TGB EST 1000 Page 207 Service Manual Download

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7-1. STEERING SYSTEM AND SUSPENSION

7-1-1

WHEEL AND TIRE

GENERAL

WARNING

Torque wrench tightening specifications
must strictly be adhered to.

Castle Nut

Torque:

950-1200 kgf-cm

Wheel Nut

Torque:

680-720 kgf-cm

WHEELS

Removal

1. Position the vehicles on a level surface.

2. Stop the engine, place the transmission in

PARK and lock the parking brake.

3. Loosen the wheel nuts slightly.

4. Elevate the appropriate side of the vehicle by

placing a suitable stand or jack under the

frame.

5. Remove the wheel nuts and remove the

wheels.

Installation

1. Verify the transmission is still in PARK and

the parking brake is locked.

2. Place the wheel in the correct position on the

wheel hub. Be sure the valve stem is toward

the outside and rotation arrows on the tire

point toward forward rotation.

3. Install the wheel nuts and finger tighten them

to align center of the wheel holes with the

center of the tapered nuts.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to the proper torque

specification.

WARNING

Do not rotate tires. The front and rear tires
have a different size. Respect direction of
rotation when applicable.

TIRES

WARNING

Do not rotate tires. The front and rear tires
have a different size. Respect direction of
rotation when applicable.

TIRE PRESSURE

WARNING

Tire pressure greatly affects vehicle
handling and stability. Insufficient pressure
may cause tire to deflate and rotate on
wheel. Excessive pressure may burst the
tire. Always follow recommended pressure.

Checks pressure when tires are cold before

using the vehicle. Tire pressure changes with

temperature and altitude. Recheck pressure if

one of these condition has changed.

TIRE PRESSURE

FRONT: 7 psi

REAR: 7 psi

Tire Inspection

Check tire for presence of slits, bulges, wear or

other damage. Replace if necessary.

Tire Replacement

WARNING

- Replace tires only with the same type and

size as original tires.

- For unidirectional thread pattern, ensure

that the tires are installed in the correct
direction of rotation.

Summary of Contents for EST 1000

Page 1: ...EST 1000 SERVICE MANUAL TAIWAN GOLDEN BEE CO LTD ...

Page 2: ...construction of the Blade 1000 are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice This service manual describes basic information of different system parts and system inspection service for Blade 1000 In addition please refer to the manual contents in detailed for the model you serviced in inspect...

Page 3: ...TEM 4 1 FUEL SYSTEM 4 2 FUEL INJECTION SYSTEM 5 1 ENGINE ASSEMBLY 5 2 ENGINE TOP END 5 3 ENGINE BOTTOM END 5 4 TRANSMISSION BEAR BOX 5 5 CONTINUOUSLY VARIABLE TRANSMISSION 6 DRIVE SYSTEM 7 1 STEERING SYSTEM SUSPENSION 7 2 ELECTRIC POWER STEERING 7 3 BRAKE SYSTEM BODY COVER 8 1 ELECTRIC SYSTEM 8 2 ELECTRIC DIAGRAM ...

Page 4: ...1 GENERAL INFORMATION 1 3 SERIAL NUMBER Frame Number and Engine Number TST 000001 ...

Page 5: ...ess 2 11 Special Tools List 2 12 Specification Fuel Tank Capacity 2300 c c Oil Filter Change 2000 c c Oil change 1800 c c Engine Oil New Engine 2300 c c Bear Box Capacity 900 cc Front Capacity 350 c c Transmission Gear oil Rear Capacity 500 c c Engine Radiator 2600 c c Capacity of coolant Reservoir upper 1100 c c Clearance of throttle valve 1 3 mm Type NGK DCPR8E Spark Plug Gap 0 7 0 8 mm Idling s...

Page 6: ...ase nipple L L Code C Cleaning replaced if necessary I Inspection cleaning and adjustment L Lubrication R Replacement T Tighten Have your ATV checked adjusted and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first R...

Page 7: ...ew Tighten the fixing nut and check acceleration operation condition Free play 1 3 mm Air Cleaner Open access cover Counterclockwise turn the lid and pull out the element Loosen the screw and separate the element Clean the sponge 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 For installation reve...

Page 8: ...ith 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 valve cl...

Page 9: ...tate the engine by means of starter motor Caution Rotate the engine until the reading in the gauge no more increasing Usually the highest pressure reading will be obtained in 4 7 seconds Compression pressure 9 0 2 bar Check following items if the pressure is too low Incorrect valve clearance Valve leaking Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it...

Page 10: ...otrest Remove 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 31 0 mm or above PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 11: ...er Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system hoses Air Bleed Operation Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hose...

Page 12: ...7 3 Make sure the brake lining condition Replace the lining if the brake lining wear limitation groove close to the brake disc Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining In order to maintain brake power balance the brake lining must be replaced with one set Brake Light Switch Starting Inhibitor Switch The brake light switch is to light up br...

Page 13: ... lighting 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 all nuts and bolts Rear Cushion Press down the rear cushion for several times to check it operation Check if...

Page 14: ...ire surface is ticked with nails stones or other materials Appointed tire pressure Tire size Front Tire Rear Tire Tire pressure as cold 7 psi 7 psi Check if front and rear tires pressure is in normal Measure tire thread depth from tire central surface Replace the tire if the depth is not come with following specification Front tire 1 5 mm Rear tire 2 0 mm Nuts Bolts Tightness Perform periodical ma...

Page 15: ...AME BEARING 924384 REMOVER φ15 PARTS NO 440652 PARTS NAME BEARING 924384 REMOVER φ20 PARTS NO 440653 PARTS NAME BEARING 924384 REMOVER φ45 PARTS NO 440656 PARTS NAME L CRANK CASE OIL SEAL REMOVER PARTS NO 552303 PARTS NAME PISTON ROD CONNECTING HOLDER PARTS NO 440662 PARTS NAME CYLINDER HEAD VALVE GAP ADJUSTER PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 16: ...560001 PARTS NAME FLYWHEELREMOVER PARTS NO 560002 PARTS NAME FLYWHEEL INSTALLER PARTS NO 560003 PARTS NAME RIGHT CRANKCASE MECHNICAL SEAL INSTALLER REMOVER PARTS NO 560004 PARTS NAME DRIVE PULLEY FIXING ROD PARTS NO 560005 PARTS NAME DRIVEN PULLEY FIXING TOOL PARTS NO 560006 PARTS NAME DRIVE PULLEY REMOVER PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 17: ...PARTS NAME DEAR DIFF NEEDLE BEARING REMOVER W 440649 Ø20 mm PARTS NO 560010 PARTS NAME REAR DIFF BEARING SPACER INSTALLER PARTS NO 552312 PARTS NAME EPS STEERING BEARING SEAT SOCKET PARTS NO 560011 PARTS NAME PLAIN BEARING INSTALLER LEFT CRANKCASE PARTS NO 560012 PARTS NAME PLAIN BEARING REMOVER LEFT CRANKCASE PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 18: ...T CRANKCASE PARTS NO 560016 PARTS NAME CRANKCASE COVER LH PLAIN BEARING REMOVER LEFT CRANKCASE PARTS NO 560017 PARTS NAME GOVERNOR CUP INSTALLER REMOVER KIT DRIVE PULLEY PARTS NO 560018 PARTS NAME DRIVE PULLEY FIXING SEAT FOR INSTALL AND REMOVE PARTS NO 560019 PARTS NAME HAFT SHEAVE PRESSING TOOL PARTS NO 560020 PARTS NAME DRIVEN PULLEY FIXING SEAT FOR INSTALL AND REMOVE PDF created with pdfFactor...

Page 19: ...lve guide or seat worn out Piston ring worn out Camshaft worn out Camshaft main bearing worn out Low oil pressure Low engine oil level Clogged in oil strainer circuits or pipe oil radiator gasket Oil pump damage Oil pressure valve oil filter Dirty oil No oil change in periodical Cylinder head gasket damage Piston ring worn out Camshaft worn out Camshaft main bearing worn out Items Standard mm Limi...

Page 20: ...e Oil and oil filter must be replaced at the same time Oil change and oil filter replacement should be done with a warm engine WARNING Engine oil can be very hot Wait until engine oil is warm Place a drain pan under the engine drain plug area Clean the drain plug area Unscrew drain plug and discard the gasket ring Remove dipstick Allow oil to drain completely from crankcase NOTE Oil condition give...

Page 21: ...are not leaking Dispose oil and filter as per your local environmental regulation INSPECTION ENGINE OIL PRESSURE NOTE The engine oil pressure test should be done with a warm engine 90 and the recommended oil Remove the oil pressure switch Install PRESSURE GAUGE and ADAPTER HOSE The engine oil pressure should be within the following values OIL PRESSURE 1250 RPM 6000 RPM MINIMAL 10 psi 39 psi NORMIA...

Page 22: ...Remove oil filter drain screw and washer Drain out the oil inside the filter housing Remove three retaining screws and cover Remove oil filter Oil Filter Inspection Check and clean the oil filter inlet and outlet area for dirt and other contaminations Oil Filter Installation Install a new O ring on oil filter Install the filter into the cover Apply engine oil on O ring and grease on the end of fil...

Page 23: ...isconnect the connector from oil pressure switch Use multimeter to check the continuity Replace the oil pressure switch if necessary If OK check the continuity of the wiring harness Oil Pressure Switch Removal Unplug then unscrew the oil pressure switch Oil Pressure Switch Installation NOTE Install oil pressure switch with LOCTITE 243 TORQUE 1 7 kgf m ENGINE OIL PRESSURE VALVE The oil pressure val...

Page 24: ...L RADIATOR Oil Radiator Removal Drain engine oil Drain coolant Remove oil radiator cap retaining bolts Place rags or towels under oil cooler to catch remaining oil and coolant Remove oil radiator and discard gasket Oil Radiator Inspection Check oil radiator for cracks or other damage Replace if necessary Oil Radiator Installation For installation reverse the removal procedure Wipe off any oil and ...

Page 25: ...r needle pin thrust washer oil pump flange bolts oil pump cover screws and pull oil pump cover oil pump shaft with inner rotor and outer rotor Inspection Inspect oil pump for marks or other damages Check for scratches din crankcase between outer rotor and oil pump bore If so replace damaged parts Check inner rotor for corrosion pinholes or other damages If so replace oil pump shaft assembly PDF cr...

Page 26: ...f the oil pump as shown Difference between measurements should not exceed 0 2 mm If so replace the complete oil pump assembly NOTE When the axial clearance of the oil pump shaft assembly increases the oil pressure decreases Installation For installation reverse the removal procedure NOTE The outer rotor and inner rotor are marked When installing make sure both markings are on the upper side After ...

Page 27: ...sh break out and injure your eyes Check engine oil strainer for cracks or other damage Replace if damaged Installation For installation reverse the removal procedure REED VALVE The engine is equipped with reed valve which prevents accumulation of large oil quantities in the crankcase The reed valve is fitted into the crankcase Valve Removal Remove Reed valve three retaining bolts Stopper plate Ree...

Page 28: ...4 1 FUEL SYSTEM 4 1 1 FUEL TANK AND FUEL PUMP ...

Page 29: ...pment when working on pressurized fuel system Wear safety glasses WARNING Do not allow fuel to spill on hot engine parts and or on electrical connectors When the repair is completed ensure that all hoses are connected and secured Fuel lines remain under pressure at all times Proceed with care when removing installing high pressures test equipment Disconnect the fuel pump electrical connector to di...

Page 30: ...hould the vehicle be overturned Fuel Pump Assembly The fuel pump assembly is inserted in the fuel tank It provides fuel delivery for EFI system and encompasses the following components Electric fuel pump Fuel pre filter Fuel pressure regulator Fuel level sender Fuel Filters The fuel filter is located on the right of the fuel tank which connected fuel line before go into the fuel injector nozzle Fo...

Page 31: ...L ADAPETR between disconnected hose and fuel rail 7 Turn ignition key ON and observe fuel pressure FUEL PRESSURE 300 kPa 8 Start engine and observe fuel pressure 9 Stop engine 10 Release fuel pressure by running engine until it runs out of gas 11 Remove tool and connect hose on fuel rail Test Conclusion The fuel pressure should be within specification in static or dynamic tests Rapid fuel pressure...

Page 32: ...essure test Oetiker Clamp Replacement To secure or cut clamp on fuel lines use Oetiker pliers FUEL TANK Fuel Tank Draining Remove the fuel tank cap and siphon gas into an approved fuel container Fuel Tank Removal 1 Drain fuel tank 2 Release fuel pressure by running engine until it runs out of gas 3 Disconnect battery 4 Remove rear cover RH side cover footrest and RH rear tire 5 Disconnect the fuel...

Page 33: ...nsure there are no leaks by performing FUEL TANK LEAK AND PRESSURE TEST FUEL PUMP Fuel Pump Quick Test 1 Turn ignition key to ON 2 Listen the fuel pump operation 3 Fuel pump should runs for a few seconds then stop If fuel pump does not runs carry out the following step Check fuel pump fuse Check fuel pump relay Carry out a fuel pump input voltage test Fuel Pump Input Voltage Test 1 Remove body cov...

Page 34: ...k wiring and connector from fuse box to ECU connector Repair or replace as necessary Fuel Pump removal 1 Release fuel pressure by running engine until it runs out of gas 2 Remove the body cover 3 Disconnect fuel pump electric connector 4 Disconnect high pressure hose at fuel pump using special tool as shown 5 Remove eight fuel pump retaining bolts WARNING Fuel vapors are flammable and explosive un...

Page 35: ... operation FUEL PRESSURE INSPECTION NOTE Before disconnecting fuel hose release the fuel pressure by loosening the pressure regulator fuel hose clamp on the injector hose Always replace the clamp when the hose is removed or loosened Disconnect the battery negative cable from the battery terminal Disconnect the pressure regulator output hose and plug the hose Slowly catch the remaining fuel using a...

Page 36: ...tor If resistance at fuel pump connector is not good replace fuel gauge meter If readings are specified carry out a FUEL GAUGE METER INPUT voltage test Fuel Gauge Meter Input Voltage Test 1 Set ignition switch to ON 2 Disconnect fuel pump connector 3 Use a multimeter and measure the input voltage Pin 2 and Battery Battery Voltage If battery voltage is not read test wiring continuity between gauge ...

Page 37: ...el tank cap 4 Set vacuum pressure pump to PRESSURE and activated pump The gauge on the pump should not change in reading air should flow through the vent valve and fuel tank freely 5 Set vacuum pressure pump to VACCUM and activate pump The gauge should not change in reading air should flow through the vent valve and fuel tank freely Observe Cup There is clear cup connected with the vent hose it ca...

Page 38: ...dule Fuel pump run Repair or replace Fuel pressure within specifications Fuel pressure more than specifications Fuel pressure less than specifications Check fuel line rail for leaks Perform fuel pump test NG NG OK OK Crank or start engine Fast pressure drop Fuel pressure within specifications Fuel pressure more than specifications Fuel pressure less than specifications Verify pump check Check fuel...

Page 39: ...mponents inspection 12 Sensor circuit mal troubleshooting 24 Fault diagnosis 45 Integrated fault diagnosis program 48 Fault diagnosis note 49 Use diagnosis tool 52 Troubleshooting table 60 Comprehensive maintenance list 61 Fuel Injection System Components Throttle Body Idle Speed Controller Temperature Manifold Air Pressure Injector Throttle Position Sensor ECU Engine Coolant Temperature Sensor Cr...

Page 40: ... been removed Do not apply excessive force to the fuel pipe on the throttle body while removing or installing the throttle body Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization Prevent dirt and debris from entering the throttle bore fuel tube and return tube clean them using compressed air The throttle body is factory pre set Do not disassemble in a wa...

Page 41: ... male connector for bend and female connector for excessive opening Also check the coupler for locking looseness corrosion dust etc FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for the fuse ECU VARIOUS SENSORS Since each component is a high precision part great care shou...

Page 42: ...ess being open Poor terminal to wire connection Disconnect the negative cable from the battery Check each connector coupler at both ends of the circuit being checked for loose connection Also check for condition of the coupler lock if equipped Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibl...

Page 43: ...o the circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body groun...

Page 44: ...nnect all connectors couplers of those parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A and C Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is...

Page 45: ...fication number Starter valve vacuum difference Idle speed 1250 100 rpm Throttle grip free play 2 4 mm Fuel injector resistance Ω Manifold absolute pressure at idle 420 30 mm Hg Fuel pressure at idle 300 kPa TORQUE VALUES ECT sensor Pressure regulator mounting bolt Fuel pump mounting nut ...

Page 46: ...level Hazard control Rear Brake switch ECU Main switch Coolant sensor Winker relay Headlight relay Oil pressure switch Horn EPS controller AC Generator Ignition coil Regulator DC Power outlet Winch switch Speed sensor Fuse box Front Brake switch O2 sensor ...

Page 47: ...4 2 FUEL INJECTION SYSTEM 4 2 9 WIRING DIAGRAM With EPS ...

Page 48: ...4 2 FUEL INJECTION SYSTEM 4 2 10 Without EPS ...

Page 49: ...G CAN_L Diagnosis Tool J1 9 B Fuel Pump relay C2 15 B Y Temp Temperature LED J2 21 Blank C3 27 Gr R SGND1 Signal Ground J3 33 R Gear A C4 39 Br B Stepper B J4 45 R Gr Override switch D1 4 LG R CPS Crank position sensor K1 10 O W Main relay D2 16 Pu B K2 22 B W Fan relay D3 28 G B Stepper D K3 34 Blank D4 40 L B Stepper A K4 46 Blank E1 5 L Y CPS Crank position sensor L1 11 R VBR Start relay voltag...

Page 50: ...e and check that the MIL light Turn the ignition switch OFF Disconnect the MAP sensor 4P connector Turn the ignition switch ON Measure the voltage at the wire harness side connector Connection Yellow Black Ground Standard 5 0 0 1V Measure the voltage between the connector terminals of wire harness side Connection Yellow Black Gray Red Standard 5 0 0 1V Turn the ignition switch OFF Connect the TMAP...

Page 51: ... MIL light Turn the ignition switch OFF Disconnect the ECT sensor connector Measure the resistance at ECT sensor terminals Connection Standard 2 3 2 6 kΩ at 20 Turn the ignition switch ON Measure the voltage between the ECT sensor connector terminal of the wire harness side and ground Connection Yellow Red Ground Standard 5 0 0 1V Measure the voltage at ECT sensor connector of the wire harness sid...

Page 52: ...LLATION Disconnect the ECT sensor 2P connector from the sensor Remove the ECT sensor Install the new ECT sensor TORQUE 120 kgf cm Connect the ECT sensor 2P connector Standard TEMPERATURE RESISTANCE VALUES OHM TOL OHM 20 3500 250 60 704 45 90 260 20 ...

Page 53: ...nal and ground Connection Yellow Black Ground Standard 5 0 0 1V Measure the voltage at TP sensor terminals of the wire harness side Connection Yellow Black Gray Red Standard 5 0 0 1V Working voltage value 5 0 0 1V Full throttle open voltage 3 9 0 2V Full throttle closed voltage 0 5 0 05V WARNING Never loosen the screw of TPS result the unsteady idle Using diagnosis tool to confirm the throttle out...

Page 54: ...d sensor connector Connect the vehicle speed sensor 3P connector Start the engine Ride the vehicle and keep the engine more than 5 000 RPM about 20 seconds or more Check the MIL light Turn the ignition switch OFF Disconnect the vehicle speed sensor 3P connector Turn the ignition switch ON Measure the voltage at the wire harness side connector Connection Red Black White Standard 12 V ...

Page 55: ... Check the MIL light Turn the ignition switch OFF Disconnect the injector 2P connector and measure the resistance of the injector Connection Red Blue Green Standard 12 0 0 6Ω Check for continuity between the injector and ground Connection Red Ground Standard continuity Turn the ignition switch ON Measure the voltage between the injector connector of the wire harness side and ground Connection Red ...

Page 56: ...r does not operate replace the injector REMOVAL Disconnect the injector 2P connector Remove the bolts and fuel rail assembly Remove the injector from the intake pipe INSTALLATION Install injector on the intake pipe Being careful not to damage the O ring of injector Install fuel rail assembly and tighten the bolt TORQUE 120 kgf cm Connect the injector 2P connector ...

Page 57: ...the starter motor more than 10 seconds and then check that the MIL light Turn the ignition switch OFF Disconnect the crank position sensor 2P connector Check for continuity between the crank position sensor connector terminal and ground Connection Blue Ground Standard No continuity Crank the engine with the starter motor and measure the crank position sensor peak voltage at the crank position sens...

Page 58: ...e ignition coil 2P connector Turn the starter motor more than 10 seconds and then check that the MIL light Turn the ignition switch OFF Disconnect the ignition coil 2P connector Check for continuity between the ignition coil connector terminal and ground Connection Red Ground Standard No continuity Check for resistance between the ignition coil connector terminal and ground Standard 0 6 0 05Ω ...

Page 59: ...ot damage the throttle body It may cause incorrect throttle and idle valve The throttle body is factory pre set Do not disassemble in a way other than shown in this manual Do not loosen or tighten the white painted bolts and screws of the throttle body Loosening or tightening them can cause throttle and idle valve failure Disconnect the throttle cable end from the throttle drum ASSEMBLY Connect th...

Page 60: ...nd turn the ignition switch ON The roll over sensor is normal if the power supply is closed Incline the roll over sensor approximately 65 degrees to the left or right with the ignition switch ON The roll over sensor is normal if the power supply is open If you repeat this test first turn the ignition switch OFF then turn the ignition switch ON REMOVAL INSTALLATION Disconnect the roll over sensor 2...

Page 61: ...voltage Confirmed working voltage Volteg meter negative access to the wire harness sensor coupler 2nd pin Gray Red Voltage meter positive access to the wire harness sensor coupler first pin Red 2 Resistance Confirmation Removed O2 Sensor and the wire harness between the coupler Use of the meter Ohm stalls Measurement O2 Sensor heater resistance Measurement resistance value Ohm meter negative acces...

Page 62: ... connectors POWER INPUT LINE Turn the ignition switch ON Measure the voltage between the ECU and ground There should be battery voltage If there is no voltage check for an open circuit in Black White wire between the ECU and roll over sensor relay If the wire is OK check for the roll over sensor relay ...

Page 63: ...nsor circuit open or short CPS sensor malfunction ECU malfunction INSPECTION Step 1 1 Remove the seat set 2 Remove the left side cover 3 Turn the ignition switch OFF 4 Check the CPS sensor coupler for loose or poor contacts If OK then measure the CPS sensor resistance 5 Disconnect the CPS sensor coupler and measure the resistance CPS sensor resistance 50 5 Ω Blue Sky Blue 6 If OK then check the co...

Page 64: ...nd more Blue Sky Blue Is the voltage OK YES Blue or Sky Blue wire open or shorted to ground Loose or poor contacts on the CPS sensor coupler or ECU coupler terminal 4 or 5 If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Inspect that metal partic...

Page 65: ...ssage between throttle body and T MAP sensor T MAP sensor circuit open or shorted to ground T MAP sensor malfunction ECM malfunction INSPECTION Step 1 1 Loosen and lift up the fuel tank 2 Turn the ignition switch OFF 3 Check the T MAP sensor couple for loose or poor contacts If OK then measure the T MAP sensor input voltage 4 Disconnect the T MAP sensor coupler 5 Turn the ignition switch ON 6 Meas...

Page 66: ...speed and measure the T MAP sensor output voltage at the wire side coupler T MAP sensor output voltage Approx 2 6 V at idle speed White Yellow Gray Red Is the voltage OK YES Yellow Black or Gray Red wire open or shorted to ground or poor 18 30 or 1 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection...

Page 67: ... circuit open or shorted to ground or VSENS circuit open Sensor voltage is higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Loosen and lift up the fuel tank 2 Turn the ignition switch OFF 3 Check the TP sensor coupler for loose or poor contacts If OK then measure the TP sensor input voltage 4 Disconnect the TP sens...

Page 68: ...ity between W Br wire and Y B wire If the sound is not heard from the tester the circuit condition is OK 6 Disconnect the ECU coupler 7 Check the continuity between W Br wire and terminal 31 8 Also check the continuity between Gr R wire and terminal 27 TPS lead wire continuity Continuity sound Is the continuity OK YES Go to next step 2 NO W Br wire shorted to VSENS or SGND1 wire open 9 After repai...

Page 69: ...e or Gr R wire open or Gr R wire shorted to ground 10 After repairing the trouble clear the DTC using Diagnosis tool Step 2 1 Turn the ignition switch OFF 2 Disconnect the TP sensor coupler 3 Check the continuity between W Br wire and ground TP sensor continuity Ω Infinity White Brown Ground 4 If OK then measure the TP sensor resistance at the terminals between Bottom and Center pin 5 Turn the thr...

Page 70: ...ler between W Br wire and Gr R wire by turning the throttle grip TP sensor output voltage Throttle valve is closed Approx 0 5 0 05 V Throttle valve is opened Approx 3 8 0 05 V Is the voltage OK YES Y B W Br or Gr R wire open or shorted to ground or poor 1 31 or 27 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and...

Page 71: ...s higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Turn the ignition switch OFF 2 Check the ECT sensor coupler for loose or poor contacts If OK then measure the ECT sensor voltage at the wire side coupler 3 Disconnect the ECT sensor coupler and turn the ignition switch ON 4 Measure the voltage between Y R wire term...

Page 72: ...the continuity between Y R wire and terminal 42 7 Also check the continuity between Gr R wire and terminal 27 ECTS lead wire continuity Continuity sound Is the continuity OK YES Go to step 2 NO Y R or Gr R wire open 8 After repairing the trouble clear the DTC using Diagnosis tool Step 1 When sensor voltage is lower than specified 1 Turn the ignition switch OFF 2 Check the ECT sensor coupler for lo...

Page 73: ...T sensor resistance Approx 2 3 2 6 kΩ at 20 C 68 F Terminal Terminal Is the resistance OK YES Y R or Gr R wire open or shorted to ground or poor 42 or 27 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Replace ECT sensor with a new on...

Page 74: ...diagnosing Step 1 1 Check the ignition system couplers for poor connections Is there connection in the ignition switch couplers YES Go to step 2 NO Poor connection of couplers Step 2 1 Measure the battery voltage between input lead wires at the ECU with the ignition switch in the ON position Is the voltage OK YES Go to step 3 NO Faulty ignition switch Broken wire harness or poor connection of rela...

Page 75: ...OK YES Go to step 5 NO Faulty spark plug s Step 5 1 Inspect the ignition coils Are the ignition coils OK YES Go to step 6 NO Faulty ignition coil s Step 6 1 Measure the CPS sensor peak voltage and its resistance NOTE The CPS peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Are the peak voltage and its resistance OK YES Faulty ECU Open or short circuit ...

Page 76: ...easure the injector resistance 3 Disconnect the injector coupler and measure the resistance between terminals Injector resistance Approx 11 7 Ω at 20 C 68 F Terminal Terminal 4 If OK then check the continuity between each terminal and ground STP sensor continuity Ω Infinity Are the resistance and continuity OK YES Go to step 2 NO Replace the injector with a new one 5 After repairing the trouble cl...

Page 77: ...n or shorted to ground or poor 47 connection cylinder side If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Open circuit in the R wire 3 After repairing the trouble clear the DTC using Diagnosis tool 47 ...

Page 78: ...ve the seat 2 Turn the main switch OFF 3 Check the FP relay coupler for loose or poor contacts If OK then check the FP relay Is the FP relay OK YES Blue wire open or shorted to ground or poor 9 connection Red wire open or poor 11 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU wi...

Page 79: ... ground or VSENS circuit open Sensor voltage is higher than specified value Sensor voltage is lower than specified value INSPECTION Step 1 When output voltage is out of specified 1 Remove the seat set 2 Turn the ignition switch OFF 3 Check the Roll over sensor coupler for loose or poor contacts If OK then measure the Roll over sensor resistance 4 Disconnect the Roll over sensor coupler 5 Measure t...

Page 80: ...tinuity OK YES Go to step 2 NO Pu B wire shorted to VBR 8 After repairing the trouble clear the DTC using Diagnosis tool Step 1 When sensor voltage is lower than specified 1 Remove the seat set 2 Turn the ignition switch OFF 3 Check the Roll over sensor coupler for loose or poor contacts If OK then check the Roll over sensor lead wire continuity 4 Disconnect the Roll over sensor coupler 5 Check th...

Page 81: ... 1 1 0 2 V Pu B B 5 Dismount the Roll over sensor from its bracket and measure the voltage when it is leaned 65 and more left and right from the horizontal level Roll over sensor voltage Leaning 4 1 0 2 V Pu B B Is the voltage OK YES Y B or Pu B wire open or shorted to ground or poor 1 or 16 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire ...

Page 82: ...lead wire coupler for loose or poor contacts 4 Remove the air cleaner rubber tube 5 Turn the ignition switch ON to check the ISC operation ISC operating order 95 open full open 95 open Is the operating OK YES Go to step 2 NO Loose or poor contacts on the ISC coupler Open or short circuit in the Br B G B Y B or B Y wires If wire and connection are OK go to Step 2 6 After repairing the trouble clear...

Page 83: ...ire open or shorted to ground or poor 28 39 40 and 41 connection If wire and connection are OK intermittent trouble or faulty ECU Recheck each terminal and wire harness for open circuit and poor connection Replace the ECU with a known good one and inspect it again NO Loose or poor contacts on the ECU coupler Replace new ISC throttle body 5 After repairing the trouble clear the DTC using Diagnosis ...

Page 84: ...4 2 FUEL INJECTION SYSTEM 4 2 46 Fault Diagnosis EFI Circuit inspection ...

Page 85: ...4 2 FUEL INJECTION SYSTEM 4 2 47 Can not Start the engine or difficult to start inspection ...

Page 86: ...4 2 FUEL INJECTION SYSTEM 4 2 48 Idle flameout diagnosis ...

Page 87: ...4 2 FUEL INJECTION SYSTEM 4 2 49 Integrated Fault Diagnosis Program ...

Page 88: ...ruled out or repair after the MIL light will be extinguished but ECU fault code will be recorded so the need to get rid of fault codes Diagnosis tool for overhaul Diagnosis tool will connect to the motorcycle for coupler diagnosis according to the use of diagnostic tool testing methods when belong fuel injection system fault or parts fault according to the diagnosis tool of the fault code display ...

Page 89: ...ut of range 16 P0122 Throttle Position Sensor 1 short circuit to ground _Open circuit 17 P0123 Throttle Position Sensor 1 short circuit to battery 18 P0131 Lambda sensor 0 diagnosis short circuit to ground 19 P0132 Lambda sensor 0 diagnosis short circuit to battery 20 P0133 Lambda sensor 0 diagnosis Open circuit 21 P0171 Lambda control diagnosis O2 correction too high 22 P0172 Lambda control diagn...

Page 90: ...43 P0617 Starter 1 diagnosis short circuit to battery 44 P0651 MIL diagnosis short circuit to ground _Open circuit 45 P0652 MIL diagnosis short circuit to battery 46 P1352 Ignition diagnosis 1 short circuit to ground _Open circuit 47 P1353 Ignition diagnosis 2 short circuit to battery 48 P1508 Stepper motor diagnosis short circuit to ground _Open circuit 49 P1509 Stepper motor diagnosis short circ...

Page 91: ...ring into boot screen 3 Key ON and the diagnosis display screen appeared the words connection 4 Press the ENTER button and the system will identify the vehicle model automatically and display the vehicle info on the screen as following picture 5 Press ENTER button again for more detailed vehicle information Press button to view all information Diagnosis Use Note Press ENTER button to the function ...

Page 92: ... Vehicle Info and press ENTER to see the content This is the page of Vehicle Info press button to view all vehicle info 2 Diagnostic Trouble Code Move the cursor to Diagnostic Trouble Code and press ENTER to see the content 2 1 Current Current is for the Diagnostic Trouble Code occurred at the time 2 2 History History is for Diagnostic Trouble Code occurred in the past ...

Page 93: ... press ESC to return to the previous page After viewing the content of Current or History Diagnostic Trouble Code press ESC to return to the previous page you will see two more items on the screen Freeze Data and Erase DTC Freeze Data is the data recorded when FIRST Diagnostic Trouble Code occurred and one time only record one Diagnostic Trouble Code freeze data it s for saving the engine dynamic ...

Page 94: ...alysis of images 1 3 the waveform can be displayed as shown in the following items Freeze Data 01 03 Number of data DTC Engine speed Throttle valve volt Intake pressure MAP Freeze Data 02 03 Engine temp Lambda Control volt Battery volt Atmospheric pressure Intake air temp 2 4 Erase DTC ...

Page 95: ...GNOSTIC TROUBLE CODE DIRECTLY When you see the following picture on the screen the Diagnostic Trouble Code erasure is completed Press ESC button back to the main menu 3 Live Data Back to the main menu move the cursor to Live Data and press ENTER to view the content Press button to view all Live Data ...

Page 96: ...ne stop running This is the page after entering the Activator function Take one activation function for example move the cursor to Ignition coil item and press ENTER to continue When pressing Actuating button the test is activated and the Value column shows Open When pressing Stop Actuating button the test is de activated and the Value column shows close ...

Page 97: ...nction and press ENTER to view the content There are two items under Special Function Reset TPS and Reset Adaptive Move the cursor to Reset TPS and press ENTER Then you will see the following picture which means the RESET is completed Press ESC button to return to the previous page ...

Page 98: ...4 2 FUEL INJECTION SYSTEM 4 2 60 Troubleshooting Table ...

Page 99: ...in switch but not start Pressure 250 kPa stable value Idle state Pressure 300 6 kPa Beating situation from top to bottom Rotating throttle moment Pressure 300 6kPa sligh tly beating Fuel not enough Fuel pump relay fault Fuel pump fault Injector fault ECU fault 3 Ignition state The spark plug removed from the cylinder head but the power lines still ring Start engines or use for the diagnosis tool o...

Page 100: ... Check fault is it happen again Diagnosis toll of the fault code is it can be eliminated Start engine the fault is it will happen again Without any residual Fault Code If residual Fault Code according to the Fault Code Maintenance Form implementation of troubleshooting Throttle position sensor fault Engine temperature sensor fault Intake temperature sensor fault Manifold pressure sensor fault CPS ...

Page 101: ...al connections prior to disconnecting fuel lines 4 Remove seat and seat steady 5 Remove the following plastic parts Upper cover LH and RH side covers and footrest Heat isolation 6 Remove air cleaner and the rear bracket 7 Remove the throttle body air intake manifold 8 Drain engine oil NOTE Drain engine oil and gearbox oil only if engine overhaul and gearbox need to repair is necessary 8 Drain engi...

Page 102: ...ect condition of engine mounts Install the rear output drive shaft onto engine output shaft Connect the front output drive shaft to the engine output shaft while lowing engine Install connecting plate bolts rear and front mounting bolts then torque all mounting bolts Final Assembly Procedure 1 Fill engine with the recommended oil and quantity 2 Fill and bleed cooling system 3 Check for any leaks 4...

Page 103: ...5 1 ENGINE ASSEMBLY 5 3 AIR INTAKE SYSTEM ...

Page 104: ...fically with these components AIR CLEANER ELEMENT Air Filter Element Replacement 1 Open the service cover 2 Counter clockwise open the filter element lid and pull out the element 3 Remove the screw and separate the lid and element 4 Replace if necessary 5 For the installation reverse the removal procedure AIR CLEANER Air Cleaner Removal 1 Remove both side covers and upper cover 2 Remove the four r...

Page 105: ...5 1 ENGINE ASSEMBLY 5 5 EXHAUST SYSTEM ...

Page 106: ...Torque wrench tightening specifications must strictly be adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced MUFFLER Muffler Removal 1 Remove seat 2 Remove LH side cover 3 Detach spring from the Y exhaust pipe 4 Remove muffler retaining bolts 5 Loose the clamp of muffler 6 Discard the gasket at the end of Y exhaust pipe Muffler Inspe...

Page 107: ...r and exhaust pipe from vehicle 4 Remove the Muffler CAUTION Do not damage the O2 sensor connecting wire Y Exhaust Pipe Inspection Check Y exhaust pipe for cracks bending or other damages Replace if need Y Exhaust Pipe Installation The installation is the reverse of the removal procedure Install new exhaust gasket Clamp Torque 250 kgf cm Nut Torque 150 200 kgf cm ...

Page 108: ...5 1 ENGINE ASSEMBLY 5 8 COOLING SYSTEM RADIATOR WATER PUMP ...

Page 109: ...y be adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced PROCEDURE THERMOSTAT The thermostat is a single action type Thermostat Location The thermostat is mounted in line in the cooling system circuit Thermostat Removal 1 Remove service cover 2 Remove air filter housing 3 Remove clamp that secures thermostat housing to frame 4 Instal...

Page 110: ... 88 Replace thermostat if it does not begin to open at specified temperature Check if gasket is brittle hard or damaged If so replace gasket Thermostat Installation Reverse removal procedures Refill cooling system Bleed cooling system Check for coolant leaks RADIATOR Radiator Inspection Check radiating fins for clogging or damage Remove insects mud or other obstructions with compressed air or low ...

Page 111: ...wer end towards the front of the vehicle 7 Carefully remove radiator through LH wheel well Radiator Installation 1 For installation reverse the removal procedure However pay attention to the following details 2 Install the rubber bushings between bottom of radiator and radiator support 3 Fill radiator with recommended coolant 4 Bleed the cooling system 5 Check for coolant leaks from radiator and h...

Page 112: ...Ω position 3 Probe relay as follows TERMINAL RESISTANCE 30 87 Open Circuit OL 4 Connect battery as shown and probe relay again as follows TERMINAL RESISTANCE 30 87 0 5Ω max continuity If relay failed any test replace it RADIATOR COOLING FAN Radiator Cooling Fan Operation The ECU controls the radiator cooling fan via the input of the coolant temperature sensor CTS and the manifold air pressure and ...

Page 113: ...s located in the fuse box under the seat set Radiator Cooling Fan Test Connect the 12VDC to cooling fan connector if fan turns on check CTS wiring harness and connectors If all parts are good replace ECU If fan does not turn on refer to the following troubleshooting chart ...

Page 114: ...t drain plug if the engine is hot 1 Drain cooling system 2 Remove radiator outlet hose from water pump housing 3 Remove screws retaining water pump housing and pull water pump housing to remove it Water Pump Housing Inspection Check if gasket is brittle hard or damaged and replace as necessary Water Pump Housing Installation 1 The installation is reverse of the removal procedure 2 Install and tigh...

Page 115: ...re NOTICE Be careful not to damage impeller fins during installation WATER PUMP SHAFT AND SEALS Rotary Seal and Oil Seal Removal Assembled Engine Remove water pump housing 1 Using special tool onto the rotary seal and insert the small chisel pin strong punch with hammer on the seal plate 2 Install three screws through the tool hole 3 Screw the special tool and pull out the rotary seal NOTICE Be ca...

Page 116: ... deep socket 4 Ensure that the oil seal is properly seated in water pump cavity Rotary Seal NOTICE Read and thoroughly understand the entire procedure of installing the rotary seal before starting it 1 Apply engine oil on water pump shaft 2 Place rotary seal inside the special tool socket NOTICE Do not install the rotary seal completely into crankcase to prevent the water pump shaft plastic gear f...

Page 117: ...roper position until the rotary seal is flush with the end of water pump shaft threads NOTICE Ensure that the water pump shaft is properly adjusted with rotary seal NOTICE Ensure that the water pump shaft moves freely while pushing it toward the crankcase ...

Page 118: ...nd pull seal out NOTICE When removing water pump shaft always replace rotary seal with water pump shaft Also replace oil in crankcase 7 Remove oil seal from inside of crankcase ACG side using a pusher tool NOTICE Be careful not to damage the rotary seal surface in crankcase Water Pump Shaft Seal Inspection Disassembled Engine Inspect water pump gear for wear and damage on the snap mechanism to the...

Page 119: ... oil seal Apply engine oil on the water pump shaft and intermediate shaft Slide water pump shaft with new rotary seal into crankcase To properly install water pump shaft with rotary seal use SEAL PUSHER NOTICE Never use a hammer for rotary seal installation Only use a press to avoid damaging the ceramic component Install thrust washer and needle pin on water pump shaft NOTICE A missing thrust wash...

Page 120: ...5 1 ENGINE ASSEMBLY 5 20 AC GENERATOR SYSTEM ...

Page 121: ...ose Remove ACG cover retaining screws Pull out ACG cover ACG Cover Inspection and Cleaning Check ACG cover for cracks or other damage Replace if necessary NOTE Clean all metal components in a nonferrous metal cleaner WARNING Wear safety glasses and work in a well ventilated area when working with strong chemical products Also wear suitable non absorbent gloves to protect your hands ACG Cover Insta...

Page 122: ...OSTIC HARNESS on ACG connector 2 Set multimeter to Ω 3 Connect multimeter between any YELLOW wire and engine ground 4 Read resistance TEST PROBES RESISTANCE 20 Any YELLOW wire and engine GND Infinite open circuit 5 If there is a resistance or continuity the stator coils and or the wiring is shorted to ground and needs to be repaired or replaced 6 Re plug connectors properly Stator Dynamic Test AC ...

Page 123: ...ator Inspection Check stator windings and insulation for cracks or other damages If damaged replace it Check if stator wires are brittle hard or otherwise damaged Stator Insulation For installation reverse the removal procedure NOTICE When installing the stator take care to route wires properly and install retaining strip NOTE There is only one position for the stator notch in the ACG housing cove...

Page 124: ...way on the crankshaft for wear or damages Replace parts as necessary Rotor Installation For installation reverse the removal procedure Clean crankshaft taper and rotor with PULLY FLANGE CLEANER NOTICE Taper on crankshaft and rotor must be free of grease Clean the crankshaft oil passage and threads using PULLY FLANGE CLEANER Oil starting unidirectional clutch and install starting clutch gear Slide ...

Page 125: ...ear Perform a functional test of the starting clutch gear To do so rotate starting clutch gear in unidirectional clutch NOTE Unidirectional clutch must lock in counterclockwise direction NOTE Unidirectional clutch thrust plate and gear must be replaced at the same time if damaged Unidirectional Clutch Installation For installation reverse the removal procedure Apply LOCTITE 648 GREEN on threads of...

Page 126: ...pply engine oil on needle bearing and collar of starting clutch gear STARTER DRIVE GEARS The starter drive gears are located on the engine ACG side behind the ACG cover Starter Drive Gear Removal Remove ACG cover See procedure in this subsection Remove location pins starter double gear and idle gear Starter Drive Gear Inspection Inspect gears and location pins for wear and damage Replace parts as ...

Page 127: ...5 2 ENGINE TOP END 5 2 1 TOP END INTAKE MANIFOLD ...

Page 128: ...5 2 ENGINE TOP END 5 2 2 CYLINDER HEAD ...

Page 129: ...5 2 ENGINE TOP END 5 2 3 CYLINDERS AND PISTONS ...

Page 130: ... that are duplicated in the engine e g valves it is a strongly recommended to note their position and keep them as a group If you find a defective component it would be much easier to find the cause of failure among its group of parts e g you found a worn valve guide A bent spring could be the cause and it will be easy to know which one among the springs is the cause to replace it if you grouped t...

Page 131: ...until it run out of fuel 6 Disconnect the fuel hoses at the fuel rails CAUTION The fuel hose may still be under pressure 7 Disconnect fuel injectors wire connectors 8 Remove intake manifold to cylinder head retaining bolts then remove intake manifold Intake manifold Inspection Check intake manifold for cracks warping at flanges or any other damage Replace if necessary Intake manifold Installation ...

Page 132: ...ified torque in a criss cross sequence TORQUE 1 0 1 2 kgf m ROCKER ARM Rocker Arm Removal Remove cylinder head cover Place the cylinder at TDC ignition Remove four bolts of the camshaft holder and remove rocker arm shafts Remove rocker arm assembly Rocker Arm Inspection Inspect each rocker arm for cracks and scored friction surfaces If so replace rocker arm assembly Check the rocker arm rollers fo...

Page 133: ...ction surface if so replace parts Rocker Arm Installation NOTE Use the same procedure for exhaust and intake rocker arm Apply engine oil on rocker arm shaft Install the rocker arm shafts with flat end first Install four bolts of the camshaft holder according to the order as shown TORQUE 1 0 1 2 kgf cm ...

Page 134: ...r head Remove air cleaner Remove the intake manifold Remove the chain tensioner Remove the cylinder head cover and its gasket Remove the camshaft holder Remove the camshaft timing gear Remove the camshaft Unscrew cylinder head M6 and M10 bolts retaining cylinder head and cylinder to cylinder base Pull out cylinder head Remove timing chain guide fixed Remove and discard the cylinder head gasket Cyl...

Page 135: ...1 Nm two times then finish by tightening to 180 5 Install cylinder head M6 bolts Check timing chain guide tensioner side for movement CAMSHAFT NOTE The engine is equipped with two different camshaft Mark A to front cylinder Mark B to rear cylinder Camshaft Removal The removal procedure is the same for both camshafts Remove cylinder head cover Remove the chain tensioner Remove the rocker arm assemb...

Page 136: ... Check each lobe and bearing journal of camshaft for scoring scuffing cracks or other signs of wear Using a micrometer measure camshaft journal diameter and lobe height Replace parts that are not within specifications Front Cylinder Rear Cylinder ...

Page 137: ...e cylinder head Compress valve spring using VALVE SPRING COMPRESSOR special tool WARNING Always wear safety glasses when disassembling valve springs Be careful when unlocking valves Components could fly away because of the strong spring preload Remove valve cotters Remove valve spring compressor and withdraw valve spring retainer and valve spring Valve Spring Inspection Check valve spring for visi...

Page 138: ...cked by tapping on valve stem end with a soft hammer so that valve opens and closes a few times NOTICE An improperly locked valve spring will cause engine damage VALVES Valve Removal Remove valve spring Push valve stem then pull valves intake and exhaust out of valve guide Remove valve stem seal with SNAP ON PLIERS and discard it Valve Inspection Valve Stem Seal Always install new seals whenever v...

Page 139: ...m and valve guide in three places NOTE Clean valve guide to remove carbon deposits before measuring Change valve if valve stem is out of specification or has other damages such as wear or friction surface Replace valve guide out of cylinder head if valve guide is out of specification or has other damages such as wear or friction surface ...

Page 140: ...de or has dark spots replace the cylinder head Valve Installation For installation reverse the removal procedure Install a NEW valve stem seal Make sure thrust washer is installed before installing seal Apply engine oil on valve stem and install it NOTICE Be careful when valve stem is passed through sealing lips of valve stem seal To ease installation of cotters apply oil or grease on them so that...

Page 141: ...ttom of the cylinder If so replace cylinder Cylinder Taper Measure cylinder bore and if it is out of specifications replace cylinder and piston rings Measure cylinder bore at three recommended positions Distance between measurement should not exceed the service limit mentioned above Cylinder Out of Round Measure cylinder diameter in piston axis direction from top of cylinder Take another measureme...

Page 142: ... backside of cylinder Wrong install direction will lose the function of chain adjuster and cause timing chain damage PISTON Piston Removal Remove cylinder head Remove the cylinder Place a rag under piston and in the area of timing chain compartment WARNING Piston circlip are spring loaded Remove one piston circlip and discard it NOTE The removal of both piston circlip is not necessary to remove pi...

Page 143: ... the indicator to zero Position the dial bore gauge 20 mm above cylinder base measuring the piston pin axis Read the measurement on the cylinder bore gauge The result is the exact piston cylinder wall clearance NOTE Make sure used piston is not worn If clearance exceeds specified tolerance replace piston by a new one and measure piston cylinder clearance again NOTE Make sure the cylinder bore gaug...

Page 144: ...pin clearance Piston Installation For installation reverse the removal procedure Apply engine oil on the piston pin Insert piston pin into piston and connecting rod For each cylinder install piston with punched arrow on piston dome is pointing toward the exhaust side of the engine CAUTION Mark on top of position must show to both cylinders exhaust side Install NEW piston circlip and double check t...

Page 145: ... If the clearance is too large the piston and the piston rings should be replaced To measure the ring end gap place the ring in the cylinder in the area of 8 mm to 16 mm from top of cylinder NOTE In order to correctly position the ring in the cylinder use piston as a pusher Using a feeler gauge check ring end gap Replace ring if gap exceeds above described specified tolerance ...

Page 146: ...ression ring with the open edge facing up then the upper compression ring with the word R facing up NOTICE Ensure that top and second rings are not interchanged NOTE Use a ring expander to prevent breakage during installation The oil ring must be installed by hand Check that rings rotate smoothly after installation Space the piston ring end gap 120 apart and do not align the gaps with the piston p...

Page 147: ...5 2 ENGINE TOP END 5 2 21 TIMING CHAIN ...

Page 148: ...ION 1 Improper valve clearance adjustment and or worn out rocker arm s Re adjust valve clearance and or replace defective parts 2 Defective chain tensioner Replace chain tensioner 3 Worn out timing chain guide s Replace timing chain guide s 4 Stretched timing chain or worn out timing gears Replace timing chain and timing gears 5 Loose timing gear retaining bolts Retighten bolts to recommended torq...

Page 149: ...f necessary Check chain tensioner plunger for free movement and or scoring Check if O ring are brittle cracked or hard Replace if necessary Check spring condition Replace if damage Timing Chain Tensioner Installation For installation reverse the removal procedure NOTE Before installing the chain tensioner make sure that the camshaft timing gear can be moved back and forth Slightly turn the camshaf...

Page 150: ...chain tensioner plug Then compress the spring and screw the plug in NOTE To avoid overstressed timing chain the plug must engage into threads within the first full turn Install all other removed parts Finally tighten the plug CAMSHAFT TIMING GEARS Camshaft Timing Gears Removal Remove the cylinder head cover Turn crankshaft to TDC ignition of the respective cylinder and lock magneto flywheel Unscre...

Page 151: ...r Install and tighten timing gear retaining bolts to specified torque NOTE The hole on the timing gear sprocket should at the exhaust side TORQUE 10 Nm NOTE If a piston front or rear cylinder is set to TDC ignition the timing gear of the opposite cylinder must be in the following position Camshaft Timing Cylinder rear Turn crankshaft until piston is at TDC ignition as follow Remove spark plug of b...

Page 152: ...m mark B on the camshaft NOTE Before installing camshaft of front cylinder it should be confirm mark A on the camshaft NOTE Reconfirm the TDC ignition of front cylinder at this time the rear cylinder timing chain sprocket will show up an hole at up left corner on the intake side NOTE Check the timing chain identification hole during assemble when one cylinder camshaft on the TDC position the other...

Page 153: ...nsioner Timing gear Remove timing chain guide tensioner side and lower timing chain guide NOTE Mark the operating direction of the timing chain before removal Carefully pull the timing chain downwards and sideways then out of the crankcase Timing Chain Removal CVT Side Remove the following parts CVT cover Idle gear Cylinder head cover Chain tensioner Timing gear Remove timing chain guide tensioner...

Page 154: ...stallation is essentially the reverse of the removal procedure but pay attention to the following details NOTE Installation is the same for both timing chains TIMING CHAIN GUIDE SOCKET SCREW TIGHTENING TORQUE 1 0 1 2 kgf m Install timing chain with camshaft timing gear NOTE Ensure to carry out proper valve timing NOTICE Improper valve timing will damage engine components TIMING CHAIN GUIDE TENSION...

Page 155: ...5 3 ENGINE BOTTOM END 5 3 1 BOTTOM END ENGINE DRIVE SHAFT ...

Page 156: ...5 3 ENGINE BOTTOM END 5 3 2 CRANKCASE CRANKSHAFT ...

Page 157: ...5 3 ENGINE BOTTOM END 5 3 3 WATER PUMP OIL PUMP ...

Page 158: ...CEDURE ENGINE DRIVE SHAFT NOTE The engine drive shaft transmits the power from gearbox to the front differential and is located inside the crankcase Oil Seal Replacement Engine Drive Shaft Remove the engine To remove the rear oil seal the gearbox has to be removed from the engine To replace drive shaft oil seals refer to drive shaft removal Engine Drive Shaft Removal Remove the engine At rear of e...

Page 159: ...nents in solvent Crankcase surface is best cleaned using a combination of LOCTITE CHISEL gasket remover and a brass brush Brushes a first pass in one direction then makes the final brushing perpendicularly to the first pass NOTICE Do not wipe with rag Use a new clean hand tower only Use a suitable installer for install bearing Use LOCTITE 5910 on mating surfaces IMPORTANT When beginning the applic...

Page 160: ...R CVT Vent Backboard CVT Vent Backboard Removal Remove the following parts CVT cover Drive Pulley Driven Pulley CVT air ducting guide Disconnect vent hose Remove CVT cover bolts and pull CVT cover CVT Vent Backboard Inspection Check the CVT vent backboard for cracks or other damage Replace CVT vent backboard if damaged Clean oil breather bore in CVT vent backboard from contaminations with part cle...

Page 161: ...PLAIN BEARING REMOVER INSTALLER The CVT cover has to be supported from below with suitable support with straight surface in order to prevent damage of the sealing surface Plain Bearing Installation NOTE Do not lubricate plain bearing and or CVT cover for installation Install plain bearings with the proper PLAIN BEARING REMOVER INSTALLER in a cool PTO cover NOTICE Mark position of oil bore on CVT c...

Page 162: ...EARS The drive gears are located on the engine CVT side behind the CVT vent backboard cover Drive Gear Removal Remove CVT cover Withdraw idle gear Remove oil pump gear c clip and washer Remove the bolts and pull out water pump Remove c clip and pull out the water pump gear Drive Gears Inspection Idle Gear Oil Pump Drive Gear Water Pump Drive Gear Inspect gears for wear or other damage Replace if d...

Page 163: ...s CVT cover Drive Pulley Driven Pulley CVT air guide 4 Remove the engine from vehicle 5 Disconnect gearbox from engine 6 Remove the following parts ACG cover Rotor with starting clutch gear Starter drive gears 7 Remove the following parts CVT vent backboard cover Drive gears 8 Remove the following parts Chain tensioners Camshaft timing gears Timing chains Timing chain guides 9 Remove the following...

Page 164: ...Pull crankshaft out of crankcase Remove the water pump idle shaft and the water pump gear Remove engine oil strainer Crankcase Cleaning WARNING Use safety goggles to avoid eye injuries Clean crankcase using a part cleaner Dry crankcase using compressed air Below the oil supply lines Oil Strainer Clean the engine oil strainer same procedure as for the crankcase Crankcase Inspection Check crankcase ...

Page 165: ...instructed never use hammer to install plain bearings Use press only Install plain bearing with the proper PLAIN BEARING REMOVER INSTALLER in a cool crankcase Do not lubricate plain bearings and or crankcase for installation NOTE Place the proper crankcase support sleeve under crankcase halves before installing the plain bearing Carefully press in the plain bearings in the same direction as during...

Page 166: ...the reverse of removal procedure However pay attention to the following details Clean oil passages and make sure they are not clogged Clean all metal components in a solvent Install a new crankcase gasket Oil the plain bearings before mounting the crankshaft NOTICE Correctly reinstall crankshaft Properly reinstall engine oil strainer and bolts Reinstall water pump shafts gears Tightening sequence ...

Page 167: ...talling connecting rods Measure crankpin Compare to inside diameter of connecting rod big end Carry out the tightening procedure described in this subsection Connecting rod big end radial clearance If crankshaft pin diameter is out of specification replace crankshaft If connecting rod big end diameter or radial clearance is out of specification replace plain bearings and recheck Crankshaft Radial ...

Page 168: ... in the connecting rods tighten bolts in the following sequence 1 Tighten to 1 2 of specified torque 2 Tighten to 30 NM 2 NM 3 Torque by an additional 90 5 turn using an angle torque wrench NOTE Do not apply any thread locker NOTICE Failure to strictly follow this procedure may cause bolts to loosen and lead to severe engine damage Crankshaft Installation For installation reverse the removal proce...

Page 169: ...5 4 TRANSMISSION GEARBOX 5 4 1 TRANSMISSION GEARBOX ...

Page 170: ...cking ties removed during a procedure must be reinstalled as per factory standards TROUBLESHOOTING UNUSUAL GEARBOX NOISE AND OR VIBRATIONS 1 Low oil level in gearbox Oil leakage from gearbox Replace damaged gasket and or oil seal 2 Defective bearings Bearings do not turn smoothly Replace bearing 3 Damaged or worn gears Inspect gears for damages or missing teeth Replace respective gears GEAR INDICA...

Page 171: ... Turn ignition switch ON 3 Measure voltage as per following table PIN A and PIN B Battery Voltage If voltage is not as specified Test positive and ground separately VSS Signal Test 1 Lift rear of vehicle so that rear wheels are off the ground 2 Set transmission to Neutral 3 Turn ignition switch ON 4 Set multimeter to VDC 5 Measure voltage while slowly rotating rear wheels by hand PIN B and PIN C A...

Page 172: ...est Set shift lever in NEUTRAL position Unplug the gear switch connector Connect the ground Black cable and other cable ex Red reverse gear there should indicate the relative gear position on the dashboard Repair or replace if necessary If there is indication conducting the continuity test for each gear switch as follows Connect the connector to multimeter negative probe to ground Black and positi...

Page 173: ... bolts on the CVT air guide that retaining the gearbox Detach the gearbox from the engine Pull gearbox to separate it from engine Gearbox Disassembly NOTE During gearbox disassembly inspect the condition of each part closely Gearbox Case Remove the bolts M8x5 M6 x3 as shown Using a big flat screwdriver and a soft hammer to split the gearbox case Remove the bolts and right cover Output Drive Shaft ...

Page 174: ...rooves Gearbox Inspection Always verify for the following when inspecting gearbox components Gear teeth damage Worn or scoured bearing surfaces Rounded engagement dogs and slots Worn shift fork engagement groove Worn splines on shafts and shifting sleeves Gearbox Installation For installation reverse the removal procedure Before gearbox installation check O ring in bearing cover if brittle hard or...

Page 175: ...ce if necessary Parking Gear Check the gear tooth wear cracks or other damage Replace if necessary Output Secondary gear shaft and 17 tooth Gear Check all the gear tooth wear cracks or other damage Replace if necessary Transmission Gear Check all the gear tooth wear cracks or other damage Replace if necessary ...

Page 176: ...5 4 TRANSMISSION GEARBOX 5 4 8 SHIFT LEVER ...

Page 177: ...Place shift lever in NEUTRAL position Apply parking brake Unscrew the shift lever handle Remove the RH side cover and the top cover Detach shift rod from shift lever Detach shift lever support Remove shift lever Shift Lever Inspection Check shift lever for bending or cracks Check spring and bushing condition Check ball joint condition Replace all damaged parts Shift Lever Installation The installa...

Page 178: ... adjuster NOTE Be aware that a nut has LH threads 6 Move shift lever in R position then in H position 7 Place shift lever in NEUTRAL position 8 Check if shift lever is properly centered in neutral notch Readjust as required 9 Test the shifter to confirm that the system works properly in all positions NOTE It may be necessary to realign shift rod ball joints to allow easy movement SHIFT PLATE Shift...

Page 179: ... for Cracks Bending Spline condition Shift Plate Installation The installation is the reverse of the removal procedure However pay attention to the following Place gearbox in NEUTRAL position before shift plate installation Align shift plate using marks previously traced Tighten shift plate nut to specification TORQUE 9NM 1 Nm ...

Page 180: ...5 5 CONTINUOUSLY VARIABLE TRANSMISSION 5 5 1 CONTINUOUSLY VARIABLE TRANSMISSION CVT PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 181: ...icle when CVT cover is removed WARNING Any drive pulley repairs must be performed by an authorized TGB dealer Subcomponent installation and assembly tolerance require strict adherence to procedure detailed NOTICE Never use any type of impact wrench at drive pulley removal and installation WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clut...

Page 182: ... tool in the threaded hole of driven pulley and tighten to open the pulley To remove belt slip the belt over the top edge of fixed sheave as shown Drive belt Installation For installation reverse the removal procedure Pay attention to following details The maximum drive belt life span is obtained when the drive belt has the proper rotation direction Install it so that the arrow printed on belt is ...

Page 183: ...y on the special tool fixing seat 561018 Loosen the tuner cover screw NOTE Do not unscrew the tuner cover screw completely Using special tool 560019 and compress machine on the tuner cover Press the tuner cover and remove cover screws CAUTION Sliding sheave of drive pulley is spring loaded Slowly release compress machine and special tool remove tuner cover Remove the spring NOTICE Make sure to use...

Page 184: ...olts and nuts on the centrifugal lever Replace new centrifugal lever For installation reverse the removal order TORQUE 44 56kgf cm GOVERNOR CUP INSTALLATION For installation reverse the removal order Using hand lift up the sliding sheave and install the governor cup Install the special tool 560017 on the top of centrifugal cop Tighten the centrifugal cup TORQUE 2000 2500kgf cm PDF created with pdf...

Page 185: ...cm DRIVE PULLEY INSTALLATION For installation reverse the removal procedure Pay attention to the following details WARNING Do not apply antiseize or any lubricant on crankshaft and drive pulley tapers NOTICE Never use any type of impact wrench at drive pulley removal and installation Using mounting special tool lock the drive pulley NOTICE Do not lean the tool hook on the slider shoe guides Instal...

Page 186: ...ew removal Remove driven pulley screw locking washer and washer Discard locking washer CAUTION Driven pulley is spring loaded Hold driven pulley tight and slowly remove the driven pulley screw to release spring tension Remove the driven pulley with the spring and the cam Driven Pulley Installation For installation reverse the removal procedure TORQUE 1000 kgf cm DRIVEN PULLEY DISASSEMBLY Install t...

Page 187: ...the two C clips Lightly lift up the compress machine and remove the cam Disassemble the cam spring spring seat and outer haft sheave Slider Shoe Replacement Remove three screws and washer from the back side of outer haft sheave PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 188: ...hammer push out the slider shoe Replace and install new slider shoe CAUTION The slider shoe have two side the flat side should toward the center Tighten the screws and washer TORQUE 25 35 kgf cm PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 189: ... sheave NOTE The hole of spring seat should align the center hole of outer haft sheave Install the spring on the spring seat NOTE the bottom end of spring should insert into the hole of spring seat Install the cam on the spring NOTE the upper end of spring should insert into the hole of cam with mark A PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 190: ...counter clockwise turn the outer haft sheave to let the spline of cam align to the shaft NOTE If the spline not aligns the shaft the cam can not push down Install two C clips NOTE The flat surface of should face outward Adjust the open area of two C clips to perpendicular direction as shown PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 191: ...6 DRIVE SYSTEM 6 1 FRONT DRIVE FRONT DIFFERENTIAL PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 192: ...ift and support vehicle Place the transmission lever on P Remove caliper from knuckle Remove the following parts Wheel Cotter pin Castellated nut Washer Remove wheel hub Wheel Hub Inspection Check wheel hub for cracks or other damages Check inner splines for wear or other damages If any damage is detected on wheel hub replace it with a new one Wheel Hub Installation For installation reverse the re...

Page 193: ...es on plunging joint are worn a check of differential inner splines should be done Front Drive Shaft Installation For installation reverse the removal procedure Install a NEW stop ring Apply SYNTHETIC GREASE to the splines The wear ring should be closed to the differential Reinstall all removed parts DRIVE SHAFT BOOT Drive Shaft Boot Removal Remove the drive shaft from the vehicle Remove drive sha...

Page 194: ... temperature below 35 Drain the differential oil Remove both drive shafts Detach vent hose from front differential Remove two drive mode select cables Remove bolts and nuts securing the differential Lift up the differential and slide forward to detach from the propeller shaft Remove the front differential by pulling it from the RH side NOTICE Be careful not to knock or to bend vent hose fitting wh...

Page 195: ...he suitable length by the rotate the nuts Front Differential Installation For installation reverse the removal procedure Fill the gear oil and tighten the bolt Caution Oil standard SAE 90 hypoid gear oil Oil capacity 350c c Bolt Torque 33N m Differential Motor Disconnected the wiring connector Unscrew three differential motor bolts Installation For installation reverse the removal procedure PDF cr...

Page 196: ...6 DRIVE SYSTEM 6 6 REAR DRIVE REAR DIFFERENTIAL PDF created with pdfFactory Pro trial version www pdffactory com ...

Page 197: ...t and support vehicle Place the transmission lever on P Remove caliper from knuckle Remove the following parts Wheel Cotter pin Castellated nut Washer Remove wheel hub Wheel Hub Inspection Check wheel hub for cracks or other damages Check inner splines for wear or other damages If any damage is detected on wheel hub replace it with a new one Wheel Hub Installation For installation reverse the remo...

Page 198: ...s on plunging joint are worn a check of differential inner splines should be done Rear Drive Shaft Installation For installation reverse the removal procedure Install a NEW stop ring Apply SYNTHETIC GREASE to the splines The wear ring should be closed to the differential Reinstall all removed parts DRIVE SHAFT BOOT Drive Shaft Boot Removal Remove the drive shaft from the vehicle Remove drive shaft...

Page 199: ... set temperature below 35 Drain the differential oil Remove both drive shafts Detach vent hose from rear differential Remove the lock mode cables Remove bolts and nuts securing the differential Lift up the differential and slide backward to detach from the propeller shaft Remove the rear differential by pulling it from the RH side NOTICE Be careful not to knock or to bend vent hose fitting while r...

Page 200: ... the nuts Rear Differential Installation For installation reverse the removal procedure Fill the gear oil and tighten the bolt Caution Oil standard SAE 90 hypoid gear oil Oil capacity 500 c c Bolt Torque 330N m Differential Motor Disconnected the wiring connector Unscrew three differential motor bolts Installation For installation reverse the removal procedure PDF created with pdfFactory Pro trial...

Page 201: ...7 1 STEERING SYSTEM AND SUSPENSION 7 1 1 STEERING SYSTEM EPS MODEL ...

Page 202: ...7 1 STEERING AND SUSPENSION 7 1 2 NON EPS MODEL ...

Page 203: ...the exploded view Clean threads before applying thread locker WARNING Torque wrench tightening specifications must strictly be adhered to Locking devices e g locking tabs elastic stop nuts self locking fasteners cotter pin etc must be replaced Hoses cables or locking ties removed during a procedure must be reinstalled as per factory standards ...

Page 204: ...dashboard cover 2 Remove the two screws on the both rear mirror bracket 3 Remove the top cover screws and pull out the cover from the handlebar Handlebar Cover Inspection Check covers for cracks or other damages Replace if necessary Handlebar Cover Installation The installation is the reverse of removal procedure ...

Page 205: ...andlebar is defective and requires replacement 2 Remove four bolts from the dashboard bracket 3 Remove the dashboard 4 Remove four handlebar mounting bolts 5 Remove handlebar Handlebar Inspection Inspect the handlebar for damage cracks or bending Replace if any of these problems is detected Handlebar Installation For the installation reverse the removal procedure ...

Page 206: ...m plate 9 Remove the steering shaft cotter low end pin washer and castle nut Discard the cotter pin NOTE Always install new cotter pin after removal 10 Pull off the steering shaft from the vehicle Steering Shaft Steering Shaft Removal with EPS 1 Remove handlebar cover 2 Remove dashboard support 3 Loosen handlebar mounting bolts and remove handlebar 4 Remove the body top cover 5 Remove steering sha...

Page 207: ...red nuts 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to the proper torque specification WARNING Do not rotate tires The front and rear tires have a different size Respect direction of rotation when applicable TIRES WARNING Do not rotate tires The front and rear tires have a different size Respect direction of rotation when applicable TIRE PRESSURE WARNING Tire pressure grea...

Page 208: ...7 1 STEERING AND SUSPENSION 7 1 8 FRONT SUSPENSION ...

Page 209: ...g ties removed during a procedure must be reinstalled as per factory standards PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1 Safety lifts and supports the vehicle of the ground 2 Remove bolts and nuts retaining shock absorber 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Secure the end of shock body in a vise with its rod upward NOTICE Do not clamp direct...

Page 210: ...llation For installation reverse the removal procedure Make sure to install the proper type of shock absorber on vehicle TORQUE 48 Nm 6 LOWER A ARM Lower A Arm Removal 1 Safety lifts and supports the vehicle off the ground 2 Remove wheel 3 Remove bolts and nut securing lower ball joint to knuckle 4 Remove bolts and nuts securing A arm to frame 5 Remove A arm Lower A arm installation For installati...

Page 211: ...Using a plastic hammer carefully hit on the knuckle side to separate ball joint from knuckle NOTE A ball joint remover can be used if the ball joint is jammed into knuckle NOTICE Never hit on A arm to avoid to damage it permanently 8 Remove bolt and nut securing A arm to shock absorber 9 Remove fasteners securing A arm to frame 10 Remove A arm Upper A Arm Installation For installation reverse the ...

Page 212: ...7 1 STEERING AND SUSPENSION 7 1 12 REAR SUSPENSION ...

Page 213: ... ties removed during a procedure must be reinstalled as per factory standards PROCEDURES SHOCK ABSORBER Shock Absorber Removal 1 Safety lifts and supports the vehicle of the ground 2 Remove bolts and nuts retaining shock absorber 3 Remove shock absorber Shock Absorber Inspection Remove spring from shock absorber Secure the end of shock body in a vise with its rod upward NOTICE Do not clamp directl...

Page 214: ...on For installation reverse the removal procedure Make sure to install the proper type of shock absorber on vehicle TORQUE 48 Nm 6 TENSION BAR Tension Bar Removal 1 Safety lifts and supports the vehicle off the ground 2 Loosen and remove the bolts washer and bushing from the frame 3 Remove ball joint nut from the A arm or tension bar Tension Bar Installation For installation reverse the removal pr...

Page 215: ...wheel 3 Remove bolts and nuts securing A arm to frame 4 Remove bolts and nut securing upper knuckle 5 Carefully move brake hose aside 6 Remove A arm Upper A Arm Installation For installation reverse the removal procedure Install a new cotter pin to secure ball joint nut Both end of cotter pin must be folded TORQUE 48 Nm 6 TORQUE 48 Nm 6 ...

Page 216: ...le off the ground 2 Remove wheel 3 Remove bolts and nuts securing A arm to frame 4 Remove bolts and nut securing lower knuckle 5 Remove ball joint nut to tension bar rod 6 Remove shock absorber lower bolt 7 Remove A arm Lower A arm installation For installation reverse the removal procedure TORQUE 48 Nm 6 ...

Page 217: ...7 2 ELECTRIC POWER STEERING 7 2 1 EPS Electric Power Steering ...

Page 218: ...o the driver The greater the power steering assist the greater the load on the electrical system When electrical system is under high load battery not at full charge operating the vehicle for prolonged periods of time at slow speed and low RPM which requires higher power steering assist the battery power reserve will gradually decrease This further increase the load on the charging system and the ...

Page 219: ...ction When the EPS unit temperature is above 100 all the EPS function will stop but the steering can operate without power assist when the EPS internal board temperature decrease below 90 the power steering will back to normal and steering assist should resume normal operation Steering Torque Sensor The steering column is connected to the shaft on the EPS unit A small area of the EPS shaft is magn...

Page 220: ...ess the RESET button on the EPS function page The EPS system will engage or disengage and display MIN MAX and blank OFF When EPS system is malfunction the function block will displayed FAIL And the bottom of dashboard will show DTC code with Cxxxx Code Problem Caused C1511 Torque sensor connector poor contact C1512 Torque sensor abnormal C1513 C1514 C1515 C1521 Motor connector poor contact C1522 M...

Page 221: ...n very small increments based on the amount duration and direction of DC power delivered by the EPS module ADJUSTMENT TORQUE OFFSET RESET When replacing the following parts or adjusting steering alignment the sensor torque offset must be reset to zero for proper system operation EPS unit Steering shaft bearing Tie Rod Knuckle Ball joint Front suspension A arm Steering alignment 1 Connect vehicle t...

Page 222: ... service actions LOW POWER STEERING ASSIST 1 Low battery voltage Check battery terminals Clean repair replace or tighten as required Test battery voltage Recharge or replace battery as required Carry out an EPS unit INPUT VOLTAGE test POWER SIDE as detailed in this subsection Ensure power connector pins are clean corrosion free tight and make good contact Repair or replace wiring connectors as req...

Page 223: ...power for the EPS motor 1 To remove fuse box cover simultaneously squeeze tabs inwards on each end of fuse box cover as you pull upward on the cover 2 Using voltmeter set to Ω selection remove and test the EPS fuse 3 Replace fuse as required NOTE The color and function of fuse EPS power fuse Green 40A MAXI fuse Pink 30 A Charger fuse Pink 30A 40A 30A 30A ...

Page 224: ...d carry out the following EPS UNIT INPUT VOLTAGE TEST CONTROL SIDE EPS Unit Input Voltage Test Control Side 1 Disconnect EPS control connector and turn ignition switch ON 2 Set the ignition switch to ON 3 Test for 12 VDC power to the EPS module pin as per following table EPS control connector pin A battery GND The voltage should be battery voltage If NO voltage is measured check wires and connecto...

Page 225: ...f there is good continuity carry out the following EPS UNIT COMMUNICATION LINK CAN CONTINUITY TEST EPS Unit Communication Link CAN Continuity Test NOTE EPS unit must receive an RPM signal to provide power steering assist Disconnect the EPS control connector and the diagnostic connector Test continuity of CAN Bus Wires at PINS EPS control connector pin C diagnostic connector pin 1 Below 1 Ω EPS con...

Page 226: ...on on the voltmeter to engage the MIN function 9 Turn the handlebar momentarily against the steering frame stops to each side NOTE Do not hold steering against frame stops for and extended period of time 10 Read the MIN charging system voltage recorded while the handlebar was turned against each stop Battery terminal fuse box battery terminal at least 12 VDC Steering position LH stop RH stop NOTE ...

Page 227: ...to the torque applied and decrease with the torque as steering assist is provided NOTE Increase and decrease in torque and current readings is very brief as steering assist is quickly provided Current draw should remain within green scale but may momentarily peak to 60 amps then drop off close to 0 amps as torque applied is nulled out by steering assist A residual torque of 2 NM with a correspondi...

Page 228: ...sconnect the wiring of headlamp and power source The front cover The inlet tube Loose the handle steering lock nut Lift up and dismounting the steering shaft Torque 280 320 kgf cm Disconnect the wiring on the motor Disconnect the wiring on the controller Remove the three mounting bolts of EPS body Torque 250 300 kgf cm ...

Page 229: ...ide of vehicle NOTE Be careful do not damage the cable of torque sensor Remove the four bolts and the bracket Remove the two bolts and dismounting the brake distributor Torque 280 320 kgf cm Remove the three bolts Lift up and remove the steering lower bearing seat Torque 280 320 kgf cm Installation Install the EPS in the reverse order of removal ...

Page 230: ...g seat assembly Steering Pad Bearing Seat Oil Seal Bearing x 2 Cap Washer Plate Nut Circlip Control Unit Removal Remove four mounting bolts Disconnect the wiring as follow 1 To fuse box 2 To ECU Speed Sensor and Ignition 3 To Motor Power 4 To Torque Sensor 5 To Motor Control Remove the control unit Installation Install the control in the reverse order of removal ...

Page 231: ...R STEERING 7 2 15 Fuse Removal Simultaneously squeeze tabs inwards on each end of fuse box cover as you pull downward on the cover Replace the damage fuse Installation Install the control in the reverse order of removal ...

Page 232: ...7 3 BRAKE SYSTEM AND BODY COVER 7 3 1 BRAKE FRONT BRAKE ...

Page 233: ...7 3 BRAKE SYSTEM AND BODY COVER 7 3 2 REAR BRAKE ...

Page 234: ...3 mm REAR BRAKES Item Standard Service Limit Bake Pad Thickness 1 mm Brake Disc Thickness 4 75 mm 4 24 mm Brake Disc Run out 0 254 mm Caliper Piston Diameter 31 75 mm 31 65 mm Caliper Bore Diameter 31 85 mm 31 90 mm TORQUE SPECIFICATIONS Item Torque kgf cm Caliper Mounting Bolts 500 Handlebar Master Cylinder Clamp Bolts 70 90 Hand Master Cylinder Reservoir Cover 8 Brake Line Flare Fitting 160 200 ...

Page 235: ...e Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed Test for brake drag after any brake system service and investigate cause if brake drag is evident Make sure caliper moves freely on guide pins where applicable Inspect caliper piston seals for foreign material that could prevent caliper piston from returning freely Per...

Page 236: ...ushed switch continuity Release switch Open If switch is defective replace with a new one If the switch is good verify wire continuity between harness connector and ECU connector Brake Light Switch Replacement 1 Disconnect brake light switch connector 2 Drain rear brake line 3 Remove brake light switch from distributor NOTE Use shop rag to catch any spilled brake fluid 4 Install new sealing washer...

Page 237: ...r cylinder from vehicle Master Cylinder Inspection Check boot for crack Check rod for wear and scratch Check master cylinder housing for leak or damage Master Cylinder Installation For installation reverse the removal procedure Tighten brake light switch and front brake hoses to specification TORQUE Pedal Master Cylinder bolts 208 320kgf cm Break hose 300 350 kgf cm Brake light switch 300 350 kgf ...

Page 238: ...o knuckle 5 Remove screws securing caliper support knuckle 6 Place caliper assembly onto a support NOTICE Do not let caliper hangs the hose and do not stretch or twist hose Caliper Installation For installation reverse the removal procedure If caliper was removed for replacement Refill and bleed brake system Install new sealing washers Apply thread locker LOCTITE 243 on caliper retaining screws Ti...

Page 239: ...ng grease 9 Install brake pad pins on caliper 10 Install caliper on knuckle BRAKE DISC Brake Disc Inspection 1 Check disc surfaces for scratch or grooves on both sides 2 Measure thickness of the disc THICKNESS 4 1 mm NOTICE Brake discs must never be machined 3 Check warpage of disc Maximum disc warpage 0 2 mm Brake Disc Replacement 1 Remove caliper 2 Remove brake disc mounting bolts 3 Replace brak...

Page 240: ...7 3 BRAKE SYSTEM AND BODY COVER 7 3 9 BODY FRONT BUMPER TOP COVER SIDE COVER FOOTREST ...

Page 241: ...7 3 BRAKE SYSTEM AND BODY COVER 7 3 10 FRONT COVER REAR COVER ...

Page 242: ...holder Remove the four bolts at front and two bolts at rear of the top cover as shown Side Cover Remove both side five bolts and the side covers as shown Front Bumper Steel Remove both side retaining bolts Remove the front bumper steel NOTE After remove the front bumper steel the front lower shield detach at same time ...

Page 243: ...nect front lamp connector Remove the four retaining bolts on the front side Remove the four retaining bolts on the backside Footrest Remove both side footrest connecting bolts as shown Remove passenger footboard mounting bolts Remove footrest bracket mounting bolts ...

Page 244: ...inner fender as shown Front Cover Disconnect DC supply connector Remove two front cover retaining bolts and take out the front cover Rear Cover Remove the seat Remove the fixing plate two bolts Remove the battery and disconnect the electric parts connectors Remove rear cover retaining bolts ...

Page 245: ...Y COVER 7 3 14 Disconnect rear light lamp connector Remove both side reflector retaining nuts Remove two retaining screws on the inside of rear cover Remove the fuel hose clamp from the fuel filler assembly and detach the hose ...

Page 246: ...se retaining clip and remove the hose Remove the rear cover together with rear bumper and fender side rail Skid Plate Remove retaining bolts and plate from the bottom of the frame INSTALLATION For installation reverse the removal procedure Install the bracket set of lamp ...

Page 247: ...assing beam headlight three mounting screws Adjust the suitable aiming height of lamp Install driving beam headlight three mounting screws Adjust the suitable aiming height of lamp Install the winker position daytime running lamp five mounting screws ...

Page 248: ... Shift lever Hazard control Rear Brake switch ECU Main switch Front brake Coolant sensor Winker relay Headlight relay Oil pressure switch Horn EPS controller AC Generator Ignition coil Regulator DC Power outlet Winch switch Speed sensor Fuse box ...

Page 249: ...il through the main relay while ECU completes the circuit for each cylinder by switching it to the ground at the right moment The ECU can direct open and short circuit in the primary winding but it does not check the secondary winding Ignition Timing Ignition timing is not adjustable TROUBLESHOOTING It is good practice to check for fault codes using the diagnostic tool Always refer to the WIRING D...

Page 250: ...cuit Check fuel injectors ENGINE HARD TO START 1 spark plug faulty fouled or worn out Check spark plug condition replace if necessary 2 Low fuel pressure Test fuel pressure ENGINE MISFIRES RUNS IRREGULARLY 1 Fouled or defective worn spark plugs Check verify heat range gap replace 2 Damaged trigger wheel loose CPS Check 3 Defective ignition circuit Check ignition coil fuse and wiring condition 4 Po...

Page 251: ...USE EPS Model Remove the seat Remove the isolate shield Push inward from the both side and lift up the cap Check the fuse condition replace if necessary ESP 40 A Green MAXI FUSE 30 A Pink Charged 30 A Pink MAXI FUSE Non EPS Model Fuse Box EPS MAXI Charged ...

Page 252: ...o ECU in OFF position PIN E 12 Vdc output ECU starter and start switch Ignition Coil location Cylinder 1 rear R BK Y Cylinder 2 front R BK Bu Ignition Coil Installation Install two bolts on the bracket and tighten to the specified torque TORQUE 8 Nm 1 Ignition Coil Input Voltage Test Disconnect the 2 pin connector from the ignition coil Turn ignition switch ON Using multimeter read the voltage Pin...

Page 253: ...placing the ignition coil may be necessary as a test Disconnect ignition cables from spark plugs Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap Measure the resistance between the terminals of the primary winding Standard resistance 2 9Ω 10 Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding St...

Page 254: ... filter incorrect fuel defective ignition system incorrect spark plug gap lubricating oil entering the combustion chamber or too cold spark plug The plug face of a fouled spark plug has either a wet black deposit or a black carbon fouling Such coatings form a conductive connection between the center electrode and ground Spark Plug Analysis The plug face reveals the condition of the engine operatin...

Page 255: ...fier receives AC current from the magneto and transforms it into direct current DC The voltage regulator included in the same unit limits voltage to prevent any damage to electrical components Battery The battery supplies DC power to the electric starter for cranking the engine During engine starting it also supplies DC power to the entire electrical system At low engine RPM operation and high cur...

Page 256: ...above specification replace voltage rectifier If voltage is below specification check stator and wiring harness prior to concluding that voltage rectifier is defective TROUBLESHOOTING BATTERY REGULARLY DISCHARGED OR WEAK 1 Loose or corroded battery cables connections Tighten or repair battery cables connections 2 Worn or defective battery Change and test battery 3 Defective magneto stator Test sta...

Page 257: ... If the battery has just received a charge allow it to rest for 1 2 hours before taking a voltage reading FULLY CHARGED BATTERY VOLTAGE 12 6 Vdc minimum NOTE A battery that shows a voltage of 12 0 Vdc is considered completely discharged and need to be recharged Battery Load Test This is the best test to indicate a battery condition Use a load testing device and has a 500 Amp adjustable load Apply ...

Page 258: ...ery from vehicle Clean battery terminals and cable connections using a wire brush Apply light coat of ELECTRIC GREASE on terminals Clean battery casing using a solution of baking soda and water Rinse battery with clear water and dry well using a clean cloth Regularly charge battery as per manufacturer s recommendations WARNING Ensure to store battery in a safe place out of reach for children Batte...

Page 259: ...by the battery through a solenoid The starter solenoid receives a 12 volt input from ignition switch and the ground signal is provided by the ECU when the engine cranking conditions are met Ignition switch ON Transmission in Park or neutral position and or brake lever or pedal held Start button held NOTE If the ignition switch is left ON for more than 15 minutes engine will not start unless igniti...

Page 260: ...Defective start button or circuit Test start button 4 Defective starter solenoid or circuit Check starter solenoid 5 Defective starter motor Check starter motor PROCEDURES Start Button Wire Identification 12 V input from ignition switch Black Yellow 12 V output to ECU pin Yellow Red Start Button Resistance Test Disconnect start button connector Using multimeter measure resistance Switch released i...

Page 261: ...re voltage Black Yellow wire and Battery ground battery voltage Starter Relay Ground Signal Test 1 Disconnect pin 2 Orange Brown from relay 2 Turn ignition switch ON 3 Measure voltage Orange Brown wire and Battery positive post Battery voltage Starter Relay Winding Resistance Test Disconnect terminals from relay With a multimeter check primary winding resistance Starter Relay pin 1 and pin 2 Appro...

Page 262: ...econnect last Disconnect RED cable from starter Clean starter area Remove starter retaining screw Carefully pry starter out of the engine crankcase Starter Installation Installation is the reverse of removal procedure Make sure that starter and engine mating surface are free of debris Serious problem may arise if the starter is not properly aligned Bring starter close to its location Rotate it so ...

Page 263: ... RED cable to the starter motor make sure the battery cables are disconnected TORQUE 6 Nm First connect RED cable to battery then connect BLACK cable Connect battery cables WARNING Always connect RED cable first and BLACK cable last Test starter operation ...

Page 264: ...switch is left ON for more than 30 minutes the accessory relay will shut down Electronic Connection Inspection When replacing an electric or electronic component always check electronic connections Make sure they are tight make good contact and are corrosion free Dirty loose or corroded contacts are poor conductors and are often the source of a system or component malfunction Ensure all wire termi...

Page 265: ...ect headlight connector Using multimeter measure the voltage SWITCH POSITION WIRE COLOR VOLTAGE LO beam HI beam Green Black Battery voltage HI beam Blue Black Headlight Bulb Replacement NOTICE Never touch glass portion of an halogen bulb with bare fingers it shortens its operating life If glass is touched clean it with isopropyl alcohol which will not leave a film on the bulb NOTE The same bulb ty...

Page 266: ...e right brake lever and check continuity of brake switch connector Replace if necessary Torque Disconnect the rear brake switch connector Press the left brake lever or pedal then check continuity of brake switch connector Replace if necessary Torque Taillight Brake Light Replacement Disconnect the taillight wiring connector Loosen and remove two nuts and washers Pull taillight out through the rear...

Page 267: ...ontinuity of brake switch connector Replace if necessary Replacement Remove five screws of turn signal lamp For installation reverse the procedure of removal HORN Disconnect the wiring of horn connector Press the horn switch and check continuity Replace if necessary Horn Replacement Remove bolt of horn For installation reverse the procedure of removal ...

Page 268: ...65 NO ON NO OFF R Y R Br B L YES G B 3 X 4 1 19 40 10A 10A 10A 15A 15A 20A 10A 10A 10A 20A 9400uf 12V ECU 12V PDF 檔案使用 pdfFactory Pro 試用版本建立 www ahasoft com tw FinePrint ...

Page 269: ...65 NO ON NO OFF R Y R Br B L YES G B 3 X 4 1 19 40 10A 10A 10A 15A 15A 20A 10A 10A 10A 20A 9400uf 12V ECU 12V PDF 檔案使用 pdfFactory Pro 試用版本建立 www ahasoft com tw FinePrint ...

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