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TGB 525, Service Manual

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TGB 525 Service Manual Download Page 74

To this chapter contents

 

 

16. REAR BRAKE & REAR WHEEL & REAR CUSHION

 

 
 

Trouble Diagnosis

 

Soft brake lever

 

1.   Air inside the hydraulic system 
2.   Hydraulic system leaking 
3.   Worn master piston 
4.   Worn brake pad 
5.   Poor brake caliper 
6.   Worn brake lining/disk 
7.   Low brake fluid 
8.   Blocked brake hose 
9.   Warp/bent brake disk 

10.   Bent brake lever 

 

 
 

Hard operation of brake lever

 

1.   Blocked brake system 
2.   Poor brake caliper 
3.   Blocked brake pipe 
4.   Seized/worn master cylinder piston 
5.   Bent brake lever 

 

 
 

Uneven brake

 

1.   Dirty brake lining/disk 
2.   Poor wheel alignment 
3.   Clogged 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 well 
2. Bent rim 
3. Axle bearings are worn 
4. Faulty tires 
5. Rear axle bearing holder is faulty 

 

 
 
 

Hard Suspension

 

1. Bent damper rod 
2. Faulty swing arm pivot bushings 

 

 
 
 

Soft Suspension

 

1. Weak shock absorber damper 
2. Weak shock absorber spring 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

16-3

 

 

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Summary of Contents for 525

Page 1: ...TARGET 525 SERVICE MANUAL TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 2: ...Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV 525 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 TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www pdffactor...

Page 3: ...tion and trouble diagnosis The second chapter covers service maintenance information and special tools manual The third to the 11th chapters cover engine and driving systems The 12th chapter is cooling system The 13th to the 16th chapter is contained the parts set of assembly frame body The 17th chapter is electrical equipment The 18th chapter is wiring diagram Please see index of content for quic...

Page 4: ... BELT DRIVING SYSTEM KICK STARTER 8 9 1 9 11 FINAL DRIVING MECHANISM 9 10 1 10 10 ALTERNATOR STARTING CLUTCH 10 11 1 11 20 CRANKSHAFT CRANKCASE 11 12 1 12 11 COOLING SYSTEM 12 13 1 13 9 BODY COVER 13 14 1 14 14 FRONT BRAKE AND FRONT WHEEL 14 15 1 15 10 STEERING FRONT SUSPENSION 15 16 1 16 15 REAR BRAKE REAR WHEEL REAR CUSHION 16 17 1 17 22 ELECTRICAL EQUIPMENT 17 18 1 18 2 ELECTRICAL DIAGRAM 18 PD...

Page 5: ...SERIAL NUMBER Home page Contents Frame number Engine number PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 6: ...ollowed Engine oil Limits to use SAE 10W 40 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Grease King Mate G 3 is recommended Locking sealant Apply sealant medium strength sealant should be used unless otherwise specified Oil seal Apply with lubricant Renew Replace with a new part before installation Brake fluid Use recommended brake fluid...

Page 7: ...pped 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 acid on your...

Page 8: ...ts have an adverse effect on them Never bend or twist a control cable to prevent unsmooth control and premature worn out Rubber parts may become deteriorated when old and 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 When loosening a component which has different sized fasteners operate with a diagonal...

Page 9: ... 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 Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can g...

Page 10: ...positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables Make sure that the battery post caps are located in properly after the battery posts had been serviced If fuse burned it has to find out the cause and solved it And then replace with specified capacity fuse Before battery removal operation it has to remove the battery negative cabl...

Page 11: ...f 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 1 6 Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so tha...

Page 12: ...ight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied Secure the rubber boot firmly as applying it on wire harness Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace them Never clamp or squeeze the w...

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

Page 14: ...rrangement Vertical below center incline Transmission devices Transmission Centrifugal type Fuel Used Above 92 unleaded Speedometer 0 300 km hr Cycle Cooling 4 stroke Water cooled Horn 93 112dB A Bore Ø92 mm Muffler Expansion Pulse Type Stroke 75 6 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder Number Arrangement Single Cylinder Lubrication System Forced circulation splashi...

Page 15: ... head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0 Air inject pipe bolt 4 6 1 0 1 4 Air inject reed valve bolt 2 3 0 07 0 09 Tappet adjustment screw nut 4 5 0 7 1 1 Apply oil to thread Spark plug 1 10 1 0 1 2 Tensioner lifter bolt 2 6 1 0 1 4 Carburetor insulator bolt 2 6 0 7 1 1 Oil pump...

Page 16: ...olt Drive gear bolt Driven gear nut Swing arm pivot bolt Front suspension arm nut Front Rear cushion mounting bolt Brake lever nut Brake hose bolt Brake caliper bolt Brake disk mounting bolt Air bleed valve Exhaust muffler mounting bolt Exhaust muffler connection nut 4 1 4 2 2 4 2 8 2 2 8 4 4 2 4 1 4 6 2 13 6 11 3 2 2 6 10 10 10 8 10 8 10 14 14 10 12 12 10 10 14 10 10 6 10 6 8 5 8 7 2 40 5 00 5 00...

Page 17: ...n of CDI set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Cylinder compression pressure normal Re start by following the starting procedures Low compression pressure or no pressure Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression...

Page 18: ... Compression pressure correct Check if carburetor jet is clogged No compression pressure Cylinder piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring No clogged Clogged Remove foreign Remove spark plug No foul or discoloration Fouled and discoloration Check if engine over heat Normal Engine overheat Continually drive in acceleration or ...

Page 19: ...osen the screw Lean mixture tighten the screw Poor heat insulation gasket Carburetor lock loose Poor intake gasket 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 switch Check and adjustment Fault condition Probable causes Check ignition timing Normal...

Page 20: ...tch and shaft worn out or burned Poor initial driving Poor climbing performance Drive belt worn out or deformation Weight roller worn out Movable drive face shaft worn out Driven pulley spring deformation Driven pulley shaft worn out Greased in drive belt and driven face F Poor handling FAULT CONDITIONS PROBABLE CAUSES Steering is heavy Damaged steering bearing Damaged steering shaft bushing One w...

Page 21: ...nk cap breather hole Faulty pulse generator Faulty CDI unit Test cylinder compression Normal Abnormal Leaking head gasket Worn cylinder and piston rings Check carburetor Normal Clogged Clean Check spark plug Normal Fouled or discolored Check for engine overheating Normal Overheating Accelerate or run at high speed Normal Knocks Clean the spark plug Spark plug is incorrect heat range Excessive carb...

Page 22: ...his chapter contents 1 GENERAL INFORMATION Lubrication Points Throttle cable Front Rear brake lever pivot Wheel bearing Speedometer gear 1 17 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 23: ...To this chapter contents 1 GENERAL INFORMATION Note 1 18 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 24: ...ss 2 11 Special Tools List 2 12 Precautions in Operation Specification Fuel Tank Capacity 15 0 3L Capacity 3500 c c Engine oil Transmission Gear oil Capacity of coolant Change 3000 c c Capacity 350 c c Change 350 c c Engine radiator 2200 c c Reservoir upper 1200 c c Clearance of throttle valve 1 3 mm Type NGK CR7E Spark plug Gap 0 7 0 8 mm F Mark in idling speed BTDC 15º 1500 rpm Full timing advan...

Page 25: ... Code C Cleaning replaced if necessary I Inspection cleaning and adjustment L Lubrication R Replacement T Tighten Have your ATV checked adjusted and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first Remarks 1 Clean...

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

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

Page 28: ... 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 1500 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 speed is within standard 4 S...

Page 29: ...k CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found Cylinder Compression Pressure Warm up engine Turn off the engine Remove the trunk Remove the central cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of starter motor Caution Rotate the engine until the reading in the gauge no m...

Page 30: ...lutch cover vapor hose Remove 14 bolts of the clutch cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it Width limit 26 8 mm or above 2 7 Width Teeth 14bolts Clamp strips PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 31: ...luid 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 Screws Master cylinder cap 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...

Page 32: ...pter 14 Make sure the brake lining condition 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 maintain brake power balance the brake lining must be replaced with one set Rear brake Brake lining wear limitation groove Brake Light Switch Starting Inhibi...

Page 33: ...eration If the ATV is in forward moving and shaking check clutch disc condition Replace it Adjust screw Clutch weight Cushion Warning Do not ride the ATV with poor cushion 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 ...

Page 34: ...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 7 1psi 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 Perform periodic...

Page 35: ...EARING 924384 REMOVER φ15 PARTS NO 440652 PARTS NAME BEARING 924384 REMOVER φ20 PARTS NO 440653 PARTS NAME BEARING 924384 REMOVER φ45 PARTS NO 440654 PARTS NAME BUSHING 924739 REMOVER PARTS NO 440655 PARTS NAME R CRANK CASE OIL SEAL 924168 INSTALLER PARTS NO 440656 PARTS NAME L CRANK CASE OIL SEAL REMOVER 2 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 36: ... REMOVER PARTS NO 440660 PARTS NAME CHAIN WHEEL 924360 WASHER 924718 INSTALLER PARTS NO 440661 PARTS NAME PISTON ROD CONNECTING HOLDER PARTS NO 440662 PARTS NAME CYLINDER HEAD VALVE GAP ADJUSTER PARTS NO 440663 PARTS NAME GEAR SHAFT 924253 INSTALLER PARTS NO 440664 PARTS NAME FLYWHEEL P 2 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 37: ...LLER REMOVER PARTS NO 440668 PARTS NAME UNIVERSAL JOINT HEAD 924646 INSTALLER PARTS NO 440669 PARTS NAME CHAIN WHEEL 924360 WASHER 924718 REMOVER PARTS NO 440670 PARTS NAME ENGINE OIL FILTER 924153 INSTALLER REMOVER PARTS NO 440671 PARTS NAME WET CLUTCH SCREW NUT FIXER PARTS NO 924941 PARTS NAME MAINTENANCE TOOL PACKAGE 2 14 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 38: ...T N33701 INSTALLER REMOVER PARTS NO 552301 PARTS NAME OIL SEAL 513350 INSTALLER PARTS NO PARTS NAME PARTS NO PARTS NAME PARTS NO PARTS NAME PARTS NO PARTS NAME PARTS NO PARTS NAME PARTS NO PARTS NAME 2 15 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 39: ...Bracket Handle bar front cover Front cover ornamental Tail carrier Front body cover Rear lamp ornamental Rear lamp fender Rear body cover Seat Side cover Head lamp fender Foot board Net First housing 13 1 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 40: ...ok is properly installed during the assembly l Never compact forcefully or hammer the quard and the covers during assembly 13 2 Seat battery fixed Fuel cup Feont body cover front cover ornamental Right left side cover Right left foot board Tail carrier Tail carrier ornamental Rear body cover Bumper number plate bracket first housing Front rear protector Handle bar front cover Upper bracket assembl...

Page 41: ... Remove 2 bolts from battery fixed Then remove cable Remove 1 couplers from starting motor relay and then remove starting motor relay Remove bolts each side 1 bolts and 2 couplers Remove fuse box Installation Install in reverse order of removal procedures 13 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 42: ...m battery fixed Remove battery fixed Remove 1 screw and take off shift lever Remove fuel cap Remove bolts each side from front body cover Installation Install in reverse order of removal procedures 13 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 43: ...art of front body cover and then remove front body cover Remove front cover ornamental Remove 8 screws from right or left side cover each side 4 screws Remove right or left side cover Installation Install in reverse order of removal procedures 13 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 44: ...ot board Remove screw from tail carrier Then remove tail carrier ornamental Remove 3 bolts from tail carrier then remove tail carrier Remove the bolts from rear body cover each side Installation Install in reverse order of removal procedures 13 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 45: ...e rear body cover Remove 4 bolts from frame each side 2 bolts Remove bumper Remove 4 screws each side 2 screws from number plate bracket Remove number plate bracket Installation Install in reverse order of removal procedures 13 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 46: ...h side 1 bolt Remove right and left head lamp couplers each side 2 couplers Then remove first housing Remove 4 bolts from front bumper each side 2 bolts Remove front bumper Installation Install in reverse order of removal procedures 13 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 47: ... then remove front protector Remove bolts from rear protector each side 1 bolts Remove bolts from rear protector each side 1 bolts and then remove rear protector Installation Install in reverse order of removal procedures 13 9 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 48: ...side 2 bolts Remove handle bar front cover Remove bolts from upper bracket assembly each side 2 bolts Remove speedometer assembly couplers and then remove upper bracket assembly Installation Install in reverse order of removal procedures 13 10 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 49: ...R Remove 3 bolts form rear frame And 2 bolts from muffler Remove 4 bolts from cover Installation Install in reverse order of removal procedures 13 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 50: ...Fluid 14 8 Brake fluid replacement Air bleed 14 9 Front Brake Caliper 14 10 Brake Disk 14 11 Front Brake Master Cylinder 14 11 Mechanism Diagram Master cylinder Parking brake assy Parking brake cable Brake hose Limited switch assy Distributor Brkt Steering knuckle Brake disc Tire Pad Protective cover Caliper Front wheel hub Front rim 14 1 14 PDF created with pdfFactory Pro trial version www pdffac...

Page 51: ...bber 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 of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 3 500 2 000 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter 14 000 14 043 14 055 Ma...

Page 52: ...ke 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 pressure Front w...

Page 53: ...he front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 5 0kgf m Front Wheel Hub Removal Remove front brake caliper 2 bolts Remove cotter pin wheel hub nut and washer Remove wheel hub and brake disk 14 4 4 nuts 2 bolts Cotter pin Washer Wheel hub nut Brake Disk PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 54: ...stall the front brake disk to the wheel hub Install wheel hub and brake disk on to knuckle Install wheel hub washer and tighten the wheel hub Torque 9 0kgf m Install cotter pin 4 bolts Wheel hub nut Cotter pin Install front brake caliper Torque 3 5kgf m 14 5 2 nuts Washer PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 55: ...ced with new lining when the brake pad wear limit reaches the brake disk Caution 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 4 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minute In order to ...

Page 56: ...ed 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 The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performan...

Page 57: ...inishing the brake 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 Do not release the brake lever before the drain valve is closed Always check the brake fluid l...

Page 58: ...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 Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 18 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to ...

Page 59: ... brake performance Brake lining includes the asbestos ingredient 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 se...

Page 60: ...ed value exceeds allowable 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 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...

Page 61: ...shers Tighten the brake hose bolt to the specified torque value Torque 3 2kgf 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 Brake lever bolt Brake light switch Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and b...

Page 62: ...ng Handle 15 3 Steering Shaft 15 5 Steering Tie Rod 15 6 Knuckle 15 7 Front Cushion 15 8 Suspension Arm 15 9 Toe In 15 10 Mechanism Diagram Handle bar assy Connection place Steering shaft Steering tie rod assy Front shock absorber Upper arm set Lower arm set 15 1 15 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 63: ...re 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 tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment Front suspension noise Loose front suspension fasteners Binding suspension link Ha...

Page 64: ...ve front brake master cylinder Caution Do not let foreign materials enter into the cylinder Remove 2 screws and then remove throttle hosing holder and throttle hosing Loosen the socket bolts for the front brake master cylinder and remove front brake master cylinder Caution Do not let foreign materials enter into the cylinder 15 3 Master cylinder bolts Master cylinder bolts PDF created with pdfFact...

Page 65: ...ndle mounting bolt and then remove the handle upper holder handle Remove 2 nuts to remove handle under holder and meter bracket 4 socket bolts 2 Nuts Installation Install in reverse order of removal procedures Torque value Handlebar under holder nut 4 0kgf m Handlebar upper holder bolt 2 4kgf m 15 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 66: ...nd then remove steering shaft holder nut fixed plate pressed plate and steering shaft Inspection Check oil rings for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit Ø39 5 mm Fixed plate Oil rings 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...

Page 67: ...Inspect the ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Ball joint 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 Adjustment groove 15 6 PDF created with pdfFac...

Page 68: ...ts by ball joint driver Remove the knuckle Special Tool ball joint driver Universal holder Ball joint Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking Installation Install in reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Ball joint nut 5 0kgf m After tightened the nuts install the cotter pins Knuckle Ball joint Ball joint 15 7...

Page 69: ...hion under bolt nuts and remove the bolts Remove front cushion upper bolt nuts and remove the bolts and cushions Installation Install in reverse order of removal procedures Torque value Front cushion nut 4 6kgf m Nuts 15 8 Nuts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 70: ...sion arm Loosen under suspension arm nuts remove swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bending Suspension arm nuts and bolts Suspension arm nuts and bolts Installation Install in reverse order of removal procedures Torque value Suspension arm nut 5 0kgf m Lubricate with grease into suspension arm 15 9 PDF created with pd...

Page 71: ...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 10 3mm 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 the tie rods t...

Page 72: ...lacement Air bleed 16 9 Rear Brake Caliper 16 10 Brake Disk 16 11 Rear Brake Master Cylinder 16 11 Rear Cushion 16 14 Mechanism Diagram Switch assy Brake hose assy Limited switch Distributor Protective cover Choke cable Rear caliper Pedal master cylinder Brake pedal Rear axle housing Rear axle Tire Rear shock absorber Rear fork Rear wheel hub Rim 16 1 16 16 PDF created with pdfFactory Pro trial ve...

Page 73: ...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 hand brake 14 000 14 043 14 055 Master cylinder piston outer diameter hand brake 13 957 13 984 13 945 Master cylinder inner diameter foot brake 15 900 15 943 15 955 Master cylinder piston outer diamete...

Page 74: ...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 well 2 Bent...

Page 75: ...en the nuts Torque 2 4kgf m Remove cotter pin Remove wheel shaft connecter washer and tighten the wheel shaft connecter nut Remove the 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 Install the rear wheel and tighten the nuts Torque 2 4kgf m 16 4 Cotter ...

Page 76: ...e brake pad wear limit reaches the brake disk Caution Check the rear brake lining must be removed rear wheel first Brake lining wears limit grooves Brake disk 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 4 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minu...

Page 77: ... REAR CUSHION Rear Wheel Axle Remove rear wheel housing 4 bolts Escape rear wheel housing from rear fork assy Remove tow ball mount 4 bolts 2 bolts each side 16 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 78: ...ers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on bearing seat 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 Never install used bearings Once bearing removed it has to be replaced with new one 16 7 PDF created with pdfFactory Pro trial ver...

Page 79: ...tic or rubber components may result in their damages Fluid cup Fluid cup 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 The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performan...

Page 80: ... brake 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 Do not release the brake lever before the drain valve is closed Always check the brake fluid level when ca...

Page 81: ...sk Installation 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 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 gui...

Page 82: ...the 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 cou...

Page 83: ...seated securely in the groove Install the rubber boot into groove properly Rubber boot Piston Piston cup Cir clip Spring Master cylinder 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 ...

Page 84: ...ush rod pin fist 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 flui...

Page 85: ...shion under bolt Remove rear cushion upper bolt and then remove rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Tighten the rear cushion upper bolt and under nut to the specified torque value Torque 4 6kgf m 16 14 Rear cushion upper bolt PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 86: ... Unit 17 19 Cooling Fan Switch 17 20 Thermo unit 17 21 Water Temperature Indicator Light 17 21 Mechanism Diagram Battery Fuse box Front brake switch Starter relay C D I Unitx Hazard control unit Winker relay Main switch Shift gear control unity Rear brake switch Thermo unit 17 Headlight relay Start light winker horn brake switch Horn Rectifier Ignition coil AC Generator Spark plug Change switch 17...

Page 87: ...y The voltage must be checked with the voltmeter while charging the battery 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 Battery Capacity 12V18Ah Charging rate 1 4A 5 10 hours standard ...

Page 88: ... 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 discharging system Poor connection or short circuit of the power generation system Charging system does not operate properly Burnt fuse Poor contact open or short circuit Poor regulator Poor ACG Engine does not crank smoothly Primary win...

Page 89: ... the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 8A 9 0A Charging time 5 10H 1H Warning Keep flames away while recharging Charging is completely controlled by the ON OFF switch on the charger not by battery cables Caution Never rapid charge the battery unless in emergency Verify the battery is recharged...

Page 90: ... In the current leakage test set the current range at the largest scale then gradually 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 the specified value it may indicate a short circuit Allowable current leakage Less than 1mA Disconnect each cable one by o...

Page 91: ...inal however while the starter motor is activated the surge current the motor draws from the battery may damage the ammeter Use the kick starter to start the engine The main switch shall be turned to OFF position during the process of inspection Never tamper with the ammeter and the cable while there is current flowing through It may damage the ammeter The following problems are related to the cha...

Page 92: ...asses the condition Item Check Points Standard Value Main switch connection Bl B Battery Battery voltage ON connection Bl B Battery voltage Charging coil B B 0 1 0 5Ω 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 17 7 PDF created with pdfFactory...

Page 93: ...nect connectors of the C D I unit Check the following connectors as indicated in the table at the harness side Item Points to check Result Main switch turn to ON position Br Bl B Battery voltage Pulse generator Bl Y G R 50 170Ω Primary circuit G R B 2 9 10 Ω Ignition coil Secondary circuit TERMINAL B with no cap 15 0 10 Ω TERMINAL B with cap 20 0 10 KΩ 17 8 C D I Unit G R B1 Y LG R B B W PDF creat...

Page 94: ...e resistance between the spark plug and the primary winding Standard resistance With no cap 15 0Ω 10 With cap 20 0 10 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 95: ... is heard it indicates the relay function normally Remove the seat Disconnect the negative cable terminal of the battery Disconnect the cable positive terminal from the relay Disconnect the positive cable 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 black blue cable to th...

Page 96: ...gative 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 Starter motor cable 2 Bolts 17 11 Negative PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 97: ...d then remove meter couplers and main switch coupler Remove speedometer cable Main switch coupler Remove speedometer cable and then remove meter set main switch and handle cover speedometer cable Remove 4 nuts and meter wire and then remove speedometer and fuel meter 4 nuts 17 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 98: ...beam H3 12V 55W Dipped 12V 55W Caution Never touch the bulb with finger which will create a heat point 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 17 13 PDF created with pdfFactory ...

Page 99: ...ront winker light bulb seat Replace with new front winker light bulb 12V 21W Replacing Bulb of Position Light Pull out the position light bulb seat Replace with new position light bulb 12V 5W 17 14 Front winker bulb Position light bulb PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 100: ...W Replace with new taillight bulb 12V 5W 21W Rear Winker Light Replace with new rear winker light bulb 12V 21W Replacing Bulb of License Light Turn the license light bulb connectors by CCW Replace with new license light bulb Taillight Rear winker light 17 15 License light PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 101: ...itch Disconnect 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 Headlight switch couplers Start Switch Pin Start switch Position ...

Page 102: ...ellow Brown Winker switch Pin Position L WR R N PUSH OFF Wire color Brown Brown Green White Winker switch Horn switch Pin Position BAT3 HO FREE Wire Color Brown White Pink Horn switch Hazard switch Pin Position HD E Hazard switch Wire Color Brown White Black 17 17 Winker switch PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 103: ...Brake Switch While grasp the brake lever firmly the terminals of white black and Brown White of the brake should have continuity Replace the switch if damaged Horn Remove the horn from front fender Brake light switch Brake light switch 1 bolt Apply 12 V power source to two terminals of the horn the horn should sound Replace the horn if necessary 17 18 PDF created with pdfFactory Pro trial version ...

Page 104: ... Full 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 Bargrahpic Position Up Full 7 Bargrahpic Full Down Empty E Empty Empty Caution While conducting the test turn on the direction in...

Page 105: ...manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperature increase the coolant temperature gradually The switch should have continuity at 85 3 Caution Keep the coolant at a constant temperature at least for three minutes Sudden increase the coolant temperature will...

Page 106: ...gles when 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 result in wrong readings Thermo unit 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 f...

Page 107: ...To this chapter contents 17 ELECTRICAL SYSTEM Notes 17 22 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 108: ...Home page Contents 18 ELECTRICAL DIAGRAM 18 18 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 109: ...Home pae Contents 18 ELECTRICAL DIAGRAM Notes 18 2 PDF created with pdfFactory Pro trial version www pdffactory com ...

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