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E-TON Yukon II, Service Manual

Get the most out of your E-TON Yukon II with the comprehensive Service Manual available for free download from our website. This essential manual provides detailed instructions, maintenance tips, and troubleshooting advice to ensure optimal performance. Unlock the full potential of your vehicle by downloading the manual today from manualshive.com.

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ELEC

7 - 25

SIGNALING SYSTEM

SIGNALING SYSTEM

CIRCUIT DIAGRAM

Fuel 

lever meter

Fuel 

sender

24

25

27

26

23

Main switch

Battery
Main fuse

Brake light switch

Eng stop switch
Horn
Horn 

switch

Light control unit

T

ail/brake light

5

1

4

13

15

16

22

18

21

20

Neutral switch
Reverse switch

Shift indicator light
Buzzer

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

ST

AR

T

MAIN

ST

AR

T SW

(Natural) 12V2W

(Reverse) 12V2W

12V 21W/5W

10A

Br

Br

Br

Br

Br

R/W

R/W

R

R

R

L/ W

L/ W

R

B

Br

Br

Y

Y

Y

Y

R

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

MO

T

OR

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

14

15

17

26

21

22

16

20

20

23

Br

G/Y

B

B

W/L

W/L

G/W

G/W

G/Y

G/Y

R/B

R/B

G/W

B

G/W

L/R

L/R

B

B

Br

Br

W/B

W/B

L/B

L/B

Or

Or

L/W

B

L/W

B

Br

Br

R/B

R/B

OFF

PUSH

HORN SW

OFF

ON

OFF

RU

N

E/G ST

OP

P

P

G

G/W

B

G

G/W

B

L/R

L/B

Br

Br

Br

Br

Or

L/R

L/B

Or

8A

28

29

27

P

P

B

B

Y

Y

L/W

L/W

Br

Br

B

Y

B

Y

B

Y

G/Y

G/Y

B

Y

B

Y

B

Y

B

Br

B

Br

L/W

G/B

W/L

L/W

G/B

W/L

B

30

31

Br

Br

G/B

L/W

W/L

Br

Br

G/B

G/B

Summary of Contents for Yukon II

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

Page 2: ...er 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 expressly prohibited ...

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 INFORMATION Particularly important information is distinguished in this manual by the following notations Product and specifications are subject to change without notice This is the safety alert symbol It ...

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 supplements are given in addition to the exploded diagram and the job instruction chart 5 4 5 3 Order Job Part Q ty Remarks Pilot jet Carb chamber Float pin 1 1 Main jet 1 1 Needle jet holder 1 Needle...

Page 5: ...l Torque Wear limit clearance Engine speed Electrical data Ω V A Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lithium soap based grease Apply molybdenum disulfide grease Symbols to in the exploded diagrams indicate where to apply a locking agent and when to...

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: ...ATION 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 PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 ...

Page 8: ...TIONS 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 AND LUBRICANT TYPES 2 18 OIL FLOW DIAGRAMS 2 20 CABLE ROUTING 2 21 ENGINE 2 18 CHAPTER 2 SPECIFICATIONS ...

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 THE REAR BRAKE PADS 3 21 CHECKING THE BRAKE HOSE 3 21 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 21 CHANGING THE FINAL TRANSMISSION OIL 3 23 ADJUSTING THE DRIVE CHAIN SLACK 3 23 CHECKING THE STEERING SYS...

Page 10: ...INGS 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 AND ROCKER ARMS 4 19 CYLINDER AND PISTON 4 20 REMOVING THE PISTON 4 21 CHECKING THE CYLINDER AND PISTON 4 21 CHECKING THE PISTON RINGS 4 23 CHECKING THE PISTON PIN 4 24 INSTALLING THE PISTON 4 24 INS...

Page 11: ...SSION 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 DRUM COMP GEAR SHIFT 4 51 CRANKCASE AND CRANKSHAFT 4 45 SEPARATING THE CRANKCASE 4 46 REMOVING THE CRANKSHAFT ASSEMBLY 4 46 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 4 46 CHECKING THE CRANKS...

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: ...REAR 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 BRAKE CALIPER REPLACING THE REAR BRAKE PADS REAR BRAKE MASTER CYLINDER CHECKING THE REAR BRAKE CALIPER INSTALLING THE REAR BRAKE CALIPER CHECKING THE MASTER CYLINDER ASSEMBLING THE REAR BRAKE MASTER CY...

Page 14: ...HE 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 REMOVING THE FRONT ARMS 6 35 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6 34 CHECKING THE FRONT ARMS 6 35 CHECKING THE FRONT SHOCK ABSORBERS 6 35 CHECKING THE BALL JOINTS 6 36 INSTALLING THE FRONT AR...

Page 15: ...TION 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 REMOVING THE STARTER MOTOR 7 16 ASSEMBLING THE STARTER MOTOR 7 17 LIGHTING SYSTEM 7 21 TROUBLESHOOTING 7 22 CIRCUIT DIAGRAM 7 21 CHECKING THE LIGHTING SYSTEM 7 23 SIGNALING SYSTEM 7 25 TROUBLESHOOTING...

Page 16: ...PERFORMANCE 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 OVERHEATING 8 3 OVERHEATING 8 3 FAULTY BRAKE 8 4 POOR BRAKING EFFECT 8 4 SHOCK ABSORBER MALFUNCTION 8 4 MALFUNCTION 8 4 UNSTABLE HANDLING 8 4 UNSTABLE HANDLING 8 4 CHAPTER 8 TROUBLESHOOTING ...

Page 17: ...TION 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 engine ENGINE SERIAL NUMBER 1 1 1 1 ...

Page 18: ...ys 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 installation of all parts 5 Keep all parts away from any source of fire GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals and O rings All gasket sur faces oil seal lips and ...

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 air because this will damage the bearing surfaces Bearing CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use ...

Page 20: ...nnect 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 connections are tight 5 Check continuity with the pocket tester If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer av...

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 30 or SAE 10W 30 or SAE10W 40 or SAE15W 40 or SAE 20W 40 or SAE 20W 50 Final transmission oil SAE 80W 90 gear oil Oil capacity Engine oil Periodic oil change 0 90 L 0 79 Imp qt 0 95 US qt Periodic o...

Page 22: ...imary 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 Steel tube frame Toe in with tires touching the ground Tire Type Tubeless Size front AT21 x 7 10 rear AT22 10 10 Manufacturer front MAXXIS rear MAXXIS Type front C9207 rear C9209 Tire pressure cold ti...

Page 23: ...ront 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 Drum brake Single disc brake Headlight type Bulb Bulb voltage wattage wattage quantity Headlight 12 V 20 W 2 Tail brake light 12 V 5 W 21 W 1 Indicator lights Neutral Forward Reverse 12V 50mA 0 6W 1 1...

Page 24: ...0 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 29 510 29 610 mm 1 1618 1 1657 in 29 410 mm 1 1578 in B 25 185 25 215 mm 0 9915 0 9927 in 25 076 mm 0 9872 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links KMC 92 RH...

Page 25: ...s 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 1 40 mm 0 0394 0 0551 in EX 1 00 1 40 mm 0 0394 0 0551 in IN 0 70 1 00 mm 0 0276 0 0394 in EX 0 70 1 00 mm 0 0276 0 0394 in IN 0 55 0 85 mm 0 0217 0 0335 in EX 0 95 1 25 mm 0 0374 0 0492 in IN 4 975 ...

Page 26: ...spring 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 N at 26 00 mm 3 99 4 87 kg 7 54 9 21 lb at 1 0236 in Tilt limit IN 2 0 1 1 mm 2 0 0 04 in EX 2 0 1 1 mm 2 0 0 04 in Direction of winding top view IN Counterclockwise EX Counterclockwise Item Standar...

Page 27: ...in 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 limit EX IN EX Piston Piston to cylinder clearance 0 005 0 035 mm Piston size D Measuring point H 0 5 mm 0 02 in 5 0 mm 0 20 in Piston off set Intake side Piston off set direction Piston pin bore inside...

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 clearance T B B T Oil ring Dimensions B T End gap installed B T Crankshaft Crank width 45 00 45 05 mm 1 7717 1 7736 in 0 04 mm Runout limit C1 0 0016 in 0 04 mm C2 0 0016 in Big end side clearance D 0 1...

Page 29: ...80 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 reduction system Spur gear 2 50 1 00 1 Secondary reduction ratio Max main axle runout Max drive axle runout Carburetors 19 0 mm I D mark M J A J Main jet Air jet J N Jet needle N J Needle jet Pilot jet Valv...

Page 30: ...p 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 Oil pump Piston Piston pin Limit Standard Item 2 10 Oil pump housing to inner rotor and outer rotor clearance 0 05 0 10 mm 0 0020 0 0039 in 0 17 mm 0 0067 in ...

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 Lining thickness Shoe spring free length Leading trailing 110 5 mm 4 35 in 4 0 mm 0 16 in 60 0 mm 2 36 in 111 5 mm 4 39 in 1 5 mm 0 06 in 10 x 8 AT Fork spring free length 175 mm 6 89 in Spring rate ...

Page 32: ...0 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 diameter Caliper cylinder inside diameter Brake fluid type 2 00 mm 2 00 mm Item Standard Limit 4 7 mm 0 16 0 28 in 0 3 mm 0 00 0 12 in front 7 48 in 0 14 in CHASSIS SPECIFICATIONS 2 12 ...

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 Secondary winding resistance Spark plug cap Type Resin Resistance 3 75 6 25 k Ω Charging system Type AC magneto C1120 V30 9000 SHINGYIH Model manufacturer Nominal output 14 V 105 W at 5 000 r min Rectifier re...

Page 34: ...ush 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 manufacturer 150 A Model manufacturer Coil winding resistance 2 98 4 03 at 20 C 68 F Circuit breakers Fuse Type Amperage for individual circuit Main fuse 10 0 A 1 Item Standard Limit Ω Ω ELECTRICAL SPECIFICATI...

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 sprocket 1 12 1 2 M6 Bolt Oil pump body 2 12 1 2 M6 Bolt Separator oil 2 12 1 2 Bolt M12 1 25 2 5 Final transmission oil filler cap M12 Bolt 1 25 2 5 Final transmission oil drain plug M35 Bolt 2 8 0 8 E...

Page 36: ...e 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 9 40 4 0 28 9 14 1 4 10 1 170 17 0 123 0 35 3 5 25 3 Rear brake lever and handlebar holder 14 1 4 10 1 28 2 8 20 3 M8 28 2 8 20 3 35 3 5 25 3 75 7 5 54 2 35 3 5 25 3 35 3 5 25 3 Remarks Rear axle and...

Page 37: ...specified 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 03937 in 2 mm x 0 03937 0 08 in METRIC TO IMPERIAL Torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz S...

Page 38: ...ce 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 assembly inside Oil pipe union bolt thread and surface Gasket Oil pump assembly Idle gear 1 thrust surfaces Idle gear 2 Drive shaft serration Sprocket Drive shaft taper roller bearing Transmission bearing...

Page 39: ...t 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 Stopper guide Cylinder head cover Crankcase mating surfaces Oil pipe C D I magneto lead grommet 2 19 ...

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: ...s 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 2 Rear brake switch lead 3 Fuel sender lead 4 Starter relay lead 5 Negative battery lead 6 Generator lead 7 Head light lead 2 9 13 1 2 3 5 4 6 7 8 0 B C E D 9 10 A F C G ...

Page 42: ...F 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 pulser cord Fasten the wire harness and CVT exhaust tube with a plastic band G Pass the rear brake hose through the hose guide 8 Rectifier regulator lead 9 Tail light lead 10 Buzzer lead 1 2 3 5 4 6 ...

Page 43: ...n 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 9 11 12 10 Positive battery lead Reverse switch lead Negative battery lead 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 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: ...cable 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 Negative battery lead Positive battery lead Reverse switch lead 1 6 5 4 3 2 1 3 4 5 6 7 8 9 0 2 A E D C B ...

Page 46: ...ad 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 plastic band To starter relay To the frame A B C D E 1 6 5 4 3 2 1 3 4 5 6 7 8 9 0 2 A E D C B ...

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 right 3 Horn 4 Light controller 1 6 5 4 3 7 8 2 2 27 5 Main switch 6 Meter 7 Rear brake switch 8 Handlebar swit A B 1 3 2 4 5 6 8 7 1 2 3 4 5 6 7 8 0 1 3 7 8 2 ɐ 8 7 A A ...

Page 48: ...ect 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 leakage and replace gasket s if neces sary Check for looseness and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes fir...

Page 49: ...roperly 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 adjust if neces sary Lubricate throttle lever housing and cable 19 Front and rear brake switches Check operation and correct if necessary Check for wear and replace if necessary 20 Lights and switches Che...

Page 50: ...l 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 cover pass the fuel tank breather hose through the hole in the handlebar cover For installation reverse the removal pro cedure Disconnect the meter lead and the main switch lead 2 3 4 5 6 7 1 T R 25 ...

Page 51: ...Remove 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 removal pro cedure RACKS SEAT FENDERS AND FUEL TANK 1 2 3 T R 9 Nm 0 9 m kg 6 5 ft Ib ...

Page 52: ...d 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 For installation reverse the removal pro cedure CHK ADJ REAR FENDER FOOTREST BOARDS BETTERY AND C D I UNIT RACKS SEAT FENDERS AND FUEL TANK 3 5 2 3 4 5 6 1 6 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 ...

Page 53: ...ed 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 disconnecting the fuel hose turn the fuel cock to OFF Refer to RACKS SEAT AND FRONT PANEL Racks seat and front panel T R 12 Nm 1 2 m kg 8 7 ft Ib 1 2 3 4 4 USA 3 2 RES OFF ON FUEL T R 25 Nm 2 5 m kg 18 1 ft...

Page 54: ...top 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 pointer on the crankcase When the T mark is aligned with the sta tionary pointer the piston is at the Top Dead Center TDC When the piston is at the Top Dead Center TDC on the compression stroke there sh...

Page 55: ...ghten 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 cover Cylinder head cover Refer to CYLINDER HEAD in chapter 4 1 1 1 2 3 1 2 3 4 4 ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and let it warm up for sev eral minutes 2 Attach engine tachome...

Page 56: ...ttle 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 idling speed should be adjusted prop erly before adjusting the throttle lever free play 1 Measure throttle lever free play Out of specification Adjust Throttle lever free play 1 0 3 0 mm 0 0 4 0 12 i...

Page 57: ...ased 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 premature wear ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully opened even when the throttle lever is applied to the maximum posi tion Screwing in the ad...

Page 58: ...rn 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 increased ADJUSTING THE SPEED LIMITER 1 2 1 2 CHECKING THE SPARK PLUG 1 Remove spark plug 2 Check spark plug type Incorrect Change 3 Check electrode Wear damage Replace insulator Abnormal color Repl...

Page 59: ...eed 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 ignition timing a Warm up the engine and keep it at the specified speed Engine speed 1 600 1 800 r min CHECKING THE IGNITION TIMING b Visually check the stationary pointer to verify it is within the requi...

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 into the cylinder 5 Attach compression gauge 6 Measure compression pressure Out of specification Refer to steps c and d Compression pressure at sea level Minimum 1 050 kPa 1 000 r min 10 5kg cm 152 3 p...

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 damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly defective Repair T R 11 Nm 1 1 m kg 8 0 ft Ib MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL ...

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 higher JASO standard MA Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase Recommend...

Page 63: ...rain 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 oil leaks 11 Check engine oil level 12 Check oil lubrication by oil check bolt Refer to CHECKING THE ENGINE OIL LEVEL Quantity Total amount 1 00 L 0 88 Imp qt 1 06 US qt Periodic oil change 0 90 L 0...

Page 64: ...ck 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 რ NOTICE რ NOTICE 4 Install air filter element seals Dusty Clean the air filter element with compressed air 5 Tighten bolts screws 6 Install Air filter case covers Make sure its sealing surface matches the sealing surface of the case...

Page 65: ...pulling 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 portion of the tailpipe and the inner contact surfaces of the muffler Remove the back cover of muffler and the the muffler d Insert the spark arrester and the back cover of muffler into the muffler then ...

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 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 chap...

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 immediately In order to ensure a correct reading of the brake fluid level make sure that the top of the brake master cylinder reservoir or brake fluid reservoir is horizontal Recommended 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 to REAR BRAKE in chapter 6 2 Operate the rear brake lever Brake pad wear limit 2 0 mm 0 08 in Bleed the hydraulic brake system when ever the system is disassembled a brake hose is loosened disconnec...

Page 69: ...nnect 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 fully depress the brake pedal and hold it in position g Loosen the bleed screw Loosening the bleed screw will release the pressure and cause the brake lever to contact the grip or the brake pedal to ...

Page 70: ...5 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 adjusting the drive chain slack there should be no weight on the vehicle and all tires must be touching the ground A drive chain that is too tight will overload the engine and other vital parts and one that is...

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 25 mm 0 59 0 98 in T R 55 Nm 5 5 m kg 39 8 ft Ib ADJUSTING THE DRIVE CHAIN SLACK TIP TIP CHECKING THE STEERING SYSTEM 1 Place the machine on a level surface 2 Check steering shaft bushings and bearin...

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 0 39 0 59 in Before measuring the toe in make sure that the tire pressure is correct a Mark both front tire tread centers b Face the handlebar straight ahead c Measure the width between the marks d ...

Page 73: ...s 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 Loosen the locknuts tie rod end of both tie rods c The same number of turns should be given to both the right and left tie rods until the specified toe in is obtained This is to keep the length of the rods t...

Page 74: ...shock 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 operation Pump the shock absorbers up and down for several times Unsmooth operation Replace the front rear shock absorber assembly Refer to ADJUSTING THE SHOCK ABSOR BERS Front shock absorber Rear s...

Page 75: ...Front 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 maintained at the proper pressures TIRE CHARACTERISTICS 1 Tire characteristics influence the han dling of ATVs The tires listed below have been approved by E TONPOWERTECH Co Ltd for this model If other ...

Page 76: ...efully 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 TIRES 1 Measure tire pressure Out of specification Adjust The low pressure tire gauge is included as standard equipment If dust or the like is stuck to this gauge it will not provide the correct read...

Page 77: ...t 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 bends Replace Always balance the wheel when a tire or wheel has been changed or replaced Never attempt even small repairs to the wheel Ride conservatively after installing a tire to allow it to seat ...

Page 78: ...Lubricate 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 Lubricate the pivoting point and metal to metal moving parts of the levers steering shaft and steering knuckles Recommended lubricant Lithium soap base grease LEVERS STEERING SHAFT AND STEERING KNUCKL...

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 or vegetable oil Get immediate medical attention This is a sealed battery Never remove the sealing caps because the balance between cells will not be maintained and battery per formance will deteriora...

Page 80: ...battery 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 charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Positive tester probe positive battery ter...

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 not shorted A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging pro...

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 circuit voltage CHECKING AND CHARGING THE BATTERY CHK ADJ 3 35 ...

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 amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measur ing its open circu...

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 voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery Is the amperage higher than the standard charg ing amperage written on the battery Charger Ammeter ...

Page 85: ... 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 circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK CHECKING THE FUSES 2 Check fuse a Connect the pocket tester to the fuse and chec...

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 damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install seat Refer to SEAT FENDERS AND FUEL TANK Items Amperage rating Q ty M...

Page 87: ...KS 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 Generator lead 1 9 Negative starter motor lead 1 10 Negative battery lead 1 For installation reverse the removal pro cedure Refer to CARBURETOR in chapter 5 2 3 4 5 6 7 10 9 8 1 25 Nm 2 5 m kg 18 1 ft Ib...

Page 88: ...ST 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 the bolts nuts and then tighten them to full torque specifica tions For installation reverse the removal pro cedure NOTICE T R 35 Nm 3 5 m kg 25 3 ft Ib 3 4 5 1 5 2 5 5 4 6 T 15 Nm 1 5 m kg 10 8 ft ...

Page 89: ...ully 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 R 35 Nm 3 5 m kg 25 3 ft Ib 1 flange bolts nuts 1 1 2 1 2 ENG ENGINE TIP TIP 2 2 1 ...

Page 90: ...r 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 2 m kg 8 7 ft Ib T R 11 Nm 1 1 m kg 8 0 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib T R 6 Nm ...

Page 91: ...4 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 17 1 15 2 16 1 Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD CYLINDER HEAD ENG Holder cam shaft Knock pin Cam shaft comp Head comp cylinder Gasket cylinder head Knock pin Guide...

Page 92: ...arms 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 condition 2 Remove bolt flg small head cover assy head cylinder nut flange Working in a crisscross pattern loosen each nut 1 4 of a turn and the round hole in camshaft sprocket away from the cylinder he ...

Page 93: ...THE 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 Check cover assy head cylinder gasket cover head cylinder Cracks damage Replace CHECKING THE TIMING CHAIN GUIDES 1 Check guide tension cam chain guide cam chain Wear damage Replace 1 2 1 2 1 2 3 1 2 3...

Page 94: ...s 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 cylinder head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times Maximum cylinder head warpage 0 05 mm 0 002 in INSTALLING THE CYLINDER HEAD 1 Install ...

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 camshaft clockwise and counter clockwise to remove timing chain slack g Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide inward h While pushing the timing chain guid...

Page 96: ...sprocket 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 alignment Adjust 6 Install 1 2 1 2 1 2 3 4 bolt flg small head cover assy head cylinder nut flange pipe assy inlet 1 2 3 4 CYLINDER HEAD ENG WARNING 4 10 ...

Page 97: ...rt 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 arm 2 13 Valve exhaust 1 14 Valve inlet 1 12 Seal valve stem 2 11 Seat valve spring outer 10 Spring valve inner 2 9 Spring valve outer 2 2 8 Retainer valve spring 2 7 Cotter valve 4 Arm valve rocker 5...

Page 98: ...nd 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 AND VALVE SPRINGS a Pour a clean solvent into the intake and exhaust ports b Check that the valve seals properly There should be no leakage at the valve seat 1 2 1 2 1 1 1 2 1 2 CAMSHAFT ROCKER ARMS ...

Page 99: ...45 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 rocker arm Damage wear Replace 1 1711 1 1750 in 0 9915 0 9927 in 1 1618 1 1657 in 0 9915 0 9927 in 1 2 1 2 a b a b a b a b 2 Check rocker arm shaft Blue discoloration excessive wear pitting scratches ...

Page 100: ...ation 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 Replace the defective part s Rocker arm shaft outside diameter 9 972 9 987 mm Rocker arm to rocker arm shaft clearance 0 013 0 046 mm 0 0005 0 0018 in a a a CAMSHAFT ROCKER ARMS AND VALVES ENG 1 TIP ...

Page 101: ...n 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 Replace 3 Measure margin thickness Out of specification Replace Margin thickness Intake 0 55 0 85 mm 0 0217 0 0335 in Exhaust 0 95 1 25 mm 0 0374 0 0492 in 4 Measure runout valve stem Out of specifica...

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 seat is too wide too narrow or the seat is not centered the valve seat must be refaced Valve seat width Intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 063 in Exhaust 0 90 1 10 mm 0 0354 0 0433 in ...

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 valve into the cylinder head h Press the valve through the valve guide and onto the valve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specificat...

Page 104: ...ce 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 stem seals valves valve springs valve spring retainers Install the valve springs with the larger pitch facing upwards Smaller pitch a a b 3 Install valve cotters Install the valve cotters while compress...

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 Use a slide hammer bolt to install the rocker arm shaft sprocket away from the cylinder head 1 2 1 1 1 2 CAMSHAFT ROCKER ARMS AND VALVES ENG რ NOTICE TIP TIP 4 19 ...

Page 106: ...r 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 Piston ring oil For installation reverse the removal pro cedure 3 2 1 4 4 5 6 7 8 E E New New New New 1 T R 12 Nm 1 2 m kg 8 7 ft Ib CYLINDER AND PISTON ENG 4 20 ...

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 wall cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder...

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 maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 Piston size P Standard 57 375 57 395 mm 2 2589 2 2596 in Piston to cylinder clearance Cylinder bore C Piston skirt...

Page 109: ...ap 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 clearance Top ring 0 015 0 055 mm 0 0006 0 0022 in Limit 0 09 mm 0 0035 in 2nd ring 0 015 0 055 mm 0 0006 0 0022 in Limit 0 09 mm 0 0035 in Piston ring end gap Top ring 0 15 0 30 mm 0 0059 0 0118 in Limit ...

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 clearance Piston pin bore diameter Piston pin outside diameter Piston pin to piston clearance 0 002 0 014 mm 0 0001 0 0006 in a b a b a b INSTALLING THE PISTON 1 Install piston rings onto the piston Be sur...

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 gap a I N a 120 120 120 a b c d g f e a b c d g f e 1 2 3 2 1 3 INSTALLING THE CYLINDER 1 Install cylinder Install the cylinder with one hand while com pressing the piston rings with the other hand Be ...

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 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 55 Nm 5 5 m kg 39 8 ft Ib C D I MAGNETO T R 5 Nm 0 5 m kg 3 6 ft Ib ENG რ NOTICE 4 26 ...

Page 113: ...r 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 C D I magneto rotor nut jection on the C D I magneto rotor the woodruff key is properly seated in the keyway 2 Remove C D I magneto rotor C D I magneto rotor nut nut plate washer with flywheel pulle...

Page 114: ...starter 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 kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib BELT DRIVE 3 3 2 1 7 4 5 6 ENG 4 28 ...

Page 115: ...NSTALLING 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 Spindle comp kick start Spring kick starter O ring 10 1 Bearing radial ball Boss kick spindle 3 2 1 9 7 8 10 6 New 5 4 BELT DRIVE ENG 4 29 ...

Page 116: ...ther 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 idle spring friction start gear circlip 1 2 1 2 1 2 3 3 1 2 b a d c b a d c New New 1 2 1 2 BELT DRIVE ENG TIP TIP 4 30 ...

Page 117: ...ure 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 Face movable drive Plate ramp Roller weight Piece slide 14 14 1 Washer 15 1 Stopper pump 16 1 Stopper V BELT CLUTCH DRIVE AND DRIVEN PULLEY 7 1 2 3 4 5 15 16 x3 x3 x4 x4 6 8 9 9 10 11 12 13 7 T R 55 Nm...

Page 118: ...e 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 seal O ring 1 Face comp driven DISASSEMBLING THE SECONDARY SHEAVE LS LS LS LS T R 55 Nm 5 5 m kg 39 8 ft Ib New 1 4 5 2 3 6 7 9 8 10 13 12 14 13 15 11 1 4 5 2 3 6 7 9 8 10 13 12 14 15 11 ENG BELT DRIVE ...

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 turn 1 a a primary sheave nut secondary sheave nut clutch housing nut lock washer ratchet kick starter face drive clip boss drive face face movable drive 1 2 3 1 2 3 1 2 3 6 4 7 5 1 2 3 6 6 4 7 5 1 2...

Page 120: ...0787 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 shoe Inspect clutch shoes After removing the clutch weight spring do Replace the all three as a set 1 2 1 3 3 2 1 1 2 a a a a a CHECKING THE V BELT 1 Check Cracks damage wear Replace Grease oil Clean t...

Page 121: ...easure 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 roller weight outside diameter 1 2 a a CHECKING THE PIECE SLIDER 1 Check Damage wear Replace CHECKING THE DRIVEN PULLEY 1 Check Cracks damage wear Replace the face comp driven and face comp movable dri...

Page 122: ...ter 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 face movable drive boss drive face roller weights roller weights boss drive face 1 1 2 a a ASSEMBLING THE PRIMARY SHEAVE 1 Clean Use thinner to clean up grease dirt on the pri mary sliding sheave ca...

Page 123: ...face 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 recommended lubricant Recommended lubricant BEL RAY assembly lube 1 2 3 4 5 3 1 2 New New 5 Install Attach the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown 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 2 1 2 1 1 2 3 3 3 3 2 1 2 3 1 2 Position the V belt in the face movable drive when the pulley is at its widest position and in the face movable drive when the pulley is at its narrowest position and m...

Page 125: ...cedure 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 Shaft Nut lock Gear starter reduction Washer 1 7 Gear comp starting clutch Bearing Knock pin One way clutch comp Spring roller Cap 3 1 13 14 Roller Flange starting clutch B New 3 4 5 6 7 8 11 13 14 1 2 ...

Page 126: ...d 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 clutch is faulty and must be replaced A B gear comp starting clutch gear starter reduction starter clutch operation Burrs chips roughness wear Replace 1 2 1 2 2 1 STARTER CLUTCH AND STARTER MOTOR ENG 4...

Page 127: ...seal 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 listed Refer to C D I MAGNETO For assembly reverse the disassembly procedure OIL PUMP T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New ENG 4 41 ...

Page 128: ...UMP 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 4 42 ...

Page 129: ...ator 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 part s sprocket oil pump driven 1 4 43 ...

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 separator oil flange bolts a c b a c b 1 2 2 1 INSTALLING THE OIL PUMP 1 Install After tightening the bolts make sure the Pour a drop of clean engine oil inside the oil pump turns smoothly oil pump T R ...

Page 131: ...ssembly 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 radial Bearing ball radial Chain cam Left crankcase 10 11 1 1 Knock pin Timing chain guide Refer to SEPARATING THE CRANKCASE For installation reverse the removal pro cedure Refer to INSTALLING THE CRAN...

Page 132: ...Y 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 crankshaft assembly cannot be removed remove the timing chain from the crankshaft 1 2 Damage stiffness Replace the timing chain Damage wear Replace the timing chain guide 1 2 TIP 4 46 ...

Page 133: ...Big 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 specification Replace the crankshaft Out of specification Replace the big end Out of specification Replace the crankshaft Scratches wear Replace the crankshaft 4 Check TIP 4 47 CRANKCASE AND CRANKSHAFT ...

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 knock pins crankshaft assembly ASSEMBLINGTHE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Install onto the crankcase mating surfaces 3 Install Install the ...

Page 135: ...over 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 listed Drain Refer to BELT DRIVE Refer to V BELT DRIVE PULLEY AND DRIVEN PULLEY For installation reverse the removal pro cedure TRANSMISSION 3 4 5 5 6 8 11 9 10 12 1 2 10Nm 1 0m kg 7 2 ft lb 25Nm 2 5m k...

Page 136: ...n 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 shift 10 1 Spring transmission plate 11 1 Back position sw Remove the parts in the order listed For installation reverse the removal pro cedure ENG 4 50 TRANSMISSION ...

Page 137: ...age 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 surface 1 2 sembly drum assembly 1 2 3 3 1 2 CHECKING THE TRANSMISSION 1 Measure with a centering device and dial gauge Out of specification Replace the counter shaft Counter shaft runout limit 0 08 ...

Page 138: ...unout 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 gear shift comp final shaft runout transmission gears transmission gear engagement transmission gear movement defective gear s shaft assemblies part s REMOVING THE GEAR SET 1 Remove drain bolt and drain...

Page 139: ...ve 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 replace the bearings if they are abnormal also check that the outer races of the bear ings fit tightly in the left crankcase 1 Turn the inner race of the bearing with your finger 1 ENG 4 53 TRANSMIS...

Page 140: ...Install 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 5 5 6 7 8 8 8 6 7 4 3 3 2 3 assemble the mission cover sprocket drive plate fixing and fill the recommend oil about 0 3 liter 9 9 10 11 10 11 TRANSMISSION ENG 4 54 ...

Page 141: ...ass 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 choke comp 13 A Auto by Starter 1 1 14 Carburetor assy 1 1 For installation reverse the removal pro cedure CARBURETOR 9 10 14 6 8 7 1 5 2 3 4 12 11 CARBURETOR 13 A 13 M OR ...

Page 142: ...es 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 Throttle adjusting 1 Piston valve Cable fixed seat Air adjusting screw assy 1 2 3 7 8 5 4 6 9 TIP 6 8 9 7 10 11 12 x4 1 2 4 5 3 New CARB CARBURETOR 5 2 x4 17 13 14 15 16 ...

Page 143: ...t 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 11 12 x4 1 2 4 5 3 New x4 17 13 14 15 16 ...

Page 144: ...cks 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 Blow out all of the passages and jets with compressed air 2 Check 3 Check New 1 2 carburetor body float chamber float chamber rubber gasket float needle valve float chamber body fuel passages 1 2 New ...

Page 145: ...ve 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 Obstruction Clean Obstruction Clean Blow out the jets with compressed air Blow out the hoses with compressed air 1 2 1 2 3 4 1 2 manual piston valve spring 9 Check Sticks Replace Sticks Replace Bends cracks...

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 valve jet needle piston valve spring vacuum chamber cover INSTALLING THE CARBURETOR 1 Adjust Engine idling speed 1 600 1 800r min Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 engine idling ...

Page 147: ...c 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 a Remove the carburetor assembly b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are fine adjust the float level by slightly bending the float tang ...

Page 148: ...f 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 installation reverse the removal pro cedure FRONT AND REAR WHEELS FRONT WHEELS x4 T R 80 Nm 8 0 m kg 57 9 ft Ib T R 45 Nm 4 5 m kg 32 5 ft lb T R 40 Nm 4 0 m kg 28 9 ft Ib 2 1 3 4 5 LS WARNING Referto IN...

Page 149: ...ing 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 Axle nut 4 Rear wheel 5 Shaft connecter 1 1 T R 80 Nm 8 0 m kg 57 9 ft Ib T R 45 Nm 4 5 m kg 32 5 ft lb T R 40 Nm 4 0 m kg 28 9 ft Ib FRONT AND REAR WHEELS CHAS WARNING Refer to INSTALLING THE REAR ...

Page 150: ...use 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 both of the front wheel hubs 1 Check front wheel hub Cracks damage Replace 2 Check wheel bearings Wheel hub play wheel turns roughly Replace a Clean wheel hub exterior b Drive bearing out by pushing...

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 Install axle nut cotter pin Do not loosen the axle nut after torquing it If the axle nut groove is not aligned with the cot ter pin hole align the groove with the hole by tightening the axle nut New Fro...

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 Tighten nuts T R 40 Nm 4 0 m kg 28 9 ft Ib T R 40 Nm 4 0 m kg 28 9 ft Ib FRONT AND REAR WHEELS CHAS 1 TIP 1 ...

Page 153: ...r 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 7 Left front brake cable lever side 6 Right front brake cable lever side 8 Front brake lever 1 For installation reverse the removal pro cedure FRONT BRAKES T R 14 Nm 1 4 m kg 10 1 ft Ib 2 3 LS 1 5 4 ...

Page 154: ...s 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 1 Check brake shoes brake shoe spring Cracks damage Replace as a set When replacing the brake shoes replace the brake shoe springs at the same time 1 2 FRONT BRAKES CHAS TIP 1 2 1 2 TIP 2 Check brake...

Page 155: ...rum 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 scratches Remove Oil Use a rag soaked in lacquer thinner or solvent Scratches Use an emery cloth light and even polishing INSTALLING THE FRONT BRAKES The following procedure applies to both of the front br...

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 რ 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 plate with the pro jection of the steering knuckle 4 Install front brake cable drum side brake shoes Check that the brake shoes are properly posi tioned 5 Check brake camshaft operation Unsmooth oper...

Page 157: ...not 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 REAR AXLE REAR AXLE AND REAR AXLE HUB CHAS TIP 6 10 5 LS 6 7 8 x4 x4 x4 9 New T R 55 Nm 5 5 m kg 39 8 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 30 Nm 3 0 m kg 21 7 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R ...

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 New T R 55 Nm 5 5 m kg 39 8 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 30 Nm 3 0 m kg 21 7 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 170 Nm 17 0 m kg 123 ft Ib LT LT 1 4 LS 10 11 2 3 New LS ...

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 Remove 1 2 1 1 2 2 CHECKING THE REAR AXLE 1 Check rear axle runout Out of specification Replace Do not attempt to straighten a bent axle CHECKING THE DRIVEN SPROCKET 1 Check driven sprocket Refer to REAR S...

Page 160: ...e 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 INSTALLING THE REAR AXLE 1 Tighten nut Tighten the nut with rear axle nut wrench to specification while holding the rear axle T R 170 Nm 17 0 m kg 123 ft Ib REAR AXLE AND REAR AXLE HUB CHAS a a a a 1 2 1 2 ...

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 CALIPER REAR BRAKE 2 3 1 T R 28 Nm 2 8 m kg 20 3 ft Ib T R 30 Nm 3 0 m kg 21 7 ft Ib 4 New Cap leakage 1 Bolt leakage 1 Brake shoe comp 1 CHAS 6 14 1 2 3 1 2 3 ...

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 mounting bolts brake hose copper washers union bolt Brake caliper mounting bolt 30 Nm 3 0 m kg 21 7 ft lb Union bolt 28 Nm 2 8 m kg 20 3 ft lb 1 2 3 4 When installing the brake hose on the brake caliper ...

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 refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake...

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 brake pad pin brake pad wear limit Out of specification Replace the brake pads as a set spring washers brake pads 3 Install pad spring brake pads Always install new brake pads and brake pad spring as a s...

Page 165: ...chapter 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 THE REAR BRAKE FLUID LEVEL in chapter 3 Brake caliper mounting bolt 30 Nm 3 0 m kg 21 7 ft lb T R 8 Nm 0 8 m kg 5 8 ft Ib REAR BRAKE CHAS 6 18 ...

Page 166: ...cap 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 cylinder 1 For installation reverse the removal procedure Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 1 2 3 4 5 6 7 8 9 S T R 14 Nm 1 4 m kg 10 1 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 28 Nm 2 8 m k...

Page 167: ...CYLINDER 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 Recommended brake fluid DOT 4 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install brake master cylinder The UP mark on the brake master cylinder bracket should face up Install the brake master cylin...

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 brake performance Recommended brake fluid DOT 4 Refill with the same type of brake fluid mixing brake fluids may result in a harm ful reaction and lead to poor brake perfor mance Be careful that wate...

Page 169: ...THE 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 FLUID LEVEL in chapter 3 REAR BRAKE CHAS 6 22 ...

Page 170: ...ke 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 brake lever 1 5 Choke cable 1 STEERING SYSTEM CHAS 6 23 Refer to REMOVING THE HANDLEBAR Refer to INSTALLING THE FRONT BRAKE 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 f...

Page 171: ...AR 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 R 28 Nm 2 8 m kg 20 3 ft Ib LS LS Fasten the rear brake switch lead and handlebar switch lead ...

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 damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar 1 1 1 1 1 STEERING SYSTEM CHAS 1 TIP TIP WARNING 6 25 ...

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 tempo rarily install the rear brake lever and front brake lever assembly on the handlebar Before applying the adhesive wipe off grease or oil on the handlebar surface with a lacquer thinner 1 3 4 5 6 3 4...

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 mark and the gap at brake master cylinder holder The UP mark on the brake master cylinder bracket should face up Brake master cylinder bracket 14 Nm 1 4 m kg 10 1 ft lb handlebar grip handlebar grip In...

Page 175: ...2 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 STEM STEERING SYSTEM CHAS 6 28 X2 X2 2 1 3 4 5 6 8 7 LS LS New New New T R 35 Nm 3 5 m kg 25 3 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib 5 T R 35 Nm 3 5 m kg 25 3 ft Ib X2 T R 35 Nm 3 5 m kg 25 3 ft Ib ...

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 and steering stem should be set a right angle when assembling 1 Install lower handlebar holder nuts INSTALLING THE LOWER HANDLEBAR HOLDER T R 35 Nm 3 5 m kg 25 3 ft Ib 1 2 1 2 1 2 3 4 1 2 3 4 1 1 1 ...

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 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib 1 1 STEERING SYSTEM CHAS New TIP 6 30 1 ...

Page 178: ...rods 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 installation reverse the removal procedure Front brakes 1 1 T R 35 Nm 3 5 m kg 25 3 ft Ib New 2 3 5 4 4 New STEERING SYSTEM CHAS 6 31 T R 35 Nm 3 5 m kg 25 3 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib ...

Page 179: ...ie 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 procedure applies to both of the steering knuckles 1 Check steering knuckle sleeves Damage pitting Replace Wear damage Replace Wear damage Replace Cap REMOVING THE STEERING KNUCKLES 1 Remove steering...

Page 180: ...ie 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 ADJUSTING THE TOE IN in chapter 3 T R 35 Nm 3 5 m kg 25 3 ft Ib 1 2 1 2 1 STEERING SYSTEM CHAS TIP 6 33 ...

Page 181: ...ckles 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 FRONT SHOCK ABSORBER 2 Suspension of arm 3 Steering knuckle 5 Seal cover 4 Front suspension 4 2 7 Spacer 6 Bush 2 3 1 5 5 5 5 6 6 6 6 7 7 4 New New New T R 35 Nm 3 5 m kg 25 3 ft Ib CHAS 6 34 Disconnect ...

Page 182: ...Check 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 spring up and down Wear damage Replace bushes Wear damage Replace spacer Wear damage Replace Fatigue Replace the front shock absorber Bends damage Replace the front shock Oil leads Replace the front ...

Page 183: ...t 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 suspension of arm Front arm 35 Nm 3 5 m kg 25 3 ft lb ASSEMBLIES FRONT ARMS AND FRONT SHOCK ABSORBER CHAS 6 36 1 ...

Page 184: ...r 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 ABSORBER SWINGARM AND DRIVE CHAIN 2 CHAS 6 37 T R 35 Nm 3 5 m kg 25 3 ft Ib 6 8 3 7 4 T R 75 Nm 7 5 m kg 54 2 ft Ib x2 2 5 9 10 7 8 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 35 Nm 3 5 m kg 25 3 ft Ib T R 25 Nm 2 5 m...

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 reverse the removal procedure Refer to INSTALLING THE DRIVE SPROC KET REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN CHAS 6 38 11 12 13 ...

Page 186: ...ving 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 shaft nut b Check the swingarm side play by mov ing it from side to side If side play is noticeable check the spacer bearings and frame pivot Swingarm free play limit at the end of the swingarm 2 0 ...

Page 187: ...ange 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 chain with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it REAR SHOCK ABSORBER SWINGARM AND DRIVE CHAIN CHA...

Page 188: ...ets 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 lock washer tab along a flat side of the nut Drive sprocket nut 10 Nm 1 0 m kg 7 2 ft lb INSTALLING THE DRIVE CHAIN 1 Install drive chain masterlink 1 2 1 2 1 2 a b 2 1 3 1 REAR SHOCK ABSORBER SWINGARM...

Page 189: ...rse 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 Wire harness 1 2 3 4 6 7 8 9 10 11 14 12 13 16 15 18 17 19 20 21 5 7 1 1 3 2 4 X2 5 6 7 8 9 10 11 12 14 13 16 15 18 19 17 20 21 ...

Page 190: ...White 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 12V2W 12V 21W 5W 10A Br Br Br Br Br R W R W R R R L W L W R B Br Br Y Y Y Y R 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 ...

Page 191: ... poc ket tester to 0 and to the Ωx1 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 switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustrat...

Page 192: ...G 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 P B Y L W DIMMER SW REAR BRAKE SW FUSE FUEL LEVEL SWITCH 10A FUSE 8A Br Br Br OFF PUSH HORN SW OFF RUN E G STOP SW P B OFF ON Y R B R B GY NEUTRAL SWITCH REVERSE SWITCH R B ...

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 THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs 1 Remove bulb WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the ...

Page 194: ...dings 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 tester No continuity Replace TIP Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket 1 1 2 3...

Page 195: ...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 8A 5 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W B W B L B L B Or Or L W B L W B Br Br R B R B OFF PUSH ...

Page 196: ...occurs 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 resistance 5 Ignition coil resistance 6 Main switch 9 Pickup coil resistance 10 Battery 7 Neutral switch 8 Reverse switch 11 Wiring connections of the entire ignition system TIP Before troubleshootin...

Page 197: ...he primary coil resistance Primary coil resistance 0 19 0 25 Ω at 20 C Connect the pocket tester Ω x 1k to the ignition coil as shown Negative tester probe spark plug lead Positive tester probe ground Measure the secondary coil resistance Secondary coil resistance 6 8 9 2 KΩ at 20 C Is the ignition coil OK 6 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the mai...

Page 198: ...stem 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 CDI unit YES NO YES NO CDI MAGNETO 10 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 b...

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 8A 5 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W B W B L B L B Or Or L W B L W B Br Br R B R B OFF PU...

Page 200: ...nly 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 the engine can be started by pressing the starter switch Battery Main fuse Main switch Engine stop switch Brake light switch Starter relay Start switch Starter motor ...

Page 201: ...K 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 positive battery terminal and starter motor lead with a jumper lead WARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead otherwise the...

Page 202: ...ty 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 defects B R R L W 4 3 2 1 Replace the starter relay Replace the main switch Replace the right handlebar switch Properly connect or repair the starting system s wiring The starting system circuit is OK YES...

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: ...mature 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 specification replace the starter motor 4 Measure brush length a Out of specification Replace the brushes as a set Commutator wear limit 19 4 mm Armature coil Commutator resistance 0 027 0 033 Ω at 20 ...

Page 205: ...HE 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 installed with upper side bolt 12 Nm 1 2 m kg a ...

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 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W B W B L B L B Or Or L W B L W B Br Br R B R B OFF PUSH HORN SW OFF ON OFF RUN E G STOP P P G G ...

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 2 Main fuse Check the fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 Is the fuse OK 3 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 ...

Page 208: ...e 0 72 0 97 Ω 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 defects Replace the char ging coil assembly Properly connect or repair the charging system s wiring Replace the rectifier regulator YES NO YES NO ...

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 12V2W DC 12V 8A 5 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W B W B L B L B Or Or L W B L W B Br Br R...

Page 210: ...itch 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 handlebar switch Properly connect or repair the lighting system s wiring Check the condition of each of the lighting sy stem s circuits Refer to CIRCUIT DIAGRAM YES NO YES NO 2 Battery Check the cond...

Page 211: ...d 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 switch to the headlight coupler and hight beam indicator light are faulty and must be repaired This circuit is OK YES NO 12V 20W 2 2 1 Set the main switch to ON Start the engine Set the dimmer switch to ...

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 the tail brake light coupler tail brake light side Is the voltage within specification Replace the tail brake light bulb socket or both Wiring circuit from the main switch to the tail brake light coupl...

Page 213: ...R 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 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 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W ...

Page 214: ...e 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 continuity Refer to CHECKING THE SWITCHES Is the main switch OK 4 Wiring Check the entire signal system s wiring Refer to CIRCUIT DIAGRAM Is the signaling system s wiring properly connected and without defec...

Page 215: ...nal 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 the pocket tester DC 20 V to the horn connectors as shown Positive tester probe brown Negative tester probe pink Set the main switch to ON Push horn switch Measure the voltage DC 12 V of pink at the h...

Page 216: ...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 circuit from the main switch to the tail brake light cou pler is faulty and must be repaired This circuit is OK YES NO YES NO YES NO Y B GY B 12V 2 6 0 8W B Br GY 1 2 3 The fuel level gauge fails to operate 1 ...

Page 217: ...ectors 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 specification G Or 1 2 DC 20 V 3 Wiring Check the entire signaling system s wiring 2 Fuel level gauge Set the main switch to ON Move the float up or down Check that the display segments of the fuel level ga...

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 light bulb and Replace the reverse indicator light bulb socket or both YES NO socket OK YES NO 2 Reverse switch Check the reverse switch for continuity Refer to CHECKING THE SWITCHES Is the reverse swit...

Page 219: ...ack 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 switch to the bizzer connector is faulty and must be repaired YES NO YES NO 1 Reverse switch Check the reverse switch for continuity Refer to CHECKING THE SWITCHES Is the reverse switch OK Replace the ...

Page 220: ...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 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11 14 15 17 26 21 22 16 20 20 23 Br G Y B B W L W L G W G W G Y G Y R B R B G W B G W L R L R B B Br Br W B W B L B L B Or Or L W B L W B Br Br R B R B OFF PUSH HORN SW OFF ON ...

Page 221: ... Ω 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 Ω Ω Ω Ω Ω at 20 C Is the auto choke unit OK YES NO 2 Wiring Check the entire auto choke system s wir ing Refer to CIRCUIT DIAGRAM Is the auto choke system s wiring prop erly connected and without defects YES NO Replace t...

Page 222: ...mproperly 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 terminals broken Improper heat range Faulty spark plug cap Faulty ignition coil Faulty generator Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body Faulty alternator ex...

Page 223: ...rankshaft 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 pilot air jet Improperly adjusted idle speed throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty battery Faulty spark plug Faulty C D I unit Faulty pickup coil...

Page 224: ...r 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 Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag Primary sliding sheave Oil or grease on the V belt Roller weight s Faulty operation Worn roller weight Face driver V bel...

Page 225: ...andlebar 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 Insufficient tire pressure Steering shaft holder too tight Tires Uneven tire pressures on both sides Incorrect tire pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excess...

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