Eton 2011 Viper 90R Silver Series Service Manual Download Page 124 | Manualshive

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INSTALLING THE C.D.I. MAGNETO ROTOR

1. Install:

C.D.I. magneto rotor

Clean the tapered portion of the crankshaft
and the magneto rotor hub.
When installing the magneto rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.

2. Tighten:

nut

While holding the C.D.I. magneto with the
holding tool

, tighten the C.D.I. magneto

rotor nut

.

Do not allow the sheave holder to touch the
projection on the C.D.I. magneto rotor.

1

2

3

2

1

3

2

T

R

.

.

55 Nm (5.5 m

•

kg, 39.8 ft

•

Ib)

ENG

4 - 30

C.D.I. MAGNETO

TIP

TIP

www.Get2itParts.com

www.Get2itParts.com

www.Get2itParts.com

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Summary of Contents for 2011 Viper 90R Silver Series

Page 1: ...a 20 VIPER SILVER SERIES SERVICE MANUAL Covers Viper 90R Silver Copyright 2008 20 ETON America all rights reserved w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P...

Page 2: ...First edition May 2009 All rights reserved Any reproduction or unauthorized use without the written permission of E TON POWER TECH CO LTD is expressly prohibited w w G e t 2 i t P a r t s c o m w w w...

Page 3: ...alers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is...

Page 4: ...s are given 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 s...

Page 5: ...rical data 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 App...

Page 6: ...CATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 ENGINE 4 CARBURETOR 5 CHASSIS 6 ELECTRICAL 7 GENERAL INFORMATION 1 TROUBLESHOOTING 8 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w...

Page 7: ...NT 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 C...

Page 8: ...ING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 16 HOW TO USE THE CONVERSION TABLE 2 18 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 19 OIL FLOW DIAGRAMS 2 21 C...

Page 9: ...KING THE REAR BRAKE FLUID LEVEL 3 24 CHECKING THE REAR BRAKE PADS 3 25 CHECKING THE BRAKE HOSE 3 25 ADJUSTING THE PARKING BRAKE 3 23 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 25 CHANGING THE FINAL TRANSMI...

Page 10: ...ALVES AND VALVE SPRINGS 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 19 INST...

Page 11: ...ECONDARY SHEAVE 4 41 INSTALLING THE BELT DRIVE 4 42 TRANSMISSION 4 55 CHECKING THE TRANSMISSION 4 57 REMOVING THE GEAR SET 4 58 CHECKNG THE GEAR SET 4 59 INSTALLING THEGEAR SET 4 59 SHIFT MECHANISM 4...

Page 12: ...CHECKING THE CARBURETOR 5 4 ASSEMBLING THE CARBURETOR 5 6 INSTALLING THE CARBURETOR 5 7 MEASURING AND ADJUSTING THE FUEL LEVEL 5 8 CHAPTER 5 CARBURETOR w w G e t 2 i t P a r t s c o m w w w G e t 2 i...

Page 13: ...AND REAR AXLE HUB 6 11 REMOVING THE REAR AXLE 6 13 CHECKING THE REAR AXLE 6 14 CHECKING THE DRIVEN SPROCKET 6 14 CHECKING THE BRAKE DISC 6 14 INSTALLING THE DRIVEN SPROCKET 6 14 INSTALLING THE REAR A...

Page 14: ...OVING THE TIE RODS 6 38 CHECKING THE TIE RODS 6 38 CHECKING THE STEERING KNUCKLES 6 38 INSTALLING THE TIE RODS 6 39 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6 40 REMOVING THE FRONT ARMS 6 41 FRO...

Page 15: ...ARTING CIRCUIT OPERATION 7 11 TROUBLESHOOTING 7 12 STARTER MOTOR 7 14 CHECKING THE STARTER MOTOR 7 15 ASSEMBLING THE STARTER MOTOR 7 16 CHARGING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 18 S...

Page 16: ...LTY CLUTCH 8 3 FAULTY GEAR SHIFTING 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 FAULT...

Page 17: ...MBER The vehicle identification number is stamped into the left side of the frame MACHINE IDENTIFICATION 1 1 The engine serial number is stamped on the engine ENGINE SERIAL NUMBER 1 w w G e t 2 i t P...

Page 18: ...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...

Page 19: ...ithium 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 Befo...

Page 20: ...t properly If the pin 1 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...

Page 21: ...io 10 2 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...

Page 22: ...ratio 41 15 45 13 9 46 Third reduction system Chain drive Third reduction ratio 28 13 2 154 Transmission type V belt automatic Chassis Frame type Steel tube frame Caster angle 8 00 Camber angle 1 00 K...

Page 23: ...pendent Rear suspension Swing arm Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 50 mm 1 97 in Rear wheel travel...

Page 24: ...rive Left Cam dimensions Intake A 25 683 25 843 mm 1 0111 1 0174 in 25 583 mm 1 0072 in B 20 985 21 015 mm 0 8262 0 8274 in 20 886 mm 0 8223 in Exhaust A 25 525 25 685 mm 1 0049 1 0112 in 25 425 mm 1...

Page 25: ...d Limit B C D A Head Diameter Face Width Seat Width Margin Thickness IN 20 9 21 1 mm 0 8228 0 8307 in EX 18 9 19 1 mm 0 7441 0 7520 in IN 1 50 1 80 mm 0 0591 0 0709 in EX 1 50 1 80 mm 0 0591 0 0709 in...

Page 26: ...06 in EX 30 00 mm 1 18 in 27 00 mm 1 06 in Compressed pressure installed IN 39 14 47 77 N at 22 45 mm 3 99 4 87 kg 8 80 10 74 lb at 0 884 in EX 39 14 47 77 N at 22 45 mm 3 99 4 87 kg 8 80 10 74 lb at...

Page 27: ...essure installed 73 75 90 03 N at 25 45 mm 7 52 9 18 kg 16 57 20 23 lb at 1 00 in 73 75 90 03 N at 25 45 mm 7 52 9 18 kg 16 57 20 23 lb at 1 00 in IN Tilt limit EX IN EX Piston Piston to cylinder clea...

Page 28: ...pe 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...

Page 29: ...in 107 0 107 2 mm 0 587 0 594 in 14 9 15 1 mm Transmission V belt automatic Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Spur gear 2 47 0 61 1 Secondar...

Page 30: ...inner rotor and outer rotor clearance 0 06 0 11 mm 0 14 0 21 mm 0 04 0 12mm 0 0024 0 0043 in 0 20 mm 0 0079 in Lubrication chart Pressure feed Splashed scavenge Crankshaft pin Camshaft Rocker arm Val...

Page 31: ...lateral 2 0 mm 0 08 in Rear wheel Type Panel wheel Rim size 8 x 7 AT 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 quantit...

Page 32: ...disk maximum deflection 0 15 mm 0 006 in Pad thickness inner 3 7 mm 0 15 in DOT 4 30 23 mm 1 19 in 12 7 mm 0 50 in Single 190 0 3 5 mm 7 48 0 11 in Pad thickness outer 3 7 mm 0 15 in Master cylinder...

Page 33: ...l Model manufacturer C0510 A26 3000 SHIHLIN Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 19 0 23 at 20 C 68 F Secondary winding resistance 2 79 3 41 k at 20 C 68 F Spark plug cap Type R...

Page 34: ...ength 0 14 in Spring force 102 306gf 3 60 10 80 oz 19 5 mm 22 0 mm 0 87 in Commutator diameter 0 77in 6 mm 0 06 in 1 Mica undercut Starter relay C585A LRA0 0000 SY Model manufacturer 150 A Model manuf...

Page 35: ...l pump driven Hole cap tap adjusting Bolt M30 1 8 0 8 5 8 M8 1 25 2 5 18 M5 2 2 0 2 1 4 M5 2 5 0 5 3 6 Bolt M6 8 12 1 2 8 7 Bolt Screw Screw Screw Screw M3 2 1 0 1 0 7 Carburetor overflow drain screw...

Page 36: ...e lower stay and frame Swingarm pivot shaft and frame Front shock absorber front arm Steering stem bushing and frame M8 Steering knuckle and front arm Rear brake disc and disc bracket Rear brake calip...

Page 37: ...axle threads 2 Tighten the inside nut to 60 Nm 6 0 m kg 43 4 ft lb t u n e d i s n i e h t g n i d l o h e l i h w b l t f 3 2 1 g k m 0 7 1 m N 0 7 1 o t t u n e d i s t u o e h t n e t h g i T 3 TI...

Page 38: ...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...

Page 39: ...amshaft 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 s...

Page 40: ...id 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 20...

Page 41: ...OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 1 2 3 4 2 21 OIL FLOW DIAGRAMS SPEC SPEC w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 42: ...ad Fuel overflow Choke cable 0 Fuel hose Fuel tank breather hose A Shift switch lead Buzzer cable Crankcase breather hose Throttle valve hose 2 22 CABLE ROUTING SPEC SPEC Parking brake cable Fuel mete...

Page 43: ...r brake switch lead with a plastic band Insert the fuel tank breather hose into the hole in the handlebar cover C D Fasten rear brake hose and throttle cable with a plastic band 2 23 CABLE ROUTING SPE...

Page 44: ...and left of the steering column as shown in the illustration E F Fasten the fuel overflow hose and carburetor air vent hose with a metal band Be sure to not pinch the hose Fasten rear brake hose with...

Page 45: ...D Negative starter motor lead J Starter relay Oil catch hose Crankcase breather hose 2 25 CABLE ROUTING SPEC SPEC 1 2 3 4 5 6 7 8 C D I cable 9 Shift sensor cable 10 11 12 Buzzer cable 13 Shift motor...

Page 46: ...Fasten the wire harness negative battery lead and starter motor lead with a plastic band D Fixed the negative battery lead and negative starter motor lead by a bolt 2 26 CABLE ROUTING SPEC SPEC M C D...

Page 47: ...13 2 3 4 5 6 Battery 7 8 Shift switch lead 9 10 11 Main fuse Shift motor cable Shift sensor cable C D I unit 19 16 17 18 C D I cable 2 27 CABLE ROUTING SPEC SPEC Parking brake cable 14 15 Shift switc...

Page 48: ...hat the lead contacts the battery case Fasten the handlebar switch lead rear brake switch lead and choke cable with a plastic band To starter relay To the frame A B C D E 2 28 CABLE ROUTING SPEC SPEC...

Page 49: ...ad 9 6 7 Fasten the handlebar switch lead rear brake switch lead and choke cable with a plastic band A Front brake cable right Front brake cable left A Ignition coil 2 29 CABLE ROUTING SPEC SPEC Parki...

Page 50: ...eather 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 cl...

Page 51: ...ary 19 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 20 Front and rear b...

Page 52: ...brake hose 7 Upper handlebar holder 8 Handlebar 1 1 1 3 3 HANDLEBAR SEAT FENDERS AND FUEL TANK CHK ADJ HANDLEBAR 5 3 4 6 7 8 x4 Refer to INSTALLING THE PARKING BRAKE LEVER When installing the handleba...

Page 53: ...Seat 1 Pull back the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Footrest board L 1 4 Footrest board R 1 Refer to HANDLEBAR Handlebar 3 4 CHK ADJ SEAT FRONT PANEL AND FOOTR...

Page 54: ...der L 1 3 Front fender R 1 4 Air cleaner joint clamp screw 1 Loosen For installation reverse the removal pro cedure Refer to HANDLEBAR Handlebar 3 5 CHK ADJ HANDLEBAR SEAT FENDERS AND FUEL TANK T R 9...

Page 55: ...ect the positive lead 4 1 2 1 1 1 1 1 1 5 6 7 8 9 Rear fender L 11 Disconnect 3 6 CHK ADJ 1 2 3 4 9 11 10 T R 9 Nm 0 9 m kg 6 5 ft Ib T R 9 Nm 0 9 m kg 6 5 ft Ib For installation reverse the removal p...

Page 56: ...fender Refer to FRONT FENDER 1 Fuel hose 2 Disconnect Before disconnecting the fuel hose turn the fuel cock to OFF 2 Fuel tank 1 For installation reverse the removal pro cedure FUEL TANK AND FOOTREST...

Page 57: ...troke 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 i...

Page 58: ...e proper clearance is obtained d Hold the adjuster to prevent it from moving and then tighten the locknut e Measure the valve clearance f If the clearance is incorrect repeat the above steps until the...

Page 59: ...ew in or out until the specified idling speed is obtained 5 Detach engine tachometer Turning right Idling speed becomes higher Turning left Idling speed becomes lower 6 Adjust throttle lever free play...

Page 60: ...ster in or out until the cor rect free play is obtained d Tighten the locknut e Push in the adjuster cover After adjusting the free play turn the han dlebar to the right and left to make sure that the...

Page 61: ...ticularly for a beginner rider the speed limiter should be screwed in com pletely Screw it out little by little as their riding technique improves Never remove the speed limiter for a beginning rider...

Page 62: ...Clean spark plug with a spark plug cleaner or wire brush Standard spark plug CR7HSA NGK 5 Measure spark plug gap Use a wire gauge or thickness gauge Out of specification Regap 6 Tighten spark plug Spa...

Page 63: ...eep it at the specified speed b Visually check the stationary pointer to verify it is within the required firing range indicated on the rotor Incorrect firing range Check the pickup coil 4 Detach timi...

Page 64: ...ed air to blow away any dirt accumu lated 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 st...

Page 65: ...n pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table 7 Install spark plug 8 Connect spark plug cap Compression press...

Page 66: ...ut and wipe the dipstick clean then just rest the dipstick in the hole c Pull up the dipstick and check the oil level whether or not it is between maximum and minimum level d If the level is lower add...

Page 67: ...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 leve...

Page 68: ...may result This model is equipped with two air filter elements one located on the left side and one located on the right side of the air box 4 Check sponge materials Damaged Replace 5 Clean sponge mat...

Page 69: ...ke sure its sealing surface matches the sealing surface of the case so there is no air leak CLEANING THE SPARK ARRESTER 1 Clean spark arrester Select a well ventilated area free of com bustible materi...

Page 70: ...rtion of the tailpipe and the inner contact surfaces of the muffler d Insert the spark arrester into the muffler and align the screw holes e Insert the bolt nut and tighten it T R Screw 5 Nm 0 5 m kg...

Page 71: ...front brake lever free play is obtained Make sure that the difference between clear ances and is less than 2 mm when the front brake lever is squeezed c Tighten the locknuts b c b c CHECKING THE FRON...

Page 72: ...end length is obtained d Tighten the locknut e Slowly turn the adjusting bolt clockwise until resistance is felt f Turn it 1 8 counterclockwise g Tighten the locknut After this adjustment is performed...

Page 73: ...nt 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 read...

Page 74: ...ERS 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 rea...

Page 75: ...leed 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...

Page 76: ...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...

Page 77: ...ain adjusting nut in direction b a d Tighten the locknut e Tighten the rear wheel axle pinch bolts Excessive chain slack will overload the engine and other vital parts keep the slack within the specif...

Page 78: ...etely then slightly move the handlebar slightly in the opposite direction Tie rod end s have vertical play Replace the tie rod end s Refer to STEERING SYSTEM in chapter 6 4 Raise the front end of the...

Page 79: ...en below g If the toe in is incorrect adjust it Forward 3 Adjust toe in Be sure that both tie rods are turned the same amount If not the machine will drift right or left even though the handlebar is p...

Page 80: ...mooth operation Replace the front rear shock absorber assembly Refer to ADJUSTING THE SHOCK ABSORBERS Front shock absorber Rear shock absorber a Mark both tie rods ends This reference point will be ne...

Page 81: ...rection or with the spanner wrench Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is softer Standard position Front 2 Rear 1 Minimum positi...

Page 82: ...minimum speci fication could cause the tire to dislodge from the rim under severe riding condi tions The following are minimums Front 22 kPa 0 22 kgf cm2 3 2 psi Rear 22 kPa 0 22 kgf cm2 3 2 psi 3 Use...

Page 83: ...this machine and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires Cold...

Page 84: ...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...

Page 85: ...d 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 met...

Page 86: ...ith 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 attentio...

Page 87: ...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 volta...

Page 88: ...tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead cli...

Page 89: ...tery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage 3 40 CHECKING AND CHARGING THE BATTER...

Page 90: ...ARGING 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...

Page 91: ...r 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 Rec...

Page 92: ...terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install battery band seat Refer to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric...

Page 93: ...the continuity Set the pocket tester selector to x 1 b If the pocket tester indicates replace the fuse 3 Replace blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage c...

Page 94: ...ge 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 Main 7A...

Page 95: ...nder Refer to SEAT FENDERS AND FUEL TANK in chapter 3 2 Exhaust pipe muffler 1 3 Exhaust pipe gasket 1 4 Spark plug lead 1 5 Generator lead 2 For installation reverse the removal pro cedure 1 Cover ch...

Page 96: ...1 1 3 Upper engine mounting nut bolt 1 1 Refer to INSTALLING THE ENGINE 4 Engine assembly 1 Install all of the bolts nuts and then tighten them to full torque specifica tions For installation reverse...

Page 97: ...t be installed with the rounded end facing the direction of travel 2 Tighten upper engine mounting nut lower engine mounting nut 1 Remove drive chain master link 3 Install drive chain master link T R...

Page 98: ...Gasket exhaust pipe 1 3 Lifter comp tensioned 1 4 Gasket lifter tensioned 1 1 Spark plug lead 1 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 11 Nm 1 1 m kg 8 0 ft Ib T R 6 Nm 0 6 m kg...

Page 99: ...o REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD 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 11 Nm 1 1 m kg 8 0 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 12 Nm 1 2 m kg 8 7...

Page 100: ...nce 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...

Page 101: ...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 c...

Page 102: ...a Place a straightedge and a thickness 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...

Page 103: ...Install the camshaft cap 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 nd hole in camshaft sprocket away f...

Page 104: ...Install bolt flg small head tensioner assy 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 bolt flg sma...

Page 105: ...ocker 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 12 Valve exhaust 1 13 Valve inlet...

Page 106: ...MOVING 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 s...

Page 107: ...ensions and Out of specification Replace Camshaft lobe limit Intake 25 583 mm 1 0072 in 20 886 mm 0 8223 in Exhaust 25 425 mm 1 0010 in 20 886 mm 0 8223 in CHECKING THE ROCKER ARMS AND ROCKER ARM SHAF...

Page 108: ...iameter Out of specification 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 diamet...

Page 109: ...arance valve guide inside diameter valve stem diameter Stem to guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 00...

Page 110: ...in 4 Measure runout valve stem Out of specification Replace When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 5 Eliminate carbon dep...

Page 111: ...r the seat is not centered the valve seat must be refaced Valve seat width Intake 0 8 1 1 mm 0 0315 0 0433 in Limit 1 6 mm 0 063 in Exhaust 0 8 1 1 mm 0 0315 0 0433 in Limit 1 6 mm 0 063 in 8 Lap valv...

Page 112: ...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 specification reface and relap the valve seat...

Page 113: ...alve springs with the larger pitch facing upwards Smaller pitch 3 Install valve cotters Install the valve cotters while compressing the valve spring with the valve spring compressor and attachment 4 T...

Page 114: ...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 ENG 4 20 CAMSHAFT ROCKER ARMS...

Page 115: ...R 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 1 7 Piston ring set For installation reverse the removal pro ce...

Page 116: ...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 R...

Page 117: ...r and replace the piston and piston rings as a set Cylinder bore C 47 00 47 01 mm 1 8504 1 8508 in Taper limit T 0 05 mm 0 002 in Out of round R 0 01 mm 0 0004 in C maximum of D1 D2 T maximum of D1 or...

Page 118: ...iston 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...

Page 119: ...er Out of specification Replace the piston 4 Calculate piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Piston pin bore diameter 13 002 13 008 mm...

Page 120: ...ring rail end 2nd ring end 20 mm 0 79 in 3 Install piston piston pin piston pin clips Apply engine oil onto the piston pin piston rings and piston Be sure that the IN mark on the piston points to the...

Page 121: ...the piston rings with the other hand Be careful not to damage the timing chain damper during installation Pass the timing chain through the timing chain cavity ENG 4 27 CYLINDER AND PISTON NOTICE TIP...

Page 122: ...Q ty 1 2 3 1 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 T R 5 Nm 0 5 m kg 3 6 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 10 Nm 1...

Page 123: ...ile holding the C D I magneto rotor with the holding tool loosen the C D I mag neto nut Do not allow the sheave holder to touch the projection on the C D I magneto rotor 2 Remove C D I magneto rotor w...

Page 124: ...perly seated in the keyway of the crankshaft 2 Tighten nut While holding the C D I magneto with the holding tool tighten the C D I magneto rotor nut Do not allow the sheave holder to touch the project...

Page 125: ...t drive Arm comp kick starter Cover L side Dowel pin 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 ENG 4 31 BELT DRIVE w w G e t 2 i...

Page 126: ...on 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 start...

Page 127: ...p kick start as shown and hook the other end on the projection 3 Install plain washer circlip 4 Install kgear comp starter idle spring friction start gear Install the clip at the position shown 1 2 2...

Page 128: ...ure Removing the V belt clutch primary and secondary sheave Nut flange Washer Ratchet kick starter Face driver Face drive Nut flange Outer clutch Plate sub assy drive V belt Boss drive face Face movab...

Page 129: ...bling the plate sub assy drive Nut hex Clutch comp Spring clutch Spring driven face Collar spring Pin guide Face comp movable driven O ring Oil seal Face comp driven DISASSEMBLING THE SECONDARY SHEAVE...

Page 130: ...liding sheave oneway clutch While holding the clutch housing with the sheave holder loosen the secondary sheave nut 2 Loosen clutch carrier nut Do not remove the clutch carrier nut at this stage While...

Page 131: ...using coarse sand paper Damage wear Replace Clutch shoe thickness 4 0 mm 0 1575 in Limit 2 0 mm 0 079 in Inspect clutch shoes After removing the clutch weight spring do not use them again Replace the...

Page 132: ...Cracks damage wear Replace the face movable drive face driver and V belt CHECKINGTHE PRIMARYROLLER WEIGHTS The following procedure applies to all of the roller weights 1 Check roller weight Cracks da...

Page 133: ...guide pin 2 2 2 2 1 1 1 1 a a 1 1 4 Measure spring driven face Out of specification Replace Spring driven face free length 87 9 mm 3 46 in Limit 82 6 mm 3 25 in 5 Measure outer clutch internal diamet...

Page 134: ...e slide face movable drive plate ramp Use thinner to clean up grease dirt on the pri mary sliding sheave cam side 2 Install roller weights boss drive face 2 2 2 2 2 2 3 3 1 3 3 4 4 5 5 1 1 1 1 1 ENG 4...

Page 135: ...Install guide pin 4 Lubricate guide pin groove o ring New with the recommended lubricant Recommended lubricant BEL RAY assembly lube 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 New ENG 4 41 BELT DRIVE TIP 5 Insta...

Page 136: ...clutch nut hex While holding the clutch carrier with the rotor holding tool tighten the clutch carrier nut with the locknut wrench 1 1 3 3 2 2 2 T R 55 Nm 5 5 m kg 39 8 ft Ib 3 Install outer clutch nu...

Page 137: ...pulley is at its widest position and in the face movable drive when the pulley is at its narrowest position and make sure the V belt is tight 1 3 2 1 3 2 ENG 4 43 BELT DRIVE TIP w w G e t 2 i t P a r...

Page 138: ...nd starter motor Primary sheave 5 6 7 8 9 10 11 ENG 4 44 STARTER CLUTCH AND STARTER MOTOR 3 2 11 1 6 7 5 4 8 10 9 LS B T R 12Nm 1 2m kg 8 7ft lb T R 12Nm 1 2m kg 8 7ft lb T R 12 Nm 1 2 m kg 8 7 ft Ib...

Page 139: ...r and hold the starter clutch b When turning the starter wheel gear clock wise the starter clutch and the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c...

Page 140: ...seal Dowel pin Nut Oil pump driven gear Dowel pin Oil pump body Outer rotor Inner rotor Oil pump shaft Oil pump housing cover Dowel pin Remove the parts in the order listed Refer to C D I MAGNETO For...

Page 141: ...the oil pump Inner rotor Outer rotor Oil pump housing Inner rotor to outer rotor tip clear ance Limit 0 15mm 0 006 in Outer rotor to oil pump housing clearance 0 14 0 21 mm 0 0055 0 0083in 0 04 0 12...

Page 142: ...olts make sure the oil pump turns smoothly 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s 2 1 New 2 1 T R 12 Nm 1 2 m kg 8 7 ft Ib ENG 4 48 OIL PUMP NOT...

Page 143: ...ving the crankshaft assembly Engine Cylinder head Cylinder piston V belt clutch drive driven pulley Starter clutch C D I magneto Oil pump Right crankcase Dowel pin Crankshaft Timing chain Left crankca...

Page 144: ...soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly ENG 4 50 CRANKCASE A...

Page 145: ...nnot be re moved if the timing chain is attached onto the crankshaft sprocket CHECKINGTHE TIMING CHAIN AND TIMING CHAIN GUIDES 1 Check timing chain Damage stiffness Replace the timing chain guide Repl...

Page 146: ...pin or connecting rod Big end side clearance 0 10 0 30 mm 0 0039 0 0118 in 3 Measure crankshaft width Out of specification Replace the crank shaft Crankshaft width 44 10 44 15 mm 1 7362 1 7382 in 4 Ch...

Page 147: ...lips with lithium soap based grease and each bearing with engine oil Put the timing chain in parallel into the crank case then use hands to place the crank shaft Ass y into the crank case Manually rot...

Page 148: ...all dowel pins timing chain 4 Install crankshaft crankcase right 5 Tighten crankcase Install the timing chain so it is not visible through the opening in the left crankcase crankcase gasket a a T R 12...

Page 149: ...mp 6 1 Reverse gear comp Final shaft comp 8 9 1 1 Sprocket drive Plate fixing Remove the parts in the order listed Drain Refer to BELT DRIVE Refer to V BELT DRIVE PULLEY AND DRIVEN PULLEY For installa...

Page 150: ...ION Disassembling the counter shaft comp Counter shaft comp 1 Shift push 1 Shaft fixed 1 Shift fixed spring 2 Washer 2 Circlip 2 Fork 1 Shaft gear shift 2 Cam shift 1 Bearing 1 Knock black 1 Insulator...

Page 151: ...the final shaft Final shaft runout limit 0 08 mm 0 0031 in 5 Check transmission gears Blue discoloration pitting wear Replace the defective gear s 6 Check transmission gear engagement each pinion gea...

Page 152: ...ts and remove the mission cover pull the shaft gear shifts out and remove the fork shift remove the reverse shaft comp and counter shaft comp remove the sprocket drive and plate fixing from the final...

Page 153: ...ing replace the sprocket drive and plate fixing also check that the outer races of the bear ings fit tightly in the left crankcase if necessary Install the mission cover and final shaft comp together...

Page 154: ...0mm it must be replaced Smear with loctite 5699 and screw with torque 250N m in assembly unscrew sensor F N R A A Service limits 30 mm 1 1811 in T R 25 Nm 2 5 m kg 18 1 ft Ib 3 5 4 3 4 8 9 9 11 11 10...

Page 155: ...tor whether the action is normal shift push shaft fixed fork shift fixed spring lengthas necessary data Voltage v kg cm Torque rpm loaded No load Replace the shift motor if necessary as follow 12 12 5...

Page 156: ...it if necessary REMOVING GEAR BOX TIP The gear ratio of forward gear composition is The gear ratio of reverse gear composition is 41 45 15 13 49 47 45 15 12 13 fork shift shift motor reverse gear comp...

Page 157: ...flow hose 1 2 Air vent hose 1 3 Fuel hose 1 7 Spring 1 8 Manual starter comp 1 5 Plate 1 4 Carburetor assembly 1 6 Plunger assay starter 1 For installation reverse the removal pro cedure 9 Wire starte...

Page 158: ...ew is turned out from the seated position to its set position Cover 1 1 Spring 1 Piston valve 1 Jet needle 1 1 1 Pilot screw Float chamber 1 Starter assy Throttle stop screw 1 Bracket wire assy New 1...

Page 159: ...t pin 1 Main jet 1 1 Needle jet holder 1 Needle jet 1 Pilot jet 1 Plug 1 1 Float For assembly reverse the disassembly procedure New 1 2 3 4 5 6 8 9 7 10 11 12 13 14 15 17 18 16 10 11 12 16 17 14 13 15...

Page 160: ...truction 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 float chamber body Dir...

Page 161: ...damage wear Replace Obstruction Clean Blow out the jets with compressed air piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston...

Page 162: ...uretor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install needle jet holder main jet pilot jet 10 Check choke valve movement Sticks Replace 11 Check starter plunger...

Page 163: ...le free play at the flange of the throttle grip 1 3 mm 0 04 0 12 in Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 3 Install accelerator pump assembly 4 Install piston valve jet needle p...

Page 164: ...he float chamber mating surface 5 0 6 0 mm 0 20 0 24 in 2 Adjust fuel level 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...

Page 165: ...cedure applies to both of the front wheels 1 Cotter pin 1 Refer to INSTALLING THE WHEEL HUBS 2 Axle nut 1 3 Front wheel 1 Refer to INSTALLING THE FRONT WHEELS 4 Front brake drum 1 For installation rev...

Page 166: ...re applies to both of the rear wheels 1 Cotter pin 1 Refer to INSTALLING THE WHEEL HUBS 2 Axle nut 1 3 Rear wheel 1 Refer to INSTALLING THE REAR WHEELS 4 Rear wheel hub 1 For installation reverse the...

Page 167: ...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 Rep...

Page 168: ...heel hub Cracks damage Replace 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...

Page 169: ...tion 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 45 Nm 4 5 m kg 32 5 ft Ib T R 45...

Page 170: ...T 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 7 Left front brake cable le...

Page 171: ...ing procedure applies 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 a...

Page 172: ...f either is found to be worn to the wear limit Brake lining thickness 3 0 mm 0 12 in Limit 1 5 mm 0 06 in CHECKING THE FRONT BRAKE DRUMS The following procedure applies to each brake 1 Measure brake d...

Page 173: ...all brake camshaft brake camshaft lever Install the brake camshaft so its punch mark is positioned as shown Align the punch mark in the brake camshaft with the mark on the brake camshaft lever Left si...

Page 174: ...ll front brake cable drum side brake shoes Check that the brake shoes are properly posi tioned 5 Check brake camshaft operation Unsmooth operation Repair 6 Adjust front brake Refer to ADJUSTING THE FR...

Page 175: ...he 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 6 11 CHAS REAR AXLE AND REAR AXLE HUB 5 LS 6 7 8 9 10...

Page 176: ...or installation reverse the removal procedure 9 Rear axle hub 1 1 1 6 12 CHAS REAR AXLE AND REAR AXLE HUB 5 Axle clip 1 5 LS 6 7 8 9 10 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...

Page 177: ...frame 4 Remove rear wheels wheel hubs nuts washers 5 Remove rear axle Never directly tap the axle end with a ham mer since this will result in damage to the axle thread and spline Attach a suitable so...

Page 178: ...edged corner of the driven sprocket is facing outward Rear axle runout limit 1 5 mm 0 06 in a a 6 14 CHAS REAR AXLE AND REAR AXLE HUB CHECKING THE BRAKE DISC 1 Check brake disc DOOLQJ GDPDJH Replace 2...

Page 179: ...ding the rear axle 2 2 Tighten nut Tighten the nut with rear axle nut wrench to specification while holding the rear axle 2 T R 60 Nm 6 0 m kg 43 4 ft Ib T R 170 Nm 17 0 m kg 123 ft Ib 6 15 CHAS REAR...

Page 180: ...es to both of the rear brake calipers Rear wheel Refer to FRONT AND REAR WHEELS 1 Brake pad 2 2 Brake pad spring 1 For installation reverse the removal procedure Refer to REPLACING THE REAR BRAKE PADS...

Page 181: ...led 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 brake pads wear limit Replace the brake pads a...

Page 182: ...d Install a new brake pad spring and new brake pads 3 Install brake caliper brake caliper mounting bolts 4 Check brake fluid level Refer to CHECKING THE REAR BRAKE FLUID LEVEL in chapter 3 Brake cali...

Page 183: ...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 proced...

Page 184: ...ter cylinder reservoir rear brake master cylinder reservoir dia phragm Cracks damage Replace ASSEMBLING THE REAR BRAKE MASTER CYLINDER All internal brake components should be cleaned and lubricated wi...

Page 185: ...while holding the brake hose as shown Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts throttle cable wire harness leads etc Correct if necessar...

Page 186: ...Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 4 Air bleed brake system...

Page 187: ...bolt 1 Parking brake cable 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper assembly 1 For installation reverse the removal procedure REAR BRAKE CALIPER Refer to INSTALLING THE REAR BRAK...

Page 188: ...ng brake arm 1 Bracket brake bracket 1 Parking brake case 1 Brake pad 2 Brake pad spring 1 T R 16 Nm 1 6 m kg 11 6 ft Ib Caliper bracket 1 Brake caliper piston 1 Dust seal 1 Caliper piston seal 1 Blee...

Page 189: ...air Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled REMOVING THE PARKING BRAKE CABLE 1 Loosen nut adjusting bolt 2 Disconnect parking brake cable from parking...

Page 190: ...sure that the brake pipe touches the projection on the brake caliper Proper brake hose routing is essential to insure safe machine operation Refer to CABLE ROUTING in chapter 2 2 Fill brake reservoir...

Page 191: ...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 fluid level Brake...

Page 192: ...assembly 1 Refer to INSTALLING THE FRONT BRAKE LEVER ASSEMBLY 5 Handlebar switch 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 6 Rear brake hose 1 7 Rear brake switch 1 8 Rear brake lever 1 9 P...

Page 193: ...switch 1 For installation reverse the removal pro cedure 6 29 CHAS STEERING SYSTEM x4 T R 14 Nm 1 4 m kg 10 1 ft Ib 1 2 3 9 10 11 LS 1 5 7 8 x2 x2 T R 14 Nm 1 4 m kg 10 1 ft Ib 4 LS 6 T R 14 Nm 1 4 m...

Page 194: ...ar 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 straight...

Page 195: ...the bolt on the front side T R 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 f...

Page 196: ...djust front brake Refer to ADJUSTING THE FRONT BRAKE in chapter 3 65 66 mm 2 56 2 60 in brake master cylinder Install the brake master cylinder please align the punch mark and the gap at brake master...

Page 197: ...bracket TIP 2 Adjust parking brake Refer to ADJUSTING THE PARKING BRAKE in chapter 3 a b Install the parking brake cable lever please align the punch mark and the gap at parking brake lever 4 5 3 6 3...

Page 198: ...stem bushing 2 2 BRG steering 1 3 Steering stem 1 4 Lower handlebar holder 1 Refer to REMOVING THE STEERING STEM and INSTALLING THE STEER ING STEM For installation reverse the removal pro cedure T R...

Page 199: ...nch CHECKING THE STEERING STEM 1 Check steering stem Bends Replace Do not attempt to straighten a bent stem this may dangerously weaken the stem 2 Check steering stem bushings Wear damage Replace 6 35...

Page 200: ...ng INSTALLING THE LOCK WASHER 1 Install lock washer bolts 2 Bend the lock washer tab along a flat side of the bolt 1 Install lower handlebar holder nuts INSTALLING THE LOWER HANDLEBAR HOLDER 1 2 T R 3...

Page 201: ...S 1 Tie rod Refer to INSTALLING THE TIE RODS 1 2 Suspension of arm 1 3 Steering knuckle Refer to REMOVING THE STEERING KNUCKLES For installation reverse the removal procedure Front brakes T R 35 Nm 3...

Page 202: ...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 procedu...

Page 203: ...utside 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 N...

Page 204: ...1 1 1 Front brakes Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS 2 For installation reverse the removal procedure 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...

Page 205: ...front arms Bends damage Replace 2 Check bushes Wear damage Replace CHECKING THE FRONT SHOCK ABSORBERS The following procedure applies to both of the front shock absorber assemblies 1 Check shock absor...

Page 206: ...Replace the front arm Turns rougKO 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 25 Nm 2 5 m kg 18 1...

Page 207: ...axle hub Refer to REAR AXLE AND REAR AXLE HUB 1 Guard 1 1 2 Guard 2 1 3 Drive chain case 2 1 4 Rear shock absorber 5 Pivot nut 1 6 Pivot shaft 1 7 Swingarm 1 8 Chain tensioner assy 1 1 T R 35 Nm 3 5 m...

Page 208: ...everse the removal procedure Refer to INSTALLING THE DRIVE SPROCKET 2 14 Drive chain guide 2 T R 35 Nm 3 5 m kg 25 3 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 75 Nm 7 5 m kg 54 2 ft Ib T R 18 Nm 1 8 m kg...

Page 209: ...so that it does not drop down Before removing 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...

Page 210: ...garm CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the axle on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Clean pivot...

Page 211: ...t two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 15 link drive chain section limit maximum 239 3 mm 9 42 in 3 Clean drive chain a Wipe the drive chain with...

Page 212: ...eplace 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 fl...

Page 213: ...CDI unit Starter relay Fuse Rectifier regulator Battery Starter motor C D I magneto Ignition coil Spark plug 5 1 2 3 4 F N R shift switch 6 7 8 9 10 11 3 7 11 1 2 4 6 8 9 10 5 12 12 w w G e t 2 i t P...

Page 214: ...ite W R White Red R B Red Black W L White Blue W B White Black OFF START ST ENG STOP SW ART SW 7 5A 12V 5AH Br R B R R R R L W R Y B R W R W R B B B B L W L W G Gr Gr Gr W C Y C Y B W L W L B Y B Y MO...

Page 215: ...age wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 1 5 4 C Y R B CHECK OFF ON W R Br Br ELEC 3 OFF ON E G STOP SW 2 OFF START Br B W W B L...

Page 216: ...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 are shown in the far left column and...

Page 217: ...Pu Gr OFF PUSH Br W B B R Br B R L Y C Y B B W W L L Pu Pu W W Y Y 17 18 19 R W B B R B CHECK OFF ON MAIN SW 1 Br W R Br R B Farword Neutral Reverse L Y W R L Y W B W B B W B W B R B R B R Br R B B B...

Page 218: ...YES NO The ignition system fails to operate no spark or intermittent spark 1 Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING TH...

Page 219: ...a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 3 Spark plug cap resistance Remove the spark plug cap from...

Page 220: ...robe spark plug lead Negative tester probe green terminal Measure the secondary coil resistance Secondary coil resistance 2 55 3 45 k at 20 C 68 F Is the ignition coil OK Replace the ignition coil 5 M...

Page 221: ...the C D I magneto coupler from the wire harness Connect the pocket tester 100 to the source coil terminal Positive tester probe black red terminal Negative tester probe black terminal Measure the sour...

Page 222: ...W 1 Br W R Br R B Farword Neutral Reverse L Y W R L Y W B W B B W B W B R B R B R Br R B B B R R Gr Br Y L Y B Gr Pu C Y W Y 2 R W R W Y R Y R B B W R W R R W R W R Y R Y R B Y R Br C Y R W B B W W B...

Page 223: ...starter motor can be operated only if Battery Main fuse Main switch Brake switch Starter motor Engine stop switch You pull in the brake lever the brake switch is ON 7 5 1 2 3 4 8 9 9 10 11 10 6 C D I...

Page 224: ...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 68 F Is the battery OK Clean the battery terminals Recharge or replace the ba...

Page 225: ...WITCHES Is the main switch OK Replace the main switch Y R G Y R R 6 Brake switch Check the brake switch for continuity Refer to CHECKING THE SWITCHES Is the rear brake switch OK Replace the brake swit...

Page 226: ...installation reverse the removal pro cedure Disassembling the starter motor Remove the parts in the order listed Yoke 1 Refer to ASSEMBLING THE STARTER MOTOR Armature coil 1 Brush 1 Bracket 1 For asse...

Page 227: ...nsure proper operation of the commutator 4 Measure armature assembly resistances commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances w...

Page 228: ...gear teeth Damage wear Replace the gear 8 Check bearing oil seal O rings Damage wear Replace the defective part s Brush length wear limit 3 5 mm 0 14 in Brush spring force 1 0 3 0 N 102 306 gf 3 60 1...

Page 229: ...B B R B CHECK OFF ON MAIN SW 1 Br W R Br R B Farword Neutral Reverse L Y L Y W B W B B W B W B R B R W R B R Br R B B B R R Gr Y L Y r B B Gr Pu C Y W Y 2 W R W Y R Y R B B W R W R R W R W R Y R Y R...

Page 230: ...e battery is not being charged 1 Main fuse Check the main fuse for continuity Refer to CHECKING THE FUSE in chap ter 3 Is the main fuse OK Replace the fuse 2 Battery Check the condition of the battery...

Page 231: ...R Br R B Farword Neutral Reverse L Y L Y W B W B B W B W B R W R B R B R Br R B B B R R Gr Br Y B Gr Pu C Y W Y 2 W R W Y R Y R B B W R W R R W R W R Y R Y R B Y R C Y R W B B W W B L W Gr Gr L W G L...

Page 232: ...ERY 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...

Page 233: ...h YES NO 3 Voltage Connect the pocket tester DC 20 V to the indicator light coupler wire harness side as shown Positive tester probe yellow Negative tester probe black Set the main switch to ON Set th...

Page 234: ...cator 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 socket OK Replace the r...

Page 235: ...ON Set the main switch to ON 3 Back up horn Disconnect the white connector at the back up terminal Connect a jumper lead to the back up horn terminal and ground the jumper lead Set the shift switch to...

Page 236: ...gged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between terminals broken Improper heat range Faulty spark plug cap Ignition coil Broken or shorted primary s...

Page 237: ...se 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 pl...

Page 238: ...ark plug gap Improper 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...

Page 239: ...Steering Incorrect toe in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles Tires Uneven tire pressures on both sides Incor...

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