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17. Electrical System

17-19

Switch / Horn

Main switch

Inspection

Remove the front cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below

Pin

Position

BAT BAT1 BAT2

LOCK

OFF

ON

Wire Color

Red

Black

Blake

Replacement of main switch

Remove main switch cap.
Disconnect the coupler of the main switch and
loosen the mounting bolts (3 bolts).
Remove the main switch.
Install the new main switch and tighten the
mounting bolts.
Install the main switch coupler and cap.

Right handle switch

Remove the handle cover and front cover.
Disconnect the coupler of right handle switch.
Check the continuity between two points as
indicated in the table below

Headlight switch

Pin

Position

TL CI HL CI

●

Wire Color Brown Black Black

Blue

/White

Start and engine stop switch

Pin

Position

ST E ST E

FREE

Wire Color Black

Black

/Green

Yellow

/ Red

Sky blue/

Orange

1 blot

Start switch

2 blots

Headlight switch

Engine stop switch

Main switch coupler

Right handle switch coupler

To this chapter contents

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Содержание GTS 250

Страница 1: ...GTS 250 JOYMAX 250 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS SERIAL NUMBER...

Страница 2: ...ce Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter LM25W series scooter are different from th...

Страница 3: ...the special parts and system information There are 4 buttons Forward Contents How to use this manual and Mechanism Illustrations on the CD R version and can be access to these items by click the mouse...

Страница 4: ...8 Cylinder Piston 7 8 1 8 14 V Type Belt Driving System Kick Starter 8 9 1 9 8 Final Driving Mechanism 9 10 1 10 10 Alternator 10 11 1 11 8 Crankshaft Crankcase 11 12 1 12 14 Cooling System 12 13 1 13...

Страница 5: ...Serial Number Home page Contents...

Страница 6: ...30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil Grease King Mate G 3 is recommended Gear oil King Mate gea...

Страница 7: ...s been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame is strictly prohibited Kee...

Страница 8: ...cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent unsmooth control and premature worn out y Rubber parts may become deteriorated when old and prone to be...

Страница 9: ...e install the oil seal with the name of the manufacturer facing outside and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal y Remove...

Страница 10: ...gative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark y After service completed make sure all connection points is secured Batte...

Страница 11: ...y Check if the connector is covered by the twin connector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loose y Insert the terminal c...

Страница 12: ...ht nor have excessive slack y Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied y Secure the...

Страница 13: ...parts in all steering positions y Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction y With sand pa...

Страница 14: ...NE Clutch Centrifugal dry type Installation and arrangement Vertical below center incline 80 Reduction Transmission C V T auto speed change Fuel Used Above 92 unleaded Speedometer 0 160 km hr Cycle Co...

Страница 15: ...nder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0 Air inject pipe bolt 4 6 1 0 1 4 A...

Страница 16: ...4 10 3 5 4 5 Rear cushion upper connection bolt 1 10 3 5 4 5 Rear cushion under connection bolt 1 8 2 4 3 0 Rear fork mounting bolt 2 10 4 0 5 0 Brake hose bolt 2 10 3 0 4 0 Brake air bleeding valve 1...

Страница 17: ...hose onto fuel rich circuit Then blow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake...

Страница 18: ...1 Air cleaner clogged 1 Poor fuel supply 2 Lines in fuel tank evaporation system clogged 3 Exhaust pipe clogged 4 Fuel level too low in carburetor 5 Fuel nozzle clogged in carburetor 1 Malfunction of...

Страница 19: ...Vacuum hose crack 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or short circuit in spark plug leads 6 Malfunction of main switch 1 Insu...

Страница 20: ...amaged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial forward moving or jumpi...

Страница 21: ...n 1 16 Lubrication Points Steering shaft bearing Seat locker Clutch bearing Main stand shaft Side stand shaft Speedometer gear front wheel bearing Acceleration cable Front rear brake lever pivot To th...

Страница 22: ...pecial Tools List 2 15 Precautions in Operation Model LM25W Fuel Tank Capacity 12 000 c c capacity 1 400 c c Engine Oil change 1 200 c c capacity 180 c c Transmission Gear oil change 170 c c Engine ra...

Страница 23: ...s connections in cooling system I I I I I 34 Coolant reservoir I I I I I 35 Coolant I Replacement for every 1 year Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necess...

Страница 24: ...remove oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Eng...

Страница 25: ...ggage box Remove rear carrier Remove body covers Check all lines and replace it when they are deterioration damage or leaking Warning y Gasoline is a low ignition material so any kind of fire is stric...

Страница 26: ...ondition Air Cleaner Air Cleaner Element Remove 8 screws from the air cleaner cover and then remove the cover Remove the body cover Loosen bolt from the air cleaner air hose Remove 6 screws and then r...

Страница 27: ...r side cover Remove ignition timing hole cap located in front upper side of engine right cover Turn camshaft bolt in C W direction and let the T mark on the camshaft sprocket aligns with cylinder head...

Страница 28: ...d Specified idle speed 1500 100 rpm Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment Connect the tachometer onto engine Adjust the throttle v...

Страница 29: ...ted within the ignition advance degrees it is means that the ignition advance degree is in normal If ignition timing is incorrect check CDI set pulse rotor and pulse generator Replace it if malfunctio...

Страница 30: ...ve leaking y Cylinder head leaking piston piston ring and cylinder worn out If the pressure is too high it means carbon deposits in combustion chamber or piston head Drive Belt Remove mounting bolt lo...

Страница 31: ...the motorcycle with poor cushion y Looseness wear or damage cushion will make poor stability and drive ability Front cushion Press down the front cushion for several times to check it operation Check...

Страница 32: ...patible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system hoses Added Brake Fluid Ad...

Страница 33: ...lining Remove the brake clipper bolt and take out the clipper Caution Do not operate the brake lever after the clipper removed to avoid clipping the brake lining Pry out the brake lining with a flat...

Страница 34: ...t beam adjustment will make in coming driver dazzled or insufficient lighting Wheel Tire Caution Tire pressure check should be done as cold engine Appointed tire pressure Tire size Front tire Rear tir...

Страница 35: ...rse procedures of removal Caution y If there is rust on the posts very serious spray some hot water on the posts Then clean it with steel brush so that can remove rust for more easily y Apply some gre...

Страница 36: ...adjusting wrench NAME Tappet adjusting NO SYM 1130000 HMA H9A NO SYM 9001200 NO SYM 9001200 08 09 10 NAME R crank case bearing 6201 assembles tool NAME Left crankshaft oil seal assembly socket NAME R...

Страница 37: ...uller NO SYM 9020200 NO SYM 2210100 NO SYM 3110000 HMA NAME Steering head top thread wrench NAME Bearing driver HK1516 NAME Bearing puller 6205 NO SYM 5320010 NO SYM 9100200 HMA RB1 HK1516 NO SYM 9100...

Страница 38: ...E Drive shaft oil seal 25 40 8 socket NAME Bearing puller 6303 NO SYM 9615000 6205 NO SYM 9120200 HMA NO SYM 6303000 HMA H9A 6303 NAME Bearing driver 6201 NAME Steering stem top thread wrench NAME NO...

Страница 39: ...2 Maintenance Information 2 18 Note To this chapter contents...

Страница 40: ...ng 3 2 Engine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication...

Страница 41: ...e 0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 3 1 7kgf m Engine oil drain...

Страница 42: ...er drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O...

Страница 43: ...nd take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil p...

Страница 44: ...nd outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving sha...

Страница 45: ...d then tighten screws Torque value 0 1 0 3kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install star...

Страница 46: ...her can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 170c c when replacing Make sure that the join bolt washer can be re used and install the bolt Torque value 1 0 1 4...

Страница 47: ...3 Lubrication System 3 8 Notes To this chapter contents...

Страница 48: ...stall 4 4 Vacuum Chamber 4 4 Air Cut off Valve 4 6 Automatic by starter 4 7 Float Chamber 4 8 Adjustment of Idle Speed 4 10 Fuel Tank 4 11 Fuel Pump 4 13 Air Cleaner 4 14 Mechanism Diagram 4 Home page...

Страница 49: ...n disassembling fuel system parts pay attention to O ring position replace with new one as re assembly y There is a drain screw in the float chamber for draining residual gasoline y Do not disassemble...

Страница 50: ...ion of carburetor y Dirty fuel Intermittently misfire as acceleration y Malfunction of ignition system Late ignition timing y Malfunction of ignition system y Malfunction of carburetor Power insuffici...

Страница 51: ...and release the cable from carburetor Release the clamp strip of carburetor and then remove the carburetor Installation Install in reverse order of removal procedures Vacuum Chamber Removal Loosen dr...

Страница 52: ...heck if the vacuum piston and needle for wear out crack or other damage Check if the diaphragm for damage or crack Caution Do not damage vacuum diaphragm Installation Install in reverse order of remov...

Страница 53: ...of the air cut off valve and its cover Remove the spring and vacuum diaphragm Check if the diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Caution z Do...

Страница 54: ...omatic by starter if the circuit clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the by...

Страница 55: ...g A worn out or dirty float valve must be replaced with a new a new one Remove main jet needle jet holder needle jet slow jet and air adjustment screw Caution Take care not to damage jets and adjust s...

Страница 56: ...float valve float for proper installation y To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 18 5mm Installation o...

Страница 57: ...s Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1500 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on the analyze...

Страница 58: ...17 Fuel unit installation Install the fuel unit in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Remove the left and right side...

Страница 59: ...System 4 12 Remove fuel tank upper bolts 2 bolts Remove fuel tank under bolt 1 bolt Remove fuel tank Installation Install the fuel tank in the reverse order of removal 2 bolts 1 bolt To this chapter c...

Страница 60: ...p Its output time is 10 seconds Output quantity Min 20 c c If the output quantity is lower than 20 c c check fuel hose vacuum hose and fuel filter Removal Installation Remove floor plate Remove fuel i...

Страница 61: ...Remove the air cleaner cover 8 screws Remove element mounting screws 6 screws Remove the air cleaner element With compressed air to cleaning dirty around the element Replace it if it is too dirty to...

Страница 62: ...retor 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Item LM25W Replacement 1 200 c c Engine Oil Capacity Disassemble 1 400 c c Replacement 170...

Страница 63: ...e Open the seat Remove the luggage box 6 bolts 2 screws Refer to chapter 13 Remove right and left side covers 4 screws on each side Remove rear carrier 4 bolts Remove body cover 4 screws 1 coupler Ref...

Страница 64: ...Remove the fuel line vacuum hose and throttle valve cable from the carburetor Loosen the clamp strip of air cleaner and carburetor and then remove the air cleaner hose Remove the air cleaner inlet pi...

Страница 65: ...2 bolts Remove the air cleaner Remove the exhaust muffler 3 bolts 2 nuts Drain out coolant and remove coolant inlet hose Remove the coolant inlet hose and thermo sensor wire To this chapter contents...

Страница 66: ...emove the right rear cushion lower bolt 1 bolt Remove the rear fork bolts 2 bolts Remove the rear wheel axle nut 1 nut Remove the rear fork and rear axle collars Remove left rear cushion lower bolt 1...

Страница 67: ...bolt and then remove engine Engine Hanger Removal Remove the engine side bolts of engine hanger 1 bolt on each side Remove the engine hanger Check if the engine hanger bush and cushion rubber for dama...

Страница 68: ...ghtly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing removal Remove bearing mounting cir clip Drive the bearing out of the rear fork Bearing installation Instal...

Страница 69: ...ing puller Special Service Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the rear fork bearing Install b...

Страница 70: ...bush 28mm Rear cushion bush 20mm Pressing out Place the detent section of the bush remover toward the bush and drive both the pressing ring and bolt in to press the bush out Special Service Tools Cra...

Страница 71: ...nd hands safety for squeezing as engine installation z Do not bent or squeeze each wires or hose z Route all cables and wires in accordance with the routine layout Engine hanger nut Torque Value 7 5 9...

Страница 72: ...Head Inspection 6 8 Valve Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram 6...

Страница 73: ...2 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Inner 38 700 35 200 Free length of valve spring outer 40 400 36 900 Valve seat width 1 600 Intake 0 10...

Страница 74: ...valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure y...

Страница 75: ...move the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove...

Страница 76: ...the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side Remove the cylinder head Remove cylinder head gasket and 2 dowel pins...

Страница 77: ...cotter remove assembly tool to press the valve spring and then remove valves Caution y In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the v...

Страница 78: ...m seals Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution Do not damage the matching surface of cylinder head To this chapter c...

Страница 79: ...spect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker arm I D and wear or damage oil hole clogged Service Limit...

Страница 80: ...record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and...

Страница 81: ...When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side T...

Страница 82: ...seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the cont...

Страница 83: ...ve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve...

Страница 84: ...mbly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remove...

Страница 85: ...oid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of c...

Страница 86: ...pe 4 bolts Install inlet pipe onto cylinder head Install and tighten spark plug Torque value 1 0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can...

Страница 87: ...uge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side cov...

Страница 88: ...gram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 7 Home page...

Страница 89: ...0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small en...

Страница 90: ...inder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be remo...

Страница 91: ...n rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of c...

Страница 92: ...r of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance f...

Страница 93: ...ully Place the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that al...

Страница 94: ...tween piston and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Clean up all residues and foreign materials on the matching surface of crankcase...

Страница 95: ...en when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coo...

Страница 96: ...nism Diagram 8 1 Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 5 Drive Face 8 7 Clutch Outer Driven Pulley 8 10 Mechanism Diagram Home page Contents 5 0 6 0kg...

Страница 97: ...40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive p...

Страница 98: ...left side crank out cover remove it Remove left crankcase cover 8 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal To...

Страница 99: ...rned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Bearing replacement Remove bea...

Страница 100: ...oove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection...

Страница 101: ...e shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque va...

Страница 102: ...n remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft D...

Страница 103: ...ter diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Ser...

Страница 104: ...pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution y Make sure that two sides of pulley surfaces have to be free...

Страница 105: ...vice tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable...

Страница 106: ...nd the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner beari...

Страница 107: ...n Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch bloc...

Страница 108: ...de of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution y Its sealing end should be for...

Страница 109: ...nd clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting n...

Страница 110: ...2 Trouble Diagnosis 9 2 Disassembly of Final Driving Mechanism 9 3 Inspection of Final Driving Mechanism 9 4 Bearing Replacement 9 5 Re Assembly of Final Driving Mechanism 9 8 Mechanism Diagram 9 Fin...

Страница 111: ...river SYM 9620000 Drive shaft oil seal 25 40 8 socket SYM 9120200 HMA Bearing HK1516 driver SYM 9100200 HMA HK1516 Bearing 6204 driver SYM 9110400 6204 Oil seal drive 34 52 5 SYM 9125500 HMA Inner bea...

Страница 112: ...shaft and final shaft Remove the gasket dowel pin Remove final gear Remove counter shaft gear and 2 washers Remove final shaft Remove the drive shaft Special tool Shaft protector Caution y If non ess...

Страница 113: ...he final shaft and gear are burn wear or damage and replace it if necessary Check bearings on gear box cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and...

Страница 114: ...sing following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 Caution y Never install used bearings Once bearing removed it has to be replaced with new one Install new final shaft...

Страница 115: ...side Remove drive shaft bearing and counter shaft bearing from gear box cover using following tools Special tool Inner bearing puller SYM 6204020 or SYM 6204021 Remove oil seal and then remove final s...

Страница 116: ...Tools Assembly directs puller SYM 2341110 Use screw driver holder bearing puller lower part and turn the bearing puller upper part to install the final shaft bearing Apply with grease onto final shaf...

Страница 117: ...r 25 40 8 SYM 9120200 HMA Apply with grease onto the oil seal lip of final shaft Install counter shaft and final shaft into the gear box cover Install 2 dowel pins new gasket Install the gear box and...

Страница 118: ...rankcase Cover Removal 10 3 AC G Set Removal 10 4 Right Cover Bearing 10 4 Flywheel Removal 10 5 Starting Clutch 10 6 AC G Flywheel Installation 10 8 AC G Set Installation 10 9 Right Crankcase Cover I...

Страница 119: ...alue mm Limit mm ID of starting clutch gear 25 026 25 045 25 050 OD of starting clutch gear 42 192 42 208 42 100 Torque value Flywheel nut 5 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with a...

Страница 120: ...2 nuts Drain out the engine oil and coolant refer chapter 5 Remove coolant hoses Disconnect the couplers of the Power source output line Remove water pump cover 4 bolts Remove 10 bolts from the right...

Страница 121: ...g rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary Remove the bearing 6201with inner bearing puller Special tool Inner bearing puller SYM...

Страница 122: ...s shaft protector onto the crank shaft Special tool Shaft protector Remove starter reduction gear and shaft Pull out flywheel with AC G flywheel puller Special tool AC G Flywheel puller SYM 3110000 HM...

Страница 123: ...gear Service Limit ID 25 050 mm OD 42 100 mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage Install starting clutch driven gear onto one way clutc...

Страница 124: ...Install the components in the reverse procedures of removal Torque value 1 0 1 4kgf m Caution Cannot lock the thread of socket bolt Caution The one way clutch must to with the generator flywheel and t...

Страница 125: ...ne way clutch Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 5 0 6 0kgf...

Страница 126: ...ight Crankcase Cover Installation Install dowel pins and new gasket Remove water pump cover Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump sh...

Страница 127: ...10 Alternator Starting Clutch 10 10 Notes To this chapter contents...

Страница 128: ...nism Diagram 11 1 General Information 11 2 Trouble Diagnosis 11 2 Disassembly of Crankcase 11 3 Crankshaft Inspection 11 4 Assembly of Crankcase 11 6 Mechanism Diagram 11 0 8 1 2kgf m 0 8 1 2kgf m 1 0...

Страница 129: ...t mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Run out 0 100 Torque value Bolts for crank...

Страница 130: ...t crankcase Caution Care should be taken not to damage the contact surfaces Install left crank shaft puller into crank case disassemble Hold left crank shaft puller nut by clutch nut wrench and turn t...

Страница 131: ...ace Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Drive out left crankcase oil seal Crankshaft Inspection Use a thickness gauge to m...

Страница 132: ...k crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If any roughness noise and loose linkage are...

Страница 133: ...ft bearing into left crankcase Special tool Crank case disassemble SYM 1120000 HMA H9A L Crank shaft puller SYM 1130000 HMA H9A Clutch nut wrench SYM 9020200 Install crank shaft onto the left crankcas...

Страница 134: ...r piece certainly must install Cannot install the wrong position or leak the attire Otherwise can cause the motorcycle to have the fierce vibration Install 2 dowel pins and new gasket Install the righ...

Страница 135: ...al in the left crankcase with special tool Special tool Crank shaft install socket oil seal driver SYM 2341110 HMA RB1 Install the cam chain tensioner and tighten the bolts Torque value 1 2 1 6kgf m I...

Страница 136: ...2 3 Change of coolant 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram 12 Home page Contents Radiator filler cap Radiator Thermo switch fan Reserve tank outlet pipe Thermo unit te...

Страница 137: ...r Reservoir upper 850c c 420c c Thermostat Begins to activate at 82 92 C Stroke 0 05 3 0mm 80 C Boiling point Not pressure 107 7 C Pressurized 125 6 C Torque Value For water pump rotor 1 0 1 4kgf m To...

Страница 138: ...it Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coolant...

Страница 139: ...ntil the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then chec...

Страница 140: ...y Check by pass hole whether has the air bubble to emit y If emits without the air bubble only has the coolant to flow out then backflow pipe joint on engine flameout y Remove radiator filler cap y St...

Страница 141: ...ckflow floods Radiator Check Check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken...

Страница 142: ...fun mounting bolts 3 bolts Remove thermo switch Installation Install the removed parts in the reverse order of removal Install radiator in the reverse order of removal Upon completion check for any le...

Страница 143: ...A confirms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drai...

Страница 144: ...out of the right crankcase Special tools Inner bearing puller Water pump bearing drive Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the rig...

Страница 145: ...pecial tools Water pump bearing driver 6901 Caution y Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right...

Страница 146: ...en Torque Value 1 0 1 4kgf m Caution y The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oi...

Страница 147: ...17 for inspection of thermo unit Removal Remove the luggage box and body cover Drain out the coolant Remove the thermostat cover 2 bolts Remove the thermostat Inspection Visually inspect thermostat fo...

Страница 148: ...splayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve...

Страница 149: ...12 Cooling System 12 14 Notes To this chapter contents...

Страница 150: ...rier cap Luggage box Rear mudguard Right side cover Right body cover Floor panel Back seat Seat Under cover Meter panel Luggage box mat Main cover Rear fender Front cover Meter visor Wind screen Wind...

Страница 151: ...s y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during assembly Rear fender Under cover R L Handle covers Floor pan...

Страница 152: ...2 screws from handle upper cover rear end Remove the handle upper cover cap Loosen the 3 screws from the handle upper cover and then remove handle upper cover Installation Install in reverse order of...

Страница 153: ...h and remove the wind screen garnish Loosen 8 screws from the wind screen and remove the wind screen Loosen 4 screws from the meter visor and remove the meter visor Loosen 8 screws from the inner box...

Страница 154: ...e front cover upper side Disconnect the headlight foggy light and winker light couplers Remove the front cover Installation Install in reverse order of removal procedures Winker foggy light coupler 2...

Страница 155: ...ve reserve tank cap Loosen 4screws from right left side of the meter panel Loosen 2 screws from in side of meter panel Loosen the meter cord coupler Remove the meter panel Installation Install in reve...

Страница 156: ...1 screw from fuse box and remove it Loosen 1 screw from main switch cap and remove the cap Loosen DC power outlet mounting nut and remove DC power outlet Loosen 1 screw from battery cover and remove...

Страница 157: ...Loosen 2 bolts from inner box under side Loosen 2 bolts from inside of the inner box Disconnect the hazard light and foggy light switch couplers Remove inner box Installation Install in reverse order...

Страница 158: ...ver Remove Loosen 2 screws from the side cover side end Loosen 2 screws from the side cover upper end Remove the side cover Installation Install in reverse order of removal procedures 2 screws 2 screw...

Страница 159: ...crew and 2 bolts from the front under spoiler upper end Remove the front spoiler Installation Install in reverse order of removal procedures Rear Carrier Remove Loosen 4 bolts from the rear carrier an...

Страница 160: ...isconnect the luggage box light and switch coupler Remove the luggage box rear cover Loosen 2 bolts from luggage box front side Loosen 4bolts from luggage box rear side Remove the luggage box Installa...

Страница 161: ...ar end of floor panel Loosen right and left side screws from rear side of the body cover Disconnect the tail light coupler Remove the body cover Installation Install in reverse order of removal proced...

Страница 162: ...and body cover Loosen 4 bolts and 2 screws from floor panel Remove floor panel Installation Install in reverse order of removal procedures Front Fender Remove Loosen 4 screws from front cushion Remov...

Страница 163: ...13 Body Cover 13 14 Rear Fender Loosen 4 bolts from rear fender Remove the rear fender Installation Install in reverse order of removal procedures 2 bolts Each side 1 bolt To this chapter contents...

Страница 164: ...ction 14 4 Adding Brake Fluid 14 5 Brake fluid replacement Air bleed 14 6 Front Brake Caliper 14 7 Rear Brake Caliper 14 8 Brake Disk 14 9 Master Cylinder 14 9 Mechanism Diagram Front brake Master cyl...

Страница 165: ...void damage y Check the operation of the brake system before riding Specifications unit mm Item Standard Limit The thickness of front brake disk 4 000 2 500 The thickness of rear brake disk 5 000 3 50...

Страница 166: ...ver 1 Blocked brake system 2 Poor brake caliper 3 Blocked brake pipe 4 Seized worn master cylinder piston 5 Bent brake lever Uneven brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged bra...

Страница 167: ...replaced with new lining when the brake pad wear limit reaches the brake disk Park the motorcycle on a level ground and check if fluid level is under the LOWER mark Recommended Brake Fluid WELL RUN BR...

Страница 168: ...c or rubber components may result in their damages Remove the master cylinder cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mark brake fluid joins in t...

Страница 169: ...ystem as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve Caution y Do not release the brake lever before the drain valve is closed y A...

Страница 170: ...se bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Remove brake caliper Remove b...

Страница 171: ...Use M8 x 35 mm flange bolt only y Long bolt will impair the operation of brake disk Use two seal washers and hose bolts to lock the hoses and brake caliper in place Torque 3 0 4 0kgf m Refill up the...

Страница 172: ...the asbestos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Master Cylinder Master Cylinder Removal Caution Do not le...

Страница 173: ...brake 13 945 mm Master Cylinder Assembly Caution y It is necessary to replace the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before asse...

Страница 174: ...h 2 new washers Tighten the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together...

Страница 175: ...14 Brake System 14 12 Note To this chapter contents...

Страница 176: ...gram 15 1 Operational Precautions 15 2 Trouble Diagnosis 15 2 Steering Handle 15 3 Front Wheel 15 5 Front Cushion 15 8 Steering Stem 15 9 Mechanism Diagram Home page Contents 1 0 2 0kgf m 0 2 0 3kgf m...

Страница 177: ...Inner bearing puller SYM 6204020 Steering nut wrench SYM 6204010 Driver 32 35mm Driver 42 47mm Trouble Diagnosis Hard to steer y The steering handle stem nut is too tight y The ball and the top crown...

Страница 178: ...oosen the lock bolts for the master cylinder of the front brake Loosen the deceleration throttle cable fixing nut Loosen 1 screw from the acceleration throttle fixing plate Loosen 2 screws from the th...

Страница 179: ...remove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 0 5 0kgf m Apply with grease onto throttle cable and the sliding surface...

Страница 180: ...e brake lever to avoid the brake pad being squeezed out In case that the brake pad is accidentally squeezed out use a screwdriver to force it back to the place Loosen screw remove speedometer cable Tu...

Страница 181: ...isy and loose when being moved remove and discard it Caution y The bearing shall be replaced in pair Wheel Place the wheel on to a rotation seat to check its rim wobbling Turn the wheel with hand and...

Страница 182: ...l the dist collar Install the right side bearing Caution y Carefully install the bearing in correct and evenly y Bearing outer face should be faced up as bearing installation Install the brake disk an...

Страница 183: ...brake caliper Remove speedometer cable Loosen 4 bolts from steering stem Remove the front cushions Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Tor...

Страница 184: ...remove the seats Remove bottom cone race body with a punch Caution y Do not damage the steering stem Installation Install a new bottom cone race onto the steering stem Push the cone race until to mou...

Страница 185: ...orque value 0 25kgf m Caution y Check the steering stem that should be rotated freely and no clearance in vertical direction Install the steering stem mounting nut and tighten the nut by means of hold...

Страница 186: ...Mechanism Diagram 16 1 Operational Precaution 16 2 Trouble Diagnosis 16 2 Muffler 16 3 Rear Wheel 16 3 Rear Fork 16 5 Rear Cushion 16 6 Mechanism Diagram Home page Contents 16 3 5 4 5kgf m 2 4 3 0kgf...

Страница 187: ...t 3 2 3 8kgf m Brake clipper mounting bolts 2 9 3 5kgf m Brake disc mounting bolt 4 0 5 0kgf m Trouble Diagnosis Run out of rear wheel y Deformed or bent wheel hub y Improper tires y Loose wheel shaft...

Страница 188: ...ler mounting bolt 3 2 3 8kgf m Muffler mounting nut 1 0 1 2kgf m Rear Wheel Removal Remove the exhaust muffler Remove the rear brake caliper 2 bolts and brake hose clamp 1 bolt Caution y Care shall be...

Страница 189: ...l rim on a rotational support Rotate it by hand and measure the run out with a dial indicator Run out limit 2 0 mm Installation Install in reverse order of removal procedures Torque Value Rear wheel a...

Страница 190: ...lock cir clip Uses the bearing driver drive out the bearing Special tool Bearing driver Install new rear fork bearing and bearing puller 6303 onto rear fork Install assembly directs puller bearing pul...

Страница 191: ...hions Remove the upper bolts by left and right rear cushions and then remove the cushion Installation Install in reverse order of removal procedures Caution y The rear cushion must be replaced as a un...

Страница 192: ...nsor 17 23 Water Temperature Meter 17 23 Mechanism Diagram Home page Contents 17 Winker Hazard control unit Spark plug A C Generator Fuse box Battery Ignition coil Main switch Reg Rec Start relay Fuel...

Страница 193: ...e must be checked with the voltmeter while charging the battery y As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC generator Verify w...

Страница 194: ...tarter motor is out of work Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short circuit of the discharging...

Страница 195: ...ing Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 2A 1...

Страница 196: ...ate Fuse 20A Ignition Fuse 15A Headlight Fuse 20A Headlight Hi Lo beam Winker hazard control unit Transistor ignition Meter Meter Horn Switch Luggage box light Power outlet Open seat motor Foggy light...

Страница 197: ...passes the condition Item Check Points Standard Value Main switch connection R B Battery voltage ON Battery connection R G Battery voltage Charging coil Y Y 0 2 0 4 If the readings measured are not no...

Страница 198: ...on and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal Disconnect each cable one by one and take measuremen...

Страница 199: ...ect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A...

Страница 200: ...5 30 10 100 10 100 10 100 R G 50 200 10 100 0 1 5 5 30 50 200 L Y 50 200 10 100 50 200 10 100 50 200 AC G Thermo switch Transistor ignition Auto by start Resistor G B Y L Y R G Ignition coil W Y R Y Y...

Страница 201: ...ween the spark plug and the primary winding Standard resistance Without cap 9 20 K With cap 14 1 20 K Replacement on ignition coil Loosen 2 screws and replace the ignition coil if necessary Inspection...

Страница 202: ...battery cover Disconnect the negative cable terminal of the battery Remove the luggage box Disconnect the cable positive terminal from the start relay Rear brake switch Engine stop relay Brake light F...

Страница 203: ...egative terminal Check the continuity of the large terminal end If there is no continuity replace the relay Removal of Starter motor Turns off the main switch Remove the luggage box Disconnect the cou...

Страница 204: ...TEMP LUGG Box Speed sensor Turn right indicator Meter O SB L W L BR R G R G Speedometer Main switch Fuel unit Fuse 20A R Red W White B Black L Blue G Green SB Sky blue Y Yellow O Orange P Pink GR Gray...

Страница 205: ...front cover meter panel Refer chapter 13 Disconnect the coupler of the speedometer and take off the meter panel and meter Loosen 4 screws from meter panel Remove the speedometer Installation of meter...

Страница 206: ...switch Foggy right indicator Hi beam indicator Hi beam light Lo beam light Foggy right R Main switch Fuse 20A B Battery Winker Hazard control unit B Ignition Fuse 15A Winker switch O SB R O SB R winke...

Страница 207: ...ation Lo beam bulb 12V 55W H7 Hi beam bulb 12V 55W H7 Caution y Never touch the bulb with finger which will create a heat point y Clean the fingerprint left on the bulb with alcohol Installation Insta...

Страница 208: ...n to remove the bulb seat and bulb Replace with new bulb if necessary Specification Foggy light bulb 12V 27W Winker light bulb 12V 21W Replacement the rear winker light bulb Remove the luggage box Tur...

Страница 209: ...er turn the indicator bulb seat in C C W direction and take out the indicator bulb Uses the round nose pliers turn the illumination bulb seat in C C W direction and take out the illumination bulb Spec...

Страница 210: ...l the new main switch and tighten the mounting bolts Install the main switch coupler and cap Right handle switch Remove the handle cover and front cover Disconnect the coupler of right handle switch C...

Страница 211: ...ion R WR L FROM R PUSH OFF N FROM L Wire color Sky blue Gray Orange Brake Switch While grasp the brake lever firmly the terminals of white green and green yellow of the brake should have continuity Re...

Страница 212: ...the E position the resistance measured shall be as follows Position Resistance E Empty 97 5 107 5 F Full 4 10 Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupl...

Страница 213: ...n the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temperature i...

Страница 214: ...uld be used as a heating medium as the test temperature must be higher than 100 y Contacting the container wall by the thermometer and the thermo unit may result in wrong readings Water Temperature Me...

Страница 215: ...17 Electrical System 17 24 Note To this chapter contents...

Страница 216: ...18 Electrical Diagram 18 1 18 Home page Contents LM25W Electrical Diagram...

Страница 217: ...18 Electrical Diagram 18 2 Note Home page Contents...

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