Sym Quad Lander 300 Service Manual
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Sym Quad Lander 300 Service Manual

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Quad Lander 300
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Summary of Contents for Sym Quad Lander 300

  • Page 1 FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Quad Lander 300 SERVICE MANUAL...
  • Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the ATV, Quad Lander 300, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3: General Information

    Homepage Contents HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG Quad Lander 300ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Homepage CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-6 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-16 “V”...
  • Page 5 Home page Contents SERIAL NUMBER Frame number Engine number...
  • Page 6 Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Specifications........1-10 General Safety ........1-2 Torque Values ........1-11 Service Precautions ......1-3 Troubles Diagnosis......1-14 Specifications ........1-9 Lubrication Points ......1-19 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 is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    To this chapter contents 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 area. Run your engine in an open area, if you have ‧...

  • Page 8: Service Precautions

    To this chapter contents 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-designed parts for unsmooth control and premature worn out. SANYANG ATV may damage the ATV. Rubber parts may become deteriorated when old, Special tools are designed for remove and install and prone to be damaged by solvent and oil.
  • Page 9 To this chapter contents 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 the another, be sure they are correctly installed. In contact surface has any damage.
  • Page 10 To this chapter contents 1. GENERAL INFORMATION Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.
  • Page 11 To this chapter contents 1. GENERAL INFORMATION When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated...
  • Page 12 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.
  • Page 13 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness been twisted as With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering...

  • Page 14: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL UA30A Overall Length 1920 mm Front Double arm Suspension System Overall Width 1065 mm Rear Unit Swing Overall Height 1110 mm Front AT22x7-10 (off road) Tire Specifications Wheel Base 1190 mm Rear AT22x10-9 (off road)

  • Page 15: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL UA25A1 Overall Length 1,890 mm Front Double arm Suspension System Overall Width 1,055 mm Rear Unit Swing Overall Height 1,115 mm Front AT22x7-10 (on road) Tire Specifications Wheel Base 1,200 mm Rear AT22x10-9 (on road)

  • Page 16: Torque Values

    To this chapter contents 1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 0.45~0.6kgf-m...
  • Page 17 1. GENERAL INFORMATION 1-12...
  • Page 18 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks 2.40 Handlebar upper holder bolt Steering shaft nut 5.00 Steering tie-rod nut 5.00 5.00 Knuckle nut Steering shaft holder bolt 3.40 3.60 Tie rod lock nut 4.00 Handlebar under holder nut...

  • Page 19: Troubles Diagnosis

    To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside No fuel in fuel tank the carburetor Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.
  • Page 20 To this chapter contents 1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Engine speed can be Engine speed can not be Lines in fuel tank evaporation system increased.
  • Page 21 To this chapter contents 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) Normal Abnormal Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
  • Page 22 To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS Drive belt worn out or deformation Ramp plate of movable drive face damaged Engine can be started but Driving pulley spring broken motorcycle can not be moved. Clutch weights broken Drive slide-shaft gear groove broken Transmission gear damaged...
  • Page 23 To this chapter contents 1. GENERAL INFORMATION G. Loss power Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand Brake dragging Abnormal Spin freely Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication Check tire pressure Normal Abnormal...

  • Page 24: Lubrication Points

    To this chapter contents 1. GENERAL INFORMATION Lubrication Points Drive chain Acceleration cable/ Front & rear brake lever pivot Speedometer gear Wheel bearing 1-19...

  • Page 25: Maintenance Information

    Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ···················· 2-1 Drive Chain ··········································· 2-7 Periodical Maintenance Schedule ······ 2-2 Brake System (Disk Brake) ················· 2-10 Fuel Lines ············································· 2-3 Brake Light Switch/Starting Inhibitor Switch ··················································· 2-11 Acceleration Operation ······················· 2-3 Headlight Beam Distance ····················...

  • Page 26: Periodical Maintenance Schedule

    C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

  • Page 27: Fuel Lines

    To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines Fuel tank Remove the seat. Loosen 2 screws and 2 bolts Remove the tank cover Fuel hose Check all lines, and replace it when they are Fuel filter carburetor deterioration, damage or leaking Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

  • Page 28: Valve Clearance

    To this chapter contents 2. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35℃. 2 bolts Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. Remove cylinder head side cover.

  • Page 29: Carburetor Idle Speed Adjustment

    To this chapter contents 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition cable Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up.

  • Page 30: Ignition System

    To this chapter contents 2. MAINTENANCE INFORMATION Ignition System CDI unit Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is in normal or not. Connect tachometer and ignition light.

  • Page 31: Drive Belt

    To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Clamp strips Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Remove 9 bolts of the engine left side cover and the cover. 9 bolts Check if the belt is crack or worn out.
  • Page 32 2. MAINTENANCE INFORMATION Check The Rear Gear box 3 bolts Remove rear wheels and rear axle. Loosen 3 bolts and remove rear axle gear box under protector. Loosen the 4 bolts of Rear Gear Box from the drive Rear axle Drive shaft shaft side.

  • Page 33: Drive Chain

    2. MAINTENANCE INFORMATION Chain Propulsion System 4 bolts Check the drive chain Park the ATV on a level ground, and shift the transmission onto neutral. Measure the drive chain slack midway between the sprockets. Chain slack: 15~25mm (5/8~1 inch) Adjustment nut Adjust the chain slack Loosen the axle holder lock bolts and turn drive chain adjusting nuts until get the correct slack.

  • Page 34: Brake System (Disk Brake)

    To this chapter contents 2. MAINTENANCE INFORMATION Brake System (Disk Brake) Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.

  • Page 35: Brake Light Switch/Starting Inhibitor

    To this chapter contents 2. MAINTENANCE INFORMATION Brake Lining Wear Front brake The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark Lining closed to the edge of brake disc. Caution To check front brake lining must be remove Brake lining wear front wheel first.

  • Page 36: Headlight Beam Distance

    To this chapter contents 2. MAINTENANCE INFORMATION Headlight Beam Distance Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high. Caution To adjust the headlight beam follows related regulations. Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.

  • Page 37: Steering Handle

    To this chapter contents 2. MAINTENANCE INFORMATION Steering Handle Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.

  • Page 38: Special Tools List

    Driver shaft install bush & seal NAME NAME NAME Left crank seal driver Drive shaft puller driver SYM-1332100-HMA SYM-2341110-HMA SYM-9120200-HMA Counter shaft needle bearing NAME NAME NAME Bearing driver 6205LLU Rear axle bearing driver drive HK1516 SYM-9100100 RA1 SYM-9100410/440 SYM-9100200-HMA A3017 2-14...
  • Page 39 SYM-9100300-RB1 SYM-2341110 SYM-9615000-RA1 6000 NAME Bearing driver 6205 NAME Seal driver 14x28x7 &14x26x6 NAME Seal driver 30x40x5 SYM-9615000 SYM-9120600 RB1 RA1 SYM-9120100-RA1 (12*20*5) (6901) Water pump mechanical NAME Water pump oil seal driver NAME Water pump bearing driver NAME seal driver...
  • Page 40 To this chapter contents 2. MAINTENANCE INFORMATION NAME Inner bearing puller NAME Inner bearing puller NAME Outer bearing puller SYM-6204002 SYM-6204022 SYM-6204001 Swing arm bearing 6007 NAME Universal holder NAME Clutch nut wrench NAME puller SYM-2310000 SYM-2210100 SYM-9020200 RB1 RFA A6007...
  • Page 41 2. MAINTENANCE INFORMATION 2-17...
  • Page 42 Home page Contents 3. LUBRICATION SYSTEM Mechanism Diagram ······························ 3-1 Engine Oil Strainer Clean ······················ 3-3 Precautions in Operation ······················ 3-2 Oil Pump ················································· 3-4 Troubleshooting ···································· 3-2 Gear Oil ··················································· 3-7 Engine Oil ··············································· 3-3 Mechanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route...

  • Page 43: Precautions In Operation

    SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 750c.c. Change: 650c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) 單位:mm Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20 Oil pump Clearance between outer rotor and body 0.15~0.20...

  • Page 44: Engine Oil

    To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 45: Oil Pump

    To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Clip Remove cir clip and 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.
  • Page 46 To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Pins...
  • Page 47 To this chapter contents 3. LUBRICATION SYSTEM Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0.1~0.3kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Clip Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft.

  • Page 48: Gear Oil

    To this chapter contents 3. LUBRICATION SYSTEM Gear Oil Gear oil join bolt Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.1~1.5kgf-m Make sure that the drain bolt washer can be re-used.
  • Page 49 To this chapter contents 3. LUBRICATION SYSTEM Notes:...

  • Page 50: Fuel System

    Home page Contents 4. FUEL SYSTEM Mechanism Diagram ........... 1 Carburetor Remove / Install(for Precautions in Operation........3 UA30A-A&UA30A1-6) ........Trouble Diagnosis..........4 Air Cut-Off Valve ..........Carburetor Remove / Install(for UA30A-6) ..5 Throttle Valve............. Air Cut-Off Valve..........6 Float Chamber...........
  • Page 51 4. FUEL SYSTEM UA30A-A&UA30A1-6 Fuel tank cap Fuel tank Carburetor Fuel Strainer Fuel valve...

  • Page 52: Precautions In Operation

    To this chapter contents 4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.

  • Page 53: Trouble Diagnosis

    To this chapter contents 4. FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system )

  • Page 54: Carburetor Remove / Install(For Ua30A-6)

    To this chapter contents 4. FUEL SYSTEM Carburetor Remove / Install(for UA30A-6) Removal Drain out fuel in the float chamber. Drain bolt Turn the fuel valve lever on off. fuel valve lever 1 screw Remove 1 screw from throttle lever cap them adjustment nut remove throttle lever cap.

  • Page 55: Air Cut-Off Valve

    To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. Spring O-ring Air cut-off valve Cover Inspection Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly.

  • Page 56: Vacuum Chamber

    To this chapter contents 4. FUEL SYSTEM Vacuum Chamber Disassembly Removal Loosen drain screw, and drain out residual fuel in float chamber. Remove screws (4 screws) of vacuum chamber cover and the cover. Throttle valve Remove compress spring and vacuum piston. Spring Remove fuel needle seat, spring, and injector needle...
  • Page 57 To this chapter contents 4. FUEL SYSTEM Float Chamber Disassembly Remove 4 mounting screws and remove float chamber cover. 4 Screws Remove the float pin, float and float valve. Float valve Float Inspection Check float valve and valve seat for damage, blocking.
  • Page 58 To this chapter contents 4. FUEL SYSTEM Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns.
  • Page 59 To this chapter contents 4. FUEL SYSTEM Adjustment of Idle Speed Parking brake Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the ATV to perform the adjustments.

  • Page 60: Carburetor Remove / Install(For Ua30A-A&Ua30A1-6)

    4. FUEL SYSTEM Carburetor Remove / Install(for UA30A-A&UA30A1-6) Removal Drain out fuel in the float chamber. Drain bolt Loosen the choke cable fixed iron sheet screw from plate. 1 screw Remove the choke cable. Choke cable Disconnect the fuel hose. Release the clamp strip of air cleaner.

  • Page 61: Air Cut-Off Valve

    4. FUEL SYSTEM Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. O-ring Spring Cover Air cut-off valve Inspection Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly.

  • Page 62: Throttle Valve

    4. FUEL SYSTEM Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Throttle valve Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Spring Assembly Place the fuel needle onto the throttle valve and...

  • Page 63: Float Chamber

    4. FUEL SYSTEM Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. 3 Screws Float valve Float Remove the fuel level plate, float pin, float and float valve. Fuel level plate Inspection Check float valve and valve seat for damage, blocking.
  • Page 64 4. FUEL SYSTEM Remove main jet, needle jet holder, needle jet, Needle jet holder Main jet slow jet and air adjustment screw. Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns. Does not turn adjust screw forcefully to avoid damaging valve seat face.

  • Page 65: Adjustment Of Idle Speed

    4. FUEL SYSTEM Parking brake Adjustment of Idle Speed Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the ATV to perform the adjustments.

  • Page 66: Fuel Tank

    To this chapter contents 4. FUEL SYSTEM Fuel Tank 2 bolts Fuel tank Fuel tank removal Open the seat. Remove the front cover and front top center cover. Remove the side covers and lower side covers. Remove the front fender. Remove 2 bolts from tank cover BRKT.

  • Page 67: Air Cleaner

    To this chapter contents 4. FUEL SYSTEM Air Cleaner Removal FOR UA30A-6 Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Clamp FOR UA30A1-6 and UA30A-A Remove two nut from inner pipe and Loosen the clamp strip of air cleaner and then remove the vapor hose..
  • Page 68 4. FUEL SYSTEM Remove element mounting screw. 1 screw Loosen the clamp strip of air cleaner element, and Clamp then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry. Caution Never use gasoline or acid organized solvent to clean the element.
  • Page 69 To this chapter contents 4. FUEL SYSTEM Notes: 4-20...

  • Page 70: Engine Removal

    Home page Contents 5. ENGINE REMOVAL Precautions in Operation ..... 5-Fel! Engine Installation ........ 5-Fel! Bokmärket är inte definierat. Bokmärket är inte definierat. Removal of Engine ....... 5-Fel! Bokmärket är inte definierat. Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable. Engine shall be removal in the conditions of necessary repair or adjustment to the only.
  • Page 71 To this chapter contents 5. ENGINE REMOVAL Removal of Engine Negative Remove the seat. Remove battery negative post (-). Remove battery positive (+) post. Remove front fender and the footrest (refer chapter 13). Positive Remove starter motor wire. Starter motor wire Remove the spark plug cap.
  • Page 72 To this chapter contents 5. ENGINE REMOVAL Remove muffler protect (2 bolts). 2 bolts Loosen muffler front side bolt. bolt Remove 2 bolts, and then remove the exhaust muffler. 2 bolts Remove 2 nuts, and then remove exhaust pipe. 2 nuts...
  • Page 73 To this chapter contents 5. ENGINE REMOVAL Remove fuel pipe and by-starter . by-starter fuel pipe 1 screw Loosen 1 screw from throttle lever side cover them remove the side cover. Loosen throttle cable adjustment nut. remove the throttle cable. Clamp Release the clamp stripes and remove the carburetor .
  • Page 74 To this chapter contents 5. ENGINE REMOVAL Remove coolant drain bolt, and drain out coolant. Water hoses clamp Remove coolant inlet hoses from water pump. Drain bolt Remove the thermo-sensor wire, by-pass pipe and By-pass pipe Outlet hose coolant outlet hose. Thermo-sensor wire 2 bolts remove brake pedal and change rod.

  • Page 75: Engine Installation

    To this chapter contents 5. ENGINE REMOVAL Remove 1 screw from duct band then remove it duct band Remove gear box cover bolts (6bolts) and then remove the cover. 6 bolts Remove the rear side engine hanger mounting nuts and bolts. Remove the front side engine hanger mounting nut and bolt Remove left side engine hanger, and then remove...

  • Page 76: Cylinder Head/Valve

    Home page Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10 Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11 Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13 Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-14 Cylinder Head Inspection···················...

  • Page 77: Precautions In Operation

    To this chapter contents 6. CYLINDER HEAD/VALVE Precautions in Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. Specification Item Standard...

  • Page 78: Troubleshooting

    To this chapter contents 6. CYLINDER HEAD/VALVE Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1.

  • Page 79: Cylinder Head Removal

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Removal 2 nuts Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove the Thermostat bolts thermostat. Remove hole bolt and spring for the cam chain tensioner.
  • Page 80 Cam shaft setting plate Remove cam shaft setting plate (1 bolt). Rocker arm shafts Remove rocker arm shafts and rocker arms. Special Service Tool: Tool no:SYM-1445100 TOOL number: rocker arm and cam shaft puller Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts.
  • Page 81 In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Tool no:SYM-1471110/20-4v TOOL number: valve cotter remove & Valve cotter remove assembly tool and assembly tool...

  • Page 82: Cylinder Head Inspection

    To this chapter contents 6. CYLINDER HEAD/VALVE Remove valve stem seals. Valve stem 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. Cylinder Head Inspection Check if spark plug and valve holes are cracked.
  • Page 83 To this chapter contents 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
  • Page 84 To this chapter contents 6. CYLINDER HEAD/VALVE Valve guide Caution 5.0 mm valve guide reamer Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and 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 valve...

  • Page 85: Valve Stem Replacement

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated Valve guide driver 5.0mm plate or toaster. Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it.

  • Page 86: Valve Seat Inspection And Service

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 87 To this chapter contents 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.

  • Page 88: Cylinder Head Reassembly

    To this chapter contents 6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Valve spring retainer Lubricate valve stem with engine oil, and then Valve stem seal insert the valve into valve guide.

  • Page 89: Cylinder Head Installation

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
  • Page 90 To this chapter contents 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the Timing mark timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution 2 bolts Make sure timing marks are matched.

  • Page 91: Valve Clearance Adjustment

    To this chapter contents 6. CYLINDER HEAD/VALVE Install Air Injection system (AI) pipe. (4 bolts) 4 bolts Spark plug Install inlet pipe onto cylinder 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 not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise...

  • Page 92: Cylinder/Piston

    Home page Contents 7. CYLINDER/PISTON Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7 Trouble Diagnosis································ 7-2 Cylinder Installation ························· 7-7 Cylinder and Piston Removal ············· 7-3 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m...

  • Page 93: Precautions In Operation

    To this chapter contents 7. CYLINDER/PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. UA25A Specification Unit：mm Item Standard Limit 74.995~75.015 75.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring...

  • Page 94: Cylinder And Piston Removal

    To this chapter contents 7. CYLINDER/PISTON Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
  • Page 95 To this chapter contents 7. CYLINDER/PISTON Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.
  • Page 96 To this chapter contents 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.

  • Page 97: Piston Ring Installation

    To this chapter contents 7. CYLINDER/PISTON Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.

  • Page 98: Piston Installation

    To this chapter contents 7. CYLINDER/PISTON Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily.
  • Page 99 To this chapter contents 7. CYLINDER/PISTON Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken 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.。...
  • Page 100 Home page Contents 8. V-BELT DRIVING SYSTEM Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-7 Maintenance Description ···················· 8-2 Drive Face·············································8-9 Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley··················8-12 Left Crankcase Cover ························· 8-3 Mechanism Diagram 8.5~10.5kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m...

  • Page 101: Maintenance Description

    Weight of weight roller 17.700~18.300 17.200 Torque value Special Service Tools Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000 Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002 Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder:...

  • Page 102: Left Crankcase Cover

    To this chapter contents 8. V-BELT DRIVING SYSTEM Left Crankcase Cover Clamp strips Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (10 bolts) Remove 2 dowel pin and gasket. 10 bolts Left crankcase cover install Install left crankcase cover in the reverse...
  • Page 103 If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Remove the bearing 6006 with inner bearing puller. Tools number:SYM-6204025 Tools name: INNER BEARING PULLER. Bearing 6006 install with special tool. Tools number:SYM-1134600-HMA RB1 6006. Tools name: L CRANK CASE COVER BEARING INSTALL TOOL.
  • Page 104 8. V-BELT DRIVING SYSTEM Disassembly Remove 5 screws from l cover plate and remove l cover plate. 5 screws Remove 1 bolt from ratchet cover 1 bolt Remove 2 starter ratchets and 2 ratchet springs...
  • Page 105 8. V-BELT DRIVING SYSTEM Remove starter drive pulley and volute spring Caution If remove the volute spring from the l crank cover then its has to be replaced. Loosen the starter rope from the starter grip. Installation Install in reverse order of removal procedures Caution First before installing the drive pulley must establish 2 1/2 of the pressures transferred to...

  • Page 106: Drive Belt

    Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool： Tool number : SYM-2210100 Tool name: universal holder Bearing stay collar Universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
  • Page 107 To this chapter contents 8. V-BELT DRIVING SYSTEM Installation Caution Pull out driven face to avoid it closing. Driven face Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.

  • Page 108: Drive Face

    To this chapter contents 8. V-BELT DRIVING SYSTEM Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face Movable drive face boss from crankshaft.
  • Page 109 To this chapter contents 8. V-BELT DRIVING SYSTEM Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged.
  • Page 110 To this chapter contents 8. V-BELT DRIVING SYSTEM With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Movable drive face Drive face boss...

  • Page 111: Clutch Outer/Driven Pulley

    To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.
  • Page 112 To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.4 mm Free length Driven pulley...
  • Page 113 To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch weight Replacement Spring Driving plate Remove snap ring and washer, and then remove clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
  • Page 114 To this chapter contents 8. V-BELT DRIVING SYSTEM Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 115 To this chapter contents 8. V-BELT DRIVING SYSTEM Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face.

  • Page 116: Final Driving Mechanism

    Home page Contents 9. FINAL DRIVING MECHANISM Mechanism Diagram - transmission cover Inspection of Mission Mechanism ···· 9-11 ······························································ 9-1 Bearing Replacement ························ 9-13 Precautions in operation ···················· 9-2 Re-assembly of Final Driving Mechanism Trouble Diagnosis ······························· 9-2 ····························································· 9-16 Disassembly of Transmission············...

  • Page 117: Precautions In Operation

    Gear box cover 2.6~3.0kgf-m Gear oil drain bolt 1.1~1.5kgf-m Gear oil fill bolt 3.5~4.5kgf-m Tools Special tools Bearing driver (6204): SYM-9110400 Bearing driver (6205LLU): SYM-9100400-HMA Bearing driver (6305): SYM-9100400-RB1 Needle bearing driver (HK2016): SYM-9100300-RB1 Drive shaft and oil seal driver: SYM-9120200-HMA...

  • Page 118: Disassembly Of Transmission

    To this chapter contents 9. FINAL DRIVING MECHANISM Disassembly of Transmission Remove gear change lever (2 bolts).then remove the gear change lever. 2 bolts brake pedal Remove 2 c clips from brake pedal. Remove brake spring & stop switch spring Remove brake penal.
  • Page 119 To this chapter contents 9. TRANSMISSION Remove gear box cover bolts (9 bolts) and then 6 bolts remove the cover. Remove mission box. 4 bolts Disassembly of mission box. Remove 4 bolts from mission box rear cover. Remove mission box rear cover. mission box rear cover Remove 4 bolts from mission box front cover, 4 bolts...
  • Page 120 OUTPUT SHAFT WRENCH ø F07 INNER BEARING PULLER special tools ø tools number：SYM-6204025 tools name：F07 INNER BEARING PULLER. Load special tool onto the inner bearing puller. . SYM-2140101 RFA 6009 tools number：SYM-2140101 RFA 6009 tools name：RFA MISSION BOX 6009 BEARING DISMANTLING DEVICE.
  • Page 121 Cross the special tool the bearing and put in the position assembling orientate the device Load onto and orientate the device. Into the urgent nut then turn the nut install the bearing 6009. tools number：SYM-2140100 RFA A6009 tools name：RFA MISSION BOX 6009 BEARING INSTALL DEVICE WITH AIR.
  • Page 122 Into all parts them lock the mission shaft bolt with OUTPUT SHAFT WRENCH special tools. special tools tools number：SYM-2345100-RFA tools name：OUTPUT SHAFT WRENCH mission shaft bolt Installation the mission box rear cover. then Lock 4 25*40*9 OIL SEAL DRIVE...
  • Page 123 9. TRANSMISSION RR. PROPELLER SHAFT & RR. SHAET UNIVERSAL JOINT REMOVE Remove the mission box. take out the rear shaft universal joint take out the rear propeller shaft.
  • Page 124 9. FINAL DRIVING MECHANISM MISSION SYSTEM Remove Take out c-clip with outer c-clip pliers. Remove the and washer. SPIRAL BEVEL PINION Loosen 9 bolt then remove the mission cover. Tack out all parts from the mission case.
  • Page 125 To this chapter contents 9. TRANSMISSION MISSION SYSTEM Remove Remove drive shaft bearing setting plate (1 bolt). Bearing setting plate Remove the drive shaft. Special tool: Shaft protector Remove gasket and dowel pin. Caution If non- essential do not remove the drive shaft from the case upper side.

  • Page 126: Inspection Of Mission Mechanism

    To this chapter contents 9. FINAL DRIVING MECHANISM Inspection of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Measure the outer diameter of shift fork shaft, and replace it if it exceed service limit.
  • Page 127 To this chapter contents 9. TRANSMISSION Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. Drive shaft bearing Gear box Rotate each bearing’s inner ring with fingers.

  • Page 128: Bearing Replacement

    Install new final shaft, counter shaft and reverse shaft bearings into left crankcase. Special tool: Tool number：SYM-9110400 Tool name：Bearing driver (6204) Tool number：SYM-9100300-RB1 2016 Tool name：Needle bearing driver (HK2016) Drive shaft and Clutch nut wrench seal install bush Install new drive shaft bearings and baring driver into left crankcase.
  • Page 129 9. TRANSMISSION Install drive shaft. Drive shaft and Clutch nut wrench Special tool: seal install bush Tool number：SYM-2341110-HMA Tool name：Drive shaft puller Tool number：SYM-9120200-HMA Tool name：Drive shaft and oil seal install bush Clutch nut wrench Drive shaft puller Drive shaft and...
  • Page 130 AIR bearing puller Install new final shaft bearings and baring driver into left crankcase with air tools. Tool number：SYM-9100420-RB1 RFA A6305 Tool name：Mission final shaft bearing 6305 install bush with air. Install the air bearing puller and bearing driver. Turn the air bearing puller with air wrench or ratchet tool.

  • Page 131: Re-Assembly Of Final Driving Mechanism

    To this chapter contents 9. TRANSMISSION Re-assembly of Final Driving Reverse shaft Drive shaft Mechanism Install reverse shaft onto gear box. First apply some grease to hold the washer in the Reverse shaft washer illustrated position. This can prevent the washer from falling out when assembling the reverse shaft.
  • Page 132 9. FINAL DRIVING MECHANISM Align the position mark on the shift spindle sprocket with that of shift drum, and then install shift spindle. Install the final shaft and Install shift drum fixed catch ball, spring and bolt onto gear box. Shift drum fixed catch bolt Install shift drum fixed catch ball, spring and bolt onto gear box.
  • Page 133 To this chapter contents 9. TRANSMISSION Install the spiral bevel pinion. spiral bevel pinion Install final shaft cir clip washer with out cir clip pliers. final shaft cir clip Install the rear propeller shaft and rear shaft rear shaft universal joint. final shaft cir clip universal joint.
  • Page 134 9. FINAL DRIVING MECHANISM Install shaft drum fixed catch ball spring and bolt shaft drum fixed catch ball onto gear box. Add gear oil. Final gear oil: 1300c.c. Gear box oil：150 c.c. 9-19...

  • Page 135: Alternator

    Home page Contents 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram ··························· 10-1 Flywheel Removal ································ 10-4 Precautions in Operation···················· 10-2 Starting Clutch ····································· 10-5 Right Crankcase Cover Removal ······· 10-3 Flywheel Installation···························· 10-7 A.C.G. Set Removal····························· 10-3 A.C.G. Set Installation·························· 10-8 Right Cover Bearing···························· 10-3 Right Crankcase Cover Installation····...

  • Page 136: Precautions In Operation

    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 adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.0~1.4kgf-m Tools Special tools A.C.G. flywheel puller: SYM-3110000-HMA Universal holder: SYM-2210100 10-2...

  • Page 137: Right Crankcase Cover Removal

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 11 bolts Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover.

  • Page 138: Flywheel Removal

    Check the oil seal for wear or damage. Replace Oil seal it if necessary. Install a new one bearing (6201LU) by bearing driver. Special tool: Tool number：SYM-9614000-HMA 6201 Tool name：right crank case bearing 6201 puller. Bearing driver Flywheel Removal Reduction gear Flywheel nut Remove right crankcase cover.

  • Page 139: Starting Clutch

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Remove starter reduction gear and shaft. flywheel puller Pull out flywheel with A.C.G. flywheel puller. Special tool: Tool number：SYM-3110000-HMA Tool name： A.C.G. flywheel puller Remove flywheel and starting driven gear. Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear.
  • Page 140 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely, but not C.W direction. (View as shown in this figure.) One way clutch removal Starting driven gear Remove starting driven gear.

  • Page 141: Flywheel Installation

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH One way clutch Installation 3 socket bolts Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Starting driven gear Install starting driven gear.

  • Page 142: A.c.g. Set Installation

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install reduction gear shaft and reduction gear. Reduction gear A.C.G. Set Installation Wire 2 bolts Install the A.C.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase.
  • Page 143 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install right crankcase cover (11 screws). 11 bolts Install the dowel pin, new gasket and water pump cover onto crankcase cover. Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover.
  • Page 144 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Note: 10-10...
  • Page 145 Home page Contents 11. CRANKCASE / CRANK Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3 General information ···························11-2 Crankshaft Inspection ······················· 11-5 Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m Eng. Oil drain bolt 3.5~4.5kgf-m 11-1...

  • Page 146: General Information

    0.8~1.2kgf-m Engine oil drain bolt 3.5~4.5kgf-m Cylinder stud bolt 1.0~1.4kgf-m Tools Special tools L. crank shaft oil seal driver (27*42*7): SYM-1332100-HMA Trouble diagnosis Engine noise Loose crankshaft bearing Loose crankshaft pin bearing Worn out piston pin and pin hole 11-2...

  • Page 147: Disassembly Of Crankcase

    To this chapter contents 11. CRANKCASE / CRANK Disassembly of crankcase Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Cam chain setting plate Loosen 2 bolts on the right crankcase. 2 bolts 11 bolts Loosen 11 bolts on the left crankcase.
  • Page 148 To this chapter contents 11. CRANKCASE / CRANK Remove balance shaft from right crankcase. Balance shaft Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping.

  • Page 149: Crankshaft Inspection

    To this chapter contents 11. CRANKCASE / CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.

  • Page 150: Assembly Of Crankcase

    If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Special tool: Tool number：SYM-6204024 Tool name：Inner bearing puller bearing driver Assembly of crankcase Install wave washer into right crank bearing seat. Wave washer Install crank shaft on the right crankcase.
  • Page 151 To this chapter contents 11. CRANKCASE / CRANK Install 2 dowel pins and new gasket. Dowel pins Install the left crankcase onto the right crankcase. Tighten 11 bolts on the left crankcase. 11 bolts Torque value: 0.8~1.2kgf-m Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m 2 bolts 11-7...
  • Page 152 By oil seal driver (27×42×7), oil seal will knock into crank and oil seal located. installation Special tool: Tool number：SYM-11332100-HMA RB1 Tool name：crank and oil seal installation. Tensioner Install the tensioner and tighten the pivot bolt. Torque value: 0.8 ~1.2kgf-m Install the cam chain.

  • Page 153: Cooling System

    Home page Contents 12. COOLING SYSTEM Mechanism Diagram ··························12-1 System Test········································ 12-5 General Information ···························12-2 Radiator ·············································· 12-6 Trouble Diagnosis ······························12-2 Water Pump ········································ 12-8 Trouble Diagnosis for Cooling System Thermostat ········································· 12-12 ·····························································12-3 Mechanism Diagram Radiator filler cap Reserve tank By-pass pipe To cylinder head Coolant outlet pipe...

  • Page 154: General Information

    For water pump impeller 1.0~1.4kgf-m Tools Requirement Special tools Water pump bearing driver (6901): SYM-9100100 Water pump oil seal driver (Inner): SYM-9120500-H9A Water pump mechanical seal driver: SYM-1721700-H9A Inner bearing puller: SYM-6204020 Trouble Diagnosis The engine temperature is too high...
  • Page 155 To this chapter contents 12. COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.
  • Page 156 To this chapter contents 12. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12→ 0V)? temperature gauge over 3 checks? E-2.

  • Page 157: System Test

    Stop the engine. Add coolant to proper level if necessary. Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unclear trade mark refrigerant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% 12-5...

  • Page 158: Radiator

    To this chapter contents 12. COOLING SYSTEM Check reserve tank Remove the front center cover, and then remove reserve tank filler cap. Check the liquid level in the front fender right side. Add coolant to proper level if too low. Reinstall the reserve tank filler cap.
  • Page 159 To this chapter contents 12. COOLING SYSTEM Loosen the radiator 4 bolts. Coolant inlet pipe Remove coolant upper side pipes. 4 bolts Remove coolant outlet pipe. Coolant outlet pipe Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan.

  • Page 160: Water Pump

    Remove the outside bearing by inner bearing puller. Rotate the inner ring of bearing, the bearing shall move smoothly and quietly. If the bearing does not rotate smoothly or produces a noise, replace it with new one. Special tool: Tool number：SYM-6204024 Tool name：Inner bearing puller 12-8...
  • Page 161 Replacement of Mechanical Seal Remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase. Special tools: Tool number：SYM-6204024 Water pump bearing Tool name：Inner bearing puller. driver Tool number：SYM-9100100 Tool name：Inner bearing puller.Water pump...
  • Page 162 12. COOLING SYSTEM Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Tool number：SYM-9120500-H9A Tool name：Water pump oil seal driver(inner). Water pump bearing Install a new outside bearing to the right driver (6901) crankcase cover.
  • Page 163 To this chapter contents 12. COOLING SYSTEM Install the seal washer into the impeller. Caution Washer must be replaced together with the mechanical seal. Install the impeller onto the water pump shaft and Water pump rotor tighten. Torque Value: 1.0~1.4kgf-m Caution The impeller is left thread.

  • Page 164: Thermostat

    To this chapter contents 12. COOLING SYSTEM Thermostat Temperature sensor By-pass pipe Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) 2 Bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.

  • Page 165: Body Cover

    Home page Contents 13. BODY COVER Mechanism Diagram ...... 13-1 Footrest.......... 13-8 Maintenance........13-2 Meter cover........13-9 Front center cover ......13-3 Rear carrier........13-10 Fuel tank cover....... 13-3 Rear fender........13-10 Front fender........13-4 Mechanism Diagram Fuel tank cover Meter cover Seat Rear carrier...
  • Page 166 To this chapter contents 13. BODY COVER Maintenance Body covers disassemble sequence: Handle cover R/L Lower side covers Rear carrier Handle protect cover R/L Side covers R/L Lower side covers Front center cover Front center cover R/L Side covers R/L Footrests Front fender Rear fender R/L Side grilles...

  • Page 167: Fuel Tank Cover

    To this chapter contents 13. BODY COVER Front center cover Remove Loosen 2 screws from the front center cover. Please disassemble first then push the cap upward, and then remove front center cover. Installation Install in reverse order of removal procedures. 2 screws Fuel tank cover Remove...

  • Page 168: Front Fender

    To this chapter contents 13. BODY COVER Front fender Remove Remove seat. Remove fuel tank cap and fuel tank cover. Loosen the two bolts of front fender rear side. 2 bolts Remove 1 screw, and then remove fixed support catch. 1 screw Loosen the 6 screws, which connect the front fender and side lower covers, these 6 screws just...
  • Page 169 To this chapter contents 13. BODY COVER Remove right and left side covers Loosen the front fender two side bolts (each side 1 bolt). 1 Bolt Remove headlight, front winker light couplers. Headlight coupler Remove front fender under side bolts (each side 1 Winker coupler bolt).
  • Page 170 To this chapter contents 13. BODY COVER Remove front fender front side bolts (2 bolts). 2 Bolts Remove the left crankcase cover duct 1 bolt and remove it. 1Bolts Duct Remove front fender upper bolt, and then remove power outlet couplers. 1 Bolt Disassembly Remove 3 screws to remove front emblem.
  • Page 171 To this chapter contents 13. BODY COVER Remove headlights inner side 4 screws. Each side 2 screws Remove headlights front side 4 screws, and then remove headlights. 4 screws Each side Remove winker lights 4 screws, and then remove 2 screws winker lights.
  • Page 172 To this chapter contents 13. BODY COVER Remove power outlet setting nut, and then remove power outlet. Remove 4 screws, and then remove support cover Installation Install in reverse order of removal procedures. Setting nut SIDE LOWER COVER REMOVE Remove right and left side lower covers screws (each side 4 screws), and then remove side lower covers.
  • Page 173 13. BODY COVER Meter cover 5 bolts Remove Remove the front fender. Remove the radiator side 5 bolts. Speedometers couplers Main switch couplers Remove couplers of meter and main switch couplers. Remove 4 bolts from meter stay. 4 bolts Remove 3 screws and speedometer lamps, them Speedometer cable 3 screws disassemble steering cover and speedometer.

  • Page 174: Rear Fender

    13. BODY COVER Rear carrier 4 Bolts Remove Loosen 4 bolts from the rear carrier. Remove the rear carrier. Installation Install in reverse order of removal procedures. Rear fender Remove rear carrier. Pull the “Seat Release Bar” up in order to remove the seat.
  • Page 175 To this chapter contents 13. BODY COVER Remove 2 screws from rear fender front side. (each front side 1 screws) 2 screws Remove 4 bolts from under side for rear fender. 4 bolts Loosen 2 nuts from starter relay them remove 2 coupler starter relay.
  • Page 176 13. BODY COVER Remove license plate light set license pla license plate light Remove battery, CDI unit and fuse box. C.D.I unit Fuse box Remove 2 tail light wire bands and couplers 2 couplers wire band Remove rear fender. Installation Install in reverse order of removal procedures.
  • Page 177 To this chapter contents 13. BODY COVER Disassembly 2 screws Remove rear fender and rear bumper upper side 2 screws. Remove rear fender and rear bumper inner screws (each side 2 screws). Remove rear bumper and taillights. Each side 2 screws Remove tail cover and rear bumper 6 screws, and 6 screws then remove tail cover.
  • Page 178 13. BODY COVER 13-14...
  • Page 179 Home page Contents 14. FRONT BRAKE & FRONT WHEEL Mechanism Diagram···························14-1 Adding Brake Fluid ···························· 14-8 Maintenance Description ···················14-2 Brake fluid replacement / Air-bleed·· 14-9 Trouble Diagnosis ······························14-3 Front Brake Caliper···························· 14-10 Front Wheel·········································14-4 Brake Disk ·········································· 14-11 Front Wheel Hub·································14-4 Front Brake Master Cylinder ·············...

  • Page 180: Maintenance Description

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.

  • Page 181: Trouble Diagnosis

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Trouble Diagnosis Soft brake lever Hard steering 1. Air inside the hydraulic system 1. Faulty tire 2. Hydraulic system leaking 2. Insufficient tire pressure 3. Worn master piston 4. Worn brake pad 5.

  • Page 182: Front Wheel

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel axle cover (4 screws). 4 screws Remove the front wheel nuts, and then remove front wheels.
  • Page 183 Special tool: Inner bearing puller Remove front wheel hub bearing inner spacer. Inner spacer Remove inner side bearing and oil seal from wheel hub using following tools. Special tool: Tool number：SYM-6204024 Tool name：Inner bearing puller Inner bearing puller 14-5...
  • Page 184 Install front wheel hub bearing inner spacer. Install new out side bearing and seal into front wheel hub. Special tool: Tool number：SYM-9620000 Tool name ：Bearing driver (6203) Oil seal drive (24×35×7) Wheel hub nut Installation Install the front brake disk to the wheel hub.

  • Page 185: Disk Brake System Inspection

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.

  • Page 186: Adding Brake Fluid

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid Master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.

  • Page 187: Brake Fluid Replacement / Air-Bleed

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out.

  • Page 188: Front Brake Caliper

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Brake Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper.

  • Page 189: Brake Disk

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 190 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Cir clip Remove the piston and the spring. Rubber boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
  • Page 191 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. 2 socket bolts Install the brake lever, and connect leads to brake Brake lever bolt Brake light switch light switch.
  • Page 192 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Notes: 14-14...
  • Page 193 Home page Contents 15. STEERING / FRONT SUSPENSION Mechanism Diagram ··························15-1 Steering Tie-Rod ································ 15-6 Operational Precautions ····················15-2 Knuckle ··············································· 15-7 Trouble Diagnosis ······························15-2 Front Cushion ···································· 15-8 Steering Handle ··································15-3 Suspension Arm ································ 15-9 Steering Shaft ·····································15-5 Toe-In ·················································· 15-10 Mechanism Diagram 2.4kgf-m 4.0kgf-m...

  • Page 194: Handlebar Upper Holder Bolt

    To this chapter contents 15. STEERING / FRONT SUSPENSION Operational Precautions Torque Values 2.4kgf-m Handlebar upper holder bolt 4.0kgf-m Handlebar under holder nut 3.4kgf-m Steering shaft holder bolt 5.0kgf-m Steering shaft nut 5.0kgf-m Steering tie-rod nut 5.0kgf-m Knuckle nut 3.6kgf-m Tie rod lock nut 5.0kgf-m Suspension arm nut...

  • Page 195: Steering Handle

    To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter Handle protect cover Loosen the socket bolts for the front brake master brocket bolts cylinder, and remove front brake master cylinder.
  • Page 196 To this chapter contents 15. STEERING / FRONT SUSPENSION Loosen 2 screws, and then remove handle left switch and choke hosing. 2 screws 4 socket bolts Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. Remove 2 nuts to remove handle under holder and meter bracket.

  • Page 197: Steering Shaft

    To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Shaft Tie-rod nuts Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod. Cotter pin Steering shaft nut Remove the cotter pin steering shaft, and below remove steering shaft nut and washer.

  • Page 198: Steering Tie-Rod

    To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Tie-Rod Tie-rod nuts Remove Remove cotter pin and tie-rod nut from steering shaft side. Cotter pin Tie-rod nuts Remove cotter pin and tie-rod nut from wheel side. Cotter pin Inspection Inspect the tie-rod for damage or bending.

  • Page 199: Knuckle

    To this chapter contents 15. STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Tie-rod Remove cotter pin and tie-rod nut, remove tie rod. Cotter pin Universal holder Remove cotter pin and ball joint nut. Remove upper and under ball joints by ball joint driver.

  • Page 200: Front Cushion

    To this chapter contents 15. STEERING / FRONT SUSPENSION Front Cushion Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion upper bolt nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque value: Front cushion nut 4.6kgf-m...

  • Page 201: Suspension Arm

    To this chapter contents 15. STEERING / FRONT SUSPENSION Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Suspension arm nuts and bolts Loosen upper arm nuts, remove swing suspension arm bolts. Remove upper s arm.

  • Page 202: Toe-In

    To this chapter contents 15. STEERING / FRONT SUSPENSION Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height.
  • Page 203 Home page Contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Mechanism Diagram···························16-1 Disk Brake System Inspection·········· 16-10 Maintenance Description ···················16-2 Adding Brake Fluid ···························· 16-12 Trouble Diagnosis ······························16-3 Brake fluid replacement / Air-bleed·· 16-13 Rear Wheel ··········································16-4 Rear Brake Caliper ····························· 16-14 Rear Wheel Axle Connecter···············16-4 Brake Disk ··········································...

  • Page 204: Rear Axle Castle Nut

    Rear wheel axle nut 9.20kgf-m Brake lever nut 1.00kgf-m Rear 4.6kgf-m cushion mounting bolt Air-bleed valve 0.50kgf-m 9.2kgf-m Swing arm pivot bolt 2.40kgf-m Rear wheel nut Special tools Inner bearing puller: SYM-6204022 Rear axle bearing driver (6007LLU): SYM-9100100 RA1 A3017 16-2...

  • Page 205: Trouble Diagnosis

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Trouble Diagnosis Soft brake lever Vibration or Wobble 1. Air inside the hydraulic system 1. Axle is not tightened well 2. Hydraulic system leaking 2. Bent rim 3.

  • Page 206: Rear Wheel

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Removal Raise the rear wheels off the ground by placing a jack or other support under the frame. Remove rear axle cover (4 screws). 4 screws Remove the rear wheel nuts, and then remove rear wheels.

  • Page 207: Rear Wheel Axle

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Axle Remove right and left rear wheel and axle. Remove 8 bolts and remove the gear box . Remove 2 bolts, and then remove rear brake caliper.
  • Page 208 Bend out the rear wheel axle holder nut fixed plate. Fixed plate Remove rear wheel axle nuts. Special tool: Tool number：SYM-HT06007 Tool name：rear axle nut wrench (55mm) Tool number：SYM-4230200-RB1 RFA. rear axle nut socket. Tool name： Remove rear brake disk bracket and disk. Brake disk bracket 16-6...
  • Page 209 Install new out right bearing and seal into front wheel hub. Install bearing puller Apply with grease onto the oil seal lip of rear wheel axle. Special tool: SYM-2310000 RB1 RFA A6007 Tool number： bearing puller Tool name：install SYM-2313000 RB1 RFA Tool number：...
  • Page 210 Torque: 9.2kgf-m Special tool: Tool number：SYM-HT06007 Tool name：rear axle nut wrench (55mm) Tool number：SYM-4230200-RB1 RFA. rear axle nut socket. Tool name： Fixed plate After tightened the axle nut, bend the rear axle nut fixed plate.

  • Page 211: Rear Swing Arm

    Remove rear swing arm lock nut with special tool. Remove rear swing arm pivot bolt with special pivot bolt wrench. tool,. Special tool: Tool number：SYM-5220300-RFA socket. Tool name：swing arm lock nut Tool number：SYM-5220400-RFA Tool name：swing arm pivot bolt wrench. socket...

  • Page 212: Disk Brake System Inspection

    16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove rear swing arm bolt, and then remove re Special tool: Tool number：SYM-5220300-RFA Tool name：swing arm air socket. Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam...
  • Page 213 16. REAR BRAKE & REAR WHEEL & REAR CUSHION 16-11...

  • Page 214: Adding Brake Fluid

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Adding Brake Fluid Fluid cup Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir.

  • Page 215: Air-Bleed Valve

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out.

  • Page 216: Rear Brake Caliper

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Brake Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces.

  • Page 217: Brake Disk

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 218 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder 2 bolts Place a container under the brake master cylinder, remove fluid hose clamp, and drain out the brake fluid.
  • Page 219 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 13.954 mm Foot brake 15.850 mm Master Cylinder Assembly Caution It is necessary to replace the whole set...
  • Page 220 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder 2 bolts Install the master cylinder bolts and the master cylinder. Hose clamp Install brake push rod to the brake pedal, and Lock nut Adjustment nut install pin and E type clip.

  • Page 221: Rear Cushion

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Cushion Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Rear cushion under bolt Remove rear cushion upper bolt, and then remove rear cushion.

  • Page 222: Mechanism Diagram

    Home page Contents 17. ELECTRICAL SYSTEM Mechanism Diagram ··························17-1 Meters················································· 17-12 Maintenance Data·······························17-2 Light / Bulb········································· 17-13 Technical Specification······················17-2 Switch / Horn······································ 17-16 Trouble Diagnosis ······························17-3 Cooling Fan Thermo Switch ············· 17-19 Battery ·················································17-4 Thermo unit········································ 17-20 Charging System ································17-5 Water Temperature Indicator Light ··...

  • Page 223: Maintenance Data

    To this chapter contents 17. ELECTRICAL SYSTEM Maintenance Data Operational precaution When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.

  • Page 224: Trouble Diagnosis

    To this chapter contents 17. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate Battery discharged properly The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage...

  • Page 225: Battery

    To this chapter contents 17. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery... Clamp Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 226: Charging System

    To this chapter contents 17. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Black Yellow Yellow Fuse 20A Yellow Battery Regulator rectifier AC. Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal.
  • Page 227 To this chapter contents 17. ELECTRICAL SYSTEM Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...
  • Page 228 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Battery voltage...

  • Page 229: Ignition System

    To this chapter contents 17. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram Black Shift gear control unit CDI. Unit Green White Yellow Blue Fuse 15A Ignition coil Main fuse Spark plug Battery Main switch Pulse generator C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side.
  • Page 230 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Ω ± 10% Standard resistance: 0.17 Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.

  • Page 231: Starting System

    To this chapter contents 17. ELECTRICAL SYSTEM Starting System Starting circuit diagram Shift gear control unit Fuse 15A BR/Y Main switch Main fuse Brake switch Battery Change switch Starter relay Black Starter motor Green White Starter switch Yellow Brown Brake light Inspection on starter relay Open the main switch.
  • Page 232 To this chapter contents 17. ELECTRICAL SYSTEM Removal of Starter motor Negative Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. 2 Bolts Loosen the lock bolts and remove the starter motor.
  • Page 233 To this chapter contents 17. ELECTRICAL SYSTEM Meters Remove Remove the front fender. Remove the radiator side 5 bolts. Remove couplers of meter and main switch 5 bolts couplers. Meter set couplers Main switch coupler Remove 4 bolts from meter stay. 4 bolts Remove 3 screws and speedometer lamps, them disassemble steering cover and speedometer.
  • Page 234 To this chapter contents 17. ELECTRICAL SYSTEM Light / Bulb Replacing Bulb for Headlight Remove 4 screws for the headlight cover, and remove the cover. Adjustment screw 4 screws Loosen headlight bulb setting plate screw. 1 screw Remove bulb setting hook. Hook Take out the bulb connector and the bulb.
  • Page 235 To this chapter contents 17. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Front winker bulb Pull out the front winker light bulb seat. Replace with new front winker light bulb. (12V 21W) Position light bulb Replacing Bulb of Position Light Pull out the position light bulb seat.
  • Page 236 To this chapter contents 17. ELECTRICAL SYSTEM Replacing Bulb of Taillight and Rear Taillight bulb Winker Light Turn the taillight and rear winker light bulb connectors by CCW. Rear winker bulb Taillight Replace with new taillight bulb. (12V 5W/21W) Replace with new rear winker light bulb. Rear winker light (12V 21W) Replacing Bulb of License Light...

  • Page 237: 17. Electrical System

    To this chapter contents 17. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position Main switch coupler Wire Color Black Replacement of main switch Disconnect the coupler of the main switch.
  • Page 238 To this chapter contents 17. ELECTRICAL SYSTEM Headlight Switch Headlight switch BAT3 Position ● White Wire color White Blue Brown / Black Winker switch Position N PUSH OFF Brown / Wire color Pink Black Winker switch White Horn switch BAT3 Position FREE Wire Color...
  • Page 239 To this chapter contents 17. ELECTRICAL SYSTEM Front Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity.

  • Page 240: Cooling Fan Thermo Switch

    To this chapter contents 17. ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
  • Page 241 To this chapter contents 17. ELECTRICAL SYSTEM Thermo unit Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω ) 134~149 47.5~57.0 26~29 14.8~17.2 Caution Wear gloves and goggles when performing this test.
  • Page 242 To this chapter contents 17. ELECTRICAL SYSTEM 17-21...

  • Page 243: Electrical Diagram

    Home page Contents 18. ELECTRICAL DIAGRAM 18-1...
  • Page 244 Home page Contents 18. ELECTRICAL DIAGRAM Notes: 18-2...

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