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CHECKING THE REAR BRAKE CALIPER 

Recommended brake component

replacement schedule

Brake pads

As required

Caliper ass'y 

Every two years

Brake hoses

Every four years

Brake fluid

Replace when
brakes are
disassembled.

1. Check:

•  brake caliper body

Cracks/damage → Replace.

• brake fluid delivery passage 

(brake caliper body)
Blockage → Blow out with compressed air.

Replace the caliper piston seal and dust
seal whenever the brake caliper is disas-
sembled.

1

1

INSTALLING THE REAR BRAKE CALIPER

1. Install:

• brake caliper assembly
• brake caliper mounting bolts 

• brake  hose 
• copper washers 

 

• union bolt 

Brake caliper mounting bolt

30 Nm (3.0 m•kg, 21.7 ft•lb)

Union bolt

28 Nm (2.8 m•kg, 20.3 ft•lb)

1

2

3

4

When installing the brake hose on the
brake caliper, make sure that the brake pipe

touches the projection

 on the brake

caliper.

a

b

2

1

3

4

a

b

REAR BRAKE

CHAS

WARNING

რ

NOTICE

6 - 15

Содержание ATV3U 150

Страница 1: ...SERVICE MANUAL ATV3U 150 YUKON II U S CHALLENGER 150 EUR E TON POWER...

Страница 2: ...r 150 SERVICE MANUAL 2009 by E TON POWER TECH CO LTD First edition October 2009 All rights reserved Any reproduction or unauthorized use without the written permission of E TON POWER TECH CO LTD is ex...

Страница 3: ...res will be forwarded to all authorized E TON dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFOR...

Страница 4: ...on the next page 4 A job instruction chart accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the step by step format s...

Страница 5: ...l Torque Wear limit clearance Engine speed Electrical data V A Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points Apply engine oil Apply gear oil Apply molybde...

Страница 6: ...TABLE OF CONTENTS SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL GENERAL INFORMATION 1 2 7 6 5 4 3 TROUBLESHOOTING 8...

Страница 7: ...TION NUMBER 1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PI...

Страница 8: ...IONS 2 13 TIGHTENING TORQUES 2 15 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 16 HOW TO USE THE CONVERSION TABLE 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 LUBRICATION POINTS A...

Страница 9: ...CLEANING THE AIR FILTER ELEMENTS 3 17 CLEANING THE SPARK ARRESTER 3 18 CHASSIS 3 19 CHECKING THE FRONT BRAKE SHOES 3 19 ADJUSTING THE FRONT BRAKE 3 19 CHECKING THE REAR BRAKE FLUID LEVEL 3 20 CHECKING...

Страница 10: ...NGS 4 12 CHECKING THE CAMSHAFT 4 13 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 13 CHECKING THE VALVES AND VALVE SPRINGS 4 15 INSTALLING THE VALVES AND VALVE SPRINGS 4 18 INSTALLING THE CAMSHAFT...

Страница 11: ...SION 4 49 TRANSMISSION 4 49 SHIFT SHAFT 4 50 CHECKING THE TRANSMISSION 4 51 CHECKING THE SHIFT FORK 4 51 REMOVING THE GEAR SET 4 52 CHECKING THE GEAR SET 4 53 INSTALLING THE GEAR SET 4 54 CHECKING THE...

Страница 12: ...CARBURETOR 5 1 DISASSEMBLING THE CARBURETOR 5 4 CHECKING THE CARBURETOR 5 4 ASSEMBLING THE CARBURETOR 5 6 INSTALLING THE CARBURETOR 5 6 MEASURING AND ADJUSTING THE FUEL LEVEL 5 7 CHAPTER 5 CARBURETOR...

Страница 13: ...EAR AXLE AND REAR AXLE HUB REMOVING THE REAR AXLE CHECKING THE REAR AXLE CHECKING THE DRIVEN SPROCKET CHECKING THE BRAKE DISC INSTALLING THE DRIVEN SPROCKET INSTALLING THE REAR AXLE REAR BRAKE REAR BR...

Страница 14: ...E STEERING KNUCKLES 6 32 REMOVING THE TIE RODS 6 32 CHECKING THE TIE RODS 6 32 CHECKING THE STEERING KNUCKLES 6 32 INSTALLING THE TIE RODS 6 33 FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 6 34 REMO...

Страница 15: ...ION OF THE BULBS SOCKETS 7 6 ELECTRIC STARTING SYSTEM 7 11 CIRCUIT DIAGRAM 7 11 STARTING CIRCUIT OUT OFF SYSTEM OPERATION 7 12 TROUBLESHOOTING 7 13 STARTER MOTOR 7 15 CHECKING THE STARTER MOTOR 7 16 R...

Страница 16: ...ERFORMANCE 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 2 FAULTY CLUTCH 8 3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE 8 3 CLUTCH SLIPPING 8 3 POOR STARTING PERFORMANCE 8 3 POOR SPEED PERFORMANCE 8 3 O...

Страница 17: ...ION GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the front side of the frame The engine serial number is stamped on the en...

Страница 18: ...s be reused or replaced as an assembly 4 During disassembly clean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installati...

Страница 19: ...stalling oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate Oil seal Do not spin the bearing with compressed ai...

Страница 20: ...nect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure all connectio...

Страница 21: ...7 1 Standard compression pressure at sea level 1250 kPa 12 5 kg cm2 181 3 psi at 1 000r min Electric starter kick starter Starting system Lubrication system Wet sump Oil type or grade Engine oil SAE5W...

Страница 22: ...mary reduction system V belt Primary reduction ratio 2 50 1 0 1 Secondary reduction system Spur gear Secondary reduction ratio 36 14 40 15 6 857 Transmission type V belt automatic Chassis Frame type S...

Страница 23: ...ont shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Electrical Ignition system DC CDI Generator system AC magneto Battery type Lead Acid Battery capacity 12 V 8 0 Ah D...

Страница 24: ...mm 0 0039 in Camshaft Drive method Chain drive Left Cam dimensions Intake A 29 745 29 845 mm 1 1711 1 1750 in 29 645 mm 1 1671 in B 25 185 25 215 mm 0 9915 0 9927 in 25 076 mm 0 9872 in Exhaust A 29...

Страница 25: ...Stem outside diameter Guide inside diameter Item Standard Limit B C D A Head Diameter Face Width Seat Width Margin Thickness IN 27 4 27 6 mm 1 0787 1 0866 in EX 23 4 23 6 mm 0 9213 0 9291 in IN 1 00...

Страница 26: ...pring Free length IN 32 3 mm 1 27 in 29 3 mm 1 15 in EX 32 3 mm 1 27 in 29 3 mm 1 15 in Compressed pressure installed IN 33 55 41 00 N at 26 00 mm 3 42 4 18 kg 7 54 9 21 lb at 1 0236 in EX 33 55 41 00...

Страница 27: ...n 2 0 1 2 mm 0 05 in Compressed pressure installed 82 10 100 40 N at 29 00 mm 8 37 10 23 kg 18 45 22 56 lb at 1 1417 in 82 10 100 40 N at 29 00 mm 8 37 10 23 kg 18 45 22 56 lb at 1 1417 in IN Tilt lim...

Страница 28: ...0 0866 in 0 20 0 80 mm 0 0079 0 0315 in Limit Standard Item Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed 2nd ring Type Dimensions B T End gap installed Side cle...

Страница 29: ...0 in 32 0 mm 1 2598 in 20 0 mm 0 7874 in 124 9 125 1 mm 0 7047 0 7126 in 17 9 18 1 mm Transmission V belt automatic Transmission type Primary reduction system Primary reduction ratio Secondary reducti...

Страница 30: ...housing clearance 0 0059 0 0083 in 0 25 mm 0 0098 in 0 15 0 21 mm 0 00 0 15mm Lubrication chart Pressure feed Splashed scavenge Crankshaft pin Camshaft Rocker arm Valve Timing chain area Oil strainer...

Страница 31: ...wheel Rim size Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Drive chain Type manufacturer 520 KMC Link quantity 78 Front drum brake Type Brake drum inside diameter...

Страница 32: ...25 mm 0 009 in 3 00 mm 0 120 in Pad thickness inner 6 2 mm 0 24 in DOT 4 25 4 mm 1 00 in 12 7 mm 0 50 in Dual cylinder 190 0 mm 3 5 mm Pad thickness outer 6 2 mm 0 24 in Master cylinder inside diamet...

Страница 33: ...C D I unit model manufacturer C0410 V30 9001 E YANG Ignition coil Model manufacturer C051A FIA0 0010 SHIHLIN Minimum spark gap 6 0 mm 0 24 in Primary winding resistance 0 19 0 25 at 20 C 68 F Secondar...

Страница 34: ...rush overall length 0 22 in Spring force 680 920 gf 23 99 32 45 oz 19 4 mm 22 0 mm 0 87 in Commutator diameter 0 76 in 7 mm 0 07 in 1 Mica undercut Starter relay C5850 A04 0000 SHINGYIH Model manufact...

Страница 35: ...assy movable drive Nut 1 55 5 5 Outer clutch Nut M12 1 55 5 5 Plate comp drive Nut M28 1 55 5 5 Bolt Motor start comp M6 2 12 1 2 Bolt Gear comp starting clutch M22 1 95 9 5 M6 Nut Oil pump driven spr...

Страница 36: ...caliper bracket Brake hose and union bolt M10 M10 M14 M10 M10 M10 M8 35 3 5 25 3 35 3 5 25 3 35 3 5 25 3 35 3 5 25 3 55 5 5 39 8 35 3 5 25 3 25 2 5 18 1 35 3 5 25 3 35 3 5 23 5 35 3 5 25 3 80 8 0 57...

Страница 37: ...pecified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm x 0 03...

Страница 38: ...e Connecting rod Piston outside and ring groove Piston pin outside surface Crankshaft journal Camshaft profile journal Valve stem IN EX Valve stem seal Valve stem end IN EX Valve lifter Oil pump assem...

Страница 39: ...Sealant Sealant Sealant Sealant Lubrication Point Lubricant LS Primary sheave inside Collar Solid bush Secondary fixed inner surface Secondary sheave torque cam ditch Gasket Cylinder head cover Stopp...

Страница 40: ...OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 1 2 3 4 3 4 1 2 SPEC 2 20...

Страница 41: ...Bear tube 12 Rubber tube Fuel filter hose 7 Vacuum tube 2 21 A A A A 1 6 5 4 3 2 Front brake cable right Front brake cable left Throttle cable 9 7 10 11 8 12 13 0 Wire harness 1 Handlebar switch lead...

Страница 42: ...D Fasten the wire harness with a plastic band and a clamper pulser cord Fasten the wire harness and Generator lead with a plastic band E Fasten the wire harness and Starter relay lead with a clamper...

Страница 43: ...fuse on wire harness 2 23 Horn Meter lead PTC controller Light controller 2 3 4 5 Wire harness Main switch lead 0 1 6 7 16 17 13 14 15 Generator lead Negative starter motor lead Neutral switch lead 8...

Страница 44: ...1 2 SPEC CABLE ROUTING 2 24 A Pass these leads through rear fender B Fasten the power supply lead on the wire harness with a plastic band 8 9 10 11 12 13 14 15 1 0 2 3 4 5 6 7 0 12 11 10 16 17 A B...

Страница 45: ...able left Fuel tank breather hose Choke cable USA CAN Throttle cable 1 6 5 4 3 2 CABLE ROUTING 7 8 9 Neutral switch lead 2 25 Battery C D I unit Main fuse on wire harness Wire harness 0 6 5 2 3 4 1 Ne...

Страница 46: ...d is routed to the side of the battery Connect the positive battery lead to the battery so that the lead contacts the battery case Fasten the handlebar switch lead rear brake switch lead with a plasti...

Страница 47: ...ear brake switch lead with a plastic band A Fasten the Haed light leads with plastic bands B Front brake cable right Front brake cable left 0 Wire harness 1 Head light lead left 2 Head light lead righ...

Страница 48: ...ct if necessary Check engine idling speed and adjust if neces sary 5 Crankcase breather system Check breather hose for cracks or other damage and replace if necessary 6 Exhaust system Check for leakag...

Страница 49: ...operly tightened 14 15 Engine oil strainer Clean Final transmission oil 18 Lubricate Throttle lever hous ing and cable Check operation and correct if necessary Check throttle cable free play and adjus...

Страница 50: ...back the seat lock lever than pull up on the rear of the seat 4 Front panel 1 5 Fuel tank breather hose 1 1 1 6 Front plate of handlebar cover 1 7 Handlebar cover 1 TIP When installing the handlebar...

Страница 51: ...emove the parts in the order listed Racks seat and front panel Refer to RACKS SEAT AND FRONT PANEL 1 Fuel tank top panel 1 2 CVT inlet tube 1 Remove 3 Front fender 1 For installation reverse the remov...

Страница 52: ...1 2 Negative battery lead 1 Disconnect NOTICE First disconnect the negative lead then disconnect the positive lead 3 Positive battery lead 1 Disconnect 4 Battery 1 5 Rear fender 1 6 Footrest board 2...

Страница 53: ...d Front fender Refer to FRONT FENDER 1 Vacuum tube comp 1 For installation reverse the removal pro cedure FUEL TANK AND FOOTREST BARS Except for USA RACKS SEAT FENDERS AND FUEL TANK TIP Before disconn...

Страница 54: ...op dead center TDC on the compression stroke 2 Measure valve clearance Out of specification Adjust a Turn the crankshaft clockwise with a wrench b Align the T mark on the rotor with the stationary poi...

Страница 55: ...hten the locknut e Measure the valve clearance f If the clearance is incorrect repeat the above steps until the proper clearance is obtained T R Locknut 9 Nm 0 9 m kg 6 5 ft lb 4 Install C D I magneto...

Страница 56: ...tle lever free play Refer to ADJUSTING THE THROTTLE LEVER FREE PLAY Throttle lever free play 1 0 3 0 mm 0 0 4 0 12 in ADJUSTING THE ENGINE IDLING SPEED 1 ADJUSTING THE THROTTLE LEVER FREE PLAY Engine...

Страница 57: ...sed Turning out Free play is decreased ADJUSTING THE THROTTLE LEVER FREE PLAY TIP 1 2 3 2 1 Disconnect the throttle cable at the upper end Lubricate the cable with commercially lubricant to prevent pr...

Страница 58: ...n out the adjuster more than 11 0 mm 0 43 in Also always adjust the throttle lever free play to 1 0 3 0 mm 0 04 0 12 in Turning in Speed limiter length is decreased Turning out Speed limiter length is...

Страница 59: ...ed and throttle cable free play should be adjusted properly before checking the ignition timing 1 Remove Shroud cap 2 Attach engine tachometer timing light to spark plug lead TIP 1 a 1 a 3 Check ignit...

Страница 60: ...d then turn it off 3 Disconnect spark plug cap 4 Remove spark plug Before removing as park plug use compressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling i...

Страница 61: ...again Refer to the following table 7 Install spark plug 8 Connect spark plug cap Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than without oil Pistonring s wear or...

Страница 62: ...ipstick and check the oil level whether or not it is between maximum and minimum level d If the level is lower add the oil up to the proper level Recommended oil classification API service SG type or...

Страница 63: ...ain bolt 7 Fill crankcase with the specified amount of the recom mended engine oil 8 Install dipstick 9 Start the engine warm it up for several min utes and then turn it off 10 Check engine for engine...

Страница 64: ...eck Damaged Replace CLEANING THE AIR FILTER ELEMENTS 1 2 1 2 3 4 5 5 3 4 seals Place the air filter element in the original position and then install the screw CHK ADJ NOTICE NOTICE 4 Install air filt...

Страница 65: ...ulling it out of Only U S c Tap the tailpipe lightly with a soft face hammer or suitable tool then use a wire brush to remove any Remove the screw Only U S carbon deposits from the spark arrester port...

Страница 66: ...front brake lever free play Front brake lever free play a Loosen the locknuts b Turn the adjusters in or out until the specified front brake lever free play is obtained Make sure that the difference b...

Страница 67: ...Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid...

Страница 68: ...1 Remove seat front fender Refer to SEAT FENDERS AND FUEL TANK 2 Check CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicators almost touch the brake disc Replace the brake pads as a set Refer...

Страница 69: ...nect a clear plastic hose tightly to the bleed screw d Place the other end of the hose into a con tainer e Slowly apply the brake lever or brake pedal several times f Fully squeeze the brake lever or...

Страница 70: ...75 L 0 66 Imp qt 0 79 US qt Recommended oil SAE80W 90 gear oil ADJUSTING THE DRIVE CHAIN SLACK Measure the drive chain slack halfway between the drive axle and the rear axle When checking and adjustin...

Страница 71: ...e chain slack will overload the engine and other vital parts keep the slack within the specified limits The chain should be cleaned and lubricated after every use of the vehicle a Drive chain slack 15...

Страница 72: ...front arms upper and lower and or wheel bearings CHECKING THE STEERING SYSTEM 1 ADJUSTING THE TOE IN 1 Place the machine on a level surface 2 Measure toe in Out of specification Adjust Toe in 10 15 mm...

Страница 73: ...onds correctly If not turn either the right or left tie rod within the toe in speci fication ADJUSTING THE TOE IN a Mark both tie rods ends This reference point will be needed during adjustment b Loos...

Страница 74: ...hock absorber assembly spring Fatigue the front rear shock absorber assembly Refer to FRONT ARMS AND FRONT SHOCK ABSORBERASSEMBLIES and REARSHOCK ABSORBER SWINGARM AND DRIVE CHAIN in chapter 6 3 Check...

Страница 75: ...ront shock absorbers ADJUSTING THE SHOCK ABSORBERS 1 1 2 2 a b a b a b a b 1 2 CHECKING THE TIRES This model is equipped with low pressure tires It is important that they be inflated correctly and mai...

Страница 76: ...fully Fast inflation could cause the tire to burst MAXIMUM LOADING LIMIT Vehicle load limits 75 0 kg 165 35 lb Total weight of the cargo trailer hitch vertical load rider and accessories CHECKING THE...

Страница 77: ...is dangerous to ride with a worn out tire When tire wear is out of specification replace the tire immediately Tire wear limit Front and rear 3 mm 0 12 in a a CHECKING THE WHEELS 1 Check wheel Damage...

Страница 78: ...ubricate or replace Hold the cable end up and apply several drops of lubricant to the cable Recommended lubricant Lithium soap base grease LUBRICATING THE LEVERS STEERING SHAFT AND STEERING KNUCKLES L...

Страница 79: ...tact External Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg...

Страница 80: ...attery ter minals The charge state of an VRLA Valve Regulated Lead Acid battery can be checked by measur ing its open circuit voltage i e the voltage when the positive terminal is disconnected No char...

Страница 81: ...attery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are no...

Страница 82: ...voltage of an VRLA Valve Regulated Lead Acid battery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circu...

Страница 83: ...timer to the charging time determined by the open circuit voltage Refer to CHECKING AND CHARGING THE BATTERY If the required charging time exceeds 5 hours it is advisable to check the charging amperag...

Страница 84: ...charge an VRLA battery A variable voltage charger is recommended Set the charging time to a maxi mum of 20 hours Leave the battery unused for more than 30 minutes before measuring its open circuit vol...

Страница 85: ...to SEAT FENDERS AND FUEL TANK Recommended lubricant Dielectric grease CHECKING AND CHARGING THE BATTERY 1 2 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circ...

Страница 86: ...again check the electrical circuit CHECKING THE FUSES Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive...

Страница 87: ...S SEAT FENDERS AND FUEL TANK in chapter 3 1 Exhaust pipe muffler 1 2 Exhaust pipe gasket 1 3 Throttle cable 1 4 5 Choke cable 1 6 Spark plug lead 1 7 Reverse switch lead 1 8 Neutral switch lead 1 Gene...

Страница 88: ...T PIPE MUFFLER CABLE AND LEADS 1 Drive chain 1 1 2 Inlet tube c v t comp 3 3 1 3 Catch tank 1 4 Cooler comp oil assy 1 6 Engine assembly 5 Flange bolt nut Refer to INSTALLING THE ENGINE Install all of...

Страница 89: ...lly tighten the bolts and nuts The master link clip must be installed with the rounded end facing the direction of travel 2 Tighten 1 Remove drive chain master link 3 Install drive chain master link T...

Страница 90: ...assy head cylinder 1 3 Lifter comp tensioner 1 4 Gasket lifter tensioner 1 1 Spark plug lead 1 CYLINDER HEAD Refer to REMOVING THE CYLINDER HEAD and INSTALLING THE CYLIN DER HEAD x4 x4 x4 T R 12 Nm 1...

Страница 91: ...3 ft Ib T R 20 Nm 2 0 m kg 14 5 ft Ib 1 2 10 9 8 7 6 5 11 12 14 15 16 17 13 M E LS LS 3 4 New New Order Job Part Q ty Remarks 11 2 10 1 For installation reverse the removal procedure 12 1 13 1 14 1 1...

Страница 92: ...rms must have a valve clear ance when the camshaft sprocket alignment mark is aligned with the cylinder head alignment mark If not give the crankshaft one counterclock wise turn to meet the above cond...

Страница 93: ...HE CAMSHAFT SPROCKET 1 Check camshaft sprocket More than 1 4 tooth wear Replace the cam shaft comp and timing chain as a set 1 4 of a tooth correct roller sprocket CHECKING THE CYL HEAD COVER ASSY 1 C...

Страница 94: ...gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cyl...

Страница 95: ...p onto the camshaft comp and finger tighten the nut with wa When the camshaft sprocket alignment ma rk is aligned with the cylinder head alig hole in camshaft sprocket away from the f Force the camsha...

Страница 96: ...procket and timing chain 3 Install bolt flg small head lifter comp tensioner Always use a new gasket 4 Adjust timing chain tensioner 5 Check camshaft sprocket alignment mark rotor T mark Out of alignm...

Страница 97: ...t Q ty Remarks Removing the camshaft rocker arms and valves Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Cam shaft comp 1 1 1 2 Shaft in rocker arm 2 3 Shaft ex rocker a...

Страница 98: ...d weight 3 Remove camshaft comp REMOVING THE VALVES AND VALVE SPRINGS 1 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVES...

Страница 99: ...5 mm 25 185 25 215 mm Exhaust 29 510 29 610 mm 25 185 25 215 mm CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check r...

Страница 100: ...tion Replace 6 Calculate rocker arm to rocker arm shaft clearance Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Out of specification...

Страница 101: ...Exhaust 0 030 0 057 mm 0 0012 0 0022 in Limit 0 10 mm 0 0039 in a a b a b a 2 Check valve face Pitting wear Grind the face valve stem end Mushroom shape or diameter larger than the body of the stem R...

Страница 102: ...through the valve guide and onto the valve seat to make a clear pattern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve se...

Страница 103: ...d repeat the above steps After every lapping operation be sure to clean off all of the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Install the...

Страница 104: ...e Spring tilt limit Inner 2 0 1 1 mm 2 0 0 04 in INSTALLING THE VALVES AND VALVE SPRINGS 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valve spring seats valve ste...

Страница 105: ...lve INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Install camshaft comp Be sure to align the round hole in camshaft 2 Apply engine oil onto the rocker arm shafts 3 Install rocker arms rocker arm shafts Us...

Страница 106: ...to 1 Cylinder INSTALLING THE CYLINDER 1 2 Cylinder gasket 2 3 Dowel pin 2 4 Piston pin clip Refer to REMOVING THE PISTON and INSTALLING THE PISTON 1 5 Piston pin 1 6 Piston 2 7 Piston ring set 1 8 Pi...

Страница 107: ...rive the piston pin out 2 Remove piston rings Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown CHECKING THE CYLINDER AND PISTON 1 Check piston...

Страница 108: ...specification rebore or replace the cylinder and replace the piston and piston rings as a set Cylinder bore C 57 000 57 010 mm 2 2441 2 2 4 4 5 in Taper limit T Out of round R C maximum of D1 D2 T max...

Страница 109: ...p Out of specification Replace the piston ring The oil ring expander spacer s end gap cannot be measured If the oil ring rail s gap is exces sive replace all three piston rings Piston ring side cleara...

Страница 110: ...bore clearance Out of specification Replace the piston pin and piston as a set Piston pin bore diameter 15 002 15 008 mm 0 5906 0 5909 in Limit 15 040 mm 0 5921 in Piston pin to piston pin bore cleara...

Страница 111: ...ton pin clips cover the crankcase with a clean rag to prevent the piston pin clips from falling into the crank case 4 Lubricate piston piston rings cylinder Apply a liberal coating of engine oil New g...

Страница 112: ...assembly C D I MAGNETO Remarks Order Job Part Q ty 1 2 3 1 1 1 Disassemble the parts in the order listed Refer to CYLINDER HEAD Disconnect the C D I magneto lead coupler 2 1 3 x2 T R 12 Nm 1 2 m kg 8...

Страница 113: ...make sure While holding the C D I magneto with the hold Do not allow the sheave holder to touch the pro jection on the C D I magneto rotor the magneto rotor hub of the crankshaft ing tool tighten the...

Страница 114: ...tarter Cover crank case left Knock pin 4 5 6 1 2 1 Plate crank case L O ring O ring 7 1 Oil seal L Remove the parts in the order listed For installation reverse the removal pro cedure T R 12 Nm 1 2 m...

Страница 115: ...STALLING THE KICKSTARTER For installation reverse the removal pro cedure KICKSTARTER Removing the kickstarter Crankcase cover Circlip Washer Gear comp starter idle Spring friction start gear Washer Sp...

Страница 116: ...her end on the projection 3 Install 4 Install Install the clip at the position shown boss kick spindle spindle comp kick start spring kick starter spring kick starter plain washer kgear comp starter i...

Страница 117: ...re Removing the V belt clutch primary and secondary sheave Nut flange Washer Ratchet kick starter Boss drive face Face drive Outer clutch Plate comp drive V belt Gasket Clip Boss face movable drive Fa...

Страница 118: ...plate sub assy drive Nut lock Plate comp drive Roller clutch Weight set clutch Spring clutch Plate clutch Collar spring Spring driven face Collar seal Pin guide Roller Face comp movable drive Oil sea...

Страница 119: ...r loosen the secondary sheave nut 2 Loosen Do not remove the nut lock nut at this stage While holding the clutch carrier with the rotor with the socket wrench holding tool loosen the nut lock one full...

Страница 120: ...787 in Limit 19 0 mm 0 7480 in not use them again 3 Remove Remove the V belt and clutch assembly from the primary sheave side 2 1 econdary sheave assembly V belt V belt V belt width nut lock clutch sh...

Страница 121: ...asure Out of specification Replace roller weight outside diameter 17 9 18 1 mm 0 7047 0 7126 in 1 2 face movable drive face driver roller weight piece slide face comp movable drive face comp driven ro...

Страница 122: ...er clutch internal diameter 125 mm 4 92 in set Damage wear Replace the face comp driven and face comp movable drive as a set torque cam groove guide pin spring driven face out clutch internal diameter...

Страница 123: ...ace torque cam groove oil seals bearings face comp movable drive guide pin o ring spring clutch comp face comp driven guide pin groove 1 2 3 1 2 3 2 3 2 3 3 1 2 1 2 1 1 3 Install 4 Lubricate with the...

Страница 124: ...Nm 5 5 m kg 39 8 ft Ib T R 55 Nm 5 5 m kg 39 8 ft Ib 3 Install 4 Position Tighten the secondary sheave nut with the sheave holder V belt clutch nut hex outer clutch nut V belt plate sub assy drive 1...

Страница 125: ...edure Removing the starter clutch and starter motor Primary sheave 5 6 8 9 11 10 12 STARTER CLUTCH AND STARTER MOTOR T R 12 Nm 1 2 m kg 8 7 ft Ib T R 95 Nm 9 5 m kg 68 7 ft Ib O ring Starter motor Sha...

Страница 126: ...the starter wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear coun terclockwise it should turn freely otherwise the starter cl...

Страница 127: ...eal Knock pin Separator oil Oil pump chain Nut Oil pump driven sprocket Oil pump shaft Oil pump body Knock pin Outer rotor Inner rotor Plate oil pump 14 1 Knock pin Remove the parts in the order liste...

Страница 128: ...MP ENG fan cover assy cooling fan composition REMOVING THE OIL PUMP 1 Remove 1 1 2 2 A C G generator assy the right crankcase cover 3 4 4 3 Gear comp starting clutch and flange 5 6 5 6 starting clutch...

Страница 129: ...tor oil oil pump chain and oil pump driven oil pump assy Disassemble the oil pump assy 8 7 8 9 10 9 10 11 12 12 11 7 sprocket CHECKING THE OIL PUMP 1 Check Cracks damage wear Replace the defective par...

Страница 130: ...in inner rotor to outer rotor tip clearance outer rotor to oil pump housing clearance oil pump housing to inner rotor and outer oil pump assembly oil pump driven sprocket flange nut oil pump chain se...

Страница 131: ...sembly Engine Cylinder head Cylinder piston V belt clutch drive driven pulley Starter clutch C D I magneto Oil pump Right crankcase Knock pin Crankshaft Shaft drive Bearing ball radial Bearing ball ra...

Страница 132: ...1 Remove sprocket moved if the timing chain is attached onto the crankshaft sprocket CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES 1 Check 2 Check Before removing the crankshaft assembly The cran...

Страница 133: ...ig end side clearance 0 10 0 30 mm 0 0039 0 0118 in 3 Measure Crankshaft width 45 00 45 05 mm 1 7717 1 7736 in big end side clearance crankshaft width crankshaft journal crankshaft runout Out of speci...

Страница 134: ...e crank shaft to check whether it is tightly engaged with the timing chain if not install again 3 2 3 1 crankshaft timing chain crankshaft gasket crankshaft crankshaft crankcase right timing chain kno...

Страница 135: ...ver Knock pin 6 1 Spindle assy shift Shaft gear shift 8 9 1 1 Fork shift Drum comp gear shift 10 1 Shaft gear shift comp 11 12 1 1 Counter shaft comp Final shaft comp Remove the parts in the order lis...

Страница 136: ...sw SHIFT SHAFT 1 2 5 7 7 6 8 9 10 11 1 2 3 4 5 7 1 1 1 1 1 2 Fixing support catch Shaft comp rod Fixed support rod shift Boss Pin rod shift 6 1 Split pin Washer 8 9 1 1 Plate transmission Spring rod...

Страница 137: ...ge scoring wear Replace Damage scratches wear Replace the shift Damage wear Replace the shift drum as sembly Damage pitting Replace the shift drum as Bends Replace Roll the shaft gear shift on a flat...

Страница 138: ...nout limit 0 08 mm 0 0031 in 3 Measure with a centering device and dial gauge Final shaft runout limit 0 08 mm 0 0031 in 4 Check 5 Check each pinion gear to its respective wheel gear 6 Check shaft gea...

Страница 139: ...e the fork shift remove the shaft gear shift comp from the final shaft comp comp 3 3 4 3 6 5 5 6 8 7 7 10 11 11 10 9 9 8 4 3 CHECKING THE GEAR SET 1 Check the bearings should turn smoothly and quietly...

Страница 140: ...nstall the mission cover and final shaft comp together with circlip for wear or damage 1 2 1 2 install the shaft gear shifts and the fork install a new gasket and the knock pins shift assy shift 2 3 4...

Страница 141: ...ss 6 Bear tube comp 1 5 Tube rubber 1 7 Three through tube comp 1 Only Europe 2 9 A C V spring 1 10 A C V diaphragm assy 11 Oil seal 12 Air cut cable 1 8 A C V cover 1 1 Only Manual choke 13 M Manual...

Страница 142: ...s the pilot screw is turned out from the seated position to its set position Plate fixed piston cover B 1 1 Plate fixed piston cover A 1 Vacuum piston cover assy 1 Piston spring 1 1 1 1 Jet needle Thr...

Страница 143: ...Carb chamber Float pin 1 1 Main jet 1 1 Needle jet holder 1 Needle jet 1 Needle valve assy 1 1 Float For assembly reverse the disassembly procedure 10 11 12 16 17 14 13 15 CARB CARBURETOR 6 8 9 7 10...

Страница 144: ...ks damage Replace Damage Replace Damage obstruction wear Replace Dirt Clean Obstruction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b B...

Страница 145: ...e movement main jet needle jet holder needle jet Damage scratches wear Replace Cracks tears Replace Cracks damage Replace Bends damage wear Replace Cracks damage wear Replace Tightness Replace Obstruc...

Страница 146: ...he carburetor wash all Always use a new gasket needle jet holder float pin needle valve float main jet pilot jet of the parts in a petroleum based solvent 1 1 2 2 3 1 2 3 3 2 Install 3 Install piston...

Страница 147: ...Loosen the fuel drain screw d Hold the fuel level gauge vertically next to the line on the float chamber e Measure the fuel level Fuel level above the float chamber mating surface 1 2 3 a a 2 Adjust...

Страница 148: ...it falling over The following procedure applies to both of the front wheels 2 Cotter pin 1 1 Rubber cap 1 Refer to INSTALLING THE WHEEL HUBS 3 Axle nut 1 4 Front wheel 1 5 Front brake drum 1 For inst...

Страница 149: ...ng over The following procedure applies to both of the rear wheels Refer to INSTALLING THE WHEEL HUBS 1 For installation reverse the removal pro cedure 4 5 x4 2 3 1 New 2 Cotter pin 1 1 Rubber cap 1 3...

Страница 150: ...se an accident resulting in machine damage and possible operator injury Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in CHECKING THE FRONT WHEEL HUBS The following procedure applies to...

Страница 151: ...g procedure applies to both of the rear wheel hubs 1 Check wheel hub splines Wear damage Replace INSTALLING THE WHEEL HUBS The following procedure applies to both of the front and rear wheel hubs 1 In...

Страница 152: ...The arrow mark on the tire must point in the direction of rotation of the wheel 2 Tighten nuts a INSTALLING THE REAR WHEELS The following procedure applies to both of the rear wheels 1 Install wheel 2...

Страница 153: ...to INSTALLING THE FRONT BRAKES 2 Front brake cable drum side 1 3 Brake shoe plate 1 Refer to REMOVING THE FRONT BRAKES and INSTALLING THE FRONT BRAKES 4 Brake camshaft lever 1 5 Brake camshaft 1 1 1...

Страница 154: ...to each brake 1 Check brake shoe plate pivot pin brake camshaft Bends cracks damage Replace dust seal Wear damage Replace CHECKING THE FRONT BRAKE SHOES The following procedure applies to each brake...

Страница 155: ...um inside diameter Out of specification Replace Front brake drum inside diameter Front 110 5 mm 4 35 in Limit 111 5 mm 4 39 in TIP FRONT BRAKES CHAS a a a a 2 Check brake drum inner surface Oil scratc...

Страница 156: ...r Left side Right side A B A B T R 14 Nm 1 4 m kg 10 1 ft Ib FRONT BRAKES CHAS NOTICE TIP a a a 1 2 3 Install brake shoe plate When installing the brake shoe plate align the groove of the brake shoe p...

Страница 157: ...ot use the parking brake when the brake cal iper is off of the brake disc as the brake pad will be force shut 3 Brake disc brake disc bracket 1 1 Refer to REMOVING THE REAR AXLE and INSTALLING THE REA...

Страница 158: ...oil seal 1 1 For installation reverse the removal procedure 8 Rear axle hub 1 1 1 5 Axle plate fixed 1 REAR AXLE AND REAR AXLE HUB CHAS 6 11 Refer to INSTALLING THE DRIVEN SPROC 5 LS 6 7 8 x4 x4 x4 9...

Страница 159: ...nd with a ham mer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the right 2 Remov...

Страница 160: ...brake disc deflection Out of specification Replace brake disc thickness Out of specification Replace Brake disc maximum deflection 0 25 mm 0 009 in Brake disc minimum thickness 3 0 mm 0 12 in INSTALL...

Страница 161: ...in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper assembly 1 For installation reverse the removal procedure REAR BRAKE CALIPER Refer to INSTALLING THE REAR BRAKE...

Страница 162: ...t with compressed air Replace the caliper piston seal and dust seal whenever the brake caliper is disas sembled 1 1 INSTALLING THE REAR BRAKE CALIPER 1 Install brake caliper assembly brake caliper mou...

Страница 163: ...ll with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when ref...

Страница 164: ...eaned properly filled and bled after reassembly REPLACING THE REAR BRAKE PADS It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Remove 2 Measure bolts bra...

Страница 165: ...hapter 3 c Tighten the brake caliper bleed screw d Install a new brake pad spring and new brake pads 4 Install brake caliper brake caliper mounting bolts 5 Check brake fluid level Refer to CHECKING TH...

Страница 166: ...ap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch 1 4 Brake lever 1 5 Union bolt 1 6 Copper washer 2 7 Brake hose 1 Disconnect 8 Brake master cylinder bracket 1 9 Brake master cylind...

Страница 167: ...YLINDER All internal brake components should be cleaned and lubricated with new brake fluid only before installation Whenever a master cylinder is disassem bled replace the piston seals and dust seals...

Страница 168: ...inted surfaces or plastic parts Always clean up spilled brake fluid immediately Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor...

Страница 169: ...HE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Brake fluid level is under the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE REAR BRAKE FL...

Страница 170: ...e cable 2 3 Throttle cable 1 4 Front brake lever assembly 1 LEVER ASSEMBLY 6 Handlebar switch 1 Refer to INSTALLING THE REAR BRAKE MASTER CYLINDER 7 Rear brake hose 1 8 Rear brake switch 1 9 Rear brak...

Страница 171: ...R 12 Handlebar 1 For installation reverse the removal procedure STEERING SYSTEM CHAS 10 Plastic band 1 x4 T R 14 Nm 1 4 m kg 10 1 ft Ib 1 2 4 10 11 1 6 8 x2 T R 14 Nm 1 4 m kg 10 1 ft Ib 5 7 12 3 9 T...

Страница 172: ...REMOVING THE REAR BRAKE SWITCH 1 Remove rear brake switch Push the fastener when removing the rear brake switch out of the rear brake lever holder CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks...

Страница 173: ...ar side of the handlebar holder and then tighten the bolt on the front side 14 Nm 1 4 m kg 10 1 ft lb INSTALLING THE HANDLEBAR GRIPS 1 Install handlebar grips Before installing the handlebar grips tem...

Страница 174: ...the front brake lever assembly and handlebar grip 2 Adjust front brake Refer to ADJUSTING THE FRONT BRAKE in chapter 3 brake master cylinder Install the brake master cylinder please align the punch ma...

Страница 175: ...Fix plate 1 3 Steering shaft pressed holder 1 4 Collar 2 5 Steering stem bushing 1 6 Oil seal 2 2 7 Lower handlebar holder 1 8 For installation reverse the removal pro cedure Steering stem STEERING S...

Страница 176: ...may dangerously weaken the stem 2 Check fix plate steering shaft pressed holder oil seal steering stem bushings Bends damage Replace Bends damage Replace Wear damage Replace The lower handlebar holder...

Страница 177: ...nut hold the tie rod ball joint with a 14 mm wrench INSTALLING THE LOCK WASHER 1 Install lock washer bolts 2 Bend the lock washer tab along a flat side of the bolt 1 3 3 2 2 2 T R 35 Nm 3 5 m kg 25 3...

Страница 178: ...ods and steering knuckles Refer to FRONT BRAKES 1 Tie rod Refer to INSTALLING THE TIE RODS 1 2 Suspension of arm 1 3 Steering knuckle 2 4 Sleeve 1 5 Cap Refer to REMOVING THE STEERING KNUCK LES For in...

Страница 179: ...e rods 1 Check tie rod free play and movement Free play Replace the tie rod end Turns roughly Replace the tie rod end 2 Check tie rod Bends damage Replace CHECKING THE STEERING KNUCKLES The following...

Страница 180: ...e rod side which must be installed on the outside has grooves When installing the tie rod hold each tie rod ball joint with a 14 mm wrench and then tighten the tie rod end nut 2 Adjust toe in Refer to...

Страница 181: ...kles Refer to FRONT BRAKES 1 Tie rod 1 1 1 1 Front brakes Refer to REMOVING THE FRONT ARMS and INSTALLING THE FRONT ARMS 4 For installation reverse the removal procedure ASSEMBLIES FRONT ARMS AND FRON...

Страница 182: ...heck front arms seal covers CHECKING THE FRONT SHOCK ABSORBERS The following procedure applies to both of the front shock absorber assemblies 1 Check shock absorber shock absorber rod spring Move the...

Страница 183: ...Damage pitting Replace the front arm Free play Replace the front arm Turns roughly Replace the front arm INSTALLING THE FRONT ARMS The following procedure applies to both of the front arms 1 Install...

Страница 184: ...axle hub Refer to REAR AXLE AND REAR AXLE HUB 1 Protect cover 1 2 Drive chain cover 1 3 Rear shock absorber 1 4 Flange nut 5 Flange bolt 1 6 Swingarm 1 7 Seal cover 8 Oil liner 2 1 REAR SHOCK ABSORBE...

Страница 185: ...25 3 ft Ib T R 25 Nm 2 5 m kg 18 1 ft Ib 1 T R 25 Nm 2 5 m kg 18 1 ft Ib Order Job Part Q ty Remarks 9 Spacer 10 ubber sleeve 1 1 11 Lock washer 12 Drive sprocket 13 Drive chain 1 1 1 For installation...

Страница 186: ...ing the drive chain and the sprockets measure the drive chain slack and a 15 link section of the drive chain REMOVING THE SWINGARM 1 Check swingarm free play a Check the tightening torque of the pivot...

Страница 187: ...nge bolt 3 Clean plange bolt spacer Recommended cleaning solvent Kerosene CHECKING THE DRIVE CHAIN 1 Check drive chain Stiffness Clean and lubricate or replace 2 Clean drive chain a Wipe the drive cha...

Страница 188: ...kets as a set Bent teeth Replace the drive chain sprockets as a set Correct Drive chain roller Drive chain sprocket INSTALLING THE DRIVE SPROCKET 1 Install drive sprocket lock washer bolts 2 Bend the...

Страница 189: ...se switch PTC controller Main switch Battery Rectifier regulator Starter relay Pickup coil stator assembly Starter motor Head light C D I unit Rear brake switch Handlebar switch Main fuse Tail light W...

Страница 190: ...hite R B Red Black W L White Blue W B White Black W G White Green Y B Yellow Black Y W Yellow White W R B L Y L Y W B W B B L B B L B R W R W Br OFF ON OFF START MAIN START SW Natural 12V2W Reverse 12...

Страница 191: ...poc ket tester to 0 and to the x1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop s...

Страница 192: ...SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch B G W R W R W OFF ON MAIN SW Br Br OFF START START SW Br L W G Y...

Страница 193: ...the socket by pushing and turning the bulb counterclockwise Bulbs d and e are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out CHECKING...

Страница 194: ...ngs indicate no conti nuity replace the bulb CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets 1 Check bulb socket for continuity with the pocket te...

Страница 195: ...r L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5...

Страница 196: ...ccurs Minimum ignition spark gap 6 0 mm Is there a spark and is the spark gap within specification IGNITION SYSTEM TROUBLESHOOTING Check 1 Main fuse 2 Spark plug 3 Ignition spark gap 4 Spark plug cap...

Страница 197: ...e primary coil resistance Primary coil resistance 0 19 0 25 at 20 C Connect the pocket tester x 1k to the ignition coil as shown Negative tester probe spark plug lead Positive tester probe ground Meas...

Страница 198: ...m s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects Replace the pickup coil Properly connect or repair the ignition system s wiring Replace the...

Страница 199: ...B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8...

Страница 200: ...ly operate if at least one of the following conditions is met The engine stop switch is ON The brake switch is ON When at least one of the above conditions has been met the starter relay is closed and...

Страница 201: ...2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C Is the battery OK 3 Starter motor Connect the...

Страница 202: ...Refer to CHECKING THE SWITCHES Is the start switch OK 9 Wiring Check the entire starting system s wiring Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defect...

Страница 203: ...ELEC 7 15 ELECTRIC STARTING SYSTEM STARTER MOTOR O ring Starter motor front cover Brush Brush spring Armature assembly Starter motor rear cover Brush wear limit 6 5 mm Commutator wear limit 20 5 mm...

Страница 204: ...rmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of...

Страница 205: ...E STARTER MOTOR 1 Install brush set rubber seal starter motor front cover 2 Install starter motor rear cover 3 Install Starter motor bolts NOTE When install the starter motor the ground ter minal a is...

Страница 206: ...R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5 1 2 3 4 6 7 8 9 13 10 12 19 25 24 18 11...

Страница 207: ...3000 r min Measure the charging voltage Charging voltage 12 V or more at 3000 r min 15 V or less at 8000 r min NOTE Make sure the battery is fully charged Is the charging voltage within specification...

Страница 208: ...e 0 72 0 97 at 20 C Is the charging coil OK 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring properly connected and without...

Страница 209: ...R B L B Or L B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 1...

Страница 210: ...tch OK 5 Wiring Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM Is the lighting system s wiring properly con nected and without defects The dimmer switch is faulty Replace the left...

Страница 211: ...high beam indicator light couplers as shown Headlight Positive tester probe yellow Negative tester probe black Replace the headlight bulb socket or both 1 YES NO The wiring circuit from the main swit...

Страница 212: ...to the tail brake light coupler wire harness side as shown Positive tester probe yellow Negative tester probe black Set the main switch to ON Start the engine Measure the voltage DC 12 V of blue on th...

Страница 213: ...B B B G W G W B B B B B B B B B B R B R B L B Or L B Or L R L B R B R W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br...

Страница 214: ...condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 0 V or more at 20 C Is the battery OK 3 Main switch Check the main switch for continui...

Страница 215: ...al Connect a jumper lead to the horn terminal and ground the jumper lead Set the main switch to ON Does the horn sound 4 Voltage Disconnect the pink and brown connectors at the horn terminal Connect t...

Страница 216: ...of green yellow on the tail brake light cou pler wire harness side Is the voltage within specification Replace the tail brake light bulb socket or both Replace the brake light switch The wiring circui...

Страница 217: ...ctors wire har ness side as shown Positive tester probe orange 1 Negative tester probe green 2 Set the main switch to ON Set the shift rod to N Measure the voltage DC 12V Is the voltage within specifi...

Страница 218: ...must be repaired 6 The reverse indicator light fails to come on 1 Reverse indicator light bulb and socket Check the reverse indicator light bulb and socket for continuity Are the reverse indicator lig...

Страница 219: ...ck Negative tester probe ground Set the main switch to ON Measure the voltage DC 12 V of blue brown at the bizzer terminal Is the voltage within specification L B B The wiring circuit from the main sw...

Страница 220: ...W Br Br Br Br L R W W W R W R B GY G Y G W G G G W G W G G Y G Y B B W L W L MOTOR L Y L Y L Y W R L Y W W R W R W B Br W R B Br W R DIMMER SW 12V 20W 12V 20W Forward 12V2W DC 12V 8A 5 1 2 3 4 6 7 8...

Страница 221: ...ester 1 to the Auto choke unit coupler as shown Positive tester probe brown 1 Negative tester probe green black 2 Measure the auto choke unit resistance Auto choke unit resistance 30 at 20 C Is the au...

Страница 222: ...properly sealed valve seat Improperly adjusted fuel level Improperly set pilot jet Air filter Clogged air filter element ELECTRICAL SYSTEM Spark plug Improper plug gap Worn electrodes Wire between ter...

Страница 223: ...ankshaft Valve train Improperly adjusted valve clearance Improperly adjusted valve timing POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Loose pilot jet Clogged pilot jet Clogged p...

Страница 224: ...spark plug heat range Faulty C D I unit Fuel system Improper carburetor main jet improper set ting Improper fuel level Clogged air filter element Compression system Heavy carbon build up Engine oil I...

Страница 225: ...ndlebar Improperly installed or bent Steering Incorrect toe in Bent steering stem Improperly installed steering stem Damaged bearing or bearing race Bent tie rods Deformed steering knuckles Insufficie...

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