PA12B PA12C SERVICE MANUAL FOREWORD CONTENTS HOW TO USE THIS MANUAL MECHANICAL LAYOUT...
Foreword This service manual contains the technical data of each component inspection and repair for the SANYANG PA12B & PA12C 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.
How To Use This Manual This service manual describes basic information of individual parts and system inspection & service for SANYANG PA12B&PA12C 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.
Homepage Contents 1. General Information Symbols and Marks··················· 1-1 Torque Values ··························· 1-11 General Safety ··························· 1-2 Trouble Diagnosis ····················· 1-13 Service Precautions·················· 1-3 Lubrication Points····················· 1-19 Specifications···························· 1-9 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.
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 ‧...
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-genuine parts for unsmooth control and premature worn out. SANYANG vehicle may damage it. Rubber parts may become deteriorated when Special tools are designed for remove and old, and easy to be damaged by solvent and oil.
To this chapter contents 1. General Information The length of bolts and screws for assembly, 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.
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.
To this chapter contents 1. General Information When separating a connector, it locker has to Insert the terminal completely. be unlocked first. Then, conduct the service Check if the boot covers the terminal. 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...
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 when routing tape or tube if they contact a sharp edge or the harness. corner.
To this chapter contents 1. General Information Do not let the wire harness been 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 perimeters.
To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL PA12B Overall Length Front 1910 mm TELESCOPIC FORK Suspension System Overall Width Rear 760 mm SWING ARM Overall Height Front 1030 mm 2.75-18-4PR Tire Specifications Rear Wheel Base 1210 mm 3.00-17-4PR...
To this chapter contents 1. General Information MAKER SANYANG MODEL PA12C Overall Length Front 1940 mm TELESCOPIC FORK Suspension System Overall Width Rear SWING ARM 715 mm Overall Height Front 1085 mm 2.75-18-4PR Tire Specifications Wheel Base Rear 1235 mm 3.00-17-4PR Front 52.5 kg...
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 alues for those not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque...
To this chapter contents 1. General Information Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle 3.0~3.5 post Lock nut for steering stem 1.0~2.0 Steering top cone race 2.0~3.0 Front wheel axle nut 5.0~7.0 Rear wheel axle nut 11.0~13.0...
To this chapter contents 1. General Information Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Possible causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.
To this chapter contents 1. General Information B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Possible causes Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed increases.
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 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
To this chapter contents 1. General Information E. Starter Motor Malfunction Starter Motor doesn’t rotate Check and adjustment Fault condition Possible causes Pull the brake handle or step on the braking pedal 1. Burnt Fuse Braking light is activated Braking light not activated 2.
To this chapter contents 1. General Information Starting Motor rotates slowly or spins without engagement with crankshaft Fault condition Possible causes Check and adjustment Check the battery circuit by activating turning signal 1. Insufficient Battery capacity Flashing normally Not flashing or dimmed Connect the starting motor to the battery 1.
To this chapter contents 1. General Information 1. Excessive clutch plate clearance Clutch knocking 1. Worn or deteriorated rear wheel damping rubber. Transmission gear noise 2. Gear surface worn 3. Worn transmission gear set 1-18...
To this chapter contents 1. General Information Lubrication Points Throttle cable / Front braking lever / clutch lever Steering shaft bearing Speed sensor gear / Side stand bracket Min stand bracket Rear wheel Driven chain FR wheel bearing bearing 1-19...
1. General Information To this chapter contents Note: 1-20...
Note：I- inspection A- Adjust R- Replace C-Clean L-Lubrication 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.
To this chapter contents 2. Maintenance Information Lubrication System Engine oil quantity Caution Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick. (Do not screw the dipstick into engine when checking.) If oil level is near lower limit, fill in the recommended engine oil to upper limit.
To this chapter contents 2. Maintenance Information Engine Oil Strainer Cleaning Drain engine oil completely. Remove oil strainer and spring. Clean oil strainer. Check if O-ring is deformed or damaged. If not, it can be re-used. Install oil strainer and spring. Install oil strainer cap.
To this chapter contents 2. Maintenance Information Fuel System 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 Fuel filter cleaning Warning:...
To this chapter contents 2. Maintenance Information Air Filter Screw×5 Bolt×1 Air filter element Remove the right side cover. Remove the air filter cover (5 Screws, 1 Bolt) Remove the air filter element Check the filter element for dirty or damaging. Wash the air cleaner filter with high flash point solvent (for example, kerosene or diesel) Squeeze out the cleaning solvent thoroughly,...
To this chapter contents 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 tubes.
To this chapter contents 2. Maintenance Information Valve clearance inspection and adjustment. Check the intake and exhaust valve clearance by inserting the feeler gauge between the adjusting screw and the lock nut. Valve clearance： 0.05±0.02 mm 0.05±0.02 mm Adjust by loosening the lock nut first, and turning the adjusting screw until you feel slight drag on the feeler gauge.
To this chapter contents 2. Maintenance Information Idle Adjustment Caution: You should finish all the other configurations before idle speed adjustment. The engine must be fully warmed before idle adjustment. Use the main stand of the bike, and warm up the engine.
To this chapter contents 2. Maintenance Information Re- install the spark plug cap. Ignition System “F” Mark Ignition timing Caution: C.D.I ignition system is set by manufacturer so it cannot be adjusted. Ignition timing check procedure is for checking whether CDI function is normal or not.
To this chapter contents 2. Maintenance Information Cylinder Compression Test Spark plug hole Warm up engine and turn it off. Remove spark plug cap and spark plug. Install compression gauge into the spark plug hole, full open the throttle, and kick the kick starter for several times.
To this chapter contents 2. Maintenance Information Clutch Adjustment 10~20 mm Clutch lever free play inspection Slightly pull the clutch lever to check the free play before clutch disengagement. Free play：10~20 mm Clutch lever free play adjustment Lock nut Adjusting nut Before adjusting the clutch lever free play, please loosen the lock nut first.
To this chapter contents 2. Maintenance Information Drive Chain Adjustment Drive chain inspection. 10~20 mm 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.
To this chapter contents 2. Maintenance Information Steering Mechanism Caution: Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel off the ground. Turn handle from right to left and check if turning is smoothly.
To this chapter contents 2. Maintenance Information Suspension System Caution: Do not ride the motorcycle with poor cushion. Looseness, wear or damage cushion will make poor stability and maneuverability. Front cushion Press down the front cushion for several times to check its integrity. Check if any oil leaks or damage found.
To this chapter contents 2. Maintenance Information Disk Brake System Brake System Hose Check the brake hoses for corrosion or brake fluid leaking. 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.
To this chapter contents 2. Maintenance Information Air Bleed Operation Master Cylinder Cap Connect a transparent hose to draining 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 Upper limit transparent hoses.
To this chapter contents 2. Maintenance Information Drum Brake System Rear brake pedal free play Press down the brake pedal slightly, and measure the free play before brake engagement. Free play：20~30 mm 20~30mm Turn the brake-adjusting nut clockwise to decrease the free play. Or turn the nut counterclockwise to increase the free play.
To this chapter contents 2. Maintenance Information Tire Check the pressure of the tire to see if it’s in the specified pressure range. Caution: Tire pressure check should be done when the tire is cold. Specified tire pressure range Tire pressure Single ride Tire pressure when With...
To this chapter contents 2. Maintenance Information Negative pole Battery Battery removal Remove the left side cover. Remove the〝─〞negative pole first, then remove the〝＋〞positive pole. Unplug the ventilation tube Remove the battery holder and take out the battery. If the battery liquid level is too low, please remove the top plug, and fill in distilled water to the upper limit.
To this chapter contents 2. Maintenance Information Headlight Adjustment headlight adjust. screw 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.
2. Maintenance Information Special Tools Valve cover wrench Name Name Name Rocker arm shaft disassemble tool Valve remove and assemble tool SYM-1236100 SY No. SYM-1445100 SY No. SY No. SYM-1471110/20 TAPPET ADJUSTING Name Valve spring compressor Name Tappet adjusting wrench Name TOOLS SY No.
To this chapter contents 2. Maintenance Information Name Inner bearing puller set Name Outer bearing puller Name Steering Nut Wrench SY No. SYM-6204025 SY No. SYM-6204001 SY No. SYM-5320000 Name Crankcase bush puller 30mm Name Electrical Gauge Name SY No. SYM-1120310 SY No.
To this chapter contents 2. Maintenance Information Note: 2-24...
Homepage Contents 3. Fuel System Mechanism Diagram ················· 3-1 Carburetor Installation·············· 3-8 Precautions in Operation ········· 3-2 Air Cut-off Valve ························ 3-9 Troubleshooting························ 3-3 Idle Speed Adjustment ············· 3-10 Carburetor Removal·················· 3-4 Fuel Tank ··································· 3-11 Throttle Valve ···························· 3-6 Air Cleaner ·································...
To this chapter contents 3. 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. Caution 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.
To this chapter contents 3. Fuel System Troubleshooting Engine won’t start Late ignition timing No fuel in fuel tank Malfunction of ignition system Clogged fuel tube Malfunction of carburetor Excessive fuel in cylinder No spark from spark plug (malfunction of Weak engine power ignition system) Fuel system clogged...
To this chapter contents 3. Fuel System Carburetor Removal Manual fuel Automatic Fuel cock cock (Vacuum) Removal Turn the fuel cock switch to the S position ( If the fuel cock is vacuum type, it won’t be necessary) Put a container near the fuel drain screw, and loosen it.
To this chapter contents 3. Fuel System Remove the carburetor fuel tube. Loosen the Fuel tube Carb holding screw ×2 clamp from the air- cleaner side, and unplug the fuel tube. Remove the carburetor holding nuts. Remove the carburetor. A/F clamp Installation Install as the reversed order of removal procedures.
To this chapter contents 3. Fuel System Throttle Valve Disassembly Compress the throttle spring and disassemble the throttle cable, and the spring. Disassemble the needle seat and the needle Throttle valve Top cover from the throttle valve. Check the throttle valve and the needle to see if they are damaged or not.
To this chapter contents 3. Fuel System Float pin Inspection Check the float valve and valve seat to see if any damage or blocking. Check float valve for wearing, and check valve seat face for wear, dirt. Caution In case of worn out or dirty, the float valve and valve seat will not close tightly.
To this chapter contents 3. Fuel System Assemble Before assembling, please blow the fuel passages with compressed air. Assemble the main jet, jet holder, nozzle, slow Slow jet Main jet jet, and the air screw. Caution Please assemble the air screw with the ●...
To this chapter contents 3. Fuel System Air Cut-off Valve 螺絲 ×2 Removal Removal the throttle cable seat (2 screws) Remove the screws (2 screws) of the air cut-off valve and the cover. Remove the spring and vacuum diaphragm Check the diaphragm to see if deterioration or crack found.
To this chapter contents 3. Fuel System Idle Speed Adjustment Air adjusting screw Idle adjusting screw Caution Air-screw was set at factory, so no adjustment is needed. For easy installation, count the number of circles it takes to screw the air-screw to the bottom. The idle adjustment process must be done while the bike is on its main stand.
To this chapter contents 3. Fuel System Fuel Tank Outlet fuel Vacuum tube tube Fuel tank removal Manual fuel cock Turn off the fuel cock switch, and disassemble the outlet fuel tube. Vacuum operated automatic fuel cock Disassemble the outlet fuel tube and the vacuum tube.
To this chapter contents 3. Fuel System Slightly pull the fuel tank back toward the tail of the bike. This will help the fuel tank to separate from the frame. Disassemble the fuel gauge coupler. Remove the fuel tank. Caution If the fuel tank is broken or leaking, please change a new one immediately.
To this chapter contents 3、Fuel System Air Cleaner Screw ×5 Remove the air filter cover (Screw x 5, bolt x 1) Bolt×1 Remove the air filter element. Air filter element Remove the air filter holding plate and take out the air filter element. (Screw×1)。 Screw×1 Wash the air filter element with non-flammable or high flash-point solvent.
To this chapter contents 3、Fuel System Air filter assembly removal Fuel vapor recycle Remove the right body cover tube Remove the cushion. Loosen and remove t he air filter tunnel clamp and unplug the fuel vapor recycle tube. Air filter tunnel clamp Remove the air filter box mounting bolts.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Engine Oil Turn off engine, and park the scooter on flat surface with main stand. Check oil level with oil dipstick. Do not screw the dipstick in while checking. Upper If oil level is low, fill into recommended oil to limit...
Disassemble the kick-starter lever (bolt×1) Bolt×11 Remove the engine R case(bolts×11)。 Remove the centrifugal oil strainer cover. (screw×3)。 Screw×3 Remove the centrifugal oil strainer anti-loosen nut, and remove the oil strainer. Special tool： Centrifugal oil strainer special nut socket: SYM-9023100-SY125 Anti-loosen nut...
To this chapter contents 4 、 Lubrication / Clutch / Transmission Remove the initial driven gear Bolts×2 Remove the oil pump gear protective cover (bolts×2) Remove the driven gear and driven shaft. Driven shaft Remove the oil pump(screw×2)。 Caution It’s recommended to remove the oil pump holding screw with impact screw driver.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Oil pump disassembly Remove the oil pump cover(screw×2)。 screw×2 Remove the oil pump cover and the gasket. Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Service limit: under 0.35 mm Check clearance between inner and outer rotors.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Check the unevenness between rotor face and pump body Service limit: 0.11 mm Oil Pump Assembly / Installation Install inner and outer rotors into the pump body. Align the pump cover and the gasket and Screw×2 assemble it properly.
Install the oil pump gear protective cover. (Bolt×2) Torque value：0.4~0.6kgf-m Install the centrifugal oil strainer, and tighten the anti-loosen nut. Torque value：5.0~6.0kgf-m Special tool： Centrifugal oil strainer special nut socket: SYM-9023100-SY125 Anti-loosen nut Install the centrifugal oil strainer cover. (screw×3)。 Torque Value：0.3~0.4kgf-m Screw×3 4-10...
To this chapter contents 4 、 Lubrication / Clutch / Transmission Install the alignment pin and a new right Alignment pin crankcase gasket. Bolts×11 Install the right crankcase cover. ( Bolt X 11 ) Torque Value：0.8~1.2kgf-m Assemble the clutch cable. Clutch cable Bolt×1 Assemble the kick-starter, lever, and the...
Remove the centrifugal oil strainer anti-loosen nut, and remove the strainer. Special tool： Centrifugal oil strainer special nut socket: SYM-9023100-SY125 Bolt×4 Remove the clutch lifter plate holding bolts. (Bolts X 4) Remove the lifter plate and spring. Remove the 20 mm holding ring.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Turn the 20mm washer to match the indent on the main shaft with that on the washer. Remove the washer and disassemble the clutch outer 20mm Washer Disassemble the clutch center, clutch plates, Clutch center Clutch pressing plate clutch friction disks, and the pressing plate.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Clutch plate inspection Use a feeler gauge to measure the warp of each clutch plate. Service limit：under 0.2mm Clutch outer inspection Check the clutch outer to see if any cracks or damage can be found.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Install the clutch spring, lifter plate, and tighten Bolt×4 the holding bolts. (Bolt X 4) Install the lifter rod. Install the centrifugal oil strainer Lifter rod Oil strainer Assemble the right crankcase cover. (Bolt X 11) Connect the clutch cable Install the Kick-starter, kick-starter lever, and...
To this chapter contents 4 、 Lubrication / Clutch / Transmission Gear Shift Linkage Mechanism Gearshift linkage disassembly Remove the shifting lever. (Bolt X 1) Bolt×1 Drain all the engine oil. Disassemble the kick-starter, exhaust pipe, and the starting lever. Disassemble the clutch cable Remove the right crankcase cover.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Disassemble the shifting cam. (Bolt×1) Remove the 4×10mm alignment pin. Shift cam Inspection Check the shifting spindle and the fork assembly to see if any damage. Check the shifting drum stopper arm and the return spring to see if any damage or worn.
To this chapter contents 4 、 Lubrication / Clutch / Transmission Gear shift linkage mechanism installation Alignment pin Install the shifting cam by matching the 4×10mm alignment pin. Tighten the holding bolt for shifting cam. (BoltX1) Torque value：0.8~1.2kgf-m Assemble the shifting drum stopper and the return spring.
Starting Motor repairing process and cautions, please refer to Chapter 13 Specifications measurement：mm Item Service Limit 54.060 Start Driven Gear exterior diameter Starting Clutch interior diameter 54.940 Torque Value Flywheel Bolt 5.0~6.0kgf-m R crankcase cover bolts 0.8~1.2kgf-m Starting clutch inner-hexagon bolts 1.0~1.4kgf-m with screw adhesive Special Tool Flywheel puller SYM-3111000...
To this chapter contents 5. AC Generator / Starter Clutch ACG Stator Disassembly Stator Coupler ACG Stator Disassembly Remove the seat (bolts×2). Remove the ACG coupler. Remove the gear shift pedal (Bolt×1)。 Bolt×1 Remove the left crankcase chain cover (Bolts ×2).
To this chapter contents 5. AC Generator / Starter Clutch Remove the left crankcase cover(Bolt×9)。 Bolt×9 Remove foreign objects and gasket residue on the interface of crankcase and cover. Remove the ACG stator holding screws (screw×2). Screw×2 Remove the stator composition.
To this chapter contents 5. AC Generator / Starter Clutch ACG stator inspection Check the following circuit for electricity Green/White conductivity. Yellow ~ Pink 0.9Ω±10% Light Green/ Red Black/ red Black/White ~ Grounding 420Ω±10% Green/White ~ Blue/White 105Ω±10% Light Green/ Red (for the neutral gear sensor) Yellow Blue/White Pink...
Remove the flywheel with special tool- Flywheel puller, starting clutch, and the start driven gear. Special Tool： ACG Flywheel puller SYM-3111000 Flywheel puller Remove the start driven gear, and its shaft. Start driven gear Inspection on starting clutch Assemble the start driven gear onto the starting clutch.
To this chapter contents 5. AC Generator / Starter Clutch Check if the start driven gear is damaged or worn. Measure the inner diameter of start driven gear. Service limit： Inner diameter：under 10.05 mm Measure the exterior diameter of the start driven gear shaft.
To this chapter contents 5. AC Generator / Starter Clutch ACG flywheel/ Start clutch assembly Assemble the start driven gear and its gear shaft. Start driven gear Install the ACG flywheel, start clutch, and start gear. Tighten the ACG flywheel (Bolt×1). Torque Value：5.0~6.0kgf-m Bolt×9 Insert the dowel pin, set the L crankcase cover...
Homepage Contents 6. Engine Removal Precautions in Operation ···········6-1 Engine Installation ······················6-7 Engine Removal ··························6-2 Precautions in Operation General information During 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 staying on the frame: ●...
To this chapter contents 6. Engine Removal Engine Removal Drain all the engine oil out. Engine oil drain bolt Remove the left body cover. Negative pole Positive pole Remove the battery cable, first negative then positive pole. Remove the battery Caution To prevent short circuit, always connect the positive pole before the negative one.
To this chapter contents 6. Engine Removal Remove the PCV tube. PCV tube Remove the AICV tube. AICV tube Choke cable Loosen the choke cable holder screw h ld (screwX1), and remove the choke cable. Disassemble the carburetor top cover by Top cover turning counterclockwise.
To this chapter contents 6. Engine Removal Remove the fuel tube of carburetor. Fuel tube Holding nut×2 Loosen the air filter pipe strainer, and separate the pipe. Remove the carburetor holding nuts. (Nut X Remove the carburetor. Air filter pipe strainer Sleeve nut Rear wheel axle nut Loosen the rear wheel axle nut, and the...
To this chapter contents 6. Engine Removal Remove the front exhaust pipe holding nuts. (Nut X 2) Nut×2 Remove the rear exhaust pipe holding nuts. (Nut X 2) Remove the exhaust pipe. Nut×1 Bolt×4 Remove the footrest (bolt×4) Clutch lever Adjusting nut Loosen the clutch cable holding nut and adjusting nut.
To this chapter contents 6. Engine Removal Settle the engine on a rack. Remove the engine front hanger. (Nut X 4) Nut×4 Remove the engine rear holding bolts. (Nut X 2, bolt X 2) Nut×2 Nut×1 Remove the engine upper holding nut. (Nut X1, bolt×1) Pull out the bolt and remove the engine.
To this chapter contents 6. Engine Removal Engine Installation Assemble the engine in the reversed procedure of disassembly Caution When assembly, always pay attention to the possible injuries. All the wires and cables can’t be bent or pressed. Please align the wires and cables in accordance with the setting diagram.
To this chapter contents 6. Engine Removal Note:...
To this chapter contents 7. Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on cylinder-head perimeter parts. The trouble usually can be determined or by performing cylinder compression test or judging the abnormal noise. Poor Idling Compression pressure is too low.
To this chapter contents 7. Cylinder Head / Valve Cylinder Head bolt×4 Cylinder Head Removal Remove engine. (Refer to chapter 6) Remove the AI tube on the left side of the engine (bolt×4) Remove the cylinder head cap with the Cylinder head cap cylinder head cap wrench...
To this chapter contents 7. Cylinder Head / Valve Remove the cam-chain sprocket (bolt×2) Bolt×2 Tensioner bolt Caution After removing the sprocket, you must pull cam-chain out to prevent it from falling into the crankcase. Remove the 8mm bolt on the left side of the Tensioner bolt cylinder head, then remove the cam-chain tensioner holding bolt...
Screw in a 5mm bolt or use the Rocker arm and camshaft puller to pull out the rocker arm and the camshaft. Special tool： Rocker arm and camshaft puller SYM-1445100 Camshaft Inspection Check the camshaft for any wearing or loosen, also the bearing on the camshaft. Service Limit：Intake 30.8mm...
To this chapter contents 7. Cylinder Head / Valve Rocker Arm I.D. Measure the cam rocker arm Inner Diameter for wear or damage. Also check if the oil hole is clogged? Rocker arm I.D. Service Limit：Replace when it’s over 12.1mm Oil hole Contact face Rocker Arm Shaft Inspection...
To this chapter contents 7. Cylinder Head / Valve Special tool： Valve spring compressor Valve spring compressor SYM-1471100 Caution Do not over compress the valve spring. When removing the carbon deposit, beware not to damage the components inside the combustion chamber.
To this chapter contents 7. Cylinder Head / Valve Valve Stem Inspection Check if valve stem is bent, cracked or burnt. Check the operation condition of valve stem in valve guide, and measure the valve stem outer diameter. Service Limit: Intake valve: Under 5.42mm Exhaust valve: Under 5.40mm Valve Guide Inspection...
To this chapter contents 7. Cylinder Head / Valve Valve Guide Replacement Heat the cylinder head with heated plate or toaster till the temperature reaches 100~150 ℃. Valve Guide driver Caution Do not use flame to heat the cylinder head directly. Otherwise, the cylinder head will be deformed.
To this chapter contents 7. Cylinder Head / Valve Valve Seat Inspection and Refacing 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.
To this chapter contents 7. Cylinder Head / Valve Rotate the valve seat cutter clockwise and 4~5kg counterclockwise with 4 to 5 kg pressure in order to fix the uneven part. Caution Apply motor oil to the contact face while grinding it.
To this chapter contents 7. Cylinder Head / Valve Use the 45 degree cutter and cut the seat to the proper width. 1.0mm Caution Confirm that all roughness is removed. 45° Coat the valve seat surface with red paint. Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a Contact face too...
Valve stem Install the valve by using valve installer or seal valve spring compressor. Valve spring Special tool： retainer Valve remove / install tool SYM-1471120 Valve spring compressor SYM-1471100 Caution Valve spring Valve In order to avoid damaging the valve...
To this chapter contents 7. Cylinder Head / Valve Cylinder Head Installation Install the cam chain guide. Put the dowel pins and new cylinder head gasket onto the cylinder. Dowel pins Cam chain guide Gasket Install the cylinder head. Lubricate the cam shaft and install it onto the cylinder head.
To this chapter contents 7. Cylinder Head / Valve Use a T type wrench to rotate the crankshaft clockwise and align the “T” mark on the flywheel with the index mark on the left crankcase cover. Install the cam chain sprocket and align the Timing mark timing mark with the index mark on the cylinder head.
To this chapter contents 7. Cylinder Head / Valve Valve Clearance Adjustment TDC mark Caution Inspect and adjust the valve clearance when the engine is cool (under 35°C). Remove the tappet adjusting hole cap. Remove the cylinder head side cover. Use a T type wrench to rotate the crankshaft clockwise and align the “T”...
To this chapter contents 7. Cylinder Head / Valve Note: 7-18...
To this chapter contents 8. Cylinder / Piston Precautions in Operation General Information The engine must be removed from the frame before the repairing of the cylinder and the piston. Specification Measurement unit：mm Specification Subject Standard Service Limit Cylinder Inside Diameter 56.000~56.010 56.100 －...
To this chapter contents 8. Cylinder / Piston Cylinder Removal / Inspection Remove the cylinder head (refer to chapter 7). Remove the cylinder head gasket and the dowel pins Remove the cam chain guide Dowel Cam chain pins guide Remove the cylinder. Caution Prevent the camshaft chain from falling into the crankcase when removing the...
To this chapter contents 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：37.50 mm Center Calculate the taper and out of round at three levels in X and Y axis.
To this chapter contents 8. Cylinder / Piston Piston Removal / Inspection Block the crankcase and camshaft chain hole with a clean cloth in order to prevent the piston pin clip falling into the crankcase Piston pin clip Cover the holes of crankcase and cam chain with a piece of clean rag.
To this chapter contents 8. Cylinder / Piston Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston. Measure the piston ring end gap. Caution Use the piston head to push the piston ring squarely into the cylinder.
To this chapter contents 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：55.87mm Compare the measured value with service limit to calculate the clearance between the piston and cylinder.
To this chapter contents 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 ring as diagram shown. Caution Do not damage the piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
To this chapter contents 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. Install piston and piston pin and make the IN IN mark mark facing forward...
To this chapter contents 8. Cylinder / Piston Cylinder Installation Install the dowel pins and the new cylinder gasket. Dowel pins Apply clean motor oil to the cylinder bore, piston and piston rings. Install the cylinder carefully. Press the piston rings if necessary. Note Do not push the piston into the cylinder forcefully because the piston and piston...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Troubleshooting Excessive engine noise Worn connecting rod big end Worn crankshaft bearing Worn piston pin or piston pin hole Hard to shift gear Bent shift fork Bent shift fork shaft Bent shift fork claw Transmission jumps out of gear Worn gear teeth...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Crankcase Disassembly Screw ×1 Bolt ×1 Remove the 6mm screw and clutch wire hold bolt from the right crankcase. Remove the cam chain tensioner arm (bolt x Remove the cam chain.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Crankshaft Inspection Use a feeler gauge to measure left and right clearance of connecting rod big end. Service limit：0.6mm Measure the clearance of the big end at the vertical directions.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Measure the inner diameter of the crankshaft small end. Service limit：15.08mm Shift fork shaft Transmission Disassembly Remove the gear shift fork shaft. Left Center Right Remove the gear shift forks and shift drum. Right Left Center...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Transmission Inspection Check if the gear shift fork is 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.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Disassemble the gears and washers on the 4-speed main shaft and counter shaft. Arrange the gears and washers in order. Check the teeth and grooves of the gear for wear and damage.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Kick Starter Disassembly Return spring Remove the kick starter return spring. Pull out the kick starter spindle and pinion from the right crankcase. Washer Pinion Washer Circlip Remove the thrust washer and kick starter Ratchet ratchet.
Crankcase bearing removal Remove the damaged bearing by using the inner bearing puller. Special tool： Inner bearing puller SYM-6204020 Crankcase bearing installation Install the new bearings onto the crankcase by using bearing driver. Special tools：...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter 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.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Install the main shaft and counter shaft to the right crankcase. Caution Make sure the thrust washer in the position. Install the gear shift drum. Caution The letters on the left and center shift fork should face upward;...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Install the crankshaft to the right crankcase. Install the new crankcase gasket and dowel pins. Dowel pins Install the left crankcase. Screws ×9 Tighten crankcase left side screws. Torque value：0.8~1.2kgf-m 9-14...
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Tighten crankcase right side screws and Screw ×1 Bolt ×1 clutch wire holder. Torque value：0.8~1.2kgf-m Coat grease to the new counter shaft oil seal and assemble the left crankcase. Install the cam chain.
To this chapter contents 9. Crankshaft / Crankcase / Transmission / Kick Starter Note: 9-16...
To this chapter contents 10. Brake System Troubleshooting Disk Brake Soft brake lever Uneven brake 1. Dirty brake pad / disk 1. Air inside the hydraulic system 2. Poor wheel alignment 2. Hydraulic system leakage 3. Clogged brake hose 3. Worn master cylinder piston 4.
To this chapter contents 10. 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.
To this chapter contents 10. Brake System Remove the reservoir cap and diaphragm. Reservoir cap Fill the clean brake fluid. Caution Diaphragm Contaminated brake disk or pad Fluid level upper limit decreases braking performance. Foreign material will clog brake system Brake fluid and lead to decline or malfunction of braking capability.
To this chapter contents 10. Brake System Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and remove the Bolt×2 brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Brake hose bolt Confirm the brake pad wear condition.
To this chapter contents 10. Brake System Brake pad replacement Remove the brake pad guide bolt cap. Cap ×2 Loosen the brake pad guide bolts first. Bolt x 2 Remove the front brake caliper. Pull out the brake pad guide bolts. Remove the brake pads and position reed.
To this chapter contents 10. Brake System Brake Disk Inspection Brake disk Visually check the brake disk for wear or damage. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Service limit：3.0 mm Micrometer Remove the brake disk from wheel.
To this chapter contents 10. Brake System Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y axis. Replace the master cylinder if the measured values exceed service limit.
To this chapter contents 10. Brake System Installation Install the brake caliper and tighten the lock bolts. Torque value：0.8~1.2kgf-m Assemble the brake lever and connect the Bolt ×2 brake light coupler. Seal washer Connect the brake hose with 2 new washers. Tighten the brake hose bolt to the specified torque value.
To this chapter contents 10. Brake System Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust. Caution Inhaling asbestos dust may cause ● respiration system disorder or even cancer.
To this chapter contents 10. Brake System Removal Caution Brake linings must be replaced as a set. Remove the brake shoes from the brake panel by pulling out the brake shoes. Installation Apply a thin coat of grease to the brake cam and the position pin.
To this chapter contents 10. Brake System Note: 10-14...
To this chapter contents 11. Steering / Front Wheel / Front Fork Troubleshooting 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 Bent fork pipes Excessive fork fluid Steering handlebar tilted...
To this chapter contents 11. Steering / Front Wheel / Front Fork Headlight Removal Remove the headlight lock screw. Screw×1 Pull out the headlight assembly. Disconnect the headlight wire coupler and remove the headlight assembly. Headlight coupler Bolt 2 Remove the wire couplers. Remove the headlight case bolt.
To this chapter contents 11. Steering / Front Wheel / Front Fork Bolt×2 Headlight angle adjustment Loosen the headlight side bolts and adjust the headlight angle by moving the headlight case up and down. Tighten the side bolts after adjustment is finished.
To this chapter contents 11. Steering / Front Wheel / Front Fork Wolf Classic 125 R Speedometer cable Removal Remove the headlight. Disconnect wire couplers. Remove the speedometer cable. Remove the main switch locknut. Nut×2 Remove the main switch. Bolt×2 Remove the meter assembly bolt.
To this chapter contents 11. Steering / Front Wheel / Front Fork Steering Handlebar Wolf Classic 125 Removal Remove the back mirror. Remove the headlight. Disconnect the left / right handlebar switch, clutch switch, brake light switch couplers. Screw×2 Throttle cable locknut Loosen the throttle cable locknut.
To this chapter contents 11. Steering / Front Wheel / Front Fork Remove the left handlebar switch (screwx2). Screw×2 Loosen the clutch cable locknut and Locknut adjustment nut. Adjustment nut Loosen the clutch cable locknut and adjustment nut. Remove the clutch lever pivot bolt. Remove the clutch lever and clutch cable.
To this chapter contents 11. Steering / Front Wheel / Front Fork Wolf Classic125R Removal Remove the back mirror. Remove the headlight. Disconnect the left / right handlebar switch, clutch switch and brake light switch coupler. Screw×2 Throttle cable lochnut Loosen the throttle cable locknut.
To this chapter contents 11. Steering / Front Wheel / Front Fork Remove the left handlebar switch (screwx2). Screw×2 Loosen the clutch cable locknut and adjustment nut. Remove the clutch lever pivot bolt. Remove the clutch lever and clutch cable. Loosen the clutch lever bracket (boltx1).
To this chapter contents 11. Steering / Front Wheel / Front Fork Front Wheel Axle nut Removal Use a bracket to hold the bottom of engine and let the front wheel away from the ground. Remove the speedometer cable. Remove the front wheel axle locknut. Pull out the front wheel axle.
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. Apply grease to the wheel hub / bearing Bearing will be damaged in these two examples of assembly.
To this chapter contents 11. Steering / Front Wheel / Front Fork Speedometer gear retainer Oil seal Installation Install the speedometer gear retainer. Apply grease to the inner and outer side of oil seal and install oil seal into the wheel hub. Oil seal Apply grease to the inner and outer side of oil seal and install oil seal into the wheel hub.
To this chapter contents 11. Steering / Front Wheel / Front Fork Place the front wheel between the front forks. Stopper Align the groove on the speedometer gear with the raised stopper on the left front fork. Install the front wheel axle from the right fork. Wheel axle nut Install the wheel axle nut and tighten it to the specified torque value.
To this chapter contents 11. Steering / Front Wheel / Front Fork Front Fork Bolt×1 Removal Remove the front wheel and front brake parts. Remove the brake hose clamp from the right fork (boltx1). Bolt, nut Wolf Classic 125 Loosen the fork upper bolt on the top bridge (nutx2, boltx2).
To this chapter contents 11. Steering / Front Wheel / Front Fork Remove the front fender (boltx4). 2 bolts for both sides Remove the front fork bolt from the steering Bolt for both sides stem and remove the front fork. Oil seal inspection / replacement Push the fork pipe for several times to check if Scratch...
To this chapter contents 11. Steering / Front Wheel / Front Fork Coat the inner side of the new oil seal with cushion oil and then put in the fork pipe. Install the oil seal to the right position by using Stopper ring an oil seal driver.
To this chapter contents 11. Steering / Front Wheel / Front Fork Fork pipe cap Installation Caution Rotate the fork pipe during installation will make it easier to install the fork pipe. Wolf Classic 125 Install the fork pipe from the bottom of the front fork.
To this chapter contents 11. Steering / Front Wheel / Front Fork Wolf Classic 125 R Handlebar Fork pipe cap Install the fork pipe from the bottom of the front fork. Align the fork pipe cap with the steering handlebar. Bolt Hold the fork pipe by hand and tighten the front fork upper bolt and nut.
Remove the top bridge. Top bridge locknut Remove the steering stem locknut and steering upper cone race. 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.
1/2 circle and then tighten it with specific Clockwise torque value (1/4~3/8 circle). 1/4~3/8 circle Special tool： Steering stem Upper cone race wrench SYM-5320000 Torque value：0.15~0.25kgf-m Caution Do not over tighten upper cone race or ● the steering ball race may be damaged.
To this chapter contents 11. Steering / Front Wheel / Front Fork Note: 11-22...
To this chapter contents 12. Rear Wheel / Rear Cushion / Swingarm Rear Wheel Removal Remove the exhaust pipe locknuts. Nut×2 Remove the swingarm pivot bolt nut. Remove the exhaust pipe. Nut×1 Remove the rear brake adjustment nut. Remove the rear brake rod. Adjustment nut Remove the rear brake torque link.
To this chapter contents 12. Rear Wheel / Rear Cushion Loosen the drive chain adjusting nut. Adjusting nut Loosen the driven flange nut. Axle nut Flange nut Adjusting nut Insert a screw driver into the rear wheel axle and fix the axle. Remove the rear wheel axle nut.
To this chapter contents 12. Rear Wheel / Rear Cushion / Swingarm Inspection Wheel axle Put the axle on a V-block and measure the run out. Service limit：0.2 mm Bearing Clearance Turn the inner ring of each bearing to check if it rotates smoothly and quietly.
To this chapter contents 12. Rear Wheel / Rear Cushion Rubber damper×4 Driven flange rubber damper inspection Inspect the rubber dampers on the driven flange for wear or damage. Replace it if necessary. Raised part Groove Rear wheel installation Install the rear brake panel into the brake drum.
To this chapter contents 12. Rear Wheel / Rear Cushion / Swingarm Tighten the drive chain adjusting nut slightly to Adjusting nut×2 prevent it from loosening. Install the rear brake torque link. Torque value：1.8~2.5kgf-m Nut×1 Install the rear brake rod and adjusting nut. Adjust the rear brake pedal free play.
To this chapter contents 12. 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 fixing plate. Bolt×2 Remove the drive chain cover. Remove the drive chain fixing clip.
To this chapter contents 12. Rear Wheel / Rear Cushion / Swingarm Drive chain / sprocket inspection Driven sprocket Check the condition of driven sprocket teeth. Replace the sprocket if the teeth are worn out. Caution Driven sprocket and drive chain condition should be checked at the same time.
To this chapter contents 12. Rear Wheel / Rear Cushion Remove the driven sprocket (boltx4, nutx4). Driven flange inspection Check the flange for wear or damage. Bearing inspection Clearance Turn the inner ring of each bearing to check if it rotates smoothly and quietly. Meanwhile, check if the outer ring fits the Clearance wheel hub closely.
To this chapter contents 12. Rear Wheel / Rear Cushion / Swingarm Driven flange / sprocket installation Install the driven sprocket to the flange. Tighten the bolts and bend the fixing washer. Fixing washer Nut×1 Install the driven flange and sprocket to the swingarm.
To this chapter contents 12. Rear Wheel / Rear Cushion Adjusting nut×2 Drive chain adjustment Rotate the left / right drive chain adjusting nut evenly to make the drive chain slack within normal range. Rotate the adjusting nut clockwise to tighten the drive chain slack.
Check if both sides of rear cushion spring adjusters are adjusted to the same tightness. common cushion：Ⅰ、Ⅱ、Ⅲ、Ⅳ、Ⅴ nitrogen cushion：Adjusting screw thread Special tool： Steering stem locknut socket wrench Soft→ Hard→ SYM-5320000 Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ 12-13...
To this chapter contents 12. Rear Wheel / Rear Cushion Swingarm Removal Remove the swingarm pivot bolt nut. Remove the exhaust pipe, rear wheel, drive chain, drive sprocket, drive chain cover and rear cushion. Nut×1 Nut×1 Remove the rear brake torque link. Pull out the swingarm pivot bolt.
Press out Swingarm rubber bush replacement Press out the swingarm rubber bush. Special tool： Rubber bush puller / driver SYM-1120310 Press in Press in the new swingarm rubber bush. Special tool： Rubber bush puller / driver SYM-1120310 Apply grease to both sides of rubber bush after installation.
To this chapter contents 12. Rear Wheel / Rear Cushion Installation Install in the reverse order of removal. Torque value： Swingarm pivot bolt 3.5~5.0kgf-m Brake torque link locknut 1.8~2.5kgf-m Pivot bolt Rear Brake Pedal Removal Remove the swingarm pivot bolt nut. Return spring Bolt×1 Remove the step bar and exhaust pipe.
To this chapter contents 13. Electrical System Precautions in Operation Charging system When removing the battery, the disconnection sequence of cable terminals shall be strictly • observed. (First disconnect the negative cable terminal then the positive cable terminal.) The electrolyte level should be checked carefully. Add distilled water if electrolyte is not •...
To this chapter contents 13. Electrical System Technical Specification Charging system Item Specification Capacity / Type 12V7Ah / 12N7A Charging rate 0.7A / 5~10hr (standard) 3A / 1hr (quick) Battery Specific gravity of electrolyte (20ºC) 1.260~1.280 Fully charged 13.0~13.2V Voltage (20ºC) Need to be charged 12.3V Characteristic...
To this chapter contents 13. Electrical System Troubleshooting Charging system Ignition system No battery voltage No spark Poor spark plug Battery discharged The cable is poorly connected, open or The cable disconnected short-circuited The fuse is blown ~between AC. Generator / C.D.I. Improper operation of the main switch ~between C.D.I.
To this chapter contents 13. Electrical System Charging System Battery Removal Remove the left side cover. Disconnect the negative terminal wire first and then the positive terminal. Negative terminal Positive terminal Remove the battery fixing bracket (2 nuts). Remove the battery. Install in the reverse order of removal.
To this chapter contents 13. Electrical System Battery voltage inspection Use the digital voltmeter or multi meter to measure the battery voltage. Voltage Fully charged：13.0~13.2V (20°C) Insufficiently charged：Below 12.3V (20°C) Charging Remove the battery cell caps. Connect the charger positive (+) cable to the battery positive (+) terminal.
To this chapter contents 13. Electrical System Charging voltage / current inspection Connect a tachometer. Digital meter Turn on the headlight to high beam and start the engine. Ampere meter Accelerate the engine to the specified revolution per minute and measure the charging voltage.
To this chapter contents 13. Electrical System Current leakage inspection Turn off the main switch. Disconnect the negative terminal wire from the Negative terminal battery. Connect ammeter between battery negative terminal and negative terminal wire (as shown at picture). Caution In the current leakage test, set the current Put up iron range at the largest scale, then gradually...
To this chapter contents 13. Electrical System Charging circuit Main switch Regulator rectifier Battery AC Generator Regulator rectifier inspection Remove the seat and fuel tank. Disconnect the regulator rectifier 6 pin coupler and inspect the wire circuit. Wire harness circuit inspection Coupler Item (wire color) Judgment...
To this chapter contents 13. Electrical System If the readings measured are not normal, check parts in the circuit. If the parts are normal, then trouble is in the wiring. If there is nothing wrong with parts and wiring, replace the regulator rectifier. Regulator rectifier inspection Black Green Yellow Pink...
To this chapter contents 13. Electrical System Ignition System Ignition circuit C.D.I. Main switch B / W B / Y L / W G / W Exciter coil Pulse coil AC Generator Ignition coil inspection Primary coil Remove the seat and fuel tank. Measure the resistance between the terminals of the primary winding.
To this chapter contents 13. Electrical System Pulse coil inspection G / W Disconnect the AC. Generator 6 pin coupler. Measure the resistance between the terminal blue / white and terminal green / white. Standard value：105Ω±10% Caution Coil does not need to be removed from L / W ●...
To this chapter contents 13. Electrical System Spark plug inspection Check the sparking condition. If the sparking condition is not proper or the spark plug electrode is contaminated, replace it with new one. Caution Be extremely careful to carry out the sparking condition inspection.
To this chapter contents 13. Electrical System Starting System Starting circuit Main switch Starter switch Neutral lamp Y / R 矽控整流器 Fuse (15A) G / R LG / R Starter relay Neutral switch Clutch switch G / 紅 Starter motor Battery Starter relay inspection Turn the main switch.
To this chapter contents 13. Electrical System Starter motor removal Nut×1 Disconnect the starter motor wire coupler. Remove the starter motor lock bolts. Remove the starter motor. 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.
To this chapter contents 13. Electrical System Light System N gear Gear sensor Lime/ Red Black Tail / Brake light Brake switch Green/yellow Black 黑 Meter back 黑 Black light 棕 Brown Hi-beam indicator Hi/Lo dimmer Light switch Blue Headlight switch Brown bulb...
To this chapter contents 13. Electrical System Headlight bulb replacement Remove the headlight assembly fixing screw. Screw×1 Pull out the headlight assembly. Disconnect the headlight coupler and remove the headlight assembly. Coupler Bulb coupler Disconnect headlight bulb coupler. Remove the rubber protector. Rubber protector Remove the bulb.
To this chapter contents 13. Electrical System Replace the headlight bulb if necessary. Specification： Headlight bulb 12V 35W/35W Headlight installation Install in the reverse order of removal. Connect the headlight coupler. Headlight coupler Alight the headlight set with the headlight lens. Tighten the lock screw.
To this chapter contents 13. Electrical System Winker bulb replacement Remove the winker lens. Press the winker bulb slightly and rotate it clockwise. Remove the winker bulb. Replace the winker bulb if it is burned out. Specification： Winker bulb 12V 10W Installation Install in the reverse order of removal.
To this chapter contents 13. Electrical System Taillight / brake light Screw×2 Bulb replacement Remove the taillight lens screw. Caution Make sure taillight lens and case properly sealed up during assembly. Waterproof rubber Remove the lens. Press the bulb slightly and rotate it counterclockwise to remove it.
To this chapter contents 13. Electrical System Meter bulb replacement Remove the main switch and meter assembly. Nut×4 Remove the meter cover. Screw×1 Illumination bulb Tachometer Pull out the indicator bulb with bulb seat. Replace the indicator bulb if it is burned out. Specification：...
To this chapter contents 13. Electrical System Switch / Horn Main switch Inspection Remove the headlight assembly. Disconnect the main switch coupler. Main switch coupler Check the following coupler circuit. BAT1 BAT2 Color Black B / W Green B / W Replacement Locknut×1 Remove the headlight assembly.
To this chapter contents 13. Electrical System Handlebar switch Light switch Remove the headlight. Remove the right handlebar switch coupler. Check the following switch circuit. Light switch BAT2 ● Starting switch Hazard switch Color Black Brown Hazard switch ● Color Gray Orange Sky blue...
To this chapter contents 13. Electrical System Dimmer switch Left / right handlebar switch Remove the headlight assembly. Disconnect the left / right handlebar switch wire coupler. Winker switch Check the following coupler circuit. High / low beam switch Horn switch Color Brown White...
To this chapter contents 13. Electrical System Brake switch While grasp the brake lever firmly, the terminals of black and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear brake switch Front brake switch Horn Disconnect the coupler and remove the horn (bolt x 2).
To this chapter contents 13. Electrical System Fuel Unit / Fuel Level Warning Switch Fuel level warning switch inspection Remove the fuel level warning switch. Measure the switch resistance. Resistance：960Ω±10% Replace the gasket if it is deformed or damaged. Caution Make sure there is not too much fuel in the fuel tank before proceeding operation.
Home page Contents 14. Emission Control System Emission Control System Secondary Air Introduction System Mechanism································· 14-1 ···················································· 14-5 Function of Mechanism in the Positive Crankcase Ventilation Emission Control System········· 14-1 System (P.C.V.)·························· 14-8 Fuel Evaporative Emission Control Inspection Items ························ 14-9 System (E.E.C.)··························...
To this chapter contents 14. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) Construction: Reduce HC to pollute air. To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Carburetor Automatic control...
To this chapter contents 14. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge...
To this chapter contents 14. Emission Control System Catalytic Converting System (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.
To this chapter contents 14. Emission Control System Secondary Air Introduction System Construction Secondary air filter Carburetor Intake valve Flesh air Vacuum hose Engine Cylinder head Reed valve Flesh air Mixture gas First burn exhaust Exhaust valve Purged exhaust gas Air injection cut valve Vacuum Exhaust pipe...
To this chapter contents 14. Emission Control System 3. Service Points/Trouble Diagnosis: Diesel a. Malfunction of air inject cut valve (AICV). b. System hose leakage. c. abnormal ignition timing. d. lean mixture gas. e. abnormal fuel supply. Rich Exhaust Gas: a.
To this chapter contents 14. Emission Control System Warm-up test: Start engine. Remove the air injection filter. Check the air inlet if there is air-sucking sounds during idling (should hear Bo-Bo-Bo sound). Air injection cut valve Carburetor Air inlet Reed valve Air filter Secondary air inject Exhaust muffler...
To this chapter contents 14. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Exhaust pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.
To this chapter contents 14. Emission Control System Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1.
To this chapter contents 14. Emission Control System Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2) Clean the carburetor Keep the CO value in 1.5~4.5% (note 3) by adjusting...