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Sym Quad Lander 250, Service Manual

The Sym Quad Lander 250 Service Manual is a detailed and comprehensive user manual that provides valuable information and guidance for maintenance and repairs. You can easily download this manual for free from our website, ensuring hassle-free access to all essential instructions.

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION 

16-13 

 

Rear Brake Caliper 

Removal 

Place a container under the brake caliper, and 
loosen the brake hose bolt and finally remove the 
brake hose. 

 Caution 

Do not spill brake fluid on painted surfaces.

 

 
 
 
 
 

Remove two caliper bolts and the caliper. 

Inspection  

Make sure the brake linings condition.    Replace 
the linings if the brake linings wear limitation 
groove close to the brake disk. 

Installation 

Install the brake caliper and tighten the attaching 
bolts securely. 

Torque: 3.25kgf-m 

 Caution 

y

  Use M8 x 20 mm flange bolt only. 

y

  Long bolt will impair the operation of brake 

disk.

 

Use two seal washers and hose bolts to lock the 
hose and brake caliper in place. 

Torque: 3.5kgf-m 

Refill up the brake fluid to the reservoir and make 
necessary air bleeding. 
 
 

Brake lining replacement 

Remove two guide pins. 
 
 
 
Remove brake caliper cylinder, and then remove 
brake linings. 
Install new linings and brake caliper cylinder. 
Tighten the guide pins. 

Torque: 1.8kgf-m 

 

 

 

 

 

 

 

 

 

 

To this chapter contents 

2 bolts

Brake hose bolt

Guide pins

Summary of Contents for Quad Lander 250

Page 1: ...Quad Lander 250 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER ...

Page 2: ...Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV Quad Lander 250 are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department SANYANG INDUSTRY CO LTD Homepage Contents ...

Page 3: ... the special parts and system information There are 4 buttons Forward Contents How to use this manual and Mechanism Illustrations on the CD R version and can be access to these items by click the mouse If user wants to look for the content of each chapter selecting the words of each chapter on the contents can reach to each chapter There are two buttons Homepage and contents onto the top line of f...

Page 4: ...LINDER PISTON 7 8 1 8 14 V TYPE BELT DRIVING SYSTEM KICK STARTER 8 9 1 9 12 FINAL DRIVING MECHANISM 9 10 1 10 10 ALTERNATOR 10 11 1 11 8 CRANKSHAFT CRANKCASE 11 12 1 12 12 COOLING SYSTEM 12 13 1 13 14 BODY COVER 13 14 1 14 14 FRONT BRAKE AND FRONT WHEEL 14 15 1 15 10 STEERING FRONT SUSPENSION 15 16 1 16 18 REAR BRAKE REAR WHEEL REAR CUSHION 16 17 1 17 22 ELECTRICAL EQUIPMENT 17 18 1 18 2 ELECTRICA...

Page 5: ...SERIAL NUMBER Frame number Engine number Home page Contents ...

Page 6: ...se 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 is recommended Gear oil King Mate gear oil serials are recommended Bramax HYPOID GEAR OIL 140 Locking sealant Apply sealant medium strength sealant should be used unless otherwise specified Oil seal Apply with lubricant Renew ...

Page 7: ...as 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 prohibited Keeps the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery a...

Page 8: ...t cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent unsmooth control and premature worn out y Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary y When loosening a component which has different sized fasteners op...

Page 9: ...se install the oil seal with the name of the manufacturer facing outside and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal y Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage y The ends of rubber hoses for fuel vacuum or coolant should be pushed as far...

Page 10: ...egative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark y After service completed make sure all connection points is secured Battery positive cable should be connected firstly y And the two posts of battery have to be greased after connected the cables y Make sure that the battery post caps are located in properly after the bat...

Page 11: ...e y Check if the connector is covered by the twin connector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loose y Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up y Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the...

Page 12: ...ght nor have excessive slack y 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 y Secure the rubber boot firmly as applying it on wire harness y Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace them y Never clamp or squeez...

Page 13: ... parts in all steering positions y Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction y With sand paper to clean rust on connector pins terminals if found And then conduct connection operation later Do you know how to set the instrument to its measurement position and the insert locations of its tw...

Page 14: ...on Gear Sprocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 100 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A Bore Ø71 mm Muffler Expansion Pulse Type Stroke 63 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder N...

Page 15: ...on Gear Sprocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 100 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A Bore Ø71 mm Muffler Expansion Pulse Type Stroke 63 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder N...

Page 16: ...2 8 2 0 2 4 Cylinder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0 Air inject pipe bolt 4 6 1 0 1 4 Air inject reed valve bolt 2 3 0 07 0 09 Tappet adjustment screw nut 4 5 0 7 1 1 Apply oil to thread Spark plug 1 10 1 0 1 2 Tensioner lifter bolt 2 6 1 0 1 4 Carburetor insulator bolt ...

Page 17: ...nt axle castle nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 12 8 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 6 Driven gear nut 4 10 4 6 Swing arm pivot bolt 1 14 9 20 Front suspension arm nut 4 10 5 00 Front Rear cushion mounting bolt 6 10 4 60 Brake lever nut 2 6 1 00 Brake hose bolt 13 10 3 50 Brake caliper bolt 6 6 3 25 Brake disk mount...

Page 18: ...cuit Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged y No fuel in fuel tank y Check if the pipes fuel tank to carburetor and intake vacuum are clogged y Float valve clogged y Lines in fuel tank evaporation system clogged y Malfunction of fuel pump y Loosen or damaged fuel pump vacuum hose y Fuel filter clogged y Malfunction of spark plug y Spark plug fou...

Page 19: ...y Air cleaner clogged y Poor fuel supply y Lines in fuel tank evaporation system clogged y Exhaust pipe clogged y Fuel nozzle clogged in carburetor y Fuel nozzle clogged in carburetor y Malfunction of CDI y Malfunction of AC alternator y Cylinder piston ring worn out y Cylinder gasket leaked y Sand hole in compression parts y Valve deterioration y Seized piston ring y Remove foreign y Remove dirt ...

Page 20: ...Vacuum hose crack y Spark plug fouled y Malfunction of CDI y Malfunction of AC generator y Malfunction of ignition coil y Open or short circuit in spark plug leads y Malfunction of main switch y Insufficient fuel in fuel tank y Fuel filter clogged y Restricted fuel tank vent Good Abnormal Good spark Poor No air sucked Air sucked Good Poor Normal Abnormal Air sucked through carburetor gasket Adjust...

Page 21: ...r jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance y Drive belt worn out or deformation y Weight roller worn out y Movable drive face shaft worn out y Driven pulley spring deformation y Driven pulley shaft worn out y Greased in drive belt and driven face To this chapter contents Steering is heavy FAULT CONDITIONS PROBABLE CAUSES y Damaged ste...

Page 22: ... y Clean y Clean the spark plug y Spark plug is incorrect heat range y Excessive carbon deposited in combustion chamber y Wrong type of fuel y Fuel air mixture ratio is lean y Use of poor quality fuel y worn piston and cylinder y Fuel air mixture ratio is lean y Wrong type of fuel y Ignition timing too advanced y Excessive carbon deposited in combustion chamber Check tire pressure Normal Abnormal ...

Page 23: ...1 GENERAL INFORMATION 1 18 Lubrication Points Drive chain Acceleration cable Front rear brake lever pivot Speedometer gear Wheel bearing To this chapter contents ...

Page 24: ...Nuts Bolts Tightness 2 11 Special Tools List 2 12 Precautions in Operation Specification Fuel Tank Capacity 12000 c c Capacity 1400 c c Engine Oil Change 1200 c c Capacity 750 c c Transmission Gear oil Change 650 c c Engine radiator 850 c c Capacity of coolant Reservoir upper 420 c c Clearance of throttle valve 1 3 mm Type NGK CR8E Spark plug Gap 0 8 mm F Mark in idling speed BTDC 10º 1700 rpm Ful...

Page 25: ...4 Fuel lines I I 25 Cam chain I I 26 Valve clearance I A 27 Lines connections in cooling t I I 28 Coolant reservoir I I 29 Coolant I I R Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Have your ATV checked adjusted and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the ATV at the optimum condition The above m...

Page 26: ...sen 4 hooks from the air cleaner cover and then remove the cover Loosen the clamp strip and 1 screw of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Inst...

Page 27: ...amshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke Caution Do not turn the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check adjust valve clearance with feeler gauge Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Cauti...

Page 28: ...ed 1700 100 rpm Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle valve stopper screw and let engine runs in 1600 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle spee...

Page 29: ...ect check CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found Cylinder Compression Pressure Warm up engine Turn off the engine Remove the trunk Remove the central cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of starter motor Caution Rotate the engine until the reading in the ga...

Page 30: ...idth limit 22 5 mm or above Drive Chain Check the drive chain Park the ATV on a level ground and shift the transmission onto neutral Measure the drive chain slack midway between the sprockets Chain slack 15 25mm 5 8 1 inch Adjust the chain slack Loosen the axle holder lock nuts and bolts Loosen drive chain adjusting bolt lock nut and turn drive chain adjusting bolt until get the correct slack Tigh...

Page 31: ...patible 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 Air Bleed Operation Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution Before clos...

Page 32: ...he lining if the brake lining wear limitation groove close to the brake disc Caution y Do not operate the brake lever after the clipper removed to avoid clipping the brake lining y In order to maintain brake power balance the brake lining must be replaced with one set Brake Light Switch Starting Inhibitor Switch The brake light switch is to light up brake light as brake applied Make sure that elec...

Page 33: ...ck clutch operation If the ATV is in forward moving and shaking check clutch disc condition Replace it Cushion Warning y Do not ride the ATV with poor cushion y Looseness wear or damage cushion will make poor stability and drive ability Front cushion Press down the front cushion for several times to check it operation Check if it is damage Replace relative parts if damage found Tighten all nuts an...

Page 34: ...cold engine Check if tire surface is ticked with nails stones or other materials Appointed tire pressure Tire size Front tire Rear tire Tire pressure as cold 3 8 2psi Check if front and rear tires pressure is in normal Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm Nuts Bolts Tightness Pe...

Page 35: ...mbly tool NAME AC G Flywheel puller NO SYM 9001209 NO SYM 1471110 20 NO SYM 3110000 HMA NAME Left crank seal driver NAME Drive shaft puller NAME Driver shaft install bush seal driver NO SYM 1332100 HMA NO SYM 2341110 HMA NO SYM 9120200 HMA NAME Bearing driver 6205LLU NAME Rear axle bearing driver NAME Counter shaft needle bearing drive HK1516 NO SYM 9100410 440 NO SYM 9100100 RA1 A3017 NO SYM 9100...

Page 36: ... 6205 NAME Seal driver 14x28x7 14x26x6 NAME Seal driver 30x40x5 NO SYM 9615000 NO SYM 9120600 RB1 RA1 NO SYM 9120100 RA1 12 20 5 6901 NAME Water pump oil seal driver NAME Water pump bearing driver NAME Water pump mechanical seal driver NO SYM 9120500 H9A NO SYM 9100100 NO SYM 1721700 H9A 6301 6204 NAME BEARING DRIVER NAME BEARING DRIVER NAME Lock nut driver NO SYM 9610000 NO SYM 9110400 NO SYM 902...

Page 37: ...M 6204022 NO SYM 6204001 NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor NO SYM 2210100 NO SYM 9020200 NO SYM 2301000 55mm 55mm NAME Rear axle nut wrench NAME Torque wrench NAME Rear axle nut torque wrench NO SYM HT06007 NO SYM HT07004 RA1 NO SYM 4230200 NAME NAME NAME NO NO NO To this chapter contents ...

Page 38: ...ing 3 2 Engine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication Oil Route Con Rod Oil Route Oil Pump Rotate Direction Oil Strainer 3 Home page Contents ...

Page 39: ...e 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 cap 1 3 1 7kgf m Engine oil drain bolt 3 5 4 5kgf m Gear oil drain bolt 1 1 1 5kgf m Gear oil join bolt 3 5 4 5kgf m Oil pump connection screw 0 1 0 3kgf m Troubleshooting Low engine oil level y Oil leaking y Valve guide or seat worn...

Page 40: ...ter drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 3 1 7kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Engine oil capac...

Page 41: ...and take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover Remove oil pump shaft roller and shaft 2 screws To this chapter contents Clip 1 screw Roller ...

Page 42: ...and outer rotors Limit 0 20 mm Check clearance between 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 oil pump shaft and roller Install the oil pump cover and fixing pins properly Pins To this chapter contents ...

Page 43: ...nd then tighten screws Torque value 0 1 0 3kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install starting gear and generator Refer to chapter 10 To this chapter contents 1 screw Roller 2 screws Clip ...

Page 44: ...sher can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Torque value 3 5 4 5kgf m Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is in correct level Make sure that no oil leaking Gear oil drain bolt To this chapter contents Gear oil ...

Page 45: ...3 LUBRICATION SYSTEM 3 8 Notes To this chapter contents ...

Page 46: ...nosis 4 3 Carburetor Remove Install 4 4 Air Cut Off Valve 4 5 Throttle Valve 4 6 Float Chamber 4 7 Adjustment of Idle Speed 4 9 Fuel Tank 4 10 Air Cleaner 4 11 Mechanism Diagram 4 Home page Contents Carburetor Fuel unit Inlet pipe Auto fuel cock Fuel tank cap Fuel strainer Fuel tank ...

Page 47: ...y When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly y There is a drain screw in the float chamber for draining residual gasoline y Do not disassemble air cut valve arbitrarily Specification ITEM UA25A Carburetor diameter Ø22mm I D number PTG 050 Fuel level 14 8mm Main injector 110 Idle injector 35 Idle speed 1700 100rpm Throttle handle cleara...

Page 48: ...tion of carburetor y Dirty fuel Intermittently misfire as acceleration y Malfunction of ignition system Late ignition timing y Malfunction of ignition system y Malfunction of carburetor Power insufficiency and fuel consuming y Fuel system clogged y Malfunction of ignition system Mixture too lean y Clogged fuel injector y Vacuum piston stick and closed y Malfunction of float valve y Fuel level too ...

Page 49: ...e choke cable Disconnect the fuel hose Release the clamp strip of air cleaner Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the carburetor Installation Install in reverse order of removal procedures To this chapter contents 1 screw Choke cable Drain bolt Fuel pipe Vacuum pipe Clamp 2 nuts ...

Page 50: ...pection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assembly Install in reverse order of removal procedures To this chapter contents 2 screws O ring Spring Air cut off valve Cover ...

Page 51: ...valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve cable T...

Page 52: ...locking Check float valve for wearing and check valve seat face for wear dirt Caution In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one Float Pin Fuel level plate Float valve Check for wear or damage 3 Screws To this chapter contents Flo...

Page 53: ...r adjustment screw Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking fuel level Caution y Check again to ensure float valve float for proper installation y To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 14 8mm In...

Page 54: ...s 2 turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1700 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the pilot screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure rpm and CO value are in standard value after engine running in...

Page 55: ... installation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fuel tank Remove the side covers and lower side covers Remove the front fender Covers remove please refer chapter 13 Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove the vacu...

Page 56: ... the air cleaner cover 4 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install the el...

Page 57: ...4 FUEL SYSTEM 4 12 Notes To this chapter contents ...

Page 58: ...s engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutch Transmission Specification Item Capacity Replacement 1200 c c Engine oil capacity Disassembly 1400 c c Replacement 650 c c Gear oil capacity Disassembly 750 c c Engine radiator 780 c c Reservoir 420 c c AS indicator shown Coolant capacity To...

Page 59: ...ve post Remove battery positive post Remove front fender and the footrest refer chapter 13 Remove starter motor wire Remove the spark plug cap Disconnect A C Generator wire couplers Starter motor wire A C G wire couplers Spark plug cap Negative Positive To this chapter contents ...

Page 60: ...L 5 3 Remove muffler protect 2 bolts Loosen muffler front side bolt Remove 2 bolts and then remove the exhaust muffler Remove 2 nuts and then remove exhaust pipe 2 bolts 2 bolts 2 nuts To this chapter contents 2 bolts ...

Page 61: ...p strip of air cleaner duct Disconnect the carburetor upper parts and cable Release the 2 nuts of carburetor insulator and then remove the carburetor Release the clamp strips of left crankcase cover ducts and then remove the ducts 1 screw Fuel pipe 2 nuts Clamps To this chapter contents Choke cable Vacuum pipe Clamp ...

Page 62: ... inlet hoses from water pump Remove the thermo sensor wire by pass pipe and coolant outlet hose Remove gear change lever 1 bolt Remove change switch couplers 1 bolt Change switch couplers To this chapter contents Thermo sensor wire Drain bolt Outlet hose Water hoses clamp By pass pipe ...

Page 63: ...nger mounting nuts and bolts Remove the front side engine hanger mounting nut and bolt Remove left side engine hanger and then remove engine by left side Engine Installation Check if the bush of engine hanger parts for damage Install engine in the reverse procedures of removal Caution y Pay attention of foot hand safety as engine installation to avoid hurting y Do not bend or twist wires y Cables ...

Page 64: ...pection 6 7 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 0 7 1 1kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 2kgf m 3 6 4 0kgf m Home page Contents 2 4 3 0kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 2kgf m ...

Page 65: ...12 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 02mm Valve Valve clearance Exhaust 0 15 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cover bolt 1 0 1 4kgf m Exhaust pipe stud bolt 2 4 3 0kgf m Cylinder head bolt 1 0 1 4kg...

Page 66: ... valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure y Too much carbon deposit on combustion chamber or piston head Noise y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Chain wear out or loosen...

Page 67: ...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 spark plug Remove the side cover mounting blots of cylinder head and then take out the side cover 2 nuts 4 bolts Tensioner bolts Thermostat bolts 3 bolts To this chapter contents Spark plug ...

Page 68: ... remove the sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller Remove cam shafts Special Service Tool Rocker arm and cam shaft puller Cam shafts Cam shaft setting plate To this chapter contents 2 bolts Timing mark Rocker arm shaft and cam shaft puller Rocker arm shafts Rocker arm shaft and...

Page 69: ... and cylinder head y Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution y In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool Valve cotter remove assembly t...

Page 70: ...d Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 34 860mm EX Replacement when less than 34 725mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing To...

Page 71: ...6 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit Inner spring 35 20 mm Outer spring 36 90 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure rec...

Page 72: ...nce between the valve stem and valve guide Service Limit IN 0 08 mm EX 0 10 mm Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace v...

Page 73: ... When 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 Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer Caution y Using cutting oil when correcting valve guide with...

Page 74: ...e seal 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 contact condition of valve seat Valve seat grinding The worn valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat chamfer cutter Use 45 valve seat chamfe...

Page 75: ...lve 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 sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too low grind the valve seat with 60 cutter Th...

Page 76: ...emove assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve cotter remove assembly tool Tap the valve stems gently with a plastic hammer to make sure valve retainer and v...

Page 77: ...nd cylinder head Avoid 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 cylinder head right side Torque value Nut 3 6 4 0kgf m Bolt 1 0 1 4kgf m Install camshaft into cylinder head and install rocker arm rocker arm shaft Install rocker arm pin mounting p...

Page 78: ...sprocket mounting bolts Caution Make sure timing marks are matched Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and spring Install tensioner and install spring and adjustment bolt Install cylinder cover 4 bolts 4 bolts To this chapter contents 2 bolts Timing mark 3 bolts Tensioner adjustment bolt Thermostat bolts ...

Page 79: ...gn the timing mark on the cam sprocket with that of cylinder head piston is at TDC position Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler 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 cyli...

Page 80: ...agram 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 Contents 0 8 1 2kgf m 1 0 1 4kgf m ...

Page 81: ...0 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 small end 17 016 17 034 17 064 Trouble Diagnosis Low or Unstable Compression Pressure y Cylinder or piston ring worn out Knock or Noise y Cylinder or piston ring worn out y Carbon deposits on cylinder head t...

Page 82: ... gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be removed more easily Inspection Check if the inner diameter of cylinder is wear out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y values respective in the cylinder Service ...

Page 83: ...on 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 cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Service Limit Top ring 0 50 mm 2nd ring 0 65 mm To this chapter contents ...

Page 84: ...er 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 from piston bottom side and 90 to piston pin Service limit 70 380 mm Compare measured value with service limit to calculate the clearance between piston and cylinder To this chapter contents ...

Page 85: ...fully Place the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston rings can be rotated freely after installed Top ring 2 nd ring Oil ring Top groove 2 nd groove Oil groove To this chapter contents ...

Page 86: ... Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution y Do not let the opening of piston pin clip align with the piston cutout y Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Install dowel pins and n...

Page 87: ...ken 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 coolant hose onto cylinder Install cylinder head refer to Chapter 6 To this chapter contents Coolant hose ...

Page 88: ...anism Diagram 8 1 Maintenance Description 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 5 0 6 0kgf m Home page Contents 8 5 0 6 0kgf m 8 5 10 5kgf m ...

Page 89: ...0 40 990 mm 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 y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive plate nut 5 0 6 0kgf m Special Service Tools Clutch spring compressor SYM 2301000 Inner bearing puller SYM 6204002 Clutch nut wrench 39 x 41 mm SYM 9020200 Universal holder SYM 2210100 Bearing driver ...

Page 90: ...then remove the ducts 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 this chapter contents Clamp strips 9 bolts Dowel pins Left cover plate Bearing setting plate Dowel pins Drive shaft holder bearing Left cover plate gasket ...

Page 91: ... plate Check bearing on left crankcase cover Rotate bearing s inner ring with fingers Check if bearings can be turned 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 2 bolts 9 bolts To this chapter contents ...

Page 92: ...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 Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 22 5 mm Replace the belt if exceeds the service limit Caution y Using th...

Page 93: ...rive 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 value Torque value 5 0 6 0kgf m Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value Torque value 8 5 10 5kgf m Driven...

Page 94: ...en 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 Drive face boss Movable drive face Ramp plate Movable drive face Weight roller To this chapter contents Universal holder ...

Page 95: ...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 service limit Service limit 30 060 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same In order to lengthen the roller life and prevented exceptionally...

Page 96: ... 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 grease Clean it with cleaning solvent Hold drives face with universal holder Tighten nut to specified torque Torque value 8 5 10 5kgf m Install left crankcase cover Drive face boss Crank shaft Drive...

Page 97: ...vice 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 driven face and then remove O ring oil seal seat from movable driven face Inspection Clutch outer Measure the inner diameter of clutch outer Replace the clutch outer if exceed service limit Service l...

Page 98: ...nd 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 oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rot...

Page 99: ...on 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 block should not be greased If so replace it Caution Grease or lubricant will damage the clutch weight and affect the block s connection capacity Install the spring into groove with pliers Shock absorpti...

Page 100: ...ide 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 y Its sealing end should be forwarded to outside as bearing installation y Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Install snap ring into the groove of drive face Align oil ...

Page 101: ...and 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 nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch outer driven pulley and drive belt onto drive shaft Collar O ring Guide pin ...

Page 102: ...cover Final shaft Drive sprocket Reverse shaft Counter shaft Drive shaft Bearing 6304 Bearing 6205LLU Bearing 6204 Bearing 6305 Home page Contents 9 Change switch Gasket Gear oil fill bolt 3 5 4 5kgf m Drive shaft bearing setting plate Oil seal 14x26x6 Shift spindle Shift drum Shift fork Dowel pin Needle bearing HK2016 Oil seal 25x40x7 Oil seal 30x46x7 Bearing 6204 Gear oil drain bolt 0 8 1 2kgf m...

Page 103: ...n bolt 1 1 1 5kgf m Gear oil fill bolt 3 5 4 5kgf m Tools Special tools Bearing driver 6204 SYM 9110400 Bearing driver 6205LLU SYM 9100400 HMA Bearing driver 6305 SYM 9100400 RB1 Needle bearing driver HK2016 SYM 9100300 RB1 Drive shaft and oil seal driver SYM 9120200 HMA Drive shaft puller SYM 2341100 Inner bearing puller SYM 6204002 Trouble Diagnosis Engine can be started but motorcycle can not b...

Page 104: ...on The socket bolt is provided with left turn thread Remove 2 bolts and then remove the drive sprocket fixing plate drive chain and drive sprocket Remove gear fill bolt Place an oil pan under the ATV and remove gear oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value Gear oil fill bolt 3 5 4 5kgf m Gear oil drain bolt 1 1 1 5kgf m To this chapter conten...

Page 105: ...tch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft To this chapter contents Shift drum Shift spindle Shift fork shaft and fork 9 bolts Reverse shaft Counter shaft Final shaft Shift drum fixed catch bolt Drive shaft ...

Page 106: ...ft Special tool Shaft protector Remove gasket and dowel pin Caution y If non essential do not remove the drive shaft from the case upper side y If remove the drive shaft from the gear box then its bearing and oil seal has to be replaced To this chapter contents Bearing Oil seal Bearing setting plate ...

Page 107: ...asure the outer diameter of shift fork shaft and replace it if it exceed service limit Service limit 11 970 mm Measure the inner diameter of shift fork and replace it if it exceed service limit Service limit 12 010 mm Measure the claw thickness of shift fork and replace it if it exceed service limit Service limit 5 730 mm Check if the counter shaft is wear or damage To this chapter contents ...

Page 108: ...if bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Caution y If remove the drive shaft from the crankcase upper side then its bearing has to be replaced Final shaft bearing Gear box cover To this chapter contents Counter shaft bearing Reverse shaft bearing Driv...

Page 109: ...pecial tool Inner bearing puller Install new final shaft counter shaft and reverse shaft bearings into left crankcase Special tool Bearing driver 6204 Needle bearing driver HK2016 Install new drive shaft bearings and baring driver into left crankcase Install the universal bearing puller and bearing driver Turn the universal bearing puller to install drive shaft bearing Special tool Bearing driver ...

Page 110: ...install bush Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the cover inner side Special tool Inner bearing puller Remove cir clip of final shat out side bearing Drive shaft puller Drive shaft and seal install bush Clutch nut wrench To this chapter contents Driv...

Page 111: ...g puller to install drive shaft bearing Special tool Bearing driver 6205 Universal bearing puller Install new oil seal and bearing driver into gear box cover inner side Install the universal bearing puller and bearing driver Turn the universal bearing puller to install drive shaft oil seal Special tool Bearing driver 6205 Universal bearing puller To this chapter contents Inner bearing puller Beari...

Page 112: ...unter shaft reverse shaft and final shaft onto gear box Install shift drum shift fork and fork shaft onto gear box Install shift drum fixed catch ball spring and bolt onto gear box To this chapter contents Oil seal Reverse shaft Counter shaft Final shaft Drive shaft Shift drum Shift spindle Shift fork shaft and fork Shift drum fixed catch bolt ...

Page 113: ...l shift spindle Install dowel pins and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Install the shift spindle bracket drive chain protector speedometer gear box and gear change lever Add gear oil Gear oil quantity 750c c To this chapter contents Position mark Dowel pins 9 bolts ...

Page 114: ... Crankcase Cover Removal 10 3 A C G Set Removal 10 3 Right Cover Bearing 10 3 Flywheel Removal 10 4 Starting Clutch 10 5 Flywheel Installation 10 7 A C G Set Installation 10 8 Right Crankcase Cover Installation 10 8 Mechanism Diagram 5 0 6 0kgf m 1 0 1 4kgf m 0 8 1 2kgf m 10 Home page Contents ...

Page 115: ...ems of starter motor Specification Item Standard value 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 adhesive 8 mm bolts 0 8 1 2kgf m 12 mm bolts 1 0 1 4kgf m Tools Special tools A C G flywheel puller SYM 3110A00 Universal holder SYM 2210100 To this ch...

Page 116: ...moval Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set Right Cover Bearing Inspection Rotate the bearing with finger to check if the bearing rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary Remove the cir clip and then remove bearing Special too...

Page 117: ... bearing 6201LU by bearing driver Special tool Bearing driver Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with universal holder Remove flywheel nut Special tool Universal Holder To this chapter contents Flywheel nut Reduction gear Oil seal Bearing driver ...

Page 118: ...starting driven gear Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch 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 To this chapter contents flywheel puller ID OD ...

Page 119: ...tch gear The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting driven gear Remove 3 socket bolts and then remove one way clutch To this chapter contents 3 socket bolts One way clutch Starting driven gear Starting driven gear ...

Page 120: ...hexagon bolt Torque value 1 0 1 4kgf m Install starting driven gear Flywheel Installation 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 Special tool Universal Holder To this chapter contents Groove 3 socket bolts Starting driven gear ...

Page 121: ...ie the wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator Right Crankcase Cover Installation Install dowel pin 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 2 bolts 3 screws Wire To this chapter contents Reduction gear Dowe...

Page 122: ...stall right crankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover To this chapter contents 11 bolts Water pump cover bolts ...

Page 123: ...10 ALTERNATOR STARTING CLUTCH 10 10 Note To this chapter contents ...

Page 124: ... 1 General information 11 2 Trouble diagnosis 11 2 Disassembly of crankcase 11 3 Crankshaft Inspection 11 5 Assembly of crankcase 11 6 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1 2kgf m 11 Home page Contents 1 0 1 4kgf m 0 8 1 2kgf m ...

Page 125: ... chain of engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Specification Unit 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 Crankshaft Run out 0 100 Torque value Bolts for crankcase 0 8 1 2kgf m Engine oil drain bolt 3 5 4 5kgf m Cylinder stud bolt 1 0 1...

Page 126: ...e the tensioner Loosen 2 bolts on the right crankcase Loosen 11 bolts on the left crankcase Place right crankcase downward and left crankcase up Tap the left crankcase with a plastic hammer to remove it Caution Care should be taken not to damage the contact surfaces 11 bolts Cam chain setting plate Tensioner 2 bolts To this chapter contents ...

Page 127: ... right crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface 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 To this chapter contents Balance shaft ...

Page 128: ...un out of the crankshaft Service limit 0 10 mm Check 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 detected replace the bearing with new one Caution The bearing shall be replaced in pair Special tool outer bearing puller 90 mm Crank bearing Measur...

Page 129: ... bearing rotation is uneven noising or loose bearing mounted then replace it Special tool Inner bearing puller Bearing driver Assembly of crankcase Install wave washer into right crank bearing seat Install crank shaft on the right crankcase Align the position mark on the balance shaft drive gear with that of balance shaft driven gear and then install balance shaft onto right crankcase Balance shaf...

Page 130: ...nd new gasket Install the left crankcase onto the right crankcase Tighten 11 bolts on the left crankcase Torque value 0 8 1 2kgf m Tighten 2 bolts on the right crankcase Torque value 0 8 1 2kgf m Dowel pins To this chapter contents 2 bolts 11 bolts ...

Page 131: ...nkcase with care not to damage the lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Oil seal driver 27 42 7 Install the tensioner and tighten the pivot bolt Torque value 0 8 1 2kgf m Install the cam chain Install the cam chain setting plate Oil seal driver To this chapter contents Cam chain setting plate Tensioner ...

Page 132: ...e Diagnosis for Cooling System 12 3 System Test 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram Radiator filler cap Radiator Reserve tank Thermo switch fan Coolant inlet pipe Coolant outlet pipe By pass pipe Water pump Thermostat 12 Cooling fan Home page Contents To cylinder head ...

Page 133: ...50c c 420c c Thermostat Begins to activate at 82 95 Stroke 0 05 3mm Thermos switch fan Begins to activate at 98 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump impeller 1 0 1 4kgf m Tools Requirement Special tools Water pump bearing driver 6901 SYM 9100100 Water pump oil seal driver Inner SYM 9120500 H9A Water pump mechanical seal driver SYM 1721700 H9A Inner beari...

Page 134: ...nit 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 have circulated C 1 Eng stop and remove water pump cover start the motor to inspect pump its rotation Water pump repair N N A1 Refill the radiator with coolant then check for any leakage Water leakin...

Page 135: ...until 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 check again Y Replace thermostat N E Keep eng 3000 4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks Replace thermal switch N E 1 Measure thermal switch to confirm ...

Page 136: ...ely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilling system with coolant and bleeding the air bubbles y Run the engine and remove by pass pipe y Check by pass hole whether has the air bubble to emit y If emits without the air bub...

Page 137: ...elevating in the cooling system the refrigerant backflow floods Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage 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 Removal Place a water pan under the water...

Page 138: ...r shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please refer to chapter 17 for the inspection of the thermo switch Caution Liquid packing must be applied to the thermo switch before installing to avoid damaging the radiator Installation Install the removed parts in the reverse ord...

Page 139: ...e 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 bolt to drain out the coolant Remove the water hose Loosen 4 bolts and remove the pump cover Loosen 9 bolts and remove the right cover Take off the gasket and dowel pins Turn pump impeller clockwise and remove Ca...

Page 140: ...seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new mechanical seal Install the mechanical seal onto the right crankcase Special tools Water pump mechanical seal driver Mechanical seal Mechanical seal Water ...

Page 141: ... Special tools Water pump bearing driver 6901 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 to the right crankcase cover Install the cir clip to hold the inner bearing Inner bearing Water pump shaft Water pump bearing driver 6901 Water pump oil seal driver inner To this chapter contents ...

Page 142: ...ten Torque Value 1 0 1 4kgf m Caution The impeller is left thread Install the dowel pin and right cover gasket The rotation water pump impeller causes the water pump drive shaft scoop channel aligns the oil pump drive shaft flange install the right crank case 9 bolts Install the dowel pin and new gasket Install the water pump cover with 4 bolts Water pump rotor To this chapter contents ...

Page 143: ... thermometer are in contact to the wall of heated water container the reading displayed 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 begins to open 82 95 Valve stroke 0 05 3mm Installation Install the thermostat Install the thermostat cover 2 bolts Ref...

Page 144: ...13 14 Mechanism Diagram 13 Home page Contents Left handle protect cover Front fender Fuel tank cover Rear fender Left footrest Front center cover Right side cover Seat Handle cover Right footrest Left side grille Right handle protect cover Right side grille Left side cover Right side lower cover Left side lower cover Front bumper grille Front bumper cover Front grille Front emblem Rear bumper Tail...

Page 145: ...slot on the covers y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during assembly Tail cover Rear bumper Rear fender R L Footrests Handle cover Handle protect cover Rear carrier Front center cover To this chapter contents Front fender Front center cover R L Side covers R L Lower side covers R L Side covers R L Lowe...

Page 146: ...lts from handle cover right and left side Remove couplers of meter Remove speedometer cable and then remove handle cover meter cover and meter Disassembly Remove 4 screws of meter stay and meters 4 bolts Meter couplers To this chapter contents Speedometer cable 4 screws ...

Page 147: ...bolts from handle protect cover and then remove handle protect cover Installation Install in reverse order of removal procedures Front center cover Remove Loosen 2 screws from the front center cover Please disassemble first then push the cap upward and then remove front center cover Installation Install in reverse order of removal procedures 3 Screws 2 bolts To this chapter contents 2 screws ...

Page 148: ...over Remove Remove front center cover Remove seat Remove fuel tank cap Remove 1 bolt and then remove fuel tank cover Installation Install in reverse order of removal procedures To this chapter contents Fuel tank cap 1 Bolt 2 screws ...

Page 149: ...ove 1 screw and then remove fixed support catch Loosen the 6 screws which connect the front fender and side lower covers these 6 screws just be twin the front fender two side Remove right and left side lower covers rear side screws each side 3 screws and then remove side lower covers 2 bolts 1 screw To this chapter contents 6 screws 3 screws ...

Page 150: ...de 1 screw Loosen the front fender two side bolts each side 1 bolt Remove headlight front winker light and power outlet couplers Remove front fender under side bolts each side 1 bolt 1 screw 1 Bolt To this chapter contents 1 Bolt Winker coupler Headlight coupler ...

Page 151: ...front side bolts 2 bolts Remove the left crankcase cover duct Remove front fender upper bolt and then remove front fender and headlight Disassembly Remove 3 screws to remove front emblem 2 Bolts To this chapter contents 1 Bolt Duct 3 screws ...

Page 152: ...e headlights front side 4 screws and then remove headlights Remove winker lights 4 screws and then remove winker lights Remove 8 screws and then remove right and left grille Each side 2 screws To this chapter contents 4 screws Each side 4 screws Each side 2 screws ...

Page 153: ...emove power outlet Installation Install in reverse order of removal procedures Rear carrier Remove Loosen 4 bolts from the rear carrier Remove the rear carrier Installation Install in reverse order of removal procedures 4 Bolts To this chapter contents Setting nut ...

Page 154: ...r fender Loosen the 6 screws which connect the front fender and side lower covers these 6 screws just be twin the front fender two side Remove right and left side lower covers rear side screws each side 3 screws and then remove side lower covers Remove right and left side covers each side 1 screw Seat release bar To this chapter contents 6 screws 3 screws 1 screw ...

Page 155: ...ct the rear tender and frame these 2 bolts just below the rear fender light coupler side Loosen the 2 bolts which connect the rear tender and frame these 2 bolts just below the rear fender rear side Remove taillight couplers and then remove rear fender Installation Install in reverse order of removal procedures Each side 1 bolt To this chapter contents Each side 1 bolt 5 bolts Each side 1 bolt Eac...

Page 156: ...bumper and taillights Remove tail cover and rear bumper 6 screws and then remove tail cover Remove license light 2 screws and then remove license light Loosen the 10 screws and then remove taillights each side 5 screws Installation Install in reverse order of removal procedures 6 screws To this chapter contents 2 screws Each side 2 screws Each side 5 screws 2 screws ...

Page 157: ...t and frame these 6 bolts just be twin under the footrests Loosen the 4 bolts and then remove footrest bars and footrests These 4 bolts just are the right and left footrests Installation Install in reverse order of removal procedures To this chapter contents 2 bolts 2 bolts 1 bolt ...

Page 158: ...d replacement Air bleed 14 9 Front Brake Caliper 14 10 Brake Disk 14 11 Front Brake Master Cylinder 14 11 Mechanism Diagram Brake disk bolts 4 25kgf m Air bleed valve 0 5kgf m Brake caliper bolts 3 25kgf m Brake hose bolts 3 5kgf m 14 Home page Contents Front pressure control valve To rear pressure control valve Front brake master cylinder Front axle castle nuts 5 0kgf m Front wheel nuts 2 4kgf m ...

Page 159: ...tic or rubber parts to avoid damage y Check the operation of the brake system before riding y Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 3 500 2 000 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter 14 000 14 ...

Page 160: ... 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Hard steering 1 Faulty tire 2 Insufficient tire pres...

Page 161: ...eel axle cover 4 screws Remove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 2 4kgf m Front Wheel Hub Removal Remove front brake caliper 2 bolts Remove cotter pin wheel hub nut and washer Remove wheel hub and brake disk 4 nuts To this chapter contents Wheel hub nut Cotter pin 4 screws 2 bolts ...

Page 162: ...eal for wear or damage and replace it if necessary Disassembly Caution y Never install used bearings Once bearing removed it has to be replaced with new one Remove out side bearing and seal from wheel hub using following tools Special tool Inner bearing puller Remove front wheel hub bearing inner spacer Remove inner side bearing and oil seal from wheel hub using following tools Special tool Inner ...

Page 163: ...Install new out side bearing and seal into front wheel hub Special tool Bearing driver 6203 Oil seal drive 24 35 7 Installation Install the front brake disk to the wheel hub Install wheel hub and brake disk on to knuckle Install wheel hub washer and tighten the wheel hub nut Torque 5 0kgf m Install cotter pin Install front brake caliper Torque 3 25kgf m To this chapter contents 4 bolts Bearing dri...

Page 164: ...when the brake pad wear limit reaches the brake disk Caution y Check the front brake lining must be removed front wheel first Park the ATV on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 Caution y The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minute y In order to prevent has th...

Page 165: ...id on painted surfaces plastic 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 in the master cylinder Clean the dirty brake disk Caution y The dirty brake lining or disk will reduce the brake performance y To mixed non compatible brake fluid will reduce ...

Page 166: ...ke system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution y Do not release the brake lever before the drain valve is closed y Always check the brake fluid level when ca...

Page 167: ... brake disk Brake lining replacement Remove two guide pins Compress caliper mounting plate and then remove brake linings Install new linings and tighten the guide pins Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution y Use M8 x 20 mm flange bolt only y Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lo...

Page 168: ...t cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Front Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Push the lead of brake light switch and then remove brake lig...

Page 169: ...45 mm Master Cylinder Assembly Caution y It is necessary to replace the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cyl...

Page 170: ...ashers Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system 2 Washers To this c...

Page 171: ...14 FRONT BRAKE FRONT WHEEL 14 14 Notes To this chapter contents ...

Page 172: ...5 2 Trouble Diagnosis 15 2 Steering Handle 15 3 Steering Shaft 15 5 Steering Tie Rod 15 6 Knuckle 15 7 Front Cushion 15 8 Suspension Arm 15 9 Toe In 15 10 Mechanism Diagram 4 6kgf m 2 4kgf m 5 0kgf m 3 4kgf m 4 0kgf m 15 Home page Contents 5 0kgf m 5 0kgf m 5 0kgf m 3 6kgf m 5 0kgf m ...

Page 173: ...ulty steering shaft bushing y Damaged steering shaft bushing Front wheel wobbling y Faulty tire y Worn front brake drum bearing y Bent rim y Axle nut not tightened properly Steers to one side y Bent tie rods y Wheel installed incorrectly y Unequal tire pressure y Bent frame y Worn swing arm pivot bushings y Incorrect wheel alignment Front suspension noise y Loose front suspension fasteners y Bindi...

Page 174: ...der Caution Do not let foreign materials enter into the cylinder Remove 2 screws and then remove throttle hosing holder and throttle hosing Loosen the socket bolts for the front brake master cylinder and remove front brake master cylinder Caution Do not let foreign materials enter into the cylinder To this chapter contents 2 Screws Handle protect cover brocket bolts Master cylinder bolts Handle pr...

Page 175: ...e handle mounting bolt and then remove the handle upper holder handle Remove 2 nuts to remove handle under holder and meter bracket Installation Install in reverse order of removal procedures Torque value Handlebar under holder nut 4 0kgf m Handlebar upper holder bolt 2 4kgf m 2 screws To this chapter contents 2 Nuts 4 socket bolts ...

Page 176: ... holder nut fixed plate pressed plate and steering shaft Inspection Check oil rings for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit Ø39 5 mm Installation Install in reverse order of removal procedures Apply with grease onto oil liner and holder Torque value Steering shaft holder bolt 3 4kgf m Steering shaft nut 5 0kgf m Steering tie rod nut 5 0kgf m T...

Page 177: ... ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Installation Install the ball joint with adjustment groove on the wheel side Install tie rod nuts and tighten the nuts Torque value 5 0kgf m After tightened the tie rod nut install the cotter pin Cotter pin To this chapter contents Tie rod nuts Ball joint Adjustme...

Page 178: ... by ball joint driver Remove the knuckle Special Tool ball joint driver Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking Installation Install in reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Ball joint nut 5 0kgf m After tightened the nuts install the cotter pins To this chapter contents Nut Tie rod Cotter pin Ball joint Ball ...

Page 179: ...Remove front cushion under bolt nut and remove the bolt Remove front cushion upper bolt nut and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value Front cushion nut 4 6kgf m To this chapter contents Nut Nut ...

Page 180: ...ension arm Loosen under suspension arm nuts remove swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bending Installation Install in reverse order of removal procedures Torque value Suspension arm nut 5 0kgf m Lubricate with grease into suspension arm Bush To this chapter contents Suspension arm nuts and bolts Suspension arm nuts an...

Page 181: ...cle back let the wheels turn 180 degree so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5 10mm If the toe in is out of standard adjust it by hanging the length of the tie rods equally by turning the tie rod while holding the ball joint Loosen two side tie rod lock nuts turn t...

Page 182: ...eed 16 12 Rear Brake Caliper 16 13 Brake Disk 16 14 Rear Brake Master Cylinder 16 14 Rear Cushion 16 18 Mechanism Diagram Home page Contents 16 Rear pressure control valve To front pressure control valve Brake disk bolts 4 25kgf m Air bleed valve 0 5kgf m Brake caliper bolts 3 25kgf m Brake hose bolts 3 5kgf m Rear brake master cylinder A Rear brake master cylinder B Rear axle castle nuts 5 0kgf m...

Page 183: ...nd installation of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 4 000 2 500 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter hand brake 14 000 14 043 14 055 Master cylinder piston outer diameter hand brake 13 957 13 984 13 945 Master cylinder inner diameter foot brake 15 900 15 943 15 955 Master cylinder piston outer ...

Page 184: ...ven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Vibration or Wobble 1 Axle is not tightened...

Page 185: ...tallation Install the rear wheel and tighten the nuts Torque 2 4kgf m Rear Wheel Axle Connecter Removal Remove cotter pin rear wheel axle connecter nut and washer Remove right and left rear wheel axle connecter Installation Install the rear wheel shaft connecter Install wheel shaft connecter washer and tighten the wheel shaft connecter nut Torque 2 4kgf m Install cotter pin 4 nuts To this chapter ...

Page 186: ... 2 bolts and then remove rear brake caliper Remove 2 bolts and 1 nut and remove drive chain cover Remove 4 bolts to remove rear under protect Remove drive chain lock clip master link and then remove drive chain To this chapter contents Lock clip Master link 2 bolts 2 bolts 1 nut Front side 2 bolts Rear side 2 bolts ...

Page 187: ...ven sprocket Bend out the rear axle nut fixed plate Bend out the rear wheel axle holder nut fixed plate Remove rear wheel axle nuts Special tool Rear axle nut wrench 55mm Remove rear brake disk bracket and disk To this chapter contents Fixed plate 4 nuts Brake disk bracket ...

Page 188: ...ry Disassembly Caution y Never install used bearings Once bearing removed it has to be replaced with new one Remove bearing and seal from rear wheel axle bearing seat using following tools Special tool Inner bearing puller SYM 6204022 Remove bearing spacer Assembly Install new left side bearing and seal into rear wheel axle bearing seat Install rear wheel axle bearing inner spacer Install new out ...

Page 189: ...bracket and disk Install rear wheel axle nuts rear axle nut fixed plate and tighten the nuts Torque 9 2kgf m Special tool Rear axle nut wrench 55mm Rear axle nut torque wrench Torque wrench After tightened the axle nut bend the rear axle nut fixed plate To this chapter contents Fixed plate Driven sprocket holder Brake disk bracket ...

Page 190: ...ocket teeth Replace the sprocket if it worn Caution y The drive chain drive sprocket and driven sprocket must be also inspected for wear Rear swing arm Removal Remove rear under protect drive chain driven sprocket rear brake caliper brake disk and rear axle Remove 2 nuts and bolt and remove rear axle holder Remove rear swing arm lock nut Remove rear swing arm bolt and then remove rear swing arm To...

Page 191: ...h new lining when the brake pad wear limit reaches the brake disk Caution y Check the rear brake lining must be removed rear wheel first Park the ATV on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 3 Caution y The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minute y In order to pre...

Page 192: ...id on painted surfaces plastic or rubber components may result in their damages Remove the brake fluid cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in the master cylinder Clean the dirty brake disk Caution y The dirty brake lining or disk will reduce the brake performance y To mixed non compatible brake fluid will reduce brak...

Page 193: ...e system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution y Do not release the brake lever before the drain valve is closed y Always check the brake fluid level when car...

Page 194: ...stallation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution y Use M8 x 20 mm flange bolt only y Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake lining replacement Remove two guid...

Page 195: ... air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Rear Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Handle left side rear brake master cylinder A Remove brake light switch couple...

Page 196: ...der Disassembly Remove the rubber boot Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master Cylinder Inspection Check the master cylinder for damage or scratch Replace it if necessary Measure the cylinder inner diameter at several points along both X and Y directions Replace the cylinder if the measured values exceed allowable limit All...

Page 197: ...ake sure the cir clip is seated securely in the groove Install the rubber boot into groove properly Master Cylinder Install Caution Improper routing may damage leads hoses or pipes Caution Kink of brake leads hose or pipe may reduce brake performance Handle left side rear brake master cylinder A Install the rubber pad into the groove correctly Place the master cylinder onto handlebar and install t...

Page 198: ...en lock nut and turn adjustment nut and push rod bracket to adjustment brake free play Install fluid hose and clamp Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Add specified brake fluid and bleed the syste...

Page 199: ...t Remove rear cushion upper bolt and then remove rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Tighten the rear cushion upper bolt and under nut to the specified torque value Torque 4 6kgf m Rear cushion under bolt Nut To this chapter contents Rear cushion upper bolt ...

Page 200: ...nit 17 19 Cooling Fan Thermo Switch 17 20 Thermo unit 17 21 Water Temperature Indicator Light 17 21 Mechanism Diagram Starter relay Winker relay Spark plug AC Generator Fuse box Battery Ignition coil Fuel unit Main switch C D I Unit Regulator rectifier Shift gear control unit Horn Start light winker horn brake switch Headlight relay Home page Contents Thermo unit Hazard control unit 17 Rear brake ...

Page 201: ...pid charge the battery y The voltage must be checked with the voltmeter while charging the battery y As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignition timing light after replacement if necessary Technical Specification Charging system Description Specification Capacity 12V10Ah Battery Charging rate ...

Page 202: ...rter motor is out of work Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short circuit of the discharging system y Poor connection or short circuit of the power generation system Charging system does not operate properly y Burnt fuse y Poor contact open or short circuit y Poor regulator y Poor ACG Engine do...

Page 203: ...r to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1A 4 0A Charging time 5H 1H Warning y Keep flames away while recharging y Charging is completely controlled by the ON OFF switch on the charger not by battery cables Caution y Never rapid charge the battery unless in emergency y Verify the battery is re...

Page 204: ...gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse y Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short ci...

Page 205: ...ct a 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 rpm Control Charging Voltage 14 5 0 5 V 2000 rpm Caution To replace the old battery use a new battery with the same current and voltage The following problems are related to the charging system fo...

Page 206: ...ses 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 17 0 8Ω If the readings measured are not normal check parts in the circuit If the parts are normal then trouble is in the wiring If there is nothing wrong with parts and wiring replace the regulator rectifier To this chapter contents Regulator ...

Page 207: ...position Black white green Battery voltage Pulse generator Green White Blue yellow 50 170Ω Primary circuit Black yellow green 0 17 10 Ω Black yellow with no cap 3 6 10 Ω Ignition coil Secondary circuit Black yellow with cap 7 3 11KΩ Main switch Shift gear control unit Pulse generator Spark plug Ignition coil CDI Unit G B Y G W B G W L Y B W To this chapter contents G Main fuse 30A Fuse 15A B Batte...

Page 208: ...the resistance between the spark plug and the primary winding Standard resistance With no cap 3 6Ω 10 With cap 7 3 11 KΩ Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if necessary Inspection of Pulse Generator Disconnect the coupler of the pulse generator and measure the resistance between the terminals of green white and blue yellow Standard resistance 50 170Ω Ignit...

Page 209: ...the starter motor Disconnect the coupler of the relay Connect an ohmmeter to the large terminal end Connect the yellow red cable to the battery positive terminal and the yellow black cable to the battery negative terminal Check the continuity of the large terminal end If there is no continuity replace the relay Main fuse 30A Main switch Fuse 15A Brake switch Starter switch Starter relay Starter mo...

Page 210: ...t the cable negative terminal then the cable positive terminal Remove starter motor cable Loosen the lock bolts and remove the starter motor Installation of Starter motor Install in reverse order of removal procedures To this chapter contents 2 Bolts Negative Starter motor cable ...

Page 211: ...meter couplers and main switch coupler Remove speedometer cable Remove speedometer cable and then remove meter set main switch and handle cover Remove 4 nuts and meter wire and then remove speedometer and fuel meter To this chapter contents 4 nuts Each side 2 bolts Main switch coupler Meter set couplers Speedometer cable ...

Page 212: ...ith new bulb if necessary H7 12V 55W Caution y Never touch the bulb with finger which will create a heat point y Clean the fingerprint left on the bulb with alcohol Install the bulb of the headlight in reverse order of removal Upon completion of replacement turn on the main switch to ensure the headlight works well Adjust the beam and distance of the headlight if necessary To this chapter contents...

Page 213: ...ull out the front winker light bulb seat Replace with new front winker light bulb 12V 21W Replacing Bulb of Position Light Pull out the position light bulb seat Replace with new position light bulb 12V 5W To this chapter contents Position light bulb Front winker bulb ...

Page 214: ...b connectors by CCW Replace with new taillight bulb 12V 5W 21W Replace with new rear winker light bulb 12V 21W Replacing Bulb of License Light Turn the license light bulb connectors by CCW Replace with new license light bulb To this chapter contents Taillight Rear winker light Rear winker bulb Taillight bulb License light ...

Page 215: ... the coupler of the main switch Push out the main switch Align the main switch stopper with the meter cover groove and install main switch Install the main switch coupler Handle switches Disconnect the coupler of handle from front fender left side Check the continuity between two points as indicated in the table below Start Switch Pin Position ST SG FREE Wire Color Yellow Red Yellow Black To this ...

Page 216: ...lue Brown Winker switch Pin Position L WR R N PUSH OFF Wire color Pink Black Brown White Horn switch Pin Position BAT3 HO FREE Wire Color White Black Light green Hazard switch Pin Position HD E Wire Color Green Red Green Winker switch To this chapter contents Headlight switch Horn switch Hazard switch ...

Page 217: ...ed Rear Brake Switch While grasp the brake lever firmly the terminals of white black and green yellow of the brake should have continuity Replace the switch if damaged Horn Remove the horn from front fender left side Apply 12 V power source to two terminals of the horn the horn should sound Replace the horn if necessary To this chapter contents Brake light switch Brake light switch 1 bolt ...

Page 218: ...istance measured shall be as follows Position Resistance E Empty 97 5 107 5 Ω F Full 4 10 Ω Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupler to the wire harness Turn on the main switch Move the float arm to verify the proper position the fuel gauge needle indicates Arm Position Needle Position Up Full F Full Down Empty E Empty Caution While conducting the...

Page 219: ...o switch 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 temperature increase the coolant temperature gradually The switch should have continuity at 98 3 Caution y Keep the coolant at a constant temperature at least for three minutes Sudden increase the coolan...

Page 220: ...gles when performing this test Caution y Engine oil should be used as a heating medium as the test temperature must be higher than 100 y Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Water Temperature Indicator Light Disconnect the water temperature meter and connect it to engine ground Turn on the main switch The indicator light of the fuel mete...

Page 221: ...17 ELECTRICAL SYSTEM 17 22 Notes To this chapter contents ...

Page 222: ...18 ELECTRICAL DIAGRAM 18 1 18 Home page Contents QUAD LANDER 250 ELECTRICAL DIAGRAM ...

Page 223: ...18 ELECTRICAL DIAGRAM 18 2 Notes Home page Contents ...

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