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3. ENGINE REMOVAL AND INSTALLATION

3.1 SERVICE INFORMATION

3.3 ENGINE INSTALLATION

3.2 ENGINE REMOVAL

3.1 SERVICE INFORMATION

ENGINE SH

28/'

BE REMOVED

21/<

IN THE CONDITION OF NECESSARY REPAIR OR

ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM

3.2 ENGINE REMOVAL

Remove the seat and rear fender. (Chapter 11) Remove the

spark plug cap from the spark plug. Remove the exhaust

pipe.
Disconnect the carburetor cable by unscrew

LQJ

two screws

on top of the carburetor.

Take off oil pump cable from the oil pump control plate.

Oil pump is under the right side of engine.

Disconnect the wire connectors. There are three

connectors for carburetor auto-choke, starter motor

and generator respectively.

Remove the drive chain cover. This is under the chain.

Remove the drive chain retaining clip and master link,

and remove the drive chain.

Содержание VIPER 70

Страница 1: ...ETON America 2009 VIPER SILVER SERIES SERVICE MANUAL Covers Viper 70 Silver Viper 90 Silver Viper 90R Silver...

Страница 2: ...ATION 5 CYLINDER HEAD VALVES 6 CYLINDER PISTON 7 TRANSMISSION KICK STARTER 8A TRANSMISSION GEAR SET 8B SHIFTING GEAR BOX ONLY FOR VIPER 90R 9 STEERING SYSTEM 10 FRONT WHEEL SYSTEM 11 REAR WHEEL AND BR...

Страница 3: ...a doctor if electrolyte gets in your eyes Hot Parts WARNING Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these part...

Страница 4: ...stroke Compression ratio 9 0 1 Standard compression pressure at sea level 12 3 kg cm 178 4 psi 2 Electric starter kickstarter Starting system Lubrication system Wet sump Oil type or grade Engine oil Y...

Страница 5: ...M939 M940 Tubeless AT18 7 8 AT18 9 8 MAXXIS MAXXIS M939 M940 Tire pressure cold tire Maximum load 62 8 kg 150 lb Brake Front brake type Drum brake operation Right hand operation Rear brake type Single...

Страница 6: ...ive Left Cam dimensions Intake A 25 683 25 843 mm 1 0111 1 0174 in 25 583 mm 1 0072 in B 20 986 21 016 mm 0 8262 0 8274 in 20 886 mm 0 8223 in Exhaust A 25 525 25 685 mm 1 0049 1 0112 in 25 425 mm 1 0...

Страница 7: ...ndard Limit B C D A Head Diameter Face Width Seat Width Margin Thickness IN 20 9 21 1 mm 0 8228 0 8307 in EX 18 9 19 1 mm 0 7441 0 7520 in IN 1 50 1 80 mm 0 0591 0 0622 in EX 1 50 1 80 mm 0 0591 0 062...

Страница 8: ...ength IN 30 00 mm 1 18 in 27 00 mm 1 06 in EX 30 00 mm 1 18 in 27 00 mm 1 06 in Compressed pressure installed IN 39 48 N at 22 45 mm 3 99 4 87 kg 10 69 13 05 lb at 0 88 in EX 39 48 N at 22 45 mm 3 99...

Страница 9: ...2 in 5 0 mm 0 20 in Piston off set Intake side Piston off set direction Piston pin bore inside diameter 13 002 13 008 mm Piston pin outside diameter 12 996 13 000 mm H D Compressed pressure installed...

Страница 10: ...6653 1 6673in 44 10 44 15mm 1 7362 1 7382in 0 04 mm Runout limit C1 0 0016in 0 04 mm C2 0 0016in Big endside clearanceD 0 10 0 30mm 0 0039 0 0118in 0 50 mm 0 0197in Bigendradialclearance E 0 007 0 01...

Страница 11: ...system Helicalgear Primary reduction ratio Secondary reduction system Spurgear 41 15 2 733 43 14 3 071 Secondary reduction ratio 40 13 3 077 Max main axle runout Max drive axle runout Limit Standard I...

Страница 12: ...arance 0 0055 0 0083 in 0 28 mm 0 0110 in Oil pump housing to inner rotor and outer rotor clearance 0 06 0 11 mm 0 14 0 21 mm 0 04 0 12mm 0 0024 0 0043 in 0 20 mm 0 0079 in Lubrication chart Pressure...

Страница 13: ...ateral 2 0 mm 0 08 in Front drum brake Type Leading trailing Brake drum inside diameter 95 0 mm 3 74 in 96 0 mm 3 38 in Lining thickness 3 0 mm 0 12 in 1 5 mm 0 06 in Shoe spring free length 60 0 mm 2...

Страница 14: ...Item Standard Limit Brake lever and brake pedal Brake lever free play pivot front 4 0 7 0 mm 0 16 0 28 in rear 0 1 5 mm 0 0 06 in Throttle lever free play 1 0 3 0 mm 0 04 0 12 in...

Страница 15: ...l Model manufacturer C0510 A26 6000 SHIHLIN Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 19 0 23 at 20 C 68 F Secondary winding resistance 2 79 3 41 k at 20 C 68 F Spark plug cap Type R...

Страница 16: ...0 3 0 N Brush overall length 0 14 in Brush overall length 102 306gf 3 60 10 80 oz 19 5 mm 22 0 mm 0 87 in Commutator diameter 0 77in 6 mm 0 06 in 1 Mica undercut Starter relay C5850 FBF0 0000 SY Mode...

Страница 17: ...e position of the serial number is shown in the pictures below Make sure the serial number is the same as in your owner s manual The frame serial number is stamped on the front of the frame The engine...

Страница 18: ...8 9 0 8 1 2 M 6 Rear axle castle nut 70 90 7 0 9 0 30 45 M14 Swing arm pivot nut 70 90 7 0 9 0 30 45 M14 Rear brake calliper bolt 24 32 1 8 2 4 2 4 3 2 M 8 Loctite 271 Handlebar lower holder nut 30 4...

Страница 19: ...2 Loctite 638 Catalyst 7649 Camshaft holder nuts M8 14 16 1 4 1 6 10 3 11 8 Hole cap tap adjusting M30 7 9 0 7 0 9 5 2 6 6 Stud bolt M7 8 12 0 8 1 2 5 9 8 9 Starting clutch outer M28 50 60 5 0 6 0 36...

Страница 20: ...ith an asterisk should be performed by a E TON dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes rst month 1 3 6 6 12 km mi...

Страница 21: ...k uid level and ATV for uid leakage and correct if necessary Replace brake pads Whenever worn to the limit 6 Brake hoses Check for cracks or other damage and replace if necessary Replace Every 4 years...

Страница 22: ...rect if necessary 23 Lights and switches Check operation and correct if necessary Adjust headlight beams 25 Throttle lever hous ing and cable Check operation and correct if necessary Check throttle ca...

Страница 23: ...t to prevent premature wear 2 4 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing loosen the lock nut and adjust the free play of the throttle lever by turning th...

Страница 24: ...The spark plug gap should be set to 0 6 0 7mm With the sealing washer attached thread the spark plug in by hand to prevent cross threading Tighten the spark plug with 10 12 N m 2 7 IDLE SPEED Connect...

Страница 25: ...moved cleaned and lubricated Use a commercial chain lubricant to lubricate the drive chain Clean the drive chain with kerosene and wipe it dry Inspect the drive chain for possible wear or damage Repla...

Страница 26: ...rear tire Its controller is located at the handler bar on the right side Inspect the rear brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play...

Страница 27: ...res to indicate the axle center height Measure the distance between the marks Move the vehicle back carefully until the wheels have turned 180 so the marks on the tires are aligned with the axle cente...

Страница 28: ...needs to be changed every year There is a gear oil release bolt at the rear of engine Loosen this release bolt and let the dirty oil flow out The refilling oil hole is on the engine case beside gearb...

Страница 29: ...move the spark plug cap from the spark plug Remove the exhaust pipe Disconnect the carburetor cable by unscrewLQJ two screws on top of the carburetor Take off oil pump cable from the oil pump control...

Страница 30: ...bolts Remove the engine from the right side of frame 3 3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal The torque of engine hanger bolt is 24 30 Nm Route the wire...

Страница 31: ...rvice classification SE or SF When the average temperature in your riding area is within the indicated range you should use the other engine oil viscosities that s shown in the chart ENGINE OIL VISCOS...

Страница 32: ...earance 0 05 0 10 0 2 TORQUE VALUE OIL DRAIN BOLT 20 30 N m 4 2 TROUBLESHOOTING Oil lever too low high oil consumption Normal oil consumption External oil leaks Worn piston rings Faulty head gasket Oi...

Страница 33: ...it in when making this check Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge 4 4 ENGINE OIL FILTER CHANGE Remove the oil filter cap and th...

Страница 34: ...ve the oil filter cap spring and oil filter screen Check the O ring for damage or fatigue Install a new oil filter screen and spring then install the cap CAP OIL FILTER SCREEN OIL FILTER CAP SPRING O...

Страница 35: ...ter at draining Install the oil filter cap Install the oil level gauge Start the engine and let it idle speed for 2 or 3 minutes Stop the engine and check that the oil level at the upper line on the g...

Страница 36: ...Remove the cooling fan composition Remove the A C G generator assy Remove the right crankcase cover A C G GENERATOR ASSY COOLING FAN COMPOSITION...

Страница 37: ...Remove the oil pump driven sprocket Remove the oil pump assy Disassemble the oil pump OIL PUMP DRIVEN SPROCKET OIL PUMP ASSY...

Страница 38: ...l pump body to rotor clearance SERVICE LIMIT 0 12 mm Install the oil pump shaft and measure the pump rotor tip clearance SERVICE LIMIT 0 12 mm Remove the oil pump shaft and measure the pump end cleara...

Страница 39: ...NSTALLATION Install the oil pump assy Install the oil pump driven sprocket Install the A C G generator assy and cooling fan composition OIL PUMP ASSY OIL PUMP DRIVEN SPROCKET A C G GENERATOR ASSY COOL...

Страница 40: ...OMPOSITION 5 2 TROUBLESHOOTING Engine top end problems usually affect engine performance These problems can be diagnosed by a compression test or by tracing engine noise to the top end with a sounding...

Страница 41: ...ove the cylinder head cover Remove the air cleaner and carburetor Remove the inlet pipe assy Remove the shroud compositions Relax the cam chain adjuster screw HEAD COVER INLET PIPE SHROUD COMPOSITION...

Страница 42: ...t holder and dowel pins Relax the camshaft gear from cam chain and remove the camshaft INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage IN 25 583 mm SERVICE LIMIT EX...

Страница 43: ...r or damage and replace them if necessary Screw a 5mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts and rocker arms Inspect the camshaft holder rocker arms and rock...

Страница 44: ...f each rocker arm SERVICE LIMIT 10 10mm Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91mm 5 4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head Remove the cylinder head gaske...

Страница 45: ...move the valve cotters spring retainers and valve springs with a valve spring compressor INSPECTION Clean off all carbon deposits from the combustion chamber Check the spark plug hole and valve area f...

Страница 46: ...ght edge and feeler gauge SERVICE LIMIT 0 05 mm Measure the free lenght of the inner and outer valve springs SERVICE LIMITS Inner 27 0 mm Outer 30 5 mm Inspect each valve for turning burning scratches...

Страница 47: ...learance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to fit If the valve guide is...

Страница 48: ...INSTALLATION Install the new gasket and dowel pins Install the cam chain guide Install the cylinder head...

Страница 49: ...into the camshaft holder Align the T mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise Position the camshaft gear with cam chain so I mark ali...

Страница 50: ...shers and nuts TORQUE 14 16 N m TORQUE 7 11 N m Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge STANDARD VALVE 0 07 mm Relax the cam chain adjusting bolt with cou...

Страница 51: ...Install the cylinder head cover screw and install the carburetor cap to the carburetor...

Страница 52: ...N 6 4 PISTON REMOVAL 6 2 TROUBLESHOOTING 6 5 PISTON INSTALLATION 6 3 CYLINDER REMOVAL 6 5 CYLINDER INSTALLATION 6 2 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings Overheatin...

Страница 53: ...6 3 CYLINDER REMOVAL Remove the cylinder head Remove the cylinder Remove the cylinder gasket and dowel pins CYLINDER HEAD...

Страница 54: ...careful not to damage the gasket NOTE surface 6 4 PISTON REMOVAL Stuff a shop towel into the crankcase Remove the piston pin clip with needle nose pliers NOTE Do not allow the clip fall into the crank...

Страница 55: ...Spread each piston ring and remove it by lifting up at a point opposite the gap INSPECTION Inspect the cylinder walls for scratches or wear...

Страница 56: ...1 mm Calculate cylinder taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 05 mm Calculate the cylinder out of round at three levels in an X and Y...

Страница 57: ...09 mm SECOND 0 09 mm Inspect the piston for wear or damage Insert each piston ring into the cylinder and measure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to b...

Страница 58: ...Measure the piston pin O D SERVICE LIMIT 12 96 mm Measure the piston pin bore SERVICE LIMIT 13 04 mm Calculate the piston to piston pin clearance SERVICE LIMIT 0 02 mm...

Страница 59: ...ing grooves thoroughly and installthe piston ring with the mark facing up NOTE Don t interchange the top and second rings Avoid piston and piston ring damage during installation Space the piston ring...

Страница 60: ...all the piston pin with new pin clips Do not align the piston pin clip end gap with the piston cutout NOTE Do not allow the clip to fall into the Crank case 6 6 CYLINDER INSTALLATION Clean any gasket...

Страница 61: ...asket Coat the cylinder bore and piston rings with engine oil and install the cylinder NOTE R QRW OHW piston rings damage cylinder bore during installation Do not allow the cam chain WR fall into the...

Страница 62: ...CASE COVER REMOVAL 7 6 C V T ASSEMBLY 7 1 SERVICE INFORMATION If the draintube assy fills with water the tube should be drained 7 4 KICK STARTER 7 2 TROUBLESHOOTING Engine starts but can t travel Worn...

Страница 63: ...7 3 C V T DISASSEMBLY L CRANK CASE COVER REMOVAL Relax the band screw and remove the C V T inlet duct Remove the bolts and L crank case cover...

Страница 64: ...Remove the gasket and dowel pins Clean off any gasket material from L crank case surface C V T REMOVAL Relax the flange nut and remove kick starter ratchet Remove the drive face...

Страница 65: ...Relax the flange nut Remove the drive pulley assy and d riven belt Remove the drive face boss and movable driven face assy Remove the ramp plate and weight roller set...

Страница 66: ...ce spring INSPECTION Inspect the driven belt for wear tearLQJ or damage Measure the width of WKH driven belt SERVICE LIMIT 17 0 mm Inspect the weight roller for wear or damage and replace them if nece...

Страница 67: ...1 24mm Inspect the drive face collar for wear or damage Inspect the drive face boss for wear or damage Measure the O D of drive face boss SERVICE LIMIT 20 94mm Inspect the clutch outer for wear or dam...

Страница 68: ...set for wear or damage Measure the thickness of clutch weight lining SERVICE LIMIT 2 0mm Measure the length of driven face spring SERVICE LIMIT 82 6 mm Inspect the driven face assy and replace them i...

Страница 69: ...t to start the engine After the engine is started the kick starteU will stop transfer the power to the kick starter driven gear When the kick starter lever is released the kick starter gear will go ba...

Страница 70: ...KICK STARTER DISASSEMBLY Remove the L crank case cover Remove the kick starter Remove the ex cir clip and washer from kick starter spindle composition...

Страница 71: ...ck starter spindle composition and return spring Remove the kick spindle bush INSPECTION Inspect the kick starter spindle composition for wear or damage Inspect the kick return spring for fatigue or d...

Страница 72: ...and spring for wear or damage Inspect the machining surface for wear or damage 7 5 KICK STARTER ASSEMBLY Install the kick spindle bush return spring and spindle assy Install the kick driven gear and...

Страница 73: ...V T ASSEMBLY Put together the driven face assy spring and driven plate composition Compose the movable driven face composition weight roller set and drive face Install the movable drive face assy and...

Страница 74: ...Install the drive face and kick starter ratchet Install the driven belt and driven pulley assy Install the dowel pins and gasket...

Страница 75: ...Install the L crank case cover...

Страница 76: ...rom WKH frame Fill the recommend oil after reassemblLQJ the WUDQVmission cover Bring the vehicle to a full stop before shifting to drive or reverse Avoid shiftLQJ to drive when vehicle is reversing wh...

Страница 77: ...e the drain bolt and drain the oil RRVHQ the bolts and remove the WUDQVPLVVion cover Remove the dowel pins and gasket Pull the shaft gearshifts out and remove the fork shift Remove the reverse shaft c...

Страница 78: ...Remove the sprocket and fixing plate from the final shaft comp Remove the cir clip and final shaft comp...

Страница 79: ...The bearing should turn smoothly and quietly Also check that the outer races of the bearings fit tightly in the left crankcase Replace the bearings if they are abnormal Check the sprocket and fixing...

Страница 80: ...t gear comp together with cir clip Install the counter shaft comp and reverse shaft comp in the left crankcase Install the shaft gearshifts and the fork shift Install a new gasket and the dowel pins A...

Страница 81: ...ORE SHIFTING TO DRIVE OR REVERS AVOID SHIFT 1 TO DRIVE WHEN VEHICLE IS REVERSING WILL CAUSE 75 16MISSION GEAR SET TO DAMAGE 8B 2 TROUBLESHOOTING ABNORMALLY ACT IN SHIFTING AND CAN T RESET FAULTY C D I...

Страница 82: ...8B 3 THE PARTS DRAWING OF TRANSMISSION SYSTEM CVT...

Страница 83: ...XUH WR ORFDWH WKH It includeV WKH VKLIW control system Replace if WKH control system PDOIXQFLWRQV hen this wire LV connected the engine speed is limited to 4800 r min hen this wire LV cXW WKH top engi...

Страница 84: ...CE LIMIT 30 mm 0 TORQUE kgf cm Shift fixed Spring Shift Push Shaft Fixed and Fork Remove WUDQVmission cover and other parts Check shift push fixed VKDIW DQG fork for wear or damage Measure shift fixed...

Страница 85: ...pm loaded 12 800 6 0 54 No load 12 390 60 Replace it if necessary 8B 5 GEAR BOX Remove transmission cover and parts of shift mechanism Inspect gears for wear scoring chipping or breaking Replace it if...

Страница 86: ...9 STEERING SYSTEM 9 1 THE PARTS DRAWING OF STEERING SYSTEM 9 3 HANDLEBAR 9 2 TROUBLESHOOTING 9 4 STEERING SYSTEM 9 1 THE PARTS DRAWING OF STEERING SYSTEM...

Страница 87: ...handlebar INSTALLATION Put the handlebar on the lower holders Make sure the handlebar punch mark with the tops of the handlebar lower holders Install the handlebar upper holders with the L or R marks...

Страница 88: ...e cotter pins on the kingpin Unscrew the castle nut and remove the kingpin TIE ROD INSPECTION Inspect the tie rod for damage or bending Inspect the ball joint rubbers for damage wear or deterioration...

Страница 89: ...Lower minimum limit 17 19 mm STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover see section 8 1 Remove the front fender see section 11 1 Unscrew the steering shaft fixed out below shaf...

Страница 90: ...bearing is on the front part of frame The bearing should turn smoothly and quietly Also check that the bearing outer race fits in the holder Replace the bearing if necessary INSTALLATION OF STEERING S...

Страница 91: ...rary setting INSTALLATION OF KINGPIN Use grease to the kingpin lower dust seal lips and install it Pump grease to bushing and install the kingpin Tighten the kingpin nut the setting torque is 30 40 N...

Страница 92: ...10 FRONT WHEEL SYSTEM 10 1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM 10 3 FRONT WHEEL 10 2 TROUBLESHOOTING 10 4 FRONT BRAKES 10 1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM...

Страница 93: ...TMENT STICKING BRAKE CABLE BRAKE SHOES WORN WORN BRAKE DRUM BRAKE LININGS OILY GREASY OR DIRTY IMPROPER BRAKE ADJUSTMENT 10 3 FRONT WHEEL REMOVAL Raise the front wheels off the ground by placing a blo...

Страница 94: ...ONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel Remove the brake drum Measure the brake lining thickness The minimum limit 1 5 mm If they are thinner than the minimum limit replace the brake...

Страница 95: ...inner race of each bearing with fingers The bearings should turn smoothly and quietly If the race does not turn smoothly or quietly remove and discard the bearings BRAKE PANEL REMOVAL Disconnect the...

Страница 96: ...grease to the brake cam and anchor pin and install the cam in the brake panel Soak the felt seal in the engine oil and install the seal on the brake cam Install the brake arm on the cam by aligning t...

Страница 97: ...brake cable to the brake arm Install the brake arm cover Tighten the screws securely Position the brake shoes in their original locations and install the brake shoe spring Install the brake drum and...

Страница 98: ...11 REAR WHEEL AND BRAKE SYSTEM 11 1 THEPARTSDRAWINGOFREAR WHEELSYSTEM 11 3 DRIVEMECHANISM 11 2 TROUBLESHOOTING 11 4 HYFRAULICDISCBRAKE SYSTEM 11 1 THE PARTS DRAWING OF REAR WHEEL SYSTEM...

Страница 99: ...WOBBLE AXLE IS NOT TIGHTENED WELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY BRAKE DRAG INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CAM STICKING BRAKE CABLE 11 3 DR...

Страница 100: ...en sprocket axle and sprocket collar Check the driven sprocket for damage or wear Let the rear axle lie in V blocks and check the run out The run out limit is 0 5 mm Check the turning of bearing with...

Страница 101: ...mbly the drive chain on the driven sprocket Assembly the master link and retaining clip Note the retaining clip direction Install the drive chain cover Assembly the chain under cover Assembly the whee...

Страница 102: ...11 4 HYFRAULIC DISC BRAKE SYSTEM To replace brake disc To replace brake disc Remove the rear left tire...

Страница 103: ...n the photo and remove caliper Unscrew the rear wheel axle nut and then remove the mounting seat of the disc Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one i...

Страница 104: ...TO REPLACE THE BRAKE SHOE Remove the rear left tire Loosen the two bolts as shown in the photo and remove caliper Press the plate to the end Remove the brake shoe as shown in fig...

Страница 105: ...hickness of brake shoe and replace a new one if the thickness less than 1mm Press the piston to the end prior to installation of brake shoe TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open...

Страница 106: ...sed oil being drained out completely Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup to avoid air gets into brake system such like caliper and tube Loosen the bolt to vent air...

Страница 107: ...Pull left brake lever slightly to extract air from brake system Fill the brake oil to the level as shown in the cup when no air comes out Assemble the cover...

Страница 108: ...12 FENDERS AND EXHAUST PIPE 12 1 FENDERS DRAWING 12 3 EXHAUST PIPE DRAWING 12 2 HOW TO REMOVE THE FENDERS 12 4 EXHAUST PIPE REMOVE 12 5 EXHAUST PIPE INSTALLATION 12 1 FENDERS DRAWING...

Страница 109: ...astic bolts you can remove the front body covers asshown in picture 1 2 You need to remove the seat before removing the front and rear fender Loosen the bolts as shown in pictures 3 4 then you can rem...

Страница 110: ...As picture 5 you can remove the rear R L fender As picture 6 unscrew these four bolts then you can remove the rear body fender...

Страница 111: ...istly Secondly you need to disassembly the front and rear brake cable and throttle cable then disassembly the handle bar Loosen the bolt then you can remove the front body fender Picture 7 Loosen thes...

Страница 112: ...12 3 EXHAUST PIPE DRAWING...

Страница 113: ...nuts that fixed with engine Remove the exhaust pipe mounting bolts that beside the muffler body Remove the exhaust pipe carefully 12 5 EXHAUST PIPE INSTALLATION Installation is the reverse order of r...

Страница 114: ...13 ELECTRICAL SYSTEM 13 1 TROUBLESHOOTING 13 5 CHARGING 13 2 IGNITION COIL 13 3 BATTERY CAUTION 13 6 WIRING DIAGRAMS 13 4 BATTERY INSPECTION 13 1 TROUBLESHOOTING...

Страница 115: ...the spark plug cap in place STANDARD 7 4 12 k 20 C IGNITION TIMING The ignition advance is 15 3 4000rpm The Capacitive Discharge Ignition CDI system is factory pre set and does not require adjustment...

Страница 116: ...e using a voltmeter VOLTAGE Fully charged 13 1 V Undercharged Below 12 0 V BATTERY REMOVAL Remove the battery holder bolt nuts Disconnect the negative cable and then the position cable and remove the...

Страница 117: ...eStopSwitch 7 1 6 1 OFF ON 10 9 17 16 White Red White Black Cyan Yellow Blue Yellow Blue Yellow 17 18 18 Generator N F 21 16 20 6 1 0 2 1 2 2 2 22 24 21 24 24 20 22 ShiftingMotor 26 2 2 8 2 29 26 31 3...

Страница 118: ...N 1 4 3 9 5 13 1 8 6 3 1 7 8 Rectifier BrakeSwitch HandleBarSwitch LH Color Black Red Brown Black Red Green Yellow Red Black White 12 9 OFF ON 11 9 9 12 White White Black Green Yellow White Red Blue Y...

Страница 119: ...14 TROUBLESHOOTING 14 1 ENGINE DOES NOT START 14 4 LOSS POWER 14 2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 14 5 POOR HANDLING 14 3 POOR PERFORMANCE AT HIGH SPEED 14 1 ENGINE DOES NOT START...

Страница 120: ...14 2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 14 3 POOR PERFORMANCE AT HIGH SPEED...

Страница 121: ...14 4 LOSS POWER...

Страница 122: ...14 5 POOR HANDLING...

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