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Sym Track Runner 200, Service Manual

Introducing the Sym Track Runner 200 - a reliable and robust vehicle built to conquer any terrain. Enhance your riding experience by easily accessing the comprehensive Service Manual, available for free download at manualshive.com. Maximize the potential of your Track Runner 200 with this essential manual.

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10. ALTERNATOR/STARTING CLUTCH

 

 

10-4 

 

Remove the oil through guide pin from crankshaft. 

 
 
 
 
 
 
 
 
 
 
 

Pull out flywheel with A.C.G. flywheel puller.

 

Special tool: 
A.C.G. Flywheel puller 
 
 
 
 
 
 
 
 
 
 

Starting Clutch 

Removal 

Remove starting driven gear. 

 
 
 
 
 
 
 
 
 
 
 

Remove the starter reduction gear, and the shaft. 

 

 

 

 

 

 

 

 

 

To this chapter contents 

 

Flywheel puller

Guide pin 

Starting driven gear

Reduction gear

Summary of Contents for Track Runner 200

Page 1: ...Track Runner 200 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 Track Runner 180 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: ...g 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 ...

Page 4: ...YLINDER 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 8 ALTERNATOR 10 11 1 11 8 CRANKSHAFT CRANKCASE 11 12 1 12 14 COOLING SYSTEM 12 13 1 13 10 BODY COVER 13 14 1 14 14 FRONT BRAKE AND FRONT WHEEL 14 15 1 15 12 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: ...imits to use SAE 10W 30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil Grease King Mate G 3 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 lubric...

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: ...Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T auto speed change Fuel Used Unleaded Speedometer 0 90 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A Bore 61 mm Muffler Expansion Pulse Type Stroke 58 8 mm Exhaust Pipe Position and Direction Right side and Backward Cylinder Number Arrange ment Sin...

Page 15: ...Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T auto speed change Fuel Used Unleaded Speedometer 0 90 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A Bore 61 mm Muffler Expansion Pulse Type Stroke 58 8 mm Exhaust Pipe Position and Direction Right side and Backward Cylinder Number Arrange ment Sin...

Page 16: ...ype 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T auto speed change Fuel Used Unleaded Speedometer 0 90 km hr Cycle Cooling 4 stroke water cooled Horn 93 112 dB A Bore 61 mm Muffler Expansion Pulse Type Stroke 58 8 mm Exhaust Pipe Position and Direction Right side and Backward Cylinder Number Arrange ment Sing...

Page 17: ...ia mm Torque Value kgf m Remarks Cylinder head nut 4 8 2 0 2 4 Cylinder head right bolt 2 8 2 0 2 4 Cylinder head stud bolt inlet pipe 2 6 0 7 1 1 Cylinder head stud bolt EX pipe 2 7 0 5 1 0 Tappet adjustment hole cap bolt 6 6 1 0 1 4 Tappet adjustment screw nut 4 5 0 7 1 1 Apply oil to thread Spark plug 1 10 1 0 1 2 Carburetor insulator bolt 2 6 0 7 1 1 Cylinder stud bolt 4 8 0 7 1 1 Engine left ...

Page 18: ...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 10 4 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 19: ...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 20: ...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 21: ...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 22: ...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 23: ... 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 24: ...1 GENERAL INFORMATION 1 19 Parts to Be Greased Rear swing arm Front suspension arm front side And steering shaft Front suspension arm rear side Right and left Knuckle To this chapter contents ...

Page 25: ...1 GENERAL INFORMATION 1 20 Drive chain Acceleration cable Front rear brake lever pivot Speedometer gear Wheel bearing To this chapter contents ...

Page 26: ... 11 Nuts Bolts Tightness 2 11 Special Tools List 2 12 Precautions in Operation Specification Fuel Tank Capacity 8000 c c Capacity 1000 c c Engine Oil Change 800 c c Capacity 750 c c Transmission Gear oil Change 650 c c Engine radiator 780 c c Capacity of coolant Reservoir upper 420 c c Clearance of throttle valve 5 10 mm Type NGK CR8E Spark plug Gap 0 8 mm F Mark in idling speed BTDC 13º 1000 rpm ...

Page 27: ...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 28: ...e 3 screws from the air cleaner cover and then remove the cover 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 eleme...

Page 29: ...e camshaft 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 Valve clearance IN EX 0 12 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution Re che...

Page 30: ...ed 1600 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 31: ...correct 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 th...

Page 32: ...h limit 18 5mm 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 bolts and turn drive chain adjusting nuts until get the correct slack Tighten the axle holder bolts Torque 3 25kgf m Caution y Thi...

Page 33: ...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 34: ...e the 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 e...

Page 35: ...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 36: ... 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 0 8 kg cm 12psi 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...

Page 37: ... SHAFT BRG FIXING SOCKET NAME CRANK CASE BUSH PULLER NAME CRANK CASE BUSH PULLER NO SYM 9100210 H9A NO SYM 1120310 NO SYM 1120320 NAME Valve cotter remove assembly tool NAME Tappet adjusting wrench NAME Tappet adjuster NO SYM 1471110 20 NO SYM 9001200 NO SYM 9001209 NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor NO SYM 2210100 NO SYM 9020200 NO SYM 2301000 To this chapt...

Page 38: ...ater pump bearing driver NAME Water pump mechanical seal driver NO SYM 9120500 H9A NO SYM 9100100 NO SYM 1721700 H9A 6301 6204 6203 6004UZ NAME BEARING DRIVER NAME BEARING DRIVER NAME BEARING DRIVER Ø17mm NO SYM 9610000 NO SYM 9110400 NO SYM 9620000 20 32 6 25 40 8 27 42 7 NAME Oil seal driver NAME Oil seal driver NAME Oil seal driver NO SYM 9120200 NO SYM 9121600 NO SYM 9125500 To this chapter co...

Page 39: ... bush long NO SYM 1130000 L NO SYM 1130010 NO SYM 1130031 55mm NAME Extension bush short NAME Torque wrench NAME Rear axle nut torque wrench NO SYM 1130032 NO SYM HT07004 RA1 NO SYM 4230200 55mm NAME Rear axle nut wrench NAME NAME NO SYM HT06007 NO NO NAME NAME NAME NO NO NO To this chapter contents ...

Page 40: ...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 Oil through Home page Contents ...

Page 41: ...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 5 3 0kgf m Engine oil drain bolt 1 9 2 5kgf m Gear oil drain bolt 1 0 1 5kgf m Gear oil join bolt 1 0 1 5kgf m Oil pump connection bolt 0 8 1 2kgf m Troubleshooting Low engine oil level y Oil leaking y Valve guide or seat worn ...

Page 42: ...ain bolt After drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 5 3 0kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Engin...

Page 43: ...ain 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 disassemble the pump as illustration shown Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit 0 25 mm Clip 2 screws To this chapter contents ...

Page 44: ...en rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install fixing pin Install the oil pump cover and fixing pin properly Pin 1 Screw To this chapter contents ...

Page 45: ...nd then tighten bolts Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump driving chain and sprocket and then install snap ring onto oil pump shaft Install starting gear and generator Refer to chapter 10 To this chapter contents ...

Page 46: ... drain bolt and drain gear oil out Install the drain bolt after drained Torque value 1 0 1 5kgf m Make sure that the drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 1000 c c when replacing Make sure that the join bolt washer can be re used and install the bolt Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil leve...

Page 47: ...3 LUBRICATION SYSTEM 3 8 Notes To this chapter contents ...

Page 48: ... 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 Insulator Fuel tank ...

Page 49: ...sembling 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 auto by starter and air cut valve arbitrarily Specification ITEM UA18A Carburetor diameter Ø22mm I D number PTC 049 Fuel level 14 8mm Main injector 98 Idle injector 35 Idle speed 1600 100rpm Throttle handle...

Page 50: ...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 51: ...e the choke cable Remove the carburetor top parts from the carburetor Disconnect the fuel hose Release the clamp strip of air cleaner Release the 2 nuts of carburetor insulator and then remove the carburetor Installation Install in reverse order of removal procedures Screw Choke cable Clamp screws Choke cable To this chapter contents Fuel pipe 2 nuts ...

Page 52: ...nspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restrict 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 53: ...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 54: ...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 55: ... 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 Ins...

Page 56: ...1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1600 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 i...

Page 57: ...ent chapter 17 Fuel unit 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 2 screws Remove the front body cover 6 screws and 5 bolts Remove the tank cover 2 bolts Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove the vacuum tube R...

Page 58: ...strip of air cleaner and then remove the air cleaner vapor hose Remove the air cleaner cover 3 screws 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...

Page 59: ...4 FUEL SYSTEM 4 12 Notes To this chapter contents ...

Page 60: ...ransmission system only y The following parts can be serviced as engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor Specification Item Capacity Replacement 800 c c Engine oil capacity Disassembly 1000 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 ...

Page 61: ...move front fender rear fender and the footrest refer chapter 13 Remove starter motor wire from start relay Remove the spark plug cap and remove ignition cable by mounting clamp Disconnect A C Generator wire couplers Starter motor wire A C G wire coupler Spark plug cap Negative Negative Clamp To this chapter contents ...

Page 62: ...parts and cable Remove fuel pipe and vacuum pipe Release the clamp strip of air cleaner duct 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 2 bolts 2 nuts Clamp screws Fuel pipe 2 nuts Clamps To this chapter contents ...

Page 63: ...and drain out coolant Remove water hoses from water pump Remove the thermo sensor wire and coolant by pass pipe Loosen speedometer cable mounting nut and then remove the cable 1 bolt Mounting nut Thermo sensor wire Drain bolt By pass pipe Water hoses clamp To this chapter contents ...

Page 64: ...nd bolt then remove engine 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 wires have to be routed in accordance with normal layout Engine hanger Bolt Torque value 4 0 5 0kgf m 2 nuts Clip 1 nut To this...

Page 65: ...rubber bush damaged Then with the bush remover presser Ø 30mm to press the bush out and replace it with new one Engine hanger bush ψ 30mm Place the detent section of the bush remover toward the bush and drive both the pressing ring and bolt in to press the bush out Pressing In Place the flat section of the remover toward the bush and then drive the bush pressing ring and bolt in to install the bus...

Page 66: ...4 Cylinder Head Disassembly 6 6 Cylinder Head Inspection 6 7 Valve Stem Replacement 6 8 Valve Seat Inspection and Service 6 9 Cylinder Head Reassembly 6 11 Cylinder Head Installation 6 12 Valve Clearance Adjustment 6 14 Mechanism Diagram 6 2 0 2 4kgf m 0 8 1 2kgf m 0 8 1 2kgf m 1 0 1 2kgf m 2 0 2 4kgf m Home page Contents ...

Page 67: ...4 11 910 Intake 4 975 4 990 4 900 OD of valve stem Exhaust 4 955 4 970 4 900 Guide seat 5 000 5 012 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 030 0 057 0 100 Free length of valve spring 35 000 31 500 Valve Valve seat width 1 000 1 6 Tilt angle of cylinder head 0 05 Torque Value Cylinder head bolt LH 2 0 2 4kgf m Cylinder head Nut 2 0 2 4kgf m Sealing bolt of c...

Page 68: ... 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 69: ...emove 1 bolt of thermostat and then remove the thermostat Remove hole cap for the adjustment bolt of cam chain tensioner and then loosen the tensioner by turning a flat driver in C W direction Remove the side cover mounting blots of cylinder head and then take out the side cover Remove cam sprocket bolts and then remove the sprocket by prying chain out Clamp strip Vacuum tube AI Pipe bolt 2 bolts ...

Page 70: ...e the insulator out Remove cylinder head gasket and 2 dowel pins Remove chain guide Clean up residues from the matching surfaces of cylinder and cylinder head Caution y Do not damage the matching surfaces of cylinder and cylinder head y Avoid residues of gasket or foreign materials falling into crankcase as cleaning 4 Nuts 2 Insulator bolts Cylinder head mounting Carburetor insulator Dowel pin Gas...

Page 71: ...he camshaft out Use a valve compressor to press the valve spring 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 spring remover SYM 1471110 Valve spring installer SYM 1471120 Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues ...

Page 72: ...peration condition of valve stem in valve guide and measure record the valve stem outer diameter Service Limit IN 4 90 mm EX 4 90 mm Valve guide Caution Before measuring the valve guide clean carbon deposits with reamer Tool 5 0 mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer dia...

Page 73: ...operating Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 5 0 mm Caution y Check if new valve guide is deformation after pressed it in y 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 T...

Page 74: ... 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 chamfer...

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: ...ombustion chamber Use valve spring compressor to press valve spring 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 spring remover SYM 1471110 Valve spring installer SYM 1471120 Tap valve stem to make valve retainer and valve s...

Page 77: ...ounting plate Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head Install chain guide Install 2 set pins and cylinder head gasket Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Loosen the tensioner by turning a flat driver in C W directio...

Page 78: ... and align the timing mark on the sprocket with that of cylinder head Align sprocket bolt hole with camshaft bolt hole Tighten the sprocket mounting bolt Caution Make sure timing marks are matched Install a new O ring onto thermostat and tighten its mounting bolts Loosen sprocket chain tensioner and let it contact with chain plate tightly Tighten the bolt cap of tensioner adjustment hole Install A...

Page 79: ...on The gasket is paper type In case of broken replace it and clean the Remnant gasket Start the engine after assembly Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head Stop the engine after confirmed and then install the intake valve adjustment hole cap Install the seat luggage box and the body cover Caution y If lubricant does not flow to cylin...

Page 80: ...hanism Diagram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder Removal 7 3 Piston Removal 7 4 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 7 Home page Contents ...

Page 81: ...0 040 0 100 Piston Piston ring ID of piston pin boss 15 002 15 008 15 040 OD of piston pin 14 960 15 000 14 930 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 15 016 15 034 15 060 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 top...

Page 82: ...n 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 limit 61 016 mm Check cylinder if warp Service limit ...

Page 83: ...pection Measure clearance between piston rings and grooves Service Limit Top ring 0 09 mm 2nd 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 into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder pus...

Page 84: ...ter of piston pin hole Service Limit 15 04 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 60 90 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: ...nd foreign materials on the matching surface of crankcase Pay attention to not let these residues and foreign materials fall into crankcase Caution Soap the residues into solvent so that the residues can be removed more easily Install dowel pins and new gasket Coat engine oil to inside of cylinder piston and piston rings Care to be taken when installing piston into cylinder Press piston rings in o...

Page 87: ...7 CYLINDER PISTON 7 8 Notes To this chapter contents ...

Page 88: ... Mechanism Diagram 8 1 Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Kick Starter 8 4 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram 5 0 6 0kgf m 5 0 6 0kgf m Home page Contents 8 ...

Page 89: ...00 OD of driven pulley 33 965 33 985 33 940 ID of drive face 34 000 34 025 34 060 Torque value y Driven face nut 5 0 6 0kgf m y Clutch outer 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 SYM 9100100 Trouble Diagnosis Engine can be started but motorcycl...

Page 90: ...ft crankcase cover ducts and then remove the ducts Remove left crankcase cover 7 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 Clamps 7 bolts Dowel pins Kick tarter spindle Snap clip Return spring Driven gear Bush ...

Page 91: ...tarter arm kick starter spindle and return spring as well as socket Inspection Check if starter spindle driven gear for wear or damage Reassembly of Kick Starter Install bush return spring and starter spindle as diagram shown Install thrust washer and snap clip onto starter spindle Install Kick starter lever temporary Slightly rotate the lever and then align driven gear with width tooth on the sta...

Page 92: ...to belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove driving belt Remove the driving belt from the groove of driven pulley Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Service Limit 17 5 mm Replace the belt if exceeds the service limit C...

Page 93: ...en pulley that has installed the belt onto drive shaft On the drive belt another end to the movable drive face Install the clutch outer with universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face with universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Driven face To this chapter contents Nut Drive belt...

Page 94: ...al holder and then remove drive face nut Remove drive face Remove driving belt and movable drive face comp 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: ...asure the outer diameter of movable drive face and replace it if it exceed service limit Service limit 26 94 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 27 06 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 exceptiona...

Page 96: ...pulley installation Press driving 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 5 0 6 0kgf m Install left crankcase cover Drive face boss Crank shaft Drive...

Page 97: ...ial service 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 Se...

Page 98: ...face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 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 beari...

Page 99: ...formation 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 a...

Page 100: ...ther side 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 driving face Al...

Page 101: ...ing 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 driving belt onto driving shaft Collar O ring Gu...

Page 102: ...y of Final Driving Mechanism 9 4 Inspection of Mission Mechanism 9 6 Bearing Replacement 9 8 Re assembly of Final Driving Mechanism 9 10 Mechanism Diagram transmission cover Home page Contents 9 Safety switch Gasket Gear oil fill bolt 1 1 1 5kgf m Oil level gauge Transmission plate Oil seal 14x28x7 Boss Return spring Eng Hanger rubber bush Boss Eng Hanger rubber bush ...

Page 103: ...ive shaft Gear oil drain bolt 1 1 1 5kgf m Bearing 6203 Bearing 6205LU Bearing 6204 Bearing 6302 Bearing 6202 Bearing CSB204 Shift spindle arm Shift spindle bracket Shift fork shaft Shift spindle Gear shift drum Shift fork Gear shift shaft Needle bearing 4905 Oil seal 20x32x6 Oil seal 30x40x5 To this chapter contents ...

Page 104: ... driver SYM 9110400 Bearing 6302 driver SYM 9610000 Oil seal 30 40 5 driver SYM 9125500 Oil seal 20 32 6 driver SYM 9120200 Inner bearing puller SYM 6204002 Drive shaft puller SYM 1130000 L Drive shaft install bush SYM 1130010 Extension bush long SYM 1130031 Extension bush short SYM 1130032 Trouble Diagnosis Engine can be started but motorcycle can not be moved y Damaged driving gear y Burnt out d...

Page 105: ...x cover bolts 10 bolts and then remove the cover and final shaft Remove shift spindle shift drum shift fork shaft and fork Remove gear shift shaft gear and washer Remove counter shaft and gear Remove gasket and dowel pin Gear oil drain bolt Shift drum Shift spindle Counter shaft Shift fork To this chapter contents Drive sprocket bolts Shift spindle bracket 10 bolts Gear shift shaft Dowel pin Dowel...

Page 106: ...aft and gear for wear or damage Special tool Shaft protector 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 Remove the final shaft cir clip and washer Remove the final shaft Cir clip Washer To this chapter contents Bearing Oil seal ...

Page 107: ...tion of Mission Mechanism Check if the shift spindle is wear or damage Check if the shift drum is wear or damage Check if the shift fork and shaft is wear or damage Check if the gear shift shaft is wear or damage To this chapter contents ...

Page 108: ...ng 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 needle bearing Gear box cover To this chapter contents Counter shaft bearing Gear shift shaft bearing Dr...

Page 109: ...following tools Remove drive shaft oil seal Special tool Inner bearing puller Install new bearings into left crankcase Special tool Bearing driver 6204 Bearing driver 6202 Bearing driver 6203 Install drive shaft Special tool Drive shaft puller Drive shaft install bush Extension bush long Extension bush short Apply with grease onto new drive shaft oil seal lip and then install the oil seal Special ...

Page 110: ...hat out side bearing Special tool Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearings into gear box cover inner side Special tool Needle bearing driver 4905 Bearing driver 6302 Bearing driver 6204 Install new final shaft oil seal into gear box cover and then install new out side bearing Special tool Oil seal driver 30x40x5 Bearing driver 6205LU Inner ...

Page 111: ...l driving shaft Install final shaft and then install the washer and cir clip Install counter shaft and gear shift shaft onto gear box Install shift drum shift fork and fork shaft onto gear box Cir clip Final shaft washer Final shaft To this chapter contents Oil seal Counter shaft Gear shift shaft Shift drum Shift fork ...

Page 112: ...l pin and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Apply with grease onto new oil seal lip and then install the shift spindle oil seal Special tool Oil seal driver 14x28x7 Install the shift spindle bracket Add gear oil Gear oil quantity 750c c To this chapter contents Position mark Shift spindle bracket 10 bolts ...

Page 113: ...9 FINAL DRIVING MECHANISM 9 12 Notes To this chapter contents ...

Page 114: ...on 10 2 Right Crankcase Cover Removal 10 3 A C G Set Removal 10 3 Flywheel Removal 10 3 Starting Clutch 10 4 Flywheel Installation 10 7 A C G Set Installation 10 7 Right Crankcase Cover Installation 10 7 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 20 026 20 045 20 100 OD of starting clutch gear 42 175 42 200 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: ...cover Remove dowel pin and gasket A C G Set Removal Remove 2 mounted bolts from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set Flywheel Removal Remove left crankcase cover Remove oil through and spring from crankshaft Hold the flywheel by drive face with universal holder and remove its nut Special tool Universal Holder 2 bolts 9 bol...

Page 117: ...rankshaft Pull out flywheel with A C G flywheel puller Special tool A C G Flywheel puller Starting Clutch Removal Remove starting driven gear Remove the starter reduction gear and the shaft To this chapter contents Flywheel puller Guide pin Starting driven gear Reduction gear ...

Page 118: ...age Install one way clutch onto starting clutch gear Hold flywheel and rotate starting clutch 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 Remove the rollers spring caps and springs of clutch on the one way clutch that located on the back of flywheel Check each roller and plug for wear or damage Install rollers plugs a...

Page 119: ... 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 Installation Install reduction gear shaft and reduction gear Install starting clutch gear onto crankshaft To this chapter contents Reduction gear Starting driven gear ...

Page 120: ...older Install spring and oil through A C G Set Installation Install the A C G coil set onto right crankcase cover 3 screws Install pulse generator 2 screws Tie 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 Install right crankcase cover onto the crankc...

Page 121: ...10 ALTERNATOR STARTING CLUTCH 10 8 Install the water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover To this chapter contents ...

Page 122: ... 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 1 1 1 5kgf m 0 8 1 2kgf m 11 Home page Contents 0 8 1 2kgf m Gear oil drain bolt 1 1 1 5kgf m ...

Page 123: ...it 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 1 1 1 5kgf m Tools Special tools R L crank disassemble install tool SYM 1300001 H9A L crank shaft bearing driver SYM 9100200 H9A Crank shaft bearing...

Page 124: ... remove the tensioner Loosen 2 bolts on the right crankcase Loosen 7 bolts on the left crankcase Place right crankshaft case downward and left up crankcase Caution Care should be taken not to damage the contact surfaces 7 bolts Cam chain setting plate Tensioner 6 R L crank disassemble install tool 2 bolts To this chapter contents ...

Page 125: ...l SYM 1120000 H9A Remove crankshaft from 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 Check any damage in oil seal Replace with new one if damaged To this chapter contents ...

Page 126: ...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 127: ...ain turns on crank shaft puller on the bearing driver spiral tooth Gradually tightens the crank shaft puller upper cap nut presses in the bearing to locate After the bearing presses in to locate opens the R L crank case disassemble install tool takes down the bearing driver Installs crank to the left crank case Direct the crank shaft bearing fixing socket to crank shaft Left crank shaft bearing dr...

Page 128: ...ar as possible the crank spiral tooth prevented pulls the bad crank spiral tooth Gradually tightens the crank shaft puller upper cap nut drags into the crank to locate Install 2 new dowel pin and new gasket Install the right crankcase onto the left crankcase Tighten 2 bolts on the crankcase Torque value 0 8 1 2kgf m Crank case disassemble install tool Crank shaft puller To this chapter contents 2 ...

Page 129: ...the oil seal in the left crankcase with care not to damage the lip of the oil seal By oil seal driver 25 40 8 oil seal will knock into locate Special tool Oil seal driver 25 40 8 Install the tensioner and tighten the bolts Torque value 1 2 1 6kgf m Install the cam chain Install the cam chain setting plate Cam chain setting plate Tensioner Oil seal driver To this chapter contents 7 bolts ...

Page 130: ...stem 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 Radiator filler cap Reserve tank Coolant inlet pipe Coolant outlet pipe By pass pipe Thermo unit temp meter Water pump Thermostat 12 Cooling fan Cooling fan Home page Contents ...

Page 131: ...tor Reservoir upper 780c c 420 c c Thermostat Begins to activate at 71 80 Stroke 3 5 4 5 mm 80 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump rotor 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 bearing puller SYM 6204020 ...

Page 132: ...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 133: ...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 134: ...completely cooled down otherwise you may get scalded Remove the front 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 135: ...ods Radiator Check Remove the front cover front under cover and front fender refer chapter 13 check for any leakage from weld seam Remove the front under cover 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 Coolant leakage Sets at a vessel underneath the water pump disman...

Page 136: ...t 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 order of ...

Page 137: ...s the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain 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 pin Turn pump rotor clockwise and remove Ca...

Page 138: ...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 139: ... 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 140: ...ten Torque Value 1 0 1 4kgf m Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil 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 141: ...able of temperature sensor Disconnect the by pass pipe Remove the thermostat set 1 bolt Disassembly Remove the temperature sensor and O ring from the thermostat body Remove 2 bolts and separate the thermostat body from the cover Remove the thermostat 2 bolts O ring Temperature sensor Bolt Temperature sensor By pass pipe To this chapter contents ...

Page 142: ...peration is not corresponding to the temperature change then it must be replaced Technical Data Valve begins to open 71 80 Valve stroke 3 5 4 5 mm at 80 Assembly Install in reverse order of removal Caution Always use a new O ring and apply a coat of grease on it before installing Installation Apply a coat of sealant or equivalent to the thread of temperature sensor and install it on the holder Con...

Page 143: ...12 COOLING SYSTEM 12 14 Notes To this chapter contents ...

Page 144: ...er 13 3 Rear center cover 13 4 Rear carrier 13 4 Rear fender 13 5 Front fender 13 7 Footrest 13 9 Mechanism Diagram 13 Home page Contents Left handle protect cover Front fender Rear central cover Rear fender Left footrest Front central cover Footrest bar Seat Handle cover Right footrest Footrest bar Right handle protect cover ...

Page 145: ...on the body covers y Align the buckles on the guards with 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 Front fender Rear center cover Rear fender Right footrest Handle cover Handle protect cover Rear carrier Front center cover To this chapter contents ...

Page 146: ...e 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 Remove position light coupler and then remove front center cover Installation Install in reverse order of removal procedures 3 Screws 2 bolts To this chapter contents ...

Page 147: ...s and then remove rear center cover 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 2 bolts Fuel tank cap ...

Page 148: ...he rear fender Loosen the two bolts which connect the front fender and rear fender Loosen the 2 bolts which connect the rear tender and frame these 2 bolts just below the seat Loosen the 6 screws which connect the rear fender and footrest these 6 screws just be twin the rear fender two side Seat release bar 2 bolts 3 screws To this chapter contents 2 bolts ...

Page 149: ...ch connect the rear tender and frame these 2 bolts just below the rear fender Remove taillight couplers and then remove rear fender Installation Install in reverse order of removal procedures 2 bolts To this chapter contents Taillight couplers ...

Page 150: ...Remove 2 bolts and then remove rear center cover Loosen the two bolts which connect the front fender and rear fender Remove 1 screw and then remove fixed support catch Remove front center cover 2 screws 2 bolts 1 screw To this chapter contents Fuel tank cap 2 bolts 2 screws ...

Page 151: ...s which connect the front fender and footrest these 6 screws just be twin the front fender two side Remove power outlet right and left winker couplers Remove front fender Installation Install in reverse order of removal procedures 1 bolt 6 screw To this chapter contents 2 bolts Winker coupler Power outlet couplers ...

Page 152: ...two side Loosen the 6 screws which connect the rear fender and footrest these 6 screws just be twin the rear fender two side Loosen the 4 bolts and then remove footrest bar and footrest These 4 bolts just are the right and left footrest Installation Install in reverse order of removal procedures To this chapter contents 6 screw 3 screws 2 bolts ...

Page 153: ...13 BODY COVER 13 10 Note To this chapter contents ...

Page 154: ...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 155: ...plastic 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 4 000 2 500 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter 11 000...

Page 156: ... 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 157: ...in wheel hub nut and washer Remove wheel hub and brake disk Remove brake caliper mounting seat Inspection Check bearings on wheel hub Rotate each 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 wheel hub If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or ...

Page 158: ... 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 bearing puller Remove 4 socket bolts and then remove the brake disk from wheel hub To this chapter contents Inner spacer Inner bearing puller Inner bearing puller 4 bolts ...

Page 159: ...ring driver 6203 Oil seal drive 24 35 7 Installation Install the front brake disk to the wheel hub Install brake caliper mounting seat on to knuckle Caution Align the brake caliper mounting seat groove with the stopper flange 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 To this chapter contents Groove Stopp...

Page 160: ...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 161: ...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 162: ...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 163: ... 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 164: ...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 165: ...54 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 166: ...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 167: ...14 FRONT BRAKE FRONT WHEEL 14 14 Notes To this chapter contents ...

Page 168: ...Trouble Diagnosis 15 2 Steering Handle 15 3 Steering Shaft 15 6 Steering Tie Rod 15 7 Knuckle 15 8 Front Cushion 15 9 Suspension Arm 15 10 Toe In 15 11 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 169: ...y 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 Binding ...

Page 170: ...pter 13 Remove meter set and main switch couplers Remove speedometer cable Loosen 2 bolts to remove handle cover stay Loosen 4 bolts of the meter stay and then remove meter set and main switch To this chapter contents 3 Screws 4 bolts meter stay Speedometer cable 2 bolts handle cover stay Main switch coupler Meter set couplers ...

Page 171: ...ottle 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 Loosen 2 screws and then remove handle left switch and choke hosing 2 Screws 2 screws Handle protect cover brocket bolts Master cylinder bolts Handle protect cover brocket bolts Master cylinder bolts ...

Page 172: ...nd then remove the handle upper holder handle Remove 2 nuts to remove handle under holder 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 Nuts To this chapter contents 4 socket bolts ...

Page 173: ...lder 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 Oil ...

Page 174: ...ll 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 Cotter pin Tie rod nuts Tie rod nut...

Page 175: ... hole bolt nut remove bolt sleeve seal cover and knuckle Inspection Inspect the kingpin and knuckle for damaging or cracking Installation Install in reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Knuckle nut 5 0kgf m After tightened the nuts install the cotter pins Lubricate with grease into knuckle To this chapter contents Nut Tie rod Cotter nut Seal cover Sleeve ...

Page 176: ...otter pin and remove the bolt Remove front cushion upper bolt cotter pin and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value 4 6kgf m After tightened the bolts install the cotter pins To this chapter contents Cotter pin Cotter pin ...

Page 177: ...en suspension arm rear side nuts remove swing arm bolts Remove suspension arm spacer and seal covers Inspection Inspect the suspension arm spacer bush and seal cover 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 Suspension arm nuts...

Page 178: ...hicle 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...

Page 179: ...15 STEERING SUSPENSION 15 12 Note To this chapter contents ...

Page 180: ...ed 16 11 Rear Brake Caliper 16 12 Brake Disk 16 13 Rear Brake Master Cylinder 16 13 Rear Cushion 16 17 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 181: ...ation 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 4 000 2 500 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter 11 000 11 043 11 055 Master cylinder outer diameter 10 957 10 ...

Page 182: ...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 183: ...llation Install the rear wheel and tighten the nuts Torque 2 4kgf m Rear Wheel Shaft Connecter Removal Remove cotter pin rear wheel shaft connecter nut and washer Remove right and left rear wheel shaft 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 184: ...l wheel connecter Remove 2 bolts and then remove rear brake caliper Remove 3 bolts and remove drive chain cover Remove drive chain lock clip master link and then remove drive chain Remove 4 nuts and remove driven sprocket To this chapter contents 4 nuts Lock clip Master link 2 bolts 3 bolts ...

Page 185: ...ar axle nut fixed plate Remove rear wheel axle nuts Special tool Rear axle nut wrench 55mm Remove rear brake disk bracket and disk Remove rear wheel axle and driven sprocket holder To this chapter contents Brake disk bracket Driven sprocket holder Fixed plate ...

Page 186: ...sed 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 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 right bearing and seal into front wheel hub Apply wi...

Page 187: ... Rear axle nut wrench 55mm Rear axle nut torque wrench Torque wrench After tightened the axle nut bend the rear axle nut fixed plate Install driven sprocket drive chain drive chain cover and brake caliper Caution y Note the chain lock clip direction Install rear wheel shaft connecter rear wheel To this chapter contents Brake disk bracket Lock clip Master link Fixed plate Moving direction ...

Page 188: ...cts other parts of Check 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 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 ...

Page 189: ...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 190: ...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 191: ...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 192: ... 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 193: ... master cylinder 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 allowa...

Page 194: ... 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 the bolts Install...

Page 195: ...t Loosen 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...

Page 196: ...nd remove rear cushion under bolt Remove cotter pin and remove rear cushion upper bolt Installation Install rear cushion upper bolt and install cotter pin Install rear cushion under bolt and install cotter pin Rear cushion under bolt Cotter pin To this chapter contents Rear cushion upper bolt Cotter pin ...

Page 197: ...16 REAR BRAKE REAR WHEEL REAR CUSHION 16 18 Note To this chapter contents ...

Page 198: ...t Bulb 17 13 Switch Horn 17 16 Fuel Unit 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 switch Headlight relay Home page Contents Thermo unit Haz...

Page 199: ...d 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 12V8Ah Battery Charging rate 0 9...

Page 200: ...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 201: ... to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 0 9A 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 r...

Page 202: ...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 203: ...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 204: ...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 205: ...on 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 Green Black Yellow Green White Black Green White Blue Yellow Black White To this chapte...

Page 206: ...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 207: ...le of 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 20A Main switch Fuse 15A Brake switch Starter switch Starter relay Star...

Page 208: ...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 209: ...oupler Remove speedometer cable Loosen 4 bolts of the meter stay and then remove meter set and main switch Remove 4 nuts and meter wire and then remove meters Installation of Starter motor Install in reverse order of removal procedures To this chapter contents 4 nuts 3 Screws Main switch coupler Meter set couplers 4 bolts meter stay ...

Page 210: ...b if necessary 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 Headlight bulb seat H...

Page 211: ...Bulb Remove front winker lens with screw driver Replace with new front winker light bulb Replacing Bulb of Taillight Remove rubber cap of the taillight connector Remove the taillight connector and bulb To this chapter contents Taillight Rear winker light Groove ...

Page 212: ...taillight bulb Replacing the rear winker light Bulb Remove rubber cap of the rear winker light connector Remove the rear winker light connector and bulb Replace rear winker light bulb To this chapter contents Taillight Rear winker light ...

Page 213: ...ct 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 BAT2 FREE Wire Color Yellow Red Green To this cha...

Page 214: ...lue Brown Winker switch Pin Position R WR L 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 215: ...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 216: ...all 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 test turn on the d...

Page 217: ...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 a continuity at 98 102 Caution y Keep the coolant at a constant temperature at least for three minutes Sudden increase the cool...

Page 218: ...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 219: ...17 ELECTRICAL SYSTEM 17 22 Notes To this chapter contents ...

Page 220: ...18 ELECTRICAL DIAGRAM 18 1 18 Home page Contents TRACK RUNNER 180 ELECTRICAL DIAGRAM ...

Page 221: ...18 ELECTRICAL DIAGRAM 18 2 Notes Home page Contents ...

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