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Honda TRX70 Fourtrax 1986, Руководство по обслуживанию

Honda TRX70 Fourtrax 1986 - это надежный квадроцикл с мощным двигателем, идеальным для различных приключений на природе. Для обслуживания и ремонта вы можете бесплатно загрузить Service Manual на manualshive.com. Этот мануал поможет вам легко и быстро ухаживать за вашим квадроциклом.

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Содержание TRX70 Fourtrax 1986

Страница 1: ...B6 B7 TRX70 FOURTRAX...

Страница 2: ......

Страница 3: ...ents Parts that don t meet HONDA s design specifications may cause damage to the Fourtrax 2 Use the special tools designed for this product to avoid damage and incorrect assembly 3 Use only metric too...

Страница 4: ...t side of the frame The engine serial number is stamped on the lower part of the left crankcase 1 2 After 86 After S6 The frame serial number is stamped on the right side of the lower main frame 31 CA...

Страница 5: ...4 in 795 mm 31 3 in 795 mm 31 3 in 895 mm 33 2 in 615 mm 124 2 in 610 mm 24 1 in 570 mm 22 4 in 210 mm 8 3 in 85 mm 3 3 in 86 85 kg 1187 Ib After 86 86 5 kg 190 Ib Backbone Pressed 5 spw x 70T 5 spw x...

Страница 6: ...III 1 350 1 Gear ratio tv 1 043 1 Final reduction 2 769 drive sprocket 13T driven sprocket 36T Gear shift pattern Left foot operated return system N 1 2 3 4 ELECTRICAL Ignition system COl Starting sys...

Страница 7: ...Handlebar lower holder nut 2 10 40 4814 0 4 8 29 351 Front wheel bolt B B 24 3012 4 3 0 17 221 Front axle nut 2 12 55 6515 5 6 5 40 47 Drive chain tensioner nut 2 10 40 S0 14 0 5 0 29 36 Front brake...

Страница 8: ...6 0040300 1 1 2 1 19 20 Pilot 17 mm 07746 0040400 10 11 12 20 Pilot 30 mm 07746 0040700 12 7 Bearing remover shaft 07746 0050100 EqUiValents available in U S A 11 12 Bearing remover head 15 mm 07746 0...

Страница 9: ...hly before applying tape 00 not use a wire or harness with a broken insulator Repair by wrapping them with protective tape or replace them Route wire harnesses to avoid sharp edges or corners Avoid th...

Страница 10: ...GENERAL INFORMATION 1 8 1 FRONT BR E PRIMARY CABLE 2 THROTTLE 3 REAR BRAKE CABLE _ 4 ENGINE STOP SWITCH WIRE After 86 J I l J I j 5 IGNITION It SWITCH W IRE 16 FR NT BRAKE SECONDARY CABLES...

Страница 11: ...CRANKCASE TUBE After 86 GENERAL INFORMATION After 86 3 IGNITION I 5 REAR BRAKE PEDAL CABLE After 86 3 IGNITION CARBURETOR DRAIN TUBE THROTTLE CABLE 7 CARBURETOR I VENT TUBE 2 CRANKCASE BR ATI ER TUBE...

Страница 12: ...f 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into any new vehicle for the purpos...

Страница 13: ...MEMO...

Страница 14: ...CATION ENGINE LUBRICATION SYSTEM CRANKCAS CYLINDER CYLINDER RIGHT CVLlNDER HEAD COVER CAMSHAFT IlOll HEAD PUMP RIGHT CLUTCH CRANKCASE r ADJUSTING HCENTRIFUGAL CRANKSHAFT CRANKCAS Oil FILTER COVER SCRE...

Страница 15: ...rn valve guide or seal Worn piston rings STANDARD I SERVICE LIMIT Approximately 0 7 lit 0 74 US qt 0 62 Imp ql at draining 0 8 lit 10 85 US qt 0 70 Imp qtl at engine assembly Honda 4 stroke oil SAE OW...

Страница 16: ...engine stop switch OFF pull the recoil starter sev eral times to completelv drain any residual oil Check the condition of the drain plug sealing washer If it is damaged replace it with a new one Inst...

Страница 17: ...lutch outer cover and the inside of the clutch outer using clean lint free cloth NOTE Do not allow dust and dirt to enter the crankshaft oil passage Do not use compressed air Remove the ojl fitter scr...

Страница 18: ...ivot points with a commercially available cable lubricant 86 shown After 86 similar THROTIlE ARM PIVOT CABLE BRAKE CABLE END BRAKE LEVER PIVOT PARKING LEVER PIVOT STEERING SHAFT BEARING AND BUSHING t...

Страница 19: ...Special Valve adjusting wrench set Valve adjusting screw Valve adjusting wrench 3 MAINTENANCE 3 1 DRIVE CHAIN 3 2 DRIVE CHAIN SLIDER 3 4 BRAKE SHOE WEAR 3 4 BRAKE SYSTEM 3 4 CLUTCH SYSTEM 3 5 SPARK AR...

Страница 20: ...N 1 1 3 4 AlA CLEANER NOTE 1 C 3 5 SPARK PLUG 1 3 6 VALVE CLEARANCE 1 1 3 6 ENGINE OIL R R 2 2 ENGINE OIL STRAINER SCREEN C 2 3 ENGINE OIL CENTRIFUGAL FilTEA C 2 3 CARBURETOR IDLE SPEED 1 1 3 7 DRIVE...

Страница 21: ...PARK PLUG 1 3 6 VALVE CLEARANCE 1 1 3 6 ENGINE OIL R R 2 2 ENGINE OIL STRAINER SCREEN C 2 3 ENGINE OIL CENTRIFUGAL FILTER C 2 3 CARBURETOR IDLE SPEED 1 1 3 7 DRIVE CHAIN NOTE 1 I l I l 3 8 DRIVE CHAIN...

Страница 22: ...in place Finger tighten the cup first then torque it to specification TORQUE 3 5 N m 0 3 0 5 kg m 2 4 fHb After installing turn the fuel valve ON and check that there are no fuel leaks THROTTLE OPERA...

Страница 23: ...ver and gas ket Separate the set plate and inner pipe from the element Pull the element f rom the air cleaner case Wash t he element in non flammable solvent squeeze out the solvent thoroughly and all...

Страница 24: ...ons if dam aged With the sealing washer anached thread the spark plug in by hand to prevent crossthreading Tighten the spark plug to the specified torque TORQUE 12 19 N m 11 2 1 9 kg m 9 14 ft Ibl Con...

Страница 25: ...TE Inspect and adjust the carburetor idle speed after aU other engine adjustments are within specification The engine must be warm for accurate idle inspection and adjustment Connect a tachometer Warm...

Страница 26: ...ting nut and adjust the drive chain slack Tighten the lock nut and adjusting nut TORQUE 40 50 N m 14 0 5 0 kg m 29 36 ft lbJ Recheck the amount of the drive chain slack and install the in spection hol...

Страница 27: ...7 mm 136 21 Inl Inspect the sprocket teeth for excessive wear or damage Re place jf necessary NOTE Never install a new drive chain on worn sprockets or a worn chain on new sprockets Both chain and spr...

Страница 28: ...T 37 0 mm 1 46 inl BRAKE SHOE WEAR Replace the brake shoes if the indicator plate aligns with the brake panel indo mark when the brake lever is applied BRAKE SYSTEM FRONT Check the brake lever and cab...

Страница 29: ...y cable adjusting nuts 8S required to equalize the brake effect If the equalizer arm had inclined excessively to one side spect the brake drum and brake lining on that side Tighten the secondary cable...

Страница 30: ...play by turning the adjusters at the lower end of the cables NOTE Make sure the cut out of the adjusters is seated on the brake arm pin CLUTCH SYSTEM Stop the engine Aemove the clutch adjuster cap an...

Страница 31: ...nd fasteners 8t regular intervals shown in the Maintenance Schedule page 3 21 Check that all chassis nuts and bolts Bfa tightened 10 their COf rect torque values page 1 5 Check that all cotter pins an...

Страница 32: ...ls facing straight ahead Mark the centers of the tires with chalk to indicate the axle center height Measure the distance between the chalk marks Slowly move the vehicle back until the wheels have tur...

Страница 33: ...MEMO...

Страница 34: ...FUEL SYSTEM 5 9 N m 0 5 0 9 kg m 4 0...

Страница 35: ...rings Replace then during reassembly SPECIFICATIONS Fuel tank ITEM STANDARD Fuel capacity 3 8 lit 11 00 US gal 0 84 Imp gal Fuel reSer l8 capacity 0 9 lit 0 24 US gal 0 20 Imp gal Carburetor ITEM STAN...

Страница 36: ...ct pilot screw adjustment Ignition malfunction Rich mixture lean mixture Air cleaner dirty Insulator leaks Fuel strainer screen clogged Fuel tank cap breather hole clogged l ean mixture Carburetor fue...

Страница 37: ...KHp uDl lle away rom jllunu or sparks Wipe up spill d flU oIine at once INSTALLATION Install the fuel tank in the reverse order of removal Install the front fender and seat reaT fender pages 13 2 3J...

Страница 38: ...at the carburetor then remove the carburetor Remove the carburetor top THROTTLE VALVE OISASSEMBLY Remove the throttle cable from the throttle valve while depressing the throttle valve spring CAUTION T...

Страница 39: ...ct the throttle valve and jet needle surface for dirt scratches or wear CARBURETOR DISASSEMBLY Remove the float chamber Remove the float arm pin float and float valv8 Inspect the float valve seat for...

Страница 40: ...and jets with compressed air CARBURETOR ASSEMBLY Clean all pans in non flammable or high flash point solvent and blow dry with compressed air Carburetor assembly is essentially the reverse order of d...

Страница 41: ...heck the O ring on the intake pipe flange for wear or damage Install the carburetor Install the intake pipe mounting bolts with the tear brake cable holder and tighten them to the specified torque TOR...

Страница 42: ...ENT The carburetor must be adjusted for high altitude riding labove 5 000 ttl 1 500 mL SPECIFICATIONS Below Above 5 000 ft 1 500 m 4 500 ft n 350 m Main jet 62 60 Pilot screw Factory preset 1 4 screw...

Страница 43: ...MEMO...

Страница 44: ...ENGINE REMOVAUINSTALLATION 5 0 12 4 3 0 kg m 17 22 ft Ibl...

Страница 45: ...S Engine hanger bolt Rear fenderlfoot peg guard bolt Foot peg guard bolt A Foot peg guard bolt B Foot peg mounting bolt Brake pedal bolt After 86 1 0 8 lit 0 85 US qt 0 70 Imp qtl at engine assembly 0...

Страница 46: ...he spark plug the exhaust pipe page 13 3 the foot peg and foot peg guard page 8 3 Disconnect the wire connectors and remove the wire from frame clamps Remove the three recoil starter mounting bolts an...

Страница 47: ...GINE INSTALLATION Engine installation is essentially the reverse order of removal Use a floor jack or other adjustable support to carefully maneu ver the engine into place TORQUE Engine hanger bolt 24...

Страница 48: ...CYLINDER HEADNALVES 10 1 4 N m 11 0 1 4 kg m 7 10 h lbl 10 14N m 1 0 1 4 kg m 7 10 ft lbl 5 9 N m 0 5 0 9 kg m 4 7 ft lbl 6 0...

Страница 49: ...mpression pressure 1 200 150kPa 900 kPa 1l2 0 1 5kg cm2 170 21 psiI 19 0 kg cm1 128 psi Camshaft Cam lobe N 26 0711 026 25 69 1 0 11 height EX 26 07 11 026 25 69 11 011 Oil clearance 0 010 0 025 0 000...

Страница 50: ...000 U S A onlyl 07959 KM30100 07742 0010100 or 07942 3290100 07757 0010000 or 07957 3290001 Performance problems related to the cylinder head can usually be diagnosed by a compteuien test or by tracin...

Страница 51: ...nting bolts Turn the flywheel counterclockwise and align the T mark with the index mark Remove the cam chain tensioner sealing bolt and spring page 94 Make sure that the O mark on the cam sprocket ali...

Страница 52: ...the head gasket O rings and dowel pins CYLINDER HEAD DISASSEMBLY Remove the cylinder head side cover and gasket Remove the valve inspection hole caps and O rings Screw an 8 mm bolt into the rocker ar...

Страница 53: ...ressor attachment 07959 KM30100 Remove carbon deposits from the combustion chamber Clean otf the head gasket surface NOTE Avoid damaging the gasket surface Gasket material will come off easier if soak...

Страница 54: ...nal 1 0 in the cylinder head Determine the camshaft journal oil clearance SERVICE LIMIT 0 05 mm 0 002 in VALVE SPRING Measure the free length of the inner and outer valve springs SERVICE LIMIT Inner 2...

Страница 55: ...0 004 in NOTE If the stem ta guide clearance exceeds the service limits de termine if a new guide with standard dimensions would bring the clearance within tolerance If so replace the guides as necess...

Страница 56: ...mer 07984 098000A or 07984 0980000 U S A onlyl VALVE SEAT INSPECTION REFACING Clean both intake and exhaust valves thoroughly to remove carbon deposits Apply a light coating of prussian blue to each v...

Страница 57: ...ide is replaced Use a 32 cutter to remove 1 4 of the existing valve seat mate rial NOTE Follow the instructions supplied with the Valve Seat Refaclng Equipment Use a 60 cutter to remove the lower 1 4...

Страница 58: ...the seat apply lapping compound to the valve face and lap the valve using light pressure NOTE Take care not to allow the compound to enter between the valve stem and guide After lapping wash all resi...

Страница 59: ...port the cylinder head abow the work bench surface to pre vent possible valve damage Install the camshaft aligning the cam tobes with the cylinder head cutouts Apply a thin coat of engine oil to the r...

Страница 60: ...n the cylinder and oil hole Remove the cylinder gasket and throughly clean the gasket surface Install 8 new gasket and O rings collars and the dowel pins Install the cylinder head and cylinder head bo...

Страница 61: ...lt TORQUE 10 14 N m 11 0 1 4 kg m 7 10 ft lb Tighten the cylinder mounting bolt TORQUE 10 14 N m 11 0 1 4 kg m 1 10 ft Ibl Install the intake pipe mounting bolts Turn the flywheel counterclockwise and...

Страница 62: ...ylin der head notch nghten the cam sprocket cover bolt Install the spark plug cap Adjust the valve clearance page 3 61 Install the recoil starter and tighten the mounting bolts Install and tighten the...

Страница 63: ...MEMO...

Страница 64: ...CYLINDER PISTON j j 7 13 N m 0 7 1 3 kg m 5 9 ft b 10 14 11 0 1 4 kg m 7 10 ft Ibl 7 0...

Страница 65: ...6 0 014 0 5 0 02 pin SECOND 0 5 0 35 0 006 0 014 0 5 O O2 OIL 0 2 0 5 0 008 0 019 Piston 0 0 46 980 47 000 1 8469 1 8504 46 90 1 847 Piston pin bore 13 002 13 008 0 5119 0 5121 1 13 06 0 5 14 Connecti...

Страница 66: ...in X and Y axis SERVICE LIMIT 47 05 mm 1 852 Inl Calculate the taper and out of round SERVICE LIMITS Taper 0 10 mm O OO4lnl Out of round 0 10 mm 0 004 inl Check the cylinder head meting surface for w...

Страница 67: ...ION PISTON RING Insert each piston ring into the cylinder and measure the end gap SERVICE UMIT TOP SECOND 0 5 mm 10 02 In Measure the piston ring te groove clearance SERVICE UMIT TOP SECOND 0 12 mm 0...

Страница 68: ...gauge SERVICE LIMIT 13 10 mm 0 516 in See section 10 for connecting rod replacement procedures PISTON RING INSTALLATION Install the piston rings with the marks facing up NOTE After installation the r...

Страница 69: ...p NOTE Install the piston with the marX facing the exhaust side Do not align the piston pin clip end gap with the piston cut out CYLINDER INSTALLATION Install the dowel pins new a ring and 8 new gaske...

Страница 70: ...guide roller and tighten the guide roUer bolt TORQUE 7 13 N m O 7 1 31cg m 6 9 Ib Looaety Mm 1 the cytlndet mounting bott Install the cytinder head section 6 Tighten the cytinder mounting bolt TORQUE...

Страница 71: ...MEMO...

Страница 72: ...CLUTCH OIL PUMP GEARSHIFT LINKAGE After 86 g m 6 9 ft lbl 8 12 N m 10 8 1 2k 8 0 38 45 N m 13 8 4 5 kg m 27 33 ft lbl...

Страница 73: ...ft pedal bolt Foot peg guard bolt A Foot peg guard bolt B Foot peg mounting bolt Clutch adjusting screw lock nut Rear fender foot peg guard bolt Brake pedal bolt After 86 TOOLS Common Lock nut wrench...

Страница 74: ...ngage Plate warpage CkJtch drags when disengaged Utter mechanism damaged 8 2 Hard shifting Improper clutch adjustment Shift forks bent Shift spindle bent Shift drum stopper bent Shift drum cam groo l8...

Страница 75: ...t step rubber the four foot peg mounting bolts and pull the foot peg Qut of the frame from the left side After 86 Remove the brake pedal page 12 41 Remove the right crankcase cover bolts and the cover...

Страница 76: ...ver by removing the three screws Straighten the lock washer tab Remove the lock nut while holding the clutch outer as shown Remove the washer and lock washer Remove the clutch assembly TOOLS Lock nut...

Страница 77: ...g using a screwdriver Remove the clutch plates discs center drive gear outer and rollers Remove the clutch damper springs Place a wood block under the drive plate Remove the screws loosening 2 or 3 tu...

Страница 78: ...clutch discI if they show ligna of Icoring Of dis coIot atlon M ur the disc thicitnel SERVICE UMIT DISC A 2 3 mm 10 09 In DISC 8 3 0 mm 0 12 In Check the rollerl and plat for xc we r or ctam ge and r...

Страница 79: ...CE UMIT 21 05 mm 10 829 in GEARSHIFT LINKAGE REMOVAL Remove the following parts geerahift pedal drum atopper arm drum Itopper plate and washer gearshift spindle pins from the gearshift drum Check the...

Страница 80: ...shown Tighten the pivot bolt Install the gearshift pedal and tighten the bolt TORQUE 12 14N m 11 2 1 4kg m 9 10ft lbl Rotate the spindle and check the linkage for smooth operation OIL PUMP REMOVAL Rem...

Страница 81: ...oil pump cover gasket in place measure the rotor end clearance SERVICE LIMIT 0 12 mm 0 005 in INSTALLATION Install the oil pump cover with a new gasket and tighten the cover screws Inslall the oil pu...

Страница 82: ...3 DRIVE GEAR OUTEA 12 CLUTCH PLATE A 7 CLUTCH FREE SPRING 8 CLUTCH FRICTION DISC B 11 CLUTCH FRICTION DISC A Place the clutch springs on the drive plate and install the drive plate in the clutch outer...

Страница 83: ...the set ring Install the primary drive gear Make sure the one way clutch assembly is installed correctly by turning the primary drive gear The primary drive gear should turn clockwise freely and shou...

Страница 84: ...plain washer with the OUTSIDE mark facing out Install and tighten the lock nut TORQUE 38 45 N m 3 8 4 5 kg m 27 33 ft Ibl Bend the lock washer up into the lock nut TOOLS Lock nut wrench 20 x 24 mm 07...

Страница 85: ...the clutch lever is aligned with the oil pass pipe crankshaft BRAKE PEDAL PIVOT After 86 REMOVAL Remove the brake pedal pivot assembly INSTALLATION Install the spring Check the pivot to see if it has...

Страница 86: ...er assemblv in the crankcase cover by fining the tang in the boss Install the O ring washer and lock nut onto the adjusting screw and tighten the lock nut TOROUE 8 12 N m 10 8 1 2 kg m 6 9 ft Ibl 86 I...

Страница 87: ...guard Tighten the foot peg guard bolt A and B TORQUE VALUES Foot peg guard bolt A 24 30 N m 12 4 3 0 kg m 17 22 ft Ibl Foot peg guard bolt B 30 40 N m 13 0 4 0 kg m 22 29 ft lbJ Tighten the four rear...

Страница 88: ...j RECOIL STARTER ALTERNATOR CAM CHAIN TENSIONER 1 20 25 N m 12 0 2 5 kg m 15 18 ft lbl 6 9 ft lbl 30 38 N m 1 kg m 22 21 ft Ibl 9 0...

Страница 89: ...9 5 mm in ITEM STANDARD SERVICE LIMIT Cam chain tensioner TORQUE VALUES Starter driven pulley bolt Flywheel nut Cam chain tensioner sealing bolt Friction plate bolt TOOLS Common Flywheel puller Univer...

Страница 90: ...ey and starter spring The spring con pop out ojthe housing if care is not used Untie the starter rope and remove the starter handle Release the starter rope slowly Remove the drive pulley 2 FRICTION 0...

Страница 91: ...the left crankcase cover and cover gasket Drain the engine oil page 2 2 Remove the starter driven pulley by removing the four attach ing bolts Hold the flywheel and remove the flywheel nut and washer...

Страница 92: ...Inl Check the push rod for wear Of damage and measure the push rod 0 0 SERVICE LIMIT 1 94 mm 10 470 In Replace either part if its measurement does not fell within ser vice limit Check the operation of...

Страница 93: ...g m 22 27 ft Ibl TOOL Universal holder 07725 0030000 NOTE Aoute the stator wire correctly page 1 9 LEFT CRANKCASE COVER INSTALLATION Install t he starter driven pulley and tighten the four mounting bo...

Страница 94: ...arter spring The spring elln pop ouf 0 the housing if care is not used Apply grease to the pulley shaft and install the pulley in the housing Preload the starter spring by turning the pulley 2 turns c...

Страница 95: ...he friction spring onto the friction plate Install the plate by hooking the friction spring on the ratchet hook Tighten the friction plate bolt to the specified torQue TORQUE 8 12 N m 0 8 1 2 kg m 6 9...

Страница 96: ...I TRANSMISSION CRANKSHAFT I I 10 0...

Страница 97: ...0 0 19 979 20 000 0 1866 0 1874 Mainshaft 0 0 16 983 16 994 10 6686 0 669 1 Countershaft 0 0 16 966 16 984 0 6680 0 6681 Shift drum 0 0 33 950 33 915 1 3366 1 3376 Shift fork 1 0 34 000 34 02511 3386...

Страница 98: ...nkcase bolts Place the engine with the left side facing up and ssparate the ft and right crankcase halves Aemove the dowel pins and gasket CRANKSHAFT REMOVALJINSPECTION Remove the crankshaft from righ...

Страница 99: ...he bearing inner face fits tightly on the crankshaft Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely on the crankshaft NOTE Replace crankshaft bearings...

Страница 100: ...t the shift forks so that they can be placed back in their original po ltlons Inspect the guide pins for wear Of damage INSPECTION Check the shift forks for weaf bending or damage Measure the 1 0 of t...

Страница 101: ...5 mm O 867 inJ Countarshaft 16 95 mm 10 667 inl Check the gearshift drum hole for wear or damage Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also...

Страница 102: ...th clean engine oil Assemble the transmission shafts and gears noting the loca tions of the thrust washers and snap rings NOTE Make sure the snap rings are seated properly 1 C4 GEAR 24T o8OOI r171 M2...

Страница 103: ...Turn the mainshaft by hand to make sure the gears rotate free I TRANSMISSION CRANKSHAFT COUNTEASHAFT Apply clean engine oil to the crankshaft and install it in the II I CF AIN IAIFT crankcase Install...

Страница 104: ...aJl and tighten the neutral indicator shaft lnatall b drive sprocket and cam chain Connect the crankcase breather tube Trim the protruding gasket material from the cvlinder base gllket aorf c e Instal...

Страница 105: ...MEMO...

Страница 106: ...ING SYSTEM 50 SO N m i 15 0 6 0 v _ 36 43 ft Ib 35 43 N m 24 30 N m kg m 17 22 ft Ib After 86 I 13 5 4 3 kg m 25 31 h lb 35 43 1 11 5 4 3 kg m 25 31 h lb 4 7 10 4 0 7 kg m 3 5 h Ibl 24 30 N m 2 4 3 0...

Страница 107: ...shaft bushing holder nut Front brake arm nut TOOLS Common Driver Attachment 24 26mm Attachment 32 35mm Pilot 15mm Pilot 17mm Bearing remover shaft Bearing remover head 15mm Bearing remover head 17mm...

Страница 108: ...not track straight Bent tie rods Wheel Installed incorrectly Front whHl wob ing Bent rim Worn front brake drum bearing Faulty tir Axle nut not tightened properly Poor brake performance Improper brake...

Страница 109: ..._ Remove the rear brake lever and disconnect the rear brake cable Free the handlebar switch wire from the handlebar by remov ing the wire bands Remove the engine stop switch by removing the two screw...

Страница 110: ...wer holder Align the punch mark on the handlebar with the top of the lower holder Install the upper holders with the L or R mark facing forward Tighten the forward bolts first then tighten the rear bo...

Страница 111: ...ive NOTE Allow the adhesive to dry for an hour before using Install the rear brake lever and connect the rear brake cable to the lever Innall the wire bands If the throttle cable was disconnected from...

Страница 112: ...nt brake pri mary cable to the lever Check the throttle lever for smooth operation Adjust as follows Throttle lever free play page 3 4 Brake lever free play page 3 10 FRONT WHEEL REMOVAL Raise the fro...

Страница 113: ...lhe rim and lose air pressure durinr ridinr While holding the breaker arm assembly at an approximate 45 position insert the blede of the breaker arm between the tire and rim Push the breaker arm inwar...

Страница 114: ...e tire REMOVAL EXCEPT U S A NOTE This service requires the Tire Bead Breaker Set 07772 0050000 or 07712 0050001 tnot available in U S A CAUTION Do not apply WQt r soapy water oil etc to the tire rim a...

Страница 115: ...e for puncturing objects Chalk mark the punc tured area and remove the puncturing object Inspect and measure the injury Tire repairs for injuries larger than 15 mm 15 8 in should be a section repair S...

Страница 116: ...the lining from the patch and center it over the injury Press the patch against the Injury using a special rolier NOTE Allow cement to dry until tacky before applying patch Do not touch the cement wit...

Страница 117: ...ways replace the front brake linings in pairs 10 assure even operation Measure the brake drum i D SERVICE LIMIT 86 0 mm 3 38 in BRAKE DRUM BEARING INSPECTION Turn the inner fsce of each bearing with y...

Страница 118: ...ubidel 07746 0050400 Bewfng remove head 17mm or equiv t commerc lv Ivdabte In U S A lnslde 07746 0050500 I INSIDE BEARING 21 DISTANCE OLLAR m INSIDE OUST SEAL Pack all bearing cavities with grease Dri...

Страница 119: ...spring end brake shoes NOTE Mark the shoes to indicate their original positions before re moving them Remove the screws and the brake arm cover Disconnect the brake secondary cable from the brake arm...

Страница 120: ...YSTEM Remove the following pans brake arm and cam return spring indicator plate and fait seal BRAKE PANEL ASSEMBLY 1 BRAKE ARM 2 FELT SEAL 7 INDICATOR PLATE 8 RETURN SPRING 11 14 3 BRAKE PANel 4 BRAKE...

Страница 121: ...late by aligning the tab or the plate with the slot on the brake cern Install the brake arm on the cam by aligning the punch marks Tighten the brake arm bott and nut to the specified torQue TORQUE 4 7...

Страница 122: ...iginal locations and install the brake shoe epring a BI __ __ Gr u 011 1M bnlke linin s cn stoppln potu KNP 011 Unln In 1I11 the brake drum and tighten the front IIxle nut to the speclfied torque TORQ...

Страница 123: ...move the tie rods Remove the kingpin nut and washer and the kingpin knuckle Remove the dust seal TIE ROD INSPECTION Inspect the tie rod for damage Inspect the ball joint rubbers for damage wear or det...

Страница 124: ...otter pin and nut cotter pins and bushing holder nuts and bushing holder steering shaft with bushing Remove the bushing from the shaft BUSHING INSPECTION Inspect the bushing for wear or damage replace...

Страница 125: ...lot 15mm Install the snap ring 07749 0010000 07746 0010100 07746 0040300 ApplV grease to the dust seal lips and install the dust seal INSTALLATION Install the steering shaft with the bushing Apply gre...

Страница 126: ...e removed drive in new bushings TOOLS Dri r Attachment 24x26mm POOl 15mm upper PUot 17mm lower 07749 0010000 07746 0010700 07746 0040300 07746 0040400 Install the ball joint with the l mark on the ste...

Страница 127: ...ile holding the ball joint TORQUE 35 43 N m 13 5 4 3 kg m 26 31 ft Ibl Install the cotter pins TIghten the kingpin nut to the specified torque TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft bl Install a new c...

Страница 128: ...REAR WHEEL BRAKE DRIVE MECHANISM 24 30 N m 12 4 3 0 kg m 11 22 ft lbl After 86 12 0 0 7 1 2 kg m 5 9 ft lbl...

Страница 129: ...equired to support the Fourtrllx Refer to Hction 11 for tire servicing SPECIFICATIONS TORQUE VALUES Rear wheel bolt Rear axle nut Rear brake IIrm nut ITEM Rear brake pedal After S6 TOOLS Common Driver...

Страница 130: ...l repair and mounting refer to pages 11 7 through 11 O REAR BRAKE REMOVAL Grms on lh brake lininls reduces stoppin power 4HP rNU olf the Iinin s Remove the rear wheel NOTE The brake shoe can be inspec...

Страница 131: ...inings Inspect the brake drum for wear or damage Replace if necessary Measure the brake drum I D SERVICE LIMIT 131 0 mm 15 15 inl Replace if necessary DISASSEMBLY Expand and remove the brake shoes an...

Страница 132: ...four bolts and the brake panel REAR BRAKE PEDAL After 86 REMOVAL Remove the brake cable guard Loosen the rear brake pedal adjuster Remove the rear brake pedal bott end brake pedal INSTALLATION Instal...

Страница 133: ...cable guard Adjust the tear brake pedal free plav page 3 11 DRIVE MECHANISM REMOVAL Remove the rear wheel and the tear brake page 12 2 Remove the skid plate and the drive chain cover Remove the drive...

Страница 134: ...ocks and measure the runout SERVICE LIMIT 0 6 mm 10 02 In Turn the inner race of each bearing with your finger The bear ings should turn smoothly end quietlV Also check that the bearing outer race fit...

Страница 135: ...Drive in the new bearings squarelv TOOLS Drivet Anachment 52 x 55 mm Pilot 30 mm INSTALLATION 07749 0010000 07746 0010400 07746 0040700 Apply grease to the dust seal lips and install dust seals Instal...

Страница 136: ...ak the felt seals in clean engine oil before installing ApplV grease to the brake cam and anchor pin Install the brake cam with felt seal Install the brake arm spring and felt seal Install the wear in...

Страница 137: ...Make sure the rear brake lever and pedal have the proper amount of free play pages 3 11 12 Install the brake shoes and springs NOTE Install the brake shoes to their original positions Spring hook s di...

Страница 138: ...RQUE 60 80 N m 16 0 8 0 kg m 43 68 ft Ibl Install a new cotter pin Install the reef wheel and tighten the wheel bolts to the speci fied torque TORQUE 24 30 N m 12 4 3 0 kg m 17 22 ft lbI Adjust the fo...

Страница 139: ...ng bolts and nuts from the rear fender and foot peg guard Remove the underside seat rear fender mounting bolts Pull the seat rear fender up and remove it backward Remove the handlebar page 11 3 Remove...

Страница 140: ...XHAUST PIPE Remove the fender mounting bolts and fuel tank cap Pull the front fender upward INSTALLATION Install the front fender in the reverse order of removal 111 FENDER 13 2 After 86 2 REAR 2 FRON...

Страница 141: ...nting bolts and washers t ighten the bolts TORQUE 10 14 N m f1 0 1 4 kg m 7 1 0 ft Ibl 1 41COl LA S q EXHAUST PIPE REMOVAL S8 Remove the exhaust pipe joint cap nuts After 86 Remove the brake cable gua...

Страница 142: ...ssembly INSTALLATION After 88 Apply klcking agent to the protector mounting screws Install the e haust pipe in the reverse order of removal TORQUE EXHAUST MUFFLER MOUNTING BOlT5 30 35 N m 3 0 3 5 kg m...

Страница 143: ...MEMO...

Страница 144: ...1 W G 2 L ___ _ _ _ 3 COl UNIT J Burf G G H ct iJ 6 IGNITtON 1 COil 11 ENGINE STOP SWITCH 5 SPARK PLUG t After 88 2 IGNITION SWITCH 3 UNIT GNITIC N COIL 5 PLUG NElUTI AI SWITCH luJV GIW 2v _ I yl SuIV...

Страница 145: ...coil resistance Pulse genefetO resiSUlnce TOOLS Inspection adaptor Ie 1 Spark adaptor Digital multitester or Circuit tester SANWAJ or Circuit tester KOWA T OUBLESHOOTI NG Engine tarts but stope Impro...

Страница 146: ...coil resistance STANDARD 3 69 4 51 ItO lat 20 C 6S0 F PERFORMANCE TEST Except U S A I Check the ignition coil with COl taster NOTE Follow the COl tester manufacturer s instruction TOOLS Inspection ad...

Страница 147: ...or accurate testing it is necessary to use a specified electrical tester Use of an im proper tester may give false readings Use Sanwa Circuit Tester 07308 0020000 Kowa Cir cuit Tester ITH SH l l or Ko...

Страница 148: ...ULSE GENERATOR INSPECTION Remove the rear fender page 13 11 Disconnect the pulse generator wlr connectors Me suf the resistance between the blue yellow wire and ground STANDARD 80 120 0 at 20oe 88 FI...

Страница 149: ...NT Disconnect the ignition switch connectors Remove the upper holder cover Push in the locking lugs then remove the switch from the cover Install the new ignition switch in the reverse order of remova...

Страница 150: ...Remove the rear fender page 13 1 Disconnect the neutral switch wlr connector Check for continuity between the light gr en rad wire end ground The neutral switch Ie funcUonal If continuity exist with t...

Страница 151: ...Ck Y Yellow B Bloo G Green A A d W White 5 SPARK PlUG Br Brown o Orange Lb Light BI Lg Light Gr en P Pink Gr Grey 15 WIRING DIAGRAMS ENGINE STOP SWITCH CONTINUITY OFF RUN OFF COLOR 4 PULSE GENERATOR...

Страница 152: ...ION SWITCH 15 2 12 COl UNIT c C B 8J1W G 0 t J171 IGNITION COIL 8 ENGINE STOP SWITCH FF RUN FF COLOR BJ Slack 6 SPARK PLUG IB Y V llow BLI Slue St Brown 5 PUl SEA o 0 11110 Q Green R Red L b Lilt lt B...

Страница 153: ...obabM Cau No fuel in fuel tank Clogged fuel line or fuel strainer Clogged float valve Clogged fuel tank cap breather hole Faulty spark plug Loose spark plug cap or wiring Faulty ignition switch After...

Страница 154: ...d air cleaner ENGINE SPEED INCREASED 31 Restricted air vent tube I 41 Clogged fuel tank cap breather hoi 51 Clogged muffler 5 Check ignition timing INCORRECT 1 Faulty COl unit 121 Faulty pulse generat...

Страница 155: ...l air mil ture too lean 131 Use of improper grade of fuel 4 Excessive carbon build up in com bustion chamber 5 Ignition timing too ad lanced Faulty COl unit or pulse gener ator POOR PERFORMANCE AT LOW...

Страница 156: ...flywheel installation FUEL FLOW RESTRICTED f 1 Lack of fuel in tank t21 C g8d fuel line or fuel strainer 3 Clogged fuel tank cap breather hoi 14 Clogged fuel valve CLOGGEO Clean INCORRECT Cam sprocke...

Страница 157: ...Schedule _ Model Identification _ Neutral Switch Noise Emission Control System Nuts Bolts Fasteners Oil Filter Rotor And Screen Pump Pilot Screw Adjustment Piston Installation Removal Pulse Generator...

Страница 158: ...INDEX Vr N C1e 8nCe Gulde Reptacernent Seat ionIRefacing WheetII11 _0100 17 2 HI IH 8 8 3 13 16 1 58...

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