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5-28

EMS(Engine Management System)

REMOVE

●

Disconnect the ISA coupler.

●

Loosen 2 ISA screws.

●

Located on the throttle body.

●

Remove the center cover.

CAUTION

△

12. ISA(Idle Speed Actuator)

●

Before disassembly, the key is off.

●

Remove the ISA.

ASSEMBLY

●

Assembly is the reverse order of removal.

ISA COUPLER

ISA

INJECTOR

ISA SCREW

Содержание B-BONE

Страница 1: ......

Страница 2: ......

Страница 3: ...information and troubleshooting guide Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be reprod...

Страница 4: ......

Страница 5: ...OCATION 1 1 SPECIFICATIONS 1 2 TORQUE VALUES 1 4 STANDARD TORQUE VALUES 1 5 SYMBOLS ABBREVIATIONS 1 5 WIRINGDIAGRAM 1 6 GENERALSAFETY 1 10 SERVICERULES 1 10 CAUTION WHEN WIRING 1 14 SERIAL NUMBER LOCA...

Страница 6: ...1 2 SERVICE INFORMATION 7 1 1 2 stroke SOHC ATDC 1 910mm 750mm 1 090mm 1 360mm 755mm 126mm 130kg 277kg 60 2 00 2 25 25 80 90 70 13 8 380 6 8 1 0 1 05 MARKED CONTENTS APPLY TO EURO 2 ONLY 90mm...

Страница 7: ...55W 12V 55W 12V 5W 12V 10W 4 12V 21 5W LED LED LED 12V 5W TYPE VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY R...

Страница 8: ...1 4 SERVICE INFORMATION...

Страница 9: ...SERVICE INFORMATION 1 5...

Страница 10: ...1 6 SERVICE INFORMATION...

Страница 11: ...1 7 SERVICE INFORMATION...

Страница 12: ...1 8 SERVICE INFORMATION...

Страница 13: ...1 9 SERVICE INFORMATION...

Страница 14: ...person are working always pay attention to other worker s action and alway have safety in mind 6 The skin exposed to used engine oil can be a major reason of the skin cancer Pay attention not to expos...

Страница 15: ...nuts and pieces must be tightened from the bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test a...

Страница 16: ...may damage the bearing Prior to installation apply oil or grease to the bearing 16 Install the snap ring so that chamfered side directs to the load applied side After installation check the proper in...

Страница 17: ...ntact surface of each case of the engine while removing gasket material completely Remove damaged contact surface by wiping with the oil stone equally 23 Pay attention not to bend the cable excessivel...

Страница 18: ...tion of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After connecting the terminal apply the grease to the termi...

Страница 19: ...following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting t...

Страница 20: ...the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start from the frame replace...

Страница 21: ...ness not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please rea...

Страница 22: ...MEMO...

Страница 23: ...10 2 11 SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDERCOMPRESSION RESSURE CARBURETOR IDLE SPEED TRANSMISSION OIL ENGINE OIL...

Страница 24: ...2 2 INSPECTIONS ADJUSTMENTS...

Страница 25: ...2 3 INSPECTIONS ADJUSTMENTS...

Страница 26: ...UT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT ADJUSTNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT LOCKNUT L...

Страница 27: ...IALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPECIALBOLT SPARKPLUGCAP SPARKPLUGCAP SPARKPLUGC...

Страница 28: ...JUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST...

Страница 29: ...TGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS OILSIGHTGLASS UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER U...

Страница 30: ...E HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE R...

Страница 31: ...STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREA...

Страница 32: ...URE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESS...

Страница 33: ...ng surfaces not shown here CONTROL CABLE LUBRICATION Periodically disconnect the upper end of the throttle cable and that of clutch cable then apply oil after cleaning Change it when the cable lengthe...

Страница 34: ...MEMO...

Страница 35: ...3 FRONT COVER 3 3 FRONTFENDER 3 4 FRONT UNDER COVER 3 4 SEAT 3 5 REAR FENDER 3 5 REAR UPPER COVER 3 5 REAR UNDER COVER 3 5 SEAT SUPPORT PIPE 3 6 CENTER COVER 3 6 TRUSS PIPE 3 7 FLOOR SIDE COVER 3 7 F...

Страница 36: ...chart shows arrows connected in the order of disassembling covers INNER BOX FR COVER FR FENDER FR WHEEL FR UNDERCOVER SEAT RR FENDER RR UPPERCOVER RR UNDERCOVER SEATSUPPORTPIPE CENTERCOVER UNDERCOVER...

Страница 37: ...CREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD...

Страница 38: ...EW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW S...

Страница 39: ...WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FE...

Страница 40: ...AT SEAT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPORT SEAT SUPPO...

Страница 41: ...APPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW TAPPING SCREW BATTERY COVER BATTE...

Страница 42: ...AL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHE...

Страница 43: ...FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOM...

Страница 44: ...MEMO...

Страница 45: ...4 1 LUBRICATION SYSTEM 4 1 4 2 4 3 4 3 4 4 4 7 4 8 4 4 4...

Страница 46: ...Inclusion of water Low or no oil pressure Close oil valve relief Clogged oil strainer Worn and faulty oil pump Internal oil leaks Inadequate oil viscosity Shout of oil quantity Oil pump drivegear or s...

Страница 47: ...APPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOL...

Страница 48: ...FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL...

Страница 49: ...DY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE...

Страница 50: ...SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILP...

Страница 51: ...OVER RADIATOR COVER RADIATOR COVER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIATOR RUBBER RADIA...

Страница 52: ...T OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL...

Страница 53: ...ode table 5 9 How to remove the fault code 5 10 EMS trouble shooting 5 10 6 ECU Electronic Control Unit 5 11 7 THROTTLE BODY 5 12 8 INJECTOR 5 16 9 MAPAT Manifold Air pressure Sensor temperature senso...

Страница 54: ...ause these parts may be damaged by the impact of the drop Do not touch the ECU terminal because it may be damaged by the static The ignition key off when assembly and disassembly of the ECU coupler ot...

Страница 55: ...ipe and injector The fuel in tank being high pressed by fuel pump moves to the division pipe through fuel filter Next the fuel is supplied to injector being highly maintained as regulated pressure abo...

Страница 56: ...5 4 EMS Engine Management System 3 TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO 6 7 8 11 13 14 15 16 21 29 32 36 38 were not connected 4 WIRING DIAGRAM OF THE ECU...

Страница 57: ...n the main key is turned on Remarks 1 If the EMS has some problem and the MIL on and off engine starting and driving are temporary by the EMS s fail safe function But the EMS is not normal condition s...

Страница 58: ...inimum driving of vehicle MILon off INTAKE MIL INTAKE MILon on INTAKE INTAKE The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order intake in...

Страница 59: ...r to check the malfunction of vehicle is placed in the rh side cover Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool The...

Страница 60: ...ect information to driver If the MILon when engine is working engine is able to be operated by fail safe However in the event that Injector Fuel pump Ignition coil has something wrong vehicle may not...

Страница 61: ...e speed actuator failure ISA 22 3 Electrical fuel pump failure EFP 23 4 Intake Manifold absolute pressure signal failure IMP 12 5 Throttle position signal failure TPS 13 6 O2 sensor heater output fail...

Страница 62: ...e ignition key on off If many problems happened in the EMS parts at the same time only one defect code will is displayed by the priority order Even thought repair a fault and remove the memorized faul...

Страница 63: ...PPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE CENTER COVER CENTER COVER CENTER COVER CENTER...

Страница 64: ...dy ass y Remove the each component parts securing throttle body and check 5 12 EMS Engine Management System CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER C...

Страница 65: ...T SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SEN...

Страница 66: ...h new one INSTALLATION OF INSULATOR AND THROTTLE BODY Installation of insulator and throttle body in the reverse order of removal Check the o ring when the insulator assembly Assemble the insulator ga...

Страница 67: ...diagnostic tool The vehicle is warms up enough to adjust the idling speed The vehicle is warms up enough to adjust the idling speed ENGINE TEMPERATURE OVER 100 IDLE SPEED ACTUATOR APROXIMATELY 20 INSP...

Страница 68: ...R CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTO...

Страница 69: ...e resistance is normal turns on the ignition key If the fuel pump operated for 3 seconds the power supply relay of injector is normal 6 Measure between the voltage of coupler Measuring terminal BLACK...

Страница 70: ...SOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR M...

Страница 71: ...4 Measure the input voltage of MAPAT intake pressure sensor intake temperature sensor s coupler Input voltage 4 5 5 5 V Measuring terminal MAPAT 3 terminal MAPAT 1 terminal Remarks Measuring unit of...

Страница 72: ...294 V 5 If the measured voltage is not normal Check the P electric wire P G electric wire P L electric wire to see if they have been broken or have short circuited Replace the MAPAT sensor with the ne...

Страница 73: ...no problem ECU is broken Replace the ECU with the new one it rechecks 4 Turn on the ignition key Start the engine and idling 5 Measure the voltage of intake pressure sensor for ECU check Measuring the...

Страница 74: ...TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAP...

Страница 75: ...isassemble the TPS coupler 4 Turn on the IGNITION KEY Measuring terminal ECU NO 18 Gr B GRAY BLACK ECU NO 4 W R WHITE RED Measure the terminal voltage of TPS s coupler Measuring voltage 4 5 V 5 5 V Re...

Страница 76: ...9 If resistance and continuty are normal connect the TPS coupler 10 Turn on the ignition key 11 Measure the TPS voltage of wire harness to check the ECU Rotate the throttle lever measure the voltage...

Страница 77: ...the key is off ASSEMBLY Assembly is the reverse order of removal Disconnect the ETS RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHR...

Страница 78: ...LUE ECU No 4 W R WHITE RED Measure the terminal voltage of ETS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit for voltage voltage V If the voltage value is not normal Check to see if t...

Страница 79: ...e ETS Engine Temperature Sensor Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil Read the temperature of thermometer depending upon oil temperatu...

Страница 80: ...COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA COUPLER ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA ISA...

Страница 81: ...r of ISA measure the resistance between ISA terminals ISA resistance 31 5 38 5 20 remarks Measuring unit of resistance Resistance R 4 If there is not problem check about the level of electricity flow...

Страница 82: ...ge measuring unit Voltage V If the measured voltage is normal Checkthe B R electricwire L G electricwire W R electricwireto see if they have been broken or have short circuited if there is a bad conta...

Страница 83: ...PLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPL...

Страница 84: ...ition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 Disassemble the coupler of oxygen O2 sensor and turn on ignition key 4 Measure in...

Страница 85: ...BY OXYGEN O2 SENSOR LAMBDA SIGNAL 1 Turn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 The wire harness to check the...

Страница 86: ...e Measuring terminal B Y electric wire G electric wire output voltage 9V 15V Remarks measuring unit of voltage voltage V If the measured voltage is normal Checkthe R Y electricwire B electricwire G el...

Страница 87: ...RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SHROUD COMP RH SH...

Страница 88: ...r Assembly is the reverse order of removal MEASUREMENT RESISTANCE Remove the seat Remove the LH side cover Disconnect the ACG coupler and L G connector Measure the resistance between G and L STANDARD...

Страница 89: ...e ENGINE SINK ON change OFF to ON it s okay Check if ENGINE SINK ON is OFF while start up Remove the A C generator If there are over 10 spots on the flywheel protrusion replace it Check the CKP is wor...

Страница 90: ...Measure terminal No 30 pin of wire harness for inspection Red wire of coupler of CKP Measuring resistance 0 1 Check the wiring of crank signal B Measure terminal No 22 pin of wire harness for inspecti...

Страница 91: ...PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SETTING PLACE FUEL PUMP SE...

Страница 92: ...ystem CONNECTOR WIRING LOCATION FUNCTION COLOR C D B A FUEL UNIT FUEL UNIT2 PUMP GROUND YELLOW GREEN RED BLACK The terminal arrangement of the fuel pump The following color chart is the internal color...

Страница 93: ...red resistance value is out of standard at float position replace the fuel unit The FLOAT position F 140 5 mm 1 2 83 5 mm E 28 5 mm Terminals resistance 40 5 220 5 400 3 CHECK THE BLOW PRESSURE OF FUE...

Страница 94: ...rnthelgnitionkeyon Pressthepowerbuttonofthe diagnostictool Presstheenterbuttonintheinitial screen Presstheenterinthe vehicle diagnosisscreen Presstheenterbuttononthe resettingECUvalues Presstherestbut...

Страница 95: ...5 43 EMS Engine Management System Press theenterbuttonwhenitis ready WhentheECUwas initialized turnoffthelgnition keyandthenturnontheignitionkey...

Страница 96: ...erbuttonofthediagnosistool Press theenterbuttonontheinitial screen Press thebuttonatthevehicle diagnostic screen Press theenterbuttononthecurrentdata By looking the displayed figure on the ISA PWM adj...

Страница 97: ...diagnostic tool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Pressthe enterbuttonontheinitial screen Pressthe enterbuttononthevehiclediagnosisscreen Presstheenterbuttononthe...

Страница 98: ...tool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Press the enterbuttonontheinitial screen Presstheenterbuttononthe vehiclediagnosisscreen Press the enterbuttononthecurrentd...

Страница 99: ...MEMO...

Страница 100: ...MEMO...

Страница 101: ...desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogge...

Страница 102: ...or is blocked Compression pressure is low Air Fuel mixture is extremely lean Fuel jet is blocked Bad ventilation of air in tank cap Fuel strainer screen is blocked Fuel tank is bent creased or blocked...

Страница 103: ...TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL...

Страница 104: ...AL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL PAN SCREW SPECIAL...

Страница 105: ...ER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET FLOAT CHAMBER SET ARM PIN ARM PIN ARM PIN ARM PIN...

Страница 106: ...the compressed air CARBURETORBODY TOP SET COMPRESSION SPRING FLOATCHAMBERSET SCREWSET AUTOBYSTARTERSET NEEDLEJETHOLDER MAINJET 95 SLOWJET NEDDLEJETCOMP VACUUMPISTONCOMP FLOAT VALVESET FLOATCOMP DIAPHR...

Страница 107: ...n screws SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SCREWSET SC...

Страница 108: ...ATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT...

Страница 109: ...MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCREW PILOTSCRE...

Страница 110: ...CCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELE...

Страница 111: ...NGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FUELP...

Страница 112: ...UELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP FUELPUMP After install the fuel pump check the blowing quantity of fuel in the outlet tube NOTE Check the gaske...

Страница 113: ...l or installation The following works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 12 STARTING CLUTCH SECTION 9 OIL PUMP SECTION 4 A C GENERATOR SECTION 9...

Страница 114: ...MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD MUDGUARD...

Страница 115: ...ECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER SECONDARY AIRFILTER REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARCUSHION REARC...

Страница 116: ...8 0 LH CRANKCASECOVER CONTINUOUSL YV ARIABLETRANSMISSION LH CRANK CASE COVER...

Страница 117: ...ELT WIDTH 22mm 20 5mm WEIGHT ROLLER OUTER DIAMETER 19 95 20 02mm 19 50mm CLUTCH OUTER AND INNER DIAMETER 125 0 125 2mm 125 5mm DRIVEN FACE SPRING PLAY 140mm 135mm DRIVEN FACE OUTER DIAMETER 33 965 33...

Страница 118: ...EN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN P...

Страница 119: ...FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVE...

Страница 120: ...LLEYSUBASS Y DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT...

Страница 121: ...PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABLE DRY FACE COMP MOVABL...

Страница 122: ...TE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE G...

Страница 123: ...REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR R...

Страница 124: ...SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE SPRING GUIDE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE DRIVE PLATE...

Страница 125: ...nd guide pin rollers and the movable driven face Remove the O ring from movable driven face Remove the oil seal from the movable driven face Remove the movable driven face SEAL COLLAR MOVABLE DRIVEN F...

Страница 126: ...aring with your finger Check that the bearing turns smoothly and quietly and that the bearing outer race fits securely Replace the bearing 8 11 MOVABLE DRIVEN FACE SPRING INSPECTION Measure the free l...

Страница 127: ...34 060mm Check the driven face for damage or excessive wear replace as necessary Measure the O D of the driven face replace if the service limit is exceeded SERVICE LIMIT 33 785mm Install in a new inn...

Страница 128: ...face Install the movable face on the driven pulley face Install the guide rollers and guide pins Install the seal collar DRIVENPULLEYSUBASS Y Install the spring guide driven face drive plate ass y Com...

Страница 129: ...i fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi fi DRIVEN PULLEY D...

Страница 130: ...9 0 A C GENERATOR STARTER CLUTCH sai COOLING FAN FLY WHEEL STARTER COMP SAI LID VALVE...

Страница 131: ...9 9 9 9 9 9 9 9 1 A C GENERATOR STARTER CLUTCH 9 16...

Страница 132: ...SHROUD RH SHROUD RH SHROUD RH SHROUD SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE SAI TUBE S...

Страница 133: ...A C G ROTOR PULLER A C G ROTOR PULLER A C G ROTOR PULLER DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE...

Страница 134: ...K CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER SAI REED VALVE SAI REED VALVE SAI REED VALVE SA...

Страница 135: ...CASE COVER RH CRANK CASE COVER OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SE...

Страница 136: ...ET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTI...

Страница 137: ...EAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER ONEWAY CLUTCH SET STARTER ON...

Страница 138: ...HER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER...

Страница 139: ...MEMO...

Страница 140: ...10 0 CYLINDER HEAD VALVES FLANGE NUT INVALVEROCKERARM CAM SHAFT HORDER CAM SHAFT COMP INLET VALVE CYLINDERHEADCOMP CYLINDER HEAD GASKET EX VALVE ROCKER ARM EX VALVE CARBURETORINSULATOR SAI PIPE...

Страница 141: ...T BOLT 1 0 kgf m SPARK PLUG 1 2 kgf m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m CYLINDER HEAD COVER BOLT 0 9kgf m CYLIND...

Страница 142: ...urned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 11 Excessiv...

Страница 143: ...CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER CAMSHAFTHOLDER SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL...

Страница 144: ...ETER MICROMETER MICROMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNERDIAMETER INNER...

Страница 145: ...ADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET CYLINDERHEADGASKET C...

Страница 146: ...SSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRINGCOMPRESSOR VALVESPRING VALVESPRING VALVESPRING VALVE...

Страница 147: ...AMER VALVEGUIDEREAMER VALVEGUIDEREAMER VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGUIDE VALVEGU...

Страница 148: ...ER HEAD VALVES Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and...

Страница 149: ...ng a 37 degree cutter remove of the existing valve seat material 10 9 CYLINDER HEAD VALVES Valve faces and stem tips cannot be ground If a valve face or stem tip is rough worn unevenly or contacts the...

Страница 150: ...e seat must be lowered using a 37 degree flat cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too low on the valve the seat must be raised using a 55...

Страница 151: ...CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE VALVE V...

Страница 152: ...YLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLIN...

Страница 153: ...N ROCKERARMSHAFT IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN VALVEROCKERARM IN...

Страница 154: ...CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT CAMSHAFT TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMINGMARK TIMI...

Страница 155: ...LIP TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENSIONERLIFTER TENS...

Страница 156: ...11 0 CYLINDER PISTON CYLINDER CYLINDER GASKET PISTON TOPRING SECONDRING OILRING...

Страница 157: ...ing Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston 11 SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 1 CYLINDER 11 2 PISTON PISTON RING 11 3 CYLINDER INSTALLATION...

Страница 158: ...the cylinder measurements exceed the service limits replace the cylinder SERVICE LIMIT OUT OF ROUND 0 005 mm TAPER 0 05 mm CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAINGUIDE CAMCHAI...

Страница 159: ...UGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE FEELERGAUGE Any...

Страница 160: ...11 4 CYLINDER PISTON...

Страница 161: ...K SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CON...

Страница 162: ...PISTON PISTON PISTON PISTON PISTON PISTON DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWELPIN DOWE...

Страница 163: ...MEMO...

Страница 164: ...12 0 TRANSMISSION CRANKSHAFT CRANK CASE...

Страница 165: ...12 12 1 12 2 12 3 12 6 12 7 12 8 12 9 12 10 12 1 TRANSMISSION CRANKSHAFT CRANKCASE 12 SECTION 4 4 SECTION 7 SECTION 9 SECTION 8 SECTION 8 SECTION 12 SECTION 10 AND 11...

Страница 166: ...SSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission damage Transmission seized Noise during op...

Страница 167: ...COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT...

Страница 168: ...NAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUN...

Страница 169: ...LOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT CRANK ASSEMBLY COLLAR CRANK ASSEMBLY COLLAR CRANK ASS...

Страница 170: ...NE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE MISSION COVER MISSION COVER MISSION COVER MISSION...

Страница 171: ...HAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET...

Страница 172: ...E LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE BE...

Страница 173: ...RIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER OUTER DRIVER DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT DRIVER PILOT...

Страница 174: ...NK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT CRANK SHAFT...

Страница 175: ...MEMO...

Страница 176: ...13 0 FRONT WHEEL FRONT FORK STEERING STEERINGHANDLE STEERING STEM FRONT FORK FRONT TIRE FRONTWHEEL FRONTDISK...

Страница 177: ...EERING TOP CONE RACE 0 49 1 27 f m FRONT CUSHION BOLT 1 98 2 45 f m FRONT AXLE NUT 4 41 4 9 f m BRAKE CALIPER BOLT 2 45 3 43 f m 13 SERVICE INFORMATION 13 1 TROUBLESHOOTING 13 2 STEERING HANDLE 13 3 F...

Страница 178: ...e race Insufficient tire pressure Tire is worn Steers to one side or does not track straight Bent front fork Bent front axle Bent frame Tire is worn or modification Worn wheel bearing Front wheel wobb...

Страница 179: ...OLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYL...

Страница 180: ...FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE...

Страница 181: ...EAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARINGREMOVERHEAD BEARIN...

Страница 182: ...SHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASHER GEARWASH...

Страница 183: ...ETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER GEARBOXRETAINER...

Страница 184: ...ONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTFORKBOLT FRONTF...

Страница 185: ...PRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FRONT CUSHION SPRING FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOLT FORK BOL...

Страница 186: ...face If the slider bush is extensively damaged replace the bottom case FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING FRONTFORKSPRING...

Страница 187: ...bottom case Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed TOOLS FORK S...

Страница 188: ...LT FLANGEBOLT FLANGEBOLT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT U NUT SETTING HANDLE COLLAR SETTING HANDLE COLLAR...

Страница 189: ...PTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT STEERINGTOPTHREADNUT...

Страница 190: ...14 0 REAR WHEEL SUSPENSION REAR SWING ARM...

Страница 191: ...ALUES REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION UNDER BOLT 3 5 4 5 f m REAR CUSHION ROD LOCK NUT 3 0 4 5 f m REAR AXLE NUT 6 0 8 0 f m 14 SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 2 REAR WHEE...

Страница 192: ...tened properly Insufficient air in tire Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorbe...

Страница 193: ...R REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR REARWHEELINSIDECOLLAR...

Страница 194: ...ALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT FINALSHAFT REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWI...

Страница 195: ...PRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPRESSOR REARCUSHIONCOMPR...

Страница 196: ...COMPRESSOR ATTACHMENT REAR CHUSION COMPRESSOR Install the spring with the smaller pitch side facing downward NOTE REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWI...

Страница 197: ...REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARSWINGARM REARS...

Страница 198: ...MEMO...

Страница 199: ...MEMO...

Страница 200: ...15 0 BRAKE SYSTEM...

Страница 201: ...d brake disk and pad reduces the braking performance if contaminated replace the pad with a new one and clean the disk SPECIFICATIONS 15 SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 2 BRAKE FLUID 15 3...

Страница 202: ...aminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn c...

Страница 203: ...REEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDERVALVE BREEDE...

Страница 204: ...KEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE RR BRAKEBREEDERVALVE FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELEVER FR BRAKELE...

Страница 205: ...ANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN HANGERPIN FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEBOLT FLANGEB...

Страница 206: ...AD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD RR BRAKEPAD FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER F...

Страница 207: ...R GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN CALIPER BODY CALIPER BODY...

Страница 208: ...BOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT SOCKETBOLT FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIPER FR CALIP...

Страница 209: ...BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY CALIPER BODY DISASSEMBLY Remove the rear brake caliper Check the...

Страница 210: ...C RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC RH SIM DC PISTON PISTON PISTON PISTON PISTON PISTON PISTON...

Страница 211: ...BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE LEVER BRAKE...

Страница 212: ...ry for scores scratches or nicks replace if necessary Check the primary and secondary cups for wear Check the master cylinder for scores scratches or nicks and replace if necessary Apply the recommend...

Страница 213: ...ISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK RR BRAKE DISK...

Страница 214: ...16 0 CHARGING SYSTEM 15A...

Страница 215: ...s charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to note here that the...

Страница 216: ...e broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Battery is...

Страница 217: ...BLE BATTERY REMOVAL Loosen the screws securing the battery cover and remove the battery cover Remove the battery Disconnect the negative battery cable first and then disconnect the positive cable The...

Страница 218: ...s fully charged before performing this test The amount of current flow may change abruptly if not sufficiently charged Use a battery whose voltage between its terminals is 13 0 13 2V NOTE Take precaut...

Страница 219: ...ULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REG...

Страница 220: ..._ AC GENERATOR B Y PULSE GENERATOR BATTERY 12V10AH UNIT SIDESTAND SWITCH IGNITION COIL SPARK PLUG G R MAIN SW FUSE 15A G G B W P B G B B Y G B Y HEADLIGHT RELAY IGNITION SYSYTEM 17 0 IGNITION SYSTEM...

Страница 221: ...ty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive peak voltage As inspections for co...

Страница 222: ...side stand switch 6 Faulty peak voltage adaptor 7 Faulty CDI unit in case when above No 1 6 are normal 1 Faulty spark plug or leaking ignition coil secondary current ampere 2 Faulty ignition coil 1 Th...

Страница 223: ...V TOOL PVA MULTI TESTER Installinthereverseorderofremoval ITEM GROUNDWIRE IGNITION COIL PRIMARYCOIL PULSE GENERATOR MAIN SWITCH Check that there is battery voltage between main switch wire black and g...

Страница 224: ...SCREW FAN SCREW FAN SCREW FAN SCREW FAN SCREW IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL...

Страница 225: ...TCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND DOWN SIDE STAND...

Страница 226: ...18 0 STARTER SYSTEM M CABLE CABLE STARTER RELAY STARTER MOTOR BATTERY 12V10AH FUSE Y R STARTER SWITCH REAR STOP SWITCH G Y STOP LAMP G Y FRONT STOP SWITCH B MAIN SWITCH G STARTER SYSTEM...

Страница 227: ...le to turn the starter motor quickly enough or supply adequate ignition current The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over The engine may not...

Страница 228: ...switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 6 Connect the starter magnetic switch coupler Measur...

Страница 229: ...TOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MO...

Страница 230: ...COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR OI...

Страница 231: ...T RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET RR BRACKET MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK MARK...

Страница 232: ...TIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWIT...

Страница 233: ...Apply battery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there is continuity betwee...

Страница 234: ...MEMO...

Страница 235: ...d Remove these locks prior to disassembling and insert these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity te...

Страница 236: ...KER BULB WINKER BULB WINKER BULB WINKER BULB WINKER BULB HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET HEAD LIGHT SOCKET...

Страница 237: ...DOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER...

Страница 238: ...ITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH...

Страница 239: ...SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADL...

Страница 240: ...GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GAUGE FUEL GA...

Страница 241: ...MEMO...

Страница 242: ...MEMO...

Страница 243: ...0 1 WIRING DIAGRAM EURO 2 WIRING DIAGRAM...

Страница 244: ...0 2 WIRING DIAGRAM EURO 3 WIRING DIAGRAM...

Страница 245: ...SERVICEMANUAL 2009 02 PRINTED 2009 02 PUBLICATION C CO OP PY Y P PR RO OH HI IB BI IT T...

Страница 246: ......

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