Linhai M565Li T3 EFI Service Manual Download

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CHAPTER 3 ENGINE

M565Li T3 EFI SERVICE MANUAL 20.0

CHAPTER 3 ENGINE PAGE. 3-

3.3 Engine Removal, Inspection & Installation

3.3.1

Engine Removal/Installation Orders and the Relative Page Numbers

Item

Description

Disassemb
ly

Inspection/M

aintenance

Assem
bly

Remark
s

Engine

Front Side

Spark Plug

3-31

3-20

3-88

Cylinder Head Cover

3-31

3-41

3-88

Timing Chain Tensioner

3-31

3-41

3-87

Start decompression

COMP

3-31

3-41

3-87

Timing driven sprocket

3-32

3-41

3-87

Camshaft

3-32

3-42

3-86

Cylinder Head

3-32

3-86

Rocker arm

3-32

3-43

3-86

Rocker arm shaft

3-43

3-86

Valve Spring

3-44

3-45

3-51

Valve

3-45

3-46

3-50

Valve Guide

3-47

Guide chain plate

3-32

3-52

3-84

Cylinder

3-32

3-52

3-84

Piston

3-33

3-53

3-84

Engine

Right Side

CVT Cover

3-33

3-55

3-88

Primary
Sheave/Secondary

Sheave/Drive Belt

3-33

3-56

3-83

CVT case

3-34

3-62

3-83

Chain holder, Tension
plate

3-34

3-62

3-83

Summary of Contents for M565Li T3 EFI

Page 1: ...ts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service Gene...

Page 2: ...ATV SERVICE MANUAL EUROPE 20 0 PN F010106A27 M565Li T3 EFI 20 0 F010106A27...

Page 3: ...ld use discretion as to how much disassembly is needed to correct any given condition All references to left and right side of the vehicle are from the operator s perspective when seated in a normal r...

Page 4: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 500 Engine CHAPTER4 Chassis CHAPTER5 Final Drive CHAPTER6 Brakes CHAPTER7 Electrical...

Page 5: ...contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of ATV Never s...

Page 6: ...INFORMATION WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts...

Page 7: ...ents Use recommended oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals an...

Page 8: ...ether 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness Use the tester on the conn...

Page 9: ...NVERSION TABLE METRIC TO IMP Known Multiplier Result Torque 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 Distance km h km m m cm mm 0 6214 0...

Page 10: ...CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER...

Page 11: ...1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 6 M565Li 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment...

Page 12: ...CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 7 M565Li...

Page 13: ...CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 1 GENERAL PAGE 1 8 NOTES...

Page 14: ...ersions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 FUEL SY...

Page 15: ...important components are explained in the following chart on the following pages Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16km h 10...

Page 16: ...r Box Sediment Tube Daily D Headlamp Inspection Daily C apply dielectric grease to connector when replaced Tail lamp inspection Daily C apply dielectric grease to socket when replaced Air Filter Main...

Page 17: ...T if necessary Rear Axle and Bearings 50 hrs 6 months I L Front Suspension 50 hrs 6 months I L T if necessary Rear Suspension 50 hrs 6 months I T if necessary Spark Plug 100 hrs 12 months I R if neces...

Page 18: ...change every two years or 200 hours 3 Transmission Oil SEA 80W 90GL5 Add to proper level on dipstick Change annually or at 100 hours 4 Rear Gear case oil SEA 80W 90GL5 Add to proper level Change annu...

Page 19: ...DX300 Grease Locate fittings and grease Every 3 months or 50 hours 18 Front prop shaft yoke SDX300 Grease Locate fittings and grease Every 3 months or 50 hours 19 Inner and outer CV Joints SDX300 Grea...

Page 20: ...on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous a...

Page 21: ...fuel to engine at system pressure Fuel Pump Module is mounted to fuel tank at bottom and supplies fuel to engine through hoses Fuel Pump module consists of Fuel Pump to generate the fuel flow and pre...

Page 22: ...lines please follow the Fuel Pressure Relief Procedure described in this section Small amount of fuel may drip after the fuel lines are disconnected In order to reduce the risk of personal injury cove...

Page 23: ...torque and miss sequence can cause unequal compression of gasket and leakage Install the fuel tank to vehicle Connect for fuel hoses with suitable hose clamps Connect fuel module coupler Follow Fuel...

Page 24: ...ATV Measure from string to rim at front and rear of rim Rear rim measurement A should be 1 16 to 1 8 1 5 to 3 mm more than front rim measurement B NOTE The steering post arm frog can be used as an ind...

Page 25: ...d level in the master cylinder reservoir to the indicated level on reservoir Use DOT 3 brake fluid NOTE Use new brake fluid or brake fluid from a sealed container to avoid contamination to system Chec...

Page 26: ...nner following the procedure outlined in the Brake chapter MECHANICS PARKING BRAKE FOR EUROPE ATV CONTROLS Check controls for proper operation positioning and adjustment Note burnishing procedure is a...

Page 27: ...ing of the parking position 7 Make sure the rear wheels turns freely without dragging and parking brake works properly CAUTION Don t over tighten the adjustor Free play of the lever 20mm 8 Field test...

Page 28: ...e jam nuts securely against the adjusters If the right hand adjustment is inadequate to attain the proper brake free play gap make adjustment at the middle of the cables adjuster jam nuts NOTE Apply t...

Page 29: ...ion Damping should be smooth throughout the range of travel Check all front suspension components for wear or damage Inspect from strut cartridges for leakage Shock spring preload can not be adjusted...

Page 30: ...TALLATION 1 With the transmission in gear and the parking Brake locked place the wheel in the correct Position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the...

Page 31: ...d replace in pairs especially in SDX300 model The use of non standard size or type tires may affect ATV handling and cause machine damage especially in SDX300 model TIRE TREAD DEPTH Always replace tir...

Page 32: ...erson 8 11 LT SwingArmPivotLeft 14 19 RefertoSWING ARM ASSEMBLY INSTALLATION 4 2SWING ARM CHAPTER4A CHASSIS SwingArmPivotRight 120 165 ThreadedPivotNut forswingarm 120 165 NutM14X1 5AttachingFrontAbso...

Page 33: ...CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20 0 CHAPTER 2 MAINTENANCE PAGE 2 20 NOTES...

Page 34: ...CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20 0 CHAPTER 2 MAINTENANCE PAGE 2 21...

Page 35: ...20 0 CHAPTER 3 ENGINE 3 1 Service information 1 17 3 2 Inspection and adjustment 18 28 3 3 Engine Removal Inspection and Installation 29 89 3 4 Cooling and lubrication system 90 100 3 5 Fuel injectio...

Page 36: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 3 1 Service information...

Page 37: ...ons 3 2 3 1 2 Fuel oil and engine coolant recommendation 3 3 3 1 3 Engine running in 3 3 3 1 4 Engine shape location of engine identification number 3 4 3 1 5 Engine general information 3 5 3 1 6 Main...

Page 38: ...ich emphasize the special meaning of DANGER WARNING and CAUTION Always pay attention to these notifications when servicing the engine DANGER indicates a high risk which should be alert to WARNING indi...

Page 39: ...ot confident to complete the whole repair please refer to the senior mechanic for support 3 1 1 General precautions When two or more persons working together pay attention to the safety of each other...

Page 40: ...unlawfully dispose of motor oil engine coolant or parts no longer used Warning If parts replacement is necessary replace the parts with LINHAI genuine parts or their equivalent When removing parts tha...

Page 41: ...ed coolant type 35 anti frozen antisepsis high boil coolant 3 1 3 Engine running in As the engine has a lot of relative motions parts such as pistons piston rings cylinder blocks and inter meshing gea...

Page 42: ...s during break in period After break in do not forget to check and maintain the engine before normal use Avoid acceleration heavily T he accelerator should be changed smoothly avoid changing heavily f...

Page 43: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 1 6 3 1 4 ENGINE SHAPE LOCATION OF ENGINE IDENTIFICATION NUMBER EIN Location of Engine identification number...

Page 44: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 1 7 Engine left side Engine Right side 3 1 5 ENGINE GENERAL INFORMATION...

Page 45: ...GK 0 8mm 0 9mm Magneto type Power Permanent Magnet AC Type 8 Combus tion system Combustion chamber Triangular combustion chamber Throttle body type D46 Ai r filter type Sponge Paper filter Gasoline RQ...

Page 46: ...Output type Front Rear shaft drive 16 Rotation of engine output When forward clockwise rear view Valves Cylinder Head mm Item Standard value Service limit Remarks Dia Of valve neck Intake valve 33 Ex...

Page 47: ...Gap of piston ring Height of piston ring Height of piston ring Width of piston ring 0 030 0 050 90 95mm 90 979 mm down along to the piston 90 91 015 0 03 1st ring R round 11 7 2nd ring R round 12 1st...

Page 48: ...er of piston pin hole Diameter of piston pin Inner diameter of small end of connecting rod Gap of piston piston pin Small end hole of connecting rod gap of piston pin Side gap of big end of connecting...

Page 49: ...ecting rod 22 95 23 00 Crankshaft beat 0 0 025 0 055 Connecting rod bearing journal 36 992 36 996 36 068 Connecting rod bearing bore 37 006 37 028 37 06 Gap of connecting rod bearing 0 01 0 032 0 065...

Page 50: ...P Standards 2600mL without oil filter replacement 2700mL with oil filter replacement 3000mL Special for four stroke motorcycle SAE 15W 40 if it s not available select alternative according to the foll...

Page 51: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 14...

Page 52: ...el when fully opening When 85 5mm Radiator cap opening pressure 110 kPa 15kPa 1 1kgf cm 2 Relations between water temp and resistant of water temp sensor Water temperature Resistant of B terminal Resi...

Page 53: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 16 Coolant type 35 anti freezing anti corrosive and high boiling point...

Page 54: ...214 Hole dia of driven pulley collar 38 10 38 14 38 30 Clearance between gearshift fork and engagement groove 0 10 0 35 0 45 Thickness of gearshift fork 5 8 5 9 5 7 Groove width of high low sliding 6...

Page 55: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 18 Throttle Body Part NO 1BK 13520 00 Fuel Injector Part NO 1BK 13510 00 Idle Speed 1500 r min 100r min...

Page 56: ...coil Primary 0 74 0 78 Secondly 10 1 11 1k Resistance of magneto coil 0 5 1 5 Resistance of speed sensor trigger 900 1000 Voltage without load cold engine 50V AC 5000r min Max output power of magneto...

Page 57: ...locker glue Primary screen cover bolt 3 M6 20 8 12 Thread locker glue Oil pressure switch 1 M10 1 12 15 Thread locker glue Screw R21 8 CVT oil passage 1 R21 8 18 22 Apply seal gum Bolt CVT air intake...

Page 58: ...sprocket 2 M6 10 8 12 Bolt decompressor starter 1 M8 32 28 32 Bolt cylinder 4 M10 40 45 Bolt cylinder installation 2 M6 132 8 12 Plug spark 1 M12 1 25 18 20 Sensor water TEMP 1 M12 1 5 16 20 Stud bol...

Page 59: ...1 M8 22 28 Thread locker glue Bolt magneto stator 3 M6 30 8 12 Thread locker glue Bolt COMP overriding clutch 6 M8 20 28 32 Thread locker glue Bolt drive pulley CVT drive pulley 1 M12 1 5 LH 55 60 Scr...

Page 60: ...ut Driven Bevel Gear 1 M16 1 5 140 160 Nut Front output shaft 1 M14 1 5 95 100 Bolt gear orientation 1 M14 1 5 38 42 Thread locker glue Bolt oil pump cover 3 M5 16 6 8 Thread locker glue Bolt oil guar...

Page 61: ...g the carburetor fuel level 11 Thickness Gauge For measuring the clearance 12 Spring Balance For measuring the spring tension 13 Tachometer For measuring engine speed 14 Oil Pressure Gauge For measuri...

Page 62: ...val of Front output shaft Bearing retainer 3 Bearing limit nut nut wrench LH188MR FZ 25 For removing Bearing limit nut 4 Drive pulley puller 1BX 17653 00 Removal of drive pulley 5 Driven pulley expand...

Page 63: ...ng parts sliding parts Inner crankcase rotating parts sliding parts Cylinder head rotating parts capacity 2600ml for changing oil 2700ml for replacing filter 3000ml Molybdenum lubrication oil piston p...

Page 64: ...e 3 18 3 2 2 Procedure of Maintenance Adjustment 3 19 3 2 3 Valve clearance 3 19 3 2 4 Engine idle speed 3 20 3 2 5 Spark plug 3 20 3 2 6 Air filter 3 21 3 2 7 Driving Belt CVT 3 22 3 2 8 Inspection o...

Page 65: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0...

Page 66: ...R Replace 10 hours or 300km 20 hours or 750km Every 50 hours or 1500km Every 100 hours or 3000km or 1 year Every 200 hours or 6000km or 2years Remark Engine Facilitating Conditions abnormal sound I I...

Page 67: ...Air Filter C R CVT system CVT Belt I R Replace every 2000km Primary Pulley Driven pulley I C Engine oil filter R R Throttle Body I I L Cooling System Water volume I I Water pipe I I Radiator valve ope...

Page 68: ...od indicated above and adjust the valve clearance to specification if necessary Remove CVT case cover 1 Remove RPM sensor 2 of left crankcase cover Remove cylinder head cover 3 Turn the crankshaft unt...

Page 69: ...GINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 21 Attention The valve clearance must be adjusted when the engine is cold Adjust the valve clearance when the piston is at the Top Dead C...

Page 70: ...insert a feeler gauge between the valve stem end and valve adjusting bolt 0 06mm thickness for intake valve 0 08mm thickness for exhaust valve tighten valve adjust bolt make sure it slightly contacts...

Page 71: ...LUG GAP Measure the spark plug gap with a feeler gauge Out of specification Adjust Spark plug gap 0 8mm 0 9mm Spark plug installation Tightening Torque 18 20N m Caution To avoid damaging the cylinder...

Page 72: ...d clean the air filter as following Remove fixing clamp 2 and top cover 1 Loosen screw 3 remove filter element 4 separate support 5 and sponge 6 Fill a wash pan of a proper size with a non flammable c...

Page 73: ...ke drive disk Loosen driven pulley nut 3 Remove driven pulley together with drive belt Remove drive belt 4 from driven wheel Warning Never use with gasoline or low flash point solvents to clean the fi...

Page 74: ...isout of service limit replace drive belt with a new one Service Limit 33 5mm Tool Vernier Caliper Installation Reverse the removal procedure for installation Pay attention to the following Insert dr...

Page 75: ...Expander turn driving pulley until the drive belt is properly seated Install CVT cover 3 2 8 Inspection of Lubrication System Check Engine Oil Level Keep the engine in a plan position Remove oil dip...

Page 76: ...ll more oil until the sufficient oil is obtained Engine oil SAE15W 40 SG or higher Replace Engine Oil Remove oil dip rod 1 drain bolt 2 and washer 3 Drain out the engine oil while the engine is still...

Page 77: ...placed replace engine oil Install oil dip rod start the engine and allow it to run for several minutes at idling speed Turn off the engine and wait for about 3 minutes and then check the oil level on...

Page 78: ...NEW o ring on oil filter cover Apply engine oil on o ring and the end of filter Install the element into oil filter bore Install the element into oil filter bore bolt Torque screws to 8 12N m 3 2 9 I...

Page 79: ...radiator with fresh water if necessary Connect water hose 4 and tighten clamp 3 securely Fill the fresh specified coolant into the radiator Loosen bleed bolt 5 on water pump when coolant flow from bl...

Page 80: ...d check coolant Fill the specified coolant until the level is between the upper and lower lines on the reservoir tank Fill coolant into the reservoir tank till between upper and lower limit Install re...

Page 81: ...e before testing Make sure battery is fully charged Remove spark plug 1 Install cylinder pressure gauge 2 in spark plug hole Keep throttle full open Press start button crank the engine a few seconds R...

Page 82: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 34 Tools Cylinder Pressure Gauge...

Page 83: ...T3 EFI SERVICE MANUAL 20 0 3 3 Engine Removal Inspection Installation 3 3 1 Removal Installation Orders and the Page Numbers table 3 29 3 3 2 Engine Removal 3 31 3 3 3 Engine Inspection 3 41 3 3 4 En...

Page 84: ...3 88 Timing Chain Tensioner 3 31 3 41 3 87 Start decompression COMP 3 31 3 41 3 87 Timing driven sprocket 3 32 3 41 3 87 Camshaft 3 32 3 42 3 86 Cylinder Head 3 32 3 86 Rocker arm 3 32 3 43 3 86 Rocke...

Page 85: ...36 3 82 Oil filter 3 36 3 63 3 82 Left Crankcase Cover Magneto Stator 3 36 3 63 3 81 Magneto Rotor 3 36 3 63 3 81 Starting Driven Gear 3 37 3 64 3 80 Starting Dual Gear 3 37 3 65 3 80 Oil pump drive g...

Page 86: ...Gear Components 3 39 3 71 3 79 Transmission Main Shaft 3 39 3 72 3 78 Shift Drum Shift Fork COMP 3 39 3 73 3 78 Drive countershaft 3 39 3 73 3 78 Crankshaft 3 40 3 76 3 79 Balance Shaft 3 40 3 77 3 79...

Page 87: ...assembly tools Drain up engine oil see5 2 8 Drain up coolant see5 2 9 Engine Front Side Spark Plug Remove spark plug with special wrench see5 2 5 Cylinder Head Cover Remove 4 bolts of cylinder head co...

Page 88: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 33 Remove tensioner and gasket...

Page 89: ...P 2 Timing driven sprocket Loosen two bolts 1 of timing driven sprocket Remove timing driven sprocket Camshaft rocker arm Loosen bolt 1 Remove camshaft holder Remove rocker arm shaft Remove rocker arm...

Page 90: ...NE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 35 diagonally Remove cylinder head Remove guide chain plate Remove dowel pin and cylinder head gasket Note Take care not to drop dowel pin...

Page 91: ...ove piston pin circlip 1 and discard it Remove piston pin circlip 1 from piston pin hole connecting rod hole Remove piston 2 from connecting rod Engine Right Side CVT Cover Remove CVT cover see 5 2 7...

Page 92: ...HAPTER 3 ENGINE PAGE 3 37 Drive pulley driven pulley Drive Belt Remove drive pulley with special tools Remove drive pulley driven pulley drive belt Tool Drive pulley puller 3 1BX 17653 00 CVT Case Rem...

Page 93: ...move CVT case Remove dowel pin Remove paper gasket and discard it Chain holder Tension plate Remove bolt 1 of tension plate Remove tension plate 2 Remove bolt 4 of chain holder Remove chain holder 3 T...

Page 94: ...UAL 20 0 CHAPTER 3 ENGINE PAGE 3 39 Remove starting motor Sector Gear Remove 4 bolts of sector gear housing cover Remove sector gear housing cover 1 Remove dowel pin and gasket Remove drive sector gea...

Page 95: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 40 Water Pump Screw out bolt of water pump Remove water pump Side Cover Remove 4 bolts remove Side Cover...

Page 96: ...M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 41 Cap Remove 3 bolts remove cap Oil Filter Screw out 3 bolts of filter cover Remove filter cover O ring Remove oil filter Left Crankcase Cove...

Page 97: ...ankcase cover Remove dowel pin and gasket Magneto Rotor Remove nut of Magneto Rotor Install special tool to rotor thread Remove rotor and woodruff key Tool Rotor assy puller 1BE 85610 00 Starting Driv...

Page 98: ...FI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 43 Oil pump drive gear Oil pump dual gear Remove oil guard bolt Remove oil guard 1 Remove two Circlip 2 by circlip plier Remove oil pump drive gear 3 oil...

Page 99: ...SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 44 Remove needle bearing 5 Remove pin shaft 6 gasket Engine Center Gear position bolt Remove gear position bolt 1 Remove spring and steel ball Right Crankca...

Page 100: ...crankcase carefully with rubber hammer knocking the case Front Output Shaft Driven Bevel Gear Remove nut of Real output coupler 1 Remove bevel gear cover bolt Remove driven bevel gear 2 Caution Do not...

Page 101: ...APTER 3 ENGINE PAGE 3 46 Remove nut 1 gasket 2 front output coupler 3 oil seal 4 front output shaft bearing ring 5 LH Remove Front Output Shaft 6 Drive Bevel Gear Screw out driven bevel gear bearing s...

Page 102: ...565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 47 Transmission Main Shaft Remove transmission main shaft 7 Shift Drum Shift Fork Drive counter shaft Remove shift drum 8 shift fork 9 and driv...

Page 103: ...3 48 Crankshaft Remove crankshaft from left crankcase Balance Shaft Remove balancer shaft from left crank case Oil bump Screw out oil pump bolt Remove oil bump 1 Note Shift drum shift fork and drive...

Page 104: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 49 Filter Net Screw out the bolt Remove filter cap 2 Remove filter net...

Page 105: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 50 3 3 3 Engine Inspection Cylinder Head Cover...

Page 106: ...heck tensioner for any damage or poor Function Damage poor function Replace Performance stability inspectionmethods Insert screw driver 3 into the slotted end of adjusting screw turn it clockwise to l...

Page 107: ...ding camshaft timing chain wheel and timing chain Camshaft Inspection Check any scratch abrasion crack or other damage on each camshaft and journal Check journal dia and height of camshaft by micromet...

Page 108: ...012mm 22 025 mm Maintenance limit 22 040 mm If parameters are beyond standards change the parts Cylinder head cover Remove rocker arm Remove rocker arm shaft 1 Remove rocker arm intake and exhaust Inc...

Page 109: ...ement wear and excessive radial play Replace rocker arm assembly if necessary Check rocker arm bore diameter If diameter is out of specification change rocker arm assembly Check adjustment screws for...

Page 110: ...Shaft Diameter New 11 973mm 11 984mm Service Limit 11 960mm Any area worn excessively will require parts replacement Valve Spring Removal Use valve spring compressor clamp to compress valve spring Va...

Page 111: ...R 3 ENGINE PAGE 3 45 Align valve spring compressor clamp with the center of Valve Remove valve lock clips Withdraw valve springcompressor valve spring retainer and valve spring 1 Valve Spring Compress...

Page 112: ...Check valve spring for visible damages If any replace valve spring Check valve spring for free length and straightness Valve Spring Free Length Normal New 40 mm Service Limit 38 2 mm Replace valves s...

Page 113: ...1 Plier Remove valve stem seal with Snap on plier and discard it 2 Valve Stem Seal Valve Inspection Valve Stem Seal Always install new seals whenever valves are removed Valve Inspect valve surface ch...

Page 114: ...es using a micrometer and a small bore gauge Change valve if valve stem is out of specification or has other damages such as wear or friction surface Valve Stem Diameter Exhaust Valve New 4 95mm 4 965...

Page 115: ...e to seat valves properly Apply some lapping compound to valve face and work valve on its seat with a lapping tool see Valve Guide Procedure below Measure valve face contact width NOTE The location of...

Page 116: ...Valve Guide Removal Use valve guide remover and a hammer drive the valve guide out of cylinder head Valve Guide Remover Valve Guide Inspection Always replace valve stem seals when ever valve guides a...

Page 117: ...nscrew the set bolt and remove the injector seat 1 Injector Seat Inspection Inspect Injector Seat for cracks or other damage Check the seal for wear or excessive using Replace it if necessary Water Te...

Page 118: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 51 Sensor Water Temperature Sensor Inspection Check 5 4 6 Thermostat Inspection Check 3 4 7...

Page 119: ...edure Pay attention to the following details Use valve guide installer to install valve guide Valve Guide Installer Push valve guide in the cold cylinder head as per following illustration Valve Guide...

Page 120: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 53 1 Thrust Surface of Cylinder Head 2 Valve Guide A Measurement from Thrust Surface to Valve Guide Top...

Page 121: ...on its seat with a lap ping tool NOTE Ensure to seat valves properly Apply marking paste to ease checking contact pattern Repeat procedure until valve seat valve face fits together Valve Installation...

Page 122: ...se the removal procedure Check 5 45 Pay attention to the following details Colored area of the valve spring mustbe placed on top To ease installation of cotters apply oil or grease on them so that the...

Page 123: ...red edge first and use following procedure 1 Insert a rocker arm pin through rocker arm pin bore 2 Install a thrust washer then proper rocker arm exhaust side or intake side 3 Push in rocker arm shaft...

Page 124: ...2 Thermostat cover 3 and two bolts 4 Injector Seat Installation For installation reverse the removal procedure Check 3 48 Upper Guide Chain Inspection Inspect Upper guide chain check for abnormal wea...

Page 125: ...mit replace with a new cylinder body Cylinder Body Distortion Service Limit 0 05mm Tool Thickness Gauge straight edge Cylinder Body Inner Diameter Inspection Check the scoring or other damages in the...

Page 126: ...measure the pistion on the 8mm direction between pistion pin by micrometer Replace pistion if out of service limit Pistion Parameter New 90 950mm 90 970 mm Service Limit 90 85 mm Pistion Ring Groove C...

Page 127: ...m Tool Straight edge Micrometer 0 25mm Pistion ring free gap and pistion ring end gap Using a feeler gauge measure each ring free gap place the ring in the cylinder To measure the ring end gap If the...

Page 128: ...ameter of Pistion pin by micrometer If out of service limit replace Pistion and Pistion pin Pistion Pin Bore service limit 22 02mm To measure the outer diameter of Pistion Pin in three difference posi...

Page 129: ...58 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Inspect seal ring of CVT Cover for ageing damage Replace a new one if necessary...

Page 130: ...59 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Drive Pulley Driven Pulley Drive Belt...

Page 131: ...1 Drive Pulley Fixed Sheave 10 Driven Pulley Fixed Sheave 2 Drive Belt 11 Driven Pulley Sliding Sheave 3 Ajusting Washer 12 Spring holder 4 Spring Drive Pulley 13 Locating pin 5 Drive Pulley Sliding S...

Page 132: ...ve pulley fixed And Sliding Sheave Remove the Cam 1 and Centrifugal Weight 2 Centrifugal Weight Inspection Inspect Centrifugal Weight and Sliding surface for wear or damage Replace a set of centrifuga...

Page 133: ...lace it if abnormal Drive Pulley Installation To install it as contrary process of removal Driven Pulley Disassembly As the illustration shows place driven pulley on the special tool base 1 Cam and sl...

Page 134: ...essor 1BA 17730 00 FZ 1 1 Driven Pulley Spring Compressor 2 Driven Pulley Turn special tool handle to compress the cam and spring Using a circlip remover a plier remove circlip Note Use special tool t...

Page 135: ...64 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 3 Circlip Remover...

Page 136: ...spring tension and remove the special tool Remove cam Remove guide pin Remove spring and sliding sheave of driven pulley 1 Cam 2 Guide Pin 3 Spring 4 Sliding Sheave of Driven Pulley Driven Pulley Ins...

Page 137: ...amage Replace if necessary 1 Drive Face of Fixed Sheave NOTE Clean fixed sheave of driven pulley before inspection NOTE Driven pulley assembly is precisely matched If only fixed sheave or sliding shea...

Page 138: ...e Inspect the 3 sliders on driven pulley for wear and other damages If the worn thickness is over the measurement illustrated in the following figure replace all 4 sliders at the same time 1 Slider 2...

Page 139: ...68 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 A 1 5mm Cam Inspection Check spring cam sliding face for wear and other damages Replace if necessary...

Page 140: ...gth If it is shorter than limit length replace it Spring free limit length A 214 0mm Driven Pulley Assembly Reverse the disassembly procedure for 1 Spring driven pulley assembly Drive Belt To inspect...

Page 141: ...ring Sleeve 1 and Oil seal 2 Replace it if necessary Lower Timing Chain Guide Inspection To inspect the lower timing chain guide for damage or ageing Replace it if necessary Tensioner Plate Inspection...

Page 142: ...damage Gearshift Sector Gear Inspection Gearshift Drive Sector Gear To inspect drive sector gear for cracks or other defects Replace it if necessary To measure Gear shaft diameter A for cracks or othe...

Page 143: ...r base on requirements of Maintenance period Crankcase LH Cover To inspect magneto coil 2 for damage or Short circuit Replace it if abnormal Smear Thread locking Adhesives on bolts and fasten base on...

Page 144: ...hten the bolt after smear thread locking adhesives by Wrench as standard torque Bolt Torque 30N m Accessory Thread locking adhesives Install driven gear Driven gear will be locked if turn it as the di...

Page 145: ...ANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Install the driven gear bearing by special tools Tool Bearing installation removal tool Dual Gear To inspect the dual gear surface for scratch or bump against Replac...

Page 146: ...MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 To inspect the gear surface for scratch bump against or plastic ageing Replace it if abnormal Oil Pump Dual Gear To inspect the gear surface for scratch bump agains...

Page 147: ...76 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3...

Page 148: ...15 O ring seal 23 O ring seal 7 Bearing 16 Oil strainer cover 24 Gearshift sensor 8 Copper spacer 17 Copper spacer 25 Spacer 9 Bolt 18 Drain Bolt 26 Oil pressure sensor Crankcase inspection Check cra...

Page 149: ...s to crankcase halves may occur if this procedure is not performed correctly NOTE Always use a press for removal of plain bearing Remove plain bearing with the proper plain bearing remove installer Ca...

Page 150: ...of the crankcase Ball Bearing and oil sealing Inspection To inspect the ball bearing for oil clearance sound or turning stationarity CAUTION Unless otherwise instructed never use hammer to install ba...

Page 151: ...ance by multimeter Replace it if abnormal To remove and clean the drain bolt 18 and Oil strainer 14 To install bearing oil seal by special tools Bearing with lubricating oil Oil seal lips with lubrica...

Page 152: ...r Replace it if necessary To inspect Bearing 8 for turning Replace it if abnormal To adjust Adjusting Spacer 5 if replace any one of Crankcase Right Drive Bevel Gear 4 Drive Bevel Gear cover 1 Detail...

Page 153: ...ut Torque 78 82N m Front Output Shaft Nut Torque 95 100N m Driven Bevel Gear To remove Nut 4 Gasket 19 Coupler 16 and Oil seal 17 To proper protect the thread of Driven Bevel gear by protector fixed b...

Page 154: ...seal 17 and O ring seal before install Bearing Stop Nut Torque 100 120N m Driven Bevel Gear Nut Torque 140 160N m Bevel Gear Spacer Adjusting Method To adjust spacer and if replace any one of Crankca...

Page 155: ...vel Gear shaft To adjust spacer thickness if out of ser vice limit Remeasure the backlash of Bevel Gear till to accord with service limit Bevel Gear backlash service limit 0 1mm 0 2mm Adjustment Metho...

Page 156: ...and Driven Bevel Gear Running the Driven Bevel Gear from front and back direction To inspect dyestuff of Bevel Gears after removed Drive and Driven Bevel Gear If it is proper gear contact surface mov...

Page 157: ...ard spot damage excessive wear Replace it if necessary Drive layshaft Combination To remove the layshaft as picture To inspect gear surface for hard spot damage excessive wear To inspect bearing and b...

Page 158: ...fting fork clearance as pic ture indication Check fit clearance by feeler gauge Replace shifting fork or gears or together replacement if clearance out of service limit Shifting fork standard gap 0 10...

Page 159: ...ard values 6 05mm 6 15mm To measure the thickness of shifting fork by vernier caliper Standard values 5 80mm 5 90mm To inspect shifting fork and for damage curve Replace it if with defects Install shi...

Page 160: ...NE PAGE 3 To roll the shift fork rod on the slab Re place it if curve To inspect the shift fork spring for broken damage Replace it if any defects To inspect Shift Drum Cam for crack wear Replace it i...

Page 161: ...Shift fork shaft 2 Parking Arm 3 Retainer ring 4 shift fork 5 Thin shift fork spring 6 Thick shift fork spring 7 Spring seat Note With right installation process to install the new retainer To install...

Page 162: ...ide Crankshaft Axial Play New 0 050mm 0 450mm Service Limit 0 6mm If play is out of specification replace crankcase and or crankshaft Connecting Rod Big End Axial Play Using a feeler gauge measure the...

Page 163: ...shaft and balance shaft gear Replace it if damage To inspect balance shaft gears for crack scratch or others Replace it if damage Oil Pump Inspection To inspect all parts of Oil Pump Replace it if an...

Page 164: ...l parts before install Without any cracks for all parts before Replace oil pump if out of service limit Bottom Clearance standard value 0 1mm 0 15mm Limit value 0 2mm Backlash Standard value 0 08mm 0...

Page 165: ...ft Driven Bevel Gear and fasten bolt as standard torque Detail as picture indication Front output shaft nut 1 standard torque 95 100N m Driven Bevel Gear Seat erection bolt 8 standard torque 40N m Shi...

Page 166: ...PTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 1 Nut 5 Adjusting Spacer 2 Land 6 Driven Bevel Gear 3 front output shaft 7 Coupler 4 Crankcase right 8 Bolt 9 Washer 10 Nut 11 W...

Page 167: ...cture indication install into crankshaft Keep a strip of straight line for marks on crankshaft oil bore of balance shaft neck Running the crankshaft and balance shaft to inspect whether match for bala...

Page 168: ...3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Mould assembling light touch to well done by rubber hammer Tighten the bolt as standard torque Torque M6 10N m M8 25N m Note opposite angles cross and...

Page 169: ...Primary Strainer Install primary strainer and cover 2 Tighten bolt as standard torque Standard torque 8N m Shift Sector Gear Install shift sector gear tighten bolt Install locating pin and gasket Clos...

Page 170: ...g that hold by pliers Replace and reinstall it ifnot Standard Torque 7N m 1 Outer rotor Oil pump 4 Oil Pump 2 Roller pin 5 Oil pump shaft 3 Inner rotor Oil pump 6 Bolt Oil Pump driving gear Oil pump d...

Page 171: ...tor Combination Install woodruff key into crankshaft key groove Install Magnetor Rotor Combination Install Nut 1 and Washer 2 Standard Torque 160 170N m Left Crankcase Install Locating Pin 1 and seali...

Page 172: ...ICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Install left crankcase Install left crankcase fastening bolt Shaft Sleeve Blanking Cap Install shaft sleeve Install blanking cap and tighten bolt Installation k...

Page 173: ...FI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Oil filter Install new oil filter and O ring seal tighten bolt Water Pump Install water pump and tighten bolt Starting motor Install starting motor tight...

Page 174: ...hain Guide 3 Tensioner plate CVT case Install dowel pin 6 gasket 3 and gasket 9 install CVT case to the right crankcase Install bolt 2 bolt 7 and bolt 10 Install guide 13 and screw 4 Drive pulley driv...

Page 175: ...104 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 Tool Driven pulley expander 1BX 17654 00 1 driven pulley expander 2 driven pulley 3 Drive belt...

Page 176: ...Driven pulley nut tightening torque 110 120N m 1 CVT assy 2 Bolt 3 Nut Engine top side Piston Install the piston rings in the order of oil ring ring ring the first member to go to the oil ring groove...

Page 177: ...GE 3 106 of piston ring moving The gaps of three rings should tagger 120 and the gaps should not face the axial direction of piston pin or the main push surface of piston 1 Do not face to the main pus...

Page 178: ...t and cylin der wall Hold each piston ring with proper position insert piston into the cylinder WARNING Use a new cylinder gasket to prevent oil leakage NOTE When installing the piston the mark on pis...

Page 179: ...ankshaft and rotate the piston to top dead center of crankshaft Cylinder head Install cylinder head tighten bolts diagonally to the specified torque Cylinder head cover bolt tightening torque Initial...

Page 180: ...rm Install camshaft Install rocker arm Install rocker shaft 1 Rocker arm 4 Adjusting screw 2 Exhaust rocker 5 Nut 3 Intake rocker 6 Camshaft Install camshaft holder into the groove of camshaft Tighten...

Page 181: ...eft cover If not alignment rotate camshaft and make them be aligned 1 carved line of magneto Install timing driven sprocket make the carved line of sprocket and the contact sur face of cylinder head c...

Page 182: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 111 1 chain sprocket fastening bolt 2 carved of timing chain sprocket 3 the contact surface of cylinder head cov...

Page 183: ...stall timing chain tensioner and new seal gasket 1 Install fixed bolt 2 and fasten it to the specified torque Chain tensioner bolt specified torque 10N m after installing tensioner use flat head screw...

Page 184: ...CE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 113 8N m Cylinder Head Cover Put rubber ring on cylinder head cover install cylinder head cover tighten bolt Spark plug install and tighten spark plug 3 CVT cove...

Page 185: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 114 Blank page for technology improvement...

Page 186: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 115...

Page 187: ...4 3 Inspection of cooling circuit 3 4 4 Inspection cooling of Radiator Water Hoses Radiator Cap 3 4 5 Inspection of Fan Motor 3 4 6 Inspection of Water Temperature Sensor 3 4 7 Inspection of Thermost...

Page 188: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0...

Page 189: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 90 3 4 1Engine cooling systemchart...

Page 190: ...mixture of 50 distilled water and 50 ethylene glycol antifreeze This 50 50 mixture provides the optimized corrosion resistance and the fine heat protection The coolant will protect the cooling sys te...

Page 191: ...open radiator cap when the engine is still hot Or you may be injured by scalding fluid or steam Coolant is harmful DO NOT swallow or stain your skin or eyes with coolant In case of accidental swallow...

Page 192: ...radiator cap Install radiator cap to cap tester slowly increase pressure to 108kPa and if the cap hold the pressure for at least 10 seconds If the cap cannot meet the pressure requirement replace it...

Page 193: ...Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 94 Tool Radiator Cap Tester Radiator Inspection and Cleaning Remove dirt or trash from radiator with compressed air Correct the radiator fins with...

Page 194: ...el Fill coolant if necessary 3 4 5 Inspection of Fan Motor Remove fan motor from radiator Turn the vanes and check if they can turn smoothly Check fan motor Make sure that the bat tery applies 12 volt...

Page 195: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 96 1 Radiator 2 Radiator Cap 3 Fan Motor 4 Mounting Nut 5 Thermo switch...

Page 196: ...g thermostat when the thermo switch closes and opens Tool ammeter Thermo switch Operating Temperature Standard OFF ON Approx 88 ON OFF Approx 82 Installation Use a new O ring and tighten the thermo sw...

Page 197: ...VICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 98 ture sensor as illustrated on the right Con nect the temperature sensor 2 to the circuit tester place it in a vessel with engine oil Place the vessel above...

Page 198: ...1 00 120 Resistance 154 16 52 4 27 3 16 2 Installation Apply a little thread locker and install it to the cylinder head by tighten ing to the specified torque Water temperature Sensor Tightening Torq...

Page 199: ...HAPTER 3 ENGINE PAGE 3 100 Remove thermostat housing Remove thermostat Check thermostat pellet for cracks If necessary replace it Test the thermostat according to the fol lowing steps Pass a string be...

Page 200: ...ing Temperature 71 3 Tool Thermometer Keep heating the water to raise the wa ter temperature When the water tempera ture reaches the specified valve the ther mostat valve should have been lifted by 3...

Page 201: ...ERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 102 Water pump is on engine left crank shaft cover Removal and Disassembly WARNING When engine is hot do not remove radiator cap or loose coolant discharge p...

Page 202: ...cover Check water pump cover seal gasket if necessary replace it Installation of water pump cover Install water pump cover reverse the re moval procedure for installation Water Pump Cover Bolts Tighte...

Page 203: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 104...

Page 204: ...0 0 CHAPTER 3 ENGINE PAGE 3 105 Check impeller for smooth turning install the new O ring Use the new O ring to prevent leakage Apply grease to O ring Install water pump and tighten the bolts and bleed...

Page 205: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 106 Connect water tubes Inject coolant...

Page 206: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 107 3 4 9 Inspection of Engine Lubrication System...

Page 207: ...CHAPTER 3 ENGINE PAGE 3 108 Add oil to the engine parts piston cylin der body camshaft and so on which run at high speed Engine lubrication should be special oil Engine oil is not only used as lubrica...

Page 208: ...ENGINE M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 3 ENGINE PAGE 3 109 3 4 10 Inspection of Lubrication system Refer to 5 2 8 inspection of lubrication system 3 4 11 Inspection of engine oil pump Refer...

Page 209: ...5 1 ECU 3 3 2 INJECTOR 3 3 3 Throttle Body Assembly with stepper motor 3 3 4 Engine Cool ant Temperature Sensor 3 3 3 Intake Air Pressure and Temperature Sensor MAP MAT 3 3 6 Oxygen Sensor 3 3 7 Ignit...

Page 210: ...CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20 0...

Page 211: ...1 1 Description Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors It also provides the necessary computation adaptability and output co...

Page 212: ...llow mud or other debris to accumulate on the surface of the ECU Having mud or debris accumulated on the ECU casing reduces its heat dissipation efficiency DO NOT Apply any voltage relative to any poi...

Page 213: ...EEPROM Reset During reset all outputs shall be set to a predefined state The controller shall monitor itself for proper operation and enter reset should any internal errors be detected The controller...

Page 214: ...f use Vehicle No Date of return 3 5 2 INJECTOR 3 5 2 1 Appearance The figure below shows the standard Multec 3 Fuel Injector appearance 3 5 2 2 Seal rings Seal rings for injectors refer to Figure 12 a...

Page 215: ...seal rings when re installing an injector If re use is necessary carefully inspect each seal ring for any signs of damage as even minor defects can lead to fuel vacuum leakage Always install injector...

Page 216: ...th the flow tolerance requirements after exposure to the following temperature environments Also they will not experience unacceptable external leakage any type of physical degradation or loss of serv...

Page 217: ...pply load to the injector tip for installation Apply load to 45 deg angle on nylon over mold see DO NOT Pound injectors into manifold during assembly to engine Can damage injectors or seal rings DO NO...

Page 218: ...turn any dropped damaged or suspect material with a tag that describes the problem Ensure fast and correct diagnosis of root cause 3 5 2 10 Installation guide lines Follow these guidelines to prevent...

Page 219: ...mely hot Shut off ignition Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine Disconnect the electrical connector from the injector...

Page 220: ...ional changes and the collection of other particles attracted by the tacky surface The flow restrictions can degrade emissions and drivability Other fuel and environmental conditions may cause crystal...

Page 221: ...ive system comprised of the following subsystems the main casting body bearing system shaft and valve system return spring system cable interface system throttle position sensing system and the bypass...

Page 222: ...le position sensor coupler stepper motor coupler and MAP MAT sensor coupler if this sensor is mounted on the throttle body Disconnect accelerator cable from throttle body Remove air cleaner outlet hos...

Page 223: ...the throttle body area Ensure proper operation DO Unload and install units one at a time from packing trays Damage may be done to critical components DO Return any dropped damaged or suspect material...

Page 224: ...the throttle linkage attached Damage could occur DO NOT Let the by pass holes be blocked by dirt or foreign particles This could effect idle stability DO NOT Rake stage or handle parts in a manner tha...

Page 225: ...ly Relative Humidity 0 to 100 RH Typical Pressure When installed at the minimum torque the sensor shall be capable of sealing engine coolant with a positive pressure of 206 8 kPa 30 psi at 135 C appli...

Page 226: ...ge varies as the intake air pressure 3 5 5 2 Appearance The appearance of the MAP MAT Sensor is shown as above 3 5 5 3 Operating Environment This device is intended for use in inlet manifold for sensi...

Page 227: ...This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine It consists of the wide range sensor and stoichiometric sensor Usually we use stoichiometric...

Page 228: ...oportion x MMT 0 0085g L Si 4ppm 3 5 7 Ignition Coil 3 5 7 1 Description and Working Principle This coil provides energy to the spark plug in the combustion chamber The coil itself doesn t have a driv...

Page 229: ...bly leading to personal injury DO NOT Use a screw driver to asset in removing secondary boots from the secondary tower Use tools designed for secondary removal It is possible to damage a secondary lea...

Page 230: ...ents Dedicated wiring is required This prevents electrical cross talking between components which can lead to component malfunction DO NOT Apply voltage to the ignition system other than vehicle syste...

Page 231: ...ge and current which the module could be subjected to could cause module performance degradation or failure DO Connection of the module back plate to vehicle ground is desirable whenever possible This...

Page 232: ...eads allow the engine to cool The heat of the engine in combination with a spark plug that is still hot may cause the spark plug threads to strip the cylinder head upon removal Use goggles to protect...

Page 233: ...re the spark plug thread is free of dings and burrs If necessary use a thread chaser and seat cleaning tool 2 Make sure the spark plug gasket seat is clean then thread the gasket to fit flush against...

Page 234: ...e diagnostic socket Never test electrical signals that exceed the limit of specifications Test cannot be performed by the person who is driving the car This unit should be used and stored in the follo...

Page 235: ...h back light for displaying all the information during testing Keyboard There are 5 keys one is reserved on the main unit for selecting and controlling test steps 3 5 9 Preparations Connection Find th...

Page 236: ...be used to diagnose Delphi Engine Management System with functions Read DTC Clear DTC Data Stream Status Stream and Record Data Operations When the unit is powered up the screen will display the inte...

Page 237: ...ontinue the interface will display as below Diagnostic Function Here we take diagnostic function for demonstration Select diagnostic function and press the screen will display an interface to indicate...

Page 238: ...a Stream Status Stream Record Data Press or key to select function you needed 1 Read DTC Select Read DTC and press it will display fault code as below Press or key to move icon and select fault code t...

Page 239: ...below 3 Data Stream Select Data Stream and press it will display as below Press or key for page up down to view more Press key to exit 4 Status Stream Select Status Stream and press the interface will...

Page 240: ...rs were input When all the 7 numbers were set press the screen will display a message for confirmation of the Plate Number input Press to return to the previous interface to input the code again or pr...

Page 241: ...ding the below table Fault code Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant Oil...

Page 242: ...gnal P0351 Cylinder 1 Ignition Coil Malfunction P0352 Cylinder 2 Ignition Coil Malfunction P0505 Idle Speed Control Error P0562 System Voltage Low P0563 System Voltage High P0650 MIL Circuit Malfuncti...

Page 243: ...ve clearance No Sparking from Spark Plug 1 Fouled spark plug 2 Wet spark plug 3 Defective ignition coil 4 Open or short circuit with pickup coil 5 Faulty generator No Fuel Reach Into Carburetor 1 Clog...

Page 244: ...roper valve clearance 2 Improper valve seating 3 Faulty valve guide 4 Worn rocker arm or rocker arm shaft 5 Fouled spark plug 6 Improper spark plug gap 7 Faulty ignition coil 8 Clogged idle vale inlet...

Page 245: ...per valve timing 6 Faulty ignition coil 7 Weak high pressure oil pump resulting in poor fuel supply 8 Dirty air filter Replace Replace Clean or replace Adjust or replace Adjust Replace Adjust or repla...

Page 246: ...or rocker arm shaft 13 Air leakage from air intake pipe 14 Excessive engine oil Adjust Replace Adjust Replace Replace Replace or Correct Clean or replace Clean or replace Clean or replace Adjust fuel...

Page 247: ...it in combustion 4 Worn piston pin or pin hole 5 Worn piston ring or piston ring Replace Replace Clean Replace Replace groove Noise from Timing chain 1 Stretched chain 2 Worn sprocket wheel 3 Faulty c...

Page 248: ...sheave Replace Noise from Transmission 1 Worn or damaged gear 2 Worn or damaged input or output shafts 3 Worn bearing Replace Replace Replace Slipping Clutch 1 Worn or damaged clutch shoes 2 Weakened...

Page 249: ...rts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service 4 1...

Page 250: ...Tighten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground WARNING DO NOT reuse old bolts Seriou...

Page 251: ...spring and collapse strut body 5 Remove two pinch bolts from strut body 6 Remove strut body 7 Install front shock cartridge until bottomed in strut casting 8 Install pinch bolts with clamp s Torque p...

Page 252: ...t mounting bracket 7 Using ball joint cup removal installation toolkit remove ball joint cup from strut housing Refer to photos at right Install puller guide 1 Thread bolt 2 with nut 3 onto bal joint...

Page 253: ...4 5 STEERING POST ASSEMBLY Note 1 Hand tighten the crown nut of the steering post 2 Align cotter pin hole 3 Install cotter pin Bend both ends of cotter pin around nut in opposite directions 4 Check st...

Page 254: ...CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 4 CHASSIS PAGE 4 6 NOTES...

Page 255: ...DISASSEMBLY INSPECTION 5 3 FRONT HUB REMOVAL INSPECTION 4x4 ATV500 5 3 b FRONT HUB INSTALLATION 4X4 ATV500 5 4 FRONT HUB BEARING REPLACEMENT 4X4 5 5 FRONT DRIVE AXLE INNER AND OUTER CV JOINT REMAVAL I...

Page 256: ...DISASSEMBLY INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning t...

Page 257: ...result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play by grasping the ti...

Page 258: ...Install a new cotter pin Tighten nut slightly if necessary to align cotter pin holes 6 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of Spindle in different direc...

Page 259: ...only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4 Inspect bearing NOTE Due to extremely close tolerances and minimal wear the bearings must be inspec...

Page 260: ...Outer board boot 4 Boot band B 5 Stopper ring 6 Outer CV joint 7 Circlip 8 Bearing 9 stopper ring 10 Inboard boot NOTE Always order and replace 6 and 8 together REMOVAL 1 Place the vehicle on level gr...

Page 261: ...the boots are damage and left un repaired the driveshaft joints will fair prematurely by allowing the joint to be exposed to dirt mud and moisture This also allow the loss of critical lubrication 1 C...

Page 262: ...shaft stopper ring has locked into the front differential side gear groove 4 Carefully install the outer CV joint spindle into the strut install the front hub and wheel 5 Install the ball joint on the...

Page 263: ...ter INNER CV JOINT INSPECTION 1 Clean the bearing assembly in solvent and thoroughly dry 2 Inspect the steel balls bearing case and the bearing race for wear or damage 3 Check for wear or damage to th...

Page 264: ...amaged replace the drive axle Check the movement of the joint NOTE Inner CV joint must be replaced with the bearing as an assembly 5 8 FRONT DRIVE AXLE ASSEMBLY 4X4 1 The rubber boots are not identica...

Page 265: ...a liberal amount of molybdenum disulfide grease to the bearing assembly Work the grease in between the balls the race and the case Make sure all voids are filled with grease 9 Apply a liberal amount...

Page 266: ...onto each boot CAUTION It is critical to avoid undue stress on the rubber boots after the drive axle is installed and the vehicle is run Don t twist the boot and always set the both ends in designed p...

Page 267: ...the rear wheel driving shaft nut than remove the nut 3 Remove the rear disc brake caliper 4 Remove the link RR Stabilizer 5 Remove the mounting bolt of rear shock absorber and upper and lower A arm T...

Page 268: ...tor to take down the rear hub 8 Remove oil seal 9 Remove the snap spring of the rear hub 10 Using bearing extractor to take down the hub bearing Notice when reassembling hub bearing that were removed...

Page 269: ...G 151 3 5 BEVEL GEAR BEARING HOUSING 28 REAR GEAR BEARING HOUSING 6 OIL SEAL 35 61 9 29 OIL SEAL 30x50x13 5 7 ADJUST SHIM 30 BOLT M8 25 8 O RING 69 3 31 BOLT M10x25 9 BEARING 6305 32 NUT M8 10 BEARING...

Page 270: ...x with a high pressure water jet 1 Remove the oil drain plug A and let the oil drain from the gearbox Important Clean the plug carefully Replace the sealing washer B before it s assembled Fig 1 Fig 1...

Page 271: ...ner L with the special tool Remove the bearing M and the oil seal P from the bevel gear bearing housing N Fig 4 Fig 4 5 Remove the six bolts M8 25 Q and the two bolts M10 1 25 25 R Remove the ring gea...

Page 272: ...st shim Y from the bevel gear comp driven X Fig 7 Fig 7 8 Remove the O ring Z the oil seal 65 90 9 a and the bearing b from the ring gear bearing housing T Fig 8 Fig 8 5 12 REAR GEAR CASE ASSEMBLY Imp...

Page 273: ...comp driven E in the bore of bearing A Mount the adjust shim F in the other neck of the bevel gear comp driven E Fig 2 Fig 2 3 Mount the needle bearing H and the needle bearing into the suited hole o...

Page 274: ...ole of the rear gear case G Fig 5 Fig 5 6 Mount the shaft neck of the bevel gear comp driven E in the suited hole of the needle bearing H Make the ring gear bearing housing C and the rear gear case G...

Page 275: ...ring a into the groove of the ring gear bearing housing Z Mount the oil seal Y into the suited hole of the bevel gear bearing housing Z Fig 9 Fig 9 10 Mount the adjust shim b in the shaft neck of the...

Page 276: ...ply some Loctite 242 threadlocker on screw thread Tighten the nut M12 1 25 h to a torque of 50 60N m Fig 13 Fig 13 14 Mount the oil seal 65 90 9 j in the ring gear bearing housing C on the right Fig 1...

Page 277: ...CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019 0 CHAPTER 5 FINAL DRIVE 5 23 5 13 FRONT GEAR CASE DISASSEMBLY FRONT GEARCASE EXPLODED VIEW...

Page 278: ...ear 10 Adjust Shim 83 71 36 Bolt 11 Adjust Shim 61 48 37 Bracket Differential 12 Oil Seal 38 Shim 13 Bearing 16007 39 Washer 14 Retainer 62 40 Top Bracket Differential Gear 15 Drive Clutch Cover 41 Be...

Page 279: ...the gearbox make sure GEAR MOTOR A is protected if mounted Never clean the gearbox with a high pressure water jet Fig 0 Fig 0 1 Remove the DRAIN BOLT A and let the oil drain from the gearbox Important...

Page 280: ...NAL DRIVE M565Li SERVICE MANUAL 2019 0 CHAPTER 5 FINAL DRIVE 5 26 4 Remove the COUPLER A Fig 4 Fig 4 5 Remove the OIL SEAL A Fig 5 Fig 5 6 Remove the four SCREW A Fig 6 Fig 6 7 Remove the GEAR MOTOR A...

Page 281: ...bolts H M8 L28 Fig 8 Fig 8 9 Remove the GEAR CASE ASSY FRONT AXLE A and CASE COVER ASSY FRONT AXLE B Fig 9 Fig 9 10 Remove the DIFFERENTIAL GEAR ASSY A Fig 10 Fig 10 11 Remove ADJUST SHIM A Fig 11 Fi...

Page 282: ...19 0 CHAPTER 5 FINAL DRIVE 5 28 14 Remove the DRIVE CLUTCH A Fig 14 Fig 14 15 Remove the RETAINER 62 B Fig 15 Fig 15 16 Remove the DRIVE CLUTCH COVER A Fig 16 Fig 16 17 Remove the ADJUST SHIM A Fig 17...

Page 283: ...CE MANUAL 2019 0 CHAPTER 5 FINAL DRIVE 5 29 19 Remove the BEARING RETAINER A with tool B Fig 19 Fig 19 20 Remove the DRIVE PINION GEAR A Fig 20 Fig 20 21 Remove the BEARING 61912 A Fig 21 Fig 21 22 Re...

Page 284: ...PIN A Fig 23 Fig 23 24 Remove the DRIVE GEAR A and WEARING RING B and GEAR CENTER DIFFERENTIAL C and GEAR SHAFT CENTER DIFFERENTIAL D and PIN E and BRACKET DIFFERENTIAL F Fig 24 Fig 24 25 Remove the D...

Page 285: ...differential D and pin E and bracket differential F then mount pin T Fig 1 Fig 1 2 Put driven gear A and washer B and shim C and adjust shim D and differential gear E as shown Fig 2 Fig 2 3 Mount the...

Page 286: ...NAL DRIVE M565Li SERVICE MANUAL 2019 0 CHAPTER 5 FINAL DRIVE 5 32 Fig 4 Fig 4 5 Mount the retainer 62 A Fig 5 Fig 5 6 Mount the drive clutch A Fig 6 Fig 6 7 Mount the pin shaft A and the shift fork B...

Page 287: ...PTER 5 FINAL DRIVE 5 33 8 Mount the screw A Fig 8 Fig 8 9 Mount the adjust shim A Fig 9 Fig 9 10 Mount the differential gear assy A to the gear case assy C do not forget put adjust shim I to the case...

Page 288: ...o a torque of 20 25Nm Fig 11 Fig 11 12 Mount the gear motor A Important Before assemble the gear motor make sure that the shift fork S is in their correct position as shown Fig 12 Fig 12 13 Mount the...

Page 289: ...Mount the O ring A Fig 16 Fig 16 17 Apply some Loctite 263 thread locker on screw thread mount the nut A tighten it to a torque of 50 60Nm Fig 17 Fig 17 18 Mount the oil seal A and oil seal B mount t...

Page 290: ...CHAPTER 5 FINAL DRIVE LH500ATV D SERVICE MANUAL 14 0 CHAPTER 5 FINAL DRIVE 5 36 NOTES...

Page 291: ...SHING PROCEDURE 6 5 FLUID REPLACEMENT BLEEDING PROCEDURE 6 6 HAND BRAKE MASTER CYLINDER REMOVAL INSPECTION INSTALLATION 6 7 FRONT PAD REMOVAL INSPECTION INSTALLATION 6 8 FRONT DISC INSPECTION REMOVAL...

Page 292: ...0 167 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051m m Brake Disc Run out 0 005 0 12 7m m 6 2 TORQUE Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bol...

Page 293: ...ake pads both hydraulic and mechanical must be burnished to achieve full braking effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake p...

Page 294: ...diaphragm from reservoir 3 Inspect vent slots in cover and remove any debris or blockage 4 If changing fluid remove old fluid from reservoir with a brake fluid pump or similar tool NOTE Do not remove...

Page 295: ...o maintain level in reservoir CAUTION Maintain at least 1 2 13mm of brake fluid in the reservoir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder h...

Page 296: ...inished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Remove master cylinder from handlebars INSPECTION Inspect parking brake for wear If teeth or locking cam are worn...

Page 297: ...all Severe injury m ay occur if machine tips or falls 2 Remove the front wheel 3 Remove caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers w...

Page 298: ...e brake system 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counter clockwise 6 Install reservoir cap Hand and or Foot Brake Master Cylinde...

Page 299: ...eded contact the ATV manufacture via the agent for the parts and special instruction REMOVAL 1 Remove wheel remove caliper from the strut 2 Loosen and remove brake hose s to caliper Place a container...

Page 300: ...o caliper bore slowly with pads installed NOTE Brake fluid will be forced through compensating port into m aster cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid fr...

Page 301: ...ing a flare nut wrench remove hose s Place a container to catch brake fluid draining from brake hose 3 Remove caliper 4 Remove brake pad as described above 5 Inspect surface of caliper for nicks scrat...

Page 302: ...dial indicator Replace disc if worn beyond service limit Brake Disc Thickness New0 177 0 187 4 496 4 750mm Service Lim it 0 167 4 242 mm Brake Disc Thickness Variance Service Limit 0 002 0 051mm diff...

Page 303: ...E 6 13 6 13 FOOT BRAKE PEDAL FOR B TYPE ADJUSTING If the push rod joint is reinstalled adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt ho...

Page 304: ...CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20 0 CHAPTER 6 BRAKES PAGE 6 14 NOTES...

Page 305: ...AND SERVICE 7 2 BATTERY 7 3 IGNITION SYSTEM 7 4 CHARGING SYSTEM 7 5 ELECTRICS STARTING SYSTEM 7 6 COOLING SYSTEM 7 7 LIGHTING SYSTEM 7 8 GEAR SHIFT SWITCH TEST 7 9 SPEEDOMETER SYSTEM 7 10 MAIN SWITCH...

Page 306: ...T 1 The headlight beam can be adjusted vertically all models and horizontally except the light on handlebar 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall...

Page 307: ...initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery must be fully charged before use 1 Remove vent plug from vent fitting...

Page 308: ...related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gra...

Page 309: ...Terminal board or connections wet corroded Poor ignition coil ground e g coil mount loose or corroded Faulty stator measure resistance of all ignition related windings Incorrect wiring inspect color c...

Page 310: ...5 Spark plug cap resistance entire ignition system 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT Check the battery condition Refer to BATTERY INSP...

Page 311: ...lty Minimum spark gap 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK Tester lead Spark plug side Tester lead High tension cord side 5 Spark plug cap resistance Remover the spark plug cap Connect the poc...

Page 312: ...ire harness Connect the pocket tester 1 to the ignition coil Check if the primary coil has the specified resistance Primary coil resistance 3 6 4 8 20 Tester lead Spark plug lead Tester lead Green Ter...

Page 313: ...OUT OF SPECIFICATION Check the pickup coil has the specified resistance Primary coil resistance 115 145 20 Replace the pickup coil NO CONTINUITY MEETS SPECIFICATION 8 Main switch CHECK SWITCHES Repla...

Page 314: ...e engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable Check for current draw with the key off if the draw is excessive loads...

Page 315: ...RECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead Connect the pocket tester DC20V to the battery Test lead Battery te...

Page 316: ...ter X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 5 0 8 20 OUT OF SPECITICATION Replace the stator coil MEET...

Page 317: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 13 7 5 ELECTRICS STARTING SYSTEM DI AGRAM...

Page 318: ...tch 7 gear shift switch 8 front rear brake switch 9 starter switch 10 wiring connection entire starting system 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check...

Page 319: ...d terminal WARNING A wire used as a jumper lead must have the equivalent capacity as that of the battery lead or more otherwise it may burn This check is likely to produce sparks so be sure that no fl...

Page 320: ...hift switch CHECK SWITCHES NO CONTINUITY Replace the handlebar switch 8 Front rear brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 9 Starter switch CHECKING SWITCHES NO CONTINUIT...

Page 321: ...NUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 17 7 6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check 1 Fuse Main Fan 2 Battery 4 Fan motor inspection 3 Main switch 5 Thermo switch 6 relay 7 Wiri...

Page 322: ...ECK SWITCHES NO CONTINUITY Replace the main switch 4 1 Fan motor inspection 1 Connect the battery to the fan motor Battery lead Green Blue terminal Battery lead Green ground Check the fan motor operat...

Page 323: ...al care Never subject it to strong shocks or allow it to be dropped Should it be dropped it must be replaced Do not touch the thermo switch to the bottom of the heated vessel 88 3 Thermo switch ON 80...

Page 324: ...g the coolant if the thermostat or the fan fails to work the coolant temperature will keep rising The heat alarm unit operates the moment the temperature reaches 115 5 an engine now to have the circui...

Page 325: ...the heated vessel Coolant temperature Resistance OUT OF SPECIFICATION Replace the thermo unit 80 47 5 56 8 100 26 2 29 3 MEETS SPECIFICATION 8 Voltage Connect the pocket tester DC20V to the Temperatu...

Page 326: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 22 7 7 LIGHTING SYSTEM...

Page 327: ...to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminals Recharge or replace...

Page 328: ...CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the headlight and high beam indicator light couplers A When the dimmer switch is on low beam B When dimmer s...

Page 329: ...ulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Black terminal Tester lead Green terminal Turn the main switch to on Turn the lights switch to...

Page 330: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 26 7 8 GEAR SHIFT SWITCH TEST DI AGRAM...

Page 331: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 27 Switch table...

Page 332: ...eed angle revolution and length etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack B Main Technical Parameter for sensor Item Code Vol value Unit...

Page 333: ...V V LCD Meter For M565 T3 EFI 1 Neutral indicator light 11 4WD and front difflock indicator 2 High beam indicator light 12 Fuel gauge Indicator 3 Turn indicator light 13 EFI Malfunction indicator 4 Re...

Page 334: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 30 7 10 MAIN SWITCH AND HANDLE SWITCH HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL...

Page 335: ...he fuel tank 2 Measure the resistance with an ohmmeter across the sensor terminal and its body 3 If the reference values are not indicated the sensor is faulty Resistance Sensor terminal its body Refe...

Page 336: ...ELECTRIC 4WD SHIFT Fig 1 1 The rider shifts 2WD to 4WD by the Switch on handlebar 2 When shift 2WD 4WD or Diff Lock the mechanics in the front gear box maybe still engaged disengaged the mechanics wou...

Page 337: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL PAGE 7 33 7 13 WIRING DIAGR...

Page 338: ...CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16 0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8 34...

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