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TGB BLADE 500, Service Manual

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TGB BLADE 500 Service Manual Download Page 273

15-2. ELECTRIC POWER STEERING

 

15-2-6 

TROUBLESHOOTING 

NO POWER STEERING 

1. EPS malfunction. 

- If the CHECK ENGINE light is on and a EPS 

FAULT message is visible in the dashboard, 

check for fault code at the bottom of 

dashboard. 

2. No power to EPS unit. 

- Carry out an EPS unit FUSE test. Replace 

as required. 

- Carry out an EPS unit INPUT VOLTAGE 

test (POWER SIDE). Repair or replace 

wiring/connectors as required. 

- Carry out an EPS unit INPUT VOLTAGE 

test (CONTROL SIDE). Repair or replace 

wiring/connectors as required. 

3. NO ground to EPS unit. 

- Carry out an EPS unit GROUND CIRCUIT 

test. Repair or replace wiring/connectors as 

required. 

4. No engine RPM signal from ECU. 

- If engine RPM can be displayed in the 

dashboard when the engine is running, carry 

out an EPS unit COMMUNICATION LINK 

(can) CONTINUITY test. Repair or replace 

wiring/connectors as required. 

- If engine RPM cannot be displayed in the 

dashboard, use diagnostic tool to check for 

applicable fault codes. Carry out service 

actions. 

 

 

LOW POWER STEERING ASSIST

 

1. Low battery voltage. 

- Check battery terminals. Clean, repair, 

replace or tighten as required. 

- Test battery voltage. Recharge or replace 

battery as required. 

- Carry out an EPS unit INPUT VOLTAGE test 

(POWER SIDE) as detailed in this 

subsection. Ensure power connector pins 

are clean, corrosion free, tight and make 

good contact. Repair or replace 

wiring/connectors as required. 

- Carry out an EPS SYSTEM LOAD TEST as 

detailed in this subsection. 

2. Low input voltage to EPS unit. 

- Carry out an EPS unit INPUT VOLTAGE test 

(POWER SIDE) as detailed in this 

subsection. Ensure power connector pins 

are clean, corrosion free, tight and make 

good contact. Repair or replace 

wiring/connectors as required. 

3. Faulty EPS ground circuit.

 

- Carry out an EPS GROUND CIRCUIT test. 

Ensure EPS ground connector pins and 

frame ground post are clean, corrosion free, 

tight and make good contact. Repair or 

replace wiring/connector as required. 

 

ASYMMETRICAL POWERT STEERING 

ASSIST (SIDE TO SIDE)

 

1. Torque sensor not reset to zero.

 

- Ensure steering alignment is within 
specification and carry out the TORQUE 
OFFSET RESET procedure detailed in this 
subsection. 

 

 

 

 

 

 

 

 

Summary of Contents for BLADE 500

Page 1: ...SERVICE MANUAL TAIWAN GOLDEN BEE CO LTD ...

Page 2: ...cused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV 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 FORWARD ...

Page 3: ...ion 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 quick...

Page 4: ...PISTON 7 8 1 8 12 V TYPE BELT DRIVING SYSTEM KICK STARTER 8 9 1 9 12 DRIVE SYSTEM 9 10 1 10 10 ALTERNAOTOR STARTING CLUTCH 10 11 1 11 20 CRANKSHAFT CRANKCASE 11 12 1 12 10 COOLING SYSTEM 12 13 1 13 10 BODY COVER 13 14 1 14 12 FRONT BRAKE AND FRONT WHEEL 14 15 1 15 10 STEERING FRONT SUSPENSION 15 16 1 16 14 REAR BRAKE REAR WHEEL REAR CUSHION 16 17 1 17 22 ELECTRICAL EQUIPMENT 17 18 1 18 2 ELECTRICA...

Page 5: ...Frame Number Engine Number SERIAL NUMBER ...

Page 6: ... the symbols or marks Warning Means that serious injury or even death may result if procedures are not followed Caution Means that equipment damages may result if procedures are not followed 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 Oil seal Apply with lubricant Re...

Page 7: ... the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is 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 ...

Page 8: ...ause most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent unsmooth control and premature worn out Rubber parts may become deteriorated when 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 ...

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

Page 10: ... open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secured Battery 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 ...

Page 11: ...connector boot completely and secured properly Before terminal connection check if the boot is crack or the terminal is loose 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 that only the insulated surfaces contact the w...

Page 12: ...r pull too tight nor have excessive slack Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be 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 s...

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

Page 14: ...Max Torque 33 3 5000 Nm rpm Ignition ECU Starting System Electrical starter Air filtration Sponge Suspension System Front Double A Arm Rear Double A Arm Tire Specifications Front 25X8 12 26X8 14 26X9 14 Rear 25X8 12 26X10 14 26X11 14 Rim Aluminum Steel Brake System Front Disk Ø 190 mm Rear Disk Ø 200 mm Performance Max Speed 55 90 km hr Climb Ability 25 ﾟ Reduction Primary Reduction Belt Secondary...

Page 15: ...1 GENERAL INFORMATION 1 10 Capacity 500 ml Spark Plug NGK DCR8E Battery 12 18 V AH Lamps Front Lamps HI LO 55 2 55 2 W Rear Lamps 5 1 W Brake Lamps 21 1 W Turn Lamps 10 4 W ...

Page 16: ...6 6000 28 3 6500 kw rpm Max Torque 33 4 4000 43 1 5500 Nm rpm Ignition ECU Starting System Electrical starter Air filtration Sponge Suspension System Front Double A Arm Rear Double A Arm Tire Specifications Front 25X8 12 26X8 14 26X9 14 25X8 12 25X8 12 26X8 14 26X9 14 Rear 25X8 12 26X10 14 26X11 14 25X10 12 25X8 12 26X10 14 26X11 14 Rim Aluminum Steel Brake System Front Disk Ø 190 mm Rear Disk Ø 2...

Page 17: ...l Gear lubrication Front Differential Spec SAE 85W 90 Capacity 350 ml Rear Gear Spec SAE 85W 90 Capacity 500 ml Spark Plug NGK DCR8E Battery 12 18 V AH Lamps Front Lamps HI LO 55 2 55 2 W Rear Lamps 5 1 W Brake Lamps 21 1 W Turn Lamps 10 4 W ...

Page 18: ...ght bolt 2 8 2 0 2 4 Cylinder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX 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 insula...

Page 19: ...ront axle castle nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 12 8 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 60 Driven gear nut 4 10 4 60 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 m...

Page 20: ...Malfunction of Ignition Coil set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Re start by following the starting procedures Cylinder compression pressure normal Low compression pressure or no pressure Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand...

Page 21: ...r discoloration Fouled and discoloration Remove spark plug Check and adjustment Fault condition Probable causes Malfunction of Ignition Coil Malfunction of AC alternator Check if carburetor jet is clogged Check cylinder compression pressure using compression pressure gauge Ignition timing correct Incorrect ignition timing Compression pressure correct No compression pressure Cylinder piston ring wo...

Page 22: ... Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch No air sucked Air sucked Good spark Poor Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack Air sucked through carburetor gasket Adjust the ...

Page 23: ...en Transmission gear damaged Clutch weights spring broken Clutch outer stuck with clutch weights Connection parts in clutch and shaft worn out or burned 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 Damaged steering bearing Damaged steering shaft bushing...

Page 24: ...advanced Excessive carbon deposited in combustion chamber Normal Abnormal Normal Abnormal Accelerate lightly engine speed can be increase Check tire pressure Raise wheels off ground and spin by hand Spin freely Abnormal Check ignition timing Normal Abnormal Test cylinder compression Brake dragging Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication Punctured tire Faulty tir...

Page 25: ...1 GENERAL INFORMATION 1 20 Oil and Lubrication Points Brake Fluid Grease ...

Page 26: ...1 GENERAL INFORMATION 1 21 Gear Oil ...

Page 27: ... Fuel Tank Capacity 18000 c c Engine Oil Blade Model Capacity With Oil Radiator 3850 c c Without Oil radiator 3500 c c Oil Filter Change 3300 c c Oil change 3000 c c Target Model Capacity With Oil Radiator 3800 c c Without Oil radiator 3500 c c Oil Filter Change 3300 c c Oil change 3000 c c Transmission Gear oil Front Differential Capacity 350 c c Change 350 c c Rear Differential Capacity 500 c c ...

Page 28: ...rease nipple TOOL 552304 Universal Joint Assy R R 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...

Page 29: ...eck acceleration operation condition Free play 1 3 mm Air Cleaner Remove seat loosen 4 hooks from the air cleaner cover and then remove the cover Loosen the clamp strip and 1 screw of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean t...

Page 30: ...n the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke Caution Do not turn the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check adjust valve clearance with feeler gauge Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustmen...

Page 31: ...ecified idle speed Specified idle speed 1700 100 rpm Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle valve stopper screw and let engine runs in 1700 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment scre...

Page 32: ... timing is incorrect check CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found Cylinder Compression Pressure Warm up engine Turn off the engine Remove the trunk Remove the central cover Remove spark plug cap and spark plug Install compression gauge Full open the throttle valve and rotate the engine by means of starter motor Caution Rotate the engine until the ...

Page 33: ...ips of clutch cover and then remove the clutch 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 ...

Page 34: ...id 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 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 ...

Page 35: ...Lining Replacement refer chapter 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 Brake Light Switch Starting Inhibitor Switch The brak...

Page 36: ...e valve opening gradually to check clutch operation If the ATV is in forward moving and shaking check clutch disc condition Replace it 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 dama...

Page 37: ...be done as cold engine Check if tire surface is ticked with nails stones or other materials Appointed tire pressure Tire size Front Tire Rear Tire Tire pressure as cold 7 psi 7 psi 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 Bolt...

Page 38: ...9 REMOVER PARTS NO 440651 PARTS NAME BEARING 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 ...

Page 39: ...PARTS NO 440659 PARTS NAME FLYWHEEL REMOVER PARTS NO 440660 PARTS NAME CHAIN WHEEL 925094 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 PULLER ...

Page 40: ...E CYLINDER HEAD VALVE AND SPRING INSTALLER REMOVER PARTS NO 440668 PARTS NAME UNIVERSAL JOINT HEAD 924646 INSTALLER PARTS NO 440669 PARTS NAME CHAIN WHEEL 925094 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 ...

Page 41: ...2 MAINTENANCE INFORMATION 2 15 PARTS NO 552302 PARTS NAME FINAL DRIVE NUT N33701 INSTALLER REMOVER PARTS NO 552301 PARTS NAME OIL SEAL INSTALLER ...

Page 42: ...2 MAINTENANCE INFORMATION 2 16 Note ...

Page 43: ...3 LUBRICATION SYSTEM 3 1 Mechanism Diagram Mechanism Diagram 3 1 Precautions in Operation 3 2 Troubleshooting 3 2 Engine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 ...

Page 44: ...3000 c c Oil viscosity SAE 10W 40 Torque value Torque value oil filter 1 2 kgf m Engine oil drain bolt 2 4 kgf m Troubleshooting Low engine oil level Oil leaking Valve guide or seat worn out Piston ring worn out Low oil pressure Low engine oil level Clogged in oil strainer circuits or pipes Oil pump damage Dirty oil No oil change in periodical Cylinder head gasket damage Piston ring worn out Items...

Page 45: ...l can be drained smoothly and completely Place an oil pan under the ATV and remove oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value 2 4 kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer cap Clean oil strainer Check if O ring can be re used Install oil strainer cap Torque value 1 0 1 2 kgf m Engine oil capacity 3000c c when repl...

Page 46: ...nut has left hand threads Remove the snap ring Remove the washer Remove the oil pump driver gear Remove the pin Remove the washer Make sure that pump shaft can be rotated freely Remove 3 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover Remove oil pump shaft roller and shaft One way clutch Snap ring 3 screws Pin 1 screw ...

Page 47: ... between inner and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the oil pump shaft and roller Install the oil pump cover and fixing pins properly ...

Page 48: ...rew Oil Pump Installation Install the oil pump and then tighten 3 screws Torque value 1 0kgf m Make sure that oil pump shaft can be rotated freely Install the washer Install the pin Install the oil driven gear Install the washer Install the snap ring ...

Page 49: ... Fuel line inspection 26 Fuel flow inspection 27 Fuel pump 28 Fuel pump relay 29 Sensor circuit malfunction troubleshooting 31 Fault diagnosis 54 Integrated fault diagnosis program 57 Fault diagnosis note 58 Use diagnosis tool 60 Troubleshooting table 68 Comprehensive maintenance list 69 Fuel Injection System Components Throttle Body Idle Speed Controller Temperature Manifold Air Pressure Injector...

Page 50: ... been removed Do not apply excessive force to the fuel pipe on the throttle body while removing or installing the throttle body Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization Prevent dirt and debris from entering the throttle bore fuel tube and return tube clean them using compressed air The throttle body is factory pre set Do not disassemble in a wa...

Page 51: ... male connector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECU VARIOUS SENSORS Since each component is a high precision part great care shou...

Page 52: ...s being open Poor terminal to wire connection Disconnect the negative cable from the battery Check each connector coupler at both ends of the circuit being checked for loose connection Also check for condition of the coupler lock if equipped Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly ...

Page 53: ...e circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground Ap...

Page 54: ...ect all connectors couplers of those parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A and C Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is i...

Page 55: ...00 rpm Throttle grip free play 2 4 mm Intake air temperature sensor resistance Ω Engine coolant temperature sensor resistance Ω Fuel injector resistance Ω Ignition pulse generator peak voltage V Manifold absolute pressure at idle 420 30 mm Hg Fuel pressure at idle 300 kPa TORQUE VALUES ECT sensor Pressure regulator mounting bolt Fuel pump mounting nut ...

Page 56: ...servoir 2 Roll Over Sensor 9 Fuel Filter x 2 3 Injector 10 Ignition Coil 4 Speed Sensor 11 Throttle Position Sensor 5 Engine Coolant Temperature 12 Idle Speed Controller 6 Crank Position Sensor 13 Temperature Manifold Air Pressure 7 Pressure Regulator 14 Throttle Body ...

Page 57: ...4 1 FUEL INJECTION SYSTEM 4 1 9 WIRING DIAGRAM ...

Page 58: ...G CAN_L Diagnosis Tool J1 9 B Fuel Pump relay C2 15 B Y Temp Temperature LED J2 21 Blank C3 27 Gr R SGND1 Signal Ground J3 33 R Gear A C4 39 Br B Stepper B J4 45 R Gr Override switch D1 4 LG R CPS Crank position sensor K1 10 O W Main relay D2 16 Pu B K2 22 B W Fan relay D3 28 G B Stepper D K3 34 Blank D4 40 L B Stepper A K4 46 Blank E1 5 L Y CPS Crank position sensor L1 11 R VBR Start relay voltag...

Page 59: ...lamp condition LED Always ON Sometimes ON Always OFF Good condition Malfunction code Malfunction code PROBLEM SYMPTOMS Difficult Starting No cranking No initial combustion No combustion Poor starting at cold warm always Other_______________ Poor Drivability Hesitation on acceleration Back fire After fire Lack of power Surging Abnormal knocking Engine rpm jumps briefly Other _______________ Poor Id...

Page 60: ...nous Uphill Down hill Tar macadam Gravel Other __________ ATV condition Engine condition Cold Warming up phase warmed up Always Other at starting Immediately after start Racing without load Engine speed rpm ATV condition During driving Constant speed Accelerating Decelerating Right hard corner Left hand comer At shop ATV speed when problem occurs km h mile h Other _____________ NOTE The above form...

Page 61: ...e and check that the MIL light Turn the ignition switch OFF Disconnect the MAP sensor 4P connector Turn the ignition switch ON Measure the voltage at the wire harness side connector Connection Yellow Black Ground Standard 5 0 0 1V Measure the voltage between the connector terminals of wire harness side Connection Yellow Black Gray Red Standard 5 0 0 1V Turn the ignition switch OFF Connect the TMAP...

Page 62: ... MIL light Turn the ignition switch OFF Disconnect the ECT sensor connector Measure the resistance at ECT sensor terminals Connection Standard 2 3 2 6 kΩ at 20 Turn the ignition switch ON Measure the voltage between the ECT sensor connector terminal of the wire harness side and ground Connection Yellow Red Ground Standard 5 0 0 1V Measure the voltage at ECT sensor connector of the wire harness sid...

Page 63: ...LLATION Disconnect the ECT sensor 2P connector from the sensor Remove the ECT sensor Install the new ECT sensor TORQUE 120 kgf cm Connect the ECT sensor 2P connector Standard TEMPERATURE RESISTANCE VALUES OHM TOL OHM 20 3500 250 60 704 45 90 260 20 ...

Page 64: ...nal and ground Connection Yellow Black Ground Standard 5 0 0 1V Measure the voltage at TP sensor terminals of the wire harness side Connection Yellow Black Gray Red Standard 5 0 0 1V Working voltage value 5 0 0 1V Full throttle open voltage 3 9 0 2V Full throttle closed voltage 0 5 0 05V WARNING Never loosen the screw of TPS result the unsteady idle Using diagnosis tool to confirm the throttle out...

Page 65: ...d sensor connector Connect the vehicle speed sensor 3P connector Start the engine Ride the vehicle and keep the engine more than 5 000 RPM about 20 seconds or more Check the MIL light Turn the ignition switch OFF Disconnect the vehicle speed sensor 3P connector Turn the ignition switch ON Measure the voltage at the wire harness side connector Connection Red Black White Standard 12 V ...

Page 66: ...N Check the MIL light Turn the ignition switch OFF Disconnect the injector 2P connector and measure the resistance of the injector Connection Red Blue Green Standard 12 0 1Ω Check for continuity between the injector and ground Connection Red Ground Standard continuity Turn the ignition switch ON Measure the voltage between the injector connector of the wire harness side and ground Connection Red G...

Page 67: ...r does not operate replace the injector REMOVAL Disconnect the injector 2P connector Remove the bolts and fuel rail assembly Remove the injector from the intake pipe INSTALLATION Install injector on the intake pipe Being careful not to damage the O ring of injector Install fuel rail assembly and tighten the bolt TORQUE 120 kgf cm Connect the injector 2P connector ...

Page 68: ...urn the starter motor more than 10 seconds and then check that the MIL light Turn the ignition switch OFF Disconnect the crank position sensor 2P connector Check for continuity between the crank position sensor connector terminal and ground Connection Blue Ground Standard No continuity Crank the engine with the starter motor and measure the crank position sensor peak voltage at the crank position ...

Page 69: ...n check that the MIL light Turn the ignition switch OFF Disconnect the ignition coil 2P connector Check for continuity between the ignition coil connector terminal and ground Connection Red Ground Standard No continuity Crank the engine with the starter motor and measure the ignition coil peak voltage at the ignition coil 2P connector Connection Red Black Yellow Standard 0 7V Check for resistance ...

Page 70: ...ot damage the throttle body It may cause incorrect throttle and idle valve The throttle body is factory pre set Do not disassemble in a way other than shown in this manual Do not loosen or tighten the white painted bolts and screws of the throttle body Loosening or tightening them can cause throttle and idle valve failure Disconnect the throttle cable end from the throttle drum ASSEMBLY Connect th...

Page 71: ...essure regulator Disconnect injector fuel hose 2 to release fuel pressure Disconnect fuel supply hose 1 Disconnect fuel return hose 3 NOTE Recommends that hose clamp be discarded and replaced each time they are removed or loosened They are one time usage only Special Tool Install the pressure regulator in the reverse order of removal TORQUE 100kgf cm ...

Page 72: ...rn the ignition switch ON The roll over sensor is normal if the power supply is closed Incline the roll over sensor approximately 65 degrees to the left or right with the ignition switch ON The roll over sensor is normal if the power supply is open If you repeat this test first turn the ignition switch OFF then turn the ignition switch ON REMOVAL INSTALLATION Disconnect the roll over sensor 2P con...

Page 73: ... connectors POWER INPUT LINE Turn the ignition switch ON Measure the voltage between the ECU and ground There should be battery voltage If there is no voltage check for an open circuit in Black White wire between the ECU and roll over sensor relay If the wire is OK check for the roll over sensor relay ...

Page 74: ...NSPECTION NOTE Before disconnecting fuel hose release the fuel pressure by loosening the pressure regulator fuel hose clamp on the injector hose Always replace the clamp when the hose is removed or loosened Disconnect the battery negative cable from the battery terminal ...

Page 75: ...DARD 300 kPa If the fuel pressure is higher than specified inspect the following Pinched or clogged fuel return hose Pressure regulator Fuel pump If the fuel pressure is lower than specified inspect the following Fuel line leaking Clogged fuel filter Pressure regulator Fuel pump After inspection remove the fuel pressure gauge and reinstall and tighten the fuel hose clamp using the new clamp Always...

Page 76: ...m 10 seconds at 12V If the fuel flow is less than specified inspect the following Pinched or clogged fuel hose and fuel return hose Clogged fuel filter Pressure regulator Fuel pump After inspection connect the fuel return hose Start the engine and check for leaks FUEL PUMP INSPECTION Turn the ignition switch ON and confirm that the fuel pump operates for a few seconds If the fuel pump does not ope...

Page 77: ...tion of fuel filter with IN mark INSTALLATION Place new packing onto the fuel tank Install the fuel pump being careful not to damage the fuel pump wire Install and tighten the fuel pump mounting nuts in the sequence shown TORQUE 120 kgf cm FUEL PUMP RELAY Disconnect the fuel pump relay 5P connector remove the fuel pump relay Connect the ohmmeter to the fuel pump relay connector terminals 30 and 87...

Page 78: ...ime use only Clamp the fuel return hose Disconnect the fuel return hose at the pressure regulator Install the following Fuel hose with mark Air vent hose Fuel pump reserve sensor 2P connector NOTE Always replace new clamp while disassemble or loosen Connect the fuel hose to the pressure regulator Connect the fuel pump reserve sensor 2P connector Connect the fuel output hose to the fuel rail with n...

Page 79: ...sor circuit open or short CPS sensor malfunction ECU malfunction INSPECTION Step 1 1 Remove the seat set 2 Remove the left side cover 3 Turn the ignition switch OFF 4 Check the CPS sensor coupler for loose or poor contacts If OK then measure the CPS sensor resistance 5 Disconnect the CPS sensor coupler and measure the resistance CPS sensor resistance 115 10 Ω Blue Sky Blue 6 If OK then check the c...

Page 80: ...nd more Blue Sky Blue Is the voltage OK YES Blue or Sky Blue wire open or shorted to ground Loose or poor contacts on the CPS sensor coupler or ECU coupler terminal 4 or 5 If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Inspect that metal partic...

Page 81: ...ssage between throttle body and T MAP sensor T MAP sensor circuit open or shorted to ground T MAP sensor malfunction ECM malfunction INSPECTION Step 1 1 Loosen and lift up the fuel tank 2 Turn the ignition switch OFF 3 Check the T MAP sensor couple for loose or poor contacts If OK then measure the T MAP sensor input voltage 4 Disconnect the T MAP sensor coupler 5 Turn the ignition switch ON 6 Meas...

Page 82: ...speed and measure the T MAP sensor output voltage at the wire side coupler T MAP sensor output voltage Approx 2 6 V at idle speed Yellow Black Gray Red Is the voltage OK YES Yellow Black or Gray Red wire open or shorted to ground or poor 18 30 or 1 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection...

Page 83: ... circuit open or shorted to ground or VSENS circuit open Sensor voltage is higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Loosen and lift up the fuel tank 2 Turn the ignition switch OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then measure the TP sensor input voltage 4 Disconnect the TP sens...

Page 84: ...ity between W Br wire and Y B wire If the sound is not heard from the tester the circuit condition is OK 6 Disconnect the ECU coupler 7 Check the continuity between W Br wire and terminal 31 8 Also check the continuity between Gr R wire and terminal 27 TPS lead wire continuity Continuity sound Is the continuity OK YES Go to next step 2 NO W Br wire shorted to VSENS or SGND1 wire open 9 After repai...

Page 85: ...B wire or Gr R wire open or Gr R wire shorted to ground 10 After repairing the trouble clear the DTC using Diagnosis tool Step 2 1 Turn the ignition switch OFF 2 Disconnect the TP sensor coupler 3 Check the continuity between W Br wire and ground TP sensor continuity Ω Infinity White Brown Ground 4 If OK then measure the TP sensor resistance at the terminals between Bottom and Center pin 5 Turn th...

Page 86: ... coupler between W Br wire and Gr R wire by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 1 1 V Throttle valve is opened Approx 4 4 V Is the voltage OK YES Y B W Br or Gr R wire open or shorted to ground or poor 1 31 or 27 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor...

Page 87: ...s higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Turn the ignition switch OFF 2 Check the ECT sensor coupler for loose or poor contacts If OK then measure the ECT sensor voltage at the wire side coupler 3 Disconnect the ECT sensor coupler and turn the ignition switch ON 4 Measure the voltage between Y R wire term...

Page 88: ...the continuity between Y R wire and terminal 42 7 Also check the continuity between Gr R wire and terminal 27 ECTS lead wire continuity Continuity sound Is the continuity OK YES Go to step 2 NO Y R or Gr R wire open 8 After repairing the trouble clear the DTC using Diagnosis tool Step 1 When sensor voltage is lower than specified 1 Turn the ignition switch OFF 2 Check the ECT sensor coupler for lo...

Page 89: ...T sensor resistance Approx 2 3 2 6 kΩ at 20 C 68 F Terminal Terminal Is the resistance OK YES Y R or Gr R wire open or shorted to ground or poor 42 or 27 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Replace ECT sensor with a new on...

Page 90: ...diagnosing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition switch couplers YES Go to step 2 NO Poor connection of couplers Step 2 1 Measure the battery voltage between input lead wires at the ECU with the ignition switch in the ON position Is the voltage OK YES Go to step 3 NO Faulty ignition switch Broken wire harness or poor connection of rela...

Page 91: ...OK YES Go to step 5 NO Faulty spark plug s Step 5 1 Inspect the ignition coils Are the ignition coils OK YES Go to step 6 NO Faulty ignition coil s Step 6 1 Measure the CPS sensor peak voltage and its resistance NOTE The CPS peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Are the peak voltage and its resistance OK YES Faulty ECU Open or short circuit ...

Page 92: ...easure the injector resistance 3 Disconnect the injector coupler and measure the resistance between terminals Injector resistance Approx 11 7 Ω at 20 C 68 F Terminal Terminal 4 If OK then check the continuity between each terminal and ground STP sensor continuity Ω Infinity Are the resistance and continuity OK YES Go to step 2 NO Replace the injector with a new one 5 After repairing the trouble cl...

Page 93: ...n or shorted to ground or poor 47 connection cylinder side If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Open circuit in the R wire 3 After repairing the trouble clear the DTC using Diagnosis tool 47 ...

Page 94: ...the seat 2 Turn the main switch OFF 3 Check the FP relay coupler for loose or poor contacts If OK then check the FP relay Is the FP relay OK YES Blue wire open or shorted to ground or poor 9 connection Red wire open or poor 11 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with ...

Page 95: ...it open or short TO sensor malfunction ECU malfunction TO sensor circuit open or shorted to VSENS or ground circuit open TO sensor circuit shorted to ground or VSENS circuit open Sensor voltage is higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Remove the seat set 2 Turn the ignition switch OFF 3 Check the Roll ov...

Page 96: ... YES Go to step 2 NO Pu B wire shorted to VBR 8 After repairing the trouble clear the DTC using Diagnosis tool When sensor voltage is lower than specified 1 Remove the seat set 2 Turn the ignition switch OFF 3 Check the Roll over sensor coupler for loose or poor contacts If OK then check the Roll over sensor lead wire continuity 4 Disconnect the Roll over sensor coupler 5 Check the continuity betw...

Page 97: ...Pu B B 5 Dismount the Roll over sensor from its bracket and measure the voltage when it is leaned 65 and more left and right from the horizontal level Roll over sensor voltage Leaning 3 7 4 4 V Pu B B Is the voltage OK YES Y B or Pu B wire open or shorted to ground or poor 1 or 16 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for...

Page 98: ...lead wire coupler for loose or poor contacts 4 Remove the air cleaner rubber tube 5 Turn the ignition switch ON to check the ISC operation ISC operating order 95 open full open 95 open Is the operating OK YES Go to step 2 NO Loose or poor contacts on the ISC coupler Open or short circuit in the Br B G B Y B or B Y wires If wire and connection are OK go to Step 2 6 After repairing the trouble clear...

Page 99: ...28 39 40 and 41 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Loose or poor contacts on the ECU coupler Replace new ISC throttle body 5 After repairing the trouble clear the DTC using Diagnosis tool Measure the resistance between A ...

Page 100: ...4 1 FUEL INJECTION SYSTEM 4 1 52 Fault Diagnosis EFI Circuit inspection ...

Page 101: ...4 1 FUEL INJECTION SYSTEM 4 1 53 Can not Start the engine or difficult to start inspection ...

Page 102: ...4 1 FUEL INJECTION SYSTEM 4 1 54 Idle flameout diagnosis ...

Page 103: ...4 1 FUEL INJECTION SYSTEM 4 1 55 Integrated Fault Diagnosis Program ...

Page 104: ...ruled out or repair after the MIL light will be extinguished but ECU fault code will be recorded so the need to get rid of fault codes Diagnosis tool for overhaul Diagnosis tool will connect to the motorcycle for coupler diagnosis according to the use of diagnostic tool testing methods when belong fuel injection system fault or parts fault according to the diagnosis tool of the fault code display ...

Page 105: ...temperature intermittent diagnosis failure 17 P0121 TPS position sensor adaptation diagnosis out of range 18 P0122 Throttle Position Sensor 1 SCG_OL 19 P0123 Throttle Position Sensor 1 SCP 20 P0131 Lambda sensor 0 diagnosis SCG 21 P0132 Lambda sensor 0 diagnosis SCP 22 P0133 Lambda sensor 0 diagnosis OL 23 P0151 Lambda sensor 1 diagnosis SCG 24 P0152 Lambda sensor 1 diagnosis SCP 25 P0153 Lambda s...

Page 106: ... diagnosis too low _VBK 51 P0563 Battery voltage diagnosis too high _VBK 52 P0608 Reference voltage diagnosis SCP 53 P0609 Reference voltage diagnosis SCG_OL 54 P0615 Starter 1 diagnosis OL 55 P0616 Starter 1 diagnosis SCG 56 P0617 Starter 1 diagnosis SCP 57 P0630 VIN coherence 58 P0651 MIL diagnosis SCG OL 59 P0652 MIL diagnosis SCP 60 P1352 Ignition diagnosis 0 SCG_OL 61 P1353 Ignition diagnosis...

Page 107: ... Method of Use 1 Connected to the diagnostic connector for diagnosis tool NACS TGB interface Transfer Cable TGB 3 pin 6 pin Diagnosis Cable Vehicle 2 When the IG of the motorcycle is on the system starts to run entering into boot screen 3 Key ON and the diagnosis display screen appeared the words connection 4 Press the ENTER button and the system will identify the vehicle model automatically and d...

Page 108: ...e Note Press ENTER button to the function menu Options main functional areas 1 Vehicle Info 2 Diagnostic Trouble Code 3 Live Data 4 Actuator 5 Special Function Press button to choose one function 1 Vehicle Info Move the cursor to Vehicle Info and press ENTER to see the content This is the page of Vehicle Info press button to view all vehicle info ...

Page 109: ...ent Current is for the Diagnostic Trouble Code occurred at the time 2 2 History History is for Diagnostic Trouble Code occurred in the past Move the cursor to Current and press ENTER to continue After entering the page press to view all the Diagnostic Trouble Code After viewing the Diagnostic Trouble Code press ESC to return to the previous page ...

Page 110: ... more items on the screen Freeze Data and Erase DTC Freeze Data is the data recorded when FIRST Diagnostic Trouble Code occurred and one time only record one Diagnostic Trouble Code freeze data it s for saving the engine dynamic data for further analysis Erase DTC is the function to erase all Diagnostic Trouble Code in both Current and History 2 3 Freeze Data This is the content you will see when ...

Page 111: ... 02 03 Engine temp Lambda Control volt Battery volt Atmospheric pressure Intake air temp 2 4 Erase DTC Move the cursor to Erase DTC item and press ENTER to EARSE ALL DIAGNOSTIC TROUBLE CODE DIRECTLY When you see the following picture on the screen the Diagnostic Trouble Code erasure is completed Press ESC button back to the main menu ...

Page 112: ...o the main menu move the cursor to Live Data and press ENTER to view the content Press button to view all Live Data 4 Actuator Move the cursor to Activator and press ENTER to see the content To perform this function IG must be ON and engine stop running ...

Page 113: ...ve the cursor to Ignition coil item and press ENTER to continue When pressing Actuating button the test is activated and the Value column shows Open When pressing Stop Actuating button the test is de activated and the Value column shows close 5 Special Function Move the cursor to Special Function and press ENTER to view the content ...

Page 114: ...ere are two items under Special Function Reset TPS and Reset Adaptive Move the cursor to Reset TPS and press ENTER Then you will see the following picture which means the RESET is completed Press ESC button to return to the previous page ...

Page 115: ...ION SYSTEM 4 1 67 Troubleshooting Table Notes 1 Integrated test motorcycle according to the Comprehensive Maintenance list implementation 2 Spare parts according to the EFI System components description implementation ...

Page 116: ...g fault Roll over sensor fault ECU No 12 pin fault Ignition coil fault Crankshaft position sensor fault 4 Engine vacuum Diagnosis tool to detect the use of Manifold pressure of diagnosis tool Manifold pressure 32 38 kPa Valve clearance abnormal Intake system leak 5 Injection state The injector removed from the throttle body but not dismantle pipeline Main switch ON but not start engine Investigati...

Page 117: ... engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutch Crankcase RH cover Clutch housing assy Unidirectional clutch Clutch assy Specification Torque Value Engine hanger bolt 5 4 5 9kgf m Exhaust muffler mounting bolt 2 8 3 2kgf m Exhaust muffler connection nut 1 0 1 4kgf m Item Capacity Engine oi...

Page 118: ... the following Steps Reinstall the engine by reversing the removal procedure Before removal the engine Drain engine oil Remove the seat Remove the seat lock plate Remove battery negative post Remove battery positive post Remove the starter motor wire Remove the front fender side cover L and R Remove the footrest nut guard L and R Remove the Fuel tank cover ...

Page 119: ...5 ENGINE REMOVAL 5 3 Remove the gearshift lever Remove the fuel hose and vacuum hose Remove the air cleaner Remove the cover of throttle body Fuel pipe Vacuum pipe ...

Page 120: ...E REMOVAL 5 4 Remove the speedometer cable Remove the gearshift mud Remove the connector of lead wire Remove the signal generator lead wire connector and generator lead wire connector Remove the spark plug cap ...

Page 121: ...5 ENGINE REMOVAL 5 5 Remove the right footrest Remove the brake pedal Remove the muffler Remove the exhaust pipe ...

Page 122: ...t and rear tube Remove the front shaft bolts and springs Remove the selflock nut and take out the bolt Note Install the selflock nut with specified torque 540 590 kgf cm Remove the nut onto the bush and take down engine bolster each side ...

Page 123: ...nd take out the bush from first hole each side Remove the selflock nut and take out the bolt Note Install the selflock nut with specified torque 540 590 kgf cm Take down the bush each side Note The flange of bush points to inside Longer Front hole Inside ...

Page 124: ...ve the nut and selflock nut Take out the engine bolster bolt and washers Note Install the selflock nut with specified torque 540 590 kgf cm Remove the nut Take out the bush Remove the bolt and take out the engine bolster Longer ...

Page 125: ...lf locking once the nut was been removed it is no longer of any use Be sure to use new nuts For every time engine installation and tighten them according the torque standard Torque value 5 4 5 9 kgf m Install the spring shorter N P 925334 into front differential assy Install the spring into rear differential assy Front Differential Assy ...

Page 126: ...5kgf m 32 5lb ft Install the gasket Check if the gasket has been damage Please replace with the new one Apply sealant to the muffler mounting bolt Install muffler Pay attention don t damage the connector Tighten the exhaust pipe nuts and muffler bolts with specified torque Rear Differential Assy ...

Page 127: ... mounting bolt to the muffler fixed bolts and tighten them Apply sealant to the muffler mounting bolt to the muffler fixed bolts and tighten them N A Install 2 muffler s bolt comp from the rear frame At first install blot washer and bush with specified torque 30 40 kgf cm Then install the nut with specified torque 250 300 kgf cm ...

Page 128: ...ssembly Remove starter motor wire Remove oil pressure switch s wire Remove the hose Remove the spark plug cap Remove the wire Remove the thermostat Remove the spring bolt and remove the cam chain tensioner adjuster assy Spark Plug Cap ...

Page 129: ...5 ENGINE REMOVAL 5 13 Remove the engine oil pipe nuts Remove the outlet water hose ...

Page 130: ...peration 6 2 Troubleshooting 6 3 Cylinder Head Removal 6 4 Cylinder Head Inspection 6 7 Valve Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram ...

Page 131: ...12 5 030 5 000 5 012 5 030 Clearance between valve stem and guide Intake 0 010 0 037 0 080 0 010 0 037 0 080 Exhaust 0 025 0 062 0 100 0 025 0 062 0 100 Free length of valve spring Inner 36 32 5 Outer 39 5 36 0 41 1 37 6 Valve seat width 1 600 1 600 Valve clearance Intake 0 10 0 02mm 0 10 0 02mm Exhaust 0 15 0 02mm 0 15 0 02mm Torque Value Cylinder head cover bolt 1 0 1 2kgf m Exhaust pipe stud bo...

Page 132: ... or bent valve Improper valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure 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 loo...

Page 133: ...move 1 bolt of thermostat and then remove the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove spark plug Remove the screws of cylinder head 2 bolts Remove the nuts of cylinder 2 nuts Thermostat bolts Tensioner bolts Bolts ...

Page 134: ...ad cover and hole bolts 4 bolts Remove fix stand for spindle cam 6 bolts Remove cam sprocket bolts and then remove the sprocket by prying chain out Remove cam chain tensioner and hole bolt Remove cam shafts Remove Rocker arm and cam shaft puller ...

Page 135: ...urfaces of cylinder and cylinder head Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the...

Page 136: ...nder head Cylinder 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 33 12mm EX Replacement when less than 33 10mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of cam...

Page 137: ...n it is less than 11 954 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit 37 6mm spring 41 1 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure re...

Page 138: ... valve stem is the clearance between the valve stem and valve guide Service Limit IN 0 10 mm EX 0 15 mm Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after repla...

Page 139: ...ew valve guide is deformation after pressed 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 Usi...

Page 140: ...ne if valve seal is roughness wears 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 ...

Page 141: ...th 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 seat with 60 cutt...

Page 142: ... of valve spring should face down to combustion chamber Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve cotter remove assembly tool Tap th...

Page 143: ... First torque M10 cylinder head bolts with LOCTITLE in cross sequence to 20 Nm 1 Nm two times then finish by tightening to 180 5 Caution Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Screw M6 1 0 1 2kgf m Nut M6 1 0 1 2kgf m Install camshaft into cylinder head Install rocker arm rocker arm shaft In...

Page 144: ...k washer so that it is covering the locating pin Bend up the washer tongue positively to lock bolts Align the line Ⓐ on the generator rotor with the index mark Ⓑ on the crankcase Loosen auto tensioner adjustment bolt and remove bolt and spring Install tensioner and install spring and adjustment bolt Install thermostat 2 bolts Install cylinder cover 4 bolts Tighten cylinder head cover retaining bol...

Page 145: ...or with the index mark Ⓑ on the crankcase 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 Start the engine and make sure that engine oil flows onto the cyli...

Page 146: ...PISTON 7 1 Mechanism Diagram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram ...

Page 147: ...nd cylinder 0 04 0 058 0 12 0 04 0 058 0 12 ID of piston pin boss 22 001 22 006 22 020 22 001 22 006 22 020 OD of piston pin 21 996 22 000 21 960 21 996 22 000 21 960 Clearance between piston and piston pin 0 001 0 010 0 020 0 001 0 010 0 020 ID of connecting rod small end 22 002 22 01 22 040 22 002 22 01 22 040 Trouble Diagnosis Low or Unstable Compression Pressure Cylinder or piston ring worn ou...

Page 148: ...ston pin and piston Remove cylinder 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 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 re...

Page 149: ...it Top ring 0 09 mm 2nd ring 0 09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn 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 ...

Page 150: ...e inner diameter of piston pin hole Service Limit 20 020 mm Calculate clearance between piston pin and its hole Service Limit 0 2 mm Measure piston outer diameter Caution The measurement position is 8 mm distance from piston bottom side and 90 to piston pin Service limit 85 850 mm Compare measured value with service limit to calculate the clearance between piston and cylinder ...

Page 151: ...on ring onto piston carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rings can be rotated freely after installed Top ring N 2nd ring 2R Oil ring 110 125 125 ...

Page 152: ...residues can be removed more easily Piston Installation Install piston and piston pin and place the marks on the piston topside forward to exhaust 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 Cylinder Installa...

Page 153: ...rings Care to be taken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 ...

Page 154: ...8 V BELT DRIVING SYSTEM 8 1 Mechanism Diagram 8 1 Maintenance Description 8 2 Trouble Diagnosis 8 2 Clutch Cover 8 3 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram ...

Page 155: ...ulley boss 44 965 44 985 mm 40 935 mm ID of driven face 45 000 45 035 mm 45 600 mm Weight of weight roller 13 300 13 500 g 13 800 g Torque value Drive face nut 10 12kgf m Clutch outer nut 10 12 0kgf m Drive plate nut 10 12kgf m Special Service Tools Clutch spring compressor Inner bearing puller TGB Clutch nut wrench 27 x 15 mm TGB Universal holder TGB Bearing driver TGB Trouble Diagnosis Engine ca...

Page 156: ... and gasket Clutch cover install Install left clutch cover in the reverse procedures of removal Clutch over inspection Check bearing on clutch 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 ...

Page 157: ...n gear system 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 27 0 mm Replace the belt if...

Page 158: ...ey that has installed the belt onto drive shaft On the drive belt another end to the movable drive face Install the clutch outer Hold the clutch outer whit universal holder and then tighten nut to specified torque value Torque value 10 12kgf m Special Tool Clutch And CVT Holder 440666 Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to spe...

Page 159: ...over Hold drive face with universal holder and then remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Drive face boss Movable drive face ...

Page 160: ...boss is worn or damaged and replace it if necessary Measure the outer diameter of movable drive face boss and replace it if it exceed service limit Service limit 26 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 27 060 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same ...

Page 161: ...ng solvent Driven pulley installation By 2 screw Press drive belt into pulley groove and then pull the belt onto drive shaft Install Movable drive face and nut Loosen the 2 screws 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 10 12kgf m Install left cra...

Page 162: ...ove mounting nut with special service tool Release the clutch spring compressor and remove movable driven sheave and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable driven face and then remove O ring oil seal seat from movable driven face Inspection Clutch outer Measure the inner diameter of clutch outer Replace the clutch outer if exce...

Page 163: ...ck following items If both surfaces are damaged or worn If guide pin groove is damaged or worn Replace damaged or worn components Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 44 93 mm Inner diameter 45 60 mm Free Length Driven Face Driven Face Guide Pin Groove ...

Page 164: ...all the guide pin and guide pin roller Install the collar Install friction plate spring and into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install driven pu...

Page 165: ...8 V BELT DRIVING SYSTEM 8 12 Notes ...

Page 166: ...9 1 FRONT DIFFERENTIAL 9 1 1 FRONT DRIVE FRONT DIFFERENTIAL ...

Page 167: ...lled as per factory standards WHEEL HUB Wheel Hub Removal Lift and support vehicle Place the transmission lever on P Remove caliper from knuckle Remove the following parts Wheel Cotter pin Castellated nut Washer Remove wheel hub Wheel Hub Inspection Check wheel hub for cracks or other damages Check inner splines for wear or other damages If any damage is detected on wheel hub replace it with a new...

Page 168: ...ive wear Replace if necessary NOTE If the splines on plunging joint are worn a check of differential inner splines should be done INSTALLATION For installation reverse the removal procedure Install a NEW stop ring Apply SYNTHETIC GREASE to the splines The wear ring should be closed to the differential Reinstall all removed parts DRIVE SHAFT BOOT REMOVAL Remove the drive shaft from the vehicle Remo...

Page 169: ...not use or add other grease Install new drive shaft clamps FRONT DIFFERENTIAL REMOVAL Caution Be sure the differential set temperature below 35 Drain the differential oil Remove both drive shafts Detach vent hose from front differential Remove 2WD 4WD mode select cables Remove LOCK mode select cables Remove securing the differential bolts and nuts ...

Page 170: ... the RH side NOTICE Be careful not to knock or to bend vent hose fitting while removing front differential Loose and remove six bolts on the LOCK cover Check the shift fork oil seal replace if damage Check the LOCK cover bearing replace if necessary FRONT DIFFERENTIAL DISASSEMBLY Loose and remove six differential housing bolts then separate half housings ...

Page 171: ...NTIAL 9 1 2 Check the oil seal replace if necessary Remove the anti slip gear set A and shim B check the bearing replace if necessary Remove the C clip Remove the oil seal and discard replace new one when reassemble A B ...

Page 172: ... pull out the bearing Check the bearing replace if necessary Using plier remove the C clip Using rubber hammer lightly knock out the pivot gear Remove the C clip as shown and pull out the shift shaft Remove the oil seal and pull out the shift shaft ...

Page 173: ...ase NOTE Before apply Loctite clean the old glue Cross tighten the bolts as shown Torque 120 150kgf cm Apply the Loctite 510 on the contact surface of LOCK cover NOTE Before apply Loctite clean the old glue Install the dowel pin Cross tighten the LOCK cover bolts as shown Torque 120 150kgf cm ...

Page 174: ...ING LOCK MODE CABLE ADJUSTMENT Loose jam nut to adjust the cable length Adjust the suitable length by the rotate the nuts as shown Apply special tool 552309 1 on the position as shown and adjust the cable length 2WD 4WD MODE CABLE ADJUSTMENT Apply special tool 552309 2 on the position as shown and adjust the cable length A B ...

Page 175: ...rocedure Fill the gear oil and tighten the bolt Caution Oil standard SAE 90 hypoid gear oil Oil capacity 350c c Bolt Torque 33N m DIFFERENTIAL MOTOR Disconnected the wiring connector Unscrew three differential motor bolts INSTALLATION For installation reverse the removal procedure ...

Page 176: ...9 2 REAR DIFFERENTIAL 9 2 1 REAR DRIVE REAR DIFFERENTIAL A 4 2 4 4 kgf m B 3 0 3 5 kgf m C 0 7 0 9 kgf m D 2 0 2 2 kgf m E F 1 2 1 5 kgf m G 11 12kgf m ...

Page 177: ...e the lock mode cables Remove the four bolts and bracket as shown Remove the upper front end three bolts from the frame as shown Remove front end upper and bottom bolts as shown Lift up the differential and slide backward to detach from the propeller shaft Remove the rear differential by pulling it from the RH side NOTICE Be careful not to knock or to bend vent hose fitting while removing front di...

Page 178: ...d Install the rear differential and insert the differential shaft into the connecting shaft put the boot on the position as shown Install rear brackets and tighten with bolts washers and nuts as shown Torque 4 5 5 5kgf m Assemble the upper bracket and tighten with three bolts on the front top of rear differential as shown Torque 2 2 2 5kgf m ...

Page 179: ... keep the vent hose away from the exhaust Install the cable apply special tool 560023 to adjust the length Tighten the nut Torque 1 2 1 5kgf m Reverse the removal procedure install the relative parts Refill the gear oil to 500 cc and tighten the bolt and washer Caution Oil standard SAE 90 hypoid gear oil Oil capacity 500 c c Torque 3 0 3 5 kgf m ...

Page 180: ...ERENTIAL DISASSEMBLY Remove the differential housing eight bolts Apply rubber hammer lightly knock the case red area as shown to separate the half case Check O ring replace if necessary Remove the anti slip limited gear assy and the shims ...

Page 181: ...replace if necessary NOTE beware the foreign object falling into the slip limited gear assy Check the bearing on the left half case replace if necessary Check oil seal replace if necessary NOTE Apply grease on rear area as shown before install oil seal ...

Page 182: ...e as shown Install anti slip limited gear assy into the case and apply rubber hammer lightly knock to the position as shown Install two dowel pin on the left half case Apply Loctite 263 on the eight bolts and cross tighten NOTE Ensure the O ring install properly Torque 2 0 2 2kgf m ...

Page 183: ...ASSEMBLE Remove five bolts Apply rubber hammer light knock to separate the case Check the oil seal replace if necessary NOTE shift shaft seal recommend replace after assemble Check bearing replace if necessary Remove shift rod assy and other parts ...

Page 184: ...R DIFFERENTIAL 9 2 1 LOCK MODE ASSY ASSEMBLE Install the two dowel pin as shown Install the lock sleeve and shift rod Clean the old glue and apply Loctite 510 on the contact surface as shown Assemble the case ...

Page 185: ... S70810 is shortest bolt Torque 1 2 1 5kgf m NOTE Check and test the shift rod function Install shift rod oil seal Install bracket and tighten the two bolts Install the LOCK cable REAR DIFFERENTIAL ADJUSTMENT Using special tool to adjust the cable Adjust the suitable length by the rotate the nuts ...

Page 186: ...replace if necessary Using special tool 560010 to remove the ring snap Apply rubber hammer from the inside of case lightly knock out the gear to remove the shaft from the case NOTE Beware the knocking might damage the bearing Check the bearing replace if necessary Before install new bearing apply some lubricate oil inside the bearing ...

Page 187: ...te 263 on the ring snap and Apply special tool 560010 to install Torque 11 12kgf m Apply Loctite 263 on the four bolts and install the housing and tighten Torque 4 2 4 4kgf m DIFFERENTIAL MOTOR REMOVAL Disconnected the wiring connector Unscrew three differential motor bolts INSTALLATION For installation reverse the removal procedure ...

Page 188: ...ase Cover Removal 10 3 A C G Set Removal 10 3 Lift 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 3 0 3 5kgf m 16 18kgf m 1 0 1 5kgf m 0 8 1 2kgf m 1 0 1 5kgf m 4 0 5 0kgf m ...

Page 189: ... precaution items of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 29 OD of starting clutch gear 52 548 52 445 Torque value Flywheel nut 16 18kgf m Not to be reused should be replaced when disassembled Starting clutch hexagon bolt 1 2 1 5kgf m with adhesive 8 mm bolts 2 8 3 0kgf m 12 mm bolts 1 0 1 4kgf m Tools Special tools A C G flywheel puller 440659 ...

Page 190: ...ove dowel pin and gasket A C G Set Removal Remove 3 mounted screws from pulse generator and then remove it Prized open three fixed points Remove 3 screws from left crankcase cover and then remove generator coil set Left 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...

Page 191: ...ry Install a new one bearing 16005 by bearing driver Flywheel Removal Remove left crankcase cover Remove starter reduction gear and shaft Pull out flywheel with A C G flywheel puller Special tool A C G Flywheel puller 440659 Remove flywheel and starting driven gear Oil seal Bearing Flywheel nut ...

Page 192: ...ng clutch driven gear Service Limit ID 29 mm OD 52 54mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage Install starting clutch driven gear onto one way clutch Hold flywheel and rotate starting clutch gear The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure OD ID ...

Page 193: ...t bolts and then remove one way clutch One way clutch Installation Install the components in the reverse procedures of removal Caution Tape a tightening tape onto the thread of hexagon bolt Torque value 3 0 3 5kgf m Starting driven gear 6 socket bolts One way clutch Starting driven gear 6 socket bolts ...

Page 194: ...ve and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Caution Flywheel nut not to be reused should be replaced when disassembled Torque value 16 18kgf m Special tool Flywheel Puller 440664 Install reduction gear shaft and reduction gear Starting driven gear Groove Reduction gear ...

Page 195: ...ly to lock screws Install pulse generator 3 screws Tie the wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator Left Crankcase Cover Installation Install dowel pin and new gasket Remove water pump cover Install left crankcase cover onto the crankcase Note Align the water pump shaft indent with the water pump gear shaft Dowel pin...

Page 196: ...NG CLUTCH 10 9 Install left crankcase cover 15 screws Install the dowel pin new gasket and water pump cover onto left crankcase cover Install the water pipe Install the recoil starter assy 4 bolts Water pump bolts 15 bolts ...

Page 197: ...10 ALTERNATOR STARTING CLUTCH 10 10 Note ...

Page 198: ...11 CRANKSHAFT CRANKCASE 11 1 L CASE R CASE ...

Page 199: ... Install the oil seal with the special tool Bearing installer set 440655 Caution Change the new oil seal to prevent oil leakage NOTE Be sure the stamped mark on the oil seal faces outside OIL SEPARATOR When installing the oil guide plate apply a small quantity of Loctite 262TM Thread locker to the screw ...

Page 200: ...EARING REASEMBLY Install the bearing NOTE Be sure The sealed cover of the bearing must face outside Install the chuck Bearing NOTE When installing the Bearing chuck apply a small quantity of Loctite 262TM Thread locker to the screws ...

Page 201: ...KCASE 11 4 DRIVE BELT COVER Remove the snap ring with the snap ring pliers NOTE If any damage the bearing replace the new one Remove the bearing REASSEMBLY Install the bearing Install the snap ring with snap ring pliers ...

Page 202: ... Torque Oil pressure value 25N M 2 5kgf m 17lb ft Using an shaped tool to check the oil pressure valve Operation If the piston does not operate replace the new one ASSEMBLY Remove the generator stator Remove the oil seal retainer of crank case cover NOTE If the bearing is not abnormal noise these is not necessary to replace the new one ...

Page 203: ... bearing Apply Grease to the bearing O ring and Oil seal lip Install the oil seal NOTE When installing the oil seals be sure the stamped mark on the oil seal faces outside Apply a small quantity of Loctite 262TM Thread locker to the screws and install the bearing retainer ...

Page 204: ...er as an attachment Front fork oil seal installer 440655 Apply a small quantity of Loctite 262TM Thread locker to the thread and install and the gearshift cam stopper BALANCER Install the balancershaft Install the key Install the balancershaft driven gear Install the driven gear balancershaft by aligning the punched marks ...

Page 205: ...11 CRANKSHAFT CRANKCASE 11 8 Apply Loctite 510 Flange sealant to the mating surface of the left crankcase L CASE R CASE ...

Page 206: ... check if crankshaft rotate smoothly Fit the clamp to the bolt Check the each shaft rotates smoothly after the crankcase bolts have been tightend OIL PUMP Install the oil pump Install the washer and pin Install the oil pump driven gear Install the snap ring with snap ring pliers NOTE Assemble the oil pump gear as show ...

Page 207: ...ump drive gear bolt to the specified torque Oil pump drive gear bolt 50 N M 5 0 kgf m 37 lb ft Idler Gear Puller 440665 CAM CHAIN Install the cam chain CLUTCH SHOE Install the clutch shoe assembly Apply Loctite 262TM Thread locker to the clutch shoe nut Tighten nut to the torque with the special tool Shoe nut torque 160 N M 16 kgf m 116 lb ft Clutch And CVT Holder 440666 Caution The nut of clutch ...

Page 208: ... Caution The one way clutch outside facing must on the shaft outside NEUTRAL SWITCH Install the springs and switch contacts Install the neutral switch CLUTCH CASE Install the dowel pins and put the new gasket Tighten the clutch case bolts Install the collar OUTSIDE ...

Page 209: ...e fixed drive face MOVABLE DRIVE DRIVEN FACE AND DRIVE BELT Install the drive belt between the movable driven face and fixed driven face by tapping with a plastic mallet Caution The drive belt contact surface of the driven face should be thoroughly cleaned Install the movable driven face assembly ...

Page 210: ...face until the belt is seated in and both the drive and driven faces check the belt without slip CLUTCH COVER Install the dowel pins and new gasket Install the clutch cover OIL FILTER Apply engine oil lightly to the O ring Install the oil filter turning it by hand until feeling that the filter gasket contacts the surface of case Then Tighten it 2 turns using the oil filter wrench Oil filter Instal...

Page 211: ...ater pump gears as show Install the water pump gears with special tool Install the washer Chain Wheel Washer Installer 440660 Install the water pump gears and tighe the nut NOTE Make sure the crankshaft can turning smoothly If any resistance remove the screw re associate the screw again Install the wash ...

Page 212: ...ts Caution Be sure the one way clutch on the crankshaft is fitted into the generator rotor properly Tighten the generator rotor nut to the specified torque with the special tool Generator rotor nut 160 N M 16 0 kgf m 125 lb ft Flywheel Puller 440664 Install the output drive gear by installing the snap ring ...

Page 213: ...Reassemble the gearshift shaft Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear STARTER DRIVEN GEAR IDLE GEAR Install the starter idle gear and driver gear LEFT CRANKCASE COVER Install the dowel pins and put the new gasket ...

Page 214: ...bolt NOTE Fit the clamp to the bolt SPEEDOMETER GEARBOX Fit a new gasket and install the speedometer gearbox WATER PUMP Check the water pump shaft position with water pump gear shaft Apply engine oil on the O ring of water pump Install water pump Tighten the screw ...

Page 215: ...rter cup Tighten the starter cup nut by using a suitable bar Starter cup nut 35 N M 3 5 kgf m 25 lb ft Cup Starter Holder 440658 Install 4 studs and then put 2 gaskets and 2 O rings Install the oil pipe Put 4 spring washers and tighten 4 nuts Special torque 1 2 kgf m O ring Gasket Stud Spring Washer Nut Oil pipe ...

Page 216: ...CASE 11 19 GEARSHIFT for Parking Install the Gear Stopper 925735 Torque 2 7 kgf m Assemble the Secondary dial pole 925742 Install the Secondary dial pole by aligning the punched mark with the center of the cam driven gear ...

Page 217: ...11 CRANKSHAFT CRANKCASE 11 20 NOTE ...

Page 218: ...em Specification Pressure to open filler cap 0 9 0 15 kgf cm2 Capacity of coolant Engine radiator 2200c c Reservoir upper 1200c c Thermostat Begins to activate at 65 72 Stroke 0 05 5mm Cooling fan switch Begins to activate at 85 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump impeller 1 0 1 4kgf m Trouble Diagnosis The engine temperature is too high The water therm...

Page 219: ...ir Water hose clogged Replace thermo unit B 2 Inspect the circuits of water temperature have short or earth Y Y Y Meter problem Short or earth handle N N N Y N N N N The temperature indicated is too high A Stop and waiting for the engine is completely cooled down open cap to check the capacity of coolant in radiator A1 Refill the radiator with coolant then check for any leakage B Turn on main swit...

Page 220: ... 4000 rpm and inspect coolant flow into reserve tank after the temperature gauge over 3 checks For bleed the air bubbles completely open radiator cap and start engine while engine is cool then press water hose softly by hand to bleeding Turn the throttle repeatedly until the coolant surface becomes stable Preceding page Notice the water hose can t any unsuitable bend or twist and bleed the air bub...

Page 221: ...of coolant 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 air bubble only has the coolant to flow out then...

Page 222: ...s not high after avoids the water temperature elevating in the cooling system the refrigerant backflow floods Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink...

Page 223: ...an motor Assembly Install 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 4 bolts Please refer to chapter 17 for the inspection of the cooling fan switch Caution Liquid packing must be applied to the cooling fan switch before install...

Page 224: ...e the phenomenon possibly for the water pump inner two seal damages the engine cooling system damages or the cylinder and the cylinder head gasket damages please first dismantles the right crank case to say A confirms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen th...

Page 225: ... Whenever 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 65 72 Valve stroke 0 05 5mm Installation Install the thermostat Install ...

Page 226: ...ater jet to clean it Remove two oil pipes Remove 3 bolts from the water radiator Remove the bolt of protector s upper right corner and take down clip P Installation Install the removed parts in the reverse order of removal Note Oil radiator s capacity is 170 ml Two oil pipes total capacity is 190 ml If the oil content is empty in the engine internal oil pipe and oil radiator must to add 3 86 L eng...

Page 227: ...12 COOLING SYSTEM 12 10 Note ...

Page 228: ...13 BODY COVER 13 1 BLADE MODEL Mechanism Diagram ...

Page 229: ...covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the quad and the covers during assembly 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 Re...

Page 230: ...t Remove 2 bolts from battery fixed Remove 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 ...

Page 231: ...Remove M6 bolts from right or left foot 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 ...

Page 232: ...then remove front bumper Remove bolts from right and left headlamp 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 ...

Page 233: ... BODY COVER 13 6 Remove lock cap Remove 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 ...

Page 234: ...remove starting motor relay Remove 1 bolts from rear body covert Remove 1 nut from rear 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 ...

Page 235: ...side 2 screws and then remove rear body 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 ...

Page 236: ...ar protector each side 1 bolts and then remove bear protector Remove 7 screws from upper bracket assembly Remove speedometer assembly couplers and then remove upper bracket assembly Installation Install in reverse order of removal procedures ...

Page 237: ...13 BODY COVER 13 10 TARGET MODEL ...

Page 238: ...covers Make sure that each hook is properly installed during the assembly Never compact forcefully or hammer the quard and the covers during assembly 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...

Page 239: ...ove 2 wire from battery Remove battery 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 ...

Page 240: ...13 Remove 6 bolts from 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 ...

Page 241: ... the part 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 ...

Page 242: ...h side 5 bolts Remove right or left foot 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 ...

Page 243: ...14 BRAKE SYSTEM 14 1 BRAKE FRONT BRAKE ...

Page 244: ...14 BRAKE SYSTEM AND BODY COVER 14 2 REAR BRAKE ...

Page 245: ...Item Standard Service Limit Bake Pad Thickness 1 5 mm Brake Disc Thickness 3 75 mm 3 24 mm Brake Disc Run out 0 25 mm Caliper Piston Diameter 33 86 mm 33 81 mm Caliper Bore Diameter 33 96 mm 34 01 mm TORQUE SPECIFICATIONS Item Torque kgf cm Front Caliper Mounting Bolts 280 320 Rear Caliper Mounting Bolts 500 600 Handlebar Master Cylinder Clamp Bolts 70 90 Hand Master Cylinder Reservoir Cover 8 Bra...

Page 246: ... Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed Test for brake drag after any brake system service and investigate cause if brake drag is evident Make sure caliper moves freely on guide pins where applicable Inspect caliper piston seals for foreign material that could prevent caliper piston from returning freely Perf...

Page 247: ...continuity Release switch Open If switch is defective replace with a new one If the switch is good verify wire continuity between harness connector and ECU connector Brake Light Switch Replacement 1 Disconnect brake light switch connector 2 Drain rear brake line 3 Remove brake light switch from distributor NOTE Use shop rag to catch any spilled brake fluid 4 Install new sealing washers 5 Install b...

Page 248: ...cylinder from vehicle Master Cylinder Inspection Check boot for crack Check rod for wear and scratch Check master cylinder housing for leak or damage Master Cylinder Installation For installation reverse the removal procedure Tighten brake light switch and front brake hoses to specification TORQUE Pedal Master Cylinder bolts 280 320kgf cm Pedal reservoir bolt 100 120 kgf cm Banjor bolt A 80 kgf cm...

Page 249: ...e 5 Remove screws securing caliper support knuckle 6 Place caliper assembly onto a support NOTICE Do not let caliper hangs the hose and do not stretch or twist hose Caliper Installation For installation reverse the removal procedure If caliper was removed for replacement Refill and bleed brake system Install new sealing washers Apply thread locker LOCTITE 243 on caliper retaining screws Tighten ca...

Page 250: ... grease 9 Install brake pad pins on caliper 10 Install caliper on knuckle BRAKE DISC Brake Disc Inspection 1 Check disc surfaces for scratch or grooves on both sides 2 Measure thickness of the disc THICKNESS 4 1 mm NOTICE Brake discs must never be machined 3 Check warpage of disc Maximum disc warpage 0 2 mm Brake Disc Replacement 1 Remove caliper 2 Remove brake disc mounting bolts 3 Replace brake ...

Page 251: ...15 1 1 STEERING SYSTEM AND SUSPENSION 15 1 1 STEERING SYSTEM EPS MODEL ...

Page 252: ...15 1 1 STEERING AND SUSPENSION 15 1 2 NON EPS MODEL ...

Page 253: ...n the exploded view Clean threads before applying thread locker WARNING Torque wrench tightening specifications must strictly be adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced Hoses cables or locking ties removed during a procedure must be reinstalled as per factory standards ...

Page 254: ...e dashboard cover 2 Remove the two screws on the both rear mirror bracket 3 Remove the top cover screws and pull out the cover from the handlebar Handlebar Cover Inspection Check covers for cracks or other damages Replace if necessary Handlebar Cover Installation The installation is the reverse of removal procedure ...

Page 255: ... handlebar is defective and requires replacement 2 Remove four bolts from the dashboard bracket 3 Remove the dashboard 4 Remove four handlebar mounting bolts 5 Remove handlebar Handlebar Inspection Inspect the handlebar for damage cracks or bending Replace if any of these problems is detected Handlebar Installation For the installation reverse the removal procedure ...

Page 256: ...arm plate 9 Remove the steering shaft cotter low end pin washer and castle nut Discard the cotter pin NOTE Always install new cotter pin after removal 10 Pull off the steering shaft from the vehicle Steering Shaft Steering Shaft Removal with EPS 1 Remove handlebar cover 2 Remove dashboard support 3 Loosen handlebar mounting bolts and remove handlebar 4 Remove the body top cover 5 Remove steering s...

Page 257: ...15 1 1 STEERING SYSTEM AND SUSPENSION 15 1 1 Steering Tie Rod Assembly w EPS Steering Tie Rod Assembly w o EPS ...

Page 258: ...ed nuts 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to the proper torque specification WARNING Do not rotate tires The front and rear tires have a different size Respect direction of rotation when applicable TIRES WARNING Do not rotate tires The front and rear tires have a different size Respect direction of rotation when applicable TIRE PRESSURE WARNING Tire pressure great...

Page 259: ...15 1 1 STEERING SYSTEM AND SUSPENSION 15 1 1 FRONT SUSPENSION ...

Page 260: ... ties removed during a procedure must be reinstalled as per factory standards PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1 Safety lifts and supports the vehicle of the ground 2 Remove bolts and nuts retaining shock absorber 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Secure the end of shock body in a vise with its rod upward NOTICE Do not clamp directl...

Page 261: ...Installation For installation reverse the removal procedure Make sure to install the proper type of shock absorber on vehicle TORQUE 48 Nm 6 LOWER A ARM Lower A Arm Removal 1 Safety lifts and supports the vehicle off the ground 2 Remove wheel 3 Remove bolts and nut securing lower ball joint to knuckle 4 Remove bolts and nuts securing A arm to frame 5 Remove A arm Lower A arm installation For insta...

Page 262: ...sing a plastic hammer carefully hit on the knuckle side to separate ball joint from knuckle NOTE A ball joint remover can be used if the ball joint is jammed into knuckle NOTICE Never hit on A arm to avoid to damage it permanently 8 Remove bolt and nut securing A arm to shock absorber 9 Remove fasteners securing A arm to frame 10 Remove A arm Upper A Arm Installation For installation reverse the r...

Page 263: ...15 1 1 STEERING SYSTEM AND SUSPENSION 15 1 1 REAR SUSPENSION ...

Page 264: ...ties removed during a procedure must be reinstalled as per factory standards PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1 Safety lifts and supports the vehicle of the ground 2 Remove bolts and nuts retaining shock absorber 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Secure the end of shock body in a vise with its rod upward NOTICE Do not clamp directly...

Page 265: ...llation For installation reverse the removal procedure Make sure to install the proper type of shock absorber on vehicle TORQUE 48 Nm 6 TENSION BAR Tension Bar Removal 1 Safety lifts and supports the vehicle off the ground 2 Loosen and remove the bolts washer and bushing from the frame 3 Remove ball joint nut from the A arm or tension bar Tension Bar Installation For installation reverse the remov...

Page 266: ...heel 3 Remove bolts and nuts securing A arm to frame 4 Remove bolts and nut securing upper knuckle 5 Carefully move brake hose aside 6 Remove A arm Upper A Arm Installation For installation reverse the removal procedure Install a new cotter pin to secure ball joint nut Both end of cotter pin must be folded TORQUE 48 Nm 6 TORQUE 48 Nm 6 ...

Page 267: ...vehicle off the ground 2 Remove wheel 3 Remove bolts and nuts securing A arm to frame 4 Remove bolts and nut securing lower knuckle 5 Remove ball joint nut to tension bar rod 6 Remove shock absorber lower bolt 7 Remove A arm Lower A arm installation For installation reverse the removal procedure TORQUE 48 Nm 6 ...

Page 268: ...15 2 ELECTRIC POWER STEERING 15 2 1 EPS Electric Power Steering ...

Page 269: ...to the driver The greater the power steering assist the greater the load on the electrical system When electrical system is under high load battery not at full charge operating the vehicle for prolonged periods of time at slow speed and low RPM which requires higher power steering assist the battery power reserve will gradually decrease This further increase the load on the charging system and the...

Page 270: ...ection When the EPS unit temperature is above 100 all the EPS function will stop but the steering can operate without power assist when the EPS internal board temperature decrease below 90 the power steering will back to normal and steering assist should resume normal operation Steering Torque Sensor The steering column is connected to the shaft on the EPS unit A small area of the EPS shaft is mag...

Page 271: ...ress the RESET button on the EPS function page The EPS system will engage or disengage and display MIN MAX and blank OFF When EPS system is malfunction the function block will displayed FAIL And the bottom of dashboard will show DTC code with Cxxxx Code Problem Caused C1511 Torque sensor connector poor contact C1512 Torque sensor abnormal C1513 C1514 C1515 C1521 Motor connector poor contact C1522 ...

Page 272: ...in very small increments based on the amount duration and direction of DC power delivered by the EPS module ADJUSTMENT TORQUE OFFSET RESET When replacing the following parts or adjusting steering alignment the sensor torque offset must be reset to zero for proper system operation EPS unit Steering shaft bearing Tie Rod Knuckle Ball joint Front suspension A arm Steering alignment 1 Connect vehicle ...

Page 273: ...t service actions LOW POWER STEERING ASSIST 1 Low battery voltage Check battery terminals Clean repair replace or tighten as required Test battery voltage Recharge or replace battery as required Carry out an EPS unit INPUT VOLTAGE test POWER SIDE as detailed in this subsection Ensure power connector pins are clean corrosion free tight and make good contact Repair or replace wiring connectors as re...

Page 274: ... power for the EPS motor 1 To remove fuse box cover simultaneously squeeze tabs inwards on each end of fuse box cover as you pull upward on the cover 2 Using voltmeter set to Ω selection remove and test the EPS fuse 3 Replace fuse as required NOTE The color and function of fuse EPS power fuse Green 40A MAXI fuse Pink 30 A Charger fuse Pink 30A 40A 30A 30A ...

Page 275: ...ed carry out the following EPS UNIT INPUT VOLTAGE TEST CONTROL SIDE EPS Unit Input Voltage Test Control Side 1 Disconnect EPS control connector and turn ignition switch ON 2 Set the ignition switch to ON 3 Test for 12 VDC power to the EPS module pin as per following table EPS control connector pin A battery GND The voltage should be battery voltage If NO voltage is measured check wires and connect...

Page 276: ...If there is good continuity carry out the following EPS UNIT COMMUNICATION LINK CAN CONTINUITY TEST EPS Unit Communication Link CAN Continuity Test NOTE EPS unit must receive an RPM signal to provide power steering assist Disconnect the EPS control connector and the diagnostic connector Test continuity of CAN Bus Wires at PINS EPS control connector pin C diagnostic connector pin 1 Below 1 Ω EPS co...

Page 277: ...ton on the voltmeter to engage the MIN function 9 Turn the handlebar momentarily against the steering frame stops to each side NOTE Do not hold steering against frame stops for and extended period of time 10 Read the MIN charging system voltage recorded while the handlebar was turned against each stop Battery terminal fuse box battery terminal at least 12 VDC Steering position LH stop RH stop NOTE...

Page 278: ... to the torque applied and decrease with the torque as steering assist is provided NOTE Increase and decrease in torque and current readings is very brief as steering assist is quickly provided Current draw should remain within green scale but may momentarily peak to 60 amps then drop off close to 0 amps as torque applied is nulled out by steering assist A residual torque of 2 NM with a correspond...

Page 279: ...isconnect the wiring of headlamp and power source The front cover The inlet tube Loose the handle steering lock nut Lift up and dismounting the steering shaft Torque 280 320 kgf cm Disconnect the wiring on the motor Disconnect the wiring on the controller Remove the three mounting bolts of EPS body Torque 250 300 kgf cm ...

Page 280: ...side of vehicle NOTE Be careful do not damage the cable of torque sensor Remove the four bolts and the bracket Remove the two bolts and dismounting the brake distributor Torque 280 320 kgf cm Remove the three bolts Lift up and remove the steering lower bearing seat Torque 280 320 kgf cm Installation Install the EPS in the reverse order of removal ...

Page 281: ...ng seat assembly Steering Pad Bearing Seat Oil Seal Bearing x 2 Cap Washer Plate Nut Circlip Control Unit Removal Remove four mounting bolts Disconnect the wiring as follow 1 To fuse box 2 To ECU Speed Sensor and Ignition 3 To Motor Power 4 To Torque Sensor 5 To Motor Control Remove the control unit Installation Install the control in the reverse order of removal ...

Page 282: ...R STEERING 15 2 15 Fuse Removal Simultaneously squeeze tabs inwards on each end of fuse box cover as you pull downward on the cover Replace the damage fuse Installation Install the control in the reverse order of removal ...

Page 283: ... Meters 17 12 Light Bulb 17 13 Switch Horn 17 16 Fuel Unit 17 19 Cooling Fan Switch 17 20 Thermo unit 17 21 Water Temperature Indicator Light 17 21 Mechanism Diagram Shift gear Hazard control Pedal Brake switch C D I Main switch Front brake switch Rear brake switch Cooling fan switch Winker relay Headlight relay Oil pressure switch Horn Fan relay AC Generator Ignition coil Regulator DC Power outle...

Page 284: ...aps Unless in emergency never rapid charge the battery 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 Cap...

Page 285: ... The starter motor is out of work Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the 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 c...

Page 286: ...inal of the charger to 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 th...

Page 287: ... 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 one and take measurement of the current of ea...

Page 288: ...amage the ammeter Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 6000 rpm Control Charging Voltage 14 5 0 5 V 2000 rpm Caution T o replace the old battery use a new battery with the same current and voltage The following problems are related t...

Page 289: ...ler to the wire harness passes the condition Item Check Points Standard Value Main switch connection Bl B Battery voltage ON Battery 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 ...

Page 290: ... Points to check Result Main switch turn to ON position Br Bl B Battery voltage Pulse generator Bl Y G R 50 170Ω Ignition coil Primary circuit G R B 2 9 10 Ω Secondary circuit TERMINAL B with no cap 15 0 10 Ω TERMINAL B with cap 20 0 10 KΩ B Black R Red G Green W White Y Yellow L Blue Main Fuse 20A Main Switch Ignition Coil Pulse Generator Spark Plug Battery C D I unit B1 Y B W G R LG R B B BR B G...

Page 291: ...ap from the spark plug and measure the 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 yel...

Page 292: ...nnect 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 the battery negative terminal Check the continuity of the large terminal end If there is no continuity replace the relay B Black B1 Blue R Red G Green W White Y Yellow BR Brown F N R...

Page 293: ...motor Remove the seat Disconnect the cable negative terminal then the cable positive terminal Remove starter motor cable Loosen the lock bolts and remove the starter motor Installation of Starter motor Install in reverse order of removal procedures ...

Page 294: ...front center cover and then remove meter couplers and main switch coupler Remove speedometer cable Remove speedometer cable and then remove meter set main switch and handle cover Remove 4 nuts and meter wire and then remove speedometer and fuel meter Speedometer Cable Main Switch coupler ...

Page 295: ...ce with new bulb if necessary Main 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...

Page 296: ...ng the Front winker light Bulb Pull out the front winker light bulb seat Replace with new front winker light bulb 12V 21W Replacing Bulb of Position Light Pull out the position light bulb seat Replace with new position light bulb 12V 5W ...

Page 297: ...ght and rear winker light bulb connectors by CCW 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 ...

Page 298: ...te Brown Blue Replacement of main switch 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 Start Switch Pin ST SG Positi...

Page 299: ... Position Wire Color Red Red Green Red Yellow Blue Brown Winker switch Pin L WR R Position N PUSH OFF Wire Color Brown Brown White Green Horn switch Pin BAT3 HO Position FREE Wire Color Brown White Pink Hazard switch Pin HD E Position Wire Color Brown White Black ...

Page 300: ...ght and left side from the front differential assy Note Check if the servomotor s condition is poor please replace with the new one Remove the wire from the lock controller Then remove the servomotor Check Be sure that lock controller should not be damaged If happening please replace with the new one Installation Install the removed parts in the reverse order of removal ...

Page 301: ...e continuity Replace the switch if damaged Rear 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 Apply 12 V power source to two terminals of the horn the horn should sound Replace the horn if necessary ...

Page 302: ... Resistance E Empty 97 5 107 5 Ω F Fuel 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 Caution While conducting the test turn on the direction in...

Page 303: ...ck the cooling fan switch in the manner as described below Hang the cooling fan 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...

Page 304: ... Wear gloves and goggles 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 Water Temperature Indicator Light Disconnect the water temperature meter and connect it to engine ground Turn on the main switch The indicator light ...

Page 305: ...65 10A 10A 10A 15A 15A 20A 10A 10A 10A 10A 9400uf 12V ECU 12V ...

Page 306: ...65 10A 10A 10A 15A 15A 20A 10A 10A 10A 10A 9400uf 12V ECU 12V ...

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