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Sym Citycom.300i, Service Manual

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Sym Citycom.300i Service Manual Download Page 196

13. Body Cover

13-1

Mechanism Diagram €€€€€€€€€€€€€€€€€€€€€€€€€€€13-1

Maintenance €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-2

Handle Front Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€13-3

Wind Screen €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-4

Front Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-4

Handle upper cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€13-5

Handle lower cover€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-6

Inner Box €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-7

Side Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€13-9

Front Under Spoiler €€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-10

Side Garnish€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-10

Front Fender€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-11

Luggage Box €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-12

Rear Carrier €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-13

Rear Body Cover€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-14

Floor Panel €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-15

Under Cover €€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€€ 13-16

Mechanism Diagram

13

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Contents

Summary of Contents for Citycom.300i

Page 1: ...DK Version 1 0 2009 Citycom 300i SERVICE MANUAL FOREWORD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER...

Page 2: ...Procedures Operation Key Points and Inspection Adjustment providing technicians with service guidelines If the style or the mechanical structures of the scooter LH30W series scooter are different from...

Page 3: ...ease see index of content for quick having the special parts and system information There are 4 buttons Foreword Contents How to use this manual and Mechanism Illustrations on the CD R version and can...

Page 4: ...ton 7 8 1 8 14 V Type Belt Driving System Kick Starter 8 9 1 9 8 Final Drive Mechanism 9 10 1 10 10 Alternator 10 11 1 11 8 Crankshaft Crankcase 11 12 1 12 14 Cooling System 12 13 1 13 16 Body Cover 1...

Page 5: ...Serial Number Home page Contents...

Page 6: ...lass oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil LIQUI MOLY Racing 4T 10W 40 oil Grease LIQUI MOLY LM50 is recommended Gear oil LIQUI MO...

Page 7: ...gine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is strictly prohibi...

Page 8: ...als because most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent unsmooth control and premature worn out Rubber parts may become deteriorated when old and...

Page 9: ...ease 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 Remove res...

Page 10: ...tools like open end wrench do not contact with body to prevent from circuit short and create sp ark After service completed make sure all connection points is secured Battery positive cable should be...

Page 11: ...se 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 terminal compl...

Page 12: ...ht 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 Secure the rubb...

Page 13: ...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 sand paper...

Page 14: ...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 gasoline Speedometer 0 160 km hr Cy...

Page 15: ...Dia mm Torque Value kgf m Remarks Cylinder head nut 4 8 2 0 2 4 Cylinder head right bolt 2 8 2 0 2 4 Cylinder head stud bolt inlet pipe 2 6 0 7 1 1 Cylinder head stud bolt EX pipe 2 7 0 5 1 0 Tappet a...

Page 16: ...0 Rear fork 2 8 4 0 5 0 Rear cushion upper bolt 2 10 3 5 4 5 Rear cushion under bolt 2 8 2 4 3 0 Nut for steering post 1 10 4 0 5 0 Front cushion 4 8 2 4 3 0 Brake lever nut 2 6 0 8 1 2 Nut for the re...

Page 17: ...upplied with the fuel for fuel injector 1 Check the fuel amount in the fuel tank 2 Check the supply of the fuel gasoline hose and the vacuum tube are blocked or not 3 Malfunction of fuel pump relay or...

Page 18: ...ression pressure gauge Compression pressure correct No compression pressure Cylinder piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration piston can not be mo...

Page 19: ...nstall spark plug into spark plug cap and perform spark test against engine ground Check the fuel pump supply situation good poor Normal Clogged 1 change the fuel injector Incorrect ignition timing ma...

Page 20: ...ley spring broken Clutch lining broken Driving shaft groove broken Transmission gear damage Transmission gear worn out or burned Engine running and misfire as motorcycle initial forward moving or jump...

Page 21: ...N 1 16 Parts to Be Greased Acceleration cable Front rear brake lever pivot Steering shaft bearing Seat catch Clutch bearing Main stand pivot Side stand pivot Speedometer gear front wheel bearing To th...

Page 22: ...2 14 Precautions in Operation Specification Fuel Tank Capacity 10 000 c c capacity 1 400 c c Engine Oil change 1 200 c c capacity 180 c c Transmission Gear oil change 160 c c Capacity of coolant Engin...

Page 23: ...7 Variomatic components I I 18 Fuel cock og hoses I I I 19 Fuel filter I R R 20 Throttle function and cable A A A 21 Bolts and nuts engine I I 22 Bolts and nuts chassis I I 23 Head cylinder and piston...

Page 24: ...always replace the washer gasket on the drain plug Tighten the oil drain bolt Torque value 3 5 4 5kgf m Pour in the oil viscosity SAE 10W 40 Recommended oil LIQUI MOLY Engine oil capacity Disassembly...

Page 25: ...uel Line Cable Remove luggage box Remove rear carrier Remove body covers Remove floor panel Check all lines and replace them when they are deteriorated damaged or leaking Warning Gasoline is a low fla...

Page 26: ...ing the adjuster Tighten the locknut and check throttle operation condition Air Cleaner Air Cleaner Element Remove 9 screws from the air cleaner cover and then remove the cover Remove the air cleaner...

Page 27: ...nition timing inspection cap located on the right cover of the engine Turn the camshaft bolt clockwise and let the T mark on the camshaft sprocket align with the cylinder head mark so that piston is p...

Page 28: ...timing is located within the ignition advance degrees it means that the ignition advance degree is correct If the ignition timing is incorrect check ECU flywheel and crankshaft position sensor Replace...

Page 29: ...w Incorrect valve clearance Valve leaking Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it means too much carbon deposits in the combustion chamber or on t...

Page 30: ...t ride the motorcycle with poor cushion Loose worn or damaged cushion will make poor stability and steering Front suspension Press the front suspension for several times to check its operational condi...

Page 31: ...ompatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system hoses Added Brake Fluid...

Page 32: ...lining Remove the brake clipper bolt and take out the clipper Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat...

Page 33: ...adjustment will make in coming driver dazzled or insufficient lighting Wheel Tire Caution Tire pressure check should be done as cold engine Appointed tire pressure Tire size Front tire Rear tire Load...

Page 34: ...aution If there is rust on the posts very serious spray some hot water on the posts Then clean it with steel brush so that can remove rust for more easily Apply some grease on the posts after rust rem...

Page 35: ...utch special nut socket NAME Tappet adjusting NO SYM 1130000 HMA H9A NO SYM 9020210 HMA NO SYM 1472100 NAME R crank case bearing 6201 assembles tool NAME Left crankshaft oil seal assembly socket NAME...

Page 36: ...uller NO SYM 9020200 NO SYM 2210100 NO SYM 3110000 HMA NAME Steering head top thread wrench NAME Bearing driver HK1516 NAME Bearing puller 6205 NO SYM 5320010 NO SYM 9100200 HMA RB1 HK1516 NO SYM 9100...

Page 37: ...HMA RB1 NO SYM 6303000 A 6303 30mm 22mm NAME Bearing driver 6201 NAME Crankcase bush puller NAME Crankcase bush puller NO SYM 9614000 6201 NO SYM 1120310 NO SYM 1120320 NAME Water pump mechanical seal...

Page 38: ...2 Maintenance Information 2 17 Note To this chapter contents...

Page 39: ...ngine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication Oil Route Con Rod Oil Rou...

Page 40: ...mm Limit mm Inner rotor clearance 0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer...

Page 41: ...After drained always replace the washer gasket Install oil drain bolt Torque value 1 9 2 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Always...

Page 42: ...ain and sprocket Make sure that pump shaft can be rotated freely Remove 2 bolts on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and disassemble the pu...

Page 43: ...n rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaf...

Page 44: ...d then tighten bolts Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump driving chain and sprocket and then install snap ring onto oil pump shaft Install st...

Page 45: ...oil level inspection bolt Remove drain plug and drain oil out Install the drain plug after drained Torque value 1 0 1 4kgf m Always replace the drain plug washer when disassembled Add oil to specifie...

Page 46: ...3 LUBRICATION SYSTEM 3 8 Notes To this chapter contents...

Page 47: ...Fault Diagnosis 4 33 Integrated Fault Diagnosis Program 4 37 Air Cleaner 4 40 Fault Diagnosis Note 4 41 Warning Lamp Fault Codes Differentiation 4 42 Fault Codes and Sensors Table 4 43 Fault Code and...

Page 48: ...stem 4 2 Fuel Injection System Configuration Roll Over Sensor CPS Right O2 Sensor TA Sensor TPS AISV Left To this chapter contents Fuel Pump MAP Sensor ISC Fuel Injector ECU TW Sensor Diagnostic Coupl...

Page 49: ...2 Sensor Roll Over Sensor Throttle Position Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor INJECTOR IGN COIL FUEL PUMP CHECK LIGHT Tuning tools Diagnostic Scanner VBATT Battery Vo...

Page 50: ...this condition three major processes are done simultaneously in the carburetor 1 Air quantity measurement 2 The determination of fuel quantity 3 Mixing of fuel and air Electronic Fuel Injection Syste...

Page 51: ...art motor for continuous movement which could led to lack of battery electricity less than 10 V the electric fuel pump will not be able to move Injector Two hole injector provides intake valves with t...

Page 52: ...omsumption efficiency Specifications 1 Ignition timing 13 BTDC 1650RPM 2 Spark plug NGK CR8E Clearance 0 6 to 0 7 mm 3 Crankshaft Position Sensor electric resistance 80 160 Green White Blue Yellow 4 I...

Page 53: ...CU to make it work properly Note When starting the TDC position is not known yet CPS detects the long tooth on the flywheel determining the TDC position with the ignition timing being fixed When the e...

Page 54: ...the engine Note When the motorcycle is leaning more than 65 degrees the power of ECU will be shut off To restart the engine you need to Key on the main switch again ECU Main switch Fuse 20A Battery F...

Page 55: ...goes up as temperature goes down providing ECU temperature signals to determine the fuel injection quantity and ignition timing MAP Sensor MAP Sensor uses the piezoresistive resistor composed of silic...

Page 56: ...uel mixture with higher temperature and higher NOx concentration 1 O2 Sensor outputs feedback signal to ECU which keeps the air fuel mixture near the stoichometric ratio approximately 14 6 and forms t...

Page 57: ...lectric resistance and voltage value change determining the throttle position Function TPS determines the throttle valve position and sends signal to ECU as reference of engine control Throttle positi...

Page 58: ...le Speed Control Valve Stepper Motor ISC Function ECU controls ISC stepper motor to adjust the bypass intake air quantity and stablize the idle speed ISC Valve ECU Battery Va Va Vb Vb Step S N S S N N...

Page 59: ...tity to reduce pollutant emission Basic Principle When the engine speed and throttle opening are higher than the default value ECU controls AISV opening or closure Air Injection Solenoid Valve Reed va...

Page 60: ...prevent fuel from splashing Cautions Do not bend or twist the throttle cable Damaged cable will lead to unstable driving When disassembling fuel system parts pay attention to O ring position replace w...

Page 61: ...he vehicle 2 Key on but not to start engine confirm ECU and the diagnostic scanner can be connected or not 3 Diagnostic scanner will automatically display Version certification of the screen 4 Confirm...

Page 62: ...le opening immediately Throttle valve positioning screw has been adjusted and marked on the production line Readjustment is not suggested Treatment of abnormal phenomena If all fuel injection associat...

Page 63: ...ltage Volteg meter negative access to the inlet pressure sensor third pin Green Red Voltage meter positive access to the inlet pressure sensor first pin Yellow Black 5 Confirmed plains output voltage...

Page 64: ...e ECU then calculated the temperature and in accordance with the ECU temperature and state amendments injection time and ignition angle Testing Procedures Resistance Value Measurement Dismantled inlet...

Page 65: ...ector to properly using the probe tool or can be removed connector to voltage measurements direct measurement 2 Opened the main switch but not to start engine 3 Use volteg meter DC stalls DCV to check...

Page 66: ...osis tool screen switches to a data analysis 01 03 screen 3 Rotations throttle and check voltages Treatment of abnormal phenomena Throttle sensor damage or connector poor contact Check whether the abn...

Page 67: ...onverted into voltage signals sent to the ECU was calculated engine temperature ECU accordance with the engine warm up to amendment the injection time and ignition angle Testing Procedures Dismantled...

Page 68: ...moved O2 Sensor and the wire harness between the coupler Open the main switch but not to start engine Use volteg meter DC stalls DCV to check inlet pressure sensor voltage Confirmed working voltage Vo...

Page 69: ...engine speed to about 4500 rpm Observation O2 Sensor actuator circumstances Observation O2 Sensor voltage values that the situation changes Detection judge Working voltage value above 10V Resistance...

Page 70: ...the electronic control agencies not against removed after a single measurement Normal state after power is turned on the main switch measurement of ECU power relays red yellow line to the Green Line...

Page 71: ...tance values A phase ISCAP and ISCAN B phase ISCBP and ISCBN Inspection of the actuation testing can only be on engine not a single test Closure of the main switch Use hand to touch Idle Air Control V...

Page 72: ...ler to properly using the probe tool or can be removed coupler working voltage measurements direct measurement Open the main switch but not to start engine Use volteg meter DC stalls DCV to check fuel...

Page 73: ...re measurement will go to the demolition of the fuel hose such as injector or fuel pump hose hydraulic measurements after be sure to confirm whether there is a leakage of fuel situation in order to av...

Page 74: ...tightly by hands fuel spills should not be the case Key on and start the engine injector injection state examination Detection judge 1 Between the two pin resistance values 11 7 0 6 2 injection state...

Page 75: ...gnition coil primary circuit 2 8 15 20 C Treatment of abnormal phenomena 1 Ignition coil internal coil disconnection damaged or plugs bad contact 2 Ignition coil ignition is not abnormal proposes to r...

Page 76: ...or closing Testing Procedures Resistance Confirmation Use of the meter Ohm stalls measurement of the secondary air injection solenoid valve resistance value Detection judge Resistance value 26 2 6 20...

Page 77: ...1 PG 18 VCC TH 16 SG 05 TW 08 PM 22 09 CRK M 20 Y G G W G G R Y R B G W R L G G W B R Y B R GR G R R O Y Y Y B R G B G CPS 06 HEGO A D 11 HEGO HT Test Switch Coupler 15A 20A G P W Fuel pump relay Fuel...

Page 78: ...A D 25 G BR TA Inlet air temperature sensor A D 08 G LG ECU ground 26 No use 09 L Y CRK M Crankshaft Position Sensor 27 No use 10 W G K LINE Sequence transmission signal output input 28 No use 11 O W...

Page 79: ...CU 5V voltage sensor voltage of less than 0 2 V 1 Main switch OFF 2 Use probe inserted throttle sensor engine temperature sensor the inlet pressure sensor power connector 3 Main switch ON 4 Use voltag...

Page 80: ...1 Fuel tank inadequate 2 Fuel injector pressure less than 294 6kpr 3 Pipeline fuel spills 4 Pressure Regulating Valve abnormal 5 Fuel pump pipe leakage 6 Fuel pump abnormal 7 Fuel injector abnormal 1...

Page 81: ...recommended that engine checks whether there are other traditional institutions abnormal Idle flameout 1 Link diagnosis tool to view EFI fault content 2 In accordance with Troubleshooting procedures o...

Page 82: ...system more relevant institutions each recognized by the detection if still unable to rule out the idling flameout problem it is recommended that engine checks whether there are other traditional ins...

Page 83: ...nspection NO Injector whether injection Injector spray angle is normal Fuel pressure enough Removed the injector on the intake manifold but not removal of harness coupler Injector and injector cap tig...

Page 84: ...NG YES Use diagnosis tool to detect of the manifold pressure Engine vacuum Diagnosis tool manifold pressure for compliance with specifications Valve clearance is not normal Intake system leak Manifol...

Page 85: ...tank Remove Install fuel pump and fuel unit Remove fuel pump fixed bolts Bolt 6 remove fuel pump Install In the anti demolition order Cautions Then remove fuel pump fuel in fuel tank internal to conf...

Page 86: ...lean air cleaner Remove air cleaner cover bolt 8 Remove air cleaner filter bolt 6 Use compressed air to remove the adhesion of dirt if not too much dirt cleared please new replacement Cautions Air cle...

Page 87: ...iagnostic Scanner Connect the diagnostic scanner to the motorcycle proceed the inspection according to the use of diagnostic tool testing methods when belong fuel injection system fault or parts fault...

Page 88: ...Fault Code the implementation of the following steps 1 Main switch OFF 2 Cross access the test switch for interconnection access and without opening up cross access movement must indeed 3 Full thrott...

Page 89: ...ault Intake temperature sensor and wire 6 1630 ROS Fault Roll over sensor and wire 7 0130 O2 Sensor Fault O2 Sensorand wire 8 0201 Injector Fault injector and wire 9 0351 Ignition Coil Fault Ignition...

Page 90: ...detection procedures Please refer to the EFI System components description O2 sensor chapter 1 fault lighting long 3 short 3 Injector and wire 8 0201 Fault detection procedures Please refer to the EF...

Page 91: ...button into the main screen there are 6 major functions ECU ID DATA STREAM FREEZED DATA TROUBLE CODE ERASE TB CODE and CO ADAPTION 5 Use select button under the function press the ENTER button access...

Page 92: ...ON 3 Open the diagnosis left power switch which turn on the LCD screen the screen brightness adjustment knob to the appropriate brightness 4 SYM and cartridge content display on screen such as icon b...

Page 93: ...ional areas 1 ECU ID 2 DATA STREAM 3 FREEZED DATA 4 TROUBLE CODE 5 ERASE TB CODE 6 CO ADAPTION Use button select mobile anti white subtitles implementation of the project and then press the ENTER key...

Page 94: ...2 ECU Pin Assign 1 1 ECU ID Datas Use button select ECU ID projects press the ENTER buttom to the implementation A total of 2 page use left and right button view ECU information DIAG ID 0002000000020...

Page 95: ...d GND Page 2 9 CRK M L Y Crankshaft pos Sensor 10 K LINE W G K Line 11 FLPR O W Fuel pump relay O P 12 SOL O L 2nd air RV250 13 VCC Y B Sensor V DC 5V 14 ISCBP G B Step MTR B RV250 15 ISCAP L B Step M...

Page 96: ...tton select DATA STREAM project press the ENTER key to the implementation A total of 3 pages are able to use left and right button view injection system information On the any screen press the EXIT bu...

Page 97: ...ltage O2 SENSOR mV Idle 50 200mV O2 sensor voltage O2 HEATER Idle 3500rpm ON O2 heater actuator state ENGINE TEMP C Stable 85 95 C Engine temperature cooling water temperature In the DATA STREAM of th...

Page 98: ...CRANKSHAFT Idle CW Crankshaft functioning direction TEST TERMINAL Idle OPEN Test terminal state IDLE SET RPM 1650 RPM Idle speed goal set value ISC STEP Idle 75 95 Idle Air Control Valve stepper motor...

Page 99: ...r learning step In the DATA STREAM of the screen use button to move the left side of the project symbol selected items press the ENTER buttom lock of the project and press the F4 button showed that th...

Page 100: ...press the ENTER key to the implementation Only one page at any screen press the EXIT button the function can return to the directory screen In the FREEZED DATA of the screen use button to move the le...

Page 101: ...is that showing System is OK Press the EXIT button the function can return to the directory screen If the system has faulty code that is showing the fault code that can be used left and right or butto...

Page 102: ...TB CODE project press the ENTER key to the implementation Conditions The main switch ON or in the engine running state the fault code can be removed Fault code removed namely showing the ERASE TB SUC...

Page 103: ...select CO ADAPTION project press the ENTER buttom into the CO adjustment screen Use left and right or button CO value can be adjusted CO ADAPT CO adjusted value CO Read CO read back value Press the EX...

Page 104: ...ation Inability and slow Idle flameout Flameo ut Acceleratio n flameout Related spare parts Roll over sensor Fuel pump Ignition coil Inlet pipe Injector O2 sensor Power relay Fuel pressure adjustment...

Page 105: ...ifold pressure 32 38kPa Valve clearance abnormal Intake system leak 5 Injection state The injector removed from the throttle body but not dismantle pipeline Main switch ON but not start engine Investi...

Page 106: ...4 Fuel Injection System 4 60 Note To this chapter contents...

Page 107: ...2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism 4 AC Generator Specification Item LH30W Replacement 1 200 c c Engine Oil Capacity Disassemble 1 400 c c Replac...

Page 108: ...covers 4 screws on each side Remove rear center cover 1 screw Remove rear carrier 4 bolts Remove right and left side garnish 1 screw Remove body cover 4 screws 1 coupler 2 bolts Remove floor panel 4 b...

Page 109: ...hermo unit and TW sensor wire couplers Remove the throttle position sensor coupler Remove the TA sensor coupler Remove the AISV pipe TW sensor Thermo unit Inlet temperature sensor Secondary air pipe T...

Page 110: ...ine to be exhausted within the residual pressure the engine flameout relaxing fuel tube folder open for fuel tube Caution Demolition for the pipeline will be required for residual pressure in the pipe...

Page 111: ...3 screws from rear mudguard Remove the air cleaner connection bolts 2 bolts Remove the air cleaner Loosen the 3 bolts from muffler Loosen the muffler band bolt 1 bolt Remove the muffler 2 bolts 2 bolt...

Page 112: ...bolt Remove the rear fork bolts 2 bolts Remove the rear wheel axle nut 1 nut Remove rear brake hose clamp and rear brake caliper 2 bolts Drain out coolant and remove coolant inlet hose Inlet hose Dra...

Page 113: ...e Hanger Removal Remove the engine side bolts of engine hanger 1 bolt on each side Remove the engine hanger Check if the engine hanger bush and cushion rubber for damage If so replace with new ones In...

Page 114: ...ghtly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing removal Remove bearing mounting cir clip Drive the bearing out of the rear fork Bearing installation Instal...

Page 115: ...ing puller Special Service Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the rear fork bearing Install b...

Page 116: ...nger bushing 28mm Rear cushion bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pressing ring and bolt in to press the bushing out Specia...

Page 117: ...and hands safety for squeezing as engine installation Do not bent or squeeze each wires or hose Route all cables and wires in accordance with the routine layout Engine hanger nut Torque Value 7 5 9 5k...

Page 118: ...Head Inspection 6 8 Valve Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram 6...

Page 119: ...5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Inner 38 700 35 200 Free length of valve spring outer 40 400 36 900 Valve seat width 1 600 Intake 0 10 0...

Page 120: ...Improper valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure To...

Page 121: ...move the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove...

Page 122: ...ve the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side Remove the cylinder head Remove cylinder head gasket and 2 dowel pi...

Page 123: ...e cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the va...

Page 124: ...m seals Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution Do not damage the matching surface of cylinder head To this chapter c...

Page 125: ...spect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D and wear or damage oil hole clogged Service Limit...

Page 126: ...record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and...

Page 127: ...en pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Too...

Page 128: ...eal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the contac...

Page 129: ...seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve se...

Page 130: ...alve cotter remove assembly tool to press the valve springs and then install valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag betwee...

Page 131: ...oid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of c...

Page 132: ...pe 4 bolts Install inlet pipe onto cylinder head Install and tighten spark plug Torque value 1 0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can...

Page 133: ...gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side c...

Page 134: ...gram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 7 Home page...

Page 135: ...0 010 0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod sma...

Page 136: ...linder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be remov...

Page 137: ...n rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of c...

Page 138: ...r of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance f...

Page 139: ...refully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all p...

Page 140: ...een piston and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Clean up all residues and foreign materials on the matching surface of crankcase P...

Page 141: ...en when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coo...

Page 142: ...anism Diagram 8 1 Maintenance Precaution 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram Home page Contents 5 0 6 0kg...

Page 143: ...m 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value Drive face nut 8 5 10 5kgf m Clutch outer nut 5 0 6 0kgf m Drive plate nut 5 0 6...

Page 144: ...left side crank out cover remove it Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal To...

Page 145: ...rned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing replacement Remove bea...

Page 146: ...roove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspectio...

Page 147: ...e shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque va...

Page 148: ...n remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft D...

Page 149: ...ary Measure the outer diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed...

Page 150: ...pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution Make sure that two sides of pulley surfaces have to be free of...

Page 151: ...ice tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable...

Page 152: ...the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner bearing...

Page 153: ...n Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch bloc...

Page 154: ...de of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution Its sealing end should be forwa...

Page 155: ...nd clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting n...

Page 156: ...9 2 Trouble Diagnosis 9 2 Disassembly of Final Drive Mechanism 9 3 Inspection of Final Drive Mechanism 9 4 Bearing Replacement 9 5 Re Assembly of Final Drive Mechanism 9 8 Mechanism Diagram 9 Final s...

Page 157: ...40 8 socket SYM 9120200 HMA Bearing HK1516 driver SYM 9100200 HMA HK1516 Oil seal drive 34 52 5 SYM 9125500 HMA Inner bearing puller SYM 6204022 Outer bearing puller SYM 6204010 Drive shaft install p...

Page 158: ...x cover Remove the gasket dowel pin Remove final gear Remove counter shaft gear and 2 washers Remove final shaft Remove the drive shaft Special tool Shaft protector Caution If non essential do not rem...

Page 159: ...inal shaft and gear are worn or damaged replace it if necessary Check bearings on gear box cover Rotate each bearing s inner ring with fingers Check if bearings can be rotated smoothly and silently an...

Page 160: ...t crankcase using following tools Special tool Inner bearing puller SYM 620422 Caution Never install used bearings Once bearing removed it has to be replaced with new one Install new final shaft beari...

Page 161: ...ide Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 Remove oil seal and then remove final sh...

Page 162: ...Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the final shaft bearing Apply with grease onto final shaft...

Page 163: ...ket oil seal driver 25 40 8 SYM 9120200 HMA Install 2 dowel pins new gasket Install counter shaft and final shaft into the gear box cover Install the gear box and tighten the bolts 7 bolts Torque valu...

Page 164: ...ankcase Cover Removal 10 3 AC Generator Removal 10 4 Right Cover Bearing 10 4 Flywheel Removal 10 5 Starting Clutch 10 6 Flywheel Installation 10 8 AC Generator Installation 10 9 Right Crankcase Cover...

Page 165: ...alue mm Limit mm ID of starting clutch gear 25 026 25 045 25 050 OD of starting clutch gear 42 192 42 208 42 100 Torque value Flywheel nut 5 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with a...

Page 166: ...s 2 nuts Drain out the engine oil and coolant refer chapter 5 Remove coolant hoses Disconnect the couplers of the power source output line Remove water pump cover 4 bolts Remove 10 bolts from the righ...

Page 167: ...aring rotation is smooth and silent Check if the bearing outer parts are closed and fixed replace it if necessary Remove the bearing 6201 with inner bearing puller Special tool Inner bearing puller SY...

Page 168: ...shaft protector onto the crank shaft Special tool Shaft protector Remove starter reduction gear and shaft Pull out flywheel with AC generator flywheel puller Special tool Flywheel puller SYM 3110000...

Page 169: ...driven gear Service Limit ID 25 050 mm OD 42 100 mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage Install starting clutch driven gear onto one wa...

Page 170: ...Install the components in the reverse procedures of removal Torque value 1 0 1 4kgf m Caution Cannot lock the thread of socket bolt Caution The one way clutch must to with the generator flywheel and...

Page 171: ...e way clutch Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 5 0 6 0kgf m...

Page 172: ...Cover Installation Install dowel pins and new gasket Remove water pump cover Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump shaft Install ri...

Page 173: ...10 AC Generator Starting Clutch 10 10 Notes To this chapter contents...

Page 174: ...hanism Diagram 11 1 General Information 11 2 Trouble Diagnosis 11 2 Crankcase Disassembly 11 3 Crankshaft Inspection 11 4 Crankcase Reassembly 11 6 Mechanism Diagram 11 0 8 1 2kgf m 0 8 1 2kgf m 1 0 1...

Page 175: ...t mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Run out 0 100 Torque value Bolts for crank...

Page 176: ...to left crankcase Caution Care should be taken not to damage the contact surfaces Install left crank shaft puller into crank case disassemble Hold left crank shaft puller nut by clutch nut wrench and...

Page 177: ...ace Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Drive out left crankcase oil seal Crankshaft Inspection Use a thickness gauge to m...

Page 178: ...k crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If any roughness noise and loose linkage are...

Page 179: ...aft bearing into left crankcase Special tool Crank case disassemble SYM 1120000 HMA H9A L Crank shaft puller SYM 2341110 HMA Clutch nut wrench SYM 9020200 Install crank shaft onto the left crankcase a...

Page 180: ...r piece certainly must install Cannot install the wrong position or leak the attire Otherwise can cause the motorcycle to have the fierce vibration Install 2 dowel pins and new gasket Install the righ...

Page 181: ...al in the left crankcase with special tool Special tool Crank shaft install socket oil seal driver SYM 2341110 HMA RB1 Install the cam chain tensioner and tighten the bolts Torque value 1 2 1 6kgf m I...

Page 182: ...oolant Replacement 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram 12 Home page Contents Reserve tank filler cap Radiator Thermo switch fan Reserve tank outlet pipe Thermo unit t...

Page 183: ...gine radiator Reserve tank 1400c c 420c c Thermostat Begins to activate at 82 92 C Stroke 0 05 3 0mm 80 C Boiling point Not pressure 107 7 C Pressurized 125 6 C Recommended Coolant LIQUI MOLY Torque V...

Page 184: ...Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coolant ha...

Page 185: ...ntil the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then chec...

Page 186: ...n the engine and remove by pass pipe Check the by pass hole and see if the air bubble emit or not If there is no air bubble emit with only the coolant flow out then reinstall the pipe and shut down th...

Page 187: ...age from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Remove Place a...

Page 188: ...fun mounting bolts 3 bolts Remove thermo switch Installation Install the removed parts in the reverse order of removal Install radiator in the reverse order of removal Upon completion check for any l...

Page 189: ...A confirms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain...

Page 190: ...ht crankcase Special tools Inner bearing puller Water pump bearing drive SYM 9100100 Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the right...

Page 191: ...r Special tools Water pump bearing driver 6901 SYM 9100100 Caution Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing...

Page 192: ...en Torque Value 1 0 1 4kgf m Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil...

Page 193: ...17 for inspection of thermo unit Removal Remove the luggage box and body cover Drain out the coolant Remove the thermostat cover 2 bolts Remove the thermostat Inspection Visually inspect thermostat f...

Page 194: ...played is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve...

Page 195: ...12 Cooling System 12 14 Notes To this chapter contents...

Page 196: ...4 Front Cover 13 4 Handle upper cover 13 5 Handle lower cover 13 6 Inner Box 13 7 Side Cover 13 9 Front Under Spoiler 13 10 Side Garnish 13 10 Front Fender 13 11 Luggage Box 13 12 Rear Carrier 13 13...

Page 197: ...e that each hook is properly installed during the assembly Never compact forcefully or hammer the guard and the covers during assembly Rear body cover Under cover Handle lower covers Floor panel Wind...

Page 198: ...e cover Loosen 2 screws from left and right side for handle front cover after side Wind Screen Remove the 5 screws from to meter visor Remove handle meter visor Installation Install in reverse order o...

Page 199: ...n 3 bolts from the front cover front end Loosen 8 screws from each side 4 screws for front cover after side Disassemble the headlight coupler Remove the front cover Installation Install in reverse ord...

Page 200: ...the 4 screw from the handle lower cover rear side Disassemble the winker relay and brake light couplers Remove the handle upper cover Installation Install in reverse order of removal procedures Winker...

Page 201: ...e 2 screws from handle lower cover Remove the handle stand nut and bolt Improve the direction handle up Remove the handle lower cover Installation Install in reverse order of removal procedures To thi...

Page 202: ...ove main switch cap bolt then remove main switch cap Loosen 2 screws from the front spoiler Open inner box lid Remove 1 screw from the inner box in side Remove 1 screw from reserve tank lid Remove 1 b...

Page 203: ...crew and 1 bolt from left and right side for inner box down side Remove reserve tank cap then separate the reserve Remove the inner box Installation Install in reverse order of removal procedures Rese...

Page 204: ...en 1 screw from left and right side for side covers font side Loosen 1 screw from left and right side for side covers rear upper side Remove side cover Installation Install in reverse order of removal...

Page 205: ...er front side Remove the front spoiler Installation Install in reverse order of removal procedures Side Garnish Loosen 1 screw from left and right side for side garnish Remove the left and right side...

Page 206: ...B Installation Install in reverse order of removal procedures Remove front fender A Loosen 3 bolts from the front fender above the inside Loosen 2 screws from the front fender above the inside Remove...

Page 207: ...crews from the battery cover Remove the battery cover Loosen 6 bolts from luggage box Disconnect the luggage box light and switch coupler Remove the luggage box Installation Install in reverse order o...

Page 208: ...center cover Loosen 2 bolts front tail light upper side Loosen each side 2 bolts from body inside Remove the rear carrier Installation Install in reverse order of removal procedures To this chapter co...

Page 209: ...rews from rear end of floor panel Loosen 2 bolts from rear fender Disconnect the tail light coupler Remove the body cover Installation Install in reverse order of removal procedures Tail light coupler...

Page 210: ...box luggage box and body cover Remove each side 2 caps from floor panel Loosen 4 bolts from floor panel Loosen each side 1 screws from floor panel rear side Remove floor panel Installation Install in...

Page 211: ...13 Body Cover 13 16 Under Cover Each side 2 bolts from under cover Remove the under cover Installation Install in reverse order of removal procedures Each side 2 bolts To this chapter contents...

Page 212: ...e Description 14 2 Trouble Diagnosis 14 3 Disk Brake System Inspection 14 4 Adding Brake Fluid 14 5 Brake Fluid Replacement 14 6 Front Brake Caliper 14 7 Rear Brake Caliper 14 8 Brake Disk 14 9 Master...

Page 213: ...d damage Check the operation of the brake system before riding Specifications unit mm Item Standard Limit The thickness of front brake disk 4 000 2 500 The thickness of rear brake disk 5 000 3 500 Fro...

Page 214: ...ver 1 Blocked brake system 2 Poor brake caliper 3 Blocked brake pipe 4 Seized worn master cylinder piston 5 Bent brake lever Uneven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged bra...

Page 215: ...replaced with new lining when the brake pad wear limit reaches the brake disk Park the motorcycle on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid LIQUI MOLY...

Page 216: ...stic or rubber components may result in their damages Remove the master cylinder cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins i...

Page 217: ...ed below 1 Tightly hold the brake lever and open the valve around 1 4 turns and then close the valve Caution Do not release the brake lever before the drain valve is closed Always check the brake flui...

Page 218: ...bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Remove brake caliper Remove bra...

Page 219: ...Use M8 x 35 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the br...

Page 220: ...he asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Master Cylinder Master Cylinder Removal Caution Do not let...

Page 221: ...brake 13 945 mm Master Cylinder Assembly Caution It is necessary to replace the whole set comprising piston spring piston cup and cir clip Make sure there is no dust on all components before assembli...

Page 222: ...h 2 new washers Tighten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together...

Page 223: ...14 Brake System 14 12 Note To this chapter contents...

Page 224: ...gram 15 1 Operational Precautions 15 2 Trouble Diagnosis 15 2 Steering Handle 15 3 Front Wheel 15 5 Front Cushion 15 8 Steering Stem 15 9 Mechanism Diagram Home page Contents 1 0 2 0kgf m 0 2 0 3kgf m...

Page 225: ...0 SYM 5321100 Inner bearing puller SYM 6204020 Steering nut wrench SYM 6204010 Driver 32 35mm Driver 42 47mm Trouble Diagnosis Hard to steer The steering handle stem nut is too tight The ball and the...

Page 226: ...oosen the lock bolts for the master cylinder of the front brake Loosen the deceleration throttle cable fixing nut Loosen 1 screw from the acceleration throttle fixing plate Loosen 2 screws from the th...

Page 227: ...n remove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 5 0kgf m Apply with grease onto throttle cable and the sliding surfac...

Page 228: ...squeezed out In case that the brake pad is accidentally squeezed out use a screwdriver to force it back to the place Loosen screw remove speedometer cable Turn loose the axle nut Loosen the socket bo...

Page 229: ...oisy and loose when being moved remove and discard it Caution The bearing shall be replaced in pair Wheel Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and m...

Page 230: ...l and install the dist collar Install the right side bearing Caution Carefully install the bearing in correct and evenly Bearing outer face should be faced up as bearing installation Install the brake...

Page 231: ...brake caliper Remove speedometer cable Loosen 4 bolts from steering stem Remove the front cushions Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Tor...

Page 232: ...o remove the seats Remove bottom cone race body with a punch Caution Do not damage the steering stem Installation Install a new bottom cone race onto the steering stem Push the cone race until to moun...

Page 233: ...Torque value 0 25kgf m Caution Check the steering stem that should be rotated freely and no clearance in vertical direction Install the steering stem mounting nut and tighten the nut by means of holdi...

Page 234: ...Mechanism Diagram 16 1 Operational Precaution 16 2 Trouble Diagnosis 16 2 Muffler 16 3 Rear Wheel 16 3 Rear Fork 16 5 Rear Cushion 16 6 Mechanism Diagram Home page Contents 16 3 5 4 5kgf m 2 4 3 0kgf...

Page 235: ...fler mounting bolt 3 2 3 8kgf m Brake clipper mounting bolts 2 9 3 5kgf m Brake disc mounting bolt 4 0 5 0kgf m Trouble Diagnosis Run out of rear wheel Deformed or bent wheel hub Improper tires Loose...

Page 236: ...f m Muffler mounting nut 1 0 1 2kgf m Rear Wheel Removal Remove the exhaust muffler Remove the lower bolt of the right side rear cushion Remove 2 bolts and rear axle nut of the rear fork Remove the re...

Page 237: ...t Rotate it by hand and measure the run out with a dial indicator Run out limit 2 0 mm Installation Install in reverse order of removal procedures Torque Value Rear wheel axle nut 11 0 13 0kgf m Rear...

Page 238: ...lock cir clip Uses the bearing driver drive out the bearing Special tool Bearing driver Install new rear fork bearing and bearing puller 6303 onto rear fork Install assembly directs puller bearing pul...

Page 239: ...shions Remove the upper bolts by left and right rear cushions and then remove the cushion Installation Install in reverse order of removal procedures Caution The rear cushion must be replaced as a uni...

Page 240: ...mo Switch 17 21 Thermo Unit 17 22 Water Temperature Meter 17 22 Mechanism Diagram Home page Contents 17 Spark plug Fuse box Battery Ignition coil Main switch Fuel pump unit Horn Passing Beam Winker Ho...

Page 241: ...never rapid charge the battery The voltage must be checked with the voltmeter while charging the battery As ECU does not require an ignition timing check In case ignition timing is incorrect check ECU...

Page 242: ...s Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection or short...

Page 243: ...ect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 2A 5A Chargi...

Page 244: ...17 Electrical System 17 5 FUSE Fuse circuit diagram To this chapter contents...

Page 245: ...passes the condition Item Check Points Standard Value Main switch connection R B Battery voltage ON Battery connection R G Battery voltage Charging coil Y Y 0 2 0 4 If the readings measured are not n...

Page 246: ...tion and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal Disconnect each cable one by one and take measurem...

Page 247: ...tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 6000 r...

Page 248: ...tion sensor negative 09 pin L Y Crankshaft position sensor positive 18 pin G W Ignition coil driver To this chapter contents ECU CPS Roll over sensor AC G B Y L Y Ignition coil R Y G W R G L W W R B G...

Page 249: ...ignition coil Remove the cap from the spark plug Loosen 2 bolts and replace the ignition coil if necessary Inspection of crank position sensor Remove luggage box bolt 6 Disconnect the coupler of the...

Page 250: ...remove battery cover Disconnect the negative cable terminal of the battery Remove the luggage box Disconnect the cable positive terminal from the start relay Rear brake switch Engine stop relay Brake...

Page 251: ...egative terminal Check the continuity of the large terminal end If there is no continuity replace the relay Removal of Starter motor Turns off the main switch Remove the luggage box Disconnect the cou...

Page 252: ...Yellow Hi beam Side stand Turn L Turn R ILLUMI EFI SP RPM Speed sensor Turn right indicator Meter O SB L BR B Y R G Speedometer Main switch Fuel unit Fuse 20A R Red W White B Black L Blue G Green SB...

Page 253: ...ver handle upper cover Refer chapter 14 Disconnect the coupler of the speedometer and take off the meter Loosen 4 screws from meter panel Remove the speedometer Installation of meter Install in revers...

Page 254: ...hermo switch Hi beam light R Main switch Fuse 15A B Battery Winker unit B Ignition Fuse 20A Winker switch O SB R O SB R winker indicator FR R winker light RR R winker light L winker indicator FR L win...

Page 255: ...ulb 12V 35W Hi beam bulb 12V 35W Caution Never touch the bulb with finger which will create a heat point Clean the fingerprint left on the bulb with alcohol Installation Install the bulb of the headli...

Page 256: ...t and bulb Replace with new bulb if necessary Specification Position light bulb 12V 5W Winker light bulb 12V 21W Rear winker light bulb replacement Remove the luggage box Turn the winker light bulb se...

Page 257: ...stall the new main switch and tighten the mounting bolts Install the main switch coupler and cap Right handle switch Remove the handle cover and front cover Disconnect the coupler of right handle swit...

Page 258: ...osition R WR L FROM R PUSH OFF N FROM L Wire color Sky blue Gray Orange Brake Switch While grasp the brake lever firmly the terminals of white green and green yellow of the brake should have continuit...

Page 259: ...E position the resistance measured shall be as follows Position Resistance E Empty 97 5 107 5 F Full 4 10 Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupler t...

Page 260: ...h in the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperatur...

Page 261: ...ould be used as a heating medium as the test temperature must be higher than 100 Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Water Temperature Met...

Page 262: ...17 Electrical System 17 23 Note To this chapter contents...

Page 263: ...function Combustion chamber Combustion chamber 4 valve combustion chamber The semi circular combustion chamber is designed to balancing the air stream to achieve the combustion stability Exhaust syst...

Page 264: ...valve forces HC off from activated carbon and then sucks it into engine together with air from bottom of the canister The canister can be used repeatedly without reducing its performance because of th...

Page 265: ...et then plug it The pressure at the gauge should not drop to below 10mmAq within 10 seconds 3 PCV Function Test 1 Disconnect the hose of connection to the activated carbon canister and then connect a...

Page 266: ...catalytic converter is to transfer unburned CO HC and NOx to harmless CO2 H2O N2 gases 2 Pt Pd Rh etc precious metals are used into the catalytic converter so use only unleaded gasoline to prevent fro...

Page 267: ...then separated by the separator The separated vapor will be sucked into combustion chamber by engine negative pressure to be burned again instead of discharging into atmosphere Drain liquidized fuel...

Page 268: ...s within standard 2 Remove the exhaust pipe and shake it gently for noise Fuel Supply System 1 Clean the air filter 2 Check the air filter 3 Clean the carburetor fuel jet air jet and all circuit with...

Page 269: ...Conduct periodical inspection check one time for 3000 km 3 months Test exhaust emissions at idle speed Adjust ECU Clean fuel injector Replace fuel injector Keep the CO value in 0 5 2 5 note 3 by adju...

Page 270: ...19 Electrical Diagram 19 1 Home page Contents LH30W EFi Electrical Diagram 19...

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