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VI. Inspection and adjustment

This section introduces the technical requirements for proper inspection, maintenance and adjustment of various parts of the G400C motorcycle.

Unless stated or indicated in the maintenance period table, you should check and adjust all parts of the G400C motorcycle prior to use.

Periodic maintenance is a combination of verification and service operations performed through the Genuine Motorcycles dealer network. To

properly maintain your motorcycle, it is normal during these operations that some parts may be replaced; components are inspected for adjustment

variations from their original settings as a result of normal wear and tear of the parts and usage of the motorcycle. These interventions do not

constitute flaws in the motorcycle; on the contrary, their purpose is to prevent any problems for your motorcycle to continue operating properly.

It is mandatory to replace parts and lubricants according to the maintenance table.

To maintain your warranty, you are required to have your vehicle inspected by a Genuine dealer after the initial 800Km of use. Your dealer will inspect

your vehicle and perform any maintenance and adjustments that may be necessary after the initial break-in period.

Содержание Dirt Track 650

Страница 1: ...Dirt Track 650 Owners Manual ...

Страница 2: ...motorcycle For your safety please pay a great importance to the cautions as follows Warning Any ignorance of the mentioned below information may lead to safety problems Caution Any ignorance of the mentioned below information may cause the damage of motorcycle parts or it may compromise the driving safety of the motorcycle itself Please fill in the blank with the serial Nos of the motorcycle Frame...

Страница 3: ...ssengers 7 Gasoline and exhaust fumes 8 Modifications 8 Fuel Saving tips 9 III Vehicle Layout 10 12 Instrument Gauges 13 Gauge Check 14 15 IV Controls 16 Ignition Switch 16 Switches on right handlebar 17 Switches on left handlebar 18 Adding Fuel 19 Gear Shift Lever 19 Mirrors 20 Clutch lever 20 Throttle 20 Brakes 21 Anti Lock Braking System 21 Side stand 22 Helmet holder 22 V Proper Operation 23 E...

Страница 4: ...2 43 Drive Chain 43 44 Fork functionality check 45 47 Battery 47 48 Fuse Replacement 49 Turn signals 49 Side stand 49 Bolts nuts and fasteners 50 Vehicle Washing 50 Storage 51 Special Torque Values 51 Standard Torque Values 52 VII Engine Management System 53 EFI System Composition 53 Major Components of EFI System 54 55 Circuit schematic drawing 56 Definition ECU pins 57 EMS failure diagnosis code...

Страница 5: ...ight 180kg Curb weight 150kg Vehicle body Front suspension device Rear suspension device Front Tire size Rear Tire size Front wheel pressure Rear wheel pressure Front brake Rear brake Fuel tank volume Spring hydraulic composite damping Spring hydraulic composite damping 120 80 18 130 80 18 Normally loaded 225 kPa Normally loaded 225 kPa Single disc type Diameter Φ320mm Single disc type Diameter Φ2...

Страница 6: ...charge volume Engine oil filter element Electric motor starting Idle speed Single cylinder Oil cooling 4 stroke engine 100 0mm 82 0mm 643 7cc 8 3 1 29 5 kw 6000 rpm 49 8 N m 4500rpm Intake 0 07 0 10 mm Exhaust 0 08 0 12 mm Oilpaper filte Oil cooling Pressure Splash SJ15W 40 MA2 engine oil in warm weather and SJ10W 30 MA2 in cold weather climates 2 2L Oil paper filter Electric 1500 150r min ...

Страница 7: ... to and back type Sequence I N Ⅱ Ⅲ Ⅳ V Electrical system Accumulator capacity Power supply system Fusible cutout Spark plug Spark plug gap Ignition coil type Fuel supply mode Ignition mode Front lamp Front position lamp Turn lamp Stop Rear position lamp 12V11 2A h DC power supply and the electric generator is only used to recharge the accumulator 15A 10A DPR8EA 9 0 6 0 7mm Open magnetic circuit El...

Страница 8: ...following Wear protective gear Wearing appropriate protective wear can prevent or reduce injuries from accidents Helmet The majority of serious motorcycle injuries and deaths are the direct result of a head injury Drivers and passengers should always wear a helmet to prevent or reduce the chance of head injury Eye and Face Protection A plastic face shield can help prevent accidents by guarding the...

Страница 9: ...limits Do not travel faster than you are able to safely control the vehicle Always travel at a speed that is proper for the operating conditions your ability and experience Always inspect your motorcycle each time you use it to make sure it is in safe operating condition Always follow the inspection and scheduled maintenance procedures described in this manual Test your brakes after operating in w...

Страница 10: ...y out of blind spots of other motorists When you come to an intersection move to the portion of your lane that will bring you into another driver s field of sight at the earliest possible moment Know Your Motorcycle Get training if you are inexperienced Beginners should get training from a certified instructor Become familiar with the motorcycle at slow speeds first Even if you are an experienced ...

Страница 11: ...y Caution The design of the motorcycle requires even distribution of all loads Be aware that improper loading of goods will adversely affect the performance and stability of the vehicle Keep the load low and distribute the load evenly An uneven load can cause the motorcycle to drift to one side Carrying excess load on your motorcycle can cause an accident or crash resulting in severe injury or eve...

Страница 12: ... park the vehicle near walkways Passenger should pay special attention to avoid exhaust burns Hay or other flammable items will create fire if too close to the exhaust system Modifications Any modifications to this motorcycle removal of original equipment or use of unapproved accessories may cause it to be unsafe for use and may trigger severe accidents Some modifications may also make your motorc...

Страница 13: ... few minutes Do not fill up fuel tank above cap neck This instruction book illustrates the notes for the standard and safe operation method and basic maintenance To ensure a comfortable and safe riding experience please read this instruction book carefully The pictures and illustrations in this book may be different from the actual vehicle due to cosmetic differences between models The vehicle is ...

Страница 14: ... rear view mirror Meter Ignition steering lock block Right hand rear view mirror Left handlebar Clutch control lever Switches on left handlebar Throttle twist grip Front brake control lever Switches on right handlebar Fuel tank lock ...

Страница 15: ...11 Rear shock absorber Saddle Front wheel Front shock absorber Muffler Pedal rear brake ABS rear sensor ring ...

Страница 16: ...12 Gearshift pedal Front turn light Rear turn light Rear wheel ABS front sensor ring ...

Страница 17: ...13 Instrument Gauges High beam indicator Neutral indicator Turn indicator Speed indicator Odometer RPM indicator Engine failure light ABS indicator Fuel level indicator A B ...

Страница 18: ...dicator The instrument RPM instructions with stepper motor indicator The indicated span 0 12000RPM Turn the ignition switch to the on position The tachometer will sweep to the Redline and back indicating that the tachometer needle is functioning properly 7 Fuel quantity display The instrument of oil quantity display using bar code display the display range 1 6 lattice When the fuel level indicator...

Страница 19: ...it up and then goes out after a short period of time If the ABS lamp is always on after the ignition or suddenly light up in the process of driving these mean that there are faults in the ABS the ABS is disabled But the braking system itself is still working only the ABS control system is failed Instrument button operation instructions Press the left build A Switching between big and small mileage...

Страница 20: ...on when riding If the key is moved to the position during riding all electrical systems will be off While riding do not remove the main switch key in order to avoid an accident If necessary stop the motorcycle prior to removing the key Before removing the key make sure the handle bar is locked If the engine is not started after turning the key to the position the battery will discharge over time D...

Страница 21: ...le falls over with the engine running Caution The Kill switch should only be used in emergency situations During riding turning the switch from to can be dangerous and cause damage to the engine Use the kill switch to stop the engine only if necessary Make sure that the main switch is in the off position if it is in the run position and the engine is powered off with the kill switch the battery is...

Страница 22: ...of the direction indicator will stop the turn signal from flashing Caution when finished turning the direction indicator switch will not be back to original position automatically please switch it manually Driving with light on will obstruct traffic Horn button When the main switch is in the on position if you press the horn button it will emit a loud sound Overtaking lamp switch Pull the yellow b...

Страница 23: ...EL TANK Fill fuel tank to 1 2 inch below the fill neck to prevent fuel spillage 5 Gear Shift Lever Gears are selected using the shift lever This motorcycle is equipped with a sequential transmission When in neutral N pull in the clutch and press down on the lever to select 1st gear Press up on the lever to select 2nd 5th gears Downshift by pressing down on the lever Always use the clutch when up s...

Страница 24: ... on the left side is used to disengage the transmission when vehicle is not moving and for shifting gears Pull lever in completely before shifting Once the gear has been engaged slowly release the lever 8 Throttle twist grip The throttle controls engine rpm speed To increase engine rpm rotate the grip toward you To reduce engine rpm rotate the grip away from you The throttle will automatically ret...

Страница 25: ...e lever is located on the right hand side of the handlebar Pull toward the grip to slow down or stop the vehicle Rear brake pedal The rear brake pedal is located near the right foot peg Press down on the rear brake lever to slow down or stop the vehicle 10 Anti Lock Braking System ABS The ABS unit installed in the middle of the frame is composed of the hydraulic control unit ECU control unit and t...

Страница 26: ...elmet holder is located on the left hand side of the motorcycle To hook on the helmet insert the ignition key and turn it so that the pin lowers then hook the helmet strap on the pin and turn the key clockwise to remove it Raise the pin with a finger until it locks into place WARNING The helmet holder is to be used only when the motorcycle is parked It is prohibited to ride with the helmet hooked ...

Страница 27: ...throttle twist grip about 1 8 turn but never over 1 4 turn if the vehicle has trouble starting If the engine starts then stalls during idle restart the engine and keep the engine running at a slightly higher speed by lightly applying throttle until engine warm up is complete Do not rev the engine during the warm up phase as this can damage the Oxygen sensor Engine Stop Stop the engine by turning i...

Страница 28: ...rs for the first 800 km Do not overload the engine with excessive weight during the first 800 km Engine Maintenance When the engine has been run in for 500 miles a mandatory first service and inspection is required to be performed by an authorized Genuine Service Center to maintain the limited warranty that may apply 1 Replace the engine oil 2 Valve gap inspection and adjustment 3 Inspect the spar...

Страница 29: ...check Check the brake system for normal function Check the condition of the brake fluid level pad shoe wear and brake lines cables prior to operating the vehicle If the level of the brake fluid is lower than the minimum level line inspect brake lines for leaks or cracks If a fluid leak is found please do not ride the vehicle and contact your authorized Genuine dealer for inspection and repair 6 Ca...

Страница 30: ...e longevity please do not accelerate or decelerate drastically Launch and Shifting Gears 1 While sitting on the motorcycle with the engine running at idle in neutral raise the side stand and place both feet firmly on the ground Pull the clutch lever to the handlebar and push the gear shift pedal down with your left foot to change the gear from neutral to 1st gear 2 Gradually turn the throttle twis...

Страница 31: ... under the legal limit Brake Usage Use the front and rear brake simultaneously for maximum braking power Avoid unnecessary sudden braking Caution If you only use the front or rear brake the motorcycle may become upset and a crash could result When riding in rain or on wet road avoid sudden braking Accidents can occur slow down and brake cautiously Avoid repeated braking dragging the brake as this ...

Страница 32: ...ic free location After driving the muffler will be very hot Park the motorcycle away from pedestrians children animals flammable materials etc Park with side stand Place the motorcycle on horizontal ground lower the side stand and move the handle bar to the left If the motorcycle is placed on uneven terrain the motorcycle may possibly fall down If the handle bar is moved to the right side or the m...

Страница 33: ...tions that some parts may be replaced components are inspected for adjustment variations from their original settings as a result of normal wear and tear of the parts and usage of the motorcycle These interventions do not constitute flaws in the motorcycle on the contrary their purpose is to prevent any problems for your motorcycle to continue operating properly It is mandatory to replace parts an...

Страница 34: ...I R I R I Fuel Filter I I I I I Air Cleaner Body C C C C C C Drive Chain Chain Tension I L I L I L I L I L I L I Maintenance Period Table Continued on next page For optimum performance the motorcycle should be checked and maintained at periodic intervals The meanings of capitalized letters in the table below are as follows I Inspection inspect then clean lubricate adjust refill repair or replace i...

Страница 35: ... Tire Tire Pressure I I I I I I I Inspection by user is expected Maintenance is suggested to be performed by authorized genuine dealer Inspection by user is expected Maintenance is required to be performed by authorized Genuine Service personnel a While operating the vehicle in a dusty area the service interval will need to be more frequent b When the odometer reads more than the given maximum val...

Страница 36: ...ion of inspection mount the cam phase sensor eyehole cover and upper eyehole cover in turn 2 Engine Oil Use SJ 15W40 in the summer or 10W30 in the winter in order to ensure maximum engine performance Using a high quality engine oil designed and tested for use in your vehicle will also extend the life of the engine Using lighter weight engine oil in cooler climates is acceptable Caution Insufficien...

Страница 37: ...fill plug and slowly refill engine with 1 8L oil per specification into the crankcase Re insert the oil fill plug Caution When the engine is at an operating temperature the engine oil may be very hot so be careful not to burn yourself Place the motorcycle on a flat surface Remove the drain plug then drain engine oil Once all oil has been removed clean the gasket and drain plug thoroughly tighten p...

Страница 38: ...ed by an Authorized Genuine Motorcycle dealer Cleaning the Oil Filter Remove the engine oil filter cover and remove the engine oil filter element Clean the filter cover and filter element with cleaning agent and then re install the clean engine oil filter Replace oil filter as required Inspect for damage of the engine oil filter cover and its 0 ring seal replace 0 ring as required Re install the e...

Страница 39: ...tates within a small angle the flywheel is not on the compression stroke but exhaust intake stroke In this case continue to turn the flywheel clockwise 360 degrees to reach top dead center position of the compressing stroke where the valve clearance can be adjusted Check the valve clearance by inserting a clearance gage into the gap between adjusting screw and the end of the valve Valve Adjustment...

Страница 40: ...ir to dislodge dust and other debris Replace the filter if there are perforations or an excess build up of debris that cannot be easily removed Caution The air filter must be installed or the engine will ingest dust and dirt and an unbalanced air fuel ratio resulting in a shorter engine life Water should never enter into the filter area if possible Take special care when washing the motorcycle Nev...

Страница 41: ...er will check whether the ignition advance angle is between 0 15 If the ignition advance angle is more than 15 it indicates the throttle valve s intake flow at idle speed is insufficient and at this point the idle speed is unstable or null if the ignition advance angle is less than 0 it indicates the intake flow at idle speed is too high and at this point the idle speed is often as high as 1800 r ...

Страница 42: ...the adjuster until free play is within specification Tighten the retaining Nut A and re install the protective rubber lagging Adjusting methods Coarse adjustment If the fine adjustment is not sufficient remove the throttle cable from the throttle body and unscrew the retaining Nut B to increase the free play Tighten the retaining Nut B after the adjustment After all adjustments verify the throttle...

Страница 43: ...ere is a potential brake system fault Inspect brake system thoroughly Brake lever free play 10 20mm Rear Brake Push the brake pedal downward by hand check the brake pedal free play The rear brake pedal free play should be at least 18mm but no more than 25 mm If the free play is outside this range the pedal can be adjusted by adjusting the rear brake adjustment nut near the rear wheel To make adjus...

Страница 44: ...ble Avoid contact with skin and eyes If you come in contact with brake fluid immediately run under water and contact a doctor If brake fluid comes in contact with your eyes immediately seek medical attention Caution Brake fluid cannot exceed the upper limit When adding brake fluid use special care Do not allow dust water or other foreign material to contaminate the master cylinder If brake fluid i...

Страница 45: ... fluid spills onto plastic or painted surfaces wipe off immediately In the event brake fluid splashes into the eyes or on the skin immediately flush with large amounts of fresh water and immediately see a doctor Brake Pads If the brake pad wear indicator gaps touch the side of the brake disc the brake pads need replacement Caution It is very important to keep the brake discs away from oil or any f...

Страница 46: ...nd rear will compromise motorcycle stability and handling Using the motorcycle with the tires inflated to an incorrect pressure or with worn or deteriorated tires may cause serious injury or death if losing control of the motorcycle 9 Clutch Check the clutch lever free play Clutch lever free play 10 20mm The clutch is adjusted by stretching the cable using the adjusting unit positioned on the hand...

Страница 47: ... clutch from disengaging A tight clutch cable will cause poor clutch engagement and damage the clutch 10 Drive Chain DriveChainTension Park the motorcycle on level ground with the main stand and shift the transmission to the neutral position Check the driving chain tension Press the chain by hand both up and down to check the range of movement of the lower chain Chain Adjustment Loosen the rear wh...

Страница 48: ...e condition of the chain there may not be any damaged rollers loosened pins or missing O rings Check the condition of the pinion and crown teeth if the teeth are as shown in Figure A they are in good condition while if they are as shown in Figure B they are to be replaced Note If worn the pinion crown and chain have to be replaced using a new chain with a worn pinion or crown the chain will rapidl...

Страница 49: ...turn Stand in front of the motorcycle Firmly hold the lower part of both fork legs and move the fork forward and backward checking that there is no play Warning If you feel any play during the movement have proper tightening of the steering bearings checked by a Genuine Motorcycles dealer for service Removing the front wheel Position the motorcycle in such a way that the front wheel is lifted from...

Страница 50: ...elative paragraph Tighten the nut 1 and the nut of the tensioners 3 Caution Do not operate the rear brake pedal when the wheel has been removed this causes the caliper pistons to move outwards After removal lay down the wheel with brake disc on top After reassembly depress the brake pedal until the pads are against the brake disc Rear shock absorber spring preload The rear shock absorber 1 spring ...

Страница 51: ...it in a dry place After an intensive use of the battery it is advisable to carry out a standard slow charging cycle Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle BatteryCheck To remove the left side panels operate as follows Detach the panel from the bottom attachment by pulling it outwards Lift out the panel ...

Страница 52: ...rcycle Charge the battery as soon as possible Your battery will be damaged if it remains unchanged for a long period of time Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal The voltage reaches a constant value only after a few hours therefore it is suggested NOT to m...

Страница 53: ...here of the electric parts is shorted unexpectedly Caution Do not use any fuse over 15A 14 Turn signal light Remove the lamp lampshade Lightly press bulb rotate in counter clockwise Install new bulb in opposite order as below Turn lamp bulb specifications 12V10W 15 Side stand Secure the motorcycle in an upright position that allows the vehicle to stand without using the side stand Inspect the side...

Страница 54: ...and oil plug with lubricating oil Protect your electric system to avoid any foreign materials entering When washing the motorcycle please remove the air cleaner cover and filter and use foam or cotton to protect the intake channel When washing block the muffler to avoid water getting into the muffler and engine 18 Maintenance Prior to Storage If the motorcycle will be stored for a long period of t...

Страница 55: ...flywheel fastening nut 1 M10 1 25 27 33 Spark Plug 1 M12 1 25 13 15 Front wheel axle 1 14 30 37 Real wheel axle nut 1 16 44 66 Swing arm shaft nut 1 14 44 52 Engine hanging bolt 3 10 29 36 Engine cover bolt 6 8 18 26 Steering handlebar clamp bolt 4 8 15 22 Front fork tube cap nut 1 21 44 52 Brake disc bolt 6 M8 25 15 22 ...

Страница 56: ... dimensions Torque value ft lb 5mm bolt nut 3 5 4 5 6mm bolt nut 6 9 8mm bolt nut 13 18 10mm bolt nut 22 30 12mm bolt nut 37 44 5mm Screw 2 5 3 5 6mm Screw 5 8 6mm spool bolt nut 7 10 8mm spool bolt nut 15 22 10mm spool bolt nut 22 30 ...

Страница 57: ...ed by ECU to get the optimal combustible mixture of fuel and air and Ignition timing which meet all engine operating conditions Through the engine and actuator components on the vehicle ignition coil fuel injector idle speed control valve and so on the fuel and spark are precisely controlled and corrected with closed loop System composition 1 Sensors Intake air pressure sensor load information int...

Страница 58: ...54 Major Components of EFI system Cylinder Head Temperature Sensor Fuel Injector Throttle body Intake air pressure sensor Throttle sensor Idle speed control valve ...

Страница 59: ...55 Electronic Control Unit ECU Oxygen sensor ...

Страница 60: ...56 Circuit schematic drawing ...

Страница 61: ... 5 J2 5 INJA 6 J1 6 TACH 6 J2 6 7 J1 7 CANLo 7 J2 7 O2AHTR 8 J1 8 CANHi 8 J2 8 IAT_MAT 9 J1 9 GND 9 J2 9 FUEL PUMP RELAY 10 J1 10 10 J2 10 5VRTN 11 J1 11 IACALo 11 J2 11 MAP 12 J1 12 IACBHi 12 J2 12 TPS 13 J1 13 IACBLo 13 J2 13 CRANK LO 14 J1 14 14 J2 14 CLT 15 J1 15 15 J2 15 IGN 16 J1 16 DIAG 16 J2 16 5VREF 17 J1 17 FUEL PUMP RECIRCULATION 17 J2 17 O2A 18 J1 18 PNSW 18 J2 18 VBATT ...

Страница 62: ...oxygen sensors 05 Engine coolant temperature 1C OBD requirements to which vehicle or engine is certified 06 Short Term Fuel Trim Bank1 20 PIDs 21 to 40 which are supported by the Powertrain controller 07 Long term Fuel Trim bank1 21 Distance Travelled with MIL Commanded On 08 Short Term Fuel Trim Bank2 40 Supported PIDs 41h 60h 09 Long term Fuel Trim bank2 4D Engine run time while MIL is 0B Intake...

Страница 63: ...status 04 Calculated Load Value 05 Engine Coolant Temperature 07 Long term Fuel Trim bank1 09 Long term Fuel Trim bank2 0B Intake manifold absolute pressure 0C Engine RPM 0D Vehicle speed 11 Throttle position 20 PIDs 21 to 40 which are supported by the Powertrain controller 60 PID used to determine PID support for PIDs 0x61 0x80 7F Engine run time ...

Страница 64: ...131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow 131 N A P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 N A Oxygen Sensor Heater P0032 O2S Heater Circuit High Voltage KsDGDM_O2_1_HeaterShortHigh 32 N A P0031 O2S Heater Circuit Low Voltage KsDGDM_O2_1_HeaterShortLow 31 N A Fuel Injector P0201 Injector 1 Circuit Malfunction KsDGDM_INJ_CYL_A_Fault 201 N A P0202 Injector 2 Circuit Malfun...

Страница 65: ...witch Diag P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 N A CCP P0445 CCP short to high CCP KsDGDM_CCP_CircuitShortHigh 445 N A P0444 CCP short to low open CCP CAN KsDGDM_CCP_CircuitShortLow 444 N A BLM MaxAdapt P0171 BLM Max Adapt Kohler Special BLM KsFDIAG_BLM_MaxAdapt 171 N A BLM MinAdapt P0172 BLM Min Adapt Kohler Special BLM KsFDIAG_BLM_MinAdapt 172 N A PE system Lean P0174 PE...

Страница 66: ... with Service 05 Status of system monitoring tests can be read with Service 01 PID 01 On board monitoring test results can be read with Service 06 Distance travelled while MIL is activated can be read with Service 01 PID 21 Number of warm ups since DTCs cleared can be read with Service 01 PID 01 Distance travelled since DTCs cleared can be read with Service 01 PID 01 Time run by the engine while M...

Страница 67: ...do not necessarily indicate a faulty component system If test results indicate a failure after additional driving then the MIL will be illuminated and a DTC will be set and reported with service 03h indicating a faulty component system This service can always be used to request the results of the latest test independent of the setting of a DTC Test results for these components systems are reported...

Страница 68: ...he fuel line needs to be removed please release the pressure first and make service is completed in a ventilated area by genuine technicians 5 When disassembling the fuel pump make sure the power is off or it may cause fire 6 The fuel pump cannot be contaminated with air or water as it will shorten the useful life The positive and negative poles of the fuel pump cannot be reversed 7 The ignition s...

Страница 69: ...65 VIII Electrical system diagram ...

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