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TGB Blade 525 Service Manual Download Page 202

To this chapter contents

 

 

16. REAR BRAKE & REAR WHEEL & REAR CUSHION

 

 
 

Brake Disk

 

Inspection

 

Visually check the brake disk for wear or break. 
Measure the thickness of the disk at several 
places.  Replace the disk if it has exceeded the 
service limit. 

Allowable limit: 2.5 mm

 

 

 

Brake disk

 

 

 
 
 
 
 
 
 
 

 
 

Micrometer

 

 

 
 
 
 

Remove the brake disk from rear wheel axle. 
Check the disk for deformation and bend. 

Allowable limit: 0.30 mm

 

 

  Caution

 

 

●

 

The dirty brake lining or disk will reduce the 

brake performance. 

●

 

Brake lining includes the asbestos ingredient, 

cannot use the air-gun to be clean, the operator 
should dress the mouthpiece and the glove, use 
vacuum cleaner clean it. 

 

 

Rear Brake Master Cylinder

 

Master Cylinder Removal

 

 

  Caution

 

 

Do not let foreign materials enter into the 
cylinder. 

 

  Caution

 

 

The  whole  set  of  master  cylinder,  piston,  spring, 
diaphragm  and  cir  clip  should  be  replaced  as  a 
set. 

 

 
 
 
 
 

 

 
 

 

Brake lever bolt

 

 

 
 
 
 
 
 
 
 
 
 
 

 

Brake light switch coupler

 

 

Brake lever nut

 

 
 

Handle left side 

–

 rear brake master cylinder A

 

Remove brake light switch coupler. 
Drain out the brake fluid. 
Remove the brake hose. 
Remove the brake lever from the brake master 
cylinder. 
Remove the master cylinder socket bolts and the 
master cylinder. 

 
 
 
 

 

2 socket bolts

 

 
 
 
 

16-11

 

 

PDF created with pdfFactory Pro trial version 

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Summary of Contents for Blade 525

Page 1: ...BLADE 500 525 SERVICE MANUAL TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 2: ...Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV BLADE 525 500 are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice Service Department TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www...

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

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

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

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

Page 7: ...pped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is strictly prohibited Keeps the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your...

Page 8: ...ts have an adverse effect on them Never bend or twist a control cable to prevent unsmooth control and premature worn out Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary When loosening a component which has different sized fasteners operate with a diagonal...

Page 9: ... the oil seal with the name of the manufacturer facing outside and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can g...

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

Page 11: ...f the connector is covered by the twin connector boot completely and secured properly Before terminal connection check if the boot is crack or the terminal is loose 1 6 Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so tha...

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

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

Page 14: ...fugal wet type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 300 km hr Cycle Cooling 4 stroke Water cooled Horn 93 112dB A Bore Ø92 mm Muffler Expansion Pulse Type Stroke 75 6 mm Exhaust Pipe Position and Direction Left side and Backward Cylinder Number Arrangement Single Cylinder Lubrication Syst...

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

Page 16: ...e nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 12 8 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 6 Driven gear nut 4 10 4 6 Swing arm pivot bolt 1 14 9 20 Front suspension arm nut 4 10 5 00 Front Rear cushion mounting bolt 6 10 4 60 Brake lever nut 2 6 1 00 Brake hose bolt 13 10 3 50 Brake caliper bolt 6 6 3 25 Brake disk mounting bolt 11 8...

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

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

Page 19: ...osen the screw Lean mixture tighten the screw Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch Check and adjustment Fault condition Probable causes Check ignition timing Normal...

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

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

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

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

Page 24: ...ools List 2 12 Precautions in Operation Specification Fuel Tank Capacity 18000 300 c c Capacity 3700 c c Engine Oil Transmission Gear oil Capacity of coolant Change 3200 c c Capacity 350 c c Change 350 c c Engine radiator 2200 c c Reservoir upper 1200 c c Clearance of throttle valve 1 3 mm Type NGK CR7E Spark plug Gap 0 7 0 8 mm F Mark in idling speed BTDC 20º 1500 rpm Full timing advanced BTDC 51...

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

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

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

Page 28: ... adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle valve stopper screw and let engine runs in 1500 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 S...

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

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

Page 31: ...luid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system hoses Screws Master cylinder cap Air Bleed Operation Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution...

Page 32: ...pter 14 Make sure the brake lining condition Replace the lining if the brake lining wear limitation groove close to the brake disc Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining In order to maintain brake power balance the brake lining must be replaced with one set Rear brake Brake lining wear limitation groove Brake Light Switch Starting Inhibi...

Page 33: ...eration If the ATV is in forward moving and shaking check clutch disc condition Replace it Adjust screw Clutch weight Cushion Warning Do not ride the ATV with poor cushion Looseness wear or damage cushion will make poor stability and drive ability Front cushion Press down the front cushion for several times to check it operation Check if it is damage Replace relative parts if damage found Tighten ...

Page 34: ...Check if tire surface is ticked with nails stones or other materials Appointed tire pressure Tire size Front tire Rear tire Tire pressure as cold 5 1psi Check if front and rear tires pressure is in normal Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm Nuts Bolts Tightness Perform periodic...

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

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

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

Page 38: ...TEM 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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 39: ...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 Standard mm Limit mm Inner rotor clearance 0 15 0 20 Clearance between outer rotor and body...

Page 40: ... 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 replacing Replace The Oil Filter Same as oil change drain the oil out Remove the oil filter by special tool Apply engine oil lightly to the gasket of the new oil filter when installation ...

Page 41: ...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 PDF created with pdfFactory Pro tri...

Page 42: ...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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 43: ... 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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 44: ...PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 45: ...on 4 2 Trouble Diagnosis 4 3 Carburetor Remove Install 4 4 Air Cut Off Valve 4 5 Throttle Valve 4 6 Float Chamber 4 7 Adjustment of Idle Speed 4 9 Fuel Tank 4 10 Air Cleaner 4 11 Mechanism Diagram 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 46: ...uel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassemble air cut valve arbitrarily Specification ITEM BSR33 Carburetor diameter Ø33mm I D number 33_77 Fuel level 31 5 0 5mm Main injector 122 5 Idle injector 35 Idle speed 1500 100rpm Throttle handle clearance 1 3 mm Pilot screw...

Page 47: ...or Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system Mixture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogged fuel ta...

Page 48: ... clamp screws Loosen the carburetor side cap 3 screws Remove cap Disconnect the throttle cable Disconnect the starter cable Remove the carburetor Installation Install in reverse order of removal procedures Clamp Clamp Start cable PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 49: ...ng and valve Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assembly Install in reverse order of removal procedures 2 screws Air cut off valve PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 50: ... Valve Disassembly Remove carburetor top comp Remove the spring holder needle set jet and piston valve Remove the cable adjuster assy Cable adjuster assy 2 screws PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 51: ...alve for wearing and check valve seat face for wear dirt Cautions In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one 4 screws Float Screw Pin Float valve Float Float valve Pin Check for wear or damage PDF created with pdfFactory Pro trial...

Page 52: ...moved Install the float valve float and float pin Checking fuel level Caution Check again to ensure float valve float for proper installation To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 31 5 0 5mm Installation of carburetor Install carburetor in the reverse order of removal Following adjustments must be made...

Page 53: ... Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1500 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the pilot screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure rpm and CO value are in standard value after engine running in stable I...

Page 54: ...allation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fuel tank Remove the side covers and lower side covers Remove the front fender Covers remove please refer chapter 13 Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove fuel tank fro...

Page 55: ...he air cleaner cover 4 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install the elem...

Page 56: ...4 FUEL SYSTEM 4 12 Notes PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 57: ... 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 55N m 5 5kgf m or 40lb ft Exhaust muffler mounting bolt 2 8 3 2kgf m Exhaust muffler connection nut 1 0 1 4kgf m Item Capac...

Page 58: ...dure 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 Before remove battery positive post Be sure remove negative post first Caution PDF created with pdfFactory Pro tr...

Page 59: ...3 Remove the gearshift lever Remove the fuel hose and vacuum hose Remove the air cleaner Remove the carburetor Air cleaner Carburetor Fuel pipe Vacuum pipe PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 60: ...ter 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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 61: ...E REMOVAL 5 5 Remove the right footrest Remove the brake pedal Remove the L and R muffler Remove the exhaust pipe Remove the front and rear tube PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 62: ... Remove the engine mounting bolts and nuts Remove the engine mounting bracket Remove the engine bolsters Remove the flange bolts and take down engine bolster Remove the engine from the right side PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 63: ...moval Torque value 55 N m 5 5kgf m or 40lb ft The engine mounting nuts are self 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 Caution PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 64: ...the front propeller shaft flange coupling bolts Tighten them to the standard torque Torque value Front and rear propeller shaft flange coupling bolt 45N m 4 5kgf m 32 5lb ft Install the new gasket 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 PDF created with pdfFactory Pro t...

Page 65: ...ust pipe nut Connector bolt Muffler mounting bolt 25N m 2 5kgf m 16 5lb ft Apply sealant to the muffler mounting bolt to the muffler fixed bolts and tighten them PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 66: ...ine Disassembly Remove starter motor wire Remove the spark plug cap Remove the thermostat Remove the spring bolt and remove the cam chain pensioner adjuster assy PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 67: ...ove the engine oil pipe bolts Remove the recoil starter Remove the valve timing check plug Turn the crankshaft and let the T D C line on the rotor with index mark PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 68: ...5 ENGINE REMOVAL 5 12 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 69: ...Tighten the drain bolt to specified torque Pour the oil through the filler hole Tighten the filler cap to the specified torque Be sure the differential set temperature below 35 SAE 90 hypoid gear oil Oil standard Oil capacity 300c c Oil filler nut Drain nut Drain bolt 33N m Oil filler nut 3 6N m Caution PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 70: ...Drain oil nut Tighten the drain blot Remove the oil check bolt Pour the specified oil through the filler hole until the oil lever reach the hole lower lever Tighten the oil level bolt Tighten the filler cap Final gear oil drain boil 34 N m 3 4 kgf m 24 lb ft Final gear oil filler cap 34 N m 3 4 kgf m 24 lb ft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 71: ...5 ENGINE REMOVAL 5 14 Note PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 72: ...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 6 1 1 0 1 4 kgf m 1 0 1 4kgf m 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 73: ...learance between Intake 0 010 0 037 0 080 Valve valve stem and guide Exhaust 0 025 0 062 0 100 Free length of valve Inner 36 32 5 spring outer 39 5 36 0 Valve seat width 1 600 Intake 0 10 0 02mm Valve clearance Exhaust 0 15 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cover bolt 1 0 1 4kgf m Exhaust pipe stud bolt 2 4 3 0kgf m Cylinder head bolt 1 0 1 4kgf m Cylinder head Nu...

Page 74: ...valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto tensioner we...

Page 75: ...n 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 nuts of cylinder head 2 nuts Remove the screws of cylinder head 2 screws Spark plug 6 4 Thermostat bolts Tensioner bolts 2 Nuts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 76: ...ve cam sprocket bolts and then remove thesprocket by prying chain out Remove cam chain tensioner and hole bolt 3 bolts T 6 bolts Remove cam shafts Remove Rocker arm and cam shaft puller Cam shafts Rocker arm shaft and cam shaft puller 6 5 2 bolts 1 bolt Chain tensioner 1 bolts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 77: ...inder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Gasket Chain guide Dowel pins Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool...

Page 78: ...r Head Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 33 392mm EX Replacement when less than 33 277mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and beari...

Page 79: ...ate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit Inner spring 32 5 mm Outer spring 36 0 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure record the valve...

Page 80: ...the valve stem and valve guide Service Limit IN 0 10 mm EX 0 15 mm 5 0 mm valve guide reamer Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve g...

Page 81: ...ssed it in When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer Caution Using cutting oil when correcting valve gu...

Page 82: ...ness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut...

Page 83: ...e contacting with valve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too low grind the valve se...

Page 84: ...tion 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 the valve stems gently with a plastic hammer ...

Page 85: ...ials falling into crankcase as cleaning Chain guide Dowel pins Gasket Install 4 washers and tighten 4 bolts on the cylinder head upper side and then tighten 4 cylinder head nuts to the specified torque 2 M6 2 M8 Cylinder head bolt Bolt 3 6 4 0kgf m 4 bolts Screw M6 1 0 1 4kgf m Nut M8 2 0 2 5kgf m Install camshaft into cylinder head Install rocker arm rocker arm shaft Install cam chain tensioner i...

Page 86: ...sher so that it is covering the locating pin Timing mark 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 3 bolts 3 bolts 6 15 2 bolts A B Tensione...

Page 87: ...e 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 cylinder head Stop the engine after confirmed and then in...

Page 88: ...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 0 7 1 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 89: ...2 006 22 020 OD of piston pin 21 996 22 000 21 960 Clearance between piston and piston pin 0 001 0 010 0 020 ID of connecting rod small end 22 002 22 01 22 040 Trouble Diagnosis Low or Unstable Compression Pressure Cylinder or piston ring worn out Knock or Noise Cylinder or piston ring worn out Carbon deposits on cylinder head top side Piston pin hole and piston pin wear out Smoking in Exhaust Pip...

Page 90: ...der gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be removed more easily Inspection Check if the inner diameter of cylinder is wear out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y values respective in the cylinder Service...

Page 91: ...eck if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Service Limit Top ring 0 50 mm 2nd ring 0 65 mm 7 4 PDF created with pdfFactory Pro trial version www pdf...

Page 92: ...on pin hole Service Limit 22 020 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 92 250 mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 5 PDF created with pdfFactory Pro trial ver...

Page 93: ... 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 7 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 94: ...Installation Install piston and piston pin and place the marks on the piston top side 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 mark Cutout Cylinder Installation Install dowel pins and ne...

Page 95: ...stalling piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 Coolant hose 7 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 96: ...EM 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 8 8 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 97: ... mm 40 935 mm ID of driven face 45 000 45 035 mm 45 600 mm Weight of weight roller 18 300 18 500 g 18 800 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 can be started but motorcy...

Page 98: ... 2 clamp strips of clutch cover ducts and then remove the ducts Remove clutch cover 14 bolts Remove 2 dowel pin and gasket Clutch cover install Install left clutch cover in the reverse procedures of removal Dowel pins 8 3 14 bolts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 99: ...otate bearing s inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it 8 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 100: ... 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 exceeds the ...

Page 101: ...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 Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value Torque value 10 12kgf m Universal holder Univers...

Page 102: ...ove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Universal holder Movable drive face Drive face boss Remove ramp plate Remove weight rollers from movable drive face Ramp plate Movable drive face Weight roller 8 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 103: ...er 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 In order to lengthen the roller life and prevented exceptionally wears the o...

Page 104: ...stallation 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 screw 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 crankcase cover 8 9 Drive belt ...

Page 105: ...l Release the clutch spring compressor and remove movable driven sheave and spring from driven pulley Remove seal collar from driven pulley Clutch nut wrench Clutch spring compressor Collar Remove guide pin guide pin roller and movable driven face and then remove O ring oil seal seat from movable driven face Movable driven face Seal Guide pin O ring Guide pin Guide pin roller Inspection Clutch out...

Page 106: ...s 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 Driven face Movable driven face Guide pin groove 8 11 PDF created with pdfFactory Pro trial version w...

Page 107: ...pin O ring Guide pin Guide pin roller Install the collar 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 dri...

Page 108: ...PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 109: ...t rear shaft and front shaft Remove the c ring from the universal joint assy Remove the driven output front shaft with a chisel Remove the joint parts Using a vise let the driven output rear shaft held in movable Replace the removed nut and use a new one when reassemble PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 110: ...move the nut Remove the bearing by tapping with the hammer and tool Remove the universal joint assy Remove the parts Rear universal joint disassembly Remove the c rings from the universal joint assy PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 111: ...ven output rear shaft and remove the nut Unlock the nut with a chisel Remove the NTT from Driven output front shaft When reassemble with a new nut Must be replaced the new bearing and oil seal when reassembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 112: ...ing a vise held the driven output front shaft and remove the nut Remove the washer driven bevel gear and bearing Remove the parts Replace the new nut fro reassemble Must be replaced the new bearing and oil seal for reassemble PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 113: ... bearing to the joint and turning the joint If excessive play is noted must be replace the new bearing Reassemble the driven output rear shaft and front shaft In the reverse order of disassembly Pay attention to the following items Stake the nut with a punch After The tooth contact and backlash have been adjusted and checked PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 114: ...ly thoroughly clean all parts with solvent Using a vise hold the bevel gear Tighten the new nut to the specified torque Stake the nut with a punch Apply grease to the bearing and seal lip Torque 100N m 10kgf m 73lb ft PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 115: ...ecked Put the bearing rings and shaft in the crankcase Position the bearing pin to the pin grooves in the crankcase Check the gear backlash and tooth contact correctly Tooth face contact 80 up Remove the driven output Rear Front shaft Remove the bevel gear Clean tooth face Tighten the bevel gear nut and output rear shaft to the specified torque Stake the nut with a punch The bearing knock pin shou...

Page 116: ...cked Install the new c ring by tapping and hammer copper After reassembling the universal joint assy Check the joint assy Movement smoothly If movement have a large resistance Tapping the bearing with the plastic mallet lightly Tooth contact face contact 80 up Using the new c ring for reassembly Tool 440668 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 117: ...teeth with engine oil l Tighten the drive bevel gear nut and rear out put Shaft nut to the specified torque Rear output shaft nut 100 N M 10 0 kgf m 73 lb ft Drive bevel gear nut 100 N M 10 0 kgf m 73 lb ft Ⓐ l Stake the collar of the nut Ⓐ into the notch in the shaft Ⓐ NOTE After the tooth contact have been checked and adjusted reassemble the joint PDF created with pdfFactory Pro trial version ww...

Page 118: ...e keep the drive belt drive face and driven face away from any greasy matter l Install the output shaft assembly with a plastic mallet l Install the shim drive bevel gear and washer l Tighten the bevel gear nut to the specified torque Bevel gear nut torque 100 N M 10 0 kgf m 73 lb ft l Use a center punch stake the nut PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 119: ...ve of the crankcase TRANSFER GEARSHIFT l Install the transfer related parts l Install the spacer spring shaft and reverse idle gear l Install the washer CRANKCASE l Clean R and L crankcase surfaces with cleaning solvent l Fit the dowel pins on the hole l Apply engine oil to the gears and conrod PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 120: ...9 FINAL DRIVING MECHANISM 9 12 Note PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 121: ... 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 5 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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 122: ...or 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 PDF created with pdfFactory Pro tri...

Page 123: ...A C G Set Removal Remove 3 mounted screws from pulse generator and then remove it 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 necessary Remove the bearing 3 screws 3 bolts Wire 15 b...

Page 124: ...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 Remove flywheel and starting driven gear Flywheel nut Oil seal Bearing PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 125: ...mit 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 PDF created with pdfFactory Pro trial version ww...

Page 126: ...lutch One way clutch Installation Install the components in the reverse procedures of removal Torque value 3 0 3 5kgf m 6 socket bolts One way clutch Starting driven gear Starting driven gear 6 socket bolts Tape a tightening tape onto the thread of hexagon bolt Caution PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 127: ...lywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 16 18kgf m Special tool Universal Holder Install reduction gear shaft and reduction gear Starting driven gear Groove Reduction gear Flywheel nut not to be reused should be replaced when disassembled PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 128: ...he indent of crankcase 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 Make sure that the wire harness is placed under pulse generator 3 screws 3 bolts Wire PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 129: ...case 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 15 bolts Water pump bolts PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 130: ...10 ALTERNATOR STARTING CLUTCH 10 10 Note PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 131: ...11 CRANKSHAFT CRANKCASE 11 1 L CASE R CASE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 132: ...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 l When installing the oil guide plate apply a small quantity of Loctite 262TM Thread locker to the screw PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 133: ...ing NOTE Be sure The sealed cover of the bearing must face outside l Install the chuck Bearing NOTE When installing the Bearing chuck apply a small quantity of Loctite 262TM Thread locker to the screws PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 134: ... the snap ring with the snap ring pliers NOTE If any damage the bearing replace the new one l Remove the bearing REASSEMBLY l Install the bearing l Install the snap ring with snap ring pliers PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 135: ... 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 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 136: ...aring O ring and Oil seal lip l Install the oil seal NOTE When installing the oil seals be sure the stamped mark on the oil seal faces outside l Apply a small quantity of Loctite 262TM Thread locker to the screws and install the bearing retainer PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 137: ...e out the recoil starter related parts from the housing Ratchet Nut Ratchet guide Friction plate WARNING When removing the plastics disc Wear eye and hand protection because the spring may Quickly unwind and cause an injury Spacer Spring cover Spring Pin Reel PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 138: ... spiral spring End l Hook the rope onto the hook part of the reel turn thereel clockwise 5 times with the rope l Install the ratchet related parts NOTE l Apply the shaft and ratchet with Grease l Pull the rope and check that the ratchet is pushed out Wear eye and hand protector when reassembly the reel because the spring may quickly unwind and cause an injury PDF created with pdfFactory Pro trial ...

Page 139: ...al installer 440655 l Apply a small quantity of Loctite 262TM Thread locker to the thread and install and the gearshift cam stopper BALANCER l Install the balancershaft l Install the key l Install the balancershaft driven gear l Install the driven gear balancershaft by aligning the punched marks PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 140: ...11 CRANKSHAFT CRANKCASE 11 10 l Apply Loctite 510 Flange sealant to the mating surface of the left crankcase L CASE R CASE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 141: ...l Fit the clamp to the bolt l Check the each shaft rotates smoothly after the crankcase bolts have been tightend OIL PUMP l Install the oil pump l Install the washer and pin l Install the oil pump driven gear l Install the snap ring with snap ring pliers NOTE l Assemble the oil pump gear as show PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 142: ... specified torque Oil pump drive gear bolt 50 N M 5 0 kgf m 37 lb ft Rotor holder 440665 CAM CHAIN l Install the cam chain CLUTCH SHOE l Install the clutch shoe assembly l Apply Loctite 262TM Thread locker to the clutch shoe nut l Tighten nut to the torque with the special tool Shoe nut torque 160 N M 16 kgf m 116 lb ft Rotor holder 440666 CAUTION The nut of clutch shoe has left hand threads PDF c...

Page 143: ...Install the springs and switch contacts l Install the neutral switch CLUTCH CASE l Install the dowel pins and put the new gasket l Tighten the clutch case bolts l Install the collar The one way clutch outside facing must on the shaft outside OUTSIDE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 144: ...DRIVEN FACE AND DRIVE BELT l 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 l Install the movable driven face assembly PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 145: ...nd both the drive and driven faces check the belt without slip CLUTCH COVER l Install the dowel pins and new gasket l Install the clutch cover OIL FILTER l Apply engine oil lightly to the O ring l 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 wrench 440670 PDF created with p...

Page 146: ...all the water pump gears with special tool l Install the wash Bearing installer set 440660 l 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 l Install the wash PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 147: ...clutch on the crankshaft is fitted into the generator rotor properly l 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 Rotor holder 440664 l Install the output drive gear by installing the snap ring PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 148: ...Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear STARTER DRIVEN GEAR IDLE GEAR l Install the starter idle gear and driver gear LEFT CRANKCASE COVER l Install the dowel pins and put the new gasket PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 149: ...SPEEDOMETER GEARBOX l Fit a new gasket and install the speedometer gearbox WATER PUMP l Check the water pump shaft position with water pump gear shat l Apply engine oil on the O ring of water pump l Install water pump l Tighten the screw PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 150: ... oil to the O ring and lip of the oil seal l Install the starter cup l 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 installer 440658 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 151: ...ns to activate at 65 72 Stroke 0 05 5mm Thermos switch fan 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 Tools Requirement Special tools Water pump bearing driver 6901 TGB 440640 Water pump oil seal driver Inner TGB 440641 Water pump mechanical seal driver TGB 440642 Inner bearing puller TGB 440645 Trouble Diagnosis ...

Page 152: ...back to zero Y B 1 Measure thermo unit to confirm voltage 6V Y B 2 Inspect the circuits of water temperature have short or earth N Replace thermo unit Y Short or earth handle N Meter problem C Open radiator cap and N softly throttle inspect coolant have circulated Y C 1 Eng stop and remove water pump cover start the motor to inspect pump its rotation Y Water pump repair Water hose clogged D Close ...

Page 153: ...ard correct and check again E 3 Keep eng 3000 4000 rpm and inspect coolant flow into reserve tank after the temperature gauge over 3 checks Y E 4 Remove thermostat from holder then heats it by water directly to check its operation N Replace thermostat Y Refill with coolant then check again For bleed the air bubbles completely open radiator cap and start engine while engine is cool then press water...

Page 154: ...ne is completely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilling system with coolant and bleeding the air bubbles Run the engine and remove by pass pipe Check by pass hole whether has the air bubble to emit If emits without the ...

Page 155: ... temperature elevating in the cooling system the refrigerant backflow floods Upper Lower Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Removal Place a ...

Page 156: ... 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 thermo switch Caution Liquid packing must be applied to the thermo switch before installing to avoid damaging the radiator ...

Page 157: ...er 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 the drain bolt to drain out the coolant...

Page 158: ...ever the thermostat and the thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve begins to open 65 72 Valve stroke 0 05 5mm Installation Install the thermostat Install the t...

Page 159: ...PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 160: ...13 BODY COVER Mechanism Diagram 13 1 13 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 161: ...properly installed during the assembly l Never compact forcefully or hammer the quard and the covers during assembly 13 2 Fuel tank cover Right and left foot board Right and left foot board Right and left front internal fender Right and left front shock mount front bumper Front air inlet plate Right and left head lamp support body cover Rear body cover Front protector rear protector Upper bracket ...

Page 162: ...emove cable and battery fixed Remove 1 screw and take off shift lever Remove fuel cap Remove 4 screws and then remove fuel tank cover Installation Install in reverse order of removal procedures 13 3 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 163: ...ot board remove right or left foot board each side 3 bolts Remove bolts from right or left front internal fender each side 5 bolts and then remove right or left front internal fender Remove 4 bolts from front bumper Remove 2 screws from front bumper Installation Install in reverse order of removal procedures 13 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 164: ...from right and left head lamp support each side 2 bolts Remove bolts from front air inlet plate each side 2 bolts and then remove front air inlet plate Remove bolts from front body cover each side 1 bolts Installation Install in reverse order of removal procedures 13 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 165: ...ve power source couplers and then remove front body cover Remove bolts each side 1 bolts Remove 2 couplers Installation Install in reverse order of removal procedures 13 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 166: ...olts from rear body covert Remove 1 nut from bear reflector assembly each side 1 bolts Remove number plate lamp couplers rear lamp assembly couplers L R and turn signal lamp couplers L R Installation Install in reverse order of removal procedures 13 7 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 167: ...dy covert Remove 2 bolts from front protector Remove 2 bolts from front protector and then remove front protector Remove bolts from bear protector each side 1 bolts Installation Install in reverse order of removal procedures 13 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 168: ...e bear protector Remove bolts from upper bracket assembly each side 2 bolts Remove speedometer assembly couplers and then remove upper bracket assembly Installation Install in reverse order of removal procedures 13 9 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 169: ...13 BODY COVER 13 10 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 170: ...8 Brake fluid replacement Air bleed 14 9 Front Brake Caliper 14 10 Brake Disk 14 11 Front Brake Master Cylinder 14 11 Mechanism Diagram 14 1 Front brake master cylinder Brake hose bolts 3 5kgf m Front pressure control valve Air bleed valve 0 5kgf m To rear pressure control valve Brake caliper bolt 3 25kgf m Bearing Brake caliper Brake pad Brake disc PDF created with pdfFactory Pro trial version ww...

Page 171: ...parts to avoid damage Check the operation of the brake system before riding Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 3 500 2 000 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter 14 000 14 043 14 055 Master ...

Page 172: ...ke lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Hard steering 1 Faulty tire 2 Insufficient tire pressure Front w...

Page 173: ...emove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 5 0kgf m 4 nuts Front Wheel Hub Removal Remove front brake caliper 2 bolts 2 bolts Remove cotter pin wheel hub nut and washer Remove wheel hub and brake disk Wheel hub nut Cotter pin 14 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 174: ...nstall the front brake disk to the wheel hub Install wheel hub and brake disk on to knuckle Install wheel hub washer and tighten the wheel hub nut Torque 9 0kgf m Install cotter pin 4 bolts Wheel hub nut Cotter pin Install front brake caliper Torque 3 5kgf m 2 bolts 14 5 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 175: ...ced with new lining when the brake pad wear limit reaches the brake disk Caution Check the front brake lining must be removed front wheel first Park the ATV on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 4 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minute In order to ...

Page 176: ...ed surfaces plastic or rubber components may result in their damages Remove the master cylinder cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in the master cylinder Clean the dirty brake disk Caution The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake performan...

Page 177: ...finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution Do not release the brake lever before the drain valve is closed Always check the brake fluid ...

Page 178: ...to the brake disk Brake lining replacement Remove two guide pins Compress caliper mounting plate and then remove brake linings Install new linings and tighten the guide pins Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 18 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to ...

Page 179: ... brake performance Brake lining includes the asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Front Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a se...

Page 180: ...ed value exceeds allowable limit Allowable limit 13 945 mm Master Cylinder Assembly Caution It is necessary to replace the whole set comprising piston spring piston cup and cir clip Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master...

Page 181: ...shers Tighten the brake hose bolt to the specified torque value Torque 3 2kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes Brake light switch Brake lever bolt Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and b...

Page 182: ...teering Tie Rod 15 6 Knuckle 15 7 Front Cushion 15 8 Suspension Arm 15 9 Toe In 15 10 Mechanism Diagram 300 350 kgf cm 300 350 kgf cm 250 350 kgf cm 700 900 kgf cm 15 450 550 kgf cm 250 350 kgf cm 400 430 kgf cm 400 430 kgf cm 450 550 kgf cm 450 550 kgf cm 450 550 kgf cm 600 kgf cm 450 550 kgf cm 15 1 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 183: ...re Faulty steering shaft bushing Damaged steering shaft bushing Front wheel wobbling Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Steers to one side Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment Front suspension noise Loose front suspension fasteners Binding suspension link Ha...

Page 184: ...o not let foreign materials enter into the cylinder Handle protect cover brocket bolts Master cylinder bolts Remove 2 screws and then remove throttle hosing holder and throttle hosing 2 Screws Loosen the socket bolts for the front brake master cylinder and remove front brake master cylinder Caution Do not let foreign materials enter into the cylinder Master cylinder bolts Handle protect cover broc...

Page 185: ...ndle mounting bolt and then remove the handle upper holder handle Remove 2 nuts to remove handle under holder and meter bracket 4 socket bolts 2 Nuts Installation Install in reverse order of removal procedures Torque value Handlebar under holder nut 4 0kgf m Handlebar upper holder bolt 2 4kgf m 15 4 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 186: ...nd then remove steering shaft holder nut fixed plate pressed plate and steering shaft Inspection Check oil rings for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit Ø39 5 mm Fixed plate Oil rings Installation Install in reverse order of removal procedures Apply with grease onto oil liner and holder Torque value Steering shaft holder bolt 3 4kgf m Steering...

Page 187: ...Inspect the ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Ball joint Installation Install the ball joint with adjustment groove on the wheel side Install tie rod nuts and tighten the nuts Torque value 5 0kgf m After tightened the tie rod nut install the cotter pin Adjustment groove 15 6 PDF created with pdfFac...

Page 188: ...all joints by ball joint driver Remove the knuckle Special Tool ball joint driver Universal holder Ball joint Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking Installation Install in reverse order of removal procedures Torque value Steering tie rod nut 5 0kgf m Ball joint nut 5 0kgf m After tightened the nuts install the cotter pins Knuckle Ball joint Ball jo...

Page 189: ... cushion under bolt nut and remove the bolt Remove front cushion upper bolt nut and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value Front cushion nut 4 6kgf m Nut Nut 15 8 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 190: ...sion arm Loosen under suspension arm nuts remove swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bending Suspension arm nuts and bolts Suspension arm nuts and bolts Installation Install in reverse order of removal procedures Torque value Suspension arm nut 5 0kgf m Lubricate with grease into suspension arm 15 9 PDF created with pd...

Page 191: ...the wheels turn 180 degree so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 10 3mm If the toe in is out of standard adjust it by hanging the length of the tie rods equally by turning the tie rod while holding the ball joint Loosen two side tie rod lock nuts turn the tie rods t...

Page 192: ...e fluid replacement Air bleed 16 9 Rear Brake Caliper 16 10 Brake Disk 16 11 Rear Brake Master Cylinder 16 11 Rear Cushion 16 14 Mechanism Diagram 16 1 Rear brake master cylinderB Rear brake master cylinder A Rear pressure control valve To Brake calipers Brake caliper Brake disc Brake pad Brake disc bolts 4 26kgf m Brake caliper bolts 3 26kgf m 16 PDF created with pdfFactory Pro trial version www ...

Page 193: ...on of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 4 000 2 500 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diameter hand brake 14 000 14 043 14 055 Master cylinder piston outer diameter hand brake 13 957 13 984 13 945 Master cylinder inner diameter foot brake 15 900 15 943 15 955 Master cylinder piston outer diameter foot...

Page 194: ...Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Deformed or warped brake disk Brake noise 1 Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Vibration or Wobble 1 Axle is not tightened well 2 Bent...

Page 195: ...en remove rear wheels Installation Install the rear wheel and tighten the nuts Torque 2 4kgf m Removal Remove the brake caliper 2 nuts and then remove the brake caliper Installation Install the rear wheel shaft connecter Install wheel shaft connecter washer and tighten the wheel shaft connecter nut Torque 2 4kgf m Install cotter pin 16 4 PDF created with pdfFactory Pro trial version www pdffactory...

Page 196: ...e brake pad wear limit reaches the brake disk Caution Check the rear brake lining must be removed rear wheel first Brake lining wears limit grooves Brake disk Park the ATV on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BRAKE OIL DOT 4 Caution The vehicles inclined or just stop the survey oil level could not be accurate had to settle the 3 5 minu...

Page 197: ... REAR CUSHION Rear Wheel Axle Remove rear wheel housing 4 bolts Escape rear wheel housing from rear fork assy Remove tow ball mount 4 bolts 2 bolts each side 16 6 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 198: ...ers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on bearing seat If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Caution Never install used bearings Once bearing removed it has to be replaced with new one 16 7 PDF created with pdfFactory Pro trial ver...

Page 199: ... plastic or rubber components may result in their damages Fluid cup Fluid cup Remove the brake fluid cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in the master cylinder Clean the dirty brake disk Caution The dirty brake lining or disk will reduce the brake performance To mixed non compatible brake fluid will reduce brake perf...

Page 200: ... brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution Do not release the brake lever before the drain valve is closed Always check the brake fluid level when ca...

Page 201: ...sk Installation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution Use M8 x 20 mm flange bolt only Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque 3 5kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake lining replacement Remove two gui...

Page 202: ...se the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Rear Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Brake lever bolt Brake light switch coupler Brake lever nut Handle left ...

Page 203: ...clip is seated securely in the groove Install the rubber boot into groove properly Rubber boot Piston Piston cup Cir clip Spring Master cylinder Master Cylinder Install Caution Improper routing may damage leads hoses or pipes Caution Kink of brake leads hose or pipe may reduce brake performance Handle left side rear brake master cylinder A Install the rubber pad into the groove correctly Place the...

Page 204: ...ush rod pin fist Loosen lock nut and turn adjustment nut and push rod bracket to adjustment brake free play Install fluid hose and clamp Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Add specified brake flui...

Page 205: ...shion under bolt Remove rear cushion upper bolt and then remove rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Tighten the rear cushion upper bolt and under nut to the specified torque value Torque 4 6kgf m Rear cushion upper bolt 16 14 PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 206: ...PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 207: ...ing Fan Thermo Switch 17 20 Thermo unit 17 21 Water Temperature Indicator Light 17 21 Mechanism Diagram Starter relay Fuse box Front brake switch Battery C D I Unitx Hazard control unit Winker rela Main switch Shift gear control unity Rear brake switch Thermo unit 17 DC Power outlet Start light winker horn brake switch Headlight relay Horn Regulator rectifier AC Generator Spark plug Ignition coil ...

Page 208: ...y The voltage must be checked with the voltmeter while charging the battery As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify with an ignition timing light after replacement if necessary Technical Specification Charging system Description Specification Battery Capacity 12V18Ah Charging rate 1 4A 5 10 hours standard ...

Page 209: ... of work Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection or short circuit of the power generation system Charging system does not operate properly Burnt fuse Poor contact open or short circuit Poor regulator Poor ACG Engine does not crank smoothly Primary win...

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