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Sym Quad Raider 600, Service Manual

The Sym Quad Raider 600 is a powerful and versatile ATV designed for off-road adventures. Ensure peak performance with the Service Manual, available for free download from manualshive.com. This comprehensive manual provides detailed instructions for maintenance and repair, keeping your Quad Raider in top condition for all your outdoor excursions.

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12. CRANKCASE / CRANKSHAFT 

 

12-8 

 
Clean the crankshaft. 
Apply a layer of grease on the lip of oil seal, Puts 
on the left crank shaft. 
Install the oil seal in the left crankcase 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: 
Tool number

：

SYM-11332100-HMA RB1 

Tool name

：

Crank and oil seal installation. 

 
 
 

 
 
 
 
 
 
 
 

 

 
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. 

 

 

 

 

  crank and oil seal 

installation

 

 

 

Cam chain setting plate

Tensioner

 

Summary of Contents for Quad Raider 600

Page 1: ...FOREWORD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Quad Raider 600 SERVICE MANUAL...

Page 2: ...strations and focused on Service Procedures Operation Key Points and Inspection Adjustment providing technician with service guidelines If the style and construction of the ATV QuadRaider 600 are diff...

Page 3: ...acquire the special parts and system information quickly There are 4 buttons Foreword Contents How to use this manual and Mechanism Illustrations on the PDF version and can be access to these items by...

Page 4: ...7 8 1 8 17 V BELT DRIVING SYSTEM 8 9 1 9 14 TRANSMISSION 9 10 1 10 16 WHEEL DRIVE SHAFT PROPELLER SHAFT 10 11 1 11 11 A C GENERATOR STARTING CLUTCH 11 12 1 12 8 CRANKCASE CRANKSHAFT 12 13 1 13 14 COO...

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

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

Page 7: ...n after the engine 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 st...

Page 8: ...oil seals 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 o...

Page 9: ...fill the groove with grease 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 dam...

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

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

Page 12: ...neither pull too tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be ap...

Page 13: ...acent or surrounding 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 instruc...

Page 14: ...ndary Reduction 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...

Page 15: ...6 4 0 Cylinder head right bolt 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 pip...

Page 16: ...l nut 8 10 2 40 Front 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...

Page 17: ...minutes and connect a hose onto fuel rich circuit Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged No fuel in fuel tank Check if the pipes fuel tank to carbu...

Page 18: ...tion Fouled and discoloration No knock Knock Air cleaner clogged Poor fuel supply Lines in fuel tank evaporation system clogged Exhaust pipe clogged Fuel nozzle clogged in carburetor Fuel nozzle clogg...

Page 19: ...Poor carburetor O ring Vacuum hose crack Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main sw...

Page 20: ...gine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Drive belt worn out or deformation Ramp plate of movable drive face damaged D...

Page 21: ...and piston rings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fu...

Page 22: ...1 GENERAL INFORMATION Lubrication Points Acceleration cable Front rear brake Lever Pivot To this chapter contents Wheel bearing 1 17...

Page 23: ...2 12 Nuts Bolts Tightness 2 12 Special Tools List 2 13 Precautions in Operation Specification Fuel Tank Capacity 12000 c c Capacity 1400 c c Engine Oil Change 1200 c c Capacity 1300 c c Transmission G...

Page 24: ...I I 24 Fuel lines I I 25 Cam chain I I 26 Valve clearance I A 27 Lines connections in cooling I I 28 Coolant reservoir I I 29 Coolant I I R Code I Inspection cleaning and adjustment R Replacement C Cl...

Page 25: ...in its flange part Remove rubber boot loosen fixing nut and then adjust it by turning the adjusting screw Tighten the fixing nut and check acceleration operation condition Free play 1 3 mm Air Cleane...

Page 26: ...erature is below 35 Remove front fender fuel tank cover and fuel tank Remove cylinder head cover Remove cylinder head side cover Turn camshaft bolt in C W direction and let the T mark on the camshaft...

Page 27: ...ssion 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 r...

Page 28: ...full transistor ignition set 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 c...

Page 29: ...th the periodical maintenance schedule to replace it Width limit 32 7 mm or above Propeller Shaft Remove 3 bolts from the propeller shaft connector Check the propeller shaft for any wear Check the rub...

Page 30: ...Front Differential Please exchange the whole assembly if necessary Rear Axle Gearbox Check the rear axle gearbox for abnormal noise or unsmooth rotation Caution Do not attempt to disassemble the Rear...

Page 31: ...e 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 tr...

Page 32: ...on Replace the lining if the brake lining wear limitation groove close to the brake disc Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining In order to...

Page 33: ...h operation If the ATV is in forward moving and shaking check clutch disc condition Replace it Cushion Front cushion Press down the front cushion for several times to check it operation Check if it is...

Page 34: ...d 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 pressu...

Page 35: ...NAME AC G Flywheel puller NO SYM 2301000 HMA NO SYM 1471110 20 NO SYM 3110000 HMA NAME KNUCKLE BODY BRG 6006 driver NAME Drive shaft puller NAME Driveshaft BRG 6228 driver NO SYM 5024000 REA 6006 NO S...

Page 36: ...OUTPUT SHAFT OIL SEAL 38 52 7 NO SYM 9100500 REA A6328 NO SYM 9120900 REA NO SYM 9120800 REA 12 28 7 6901 NAME Water pump oil seal driver NAME WATER PUMP BRG 6001 driver NAME Water pump mechanical sea...

Page 37: ...ch NAME Crankcase tool NO SYM 2210100 NO SYM 9020200 NO SYM 1120000 ALL 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...

Page 38: ...E PULLEY DRIVEN FACE expander NO SYM 9615010 REA 6006 NO SYM 2343110 REA 6307 NO SYM 2321000 REA NAME CLUTCH COVER 35 55 8 OIL SEAL NAME DRIVEN PULLEY Disassemble tool NAME PULLEY DRIVEN FACE SEAL COL...

Page 39: ...UP LWR 40 44 20 assemble tool NAME L COVER FR BRG 6302 driver NAME Drive plate fixer NO SYM 9100100 REA NO SYM 9615000 REA 6302 NO SYM 2230000 REA NAME NAME NAME NO NO NO NAME NAME NAME NO NO NO NAME...

Page 40: ...age 3 LUBRICATION SYSTEM Contents Mechanism Diagram 3 1 Precautions in Operation 3 3 Troubleshooting 3 3 Engine Oil 3 4 Engine Oil Strainer Clean 3 4 Oil Filter Unit 3 5 Oil Pump 3 6 Mechanism Diagram...

Page 41: ...To this chapter contents 3 LUBRICATION SYSTEM Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Con Rod Oil Route Valve Rocker Arm Oil Route 3 2...

Page 42: ...mmended SYM Hypoid gear oil Items Standard 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...

Page 43: ...bolt After 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 the oil strainer and spring Clean the oil str...

Page 44: ...Filter Unit Remove the oil filter unit with special tool Special Service Tool Tool No SYM 1445100 Install the oil filter unit by hand Lock the oil filter unit with special tool Special Service Tool To...

Page 45: ...chapter 10 Remove the cir clip and take out the oil pump sprocket Make sure that pump shaft can be rotated freely Remove 3 screws on the oil pump and then remove the oil pump Oil Pump Disassembly Remo...

Page 46: ...er rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install the inner and outer rotors into the pump body Align the indent on driving shaft...

Page 47: ...pump screw Oil Pump Installation Install the oil pump and then tighten screws Torque value 0 1 0 3kgf m Make sure that oil pump shaft can be rotated freely Install the oil pump sprocket and then inst...

Page 48: ...To this chapter contents 3 LUBRICATION SYSTEM Notes 3 9...

Page 49: ...ent of Idle Speed 4 9 Fuel Tank 4 10 Air Cleaner 4 11 Mechanism Diagram 4 1 Precautions in Operation 4 2 Trouble Diagnosis 4 3 Carburetor Removal Installation 4 4 Air Cut off Valve 4 5 Mechanism Diagr...

Page 50: ...ke unstable drive ability When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual ga...

Page 51: ...rrect idle speed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carbureto...

Page 52: ...Loosen throttle cable adjustment nut and remove throttle cable Remove the sleep adjustment wire Disconnect the fuel hose and by starter and drain tube Release 2 clamps strip of air cleaner and inner...

Page 53: ...ver spring and valve Inspection 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...

Page 54: ...ws of vacuum chamber cover and the cover Remove compress spring and vacuum piston Remove fuel needle seat spring and injector needle Check if the vacuum piston for wear out crack or other damage Check...

Page 55: ...valve seat for damage blocking 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...

Page 56: ...t slow jet and air 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 Cau...

Page 57: ...ard turns Standard turns 2 turns Warm up engine adjust the throttle stopper wire of throttle valve to standard RPM Idle speed rpm 1700 100 rpm Connect the hose of exhaust analyzer to exhaust front end...

Page 58: ...the side covers and lower side covers Remove the front fender Remove fuel unit wire from tank Covers remove please refer chapter 13 remove 2 fuel tubes from fuel valve Remove 4 bolts from tank rear s...

Page 59: ...the clamp strip of air cleaner and then remove the air cleaner vapor hose Remove the air cleaner 4 bolts Installation Install the tank in the reverse order of removal Cleaning air cleaner element Remo...

Page 60: ...lammable 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...

Page 61: ...To this chapter contents 4 FUEL SYSTEM 4 13 Notes...

Page 62: ...lutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutch Specification Item Capacity Replacement 2400 c c Replacement with oil filter changed 2700 c c Engine oi...

Page 63: ...tive Remove the battery negative terminal Remove the battery positive terminal Remove front fender and the footrest refer chapter 13 Remove the starter motor wire Remove the spark plug cap Disconnect...

Page 64: ...eed adjustment nut Remove 2 bolt on the muffler Remove the muffler Remove the throttle cable Remove 2 nuts and 1 bolt Remove the exhaust pipe Remove the choke cable and ventilation tube Remove 2 nuts...

Page 65: ...GINE REMOVAL 5 4 Remove 2 manifold clamps Remove the carburetor Remove 4 bolts Remove the air cleaner Remove 2 bolts Remove the muffler Remove 2 nuts and 1 bolt Remove the exhaust pipe Manifold clamps...

Page 66: ...mostat cover Remove the PCV pipe Remove 2 bolts Remove the starter motor Remove 3 bolts on the front propeller shaft connector Remove the front propeller shaft Remove 3 bolts on the rear propeller sha...

Page 67: ...and then remove engine by left side Engine Installation Check the bush of engine hanger parts for any damage Install the engine in the reverse procedures of removal Caution Be careful when removing a...

Page 68: ...ection 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 1k...

Page 69: ...5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Inner 33 700 30 100 Free length of valve spring outer 38 800 35 200 Valve seat width 1 600 Intake 0 10 0...

Page 70: ...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 71: ...then remove the thermostat Remove the bolt and spring of the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts R...

Page 72: ...on the cam sprocket with that of cylinder head to make the piston at TDC position Loosen 2 bolts from the cam sprocket Remove the cam sprocket disk and washer Remove the cam sprocket Special Service T...

Page 73: ...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 In order to avoid loos...

Page 74: ...Head 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 Se...

Page 75: ...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 va...

Page 76: ...ce 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 r...

Page 77: ...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 78: ...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 79: ...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 sea...

Page 80: ...e cotter remove assembly tool to press the valve spring and then remove the valves Caution To avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valv...

Page 81: ...ylinder head Prevent the 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 hea...

Page 82: ...olt hole Tighten the sprocket mounting bolts Caution Make sure timing marks are matched Install the cylinder head side cover 3 bolts Install the thermostat 2 bolts Loosen auto tensioner adjustment bol...

Page 83: ...nd align 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...

Page 84: ...6 CYLINDER HEAD VALVE 6 17 Notes To this chapter contents...

Page 85: ...N Mechanism Diagram 7 1 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Mechanism Diag...

Page 86: ...piston and cylinder 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 o...

Page 87: ...in clip and then remove the piston pin and piston Remove the cylinder gasket and dowel pin Clean up all residues or foreign materials from the two contact surfaces of cylinder and crankcase Caution We...

Page 88: ...d ring 0 09 mm Remove piston 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 int...

Page 89: ...e the inner diameter of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure the piston outer diameter Caution The measurement posit...

Page 90: ...iston ring onto piston carefully 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...

Page 91: ...moved more easily Piston Installation Install the piston and piston pin and place the IN marks on the piston topside forward to inlet valve Install new piston pin clip Caution Do not let the opening o...

Page 92: ...ston rings Care to be taken 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 wi...

Page 93: ...Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 3 Drive Plate 8 4 Movable Drive Face Disassembly 8 6 Driven Pulley Disassembly 8 13 Mechanism Diagram Home page...

Page 94: ...0 965 40 985 mm 40 945 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 19 700 20 300 g 19 200 g Torque value Drive face nut 8 5 10 5kgf m Clutch outer nut 5 0 6 0kgf m Drive pl...

Page 95: ...emove left crankcase cover bolts 17bolts Remove 2 dowel pin and gasket Left crankcase cover installation Install left crankcase cover in the reverse procedure of removal Drive Belt Loosen 1nut from th...

Page 96: ...ry Measure the width of drive belt as diagram shown Service Limit 29 2 mm Replace the belt if exceeds the service limit Caution Using the genuine parts for replacement The surfaces of drive belt or pu...

Page 97: ...outer One way Clutch Inspection Check each roller for wear or damage Hold the clutch outer and turning the one way clutch for right side Loosen the drive plate nut with special tool Remove the drive p...

Page 98: ...ht roller 8pcs Inspection The weight rollers are to press movable drive face by means of centrifuge force Thus if weight rollers are worn out or damaged the centrifuge force will be affected Check if...

Page 99: ...able drive face and replace it if it exceed service limit Service limit 36 055 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same In or...

Page 100: ...nd 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 Remove the bearing 6302 with inner bearing pul...

Page 101: ...02 with special tool Tool name L COVER FR BRG 6302 bearing IN puller with air Tool NO SYM 9615000 REA A6302 Put the caller and nut Install the bearing with air or head tool SYM 9615000 REA A6302 SYM 9...

Page 102: ...e bearing Install the bearing 6006 with special tool Tool name L COVER FR BRG 6006 bearing driver Tool NO SYM 9615010 REA 6006 Knock the bearing to the objected position Install the cir clip SYM 96150...

Page 103: ...Remove the spring plate and centrifugal clutch plate Remove 5 springs from the drive plate Check if spring is damaged or insufficient elasticity Remove 5 clutch weights Check if spring is damaged or...

Page 104: ...m Apply grease onto setting pins Install the spring into groove with pliers Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins Cauti...

Page 105: ...ing plate and centrifugal clutch plate Install 5 e ring in the drive plate Driven Pulley Disassembly Disassemble the driven pulley with special tool Apply special tool compressor onto the pulley Speci...

Page 106: ...EM 8 14 Remove cir clip with pliers Loosen the special tools nut Remove the driven pulley collar and 4 roller guides Remove the movable driven face nut Cir clip Drive pulley collar 4 roller guides To...

Page 107: ...Replace it if exceeds service limit Service limit Outer diameter 40 945 mm Inner diameter 41 070 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necess...

Page 108: ...ecial tool to keep the driven face assy open Do not oppress friction plate in order to avoid distortion or damage Install the movable drive face assy Hold the movable drive face assy with the MDF hold...

Page 109: ...8 V BELT DRIVING SYSTEM 8 17 Notes To this chapter contents...

Page 110: ...cement 9 9 Transmission Reassembly 9 12 Mechanism Diagram Final shaft Reverse Shaft Drive shaft Home page Contents Shift fork Shift Drum Counter Shaft Left crank case Radial Ball Bearing 6307 Bevel Ge...

Page 111: ...Bearing driver 6307 SYM 2343110 REA 6307 Bearing driver 2220 SYM 9100400 REA 2220 Bearing driver 6307 SYM 2346000 REA A6307 Final shaft gear stopper SYM 2343100 REA Needle bearing driver HK2016 SYM 9...

Page 112: ...pedal Remove brake spring stop switch spring Remove brake penal Remove the front and rear propeller shaft Remove the engine from the frame before performing the transmission disassembly Remove the fr...

Page 113: ...rear output shaft covers Remove 13 bolts from the right crankcase Remove the right crankcase from the left crankcase Remove the counter shaft shift fork and the shift drum 4 bolts Shift drum Shift for...

Page 114: ...ve 4 bolts Remove the shims from the bevel gear housing Remember the number of the shims and put the same number of shims when reassembling Remove the shims from the final shaft Remember the number of...

Page 115: ...drive shaft Remove the output shaft Caution Do not remove the drive shaft from the crankcase if unnecessary When removing the drive shaft from the crankcase then the bearing has to be replaced Bearin...

Page 116: ...Measure the outer diameter of shift fork shaft Replace it if it exceed service limit Service limit 13 966 mm Measure the inner diameter of shift fork Replace it if it exceed service limit Service lim...

Page 117: ...bearing outer ring is mounted on gear tightly If the 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 T...

Page 118: ...g from the left crankcase Remove the drive shaft bearing from the shaft by outer bearing puller Replace the drive shaft bearing with new one by bearing driver Special tool Tool number SYM 2341110 REA...

Page 119: ...number SYM 6204025 Tool name Inner bearing puller Remove the counter shaft bearing on the right crankcase with inner bearing puller Special tool Tool number SYM 6204025 Tool name Inner bearing puller...

Page 120: ...iver Install the counter shaft bearing with the bearing driver Special tool Tool number SYM Tool name Counter shaft bearing driver Install the drive shaft needle bearing with the bearing driver Specia...

Page 121: ...ift fork Install the shift drum Rotate the shift drum and make sure it can rotate smoothly Install the final shaft onto the right crankcase Put the same numbers of shim which were removed during remov...

Page 122: ...umber SYM 2343100 REA Tool name Final shaft stopper Reassemble the right and left crankcase Install the gearshift spindle Align the concave marks on the shift gear and the shift drum gear Install 2 do...

Page 123: ...9 TRANSMISSION 9 14 Install the change lever arm Keep the level mark on the change lever arm horizontal Change lever arm Level mark To this chapter contents...

Page 124: ...ve Shaft Removal 10 3 Wheel Drive Shaft Disassembly 10 4 Wheel Drive Shaft Inspection 10 7 Repair Pack 10 8 Wheel Drive Shaft Assembly 10 10 Front and Rear Propeller Shaft 10 14 Mechanism Diagram 10 H...

Page 125: ...nnot move Damaged wheel drive shaft Damaged propeller shaft Damaged front differential or rear axle gear box Noise Worn or burnt drive shaft Worn or burnt steel ball Worn or burnt gear Gear oil leaks...

Page 126: ...e front brake caliper and disk Remove the tie rod Remove the knuckle body Remove the wheel drive shaft with special tool Rear wheel drive shaft removal Remove the rear wheel Remove the rear wheel conn...

Page 127: ...r boot bands Remove the UJ rubber boot Disassemble the wheel drive shaft UJ assembly with rubber hammer special tool Tools name Wheel driveshaft assembly seat Tools number SYM 4423000 REA Caution Do n...

Page 128: ...Tools number SYM 4423500 REA Remove the inner race and cage from the outer race Clean the inner race outer race steel balls and cage Double Offset Joint Disassembly Open DOJ band clip with scrapper R...

Page 129: ...HAFT PROPELLER SHAFT 10 6 Remove the inner cir clip with screw drive Disassemble DOJ assembly Clean the DOJ assembly Remove the cir clip from the drive shaft Remove the steel balls from cage To this c...

Page 130: ...ace of these parts for wear or scratch Replace DOJ or UJ assembly if any stepped scratch is found Check the inside surface of UJ outer race Replace UJ assembly if it is damaged Check the inside surfac...

Page 131: ...VE SHAFT PROPELLER SHAFT 10 8 Repair Pack Check if DOJ UJ boot is damaged Replace DOJ or UJ assembly if it is damaged Remove the DOJ UJ boot Remove the DOJ UJ cage Remove the DOJ UJ boot To this chapt...

Page 132: ...assemble and clean all spare parts Check if there is any corrosion on the surface of these parts Replace DOJ or UJ assembly if any damaged part is found Clean the DOJ UJ cage Unpack DOJ Repair Pack Un...

Page 133: ...s inner race and cage then drive shaft into the assembly Assemble exit cir clip onto drive shaft Grease into the DOJ outer race Caution Please use the grease of the repair pack Using other oil may cau...

Page 134: ...l drive shaft and cir clip into DOJ outer race Install DOJ boot outside band Install DOJ boot Pull and open DOJ boot Pressure balancing that make it inside and external Deduct DOJ band closely with ru...

Page 135: ...boot and Pour into the grease Pour grease into the UJ boot inside Caution Please use the grease of the repair pack Using other oil may cause the part to be damaged Assemble cir clip with the tool Str...

Page 136: ...10 WHEEL DRIVE SHAFT PROPELLER SHAFT 10 13 Install UJ boot Pull and open DOJ boot to balance the inside and outside pressure Install band with rubber hammer To this chapter contents...

Page 137: ...e engine and propeller connector Remove the front propeller shaft connector Remove the front propeller shaft connector spring spring pin and shaft Propeller shaft disassembly Remove the front side exi...

Page 138: ...rubber boots Drive shaft inspection Check if the spur gear has is damaged or not Please replace new parts if it has split or damaged Check if the propeller shaft is split or damaged Please replace new...

Page 139: ...DRIVE SHAFT PROPELLER SHAFT 10 16 Check if the propeller shaft rubber boot is damaged or not Propeller shaft installation Install in the reverse order of removal procedures Rubber boot To this chapter...

Page 140: ...Starter Cover Removal 11 5 One Way Clutch Installation 11 7 Flywheel Installation 11 8 A C Generator Installation 11 9 Right Crankcase Cover Installation 11 9 Mechanism Diagram Recoil Starter Grip Re...

Page 141: ...and precaution items of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 27 026 27 045 27 050 OD of starting clutch gear 45 192 45 283 45 183 Torque value Flywhee...

Page 142: ...il starter cover Remove the recoil starter cover and gasket Remove the water pump cover 5 bolts A C Generator Removal Remove the connector bolt and starter pulley Remove 12 mounted screws from the rig...

Page 143: ...tarting Clutch Gear Inspection Remove the 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 27 050 mm OD 45 183 mm...

Page 144: ...ar onto one way clutch Hold the flywheel and rotate starting clutch gear The starting clutch gear should be rotated in C C W direction freely but not C W direction Recoil Starter Cover Removal 3 bolts...

Page 145: ...olute spring is removed from the recoil starter cover it should be replaced with a new one 2 springs Volute spring Remove the starter grip rubber Starter rope Disassemble the starter grip and rope Sta...

Page 146: ...One Way Clutch Installation 3 bolts Install the components in the reverse procedures of removal Caution Tape a tightening tape onto the thread of hexagon bolt Torque value 1 0 1 4kgf m One way clutch...

Page 147: ...TCH Flywheel Installation Install the reduction gear shaft and reduction gear Assemble the starting driven gear of the flywheel Align the key on crankshaft with the flywheel groove and then install th...

Page 148: ...tion Make sure that the wire harness is placed under pulse generator Right Crankcase Cover Installation Install the dowel pin and new gasket Remove the water pump cover Install the right crankcase cov...

Page 149: ...To this chapter contents 11 A C GENERATOR STARTING CLUTCH Install the water pump cover 5 bolts Assemble the gasket Assemble the starter cover on the right crankcase cover 5 bolts 5 bolts 11 10...

Page 150: ...To this chapter contents 11 A C GENERATOR STARTING CLUTCH 11 11 Note...

Page 151: ...CRANKSHAFT Mechanism Diagram 12 1 Crankcase Disassembly 12 3 Crankshaft Inspection 12 5 Crankcase Assembly 12 6 General Information 12 2 Trouble Diagnosis 12 2 Mechanism Diagram 1 0 1 4kgf m 12 Eng O...

Page 152: ...aft bearing the driving 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...

Page 153: ...am chain tensioner Loosen 2 bolts on the left crankcase Loosen 13 bolts on the right crankcase Place left crankcase downward and right crankcase up Tap the right crankcase with a plastic hammer to rem...

Page 154: ...emove crankshaft from left crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage the contact face of the gasket It is better to moisten...

Page 155: ...V block measure run out of the crankshaft Service limit 0 10 mm Check crankshaft bearing Use hand to crank the bearing to see if it moves freely smoothly and noiseless Check the inner ring to see if...

Page 156: ...ion is uneven noising or loose bearing mounted then replace it Special tool Tool number SYM 6204024 Tool name Inner bearing puller bearing driver Crankcase Assembly Install wave washer into right cran...

Page 157: ...nstall 2 dowel pins and 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 va...

Page 158: ...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 Tool number SYM 11332100 HMA RB1 Tool name Crank and oil seal installation Inst...

Page 159: ...ing System Troubleshooting 13 3 System Test 13 5 Radiator 13 6 Water Pump 13 8 Thermostat 13 13 Mechanism Diagram Radiator filler cap Radiator Reserve tank Thermo switch fan Coolant inlet pipe Coolant...

Page 160: ...er 850c 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 imp...

Page 161: ...lem N D Close radiator cap measure thermo unit to confirm if voltage reduce when temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect if the coolant circulate o...

Page 162: ...tle repeatedly 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 coolan...

Page 163: ...tely 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...

Page 164: ...oding when the temperature rises Radiator Check Remove the front center cover side covers and front fender Refer to chapter 13 check for any leakage from weld seam Blow the radiator fins with compress...

Page 165: ...sert the fan into the motor 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...

Page 166: ...or the cylinder head gasket damage Check the water pump seals first If the water pump seals are ok inspect the cooling system of the cylinder and the cylinder head Water pump removal Remove the recoil...

Page 167: ...ing by inner bearing puller Drive the mechanical seal and inner seal out of the right crankcase Special tools Tool number SYM 6204024 Tool name Inner bearing puller Caution Replace a new mechanical se...

Page 168: ...Tool number SYM 6001300 REA A6001 Tool name Water pump bearing 6001 inner puller Assemble the bearing for the crankcase with special tool Install the bearing with head or air tool Caution Do not reuse...

Page 169: ...over Install the seal washer into the impeller Caution Washer must be replaced together with the mechanical seal Install the impeller onto the water pump shaft and tighten Torque Value 1 0 1 4kgf m Ca...

Page 170: ...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...

Page 171: ...t and the 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...

Page 172: ...13 COOLING SYSTEM 13 14 NOTES To this chapter contents...

Page 173: ...4 Footrest 14 5 Rear Carrier 14 6 Rear Fender 14 6 Mechanism Diagram Front carrier Front fender Meter cover 14 Front top cover Headlight Right side cover Front grille Footrest Suspension arm cover Lef...

Page 174: ...Covers Front Bumper Cover Rear Center Up Cover Tail Light Low Cover Rear Carrier Rear fender Be careful not to damage various covers in assembly or disassembly operation Never injure hooks molded on...

Page 175: ...llation Install in the reverse order of removal procedures Fuel Tank Cover Removal Remove the maintenance cover Remove the front top cover Remove the seat Remove the fuel tank cap Remove the fuel tank...

Page 176: ...the right and left side covers Remove 4 screws from footrest Remove 4 screws from the right and left inner protectors Remove the inner protectors Disconnect the hazard control unit shift gear control...

Page 177: ...oot peg bolts each side 2 bolts Remove the foot pegs Remove 2 bolts from the right and left footrests Remove 4 screws from the rear part of the footrest Remove the right and left footrests Installatio...

Page 178: ...the rear carrier Remove the rear carrier Installation Install in the reverse order of removal procedures Rear Fender Remove the rear carrier Remove the seat Remove the rear center up cover Remove 4 s...

Page 179: ...ect the full transistor igniter 2WD 4WD control unit and battery open control unit Remove the rear fender Installation Install in the reverse order of removal procedures 2WD 4WD control unit Full tran...

Page 180: ...To this chapter contents 14 BODY COVER NOTES 14 8...

Page 181: ...15 6 Brake Fluid Replacement Air bleed 15 6 Front Brake Caliper 15 8 Brake Disk 15 9 Front Brake Master Cylinder 15 9 Mechanism Diagram Front pressure control valve Front brake master cylinder 15 Brak...

Page 182: ...plastic or rubber parts to avoid damage Check the operation of the brake system before riding Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation...

Page 183: ...er Uneven braking force 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...

Page 184: ...support under the frame Remove 4 nuts from the front wheel Remove the front wheel Installation Install the front wheel and tighten the nuts Torque 2 4kgf m Front Wheel Hub Removal Remove front brake...

Page 185: ...the brake from behind the brake caliper The brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk Caution Before checking the front brake lining front wheel m...

Page 186: ...nder Clean the dirty brake disk Caution The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performance Foreign materials will block...

Page 187: ...brake lever tightly and open the drain 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 fluid level when...

Page 188: ...on groove close to the 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 Installati...

Page 189: ...the asbestos ingredient do not use the air gun clean the caliper the operator should dress the mouthpiece and the glove use vacuum cleaner to clean it Front Brake Master Cylinder Master Cylinder Remov...

Page 190: ...e limit Allowable limit 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 component...

Page 191: ...ke 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 avoi...

Page 192: ...15 FRONT BRAKE FRONT WHEEL 15 12 To this chapter contents Notes...

Page 193: ...agnosis 16 2 Steering Handle 16 3 Steering Shaft 16 4 Steering Tie Rod 16 6 Knuckle 16 7 Knuckle Disassembly 16 8 Knuckle Assembly 16 9 Front Cushion 16 11 Suspension Arm 16 12 Toe In 16 13 Mechanism...

Page 194: ...e pressure Faulty steering shaft bushing Damaged steering shaft bushing Front wheel wobbling Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Steers to one side Bent...

Page 195: ...er Remove 2 screws and then remove throttle hosing holder and throttle hosing Loosen 2 screws and then remove handle left switch and choke hosing Loosen 2 screws and then remove 2 4 wheel drive change...

Page 196: ...bracket Installation Install in the reverse order of removal procedures Torque value Handlebar under holder nut 4 0kgf m Handlebar upper holder bolt 2 4kgf m Steering Shaft Remove Remove cotter pins a...

Page 197: ...gs for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit 39 5 mm Installation Install in reverse order of removal procedures Apply with grease onto oil liner a...

Page 198: ...bending Inspect the 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 adj...

Page 199: ...e caliper them remove front brake caliper Remove cotter pin and nut remove front brake disk After tightened the nuts install the cotter pins Remove cotter pin and castle nut from front upper and lower...

Page 200: ...cking Installation Install in the reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Ball joint nut 5 0kgf m Knuckle Disassembly Remove oil seal 40 50 6 5 40 55 8 from knuc...

Page 201: ...nuckle then lock the nut Install the bearing with special tool air tool Tools number SYM 5024000 REA A6006 Tools name wheel knuckle body bearing 6006 in puller with air Install the cir clip in 55 into...

Page 202: ...EA Tools name wheel knuckle body seal 40 55 8 in driver Assemble oil seal 40 50 6 5 by special tool Install oil seal into the knuckle body with hammer Tools number SYM 9123000 REA Tools name wheel knu...

Page 203: ...he front cushion under bolt nut and remove the bolt Remove the front cushion upper bolt nut and remove the bolt and the cushion Installation Install in the reverse order of removal procedures Torque v...

Page 204: ...arm cover and then remove the cover Loosen under suspension arm nuts Remove the swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bend...

Page 205: ...k carefully and 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 m...

Page 206: ...Suspension Arm 17 10 Disk Brake System Inspection 17 11 Adding Brake Fluid 17 12 Brake Fluid Replacement Air bleed 17 13 Rear Brake Caliper 17 14 Brake Disk 17 15 Rear Brake Master Cylinder 17 15 Mech...

Page 207: ...allation 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 h...

Page 208: ...en 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 a...

Page 209: ...ar wheels Installation Install the rear wheel and tighten the nuts Torque 2 4kgf m Rear Wheel Connecter Removal Remove cotter pin rear wheel connecter nut and washer Remove right and left rear wheel c...

Page 210: ...Loosen 2 nuts then 2 flange bolts Remove the rear wheel hub Wheel Hub Disassembly Remove 4 washer seals 2 callers from rear wheel hub Remove the oil seal 40 55 8 from rear wheel hub 2 nuts 2 bolts 4...

Page 211: ...om rear wheel hub with special tool Tools number SYM 6204025 Tools name inner bearing outer puller Remove the 4 oiled from rear wheel hub with special tool Tools number SYM 6204025 Tools name inner be...

Page 212: ...l hub oiled install tool Install 2 bearing 6006uu into the rear wheel hub with special tool Tools number SYM 5024000 REA A6006 Tools name wheel knuckle body bearing 6006 in puller with air or head too...

Page 213: ...b Assembly oil seal 40 55 8 by special tool Tools number SYM 9123200 REA Tools name wheel knuckle body seal 40 55 8 in driver Install the oil seal with special tool hammer Oil SEAL 40 50 6 5 SYM 91230...

Page 214: ...connecter Loosen 2 bolts from the rear cushion Remove the rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Tighten the...

Page 215: ...suspension arm cover and then remove the cover Loosen under suspension arm nuts Remove the swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm for damage or bending Insta...

Page 216: ...e replaced with new lining when the brake pad wear limit reaches the brake disk Caution Before checking the rear brake lining remove rear wheel first Park the ATV on a level ground and check if fluid...

Page 217: ...ainted 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 brak...

Page 218: ...rake 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 Hold the bra...

Page 219: ...llation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 20 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washe...

Page 220: ...gun to be clean the operator should dress the mouthpiece and the glove and use vacuum cleaner clean it Rear Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter int...

Page 221: ...er 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 f...

Page 222: ...ure 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 le...

Page 223: ...n 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 t...

Page 224: ...17 REAR BRAKE REAR WHEEL REAR CUSHION 17 19 Notes To this chapter contents...

Page 225: ...rmo Switch 18 19 Thermo Unit 18 20 Water Temperature Indicator Lamp 18 20 Mechanism Diagram Starter relay Winker relay Spark plug AC Generator Fuse box Battery Ignition coil Main switch Full Transisto...

Page 226: ...hecked with the voltmeter while charging the battery As Full Transistor Igniter assembly does not require an ignition timing check In case ignition timing is incorrect check Full Transistor Igniter an...

Page 227: ...ort circuited The starter motor is out of work Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the...

Page 228: ...ger 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 Keep flames awa...

Page 229: ...radually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse Do not turn the main switch to ON position during test If the leaked current exceeds...

Page 230: ...chometer 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...

Page 231: ...es 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 8 If the readings measured are not norma...

Page 232: ...ON position Red Yellow Green Battery voltage Pulse generator Green White Blue Yellow 50 170 Primary circuit Black Yellow Green 2 8 15 Black Yellow with no cap 9 0K 20 Ignition coil Secondary circuit...

Page 233: ...resistance between the spark plug and the primary winding Standard resistance With no cap 9 0 20 K With cap 14 0 20 K Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if ne...

Page 234: ...he 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 batte...

Page 235: ...he 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 the reverse order of...

Page 236: ...Remove couplers of meter and main switch couplers Remove 4 bolts from meter stay Remove 3 screws and speedometer cable Disassemble speedometer cover and speedometer To this chapter contents 4 bolts M...

Page 237: ...12V 35W Caution Never touch the bulb with finger which will create a heat point and reduce the lifetime of the bulb Clean the fingerprint left on the bulb with alcohol Install the bulb of the headligh...

Page 238: ...winker light cover Remove the winker light cover 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 ligh...

Page 239: ...2V 5W 21W Remove 2 screws Remove the rear winker light cover Pull out the rear winker bulb Replace the rear winker bulb with new one 12V 10W Caution Never touch the bulb with finger which will create...

Page 240: ...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...

Page 241: ...ue 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 Co...

Page 242: ...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 fe...

Page 243: ...hermo 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...

Page 244: ...performing this test Caution Engine oil should 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 res...

Page 245: ...18 ELECTRICAL SYSTEM 18 21 Notes To this chapter contents...

Page 246: ...Home page Contents 19 ELECTRICAL DIAGRAM 19 1 19...

Page 247: ...To this chapter contents 19 ELECTRICAL DIAGRAM Notes 19 2...

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