TGB CH1 Owner'S Manual Download | Manualshive

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10. A.C. GENERATOR/STARTING CLUTCH TGB

10-4

RIGHT CRANKCASE COVER
INSTALLATION

Install setting pin and new gasket on the
crankcase.
Replace the right crankshaft oil seal of the
crankcase and apply some oil onto the oil
seal lip.
Install right crankcase cover onto the right
crankcase. (8 bolts)

Torque value: 1.5~2.0kgf-m

MOUNTED COIL SET
INSTALLATION

Install the coil set onto right crankcase
cover. (2 bolts)
Install pulse generator. (2 bolts)

Torque: 1.5~2.0kgf-m

Tie the wire harness hose onto the indent of
crankcase.

Caution

Install A.C. generator connector and pulse
generator connector.

FLYWHEEL INSTALLATION

Make sure that there is no magnetic powder.
If so, clean up it.
Align insert on crankshaft with the flywheel
groove, and then install the flywheel.
Hold the flywheel with flywheel holder, and
tighten its nut.

Torque value: 5.0~6.0kgf-m
Special service tool:
Universal fixture

Make sure that the wire harness is placed
under the pulse generator.

Universal fixture

Auto by-start
connector

generator connector

Pulse generator
connector

Pulse generator

Coil

8 bolts

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Summary of Contents for CH1

Page 1: ...CH1 CR1 50 OWNER MANUAl MAINTENANCE HANDBOOK TAIWAN GOLDEN BEE CO LTD ...

Page 2: ... MAINTENANCE INFORMATION 2 LUBRICATION SYSTEM 3 FUEL SYSTEM 4 ENGINE REMOVAL 5 CYLINDER HEAD VALVE 6 CYLINDER PISTON 7 V TYPE BELT DRIVING SYSTEM KICK STARTER ARM 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 SPECIAL TOOL 12 ...

Page 3: ... Particulate 15 Type 4 STROKE ENGINE CO 2 5 0 5 Installation and arrangement Vertical below center incline 80 Exhaust Concentration HC Below 800 PPM Fuel Used Unleaded 92 95 Head 12V 35 35W Cycle Cooling 4 stroke forced air cooled Rear 5W Bore φ 39 0 mm Brake 21W Stroke 41 5 mm LAMPS Turn 10W 4 Cylinder Number Arran gement Single Cylinder horizontal Inflation Pressure Ffront Rear 1 75 f 2 2 10 f 2...

Page 4: ...etor heat protector connecting nuts 2 6 0 7 1 1 Engine oil draining plug 1 12 3 5 4 5 Engine oil strainer cap 1 30 1 3 1 7 Gear oil draining plug 1 8 1 0 1 5 Gear oil filling bolt 1 8 1 0 1 5 Oil pump screws 3 3 0 1 0 3 Engine left side cover bolts 9 6 0 8 1 2 Rubber washer attached Camshaft chain tensioner bolt 1 8 0 45 0 6 Hex socket bolt Camshaft chain adjuster bolts 2 6 0 8 1 2 Clutch driving ...

Page 5: ...orque Values for Reference TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE 5mm bolt nut 0 45 0 60kgf m 3mm screw 0 05 0 08kgf m 6mm bolt nut 0 80 1 20kgf m 4mm screw 0 10 0 15kgf m 8mm bolt nut 1 80 2 50kgf m 5mm screw 0 35 0 50kgf m 10mm bolt nut 3 00 4 00kgf m 6mm screw SH nut 0 70 1 10kgf m 12mm bolt nut 5 00 6 00kgf m 6mm bolt nut 1 00 1 40kgf m 8mm bolt nut 2 40 3 00kgf m 10mm bolt nut 3 50 4 50kgf m...

Page 6: ... the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged 1 Malfunction of spark plug 2 Spark plug foul 3 Malfunctio...

Page 7: ...ion No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel level too low in carburetor 6 Fuel nozzle clogged in carburetor 1 Malfunction of CDI 2 Malfunction of AC alternator 1 Cylinder piston ring worn out 2 Cylinder gasket leaked 3 Sand hole in compression parts 4 Valve deterioration 5 Seized piston ring 1 Remove fore...

Page 8: ...el cup Check if carburetor clogged 1 Incorrect ignition timing malfunction of CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation gasket 2 Carburetor lock loose 3 Poor intake gasket 4 Poor carburetor O ring 5 Vacuum hose crack 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or shor...

Page 9: ...on 2 Driving disk damaged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance 1 Driving belt worn out or deformation 2 Balance weight roller worn out 3 Driving...

Page 10: ...SSION PRESSURE 2 7 DRIVING SYSTEM 2 7 PRECAUTIONS IN OPERATION Specification capacity 850 c c Engine Oil change 750 c c capacity 120 c c Transmission Gear oil change 110 c c Clearance of throttle valve 2 6 mm Spark plug TORCH A7RC Gap 0 6 0 7 mm F Mark in idling speed Before TDC 13º 2200 rpm Full timing advanced Before TDC 26º 8000 rpm Idling speed 2200 100 rpm Cylinder compression pressure 12 2 k...

Page 11: ...acement C Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the motorcycle 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 cleaner element more ofte...

Page 12: ...assembly 850cc Change 750cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen wash it off with suitable solvent recommended using compressed air Check O ring for damage replace if necessary Reinstall st...

Page 13: ...R OIL 140 VALVE CLEARANCE ADJUSTMENT Caution Remove luggage box and front center cover Remove the left body cover left side cover Remove cylinder head cap Remove the ignition timing check hole on the cooling fan cover With T type wrench turn crankshaft in clockwise motion so that mark T on the generator flywheel aligns with the mark on the crankshaft and camshaft is at TDC position also as same as...

Page 14: ...aust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and value on the exhaust analyzer Repeat step 2 to step 4 procedures until measured value within standard Emission standard CO below2 5 0 5 HC belo...

Page 15: ...rator Replace these components if malfunction of these parts are found SPARK PLUG Appointed spark plug TORCH A7RC Remove luggage box Remove body side cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug gap 0 6 0 7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Screw the park plug into the plug hole wit...

Page 16: ...amber or piston head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase 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 above 17 5 mm Clutch pad Start the motorcycle and gradua...

Page 17: ...TIONS 3 2 TROUBLE DIAGNOSIS 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 7 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lubrication Inner passage Connecting rod Oil pump Oil strainer Crankshaft ...

Page 18: ...R OIL unit mm Items Standard Limit Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side and body 0 05 0 10 0 20 Torque value Engine oil drain plug 3 5 4 5kgf m Engine oil screen cover 1 3 1 7kgf m Gear oil drain bolt 0 8 1 2kgf m Gear oil filling bolt 1 0 1 4kgf m Oil pump connection screw 0 1 0 3kgf m TROUBLE DIAGNOSIS Low engine oil level O...

Page 19: ...bolt and tighten it Torque value 3 5 4 5 kgf m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it Torque value 1 3...

Page 20: ...to chapter10 Remove the engine right crankcase cover Make sure that the pump axle can be rotated freely Remove the oil pump driving gear nut Remove oil pump body bolts 3 bolts Remove the oil pump pin Remove the oil pump Remove the 2 O rings pump driving gear nut 3 bolts pin 2 O rings ...

Page 21: ...inner and outer rotors Limit below 0 12 mm Check clearance between rotor side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw ...

Page 22: ...e 2 O rings Install the oil pump pin Install the oil pump Install the oil pump body bolts 3 bolts Install the oil pump driving gear nut Install the alternator refer to chapter10 Install the engine right crankcase cover pump driving gear nut 3 bolts pin 2 O rings ...

Page 23: ...evel too low Standard quantity 100cc Replacement 90 cc Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it with new one Torque Value 0 8 1 2 kgf m Add new gear oil 100 c c from the gear oil filling hole and then install the gear oil filling ho...

Page 24: ...quantity adjustment screw 1 3 4 3 4 turns Torque value Fuel valve tightening nut 1 5 2 0 Kgf m Tool Special service tools Vacuum air pressure pump General service tools Fuel level gauge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline z Do not bend or twist throttle valve cable Damaged cable wi...

Page 25: ...rect idle speed z Malfunction of carburetor z Dirty fuel Intermittently misfire as acceleration z Malfunction of ignition system Late ignition timing z Malfunction of ignition system z Malfunction of carburetor Power insufficiency and fuel consuming z Fuel system clogged z Malfunction of ignition system Mixture too lean z Clogged fuel injector z Vacuum piston stick and closed z Malfunction of floa...

Page 26: ...nnectors Release the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress spring and vacuum piston vacuum hose auto by starter throttle valve cable clamp strip of isolator vacuum hose Screws ...

Page 27: ... seat to vacuum piston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm z Note direction as installing the piston set because wrong direction of the piston cab not be installed z Align the indent of vacuum diaphragm with the carburetor body fuel needle seat injector needle Piston spring piston...

Page 28: ...screws screw x 2 of the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the vacuum diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation direction Screws 2 vacuum diaphragm screws ...

Page 29: ...it clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing plate screw and then remove the plate and auto by starter from carburetor Valve inspection Check if auto by starter and valve needle for damage or wear out Installation Install auto by starter to the ca...

Page 30: ... passages with compressed air 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 z Take care not to damage jets and adjust screw z Before removing adjustment screw turn it all the way down and note the number of turns z Do not turn adjust...

Page 31: ... air volume adjustment screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO value fluctuated repeat the procedures described above for adjusting to standard value Set the adjustment screw in according to number of turns noted before it was removed z Ch...

Page 32: ...n Install the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove left body side little cover 2 screws Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With compressed air to clean dirty around the element Replace it if it is too dirty to clean Cautions The air cleaner element is made of paper so do not soap it into water or wash it with wat...

Page 33: ...lled on the frame 1 Carburetor 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Item Specification Replacement 750 c c Engine Oil Capacity Disassemble 850 c c Replacement 110 c c Gear Oil Capacity Disassemble 120 c c Torque Values Engine suspension bolt 4 5 5 5kgf m Engine suspension nut 4 5 5 5kgf m Bolt of rear shock absorber upper connectio...

Page 34: ...the spark plug Remove the fuel pipe vacuum hose and throttle valve cable from the carburetor Loose the strap screw of the air cleaner guide and then the air cleaner guide Remove the exhaust muffler Bolts 2 Nuts 2 Spark plug Bolts 2 Auto by start connector Generator connector pulse generator connector Spark plug Throttle valve cable The strap screw ...

Page 35: ... wheel Nut 1 Remove the air cleaner connection bolts 2 bolts Remove the rear brake cable nut Remove the rear brake cable Remove the rear shock absorber lower bolt Nut 1 Rear shock absorber lower bolt Bolts 2 RR Brake cable nut RR Brake cable ...

Page 36: ...ushion rubber for damage Replace them with new ones if so INSTALLATION OF ENGINE Check if the bushings of engine suspension frame and shock absorber for damaged If so replace with new ones Install the engine according to the reversing order of removal y With a bracket to support the engine to prevent from it damage by falling down as removing the engine Bushing Strap screw of guide Engine suspensi...

Page 37: ...Rear wheel axle nut Torque Value 11 0 13 0kgf m y Notice both feet and hands safety for squeezing as engine installation y Do not bent or squeeze each wires or hose y Route all cables and wires in accordance with the routine layout Rear wheel axle nut 1 Brake cable nut Rear shock absorber lower bolt RR Brake cable nut RR Brake cable Engine suspension nut ...

Page 38: ...NDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD INSPECTION 6 8 VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLATION 6 13 VALVE CLEARANCE ADJUSTMENT 6 14 MECHANISM DIAGRAM 1 0 1 4 kgf m 0 7 1 1 kgf m 1 0 1 4 kgf m 1 0 1 4 kgf m 1 8 2 2 kgf m ...

Page 39: ...9 OD of valve stem Exhaust 5 00 4 97 4 98 OD of Guide 5 00 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 030 0 057 0 100 Free length of valve spring 32 410 Valve Valve seat width 1 000 1 600 Connection Flatness of cylinder head 0 050 Torque Value Cylinder head cover bolt 0 8 1 2kgf m Cylinder head bolt LH 0 8 1 2kgf m Cylinder head Nut 1 0 1 4kgf m apply with oil ...

Page 40: ...on y Poor sealing on valve seat y Improper spark plug installation 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder surface 3 Piston y Piston ring worn out High compression pressure y Too much carbon deposit on combustion chamber or piston head Noise y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Cam chai...

Page 41: ...rewdriver to tighten the screw of camshaft chain adjuster in a clockwise motion for release adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Remove camshaft holder nuts and washers Caution Loosen the nuts diagonally by 2 ...

Page 42: ...bearing Disassembly Of Camshaft Holder With a 5 mm bolt to screw in the cam rocker arm shaft so that take it out Remove cam rocker arm Inspection Of Camshaft Holder Check if the camshaft holder cam rocker arm and rock arm shaft for wearing out or damage Caution Measure the cam rocker arm I D of the camshaft holder Service Limit Replace when it is above 10 10 mm y Further check is necessary if any ...

Page 43: ...e when it is above 9 910 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD REMOVAL Remove double seat luggage box and front center cover Remove the engine refer to Chapter 5 Remove the cooling fan cover Remove the engine shroud Remove the camshaft chain and camshaft cooling fan cover engine shroud camshaft Camsha...

Page 44: ...alve spring and valves Caution Special Service Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution y Do not damage the matching surfaces of cylinder and cylinder head y Avoid residues of gasket or foreign materials falling into crankcase as cleaning In order to avoid to ...

Page 45: ...alve stem in valve guide and measure record the valve stem outer diameter Service Limit IN 4 900mm EX 4 900mm Valve guide Caution Special Service Tool 5 0mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 030mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide...

Page 46: ...TGB 6 CYLINDER HEAD VALVE 6 9 EX 0 10mm ...

Page 47: ... seat and clean up all metal residues from cylinder head Special tool Valve guide reamer 5 mm 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 It must correct valve seat when replacing valve guide y Do not let torch heat cylinder head directly Otherwise ...

Page 48: ...ve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat Caution Use 32 cutter to cut a quarter upper part out y Do not let emery enter into between valve stem and valve guide y Clean up the emery after corrected and apply with red paint onto contact faces of valve and valve seat Replace the valve with new one if valve seat is roughness wear out or...

Page 49: ...hat a seal track will be created on contact surface Caution If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat with 45 cutter to specified width Make sure that all roughness and uneven faces had been grinded The contact surfaces o...

Page 50: ...alve spring compressor to press valve spring Install valve split locks and release the valve compressor Caution Special tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly Caution The closed coils of valve spring should face down to combustion chamber In order to avoid to loosing spring tension do not compress the spring too much Its length is based o...

Page 51: ...er arm shaft Caution With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other single hole of the cam sprocket is in upward Then install the cam chain onto the cam sprocket The tangent of rocker shaft of int...

Page 52: ...0 02mm With flat screwdriver turn the cam sprocket adjuster in counter clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the adjuster hole Tighten the bolt cap of the adjuster adjustment hole Caution Replace the O ring of the cylinder head with new one Install the cylinder head Tighten the cylinder h...

Page 53: ... 1 MECHANISM DIAGRAM 7 1 PRECAUTIONS IN OPERATION 7 2 TROUBLE DIAGNOSIS 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 MECHANISM DIAGRAM 0 8 1 2kgf m ...

Page 54: ...kirt Clearance between piston and cylinder 0 025 0 040 0 100 Piston Piston ring ID of piston pin hole 13 002 13 008 13 040 OD of piston pin 13 000 12 994 13 000 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 13 13 005 13 020 TROUBLE DIAGNOSIS Low Or Unstable Compression Pressure Cylinder or piston ring worn out Compress pressure to high Too much carbon dep...

Page 55: ...er 6 Remove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase Cylinder 2 bolts Cam chain auto adjuster Cam chain guide ...

Page 56: ...ctive in the cylinder Service limit 38 090mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Check Cylinder...

Page 57: ... the carbon in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Take out the piston rings and place them respective into cylinder below 20mm of cylinder top Measure each piston ring gaps Caution Service Limit Top ring replace if over 0 50mm 2nd ring replace if ov...

Page 58: ...he inner diameter of piston pin hole Service Limit 13 040mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 38 970mm Compare measured value with service limit to calculate the clearance between piston and cylinder The measurement position is 10 mm distance from piston bottom side and 90 to piston pin ...

Page 59: ...lace the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston rings can be rotated freely after installed Top groove 2nd groove Oil groove Top ring 2nd ring Oil ring Spacer Side ring Side ring Over 20 mm 120 ...

Page 60: ... installing piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto adjuster 2 bolts y Do not let the opening of piston pin snap ring align with the opening piston ring y Place a piece of cleaning cloth between piston skirt section and crankcase in...

Page 61: ...kness of clutch lining 4 000 Free length of driving pulley spring 97 20 OD of driving pulley 33 965 33 985 33 940 ID of sliding pulley 34 000 34 025 34 060 ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 5 0 6 0kgf m Clutch outer nut 5 0 6 0kgf m driving pulley nut 5 0 6 0kgf m Special Service Tools Clutch spring compressor Bearing puller inner type Clutch mounting nut wrench U...

Page 62: ...oor parts found Reassembly Apply with some specified grease on the gear shaft Install the friction spring of driving gear onto convex part of the case cover Install return spring and starter shaft as diagram shown Install kick starter arm temporary Rotate the lever and then align driving gear with width tooth on the starter shaft Install thrust washer and socket onto starter shaft Installation of ...

Page 63: ...ime Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited specification Service Limit 17 50mm Caution Using special service tools for tightening or loosening the nut Fixed rear wheel or rear brake only will damage reduction gear system y Using the genuine parts for rep...

Page 64: ...rsal fixture and then tighten nut to specified torque value Torque value 5 0 6 0 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily When install the driving belt if there is a arrow mark then the arrow mark must point to rotation motion If not the letters on the belt must be fo...

Page 65: ...ove driving pulley nut Remove driving pulley Remove the driving belt from the pulley Remove sliding pulley set and driving pulley hub from crankshaft Remove the belt and the starter gear Remove tilt plate Remove weight rollers from sliding pulley Crankshaft Driving pulley hub Sliding pulley Tilt plate Sliding pulley Roller driving pulley nut Starter gear ...

Page 66: ...sure each rollers outer diameter Replace it if exceed the service limit Service limit 15 92 mm Check the pulley hub if damaged or wear out Replace it if necessary Measure the pulley hub s outer diameter Replace it if exceed the service limit Service limit 20 025 mm Measure the pulley hub s inner diameter Replace it if exceed the service limit Service limit 20 028 mm Assembly Installation Install t...

Page 67: ...asher and nut Caution Hold driving pulley with universal fixture Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover The pulley surface has to be free of grease Clean it with cleaning solvent Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent To press down the up down sides of the driving belt can avoid to pressi...

Page 68: ...spring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring oil seal seat from sliding pulley INSPECTION Clutch outer Measure the inner diameter of clutch outer friction face Replace the clutch outer if exceed service limit Service limit 107 2 mm Do ...

Page 69: ...ged or worn components Measure the outer diameter of driven surface and the inner diameter of driven pulley Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the ins...

Page 70: ...sary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location Caution Install the spring snap into groove with pliers y Grease or lubricant will damage the clutch block and effect the block s connection capacity Shock absorption rubber Clutch bloc...

Page 71: ...bearing Install a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary y Its sealing end should be forwarded to outside as bearing installation y Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser y If the inner bearing equipped with oil seal on one side in the driven pulley then remove the oil seal f...

Page 72: ...belt spring and clutch 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 special nut wrench Remove the clutch spring compressor Torque value 5 0 6 0 kg m Install clutch driven pulley and driving belt onto driving shaft Oil seal O ring Spec...

Page 73: ...TE serial gear oils Oil quantity 120 c c 110 c c when replacing Tools Special service tools Inner type bearing puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover 2 0 2 4 kgf m Gear oil drain plug 1 0 1 4 kgf m Gear oil filling bolt 0 8 1 2 kgf m TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved Damaged driving g...

Page 74: ... box cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft and the gear are wear or damage Check if the final driving shaft and gear are burn wear or damage final driving shaft final driving gear countershaft countershaft gear driving shaft 7 bolts final drivin...

Page 75: ... or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Tool Press the bearing into cover with C type hydraulic presser or bearing installer Never install used bearings Once bearing removed ...

Page 76: ...er Bearing protector Install a new driving shaft bearing onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a new final driving shaft bearing onto crankcase Specified tool Press the bearing in with C type hydraulic presser or the bearing installer Apply with some grease onto the lip section of oil seal and th...

Page 77: ...eal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 0 2 4 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover Install the rear wheel Add gear oil Recommended usage SYM HYPOID GEAR OIL SAE 85W 140 110 cc standard capacity 100 cc when replacement final driving shaft countershaft final shaft gear dowel ...

Page 78: ...CAUTIONS IN OPERATION General information y Refer to chapter 5 Engine removal and installation y Refer to chapter 1 The troubleshooting and inspection of A C generator Specification Unit mm Item Service Limit ID of starting driven gear 32 060 OD of starting clutch cover 27 940 Torque value Flywheel nut 3 5 4 5kgf m Exhaust muffler bolt 6 mm 0 7 1 1kgf m Oil screen cover 1 3 1 7kgf m Special servic...

Page 79: ...muffler 2 bolts 2 nuts Remove the fan shroud Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the nut on the flywheel Special Service Tools Universal Fixture Flywheel Cooling fan Cooling fan shroud Coil Pulse generator Universal fixture Cooling fan Exhaust muffler Cooling fan shroud ...

Page 80: ...IGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 8 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase Caution Pulse generator Coil Do not damage the alternator coil Flywheel puller Coil Do not damage the connection surfaces Install a shaft protector on the right end of crankshaft to avoid damaging the c...

Page 81: ...2 bolts Torque 1 5 2 0kgf m Tie the wire harness hose onto the indent of crankcase Caution Install A C generator connector and pulse generator connector FLYWHEEL INSTALLATION Make sure that there is no magnetic powder If so clean up it Align insert on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel with flywheel holder and tighten its nut Torque value 5 0 6 0kgf...

Page 82: ...NG CLUTCH 10 5 Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Cooling fan Exhaust muffler Cooling fan shroud ...

Page 83: ...g or timing sprocket need be replaced then the crankshaft set have to replaced Specification Unit mm Item Standard Limit Left right clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Run out Below 0 030 Torque value Bolts for crankcase 0 8 1 2 kgf m Bolts for cylinder cylinder head 0 7 1 0 kgf m Engine oil draini...

Page 84: ...crankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Remove the cam chain Caution Special Service Tools Crankcase remover set 1 hex socket bolt 1 bolt z Never pry out the connection surfaces of crankcases as separating Otherwise the connection surfaces could be damaged and cause oil leaking z It have to separate the cam chain...

Page 85: ...s 2 Scrape gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase z Do not damage contact surface of the crankcase z Soap the gasket residues into solvent and the residues will be removed easily z The left and right bearings of crankshaft is to press fit onto the crankshaft ...

Page 86: ...ical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 60 mm 90...

Page 87: ...rankcase gasket Install the right crankcase and tighten the crankcase bolts 1 bolts Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution z Do not damage the cam chain as installing the crankshaft z The O ring must be installed into the bolt s...

Page 88: ...HAFT TGB 11 6 Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer Special service tools the oil seal installer ...

Page 89: ...T DISASSEMBLE PURPOSE LOOSE THE CLUTCH NUT ITEM UNIVERSAL HOLDER ITEM CLUTCH SPRING COMPRESSOR NO 440646 NO TGB 2301000 PURPOSE HOLDER THE MDF CLUTCH OUTER PURPOSE DISASSEMBLE THE CLUTCH ITEM TAPPET ADJUSTING WRENCH ITEM ACG FLYWHEEL PULLER NO NO TGB 2210100 PURPOSE ADJUST VALVE CLEARANCE PURPOSE REMOVE ACG FLYWHEEL ...

Page 90: ...NO PURPOSE OIL SEAL INSTALLATION PURPOSE OIL SEAL INSTALLATION ITEM GY6 STARTER GEAR PULLER ITEM CRANK PULLER NO TGB 2822100 GY6 NO TGB 1130000 PURPOSE REMOVE THE STARTER GEAR PURPOSE INSTALL CRANKCASE ITEM OUTER BEARING PULLER NO TGB 6204010 PURPOSE OIL SEAL INSTALLATION ...

Page 91: ...TGB 15 BRAKE SYSTEM 16 1 ...

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