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SERVICE MANUAL

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MECHANISM ILLUSTRATIONS

Summary of Contents for ATTILA RS-21 EFi 150

Page 1: ...SERVICE MANUAL FORWARD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS...

Page 2: ...otorcycle are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice This manual that contains all data il...

Page 3: ...mation and trouble diagnosis The second chapter covers service maintenance and special service tools information The third to the eleventh chapters cover engine fuel injection and driving systems The...

Page 4: ...8 Cylinder Piston 7 8 1 8 14 V Type Belt Driving System Foot Starter 8 9 1 9 6 Final Driving Mechanism 9 10 1 10 10 Alternator Starting Clutch 10 11 1 11 6 Crankcase Crankshaft 11 12 1 12 14 Body Cov...

Page 5: ...G Coil Start relay Fuel pump relay Fuel tank Fuel pump Oil level Oil strainer Front brake lever Rear brake lever Air cleaner Gear oil Inspection plug Headlight Front winker light Tail light Rear winke...

Page 6: ...wed Engine oil Limits to use SAE 10W 30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil Grease King Mate G 3...

Page 7: ...et battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist If you swallow i...

Page 8: ...gs or oil seals because most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent stiff control and premature worn out Rubber parts may become deteriorated whe...

Page 9: ...ove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal...

Page 10: ...battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secur...

Page 11: ...ny wire loose Check if the connector is covered by the twin connector boot completely and secured properly Before terminal connection check if the boot is crack or the terminal is loose Insert the ter...

Page 12: ...ull too tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied Secu...

Page 13: ...urrounding parts in all steering positions Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction With...

Page 14: ...ndary Reduction GEAR Type 4 STROKE ENGINE Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T Fuel Used Unleaded Speedometer 0 140 km...

Page 15: ...il strainer cap 1 30 1 0 2 0 Gear oil draining plug 1 8 0 8 1 2 Gear oil filling bolt 1 10 1 0 1 4 Oil pump screws 3 3 0 1 0 3 Engine left side cover bolts 8 6 1 0 1 5 Rubber washer attached Camshaft...

Page 16: ...olts 1 6 0 7 1 1 Front brake clipper mounting bolts 4 8 4 0 4 5 Drum brake arm bolts front rear 2 8 2 9 3 5 Engine suspension bracket bolts 2 10 4 5 5 5 On frame side Engine connection bolt 1 12 5 0 7...

Page 17: ...e the spark plug again and check it Dry spark plug Wet spark plug 1 No fuel in fuel tank 2 Check if the pipes fuel tank to fuel injector and intake vacuum are clogged 3 Malfunction of fuel pump relay...

Page 18: ...uled and discoloration No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel injector clogged 1 Malfunction of ECU 2 Mal...

Page 19: ...ark plug fouled 2 Malfunction of ECU 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or short circuit in spark plug leads 6 Malfunction of main switch 1 Insufficient fuel in fuel t...

Page 20: ...f movable drive face damaged 3 Driving pulley spring broken 4 Clutch weights broken 5 Drive slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial...

Page 21: ...Diagnosis 1 16 Parts To Be Greased Acceleration cable Front rear brake lever pivot Steering shaft bearing Seat lock Rear wheel bearing Main stand pivot Side stand pivot Speedometer gear front wheel b...

Page 22: ...14 Headlamp Adjustment 2 14 Nuts Bolts Tighteness 2 14 Special Service Tools Catalogue 2 15 Precautions In Operation Specification Fuel Tank Capacity 6100 c c Capacity 1000 c c Engine Oil Change 800...

Page 23: ...for every 2000km 31 2nd air jet system I I C 32 vapor control system I 33 Throttle body A I A C 34 Input signals from EFI ECU I 35 Sensors of EMS fuel injector I I Note I Inspection A Adjustment R Rep...

Page 24: ...city Disassembly 1050cc Change 800cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine rem...

Page 25: ...ng Mate HYPOID GEAR OIL 140 Fuel System Fuel Lines Remove luggage box rear carrier body covers Check all lines and replace it when they are deterioration damage or leaking Warning Fuel filter Remove l...

Page 26: ...its operation is smooth Check throttle valve cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Fre...

Page 27: ...rator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TD...

Page 28: ...ent function The cursor is for a digit and the is for denary scale Emission standard Engine RPM 1600 100rpm HC 900 ppm CO 1 5 0 5 Please refer to chapter 4 fuel system for the detailed usage of DATASC...

Page 29: ...ponents if malfunction of these parts are found Spark Plug Appointed spark plug CR8E NGK Remove trunk Remove central cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug...

Page 30: ...r piston head Driving System Drive Belt Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left side cover and the cover Check if the belt is crack or w...

Page 31: ...d or leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scr...

Page 32: ...r bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution Added Brake Fluid Add brake fluid to UPPER limit lever Recommended brake fluid DOT3 or D...

Page 33: ...ng Caution Brake Lamp Switch The brake lamp switch is to lit up brake lamp as brake applied Make sure that electrical starter can be operated only under brake applying It is not necessary to remove br...

Page 34: ...ire surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspection or depth gauge Replace the tire if tire tread dent or unusual wearing out...

Page 35: ...the front fender Caution Nuts Bolts Tighteness Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check a...

Page 36: ...nkcase bushing Name Valve spring compressor Name Valve spring compressor Parts no SYM 1120300 H9A Parts no SYM 1471100 Parts no SYM 1471110 20 Name Valve clearance adjustment wrench Name Universal fix...

Page 37: ...0400 Parts no SYM 9620000 27 42 7 25 40 8 20 32 6 Name Oil seal installer Name Oil seal installer Name Oil seal installer Parts no SYM 9125500 Parts no SYM 9121600 Parts no SYM 9120200 Name Clutch mou...

Page 38: ...il Strainer 3 3 Oil Pump Removal 3 4 Oil Pump Disassembly 3 4 Oil Pump Inspection 3 5 Oil Pump Re assembly 3 5 Oil Pump Installation 3 6 Gear Oil 3 7 Mechanism Illustration Rock Arm Cam Shaft Scoop lu...

Page 39: ...Standard mm Limit mm Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5 kg...

Page 40: ...sed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighte...

Page 41: ...e oil pump cover 2 screws and then the oil pump driving gear clamp and the gear Remove oil pump body screws 3 screws Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pump a...

Page 42: ...r rotors Limit below 0 12mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving...

Page 43: ...l pump outer cover 2 bolts Install the starting gear and the alternator Refer to chapter 10 Install the oil pump cover and fixing pin properly The elliptical hole on the driving gear is not match with...

Page 44: ...andard quantity 110cc replacement 100 cc Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make su...

Page 45: ...3 Lubrication System 3 8 NOTES This chapter Contents...

Page 46: ...ss Valve 4 15 Fuel Injector 4 15 Fuel Pump 4 15 Fuel Tank 4 16 Air Cleaner 4 19 Trouble Diagnosis Solutions Of EFi 4 20 Error Code Message and Solution Operation 4 21 EFi Data scan Operation Manual 4...

Page 47: ...ts Fuel injector Crankshaft position sensor Throttle position sensor Engine temperature sensor Intake temperature MAP sensor Fuel pump Transistor ignition coil ECU Idle air by pass valve Battery volta...

Page 48: ...se their precision easily so that fuel supply can be much more accurate The engine is equipped with a fuel injection of computerized control and its main characters are as following 1 The necessary fu...

Page 49: ...tools Vacuum air pressure pump Injection system diagnosisor Data Scan Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame wh...

Page 50: ...han 0 2V 1 Turn off the ignition switch 2 Disconnect the connectors of throttle valve position sensor and intake manifold temperature pressure sensors 3 Turn on the ignition switch 4 Measure the volta...

Page 51: ...re 1 Low fuel in fuel tank 2 The fuel pressure of the injector is lower than 2 5bar 3 Fuel leaking in pipe 4 abnormal regulator 5 Fuel pump pile leaking 6 abnormal fuel pump 7 abnormal fuel injector 1...

Page 52: ...onents item by item then check if the other traditional components on the engine is in abnormal Replace with new one for confirmation Idle speed misfire 1 Connect the Data Scan and check trouble conte...

Page 53: ...Connect the Data Scan and check trouble content if there is an abnormal CO correct value in idle speed Is fuel enough Are the battery wires loose Is the voltage enough Is the vacuum hose leaking Does...

Page 54: ...r hour The fuel pump is located inside of the fuel tank and installed a filter in front of its inlet so that can prevent from foreign materials sucking into the fuel pump to damage it and the fuel inj...

Page 55: ...then the last one is for ground Its major component is a highly precious variable resistor The input voltage range 5V DC It is located on the side of throttle body By means of the throttle valve rota...

Page 56: ...properly fuel quantity according to running conditions and environmental corrective coefficient When key off or engine stopped the fuel pump stops operating 2 The fuel filter is to filter foreign mate...

Page 57: ...ltage to ignite the spark plug by means of the transistor to open close operation of the primary current inside of the computerized system Such operation not only have max engine performance output bu...

Page 58: ...while to increase air flow and then enhance engine idle speed to prevent from unstable engine running and misfired within initial starting 2 Warm up when engine oil is in low temperature condition the...

Page 59: ...rects fuel injection and ignition timing Intake temperature and pressure sensor a sensor that is combined both pressure and NTC can detect the absolute pressure and temperature in the intake manifold...

Page 60: ...duce slowly to prevent from engine misfired negative pressure in intake manifold increasing and then to reduce HC emission Fuel Injector The 2 hole fuel injector provides two intake valves with one fu...

Page 61: ...nnect the connectors of fuel pump relay diode and fuel sender Remove the fuel cut valve screw x 4 Removal of fuel pump fuel sender Slightly knock the fuel pump mounting plate to let the plate out of l...

Page 62: ...crew x 1 Remove the body cover screw x 4 Remove the rear lamp assembly screw x 4 Disconnect the connectors of fuel pump relay regulator and fuel sender Remove the fuel pump Remove the fuel cut valve R...

Page 63: ...he fuel inlet clamper and then remove the fuel inlet and the connection hose Remove all hoses from the pressure regulator Installation Install the fuel tank in reverse procedure of removal Bolt x 4 To...

Page 64: ...embly Installation Install the air cleaner in reverse procedure of removal Application of fuel injection system diagnosisor Open the front luggage cover Connect the ECU connector and then turn on the...

Page 65: ...up types 1 ON OFF 2 ON OFF 3 ON OFF To show FLASH CODE Before turning the KEY ON wide open the throttle valve Then turn the KEY ON the CHK lamp lit up for 2 seconds and off But the CHK lamp will lit u...

Page 66: ...2 4 Application malfunction of the throttle position sensor 1 Make sure if the wire circuit of the throttle valve position sensor is loosen or short 2 If this problem symptom still existing check if t...

Page 67: ...d exceed safety limit Decreasing the speed and then the DTC code disappeared 2 Check if the CVT belt is broken P1560 2 14 Abnormal 5V driving voltage 1 Make sure if the 18th terminal of ECU is 5V 2 Ma...

Page 68: ...ss Enter to enter main menu 5 Move the key to read DTC and then press Enter key 6 The menu will show 3 functions 1 Current problem searching 2 Just occurred problem searching and 3 past problem search...

Page 69: ...urred problem searching 3 past problem list The DTC codes can be erased only under turn on the ignition switch and engine stopped Engine speed 1 Re set throttle position the command must be done after...

Page 70: ...YANG Motor Co as fig 1 3 Press the ENTER key to continue the monitor goes show CONNECTING as fig 2 Fig 1 Fig 2 When press ENTER key it shown 2 pages 1 2 2 2 of motorcycle data To select function menu...

Page 71: ...blem searching menu verify if problem occurred right now The menu will show problem symptom when problem have been detected Then conduct repairing procedure for the problem However if there is no DTC...

Page 72: ...key to back to the main menu Fig 10 Fig 11 With the cursor to select 3 history DTC codes LCD background changed into black press ENTER and then enter into problem record menu as fig 12 Fig 12 When the...

Page 73: ...m history record the problem record will be kept continuously 5 With the cursor to select 2 DTC Code Erase LCD background changed into black as fig 15 press ENTER key to erase the DTC codes as fig 15...

Page 74: ...ription CO voltage meter it is designed onto the ECU This model does not has this function Battery voltage it means that the ECU receives voltages from the terminals of power supply fuel injector tran...

Page 75: ...ion sensor This value can be a reference for the throttle position sensor damaged idle speed target value It means that the idle speed target value set by the ECU based on current engine temperature a...

Page 76: ...ith the and cursors to adjust the idle speed CO value Micro adjustment Press for one time then 1 but press for one time then 1 Macro adjustment Press for one time then 10 but press for one time then 1...

Page 77: ...o not enter this menu if not necessary Press ENTER key to left this set up function menu Fig 29 Fig 30 Fig 31 Description 1 Reset TPI adaption After replaced the throttle body with new one or idle spe...

Page 78: ...nction menu Fig 32 Fig 33 Fig 34 9 With the cursor to select 6 Waveform analysis as fig 35 press ENTER to enter into the waveform analysis menu as fig 36 1 engine speed 2 ignition timing BTDC 3 TPS an...

Page 79: ...3 instantly dynamic data values shown on the menu as fig 38 39 40 Select desired menu with cursor Fig 37 Fig 38 Fig 39 Fig 40 With the cursor to select 2 ignition timing BTDC as fig 41 press ENTER to...

Page 80: ...ct 4 Atmosphere Pressure Sensor as fig 45 press ENTER to enter into the Atmosphere Pressure Sensor menu to check current waveform as fig 46 Press EXIT key to left the Atmosphere Pressure Sensor wavefo...

Page 81: ...w one 1 If the by pass valve has to be changed erase the DTC codes with the Data Scan 2 Turn off the ignition switch and then replace the valve with new one 3 Turn on ignition switch and make sure the...

Page 82: ...code appears 3 If the code appears replace the throttle body to make sure the code can be erased 4 If the code disappears replace the throttle body 5 If the code still exists replace the ECU with new...

Page 83: ...idle speed adjustment section for idle speed CO value confirmation 9 Idle speed CO Adjustment Check for new motorcycle and every 3000km 1 Warm up the motorcycle by running it in 50km hr for 5 minutes...

Page 84: ...sk 3 Final reduction gear mechanism Specification Item Specification Replacement 800 c c Engine Oil Capacity Disassemble 1000 c c Replacement 100 c c Gear Oil Capacity Disassemble 110 c c Torque Value...

Page 85: ...fuel tank cap hex socket bolt x 4 Remove both left right body covers and central upper cover set screw x 4 Remove both left right side covers screw x4 Remove both left right pedals of rear seat screw...

Page 86: ...or of throttle position sensor Loosen the clamp of the air cleaner duct and then remove the duct Remove the fuel injector line and circuit connectors Open the latch located under the temperature senso...

Page 87: ...air duct on the engine left side and then remove the air duct Remove the air cleaner bolts bolt x 2 Remove the front end nuts of exhaust pipe Nut 2 Remove the rear end bolts of exhaust pipe Bolt 3 Re...

Page 88: ...ar brake pipe seat bolt x 2 Remove the rear brake assembly bolt x 2 Remove the front end nut of rear bracket bolt x 2 Remove the rear wheel axle nut nut x 1 Remove the rear bracket Bolt x 2 Bolt x 2 N...

Page 89: ...engine suspension nuts and then remove the bolt from the side hole Caution Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so Wit...

Page 90: ...ng out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pr...

Page 91: ...engine suspension frame Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame Engin...

Page 92: ...removal Caution Engine suspension nut Torque Value 4 5 5 5 kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5 kgf m Down 2 4 3 0 kgf m Rear wheel axle nut Torque Value 11 0 13 0 kgf m z Note bot...

Page 93: ...5 REMOVAL OF ENGINE 5 10 NOTES This chapter Contents...

Page 94: ...Disassembly 6 6 Cylinder Head Inspection 6 7 Valve Stem Replacement 6 9 Valve Seat Inspection And Service 6 10 Cylinder Head Reassembly 6 12 Cylinder Head Installation 6 14 Valve Clearance Adjustment...

Page 95: ...stem Exhaust 4 950 4 975 4 900 Guide seat 5 000 5 012 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Free length of valve spring 35 000 31 500 Valve Va...

Page 96: ...Poor sealing on valve seat z Improper spark plug installation 2 Cylinder head z Cylinder head gasket leaking or damage z Tilt or crack cylinder surface 3 Piston z Piston ring worn out High compressio...

Page 97: ...lt x 2 Remove the right cover of engine screw x 4 Remove the left cover of engine screw x 4 Remove the left cap bolt of cylinder head bolt x2 and then remove the left cap of cylinder head Remove the s...

Page 98: ...a flat screwdriver to tighten the screw of camshaft chain tensioner in a clockwise motion for release tensioner Remove the cam sprocket bolt x2 Remove the left bolt bolt x2 of cylinder head firstly a...

Page 99: ...e Tool Valve spring compressor Or with the valve spring remover installer to compress the valve spring directly Then remove the valve and valve spring Caution Special Service Tool Valve spring remover...

Page 100: ...g for looseness or wear out If any replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D Service Limit Replace when it is less than 12 10 mm Rocker Arm Shaft Measure the...

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