Sym Wolf SB 250 Ni Service Manual
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Sym Wolf SB 250 Ni Service Manual

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Wolf SB 250 Ni
SERVICE MANUAL
FOREWORD
CONTENTS
HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATION
20120309

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Summary of Contents for Sym Wolf SB 250 Ni

  • Page 1 Wolf SB 250 Ni SERVICE MANUAL FOREWORD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATION 20120309...
  • Page 2 Homepage Contents Foreword This service manual contains the technical data of each component inspection and repair for the SANYANG PD25A series motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. Copyright reserved.

  • Page 3: General Information

    How to use this manual This service manual describes basic information of individual parts and system inspection & service for SANYANG PD25A series motorcycle. In addition, please refer to the manual contents for detailed information for the model year. The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information and special tools manual.

  • Page 4: Table Of Contents

    Content Page Content Index 1-1 ~ 1-19 General Information 2-1 ~ 2-16 Maintenance Information 3-1 ~ 3-45 Injection System 4-1 ~ 4-14 Lubrication / Clutch / Transmission 5-1 ~ 5-8 AC Generator / Starting Clutch 6-1 ~ 6-8 Engine Removal 7-1 ~ 7-16 Cylinder Head / Valve 8-1 ~ 8-10...
  • Page 5 Mechanism Illustration Start / RR brake Engine stop pedal switch Starter relay Main Switch Battery Winker relay Air cleaner Headlight dimmer / Fuel tank cap Winker / Horn switch Ignition Headlight Fuse Regulator/ Rectifier Shifting pedal Meter FR. Brake lever Clutch lever Taillight FR winker...
  • Page 6 1. General Information Symbols and Marks ·················· 1-1 Torque Values(Frame) ·············· 1-11 General Safety ··························· 1-2 Torque Values ··························· 1-11 Service Precautions·················· 1-3 Troubleshooting ························ 1-12 Lubrication Points····················· 1-17 Specifications -·························· 1-9 Torque Values(Engine) ············· 1-10 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information in procedures is needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
  • Page 7 1. General Information General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed ‧ Battery emits explosive gases; flame is strictly area. Run your engine in an open area, if you prohibited.
  • Page 8 1. General Information Service Precautions Always use with SANYANG genuine parts and Never bend or twist a control cable to prevent   recommended oils. Using non-genuine parts for unsmooth control and premature worn out. SANYANG vehicle may damage it. Rubber parts may become deteriorated when ...
  • Page 9 1. General Information The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant   cover plates or boxes is different from one before reinstallation, grind with a grindstone if another; make sure they are correctly installed. the contact surface has any damage.
  • Page 10 1. General Information Before battery removal operation, you have to Lubricate the rotation face with specified   lubricant on the lubrication points before remove the battery negative (-) cable first. assembling. Avoid using tools like open-end wrench, which may contact with body or create spark. ●...
  • Page 11 1. General Information ● ● When separating a connector, its locker has to Before connecting terminals, check if the boot be unlocked first. Then, conduct the service is cracked or the terminal is loose operation. ● Insert the terminal completely. ●...
  • Page 12 1. General Information ● Do not let the wire harness contact with ● Protect wires or wire harnesses with electrical rotating, moving or vibrating components tape or tube if they contact a sharp edge or when routing the harness. corner. Thoroughly clean the surface where tape is to be applied.
  • Page 13 1. General Information ● ● Do not let the wire harness be twisted when Use sand paper to clean connector installation. pins/terminals if rust is found. And then continue the connection operation. Clean rust ● Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, use rubber covering against adjacent or surrounding parts in all steering...
  • Page 14 1. General Information Specifications Maker Model PD25A1 Overall Length Front 2005 mm TELESCOPIC FORK Suspension System Overall Width Rear 790 mm UNIT SWING Dimension Overall Height Front 1050 mm 110/70-17 54H Tire Wheel Base Rear Specifications 1320 mm 140/70-17 66H Front 82 kg Front...
  • Page 15 1. General Information Torque Values (Engine) Q’t Thread Dia. (mm) Torque Value(kgf-m) Item Remarks Cylinder stud bolt 1.0~1.4 Cylinder head nut 3.6~4.0 Cylinder head right bolt 1.0~1.4 Cylinder head side cover bolt 1.0~1.4 Cylinder head cover bolt 0.8~1.2 Cylinder head stud bolt (inlet 1.0~1.4 Cylinder head stud bolt (EX.

  • Page 16: Torque Values

    1. General Information Torque Values (Frame) Q’t Thread Dia. Torque Value Item Remarks (mm) (Kg-m) Mounting bolt for steering handle post 1.0~1.4 Lock nut for steering stem 6.0~8.0 Steering top cone race 0.15~0.25 Front wheel axle nut 6.0~8.0 Rear wheel axle nut 10.0~12.0 Rear drive sprocket nut 2.7~3.0...
  • Page 17 1. General Information Troubleshooting A. Engine cannot be started or difficult to be started Fault condition Probable causes Check and adjustment Press the fuel injector feed pipe and confirm whether there is fuel in the feed pipe Check the fuel amount in the fuel tank Check if the fuel pipe and the vacuum tube are blocked or not The fuel supply to the fuel...
  • Page 18 1. General Information B. Engine runs sluggish (Speed does not go up, lack of power) Fault condition Probable causes Check and adjustment Accelerate gradually and check 1. Clogged air cleaner engine RPM 2. Poor fuel supply 3. Fuel tank emission control system clogged Engine RPM cannot be increased Engine RPM can be increased 4.
  • Page 19 1. General Information C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Incorrect ignition timing (malfunction of Abnormal Normal ECU or AC Generator) Check for any air sucked in through the throttle body insulator 1.
  • Page 20 1. General Information E. Starter Motor Malfunction 1. Starter Motor doesn’t rotate Fault condition Possible causes Check and adjustment Pull the brake handle or step on the braking pedal 1. Burnt Fuse 2. Insufficient Battery Voltage Braking light activated Braking light not activated 3.
  • Page 21 1. General Information 2. Starting Motor rotates slowly or spins without engagement with crankshaft Check and adjustment Fault condition Possible causes Check the battery circuit by activating turning signal Flashing normally Not flashing or dimmed Insufficient Battery capacity Connect the starting motor to the battery Starting Motor Still rotating Rotates Normally...

  • Page 22: Lubrication Points

    1. General Information Lubrication Points Throttle cable / Front brake lever pivot / clutch lever Steering stem Front wheel bearing Rear wheel bearing Side stand bracket Driven chain 1-17...
  • Page 23 1. General Information NOTE: 1-18...
  • Page 24 2. Maintenance Information Steering Mechanism ················· 2-8 Precautions in Operation ········· 2-1 Periodical Maintenance Schedule Suspension System ·················· 2-9 ···················································· 2-2 Disk Brake System···················· 2-9 Lubrication System··················· 2-3 Tire·············································· 2-11 Cylinder Compression Test ····· 2-4 Battery········································ 2-12 Fuel System ······························· 2-5 Clutch Adjustment ····················...

  • Page 25: Maintenance Information

    Note: I-Inspection A-Adjust R-Replace C-Clean L-Lubricate Please have your periodical maintenance data recorded by your SYM Authorized Dealer to maintain the motorcycle in excellent condition. The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference. Whichever time or mileage comes first will be regarded as an index for maintenance.

  • Page 26: Lubrication System

    2. Maintenance Information Lubrication System Engine Oil quantity Caution Upper limit Turn off the engine; park the motorcycle on  level surface with main stand. Run the engine for 3-5 minutes, check oil  capacity after engine off for3-5 Lower limit Check oil quantity from inspection window, if oil level is near lower limit, fill in the recommended oil to upper limit.

  • Page 27: Cylinder Compression Test

    2. Maintenance Information Replace oil filter Remove bolts of oil filter chamber. Remove the filter and replace it with a new one. Caution boltx2 Oil filter is paper type and cannot be cleaned  or reused. Oil filter Cylinder compression test Warm up engine and turn it off.

  • Page 28: Fuel System

    2. Maintenance Information Fuel System Fuel filter Fuel lines Check all fuel lines, and replace when they are deteriorated, damaged or leaking. Caution Gasoline is a highly flammable substance, so  any source of fire or spark is strictly prohibited when operation. Fuel filter Filter Warning...

  • Page 29: Throttle Operation

    2. Maintenance Information Throttle operation Operate the throttle grip to see if the throttle cable 2~6 mm is going smoothly. If the throttle cable is deteriorated, twisted or damaged, please exchange it. If the cable does not go smoothly, lubricate the cable.

  • Page 30: Pcv System

    2. Maintenance Information PCV System Unplug the drain tube, and leak the deposit off. Drain the tube every 2,000 km. Caution Under rainy or full- throttle situation, the  maintenance period should be shortened. You can check the deposit amount through the transparent tube.

  • Page 31: Drive Chain Adjustment

    2. Maintenance Information Drive chain adjustment Drive chain inspection Place the bike on its main-stand with its neutral gear. Check the drive chain slack by moving the chain up and down by fingers, and measure the amount of chain slack. Standard chain slack：10~20 mm Caution Because the front and rear sprocket have...

  • Page 32: Suspension System

    2. Maintenance Information Suspension system Caution Do not ride the motorcycle with poor cushion.  Loosened, worn or damaged cushion will  make poor stability and maneuverability. Front cushion Press down the front cushion several times to check its integrity. Check if any oil leakage or damage.
  • Page 33 2. Maintenance Information Air bleeding operation Master Cylinder Cap Connect a transparent hose to air-bleeding valve. Hold the brake lever and turn the air-bleeding Diaphragm valve open. Perform this operation several times until there is no air bubble inside the transparent Upper limit hose.

  • Page 34: Tire

    2. Maintenance Information Tire Check the pressure of the tire to see if it is in the specified pressure range. Caution Tire pressure check should be done when the  tire is cold. Specified tire pressure range Tire pressure Front Rear Single Tire pressure...

  • Page 35: Battery

    2. Maintenance Information Battery Negative pole Positive pole Battery removal Remove the seat Remove the〝─〞negative pole first, then remove the〝＋〞positive pole. Remove the battery holder and take out the battery. Caution If the rust on the posts is very serious, spray ...

  • Page 36: Headlight Adjustment

    2. Maintenance Information Headlight adjustment Turn on main switch. Loosen the headlight adjustment screw to adjust headlight beam height. Caution The factory setting of the beam height is  consistent with government orders. Improper headlight beam setting will make  driver in the opposite lane dazzled and cause danger.

  • Page 37: Special Tools

    Special tools Name Name Flywheel puller Name Rocker arm shaft disassemble tool Valve remove and assemble tool SY No. SYM-1445100 SY No. SYM-3110000-HMA SY No. SYM-1471110/20 Name Valve spring compressor Name Tappet adjusting wrench Name Tappet adjusting tool SY No. SYM-1471100 SY No.
  • Page 38 2. Maintenance Information Name Inner bearing puller set Name Outer bearing puller Name Bearing driver SY No. SYM-6204020 SY No. SYM-6204001 SY No. SYM-6204024 Name Crankcase bush puller Name Cylinder pressure gauge Name Vacuum pressure gauge SY No. SYM-1120310 SY No. SYM-HT07008 SY No.
  • Page 39 2. Maintenance Information Water pump mechanical Name EFI fuel hose pliers Name EFI fuel hose removal pliers Name seal driver SY No. SYM-1768100 SY No. SYM-1768110 SY No. SYM-1721700-H9A Water pump bearing driver Water pump oil seal driver Name Name SY No.
  • Page 40 3. Fuel Injection System EFi System Diagram·································· 3-1 Fuel Tank ····················································3-37 EFi System Operation ······························· 3-2 Fuel Pump···················································3-38 EFi System Introduction ··························· 3-3 Fuel Unit······················································3-39 Fuel System ··············································· 3-4 Air Cleaner ··················································3-39 Ignition System·········································· 3-5 EFi System Diagnosis Methods················3-40 Sensors / Drives ········································ 3-6 Check Light Fault Codes Differentiation··3-41 Precautions in Operation··························...

  • Page 41: Efi System Operation

    3. Fuel Injection System EFi system operation Crankshaft Position Sensor Manifold Absolute Pressure Sensor Injector INJECTOR Throttle Position Sensor Ignition Coil IGN COIL Engine Coolant Temperature Sensor Fuel pump FUEL PUMP Engine control unit LAMBDA O2 sensor CHECK LIGHT Rollover sensor AISV AISV...

  • Page 42: Efi System Introduction

    3. Fuel Injection System EFi system introduction Based on 4-stroke SOHC engine, displacement 250 c.c. electronically controlled fuel injection. Fuel vapor will be absorbed by carbon canister; blow-by gas from crankcase will be introduced to combustion chamber. The O2 sensor enhances the efficiency of the catalytic converter by dynamically controlling the air / fuel ratio.

  • Page 43: Fuel System

    3. Fuel Injection System Fuel system Fuel pump Injector Fuel pump relay Power relay Battery System description 1. After Key-on, the sensors send signals to ECU. ECU controls the fuel pump relay to make the fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in order to save electricity.

  • Page 44: Ignition System

    3. Fuel Injection System Ignition system Intake air temperature Manifold absolute pressure Engine coolant temperature Throttle position Ignition coil Oxygen content ACG/ Flywheel Gear (23+1 Long teeth) Crankshaft position Power sensor relay Battery REG. REC Principle The computer programmed ignition system receives the signals from the crankshaft position sensor, throttle position sensor, O Sensor, MAP sensor, intake air temperature sensor, engine coolant temperature sensor.

  • Page 45: Sensors / Drives

    3. Fuel Injection System Sensors / drives Crankshaft position sensor (CPS) Function: CPS identifies the teeth on the flywheel and sends voltage signal to ECU. Crankshaft position sensor Long tooth Flywheel Description Right after the engine is started; the crankshaft position sensor identifies the TDC position by detecting the long tooth on the flywheel and ignites at the fixed angle.
  • Page 46 3. Fuel Injection System Manifold absolute pressure (MAP) / Engine water temperature (TW) / Intake air temperature (TA) sensor Map sensor TA Sensor TW Sensor Engine water temperature / Intake air temperature sensor: Use the variable resistor of negative temperature coefficient (thermistor) to identify the outside temperature. The electrical resistance value goes down when the temperature rises.
  • Page 47 3. Fuel Injection System Sensor Power relay Sensor Battery Sensor 1. Ceramics tube 2. Electrode 3. Emissions 4. Atmosphere Rich ← 14.7 → Lean Function Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts the air-fuel ratio by changing the fuel injection time.
  • Page 48 3. Fuel Injection System Throttle position sensor (TPS) Battery TPS output voltage Throttle valve opening angle Basic Principle: TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value will change, determining the throttle position. Function: TPS identifies the throttle valve position and sends signal to ECU as reference of engine control.
  • Page 49 3. Fuel Injection System Idle speed control valve (ISC stepping motor) Battery Step Function: ECU controls ISC stepping motor to adjust the bypass intake air quantity and stabilize the idle speed. 3-10...
  • Page 50 3. Fuel Injection System Air injection solenoid valve (AISV) Function: AISV introduces appropriate air quantity to reduce pollutant emission. Basic principle: When the engine RPM and throttle opening are higher than the default value, ECU controls AISV opening or closure. Fresh air Power relay AISV...

  • Page 51: Precautions In Operation

    3. Fuel Injection System Precautions in operation General information Warning Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and ● flame is strictly prohibited when working with gasoline. Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to ●...

  • Page 52: Efi System Components Description

    3. Fuel Injection System EFi system components description ECU(Electronic Control Unit) Function Description: Powered by DC 8~16V, and has 36-pin socket on the unit. ● The hardware component consists of a 16-bit microcomputer that ● is its control center. It contains the functional circuit interface of engine condition sensing and the driving actuator for the fuel injector, fuel pump, as well as ignition coil.

  • Page 53: Throttle Body

    3. Fuel Injection System Throttle body Function description: Throttle body is an inlet air flow regulating device (similar to the ● carburetor). Throttle valve pivot drives the throttle position sensor ● synchronously and makes ECU detect the throttle opening immediately. Throttle valve positioning screw has been adjusted and marked ●...

  • Page 54: Map Sensor

    3. Fuel Injection System MAP sensor Function description: Powered by 5V DC from ECU. It has 3-pin socket on the sensor. One ● terminal is for power, and one terminal is for signal output. And, the rest one is for grounding. The major component of the intake pressure sensor is a variable ●...
  • Page 55 3. Fuel Injection System TA sensor Function Description Powered by 5V DC from ECU. It has 2-pin socket on the sensor. ● One terminal is for voltage output, the other is for grounding. The major component of TA sensor is a variable resistor of ●...
  • Page 56 3. Fuel Injection System Function description: Powered by 5V DC from ECU. It has 3-pin socket on the sensor. ● One terminal is for power, and one terminal is for voltage output. And, the rest one is for grounding. Its main component is a sophisticated variable resistor. ●...
  • Page 57 3. Fuel Injection System Diagnostic tool can be used to check throttle output signals. Connect the Diagnostic tool, key-on but do not start the engine. Switch screen to “data analysis.” Rotate the throttle and check the voltage. Treatment of abnormal phenomena: Throttle output signal -close measurement...
  • Page 58 3. Fuel Injection System TW sensor: Function Description: Powered by 5V DC from ECU. It has the two-pin socket on the ● sensor. One terminal is for voltage output, and the other terminal is for ground. The major component of TA sensor is a variable resistor of ●...
  • Page 59 3. Fuel Injection System Sensor Function Description: Powered by 8-16V DC from ECU. It has the four-pin socket on the ● sensor. One terminal is for heating power output, one for heating control, one for signal grounding, and one for signal. sensor sends signal to ECU, and ECU control air / fuel ratio ●...
  • Page 60 3. Fuel Injection System Use of diagnosis tool to check O sensor work situations Connect the Diagnostic tool, key-on and start the engine. ● Completely warm up the engine. (idle running for more than "5 ● minutes") Switch screen to "DATA STREAM 01/01", select "O Sensor"...
  • Page 61 3. Fuel Injection System Rollover sensor Function description Normal Rollover sensor controls power of the power relay coil and has ● three-pin socket. When the vehicle tilt angle is greater than 65 degrees, rollover ● sensor will be the implementation of ECU system power-off. At this time, to restart the engine, the main switch has to be turn on again.
  • Page 62 3. Fuel Injection System ISC(stepping motor)： Function description: Powered by 8-16V DC from ECU. ISC has a four-pin socket. ● The 4-pin socket is composed of power supply and grounding ● circuits of two motors, ECU controls the acting of stepping motor by controlling the power supply and grounding circuit.
  • Page 63 3. Fuel Injection System Fuel pump Function Description: Powered by 8-16V DC from ECU. Fuel pump has a four-pin ● socket. The two pins are power supply and grounding. ECU controls the ● movement of fuel pump by controlling the power. Low-power-consuming DC motor (12V) drives the vane pump to ●...
  • Page 64 3. Fuel Injection System Testing Procedures 3 Fuel pressure measurement Connect fuel gauge between fuel tank and injector. ● Caution To measure fuel pressure, fuel hoses, injector side or fuel ● pump side, will be removed. After the measurement, please check if any fuel leaks.

  • Page 65: Fuel Injector

    3. Fuel Injection System Fuel injector Function Description: Powered by 8-16V DC from ECU. Fuel pump has a two-pin ● socket. Its major component is a high resistance voltage driven solenoid ● valve. The two pins are power supply and grounding. Fuel injector is ●...
  • Page 66 3. Fuel Injection System Transistor ignition coil Function Description: Powered by 8-16V DC from ECU. Fuel pump has a two-pin socket. ● The two pins are power supply and grounding. Its major component is a ● high conversion ratio transformer. The computer programmed ignition system receives the signals from ●...
  • Page 67 3. Fuel Injection System AISV Function Description: AISV has two-pin socket, one is for power supply and the other is ● for grounding. AISV acts while RPM under 3500. ● While idling, ECU controls AISV movements by controlling its ● solenoid valve grounding circuit.

  • Page 68: Efi System Circuit

    3. Fuel Injection System EFi system circuit EFi system check light Test switch Diagnostic tool coupler L/O Silicon controlled Engine-off rectifier relay W/BR Engine-off relay LG/R Side stand relay PU/R G/BR Side stand indicator Neutral gear indicator R/GR Silicon controlled rectifier Clutch switch...

  • Page 69: Ecu Pin Configuration

    3. Fuel Injection System ECU pin configuration (on ECU) ECU Pin Note Wire Wire Note Note color code color code Drive components Power + ECU power + ROLL TEST Rollover sensor signal input Test switch signal (A/D) CRK-P Crankshaft pos. Sensor+ Warning Lights O/P Neutral gear switch signal LG/R...

  • Page 70: Troubleshooting

    3. Fuel Injection System Troubleshooting EFi Circuit inspection Main switch on Bulbs blown? Fuse blown? Battery voltage too low? ECU Power line bad contact? Warning lights extinguish after 2 seconds? Poor contact the main power switch? ECU fault？ Charging line anomaly? Battery voltage above 12.5V? Battery unable to store electricity?
  • Page 71 3. Fuel Injection System Difficult or unable to start engine Difficult or unable to start engine Warning lights extinguish Inspection process in accordance with after 2 seconds? circuit inspection Use diagnostic tool to view EMS fault content Warning lights displays Fault Troubleshoot in accordance with Code? procedures on troubleshooting...
  • Page 72 3. Fuel Injection System Idle flameout diagnosis Throttle line is jammed Idle flameout and unable to revert to full closure? 1. Link diagnostic tool to view EFI fault content 2. Troubleshoot in accordance with Troubleshooting procedures Idle CO value beyond set range (1.5% ~ 2.5%)? Enough Gasoline? Throttle body whether...
  • Page 73 3. Fuel Injection System CO value revised anomaly In principle, system equipped with O Sensor, the CO value needs no adjustment. If CO value deviates from normal range, please check if O2 Sensor or other mechanisms is abnormal. Throttle line is jammed and Idle flameout unable to revert to full closure?

  • Page 74: Intergrated Troubleshooting Procedure

    3. Fuel Injection System Intergrated troubleshooting procedure Checking, Detection items and Fault status Fault reasons Parts specifications adjusting item procedures determination Battery Use meter to Is battery Battery electricity Diagnostic tool ● ● ● ● voltage measure battery voltage above Battery connector should show ●...
  • Page 75 3. Fuel Injection System Continued from previous page Observe O2 ● Whether O2 ● sensor voltage sensor voltage is Close-loop O2 sensor fault changes (Stand ● O2 sensor ● maintained systems ECU fault motorcycle and ● voltage within a certain mobility keep RPM abound specifications:...

  • Page 76: Fuel Tank

    3. Fuel Injection System Fuel tank Removal Remove the rear seat. Remove the front seat (bolt x2). Release the fuel pipe band, fuel pump coupler, EEC Bolt ×2 tube. Caution Make sure the fuel is not too much in the fuel ●...

  • Page 77: Fuel Pump

    Remove fuel pump power wire. Loosen the clamp. Power Screw× Clamp Remove fuel hose by using fuel hose removal pliers. Tool number: SYM-1768110 Fuel hose removal pliers Remove the fuel pump. Caution Check if the gasket worn or damaged. ●...

  • Page 78: Fuel Unit

    3. Fuel Injection System Fuel unit Fuel Unit power wire Remove fuel unit screw. (screw×4) Remove fuel unit. Installation Install in the reverse order of removal. Caution screw×4 Do not bend the fuel unit float arm. ● Do not fill out too much fuel in the tank. ●...

  • Page 79: Efi System Diagnosis Methods

    3. Fuel Injection System EFi system diagnosis methods When wrong signal occurs in motorcycle injection system, causing engine abnormal function or unable starting, the check light at the meter will be lighting to inform drivers to carry out maintenance. While overhauling, diagnostic tool or meter flashing lighting identification can be applied to carry out fault detection.

  • Page 80: Check Light Fault Codes Differentiation

    3. Fuel Injection System Check light fault codes differentiation Check light flashing mode When there is no diagnostic tool for fault detection, wire jump the test switch and identify the ault by check light flashing and then correct the fault. Unit: second Fault code 22 Fault code 12...

  • Page 81: Fault Codes And Sensors Table

    3. Fuel Injection System Fault codes and sensors table Fault Fault Description Parts Inspection 0120 Throttle position sensor fault TP Sensor and wire 0105 Manifold absolute pressure sensor fault MAP sensor and wire 0115 Engine temperature sensor fault (water) TW Sensor and wire 0110 Intake air temperature sensor fault TA Sensor and wire...

  • Page 82: Identification Table···································3

    3. Fuel Injection System Fault code and check light flashing lighting identification table Fault Check Check light flashing Fault Description Parts Inspection codes light state Throttle position sensor fault Lighting long 0，short 6 Throttle position sensor and wire 0120 Fault detection procedures Please refer to the "EFI System components description" throttle position sensor (TPS) chapter Manifold Absolute Pressure sensor fault lighting MAP sensor and wire...

  • Page 83: Troubleshooting Table

    3. Fuel Injection System Troubleshooting table Test items Comprehensive testing program Parts closed- Throttle Engine Fault Power Fuel Ignition Engine Injection loop Abnormal position temp. Code voltage press. state vacuum state control Detection phenomena sensor sensor system    ...

  • Page 84: Comprehensive Maintenance List

    3. Fuel Injection System Comprehensive maintenance list Maintenance Testing Procedures Test items Determine benchmarks Fault reasons Project Power and ● Use meter direct ● Battery voltage ● Battery voltage = 10V Above ● Battery electricity measurement battery voltage ● Battery connector loose voltage ●...
  • Page 85 4. Lubrication System / Clutch / Transmission Mechanism Diagram ......4-1 Clutch Disassembly......4-5 Precautions in Operation....4-2 Clutch Inspection......... 4-6 Troubleshooting ........4-3 Clutch Installation........ 4-7 Engine Oil ..........4-4 Oil Pump ..........4-9 Engine Oil Strainer Cleaning ....4-4 Gear Shift Linkage Mechanism...
  • Page 86 4. Lubrication System / Clutch / Transmission Precautions in Operation General information This chapter covers the engine oil pump and the oil exchange, also the disassembly and the  shifting linkage is covered. All these operations can be done while the engine is still on the bike.
  • Page 87 4. Lubrication System / Clutch / Transmission Troubleshooting Insufficient engine oil Clutch slips when accelerating  Oil leaks  Insufficient clutch free play  Valve guides or seals worn out  Worn clutch disks  Worn piston rings  Weak clutch springs Insufficient oil pressure Unable to disengage the clutch;...

  • Page 88: Engine Oil

    4. Lubrication System / Clutch / Transmission Engine oil Turn off the engine; park the motorcycle on level surface with main stand. Check oil level Upper limit 3-5minutes later. Check oil quantity from window, if oil level is near lower limit, fill in the recommended oil to upper limit.

  • Page 89: Clutch Disassembly

    4. Lubrication System / Clutch / Transmission Clutch disassembly Clutch cable Drain all engine oil. Remove clutch cable. bolt×12 Remove right crankcase cover(bolt×12)。 bolt×6 Remove clutch lifter(boltX6)。 Remove clutch spring. Remove clutch lock nut. Remove clutch center, friction disks, clutch plates, and pressing plate.

  • Page 90: Clutch Inspection

    4. Lubrication System / Clutch / Transmission Remove washer, clutch outer, and center guide. Washer Disassemble the clutch center, clutch plates, Clutch center Pressing plate clutch friction disks, and pressing plate. Friction disk Clutch plate Clutch inspection Clutch spring inspection Measure the free length of the 6 clutch springs.

  • Page 91: Clutch Installation

    4. Lubrication System / Clutch / Transmission Clutch plate inspection Use a feeler gauge to measure the warp of each clutch plate. Service limit：0.2mm Clutch outer inspection Check if the clutch outer is cracked or damaged. washer Clutch installation Install clutch washer, center guide. Center guide Install clutch outer and washer.
  • Page 92 4. Lubrication System / Clutch / Transmission Install clutch center, clutch plate, friction disk, Clutch lock nut and pressing plate. Tighten clutch lock nut. Clutch lifter Install clutch spring, clutch lifter; tighten 6 bolts. Install right crankcase cover. (bolt×12)。 Install clutch cable. Fill in specified engine oil.

  • Page 93: Oil Pump

    4. Lubrication System / Clutch / Transmission Lock nut Oil pump Drain all engine oil. Remove clutch cable. Remove right crankcase cover. Remove clutch assembly. Remove initial driven gear lock nut. Remove initial driven gear. Initial driven gear Remove oil pump cover. (boltX2)。 bolt×2 Remove oil pump drive gear fix circlip.
  • Page 94 4. Lubrication System / Clutch / Transmission Oil pump disassembly Remove oil pump cover. (screw×1) Disassemble oil pump. Oil pump inspection Check the clearance between oil pump body and outer rotor. Service limit: under 0.25 mm Check clearance between inner and outer rotors.

  • Page 95: Gear Shift Linkage Mechanism

    4. Lubrication System / Clutch / Transmission Gear shift linkage mechanism Gear shift linkage disassembly Remove shifting lever. (bolt×1) bolt×1 Remove cultch cable. Remove right crankcase cover. Remove cultch assembly. Take out the gear shifting spindle. Gear shifting spindle Remove the shifting drum stopper arm and the Retainer return spring.
  • Page 96 4. Lubrication System / Clutch / Transmission Remove shifting cam. (bolt×1) Remove alignment pin. Shifting cam Inspection Check if shifting spindle and the fork assembly damaged or worn. Check if shifting drum stopper arm and the return spring damaged or worn. Check if gear shifting cam damaged or worn.
  • Page 97 4. Lubrication System / Clutch / Transmission Gear shift linkage mechanism installation Install alignment pin. Install the gear shifting cam by matching the alignment pin. Tighten gear shifting cam lock bolt. (bolt×1)。 Torque value：0.8~1.2kgf-m Gear shifting cam Retainer Install shifting drum stopper and the return spring.
  • Page 98 4. Lubrication System / Clutch / Transmission NOTE: 4-14...

  • Page 99: Ac Generator / Starting Clutch

    5. AC Generator / Starting Clutch Mechanism Diagram ···················5-1 ACG Stator Disassambly ············5-3 Precautions in Operation ···········5-2 ACG Flywheel/ Starter Clutch ····5-5 Mechanism diagram 2.8~3.2kgf-m 0.8~1.2kgf-m 8.5~10.5kgf-m 0.3~0.4kgf-m 0.7~1.1kgf-m 0.3~0.5kgf-m 0.15~0.25kgf-m 0.8~1.2kgf-m...
  • Page 100 Item Standard Service limit 42.192~42.208 42.100 Start Driven Gear exterior diameter 25.026~25.045 25.050 Starting Clutch interior diameter Torque value Flywheel nut 8.5~10.5kgf-m Left crankcase cover bolt 0.8~1.2kgf-m Starting clutch inner-hexagon bolt 2.8~3.2kgf-m with screw adhesive Special tool Flywheel puller SYM-3111000-HMA...
  • Page 101 5. AC Generator / Starting Clutch ACG stator disassembly CPS coupler ACG stator disassembly Remove ACG coupler and CPS coupler. ACG coupler Remove left crankcase chain cover. (bolt×2) bolt×2 Remove left crankcase cover. (bolt×11)。 bolt×11 Remove foreign objects and gasket on the interface of crankcase and cover.
  • Page 102 5. AC Generator / Starting Clutch screw×3 Remove ACG stator holding screw. (screwX3) ACG stator inspection Remove ACG coupler and check its resistance and grounding condition with ohmmeter. Replace ACG if any abnormal situation found. Ω Ω Ω 70~80 0.42Ω±20% Ω...
  • Page 103 5. AC Generator / Starting Clutch screwX3 ACG stator assembly Rubber seal Install ACG stator. (screw×3)。 Assemble the stator wire correctly onto the L-crankcase cover with the rubber seal. Install dowel pin and new L crankcase cover gasket. Dowel pin Install left crankcase cover.
  • Page 104 5. AC Generator / Starting Clutch Remove flywheel, starting clutch, and start driven gear with flywheel puller and shaft protector. Special tool: ACG flywheel puller SYM-3111000 Shaft protector Start reduction gear ACG flywheel puller Starting clutch inspection Assemble the start driven gear onto the starting clutch.
  • Page 105 5. AC Generator / Starting Clutch ACG flywheel / starting clutch assembly Install ACG flywheel, starting clutch, and starting gear. Tighten ACG flywheel. (bolt×1)。 Torque value: 8.5~10.5kgf-m Install start reduction gear A / B and shafts.. Install dowel pin and new gasket. bolt×11 Install left crankcase cover.
  • Page 106 5. AC Generator / Starting Clutch NOTE:...

  • Page 107: Engine Removal

    6. Engine Removal Precautions in Operation ···········6-1 Engine Installation ······················6-7 Engine Removal ··························6-2 Precautions in operation General information During the maintenance of a removed engine, you need to use an adjustable rack or cart to ● support the engine. The following parts can be repaired with the engine installed on the frame: ●...
  • Page 108 6. Engine Removal Engine removal Drain all engine oil. Engine oil drain bolt Drain all coolant. Coolant drain bolt Disconnect CPS and ACG couplers. CPS coupler ACG coupler Disconnect starter motor coupler. Starter motor coupler...
  • Page 109 6. Engine Removal Loosen clutch cable lock nut and adjusting nut, remove clutch cable. Clutch cable Loosen throttle wire lock nut, remove throttle Map sensor cable. Disconnect MAP sensor and ISC couplers. Throttle wire lock nut Loosen coolant hose band, remove coolant hose.
  • Page 110 6. Engine Removal AISV tube Disconnect ignition coil coupler and AISV tube. Ignition coil Disconnect fuel hose. Fuel hose Disconnect injector and TPS couplers. Remove injector. (lock nutX2) Injector Lock nut Loosen rear wheel axle lock nut. Rear wheel lock nut Loosen drive chain adjusting nut and push the rear wheel forward.
  • Page 111 6. Engine Removal Disconnect O2 sensor coupler. O2 sensor coupler Remove exhaust pipe front lock nut. (nut×2)。 nut×2 Remove the exhaust pipe center bolt. bolt×1 bolt×1 Remove the exhaust pipe rear bolt. Remove the exhaust pipe.
  • Page 112 6. Engine Removal Settle the engine on a rack. Remove engine front hanger. (nut×4, bolt×4) nut×4 Remove engine rear holding bolts. (nut×2, bolt×2)。 Remove the engine. nut×2...
  • Page 113 6. Engine Removal Engine installation Install the engine in the reverse order of removal. Caution When assembling, always pay attention  to possible injuries. Wires, cables, tubes, and hoses cannot  be bent or pressed. Please align the wires and cables in ...
  • Page 114 6. Engine Removal NOTE:...

  • Page 115: Cylinder Head / Valve

    7. Cylinder Head / Valve Mechanism Diagram ···················7-1 Valve Guide Replacement ··········7-10 Precautions in Operation ···········7-2 Valve Seat Inspection & Refacing ······················································7-11 Troubleshooting··························7-3 Cylinder Head Assembly ············7-13 Cylinder Head Removal ··············7-4 Cylinder Head Installation ··········7-14 Cylinder Head Disassembly ·······7-6 Valve Clearance Adjustment ······7-16 Cylinder Head Inspection ···········7-8 Mechanism diagram 0.8~1.2kgf-m...

  • Page 116: Precautions In Operation

    Cam chain sprocket bolt 1.0~1.4kgf-m on threads and seats) Spark plug 1.0~1.2kgf-m Special tools Valve Guide reamer 5.0mm Valve Spring Assemble/Disassemble Tool Valve Guide driver 5.0mm SYM-1471110/20 Rocker arm shaft/ Camshaft Disassemble tool Valve Clearance Adjustment Wrench SYM-1445100 SYM-9001200 Valve Spring Compressor SYM-1471100...

  • Page 117: Troubleshooting

    7. Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on cylinder-head perimeter parts. The trouble usually can be determined by performing cylinder compression test or judging the abnormal noise. Poor idling The compression pressure is too low. Low compression pressure 1.

  • Page 118: Cylinder Head Removal

    7. Cylinder Head / Valve Cylinder head removal Remove engine. (Refer to chapter 6) Remove auto-tensioner adjusting bolt. Remove auto-tensioner. (bolt×2)。 boltX2 Remove thermostat. (bolt×2)。 boltX2 Remove AI pipe. (bolt×4)。 Remove spark plug. bolt×4 Remove cylinder head cover. (bolt×4)。 bolt×4...
  • Page 119 7. Cylinder Head / Valve Remove cylinder head side cover. (bolt×3)。 bolt×3 Remove timing-inspecting hole cap. Remove ACG cap, turn ACG flywheel counterclockwise, align “T” mark with the mark Timing marks on L crankcase; align the timing marks on cam gear and cylinder head.
  • Page 120 (bolt×1) Use Rocker arm / camshaft puller to pull out the rocker arm shafts. Rocker arm shaft Special tool: Rocker arm / camshaft puller SYM-1445100 Use Rocker arm / camshaft puller to pull out the camshaft. camshaft Special tool: Rocker arm / camshaft puller SYM-1445100 Use Valve removal / assembly tool to compress the spring, remove the valve cotter.
  • Page 121 7. Cylinder Head / Valve Remove cotters, springs, and the spring Spring retainer Intake valve Inner valve retainers. Outer spring Cotter Exhaust valve Remove valve guide oil seals. Oil seal Clean up carbon deposit in combustion chamber. Clean up cylinder head matching surface. Caution Do not damage cylinder head matching ●...

  • Page 122: Cylinder Head Inspection

    7. Cylinder Head / Valve Cylinder head inspection Cylinder head surface / hole Check if spark plug hole and valve hole cracked or damaged. Measure the cylinder head surface for warpage. Service limit: 0.05mm Camshaft Measure the camshaft. Service limit: Intake: 34.860mm Exhaust: 34.725mm Check if the camshaft bearing loosened or...
  • Page 123 7. Cylinder Head / Valve Valve spring Measure the free length of intake and exhaust valve springs. Service limit: Inner valve spring: 35.20mm Outer valve spring: 36.90mm Valve stem Check if valve stem bent, burnt, or worn. Check the operation condition of valve stem in valve guide, and measure the valve stem outer diameter.

  • Page 124: Valve Guide Replacement

    7. Cylinder Head / Valve Valve guide replacement Heat cylinder head with heating plate or Valve guide driver 5mm toaster till the temperature reaches 100~150 ℃. Caution Do not use flame to heat cylinder head ● directly. Otherwise, cylinder head will be deformed.

  • Page 125: Valve Seat Inspection & Refacing

    7. Cylinder Head / Valve Valve seat inspection and refacing Clean up all carbon deposits around intake and exhaust valves. Apply emery slightly onto valve contact surface. Grind valve seat with grinding tool. Caution Prevent emery from getting into valve stem ●...
  • Page 126 7. Cylinder Head / Valve Use the 60 degree cutter to remove the bottom 1/4 part of the seat and check the new valve seat. Old valve seat width 60° Use the 45 degree cutter to cut the seat to the proper width.

  • Page 127: Cylinder Head Assembly

    Install valve by valve spring assemble / disassemble tool. valve spring assemble / disassemble tool Special Tool: Valve Spring Assemble/Disassemble Tool SYM-1471110 Caution When installing springs, place cloth in ● combustion chamber to hold the valves avoiding bending the valve.

  • Page 128: Cylinder Head Installation

    7. Cylinder Head / Valve Install camshaft into cylinder head. Install valve rocker arm, rocker arm shaft and rocker bolt×1 Holding arm shaft holding plate. plate Cylinder head installation Clean up foreign materials on the matching surfaces of cylinder and cylinder head. Install cam chain guide.
  • Page 129 7. Cylinder Head / Valve bolt×3 Install cylinder head side cover. (bolt×3)。 Install thermostat. (bolt×2)。 Loosen cam chain auto-tensioner adjusting boltX2 bolt, remove the spring. Adjusting Install auto-tensioner (bolt×2), then install the bolt spring and adjusting bolt. Install cylinder head cover. (bolt×4) bolt×4 Install AI pipe (bolt×4) Install spark plug.

  • Page 130: Valve Clearance Adjustment

    7. Cylinder Head / Valve Valve clearance adjustment bolt×4 Remove AI pipe. (bolt×4)。 Remove cylinder head cover. (bolt×4)。 bolt×4 bolt×3 Remove cylinder head side cover. (bolt×3)。 Remove timing-inspecting hole cap. Remove ACG cap, rotate the crankshaft counterclockwise and align the “T” mark on the flywheel with the index mark on the left crankcase cover.

  • Page 131: Cylinder / Piston

    8. Cylinder / Piston Mechanism Diagram ···················8-1 Piston Removal / Inspection ······8-5 Precautions in Operation ···········8-2 Piston Rings Installation ············8-8 Troubleshooting··························8-2 Piston Installation ·······················8-9 Cylinder Removal / Inspection ···8-3 Cylinder Installation ····················8-10 Mechanism diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m...

  • Page 132: Precautions In Operation

    8. Cylinder / Piston Precautions in operation General information The engine must be removed from the frame before repairing cylinder and piston.  Specification Measurement: mm Item Standard Service limit Inside Diameter 70.995~71.015 71.100 － Warpage 0.050 Cylinder － Taper 0.050 －...

  • Page 133: Cylinder Removal / Inspection

    8. Cylinder / Piston Cylinder removal / inspection Dowel pin Remove the cylinder head. (refer to chapter 7) Remove cylinder head gasket and dowel pins. Remove cam chain guide. Cam chain guide Remove cylinder. Caution Prevent cam chain from falling into ...
  • Page 134 8. Cylinder / Piston Cylinder inspection Check if the inner diameter of cylinder is worn Exhaust side Inlet side out or damaged. Measure the cylinder inner diameter in X and Y axis at three levels. Service limit: 71.10 mm Calculate the taper and out of round at three Center levels in X and Y axis.

  • Page 135: Piston Removal / Inspection

    8. Cylinder / Piston Piston removal / inspection Block the crankcase and camshaft chain hole with a clean cloth to prevent the piston pin clip from falling into the crankcase. Piston pin Remove the piston pin circlip and remove the piston pin and piston.
  • Page 136 8. Cylinder / Piston Install piston rings respectively into cylinder 20 Piston ring mm below cylinder top. Measure the piston ring end gap. Caution Use the piston head to push the piston  rings squarely into the cylinder. Thickness gauge Service limit：...
  • Page 137 8. Cylinder / Piston Measure the outer diameter of piston pin. Caution Measure the piston outer diameter in the  direction perpendicular to the piston pin axis. Service limit: 70.38 mm Compare the measured value with service limit to calculate the clearance between the piston and cylinder.

  • Page 138: Piston Rings Installation

    8. Cylinder / Piston Piston rings installation Clean up the piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston rings as diagram shown below. Caution Do not damage the piston and piston rings as installation. ...

  • Page 139: Piston Installation

    8. Cylinder / Piston Piston installation Place a piece of clean rag under the piston. Clean all the gasket material from the contact surface. Caution Use solvent to wet the gasket material in  order to remove it more easily. IN mark Install piston and piston pin and make the IN mark facing the inlet side.

  • Page 140: Cylinder Installation

    8. Cylinder / Piston Cylinder installation Install dowel pins and new cylinder gasket. Dowel pin Apply clean engine oil to the cylinder bore, piston and piston rings. Install the cylinder carefully. Press the piston rings respectively when installing. Caution Do not force the piston into the cylinder ...
  • Page 141 9. Crank / Crankcase / Shifting gear Mechanism Diagram ··························· 9-1 Transmission Disassembly··············· 9-8 Precautions in Operation···················· 9-3 Transmission Inspection··················· 9-9 Troubleshooting ·································· 9-4 Crankcase Inspection························ 9-10 Crankcase Disassembly ····················· 9-5 Crankcase Assembly························· 9-11 Crankshaft Inspection························· 9-7 Mechanism diagram Crankcase / crankshaft 1.0~1.4kgf-m 0.8~1.2kgf-m 3.5~4.5kgf-m...
  • Page 142 9. Crank / Crankcase / Shifting gear Transmission Gear shift cam Shift fork shaft Right gear shift fork 0.8~1.2kgf-m ar shift spindle com Left gear shift fork Central gear shift fork Shift drum Shift stopper comp drum Six-speed gear Counter shaft 1.0~1.4kgf-m 1 gear 6 gear...

  • Page 143: Precautions In Operation

    Crankcase bolt 0.8~1.2kgf-m Cylinder / cylinder head bolt 1.0~1.4kgf-m Engine oil drain bolt 3.5~4.5kgf-m Oil strainer cover 1.0~2.0kgf-m Gear switch bolt 0.7~1.1kgf-m Special tools Inner bearing puller SYM-6204025 Bearing driver 6204 SYM-6204024 Bearing driver 6301 SYM-6204024 Bearing driver 6203/6004 SYM-6204024...

  • Page 144: Troubleshooting

    9. Crank / Crankcase / Shifting gear Troubleshooting Excessive engine noise Worn conrod big end  Worn crankshaft bearing  Worn piston pin or piston pin hole  Hard to shift gear Bent shift fork  Bent shift fork shaft ...

  • Page 145: Crankcase Disassembly

    9. Crank / Crankcase / Shifting gear Crankcase disassembly bolt×2 Remove the 6mm bolt from right crankcase. (boltX2) Remove the cam chain tensioner arm from right crankcase. (bolt×1) Remove cam chain. bolt×1 Lock nut Balancing shaft gear Remove balancing shaft lock nut and fix circlip from left crankcase.
  • Page 146 9. Crank / Crankcase / Shifting gear Remove the 6mm bolt from left crankcase. bolt×11 (boltX11) Balancing shaft Remove the left crankcase from the right crankcase. Remove balancing shaft. Crankshaft Shake the crankshaft gently and pull out the crankshaft.

  • Page 147: Crankshaft Inspection

    9. Crank / Crankcase / Shifting gear Crankshaft inspection Use a feeler gauge to measure left and right clearance of conrod big end. Service limit: replace if over 0.6mm Place the crankshaft on a V-block, measure the clearance of the big end at the vertical direction.

  • Page 148: Transmission Disassembly

    9. Crank / Crankcase / Shifting gear Transmission disassembly Shift fork shaft Remove the gear shift fork shaft. Left Central Right Remove shift drum, then remove left, central, and right shift fork. Left Central Right Remove the transmission mechanism. Disassemble the gears and washers on the main shaft and counter shaft, and arrange them in order.

  • Page 149: Transmission Inspection

    9. Crank / Crankcase / Shifting gear Transmission inspection Check if the gear shift fork worn, bent or damaged. Measure the inner diameter of the gear shift fork. Service limit: 12.05mm Measure the thickness of the gear shift fork claws. Service limit: 4.7mm Measure the outer diameter of the gear shift fork shaft.

  • Page 150: Crankcase Inspection

    Crankcase bearing removal Remove the damaged bearing by using the inner bearing puller. Special tool: Inner bearing puller SYM-6204025 Crankcase bearing installation Install new bearings onto the crankcase by using bearing driver. Special tools: Bearing driver 6204...

  • Page 151: Crankcase Assembly

    9. Crank / Crankcase / Shifting gear Crankcase assembly Remove the crankcase gasket and dowel pins. Clean the gasket residues off the crankcase contact surface. Caution Do not damage the contact surface of the  crankcase. Use solvent to wet the gasket material in ...
  • Page 152 9. Crank / Crankcase / Shifting gear Install shift forks (left, right) on counter shaft, and install the shift fork pin into shifting drum groove. Install shift fork (center) on main shaft, and install Guide shaft the shift fork pin into shifting drum groove. Align the holes of shift forks, then insert gear fork guide shaft.
  • Page 153 9. Crank / Crankcase / Shifting gear Install balancing shaft drive gear, and align mark woodruff key and the mark on the gear. Tighten balancing shaft drive gear bolts. Torque value: 0.8~1.2kgf-m Caution Make sure aligning woodruff key and the ...
  • Page 154 9. Crank / Crankcase / Shifting gear NOTE: 9-14...
  • Page 155 10. Cooling System Mechanism Diagram ··············· 10-1 Coolant Change ······················· 10-5 Precautions in Operation········ 10-2 Radiator ···································· 10-6 Troubleshooting ······················ 10-2 Water Pump······························ 10-8 Diagnosis of Cooling System· 10-3 Thermostat ······························· 10-12 Mechanism diagram Radiator filler cap Engine coolant outlet pipe Cooling fan Reserve tank...

  • Page 156: 10. Cooling System

    Boiling point Pressurized: 125.6ºC Torque Value Water pump rotor 1.0~1.4kgf-m Special tools Water pump bearing driver (6901) SYM-9100100 Water pump oil seal driver (Inner) SYM-9120500-H9A SYM-1721700-H9A Water pump mechanical seal driver SYM-6204020 Inner bearing puller Troubleshooting Engine temperature too high Engine temperature too low TW sensor malfunction.

  • Page 157: Diagnosis Of Cooling System

    10. Cooling System Diagnosis of cooling system The water temperature signal flashes A. Stop and waiting for A-1. Refill the radiator with the engine is completely Water leaking coolant and check for any cooled down, open cap problem leakage? to check the capacity of coolant in radiator.
  • Page 158 10. Cooling System Preceding page E. Keep eng. 3000~4000 rpm and inspect cooling fan operating. E-2. Connect cooling fan E-1. Confirm the rotating terminals with battery (12V) Replace cooling fan direction of cooling fan. directly to inspect its operation Meter unusual E-3.

  • Page 159: Coolant Change

    Shut down engine, refill coolant if necessary. ● Caution To avoid the water tank rusting, please do ● not use an unknown trademark refrigerant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% Reserve tank check Remove left-front body cover. ●...

  • Page 160: Radiator

    10. Cooling System Radiator Removal / Check Remove radiator air duct. (boltX3) Check for any leakage from weld seam. Blow radiator with compressed air. If the radiator is blocked by dirt, use low pressure bolt×3 water jet to clean it. Care shall be taken when straightening the sink fan.
  • Page 161 10. Cooling System Disconnect the fan motor coupler. coolant inlet pipe Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Remove the radiator and the cooling fan. fan motor coupler bolt×3 Disassembly Remove the cooling fan mounting bolt and the fan.
  • Page 162 10. Cooling System Water pump Water pump seal / cooling system leakage inspection Remove drain bolt to drain some coolant to ● check if there is greasiness in it. Remove engine oil gauge rule to check if ● the oil is emulsified. If the two phenomena appear, oil seals of water pump, cooling system, cylinder head, or cylinder gasket could be damaged.
  • Page 163 Replacement of Mechanical Seal Remove the inside bearing from inner side of right crankcase by inner bearing puller. Drive the seal by bearing driver. Special tool Bearing driver(6901) SYM-9100100 Caution Replace with a new mechanical seal after ● removing it.
  • Page 164 Water pump oil seal driver (inner) SYM-9120500-H9A Bearing driver Install a new outside bearing to the right crankcase cover. Special tool Bearing driver (6901) SYM-9100100 Caution Do not reuse old bearing. It must be ● replaced with a new one once it has been removed.
  • Page 165 10. Cooling System Rotor installation Install the seal washer onto the water pump shaft. Caution Washer must be replaced together with ● the mechanical seal. Rotor Install the rotor onto the water pump shaft. Torque Value:1.0~1.4kgf-m Caution The rotor is left thread. ●...
  • Page 166 10. Cooling System Thermostat Removal Remove thermostat cover. (boltX2) bolt×2 Remove thermostat Inspection thermostat Check if thermostat damaged. Place the thermostat into heated water to check its operation. Caution If the thermostat or thermometer contact ● with the container, the value displayed will be incorrect.
  • Page 167 10. Cooling System Installation Install the thermostat. Install the thermostat cover. (bolt×2) TW sensor Install hose, refill coolant and bleed out air bubble. bolt×2 10-13...
  • Page 168 10. Cooling System NOTE: 10-14...

  • Page 169: 11. Brake System

    11. Brake System Mechanism Diagram - Front Disk Brake Brake Fluid Replacement / Air Bleed ·························································11-1 ························································11-6 Mechanism Diagram - Rear Disk Brake Front Brake Caliper ······················11-7 ·························································11-2 Rear Brake Caliper ·······················11-8 Precautions in Operation ··············11-3 Brake Disk ·····································11-9 Troubleshooting·····························11-4 Brake Master Cylinder··················11-10 Disk Brake System Inspection······11-5 Mechanism diagram –...

  • Page 170: Mechanism Diagram - Rear Disk Brake

    11. Brake System Mechanism diagram – rear disk brake 1.5~2.5kgf-m 0.8~1.2kgf-m 2.4~3.0kgf-m 2.4~3.0kgf-m 11-2...

  • Page 171: Precautions In Operation

    Bake pad thickness Mark on brake pad ─ Torque value Special tool Brake hose bolt 3.0~4.0kgf-m Inner bearing puller SYM-6204020 Front brake caliper bolt 3.5~4.5kgf-m Brake disk bolt 3.7~4.3kgf-m Air bleed valve 0.8~1.0kgf-m Front wheel axle nut 6.0~8.0kgf-m R ear wheel axle nut 10.0~12.0kgf-m...

  • Page 172: Troubleshooting

    11. Brake System Troubleshooting Disk brake Soft brake lever Uneven brake Air inside the hydraulic system Dirty brake pad / disk Hydraulic system leakage Poor wheel alignment Worn master cylinder piston Blocked brake hose Poor brake caliper Warped / bent brake disk Worn brake pad Blocked brake hose / joint Low brake fluid...

  • Page 173: Disk Brake System Inspection

    11. Brake System Disk brake system inspection Brake hose joint Inspection Visually examine for leakage or damage. Inspect the brake hose joint for looseness. Turn the handle bar to right and left; press the cushion to see if there is any interference with the brake system.

  • Page 174: Brake Fluid Replacement / Air Bleed

    11. Brake System Remove the reservoir cap and diaphragm. Fill the clean brake fluid. Reservoir cap Clean the dirty brake disk. Diaphragm Caution Contaminated brake disk or pad  Fluid level upper limit decreases braking performance. Foreign material will clog brake system ...

  • Page 175: Front Brake Caliper

    11. Brake System Front brake caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt, drain brake fluid. bolt×2 Caution Do not spill brake fluid on painted  surfaces. Remove caliper bolts, (bolt×2) remove the caliper.

  • Page 176: Rear Brake Caliper

    11. Brake System guide bolt Rear brake caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt, drain brake fluid. Caution Do not spill brake fluid on painted  surfaces. Remove caliper bolts, (bolt×2) remove the caliper.

  • Page 177: Brake Disk

    11. Brake System Brake disk Brake disk Inspection Visually check if the brake disk worn or damaged. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Micrometer Remove the brake disk from wheel. Check if the disk for deformed or bent.

  • Page 178: Brake Master Cylinder

    11. Brake System Brake master cylinder Removal Caution Do not let foreign materials entering the  cylinder. Remove back mirror. bolt×2 Disconnect brake light coupler. Drain brake fluid. Remove the brake lever from brake master cylinder. Remove brake hose. Remove brake master cylinder from handlebar. (bolt×2)。 Clean the master cylinder with recommended brake fluid.

  • Page 179: 12. Steering / Front Wheel / Front Fork

    12. Steering / Front wheel / Front fork Mechanism Diagram ················· 12-1 Front Wheel ······························· 12-6 Precautions in Operation ········· 12-2 Front Fork ·································· 12-9 Troubleshooting························ 12-3 Steering Stem ···························· 12-12 Steering Handlebar ··················· 12-4 Mechanism diagram 6.0~8.0kgf-m 1.0~1.4kgf-m 3.0~3.5kgf-m 0.15~0.25kgf-m 3.0~3.5kgf-m 6.0~8.0kgf-m...

  • Page 180: Precautions In Operation

    Steering stem locknut 6.0~8.0kgf-m Front brake caliper bolt 3.5~4.5kgf-m F ront fork bolt 3.0~3.5kgf-m Special tool Cone race puller Steel ball race driver 32×35mm Steel ball race driver 42×47mm Inner bearing puller SYM-6204020 Steering stem locknut socket wrench SYM-5320000, SYM-5320010 12-2...

  • Page 181: Troubleshooting

    12. Steering / Front wheel / Front fork Troubleshooting Steering mechanism / front fork Hard steering Soft suspension Steering stem nut too tight Worn fork spring   Worn or damaged steering ball bearing / Fork seal leakage   seat Hard suspension Insufficient tire pressure...

  • Page 182: Steering Handlebar

    12. Steering / Front wheel / Front fork Steering handlebar throttle cable locknut Removal Loosen the throttle cable locknut. Remove the right handle switch screws. (screw×2)。 screw×2 Remove the throttle cable. Remove the Throttle cable throttle grip and right handle switch. Remove the front brake master cylinder.
  • Page 183 12. Steering / Front wheel / Front fork Remove the left handle switch. (screw x2) screw×2 Loosen the clutch cable locknut and adjusting locknut nut. Adjusting nut Remove the clutch lever pivot bolt. Remove the clutch lever and clutch cable. Remove the clutch lever socket.

  • Page 184: Front Wheel

    12. Steering / Front wheel / Front fork Front wheel axle locknut Removal Use a bracket to hold the bottom of engine and let the front wheel away from the ground. Remove the front wheel axle locknut. Pull out the front wheel axle. Remove the front wheel and side collar.
  • Page 185 Remove the distance collar. Pull out the right side bearing and oil seal by using the inner bearing puller. Special tool Inner bearing puller SYM-6204020 Assembly Install in the reverse order of removal. Bearing will be damaged Apply grease to the wheel hub / bearing in these two examples of assembly.
  • Page 186 12. Steering / Front wheel / Front fork Installation Oil seal Apply grease to the inner and outer side of oil seal and install oil seal into the wheel hub. bolt×5 Install brake disk. (bolt×5)。 Torque value: 1.4~1.6kgf-m Install side collar. Caution Contaminated brake pad will decrease ...

  • Page 187: Front Fork

    12. Steering / Front wheel / Front fork Front fork Disassembly Speed sensor Remove the front wheel, speed sensor and front brake caliper. 3 bolts for both sides Remove the front fender. (bolt×6)。 Loosen the front fork bolt on the top bridge. (bolt×2)。...
  • Page 188 12. Steering / Front wheel / Front fork Front fork inspection / oil seal replacement Push the fork pipe for several times to check if scratch there is any oil leakage or excessive noise. Check if there is any scratch on the fork pipe if oil leakage happens.
  • Page 189 12. Steering / Front wheel / Front fork Installation Fork pipe cap Caution  The installing will be easier by rotating the fork pipe. Install the fork pipe from the bottom of the front fork. Align the fork pipe cap with the top bridge.

  • Page 190: Steering Stem

    Remove the steering stem locknut and steering upper cone race by using stem locknut socket wrench. Top bridge locknut Special tool: Stem locknut socket wrench SYM-5320000 Remove the steering stem. Caution  Keep the steering steel balls in a container to avoid missing them.
  • Page 191 Turn the upper cone race counterclockwise 1/2 circle and then tighten it with specific torque value. (1/4~3/8 circle) Special tool: Clockwise Stem locknut socket wrench SYM-5320000 1/4~3/8 Top bridge locknut socket SYM-5320010 Steering Torque value: 0.15~0.25kgf-m...
  • Page 192 12. Steering / Front wheel / Front fork NOTE: 12-14...

  • Page 193: 13. Rear Wheel / Rear Cushion

    13. Rear wheel / Rear cushion Mechanism Diagram ······················13-1 Drive Chain / Sprocket / Flange ··13-6 Precautions in Operation ··············13-2 Rear Cushion ································13-9 Troubleshooting·····························13-2 Swingarm ······································13-10 Rear Wheel ·····································13-3 Mechanism diagram 3.5~4.5kgf-m 3.5~4.5kgf-m 10.0~12.0kgf-m 10.0~12.0kgf-m 13-1...

  • Page 194: Precautions In Operation

    Rear cushion upper bolt 3.5~4.5kgf-m Rear cushion lower bolt 3.5~4.5kgf-m Special tool Inner bearing puller SYM-6204020 Stem locknut socket wrench SYM-5320000 Rubber bush puller / driver SYM-1120310 Troubleshooting Rear wheel wobbling Rear suspension noise Bent rim Incorrect cushion nut tightening  ...

  • Page 195: Rear Wheel

    13. Rear wheel / Rear cushion Rear wheel Removal Remove the rear brake caliper. (boltX2) boltX2 Loosen the drive chain adjusting nuts on both sides. adjusting nut Remove the rear axle locknut. After removing rear axle, remove the rear wheel, right / left side collar, chain adjuster, and brake nut×1 disk.
  • Page 196 13. Rear wheel / Rear cushion Inspection Wheel axle Put the axle on a V-block and measure the run out. Service limit: 0.2 mm Bearing Rotate the bearings to check if the bearings rotate smoothly and silently. clearance Check if the outer ring of the bearing fixes firmly on the wheel hub.
  • Page 197 13. Rear wheel / Rear cushion Rear wheel installation Install in the reverse order of removal. Adjust drive chain slack. (refer to ch 2) Tighten rear wheel washer nut. Adjusting nut Tighten axle locknut. (nut×1、PIN×1) Torque value: 10.0~12.0kgf-m locknut×1 Install the caliper. 13-5...

  • Page 198: Drive Chain / Sprocket / Flange

    13. Rear wheel / Rear cushion Drive chain / sprocket / flange Drive chain / sprocket removal Remove the left crankcase rear cover. (bolt×2) bolt×2 Remove the drive sprocket bolts (bolt×2), sprocket fixing plate, and drive sprocket. bolt×2 Remove the drive chain cover. (boltX2)。 bolt×2 Remove the drive chain fixing clip and drive chain.
  • Page 199 13. Rear wheel / Rear cushion Drive chain / sprocket inspection Sprocket Check the condition of sprocket teeth. Replace the sprocket if the teeth are worn out. Caution  Sprocket and drive chain condition should be checked at the same time. Drive chain Clean and check the drive chain links condition.
  • Page 200 13. Rear wheel / Rear cushion Damper rubber inspection Damper rubber×4 Check if the damper rubbers worn or damaged, replace if necessary. Drive chain adjustment Turn the left and the right side adjusting nut evenly to make the chain slack within the standard range. Fixing nut Turn the nuts clockwise to tighten the chain, or counterclockwise to loosen the chain.

  • Page 201: Rear Cushion

    The rear cushion should be replaced as a  complete set. Do not disassemble it, or the structure and rubber bush will be damaged. Press the rear cushion to check if the rear cushions move freely. Special tool: Steering stem locknut socket wrench SYM-5320000 13-9...

  • Page 202: Swingarm

    13. Rear wheel / Rear cushion Swingarm Removal Remove rear wheel, drive chain, sprocket, and rear cushion lower bolt. bolt×1 Remove the swingarm pivot locknut. (nut×1)。 nut×1 Pull out the swingarm pivot bolt. pivot bolt Remove the swingarm pivot sleeve and dust seal.
  • Page 203 13. Rear wheel / Rear cushion Check if swingarm collars, sleeves and dust seals cracked or worn. collar Sleeve Dust seal Installation Install in the reverse order of removal. Torque value: swingarm pivot locknut 10.0~12.0kgf-m Caution The rear cushion should be replaced as a ...
  • Page 204 13. Rear wheel / Rear cushion NOTE: 13-12...
  • Page 205 14. Electrical system Mechanism Diagram ......14-1 Starting System ........14-13 Light system........... 14-15 Precautions in Operation ...... 14-2 Technical Specification ......14-3 Meter ............14-16 Troubleshooting........14-4 Light / Bulb ..........14-17 Fuse............14-5 Switch / Horn.......... 14-22 Charging System ........14-6 Fuel Unit ..........

  • Page 206: Precautions In Operation

    14. Electrical system Precautions in operation Charging system When removing battery, first disconnect the negative cable terminal, then the positive cable terminal.  The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.  When charging, the battery has to be removed from the vehicle, but do not remove the sealing cap. ...

  • Page 207: Technical Specification

    14. Electrical system Techinical specification Charging system Item Specification 12V 10Ah Capacity / Model GT12A-BS Standard:1.2A / 5~10hr Battery Charging rate Rapid:5A / 1hr Fully charged 13.0~13.2V voltage(20ºC) Need to be charged 12.6V Output 14.5~28A Charging circuit resistance (20ºС) 0.42Ω±20% (Y/Y) Leaking current Under 10mA Start charging R.P.M.

  • Page 208: Troubleshooting

    14. Electrical system Troubleshooting Charging system Ignition system No power supply No spark Disconnected battery cable Poor spark plug   Battery over discharging The cable is poorly connected, open or   The fuse is blown short-circuited  Improper operation of the main switch - Between ACG and ECU ...

  • Page 209: Fuse

    14. Electrical system Fuse Fuse circuit O2 sensor Engine-off relay Fuel pump relay Ignition coil Diagnostic tool coupler AISV Main switch Others Reg. Rec. Light Battery 14-5...

  • Page 210: Charging System

    14. Electrical system Charging system Battery removal Remove the rear seat. 注意 Electrolyte (diluted sulfuric acid) is very  toxic. Once it spread on clothes, skin, or eyes, it will cause burn. In case of being spread, flush with great quantity of water immediately, and then send to hospital.
  • Page 211 14. Electrical system Voltage inspection Measure the battery voltage by using a digital multimeter. Voltage Fully charged: 14.0~15.0V (20°C) Insufficiently charged: 12.3V (20°C) Charging Remove the battery cell caps. Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal.
  • Page 212 14. Electrical system Inspection on Charging Voltage / Current Connect a tachometer. Turn on the headlight to high beam and start the Voltmeter engine. Ammeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Charging Current: 0.6A / 2100rpm (headlight off) 1.2A / 6000rpm 14.5±0.5V/2100rpm...
  • Page 213 14. Electrical system Charging circuit Reg. Rec. Fuse 15A Fuse 10A Fuse 20A Main Starter relay switch Starter motor Battery Regulator/ rectifier inspection (KΩ) ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞...
  • Page 214 14. Electrical system Wire coupler AC Generator Remove wire strap right-up side cover. Disconnect the ACG coupler 3P coupler. Disconnect the regulator rectifier 6 pin coupler and inspect the wire circuit. Item Wire color Judgment Main switch Battery voltage (ON) R─...
  • Page 215 14. Electrical system Ignition coil Ignition coil Removal Remove side cover and seat. Remove spark plug cap. Remove ignition coil wire. Remove bolts and ignition coil. Install in the reverse order of removal. boltX2 Spark plug confirmation Remove the spark plug and install a good plug into plug cap, and then ground it to engine ground.

  • Page 216: 14. Electrical System

    14. Electrical system Ignition circuit O2 sensor TW sensor MAP sensor TA sensor Ignition coil Spark plug Ignition coil inspection Remove ignition coil connector. Measure the resistance of ignition coil. Standard value: Primary: 2.8Ω±15% Without plug cap Secondary: : 9.0KΩ±20% With plug cap: 14 .0KΩ±20% CP Sensor inspection...

  • Page 217: Starting System

    14. Electrical system Starting system Starting circuit diagram R / Y EFi system actuators Side stand Eng. Stop Relay light Side stand Switch PU/R Side stand Main Eng. Stop Switch Switch Switch Relay Silicon LG/R Controlled Fuse Rectifier Fuse 15A Neutral Light Starter Silicon Controlled Rectifier...
  • Page 218 14. Electrical system Starter motor removal nut×1 Remove the starter motor wire. (nut×1) Remove the starter motor. (bolt×2) bolt×2 Starter motor inspection Connect the battery positive terminal and starter motor power terminal. Put up iron between the battery negative terminal and starter motor case. Check the starter motor rotating condition.

  • Page 219: Light System

    14. Electrical system Light system Light circuit Brake light switch Tail light / brake light Position light High beam indicator Light switch Meter light High / low / passing beam switch Headlight Main switch Tuurn light relay Right turn light indicator Turn light switch Right turn light...

  • Page 220: Meter

    14. Electrical system Meter bolt×2 Removal Remove the headlight / meter (bolt x2). Disconnect the headlight / meter coupler. Meter coupler Headlight coupler Remove the headlight locknuts. (nut×4) nut×4 Remove the meter locknuts. (nut×3) nut×3 Remove the meter. Installation Install in the reverse order of removal. 14-16...

  • Page 221: Light / Bulb

    14. Electrical system Light / Bulb Headlight coupler Headlight bulb replacement Remove the headlight / meter. (boltX2) Disconnect the headlight coupler. Headlight wire×1 Rubber protector Remove the rubber protector. Push down the bulb fixing spring and remove the bulb. Replace with a new bulb if necessary (12V 55W/60W)。...
  • Page 222 14. Electrical system Front turn light bulb replacement Remove the front turn light lens screw. (screw×1) screw×1 Remove the front turn light bulb socket screws. screw×2 Replace the bulb. (12V 10W) Replace turn light socket if necessary. Caution Make sure turn light lens, case, and ...
  • Page 223 14. Electrical system Rear turn light bulb replacement Remove the rear turn light lens (screw x1). Caution Do not damage the lens when removing.  screw×1 Rotate the turn light bulb socket counterclockwise and pull it out from the lens. Replace the bulb.
  • Page 224 14. Electrical system Remove the front / rear seat and right / left body cover. bolt×1 Remove the rear carrier bolts (boltX4) and rear body cover upper bolt. (boltX1) bolt×4 Remove the rear body cover bolts. (4 bolts for 4 bolts for both sides both sides) Remove the rear body cover lower bolts and boltX4...
  • Page 225 14. Electrical system Disconnect the taillight / brake light coupler. Taillight / brake light coupler Remove the rear fender fixing screws. (screwX4)。 screwX4 Remove the taillight screw. screwX1 Remove the taillight assembly. Replace the taillight as an assembly if the led is burned out.

  • Page 226: Switch / Horn

    14. Electrical system Switch / horn Main switch Inspection Remove the headlight. (bolt×2) Disconnect the main switch coupler. Check the continuity between two points as Main switch coupler indicted below BAT1 BAT2 position LOCK color Replacement Remove the headlight assembly (bolt ×2). Disconnect the main switch coupler.
  • Page 227 14. Electrical system Right handle switch Remove the right handlebar switch coupler. Engine stop switch Check the following switch circuit. Headlight switch position ● Start switch Headlight switch color Cable locknut Start switch position FREE color screw×2 Engine stop switch position color Removal...
  • Page 228 14. Electrical system Left handle switch Pass switch Dimmer Disconnect the left handle switch wire coupler. switch Check the following coupler circuit. Dimmer switch Turn light switch position PASS Horn switch color Turn light switch position color Horn switch position screw×2 FREE color...
  • Page 229 14. Electrical system Brake light switch While pulling the brake lever or stepping the rear brake pedal, the terminals of black and green/yellow of the brake should have continuity. Replace the switch if damaged. Front brake switch Rear brake switch Horn Disconnect the horn coupler and remove the horn.

  • Page 230: Fuel Unit

    十三、電器裝置 Fuel unit Remove the fuel tank. (Please refer to ch.3) bolt×4 Disconnect the fuel unit wire coupler. Remove the fuel unit. (bolt×4) 注意 Do not bend or damage the float arm.  Connect the fuel unit coupler to the wire harness.

  • Page 231: Emission Control System

    15. Emission Control Emission Control Syetem Mechanism····· 15-1 Positive crankcase ventalition system (P.C.V.) ·····································································15-4 Function of mechanism in the emission control system ························································· 15-1 Air injection solenoid valve (AISV)···········15-5 Fuel Evaporative Emission Control system Ignition system···········································15-6 (E.E.C.) ························································ 15-2 Inspection Items·········································15-7 E.E.C.
  • Page 232 15. Emission Control Fuel evaporative emission control system (E.E.C.) 1. Construction: 1. Reduce air-polluting HC. 2. To absorb fuel vapor and saving fuel consumption. injector Throttle valve Fuel tank Vapor hose Evaporative gas pipe Active carbon canister Purge control valve 2.
  • Page 233 15. Emission Control Evaporative Emission Control System (E.E.C.) Inspection 1. Visual check Check all hoses for breakage. 2. Purge Control Valve (P.C.V.) function test: Disconnect the hose of connection to the active carbon canister, and then connect a T-type hose connector to pressure source as shown below: Engine vacuum Pressure gauge...
  • Page 234 15. Emission Control Positive Crankcase Ventilation System (P.C.V.) 1. Construction → blow-by gas engin Drain hose Air cleaner 2. Principle of operation 1. Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum. 2.
  • Page 235 15. Emission Control Air injection solenoid valve(AISV) Description To promote stable combustion and idle speed, an open loop is applied to maintain air / fuel ratio on 13 : 1, AISV is used to neutralize pollutants like CO and HC. ECU can accurately control AISV according to RPM and engine vacuum to avoid the backfiring situation of traditional carburetor-type bikes.
  • Page 236 15. Emission Control Ignition system Ignition circuit O2 sensor TW sensor MAP sensor TA sensor Ignition coil Spark plug Principle The computer programmed ignition system receives the signals from the Crankshaft position sensor, Throttle position sensor, O Sensor, MAP sensor, Intake air temperature sensor, Engine coolant temperature sensor.
  • Page 237 15. Emission Control Inspection items Evaporative emission control system: Visual check if charcoal canister and hose damaged.  Check if any leakage.  Check purge control valve.  Catalytic converter: Remove and shake exhaust pipe to check if any abnormal noise. ...
  • Page 238 15. Emission Control Countermeasure for abnormal emission pollutants Conduct periodical inspection (1500 km/6 months) Idle speed exhaust emissions test (note 1) Adjust injection system (note Keep CO value in 0.5~2.5% Clean fuel injector by adjusting fuel injection (note 3) Replace fuel injector Clean the carbon deposit in combustion chamber and cylinder.
  • Page 239 15. Emission Control NOTE: 15-9...
  • Page 240 15. Emission Control NOTE: 15-10...

  • Page 241: 16. Wiring Diagram

    16. Wiring diagram T2 電路圖 16-1...
  • Page 242 16. Wiring diagram NOTE: 16-2...

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