properly con nected and without defects The dimmer switch is faulty Replace the left...

Page 211: ...high beam indicator light couplers as shown Headlight Positive tester probe yellow Negative tester probe black Replace the headlight bulb socket or both 1 YES NO The wiring circuit from the main swit...

Page 212: ...to the tail brake light coupler wire harness side as shown Positive tester probe yellow Negative tester probe black Set the main switch to ON Start the engine Measure the voltage DC 12 V of blue on th...

Page 213: ...B B B G W G W B B B B B B B B B B R B R B L B Or L B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br...

Page 214: ...condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C Is the battery OK 3 Main switch Check the main switch for continui...

Page 215: ...al Connect a jumper lead to the horn terminal and ground the jumper lead Set the main switch to ON Does the horn sound 4 Voltage Disconnect the pink and brown connectors at the horn terminal Connect t...

Page 216: ...of green yellow on the tail brake light cou pler wire harness side Is the voltage within specification Replace the tail brake light bulb socket or both Replace the brake light switch The wiring circui...

Page 217: ...ctors wire har ness side as shown Positive tester probe orange 1 Negative tester probe green 2 Set the main switch to ON Set the shift rod to N Measure the voltage DC 12V Is the voltage within specifi...

Page 218: ...must be repaired 6 The reverse indicator light fails to come on 1 Reverse indicator light bulb and socket Check the reverse indicator light bulb and socket for continuity Are the reverse indicator lig...

Page 219: ...ck Negative tester probe ground Set the main switch to ON Measure the voltage DC 12 V of blue brown at the bizzer terminal Is the voltage within specification L B B The wiring circuit from the main sw...

Page 220: ...W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5 1 2 3 4 6 7 8...

Page 221: ...ester 1 to the Auto choke unit coupler as shown Positive tester probe brown 1 Negative tester probe green black 2 Measure the auto choke unit resistance Auto choke unit resistance 30 at 20 C Is the au...

Page 222: ...properly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between ter...

Page 223: ...ankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Loose pilot jet Clogged pilot jet Clogged p...

Page 224: ...spark plug heat range Faulty C D I unit Fuel system Improper carburetor main jet improper set ting Improper fuel level Clogged air filter element Compression system Heavy carbon build up Engine oil I...

Page 225: ...ndlebar Improperly installed or bent Steering Incorrect toe in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles Insufficie...

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