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TGB BLADE 250, Service Manual

The TGB BLADE 250 Service Manual is an essential companion for owners of this powerful ATV. With step-by-step instructions and detailed diagrams, this manual covers all aspects of maintenance and repair. Download it for free from our website and ensure your BLADE 250 is always in top condition.

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To this chapter contents

 

 

2. MAINTENANCE INFORMATION

 

 

 

Brake System (Disk Brake)

 

Brake System Hose

 

Make sure the brake hoses for corrosion or 
leaking oil. 

 

 
 
 
 
 
 
 
 
 

Brake Fluid

 

Check brake fluid level in the brake fluid reservoir.
 

If the level is lower than the LOWER 

limit, add brake fluid to UPPER limit. Also check 
brake system for leaking if low brake level found 

 

  Caution

 

●

 

In order to maintain brake fluid in the reservoir 

in horizontal position, do not remove the cap 
until handle stop. 

●

 

Do not operate the brake lever after the cap had 

been removed. 

Otherwise, the brake fluid 

will spread out if operated the lever. 

●

 

Do not mix non-compatible 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. 

 
 
 

 

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

 

Before closing the air bleed valve, do not release 
the brake lever. 

 

 

 

 

Diaphragm plate

 

 

Diaphragm

 

 

 
 
 
 
 
 
 
 
 

Air bubble 

Drain valve

 

 

 
 

Upper

 

 
 
 
 
 
 
 
 
 
 

 

 

 

Added Brake Fluid

 

Add brake fluid to UPPER limit lever. 
Recommended brake fluid: DOT3 or DOT4 WELL 
RUN brake fluid. 

 

  Caution

 

Never mix or use dirty brake fluid to prevent from 
damage brake system or reducing brake 
performance. 

 

 
 
 
 
 
 
 
 
 
 
 
 

Transparent hose

 

 
 
 

2-8

 

 

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Summary of Contents for BLADE 250

Page 1: ...BLADE 250 300 SERVICE MANUAL 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 BLADE 250 300 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...

Page 3: ...formation 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...

Page 4: ...ISTON 7 8 1 8 14 V TYPE BELT DRIVING SYSTEM KICK STARTER 8 9 1 9 12 FINAL DRIVING MECHANISM 9 10 1 10 10 ALTERNATOR 10 11 1 11 8 CRANKSHAFT CRANKCASE 11 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 18 REAR BRAKE REAR WHEEL REAR CUSHION 16 17 1 17 22 ELECTRICAL EQUIPMENT 17 18 1 18 2 ELECTRICAL DIAGRAM 18 PDF created with pdfFacto...

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

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

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

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: ...ocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 300 km hr Cycle Cooling 4 stroke Water cooled Horn 93 112dB A Bore Ø71 mm Muffler Expansion Pulse Type Stroke 63 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder Number Arrang...

Page 15: ...Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 300 km hr Cycle Cooling 4 stroke Water cooled Horn 93 112dB A Bore Ø71 mm Muffler Expansion Pulse Type Stroke 63 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder Number Arrangement Single ...

Page 16: ...Sprocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 300 km hr Cycle Cooling 4 stroke Water cooled Horn 93 112dB A Bore Ø75 mm Muffler Expansion Pulse Type Stroke 65 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder Number Arr...

Page 17: ...Cylinder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0 Air inject pipe bolt 4 6 1 0 1 4 Air inject reed valve bolt 2 3 0 07 0 09 Tappet adjustment screw nut 4 5 0 7 1 1 Apply oil to thread Spark plug 1 10 1 0 1 2 Tensioner lifter bolt 2 6 1 0 1 4 Carburetor insulator bolt 2 6 0 7 1 1 ...

Page 18: ...e nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 12 8 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 6 Driven gear nut 4 10 4 6 Swing arm pivot bolt 1 14 9 20 Front suspension arm nut 4 10 5 00 Front Rear cushion mounting bolt 6 10 4 60 Brake lever nut 2 6 1 00 Brake hose bolt 13 10 3 50 Brake caliper bolt 6 6 3 25 Brake disk mounting bolt 11 8...

Page 19: ...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 20: ...on pressure gauge 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...

Page 21: ...ch mixture loosen 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 ...

Page 22: ...rts in clutch 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 bus...

Page 23: ...gged fuel tank 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 Ex...

Page 24: ...ter contents 1 GENERAL INFORMATION Lubrication Points Drive chain Acceleration cable Front rear brake lever pivot Speedometer gear Wheel bearing 1 19 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 25: ... Special Tools List 2 12 Precautions in Operation Specification Fuel Tank Capacity 12000 c c Capacity 1400 c c Engine Oil Transmission Gear oil Capacity of coolant Change 1200 c c Capacity 750 c c Change 650 c c Engine radiator 850 c c Reservoir upper 420 c c Clearance of throttle valve 1 3 mm Type NGK CR8E Spark plug Gap 0 8 mm F Mark in idling speed BTDC 10º 1700 rpm Full timing advanced BTDC 27...

Page 26: ...in I I 26 Valve clearance I A 27 Cooling hoses connections I I 28 Coolant reservoir I I 29 Coolant I I R 30 Brake fluid I I Replace every 2 years Code I Inspection cleaning and adjustment R Replacement A Adjustment C Cleaning replaced if necessary L Lubrication Have your ATV checked adjusted and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the ATV at the optimum...

Page 27: ...from the air cleaner cover and then remove the cover Loosen the clamp strip and 1 screw of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install the elem...

Page 28: ...ocket 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 2 bolts Timing mark 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 adjustm...

Page 29: ... speed ATV300 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 i...

Page 30: ...eck 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...

Page 31: ...d with the periodical maintenance schedule to replace it Width limit 22 5 mm or above Drive Chain Check the drive chain Park the ATV on a level ground and shift the transmission onto neutral Measure the drive chain slack midway between the sprockets Chain slack 15 25mm 5 8 1 inch Adjust the chain slack Loosen the axle holder lock nuts and bolts Insert pin 6 to the hold when turn the wheel clockwis...

Page 32: ...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 33: ...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 34: ...eration If the ATV is in forward moving and shaking check clutch disc condition Replace it Adjust screw Clutch weight Drive plate 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 fo...

Page 35: ...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 5 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 36: ...ARTS NAME HMA COUNTER SHIFT NEEDLE BEARING DRIVER PARTS NO 440630 PARTS NAME L CRANKSHAFT OIL SEAL INSTALLER PARTS NO 440628 PARTS NAME TAPPET CLEARANCE ADJUSTER PARTS NO 440631 PARTS NAME 6205 BEARING REMOVER PARTS NO 440632 PARTS NAME 6205 BEARING INSTALLER PARTS NO 440635 PARTS NAME BRG REMOVER 2 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 37: ...CRANK CASE COVER 6201 BEARING INSTALLER PARTS NO 440637 PARTS NAME TAPPET PIN REMOVER PARTS NO 440638 PARTS NAME DRIVESHAFT REMOVER PARTS NO 440641 PARTS NAME WATER PUMP OIL SEAL INSTALLER INNER SIDE PARTS NO 440639 PARTS NAME DRIVESHAFT BEARING REMOVER PARTS NO 440642 PARTS NAME WATER PUMP OIL SEAL IRON INSTALLER 2 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 38: ...440644 PARTS NAME ENGINE VALVE REMOVER PARTS NO 440647 PARTS NAME 6204 BEARING INSTALLER PARTS NO 440645 PARTS NAME F02 BEARING REMOVER PARTS NO 440646 PARTS NAME UNIVERSAL WRENCH PARTS NO 440635 PARTS NAME BEARING REMOVER PARTS NO 440640 PARTS NAME WATER PUMP 6901 BEARING INSTALLER 2 14 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 39: ...l 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 3 Mechanism Diagram Valve Rocker Arm Press In Lubrication Oil Route Cam Shaft Spray Lubrication Con Rod Oil Route Spray Lubrication Press In Lubrication Rotate Direction Oil Pump Oil Strainer 3 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 40: ...5 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 3 1 7kgf m Engine oil drain bolt 3 5 4 5kgf m Gear oil drain bolt 1 1 1 5kgf m Gear oil join bolt 3 5 4 5kgf m Oil pump connection screw 0 1 0 3kgf m Troubleshooting Low engine oil level Oil leaking Valve guide or seat worn out Piston ring w...

Page 41: ...re washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 3 1 7kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Engine oil capacity 1200c c when re...

Page 42: ... oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Clip 2 screws Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover Remove oil pump shaft roller and shaft 1 screw Roller 3 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 43: ...ors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the oil pump shaft and roller Install the oil pump cover and fixing pins properly Pins 3 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 44: ...p and then tighten screws Torque value 0 1 0 3kgf m Make sure that oil pump shaft can be rotated freely 2 screws Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install starting gear and generator Refer to chapter 10 3 6 Clip PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 45: ...re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Torque value 3 5 4 5kgf m Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is in correct level Make sure that no oil leaking Gear oil join bolt Gear oil drain bolt 3 7 PDF created with pdfFac...

Page 46: ...To this chapter contents 3 LUBRICATION SYSTEM Notes 3 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 47: ...or 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 4 Mechanism Diagram Fuel tank cap Fuel unit Fuel tank Auto fuel cock Carburetor Fuel strainer Inlet pipe 4 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 48: ...ssembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassemble air cut valve arbitrarily Specification ITEM UA25A Carburetor diameter Ø22mm I D number PTG 050 Fuel level 14 8mm Main injector 110 Idle injector 35 Idle speed 1700 100rpm Throttle handle clearance 1 3 mm Pilo...

Page 49: ...f carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system Mixture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogg...

Page 50: ...e fuel hose Release the clamp strip of air cleaner Vacuum pipe Fuel pipe Clamp Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the carburetor ATV250 Release the clamp of carburetor insulator and then remove the carburetor ATV300 Installation Install in reverse order of removal procedures 4 4 2 nuts clamp PDF created with pdfFactory P...

Page 51: ...00C C O ring Spring Air cut off valve Cover Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assembly Install in reverse order of removal procedures 4 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 52: ...e throttle 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 Throttle cable Needle clamp Fuel needle clip Fuel needle Tighten the ...

Page 53: ...d valve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt Pin 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 Float valve Check for wear or damage 4 7 3 screws 250C C 4 screws ...

Page 54: ...t slow jet and air adjustment screw Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Needle jet Slow jet Air adjustment screw Checking fuel level Caution Check again to ensure float valve float for proper installation To ensure correct measurement position the float meter in such a way so that float chamber...

Page 55: ...ine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm ATV250 1700 100 rpm Idle speed rpm ATV300 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 af...

Page 56: ...tion Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fuel tank Remove the side covers and lower side covers Remove the front fender Covers remove please refer chapter 13 Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove the vacuum tube 4...

Page 57: ...e the air cleaner cover 4 catch hooks 4 hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Clamp 1 screw Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeez...

Page 58: ...4 FUEL SYSTEM To this chapter contents Notes 4 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 59: ... frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutch Transmission Specification Item Capacity Engine oil capacity Replacement 1200 c c Disassembly 1400 c c Gear oil capacity Replacement 650 c c Disassembly 750 c c Engine radiator 780 c c Coolant capacity Reservoir 420 c c AS indicator shown Total 1200 c c Torque...

Page 60: ...ve battery positive post Remove front fender and the footrest refer chapter 13 Negative Positive Remove starter motor wire Remove the spark plug cap Disconnect A C Generator wire couplers Starter motor wire Spark plug cap A C G wire couplers 5 2 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 61: ... muffler protect 2 bolts 2 bolts Loosen muffler front side bolt 2 bolts Remove 2 bolts and then remove the exhaust muffler 2 bolts Remove 2 nuts and then remove exhaust pipe 2 nuts 5 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 62: ...e Fuel pipe Clamp Disconnect the carburetor upper parts and cable Release the 2 nuts of carburetor insulator and then remove the carburetor ATV250 Release the clamp of carburetor insulator and then remove the carburetor ATV300 Release the clamp strips of left crankcase cover ducts and then remove the ducts Clamps 5 4 2 nuts clamp PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 63: ... from water pump Water hoses clamp Drain bolt Remove the thermo sensor wire by pass pipe and coolant outlet hose By pass pipe Outlet hose Thermo sensor wire Remove gear change lever 1 bolt 1 bolt Remove change switch couplers Change switch couplers 5 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 64: ...e the rear side engine hanger mounting nuts and bolts Remove the front side engine hanger mounting nut and bolt Remove left side engine hanger and then remove engine by left side Engine Installation Check if the bush of engine hanger parts for damage Install engine in the reverse procedures of removal Caution Pay attention of foot hand safety as engine installation to avoid hurting Do not bend or ...

Page 65: ... Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram 6 1 0 1 4kgf m 1 0 1 4kgf m 3 6 4 0kgf m 2 4 3 0kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 2kgf m 0 7 1 1kgf m 1 0 1 4kgf m 1 0 1 2kgf m 6 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 66: ...ance between Intake 0 010 0 037 0 080 Valve valve stem and guide Exhaust 0 025 0 062 0 100 Free length of valve Inner 38 700 35 200 spring outer 40 400 36 900 Valve seat width 1 600 Intake 0 10 0 02mm Valve clearance Exhaust 0 15 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cover bolt 1 0 1 4kgf m Exhaust pipe stud bolt 2 4 3 0kgf m Cylinder head bolt 1 0 1 4kgf m Cylinder h...

Page 67: ...valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto tensioner we...

Page 68: ... bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts 2 nuts Thermostat bolts Tensioner bolts Remove Air Injection system AI pipe mounting bolts Remove spark plug Remove the side cover mounting blots of cylinder head and then take out the side cover 4 bolts 3 bolts Spark plug 6 4 PDF created with pdfFactory Pro trial version www pdffactory ...

Page 69: ... sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller 2 bolts Timing mark Cam shaft setting plate Rocker arm shafts Rocker arm shaft and cam shaft puller Remove cam shafts Special Service Tool Rocker arm and cam shaft puller Cam shafts Rocker arm shaft and cam shaft puller 6 5 PDF created wi...

Page 70: ...nder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Gasket Chain guide Dowel pins Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool ...

Page 71: ...r Head Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 34 860mm EX Replacement when less than 34 725mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and beari...

Page 72: ...te the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit Inner spring 35 20 mm Outer spring 36 90 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure record the valv...

Page 73: ...the valve stem and valve guide Service Limit IN 0 08 mm EX 0 10 mm 5 0 mm valve guide reamer Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve g...

Page 74: ...ssed it in When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer Caution Using cutting oil when correcting valve gu...

Page 75: ...ness 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 cutter to cut...

Page 76: ...e contacting with valve 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 se...

Page 77: ...r Valve spring Valve stem seal Inlet valve Use a valve cotter remove assembly tool to press the valve spring and then remove valves Exhaust valve Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve cotter remove assembly tool Tap t...

Page 78: ...head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Chain guide Dowel pins Gasket Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of cylinder head right side Torque value Nut 3 6 4 0kgf m Bolt 1 0 1 4kgf m 4 Nuts 2 bolts Install camshaft into cylinder head and install rocker arm rocker arm shaft ...

Page 79: ...nting bolts Caution Make sure timing marks are matched 2 bolts Timing mark Install cylinder head side cover 3 bolts Install thermostat 2 bolts 3 bolts Thermostat bolts Loosen auto tensioner adjustment bolt and remove bolt and spring Install tensioner and install spring and adjustment bolt Tensioner adjustment bolt Install cylinder cover 4 bolts 4 bolts 6 15 PDF created with pdfFactory Pro trial ve...

Page 80: ...n the cam sprocket with that of cylinder head piston is at TDC position Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side cover...

Page 81: ...tion 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 1 0 1 4 k g f m 7 0 8 1 2 k g f m 7 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 82: ... 0 010 0 040 0 100 ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 17 016 17 034 17 064 Trouble Diagnosis Low or Unstable Compression Pressure Cylinder or piston ring worn out Knock or Noise Cylinder or piston ring worn out Carbon deposits on cylinder head top side Piston pin h...

Page 83: ...der gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be removed more easily Dowel pins 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 cylin...

Page 84: ...eck if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Service Limit Top ring 0 50 mm 2nd ring 0 65 mm 7 4 PDF created with pdfFactory Pro trial version www pdf...

Page 85: ...n pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 70 380 mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 5 PDF created with pdfFactory Pro trial ver...

Page 86: ...ce the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rings can be rotated freely after installed Top ring 2 nd ring Oil ring Top groove 2 nd groove Oil groove 7 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 87: ...stallation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution Do not let the opening of piston pin clip align with the piston cutout Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation IN mark Clip end gap Cutout Cylinder Installation Install do...

Page 88: ...stalling piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 Coolant hose 7 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 89: ... Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram 8 8 5 10 5kgf m 5 0 6 0kgf m 5 0 6 0kgf m 8 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 90: ...40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value Drive face nut 8 5 10 5kgf m Clutch outer nut 5 0 6 0kgf m Drive plate nut 5 0 6 0kgf m Special Service Tools Clutch spring compressor Inner bearing puller TGB 440645 Clutch nut wrench 39 x 41 mm TGB 440629 Universal holder TGB 440646 Bearing driver TGB 440640 Trouble Diag...

Page 91: ... the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Clamp strips 9 bolts Dowel pins Dowel pins Left cover plate Bearing setting plate Drive shaft holder bearing Left cover plate gasket 8 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 92: ...ts 9 bolts Check bearing on left crankcase cover Rotate bearing s inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it 8 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 93: ...stay collar Push the drive belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 22 5 mm Replace the belt if e...

Page 94: ...the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value Torque value 8 5 10 5kgf m Driven face Universa...

Page 95: ...rive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Universal holder Movable drive face Crankshaft Drive face boss Remove ramp plate Remove weight rollers from movable drive face Ramp plate Movable drive face Weight roller 8 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 96: ...er of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 30 060 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same In order to lengthen the roller life and prevented exceptionally wears the o...

Page 97: ...ovable drive face Drive face boss Crank shaft Driven pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Press down Drive belt Install drive face washer and nut Caution Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold drives face with universal holder Tighten nut to specified torque Torque value 8 ...

Page 98: ...ease the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Clutch nut wrench Clutch spring compressor Collar Remove guide pin guide pin roller and movable driven face and then remove O ring oil seal seat from movable driven face Movable driven face Seal Guide pin O ring Guide pin Guide pin roller Inspection Clutch o...

Page 99: ...r diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers ...

Page 100: ...deformation 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 Clutch weight Shock absorption rubber Shock abso...

Page 101: ... snap ring and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Snap ring Outer bearing Install new inner bearing Caution Its sealing end should be forwarded to outside as bearing installation Install needle bearing with hydraulic presser Install ball bearing by means of hydra...

Page 102: ...Guide pin O ring Guide pin Guide pin roller Install the collar Collar Install friction plate spring 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 ...

Page 103: ...ll bolt 3 5 4 5kgf m Reverse shaft Bearing 6205LLU Drive sprocket Bearing 6304 Drive shaft Bearing 6204 Oil seal 30x46x7 Final shaft 9 Gear oil drain bolt 0 8 1 2kgf m Cover bolt 2 6 3 0kgf m Bearing 6204 Oil seal 14x26x6 Shift fork Shift spindle Shift drum Bearing 6305 Oil seal 25x40x7 Dowel pin Needle bearing K25x29x10 Drive shaft bearing setting plate Counter shaft Needle bearing HK2016 Gasket ...

Page 104: ...il drain bolt 1 1 1 5kgf m Gear oil fill bolt 3 5 4 5kgf m Tools Special tools Bearing driver 6204 TGB 440647 Bearing driver 6205LLU TGB 440631 Bearing driver 6305 TGB 440639 Needle bearing driver HK2016 TGB 440627 Drive shaft and oil seal driver TGB 440629 Drive shaft puller TGB 440638 Inner bearing puller TGB 440645 Trouble Diagnosis Engine can be started but motorcycle can not be moved Damaged ...

Page 105: ...he socket bolt is provided with left turn thread Speedometer cable 3 bolts Socket bolt Remove 2 bolts and then remove the drive sprocket fixing plate drive chain and drive sprocket 2 bolts Remove gear fill bolt Place an oil pan under the ATV and remove gear oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value Gear oil fill bolt 3 5 4 5kgf m Gear oil drai...

Page 106: ...ing and bolt 9 bolts Shift drum fixed catch bolt Remove shift spindle shift fork shaft shift fork and shift drum Shift drum Shift fork shaft and fork Shift spindle Remove final shaft counter shaft and reverse shaft Reverse shaft Drive shaft Final shaft Counter shaft 9 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 107: ...he drive shaft Special tool Shaft protector Remove gasket and dowel pin Caution If non essential do not remove the drive shaft from the case upper side If remove the drive shaft from the gear box then its bearing and oil seal has to be replaced Oil seal Bearing 9 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 108: ...uter diameter of shift fork shaft and replace it if it exceed service limit Service limit 11 970 mm Measure the inner diameter of shift fork and replace it if it exceed service limit Service limit 12 010 mm Measure the claw thickness of shift fork and replace it if it exceed service limit Service limit 5 730 mm Check if the counter shaft is wear or damage 9 6 PDF created with pdfFactory Pro trial ...

Page 109: ...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 If remove the drive shaft from the crankcase upper side then its bearing has to be replaced Gear box Reverse shaft bearing Final shaft bearing Gear box cover Drive shaft bearing Counter shaft needle bearing Final ...

Page 110: ...nner bearing puller Install new final shaft counter shaft and reverse shaft bearings into left crankcase Special tool Bearing driver 6204 Needle bearing driver HK2016 Install new drive shaft bearings and baring driver into left crankcase Inner bearing puller Clutch nut wrench Bearing driver Drive shaft and seal install bush Drive shaft puller Install the universal bearing puller and bearing driver...

Page 111: ... install the oil seal Special tool Drive shaft and oil seal install bush Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the cover inner side Special tool Inner bearing puller Drive shaft and seal install bush Inner bearing puller Remove cir clip of final shat ou...

Page 112: ... puller Bearing driver Turn the universal bearing puller to install drive shaft bearing Special tool Bearing driver 6205 Universal bearing puller Universal bearing puller Bearing driver Install new oil seal and bearing driver into gear box cover inner side Install the universal bearing puller and bearing driver Turn the universal bearing puller to install drive shaft oil seal Special tool Bearing ...

Page 113: ...r shaft reverse shaft and final shaft onto gear box Reverse shaft Drive shaft Final shaft Counter shaft Install shift drum shift fork and fork shaft onto gear box Shift drum Shift fork shaft and fork Shift spindle Install shift drum fixed catch ball spring and bolt onto gear box Shift drum fixed catch bolt 9 11 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 114: ...le Install dowel pins and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Install the shift spindle bracket drive chain protector speedometer gear box and gear change lever Add gear oil Gear oil quantity 750c c 9 12 Position mark Dowel pins 9 bolts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 115: ...emoval 10 3 A C G Set Removal 10 3 Right Cover Bearing 10 3 Flywheel Removal 10 4 Starting Clutch 10 5 Flywheel Installation 10 7 A C G Set Installation 10 8 Right Crankcase Cover Installation 10 8 Mechanism Diagram 10 0 8 1 2kgf m 1 0 1 4kgf m 5 0 6 0kgf m 10 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 116: ...r motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 050 OD of starting clutch gear 42 192 42 208 42 100 Torque value Flywheel nut 5 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with adhesive 8 mm bolts 0 8 1 2kgf m 12 mm bolts 1 0 1 4kgf m Tools Special tools A C G flywheel puller TGB 440626 Universal holder TGB 440646 10 2 PDF created with pdf...

Page 117: ...r bolts A C G Set Removal Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set 2 screws 3 screws Right Cover Bearing Inspection Rotate the bearing with finger to check if the bearing rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary Remove the cir cl...

Page 118: ...LU by bearing driver Special tool Bearing driver Oil seal Bearing driver Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with universal holder Remove flywheel nut Special tool Universal Holder Reduction gear Flywheel nut 10 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 119: ...ven gear Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch driven gear Service Limit ID 25 050 mm OD 42 100 mm flywheel puller ID OD Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage 10 5 PDF created with pdfFactory Pro trial version www pdffa...

Page 120: ... starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting driven gear Remove 3 socket bolts and then remove one way clutch Starting driven gear 3 socket bolts One way clutch Starting driven gear 10 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 121: ...Torque value 1 0 1 4kgf m Install starting driven gear Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 5 0 6 0kgf m Special tool Universal Holder 3 socket bolts Starting driven gear Groove 10 7 PDF created with pdfFactory Pro trial version www pdffact...

Page 122: ... Tie the wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator Wire 2 bolts 3 screws Right Crankcase Cover Installation Install dowel pin and new gasket Dowel pin Remove water pump cover Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump shaft 10 8 PDF created with pdfFactory...

Page 123: ...rankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover 11 bolts Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover 10 9 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 124: ...To this chapter contents 10 ALTERNATOR STARTING CLUTCH Note 10 10 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 125: ...tion 11 2 Trouble diagnosis 11 2 Disassembly of crankcase 11 3 Crankshaft Inspection 11 5 Assembly of crankcase 11 6 Mechanism Diagram 1 0 1 4kgf m 0 8 1 2kgf m 11 0 8 1 2kgf m Eng Oil drain bolt 3 5 4 5kgf m 11 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 126: ...engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Specification Unit mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Crankshaft Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Run out 0 100 Torque value Bolts for crankcase 0 8 1 2kgf m Engine oil drain bolt 3 5 4 5kgf m Cylinder stud bolt 1 0 1 4kgf m To...

Page 127: ...ner Tensioner Cam chain setting plate Loosen 2 bolts on the right crankcase 2 bolts Loosen 11 bolts on the left crankcase Place right crankcase downward and left crankcase up Tap the left crankcase with a plastic hammer to remove it Caution Care should be taken not to damage the contact surfaces 11 bolts 11 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 128: ...case Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Drive out left crankcase oil seal 11 4 Balance shaft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 129: ...m Place the crankshaft on a V block measure run out of the crankshaft Service limit 0 10 mm 90 mm 60 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 Spe...

Page 130: ...tion is uneven noising or loose bearing mounted then replace it Special tool Inner bearing puller Bearing driver Assembly of crankcase Install wave washer into right crank bearing seat Balance shaft bearings Wave washer Install crank shaft on the right crankcase Align the position mark on the balance shaft drive gear with that of balance shaft driven gear and then install balance shaft onto right ...

Page 131: ... Dowel pins Install the left crankcase onto the right crankcase Tighten 11 bolts on the left crankcase Torque value 0 8 1 2kgf m Tighten 2 bolts on the right crankcase Torque value 0 8 1 2kgf m 11 bolts 2 bolts 11 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 132: ...are not to damage the lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Oil seal driver 27 42 7 Install the tensioner and tighten the pivot bolt Torque value 0 8 1 2kgf m Install the cam chain Install the cam chain setting plate Oil seal driver Tensioner Cam chain setting plate 11 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 133: ...ling System 12 3 System Test 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram Radiator filler cap Reserve tank By pass pipe To cylinder head 12 Coolant outlet pipe Radiator Cooling fan Coolant inlet pipe Thermo switch fan Thermostat Water pump 12 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 134: ...0c c 420c c Thermostat Begins to activate at 82 95 Stroke 0 05 3m Thermos switch fan Begins to activate at 98 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump impeller 1 0 1 4kgf m Tools Requirement Special tools Water pump bearing driver 6901 TGB 440640 Water pump oil seal driver Inner TGB 440641 Water pump mechanical seal driver TGB 440642 Inner bearing puller TGB...

Page 135: ...back to zero Y B 1 Measure thermo unit to confirm voltage 6V Y B 2 Inspect the circuits of water temperature have short or earth N Replace thermo unit Y Short or earth handle N Meter problem C Open radiator cap and N softly throttle inspect coolant have circulated Y C 1 Eng stop and remove water pump cover start the motor to inspect pump its rotation Y Water pump repair Water hose clogged D Close ...

Page 136: ...ard correct and check again E 3 Keep eng 3000 4000 rpm and inspect coolant flow into reserve tank after the temperature gauge over 3 checks Y E 4 Remove thermostat from holder then heats it by water directly to check its operation N Replace thermostat Y Refill with coolant then check again For bleed the air bubbles completely open radiator cap and start engine while engine is cool then press water...

Page 137: ...ne is completely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilling system with coolant and bleeding the air bubbles Run the engine and remove by pass pipe Check by pass hole whether has the air bubble to emit If emits without the ...

Page 138: ... cooling system the refrigerant backflow floods Upper Lower Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Removal Place a water pan under the water pum...

Page 139: ... fan motor onto fan duct and insert the fan into the motor shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please 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 ...

Page 140: ...water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain bolt to drain out the coolant Remove the water hose Loosen 4 bolts and remove the pump cover Loosen 9 bolts and remove the right cover Take off the gasket and dowel pins Turn pump impeller clockwise and remove Caution The impe...

Page 141: ...er seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Water pump bearing driver 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 Mechanica...

Page 142: ... Water pump bearing driver 6901 Caution Do not reuse old bearing It must be replaced with a new one once it has been removed Water pump oil seal driver inner Water pump bearing driver 6901 Mount the water pump shaft and the inner bearing to the right crankcase cover Inner bearing Water pump shaft Install the cir clip to hold the inner bearing 12 10 PDF created with pdfFactory Pro trial version www...

Page 143: ...lue 1 0 1 4kgf m Caution The impeller is left thread Water pump rotor Install the dowel pin and right cover gasket The rotation water pump impeller causes the water pump drive shaft scoop channel aligns the oil pump drive shaft flange install the right crank case 9 bolts Install the dowel pin and new gasket Install the water pump cover with 4 bolts 12 11 PDF created with pdfFactory Pro trial versi...

Page 144: ...ever the thermostat and the thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve begins to open 82 95 Valve stroke 0 05 3mm Installation Install the thermostat Install the t...

Page 145: ...13 BODY COVER Mechanism Diagram 13 1 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 146: ...properly installed during the assembly l Never compact forcefully or hammer the quard and the covers during assembly 13 2 Fuel tank cover Right and left foot board Right and left foot board Right and left front internal fender Right and left front shock mount front bumper Front air inlet plate Right and left head lamp support body cover Rear body cover Front protector rear protector Upper bracket ...

Page 147: ...emove cable and battery fixed Remove 1 screw and take off shift lever Remove fuel cap Remove 4 screws and then remove fuel tank cover Installation Install in reverse order of removal procedures 13 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 148: ...ot board remove right or left foot board each side 3 bolts Remove bolts from right or left front internal fender each side 5 bolts and then remove right or left front internal fender Remove 4 bolts from front bumper Remove 2 screws from front bumper Installation Install in reverse order of removal procedures 13 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 149: ...from right and left head lamp support each side 2 bolts Remove bolts from front air inlet plate each side 2 bolts and then remove front air inlet plate Remove bolts from front body cover each side 1 bolts Installation Install in reverse order of removal procedures 13 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 150: ...ve power source couplers and then remove front body cover Remove bolts each side 1 bolts Remove 2 couplers Installation Install in reverse order of removal procedures 13 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 151: ...olts from rear body covert Remove 1 nut from bear reflector assembly each side 1 bolts Remove number plate lamp couplers rear lamp assembly couplers L R and turn signal lamp couplers L R Installation Install in reverse order of removal procedures 13 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 152: ...dy covert Remove 2 bolts from front protector Remove 2 bolts from front protector and then remove front protector Remove bolts from bear protector each side 1 bolts Installation Install in reverse order of removal procedures 13 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 153: ...tector 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 9 Home page Contents PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 154: ... Front Brake Caliper 14 10 Brake Disk 14 11 Front Brake Master Cylinder 14 11 Mechanism Diagram Front brake master cylinder Front pressure control valve Brake hose bolts 3 5kgf m Air bleed valve 0 5kgf m To rear pressure control valve 14 Brake caliper bolts 3 25kgf m Brake disk bolts 4 25kgf m Bearing 6203LU Front wheel nuts 2 4kgf m Front axle castle nuts 5 0kgf m 14 1 PDF created with pdfFactory...

Page 155: ...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 Master ...

Page 156: ...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 157: ...emove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 5 0kgf m 4 nuts Front Wheel Hub Removal Remove front brake caliper 2 bolts 2 bolts Remove cotter pin wheel hub nut and washer Remove wheel hub and brake disk Wheel hub nut Cotter pin 14 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 158: ...nstall the front brake disk to the wheel hub Install wheel hub and brake disk on to knuckle Install wheel hub washer and tighten the wheel hub nut Torque 9 0kgf m Install cotter pin 4 bolts Wheel hub nut Cotter pin Install front brake caliper Torque 3 5kgf m 2 bolts 14 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 159: ...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 160: ...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 161: ...finishing 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 ...

Page 162: ...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 163: ... 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 set Push the lead of brake light switch an...

Page 164: ...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 165: ...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 light switch Brake lever bolt Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and b...

Page 166: ...To this chapter contents 14 FRONT BRAKE FRONT WHEEL Notes 14 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 167: ...teering Tie Rod 15 6 Knuckle 15 7 Front Cushion 15 8 Suspension Arm 15 9 Toe In 15 10 Mechanism Diagram 300 350 kgf cm 300 350 kgf cm 250 350 kgf cm 700 900 kgf cm 15 450 550 kgf cm 250 350 kgf cm 400 430 kgf cm 400 430 kgf cm 450 550 kgf cm 450 550 kgf cm 450 550 kgf cm 600 kgf cm 450 550 kgf cm 15 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 168: ...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 169: ...o not let foreign materials enter into the cylinder Handle protect cover brocket bolts Master cylinder bolts Remove 2 screws and then remove throttle hosing holder and throttle hosing 2 Screws 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 Master cylinder bolts Handle protect cover broc...

Page 170: ...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 171: ...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 172: ...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 173: ...all joints 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 jo...

Page 174: ... cushion under bolt nut and remove the bolt Remove front cushion upper bolt nut and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value Front cushion nut 4 6kgf m Nut Nut 15 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 175: ...n 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 Bush 15 9 PDF created with ...

Page 176: ...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 177: ...ke Caliper 16 13 Brake Disk 16 14 Rear Brake Master Cylinder 16 14 Rear Cushion 16 18 Mechanism Diagram Rear brake master cylinder A Brake hose bolts 3 5kgf m Rear pressure control valve Air bleed valve 0 5kgf m To front pressure control valve Brake disk bolts 4 25kgf m Brake caliper bolts 3 25kgf m Rear axle holder bolts 9 2kgf m Rear wheel axle nuts 9 2kgf m Rear brake master cylinder B Driven g...

Page 178: ...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 diameter foot brake...

Page 179: ...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 180: ...ation Install the rear wheel and tighten the nuts Torque 2 4kgf m 4 nuts Rear Wheel Axle Connecter Removal Remove cotter pin rear wheel axle connecter nut and washer Wheel hub nut Cotter pin Remove right and left rear wheel axle connecter Installation Install the rear wheel shaft connecter Install wheel shaft connecter washer and tighten the wheel shaft connecter nut Torque 2 4kgf m Install cotter...

Page 181: ...and then remove rear brake caliper Remove 2 bolts and 1 nut and remove drive chain cover 2 bolts 1 nut Remove 4 bolts to remove rear under protect Front side 2 bolts Rear side 2 bolts Remove drive chain lock clip master link and then remove drive chain Master link Lock clip 16 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 182: ...ket Bend out the rear axle nut fixed plate Bend out the rear wheel axle holder nut fixed plate Fixed plate Remove rear wheel axle nuts Special tool Rear axle nut wrench 55mm Remove rear brake disk bracket and disk Brake disk bracket 16 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 183: ... if necessary Disassembly Caution Never install used bearings Once bearing removed it has to be replaced with new one Remove bearing and seal from rear wheel axle bearing seat using following tools Special tool Inner bearing puller SYM 6204022 Remove bearing spacer Assembly Install new left side bearing and seal into rear wheel axle bearing seat Install rear wheel axle bearing inner spacer Install...

Page 184: ...brake disk bracket and disk Install rear wheel axle nuts rear axle nut fixed plate and tighten the nuts Torque 9 2kgf m Special tool Rear axle nut wrench 55mm Rear axle nut torque wrench Torque wrench After tightened the axle nut bend the rear axle nut fixed plate Brake disk bracket Fixed plate 16 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 185: ...ndition of the driven sprocket teeth Replace the sprocket if it worn o X Caution The drive chain drive sprocket and driven sprocket must be also inspected for wear Rear swing arm Removal Remove rear under protect drive chain driven sprocket rear brake caliper brake disk and rear axle Remove 2 nuts and bolt and remove rear axle holder Remove rear swing arm lock nut Remove rear swing arm bolt and th...

Page 186: ...ing when the 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 3 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settle t...

Page 187: ...ted surfaces plastic 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 reduc...

Page 188: ... 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 189: ...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 190: ...se 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 Brake lever bolt Brake light switch coupler Brake lever nut Handle left ...

Page 191: ...er Disassembly Remove the rubber boot Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Rubber boot Piston Piston cup Cir clip Spring Master cylinder 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 t...

Page 192: ...clip is 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...

Page 193: ...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 194: ...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 Rear cushion upper bolt 16 18 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 195: ...ing Fan Thermo Switch 17 20 Thermo unit 17 21 Water Temperature Indicator Light 17 21 Mechanism Diagram Starter relay Fuse box Front brake switch Battery C D I Unitx Hazard control unit Winker rela Main switch Shift gear control unity Rear brake switch AC Generator Thermo unit 17 DC Power outlet Start light winker horn brake switch Headlight relay Horn Regulator rectifier Spark plug Ignition coil ...

Page 196: ... 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 12V12Ah Charging rate 1 4A 5 10 hours standard 1...

Page 197: ... 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 198: ... the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 4A 7 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 199: ...al Caution 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 cabl...

Page 200: ...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 201: ...passes the condition Item Check Points Standard Value Main switch connection R B Battery Battery voltage ON 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 17 7 PDF created with pdfFactory...

Page 202: ... D I unit Disconnect 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 Black white green Battery voltage Pulse generator Green White Blue yellow 50 170Ω Primary circuit Black yellow green 0 17 10 Ω Ignition coil Secondary circuit Black yellow with no cap 3 6 10 Ω Black yellow with ca...

Page 203: ...he 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 Igniti...

Page 204: ...f a sound of Looh Looh 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 ...

Page 205: ...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 Negative 2 Bolts Starter motor cable 17 11 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 206: ...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 207: ...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 208: ...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 209: ...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 License light 17 15 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 210: ...onnect 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 ST SG FRE...

Page 211: ...te Blue Brown Winker switch Pin Position L WR R N PUSH OFF Wire color Pink Black Brown White Winker switch Horn switch Pin Position BAT3 HO FREE Wire Color White Black Light green Horn switch Hazard switch Pin Position HD E Hazard switch Wire Color Green Red Green 17 17 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 212: ...rake 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 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 213: ... resistance measured shall be as follows Position Resistance 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 Empt...

Page 214: ...n the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperature increase the coolant temperature gradually The switch should have continuity at 98 3 Caution Keep the coolant at a constant temperature at least for three minutes Sudden increase the coolant temperatur...

Page 215: ...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 216: ...To this chapter contents 17 ELECTRICAL SYSTEM Notes 17 22 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 217: ...Home page Contents 18 ELECTRICAL DIAGRAM 18 18 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 218: ...Home pae Contents 18 ELECTRICAL DIAGRAM Notes 18 2 PDF created with pdfFactory Pro trial version www pdffactory com ...

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