Baja WD400U Service Manual
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Baja WD400U Service Manual

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WD400U Service Manual
For any questions please contact Baja Motorsports at 888-863-2252

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Summary of Contents for Baja WD400U

  • Page 1 WD400U Service Manual For any questions please contact Baja Motorsports at 888-863-2252...

  • Page 2: Table Of Contents

    Content Content..............................2 Chapter I General description.......................5 Section  Special tools, instruments & meters..................6 (I) Special tools.........................7 Section 2 Identification code, label of model and engine No...............8 Section 3 Points for attention in maintenance..................8 Section 4 Specification........................12 I. How to use conversion table of unit................... 12 (1) How to use conversion table....................
  • Page 3 Section 5 Maintenance and adjustment of engine................46 (I) Cleaning of air filter......................46 (II) Inspection of spark plug....................47 (III) Adjustment of idle speed....................48 (IV) Adjustment of free clearance of throttle grip..............48 (V) Adjustment of speed limiter.................... 49 (VI) Adjustment of valve clearance..................
  • Page 4 Section 6 Troubleshooting electric starting system................. 109 Section 7 Battery will not hold charge..................... 112 Section 8 Troubleshooting........................ 114 Section 9 Inspection of lighting system................... 116 (I) Headlight not working..................... 116 (II) Taillight not working...................... 117 Section 10 Troubleshooting......................118 (I) If indicated lamp is out of work..................

  • Page 5: Chapter I General Description

    Chapter I General Description Section 1 Description . Front wheel 2. Headlight 3. Forward/Reverse lever 4. Shift pedal 5. Fuel valve 6. Hand-operated lever 7. Air choke 8. Taillight 9. Rear wheel 10. Rear luggage carrier 11. Exhaust silencer 2. Cushion 13.

  • Page 6: Section  Special Tools, Instruments & Meters

    Section 1 Special tools, instruments and meters (I) Special tools There are special tools needed to properly adjust and assemble this unit. These tools are intended to prevent maintenance defects and damage. 1. Wrench for valve adjustment, mainly used to adjusting the valve clearance. Specification: 3mm, 90890-01311 2.
  • Page 7 (II) Instruments and meters The following instruments and meters can be selected with reference to the same type of vehicle.

  • Page 8: Section 2 Identification Code, Label Of Model And Engine No

    Section 2 Identification code, label of model and engine No. Identification code Engraved in the left or right side of the front supporting main tube of engine of frame Engine No. This is engraved on the top middle part of the right crankcase of engine.
  • Page 9 4. Clip Before assembling, check all the clips carefully. Replace with a new one after removing from piston pin. When mounting clip ring (1), make the sharp end face (2) on the opposite position of impacted face (3) of clip. (see figure at left) 5.
  • Page 10 7. Check of electric parts Make sure there is no rust, dirt or moisture at the connection, if there is blow it dry or clean. The electrolyte inside the battery is corrosive, take extra precautions as to not get this on your body. When repairing wires on electrical parts, remove the wire on the terminal of negative pole of battery (see figure 7.1).
  • Page 11 B. If there is slack in the joint, bend the plug pin upward, then connect with connector plug (see figure 7.5) Before mounting the new fuse, check if the load of fuse on the components are correct, especially the portion being broken regularly, then mount the fuse having proper current value.

  • Page 12: Section 4 Specification

    Section 4 Specification I. How to use conversion table of unit (1) How to use a conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could ne conversed into imperial unit. Metric Multiply Imperial...

  • Page 13: Ii. Basic Specification

    II. Basic specification Dimensions: Shaft drive Overall length 75.5in Overall width 4in Overall height 44in Seat height 35.25in Wheel base 49in Ground clearance 7.75in Minimum turning radius 8.in Weight with oil and fuel 573lbs. Engine: Type Oil cooled 4-stroke Cylinder arrangement Forward-inclined single cylinder Displacement 387cc Bore and stroke...
  • Page 14 Chassis: Frame type Steel tube frame Caster angle Trail 2mm (0.83in.) Tire: Tubeless Type AT25 8-2 Size AT25 0-2 Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Drum brake operation Left hand and right foot operation Suspension: Front Double wishbone...

  • Page 15: Iii. Atv Body

    III. ATV body Item Standard Limit Steering system Powder metallurgy sliding Type of steering bearing bearing Type Rim, tubeless tire Front Material of rim Steel plate Wheel Size of tire AT25x8-12 Size of rim AT 12x8 Front Brake Type Hydraulic disc Type Spoke rim, tubeless tire Rear...

  • Page 16: Iv. Electric System

    IV. Electric system Item Standard Voltage of electric system Spark plug Type DR8EA/NGK Resistence 10Ω Clearance of spark plug 0.6-0.7mm (0.023-0.027in) Resistence of primary coil At 20°C(68˚F), 0.5-1.5Ω Ignition coil Resistence of secondary coil At 20°C(68°F), 10.3-12.2Ω Clearance of min. spark 6mm(0.24in) Item Standard...

  • Page 17: V. Maintenance Specification Of Engine

    V. Maintenance Specification of Engine Item Standard Limit Axle Drive Meshing clearance of last end gear 0.-0.2mm (0.004-0.008in) Meshing clearance of middle gear (forward) 0.-0.2mm (0.004-0.008in) Meshing clearance of middle gear (backward) 0.-0.25mm (0.004-0.0in) Lubrication system: Type of oil filter Wire filter net Type of oil pump Rotor type, pressure splash type lubrication Clearance of side 0.04-0.09mm (0.0015-0.0351in)
  • Page 18 V. Maintenance Specification of Engine Item Standard Limit Valve spring: Outside spring: Free length: intake/exhaust 37.2mm (.45in) Setting length when valve is closed: 32.0mm (.25in) Compressing pressure when assembling:intake/exhaust 162.8-200.1N Limit value of sqaureness:intake/exhaust 2.5˚/1.6mm Twisting direction of spring (top view):intake/exhaust clockwise Valve, valve seal, valve guide Valve clearance (it’s cold): intake 0.02-0.03mm(0.00078-.007in)
  • Page 19 V. Maintenance Specification of Engine Item Standard Limit Piston Piston size “D” 70.92-70.97mm(2.77in) Measuring point “H” (from bottom line of piston lower portion) 4.0mm(0.56in) Piston offset 0.5mm(0.0195in) Direction of piston offset Inward Clearance between piston and cylinder 0.04-0.006 0.5mm Outside diameter of piston pin 15.991-16mm(0.624-0.624in) Inside diameter of pin hole 6.002-6.03mm(0.624-0.625in)
  • Page 20 Section 5 Requirements for torque fastening Torque value of fasteners Locking component and location on ATV Hard- Size of Qty Nm ft·lb ware thread Cylinder head Bolt M10x238 Cylinder head Bolt M10x216 Front and rear valve cover Bolt M6x20 Cam timing gear cover Bolt M6x25 Oil shield plate comp...
  • Page 21 Torque value of fasteners Locking component and location on ATV Hard- Size of thread Qty Nm ft·lb ware Clutch cover Bolt M6x20 Inner left cramlcase cover Bolt M6x50 Outside left crankcase cover Bolt M6x30 Pullstarter ratchet Bolt M14x21 36 0 Internal lockup clutch net 588 435 Bearing seat/outer cover...
  • Page 22 Torque value of fasteners Locking component and location on engine Hardware Size of thread Qty Nm ft·lb Rear axel tubing Bolt M10x20 Rear protection plate Bolt M8x12 Rear axel Gearshifter Bolt M8x20 Drum brake back plate Bolt M8x40 Rear drive case Bolt M10x25 Gear shift arm...

  • Page 23: Section 6 Lubrication Point And Type Of Lubricants

    Section 6 Lubrication point and type of lubricants (I) Lubrication point and type of lubricants (ATV body) Lubricant point Type of lubricants Lip of oil seal (full) Light lithium-base grease O-ring (full) Light lithium-base grease Steering shaft (upper end, lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease...
  • Page 24 (II) Lubrication point and type of lubricants (Engine) Lubricant point (name of component) Type of Lubricant Lip of oil seal Light lithium-base grease (Crank,shift,gearshaft,spindle,shiftgear operation shaft) All bearing Lubricating oil (Crank,spindle,driving shaft,output shaft,balancing shaft,shift gear camshaft,pneumatic camshaft) O-ring (Contact position of o-ring) Light lithium-base grease Lubricating oil Stem end of intake &...

  • Page 25: Chapter Ii Maintenance And Adjustment Of Vehicle

    Chapter II Maintenance adjustment of vehicle NOTE: The correct maintenance and adjustments are necessary to ensure the vechicle’s in normal driving condition. The repair personnel should be familiar with the contents of this article. Section 1 Periodic Maintenance/Lubrication Everytime Every Item Requirement 1MO 3MO 6MO 6MO 1YR...

  • Page 26: Section 2 Disassembly And Assembly Of Cushion, Fender And Fuel Tank

    Section 2 Disassembly and assembly of Cushion, Fender and Fuel tank 1Cushion: Disassembly 1- Place the vehicle on level ground. 2- Disassemble the cushion (1) : Pull the cushion lock lever (2) up, then raise the rear of cushion. (II) Rear fender: Disassembly 1- Place vehicle on level ground.
  • Page 27 Battery Removal CAUTION: Disconnect negative wire first. 4- Disconnect the negative wire (2) and positive wire (3) of battery. 5- Remove battery clamp bracket (4) 6- Remove battery (5) 7- Remove protective bracket (6) disconnect all wires from main wire harness (7) and electrical parts from switch box (8) 9- Remove the rear fender (8)
  • Page 28 2. Installation Reverse procedure for “Disassembly”. Pay attention to the following points: 1- Install: • Rear fender (1) torque bolts to 7N.m (5ft.lbs) 3. Attach wire harness () and electrical parts connecting to switch box (2). 4. Install Protective bracket (3). 5.

  • Page 29: (Iii) Fuel Tank

    5. Install rear luggage carrier (1) Torque requirement for fasteners: Bolt (2) fastening torque: 3N·m (2ft.lbs) Bolt (3) fastening torque: 9N·m (7ft.lbs) CAUTION: Remember to install the bushing on the con- necting point of luggage carrier and frame. Fuel tank disassembly CAUTION: Seat, rear fender and rear luggage carrier will need to be removed before fuel tank disas-...
  • Page 30 Front fender disassembly 1. Place the vehicle on level ground. 2. Disassemble the front luggage carrier (1) 3. Disassemble the front plastic bumper (2) 4. Remove front metal bumper (3) 5. Remove front fender Fuel tank Installation Reverse Disassembly procedure...

  • Page 31: (Iv) Front Fender

    2. Installation Reverse procedure for “Disassembly”. 1. Install: Front fender Front metal bumper (1) 2- Install front plastic bumper (2) . The fastening torque of bolt (bumper and frame) is 16N·m (12ft.lbs). 4- Install the front luggage carrier (3) . Bolt (2) (front luggage carrier and frame).

  • Page 32: Section 3 Maintenance And Adjustment Of Vehicle Body

    Section 3 Maintenance and Adjustment of vehicle body (I) Wear inspection of front and rear brake 1.Check the front brake 1- Stop the vehicle using the front brake 2- Check: • Brake pad between caliper (2) and disc. • If pads are worn, replace. Refer to “Front wheel and front brake”...

  • Page 33: (Iii) Adjustment Of Free Clearance Of Left Lever And Rear Brake Pedal

    2. Adjustment Adjusting procedure of the free clearance of right lever: • Loosen the lock nut (1) , rotate the cable adjusting screw (2) clockwise to reduce the tension of front brake cable. • Lift the front end from the ground, rotate the two front wheels.
  • Page 34 2. Adjust • Free play of left lever. • Free play of rear brake pedal. Adjusting procedure: CAUTION: Before adjusting, depress the rear brake pedal 2-3 times. • Loosen the locking nut (1) completely, and screw in the cable adjusting screw (2) completely.

  • Page 35: (V) Lubricating Oil Level Inspection Of Rear Driving Gearcase

    CAUTION: After adjusting the steering lever, ensure the reverse gear indicator lights up when the steering lever is in the reverse position. (V) Lubricating oil level inspection of rear driving gear case. Check the lubricating oil level of the gear case. CAUTION: The engine must be in a cold state Checking procedure:...
  • Page 36 (VI) Replacing engine oil of rear driving gear case. 1. Place the vehicle on level ground. 2. Place an oil catcher under the rear driving gear case. 3. Remove: • Lower cover of gear case • Oil fillin screw plug •...

  • Page 37: (Vii) Rubber Sleeve Inspection Of Rear Wheel Fork

    (VII) Rubber sleeve inspection of rear wheel fork check • Rubber sleeve (1) If damaged or worn, replace it. Refer to chapter 3 section 6 “rear shock absorber and rear wheel fork”. (VIII) Inspection of steering system 1. Place the vehicle on level ground 2.
  • Page 38 (IX) Adjustment of toe-in on front wheels. 1. Rest the vehicle on level ground. 2. Measurement: • Toe-in, adjust if not in specification. Adjustment steps for toe-in • Mark the center of tire thread on both front wheels • Lift the front end to keep force off wheels •...

  • Page 39: (X) Inspection Of Front/Rear Shock Absorber

    (X) Inspection of front/rear shock absorbers 1. Rest the vehicle on level ground 2. Inspection: • (1) Upper part of front shock absorber. If broken or damaged, replace the front shock absorber. • Rear shock rod (rear shock absorber) If broken or damaged, replace •...

  • Page 40: (Xii) Inspection Of Tire

    (XII) Inspection of tire WARNING: This vehicle is equipped with low pressure tires, so correct filling pressure and keeping the proper pressure is very important. • Tire characteristics 1) Quality charicteristics of tire will affect the driving reliability of ATV. The following types of tires are approved by the manufacturer and can be used safely.

  • Page 41: (Xiii) Inspection Of Rim

    . Measurement • Tire pressure (normal atmospheric temperature): If out of specification, adjust. CAUTION: • The tire pressure gauge (1) is included with the tool kit (Never use high pressure). • If there is any dust or debris in the tire pressure gauge you will not receive an accurate reading.

  • Page 42: Section 4 Maintenance And Adjustment Of Electrical Appliance

    Section 4 Maintenanace and Adjustment of Electrical Appliance (I) Inspection of battery WARNING: The electrolyte is dangerous and includes sulfuric acid, so it is poisonous and corrosive. • Please operate by the following steps: a. Avoid touching any part of your body with the electrolyte especially your eyes.

  • Page 43: (Ii) Inspection Of Fuse

    5. Inspection of battery If damaged, replace it 6. Installment of battery (3) 7. Connect • Battery electrode (positive electrode (1) negative electrode (2) ) First connect the positive electrode () 8. Installment: a. Battery clamp plate (4) b. Cushion (II) Inspection of fuse CAUTION: Close the main switch when checking or replacing...
  • Page 44 2. Replacement of bad/old fuse Replacement steps: • Cut off engine and circuit • Install the new fuse. • Start the power for electrical appliance inspection. • If the fuse is not responding check the system again (Refer to “Electrical Appliance” of chapter 4) 3.
  • Page 45 6. Installment • Bulb (1) CAUTION: Be sure that the projective part of the bulb (2) is engaged with the convex groove (3) on the light seat. CAUTION: Never touch the glass part otherwise the bulb will loose illuminating value. If there are some oils on it clean off with cloth mixed with alcohol.

  • Page 46: Section 5 Maintenance And Adjustment Of Engine

    Section 5 Maintenance and Adjustment of Engine (I) Clean the air filter 1. Remove the cushion (Refer to “Cushion Remov- al” of this chapter). 2. Remove the air filter box cover (1) and air filter components. 3. Removal a. Air filter (1) b.

  • Page 47: (Ii) Inspection Of Spark Plug

    (II) Inspection of spark plug 1. Rest the vehicle on level ground and clean the spark plug with compressed air to avoid dust from entering the engine. 2. Remove the spark plug (1) The standard spark plug: DR8EA, if not correct, replace it.

  • Page 48: (Iii) Adjustment Of Idle Speed

    (II) Adjustment of idle speed 1. Rest the vehicle on level ground 2. Start the engine and warm it at idle speed of 1000-2000r/min, after several minutes, increase the engine speed to 4000-5000r/min. 3. Set the specified idle speed through adjusting the throttle adjusting screw (1) .

  • Page 49: (V) Adjustment Of Speed Limiter

    (V) Adjustment of speed limiter: The speed limiter can limit the throttle in full open- ing condition when the throttle grip is pulled to the max position, screwing the adjuster inward can stop increasing the speed. 1. Adjust speed limiting length (a) Adjustment steps: a.

  • Page 50: (Vi) Adjustment Of Valve Clearance

    (VI) Adjustment of valve clearance CAUTION: The valve clearance should be adjusted only after the engine is cold, the valve clearance should be adjusted when the piston is at the end point posi- tion of compress stroke. 1. Removal: 1) Rest the vehicle on level ground 3) Remove: a.
  • Page 51 b. Make the mark “T” on the rotor align with the mark on the crankcase. When aligned the piston ties in Top Dead Center (TDC) c. Inspection of top dead center in pressure stroke: (i) When the mark (1) on the rotor is align with mark (2) on the crankcase, the two arms must be clear.

  • Page 52: (Vii) Adjustment Of Timing Chain Tension

    3. Installation: Follow the opposite steps of “Removal”. (1) Mount: a. Valve cap (1) (side of outlet door) b. Valve cap (2) ( side of inlet door) CAUTION: (i) Valve cap (1) (2) should be placed in the upright position (3) (ii) Check if the o-ring (4) is damaged, if so re- place immediately.
  • Page 53 (VIII) Measurement of compressionforce CAUTION: Inadequate compression force will reduce the en- gine performance. Before measuring the compression force, the valve clearance should be adjusted (refer to “Adjustment of valve clearance” section). 1. Put vehicle on level ground 2. Take the spark plug off 3.
  • Page 54 d. If pressure drops below min. value: (i) Drop some oil to active cylinder. (ii) Measure the pressure again Compression read Reason Read is higher than filling Piston or rings are worn or before damaged. Read is equal when no oil Piston ring, cylinder head added or gasket may be dam-...

  • Page 55: Chapter Iii Repair And Maintenance Of Vehicle Body

    Chapter III Repair and Maintenance of Vehicle Body Section 1 Rear Differential 9. Coller 7. Oil seal . Rear transmission case 25. Thrust washer 10. Bearing retainer 18. Bearing 26. Ring gear shim 2. Left case 27. Washer 11. O-ring 19.

  • Page 56: (Ii) Inspection

    (I) Trouble • Trouble judging guidance Problem Reason A. Damaged bearing . The vehicle appears to stop or there is B. Improper clearance (free play) irregular axial run-out with an abnormal C. Damaged gear noise while the vehicle accelerates, D. Driving shaft breaks decelerates or is in idle state.

  • Page 57: (Iii) Troubleshooting Table

    It is necessary to check for bearing damage, and if there is a great deal of metal or metal fragments on the oil draining screw plug. CAUTION: It is normal for some metal fragments to be in the oil. 3. Check oil leakage Check according to following procedures.

  • Page 58: (Iv) Disassembly

    (IV) Disassembly WARNING: Ensure that the vehicle does not turn over by firmly supporting it. 1. Drain the rear differential case oil (1) Refer to section 3, chapter 2, “Replacement of engine oil of rear driving gear case” 2. Disassemble ) Cushion 2) Rear luggage carrier 3) Rear fender...
  • Page 59 1. Disassembly a. Remove: bolt (1) M6 bolt (2) M8 CAUTION: Loosen each bolt by ¼ circle and remove bolts alternately. b. Disassemble: 1) Rear driving gear case body (1) 2) Annular gear pad 3) Shift gear 4) Thrust plain pad c.
  • Page 60 d. Disassemble With a soft hammer lightly tap the main driv- ing gear (1) and remove (with thrust pad (2) and bearing (3)) CAUTION: Remove the main driving gear first if it is nec- essary to replace the gear. Replace the original bearing thrust pad, do not reuse.

  • Page 61: (V) Inspection

    (V) Inspection 1. Replace the main driving gear and shift gear if there are any scratches or wearing on the gear teeth of bevel gear pair (1) 2. Check oil seal (2) 3. Check the O-ring (3) Replace if damaged 4.

  • Page 62: Section 2 Rear Wheel/Rear Brake/Rear Wheel Axle

    Section 2 Rear wheel, rear brake, rear wheel axle No. Item Parameter Tire specification AT25x10-12 Rim Dimension 12x10 Tire air pressure (Normal Temperature) Standard value Min. value Max. value Runout Radial runout End face runout Wear limit of tire Wear limit of friction disk Rear brake hub wear limit 6mm .

  • Page 64: (I) Removal Steps

    (I) Removal steps 1. Keep front wheel from moving then put a proper stand under the frame so as to lift the rear wheels. WARNING: In order to avoid the parts falling, (which will cause danger), during the removal process, rest the vehicle firmly.
  • Page 65 8. Removal: (1) Adjusting nut, pin and spring of rear brake arm and rear brake tension rod assy. 9. Removal: (2) Rear brake cable (3) Rear brake tension rod assy 10. Brake shoe removal: () Cotter pins (2) Plate (3) Brake shoes (including springs) 10.
  • Page 66 8. Inspection (1) Inner surface of rear brake hub If there is some engine oil or scrapes, remove it and treat it. The method of treatment is as fol- lows: Removal of engine oil: Clean with cloth dipped in volatile dilute or volatile solvent. Removal of scrapes: Wipe scrapes slightly and with even force to remove them.
  • Page 67 3. Measurement The radial run-out of the piston (a) on the rear wheel axle, if out of specification, replace it. WARNING: If the axle is bent, do not straighten it force- fully. 14. Inspection: (1) Bearing on the rear wheel axle Rotate the rear wheel axle, if the axle shakes left and right in the bearing or run-out it indi- cates that the bearing is heavily worn and needs...
  • Page 68 (III) Installment steps: The reversal steps of “removal steps” are in- stallment steps. Pay attention to the following points when installing: 1. Lubrication part (1) Oil seal lip of rear wheel axle. (2) Bearing of rear wheel axle. The corresponding splint tooth of rear wheel axle.
  • Page 69 5. Installment Cam shaft of rear brake (1) Indicating plate of brake (2) Rear brake arm assy (3) CAUTION: When installing the brake indicating plate (2) to rear brake cam shaft (1) , be sure to align the projective part (a) of brake indicating plate (2) with the concave part (b) of rear brake cam shaft (1) .
  • Page 70 8. Installment (1) Brake shoe assy 9. Lubrication • Dust-proof seal Lubrication oil for dust-proof seal: lithium base grease. Warning The lubrication oil is not allowed to be used for brake shoe assy, the lithium base grease is used for rear brake hub splint groove. WARNING: The lubrication oil is not allowed to be used for splint on the right end of rear wheel axle,...
  • Page 71 5. Installment • Cotter pin () CAUTION: After fastening the torque, the nut on the rear axle is not allowed to be loose. If the nut con- cave groove is not aligned with the splint hole on the screw rod, align it by tightening up the nut.
  • Page 72 Section 3 Rear shock absorber and Rear swing arm 1. Rear shock absorber assembly 2. Bolt M12x1.25x70 3. Lock nut M12x1.25 4. Clevis pin 5. Cover 6. Washer 7. Cotter pin 8. Rear swing arm 9. Rear axle housing 10. Bolt M10x20 11.

  • Page 73: (I) Disassembling Steps

    (I) Disassembling steps 1. Take off left rear wheel, rear wheel joint plate, right rear wheel, rear brake hub, rear brake, and rear axle. Refer to “Disassembly of rear wheel/rear brake and rear wheel axle” section in this chapter. 2. Take off lower cap of gear case. 3.

  • Page 74: (Ii) Checking Steps

    5. Remove nut (1) on the rear shock absorber, bolt (2), rear shock absorber (3) . 6. Remove rear brake tension spring (1) . 7. Remove dust cap on rear arm axle. 8. Check the free play of rear wheel fork checking steps.
  • Page 75 9. Remove axle housing (1) 10. Remove driving axle hose clamp assy (front) (1), rear arm nut (right side) and rear arm joint bolt. 11. Remove rear swing arm (1) . (II) Checking steps 1. Check a: If rear shock absorber is leakage, if any, replace it.
  • Page 76 2. Check if the rear wheel fork assy is cracked, bent, and damaged. If any, replace it. Check if the rear wheel bush is cracked, bent, and damaged. If there is one of these problems, replace it. 3. Check the gear case lower cap. If there are any cracks, bends, or damage, replace this part.

  • Page 77: (Iii) Mounting Steps

    Remove bearing (3). The reverse step of “bearing and oil sealing replacing step” is the mounting step of new bearing and new oil sealing. CAUTION: Tool (4) which is matched with outer diam- eter of bearing race (7) and oil sealing. WARNING: Don’t strike the bearing inner race (5) and roller.
  • Page 78 3. Fix the rear arm bushing (1) (left), rear arm bushing (2) (right) and bushing (3) . Fixing steps: a: Fix the left rear arm bushing (1) by standard torque. Attached: Bolt torque value: 130Nm (96 ft.lbs) b: Fix the right rear arm bushing (2) until it makes contact with the bushing (3) .
  • Page 79 8. Mount the rear differential case sub-assembly (1) Refer to “Installation of rear driving gear case sub-assembly and driving shaft” section of this chapter. 9. Mount the rear wheel axle, rear brake hub, right rear wheel, rear wheel joint plate and left rear wheel.

  • Page 80: Section 4 Steering Operation System

    Section 4 Steering Operation system 1. Steering column 8. Bracket 5. Tie rod assy. 2. Pitman arm 9. Bolt M8x60 16. Nut M12 3. Upper handle holder 10. Lock washer 4. Bolt M8x35 . Collar 5. Cotter pin 2. Washer 6.
  • Page 81 (I) Removal steps of steering column . Removal • Front luggage carrier • Bumper • Front fender Refer to chapter 2, section 2 2. Removal • Ignition switch • “Neutral” indicating light wire • “Reverse” indicating light wire • “High beam” indicating light wire •...

  • Page 82: (Ii) Removal Steps Of Steering Vertical Column Welding

    (II) Removal steps of steering vertical column welding 1. Lock pad (1) Unlock locking tab on lock pad 2. Removal (2) Bolt M8x60 (3) Locking washer (4) Clip assy 3. Removal • Cotter pin • Nut M10 • Washer 0 4.

  • Page 83: (Iii) Inspection Content

    (III) Inspection content 1. Check the handlebar for any damage. If it is, replace it. 2. Inspect the steering vertical column welding assy for any bends or damage. If there is, re- place it. WARNING: In order to avoid decreasing the performance of the steering vertical column, do not straighten it forcefully if it is bent.
  • Page 84 6. Adjustment Assembly length of tie rod Adjustment steps of tie rod assembly length 1- Loosen the connecting nut [A] [B] 2- Adjusting the assembly length of tension rod by rotating the tie rod. Attached: Tie rod assembly length @: 297mm (.58in) [A] Right-handed thread [B] Left-handed thread...
  • Page 85 2. Lubricate the steering vertical column hold- er (1) and seal ring (2) during installation of the steering vertical column welding. 3. Installment Install the seal ring (1) to the steering verti- cal column welding, then install bushing (2). Finally, install the steering vertical column holder (3).
  • Page 86 7. Mounting cotter pin (1) CAUTION: Don’t loosen the nut after the torque is fixed. If the nut recess does not correspond with split pin hole on the double-screw bolt, tighten the nut to align them. WARNING: Always use new cotter pin 8.
  • Page 87 (V) Installation steps of handlebar 1. Install the lower holding seat (1) , steering tube (2) and upper holding seat (3) . WARNING: When tightening the bolt of holding seat, make sure clearance (b) is clear. Attached: bolt torque: 20Nm 2.

  • Page 88: Section 5 Front Wheel And Front Brake

    Section 5 Front Wheel and Front brake...
  • Page 89 1. Front wheel rim 12x6 26. Front wheel seal 2. Front wheel tire 25x8-12 27. Washer 3. Valve core 28. Castle nut M6 4. Lug nut 29. Cotter pin 5. Dust proof axle nut cover 30. Front brake plate protection cover 6.
  • Page 90 Item Parameter Tire specification 25x8-12 Rim dimension 12x8 Tire air pressure (normal temperature) Standard Bead seat Runout Radial End face Wear limit of tire Disassembly 1. Place vehicle on level ground. 2. Remove lug nuts (1) and dust proof cover (2) of front wheel.

  • Page 91: (Ii) Installation

    5. Remove: Brake caliper (1) Brake rotor CAUTION: • Check the brake rotor for any damage and replace if necessary. • Check brake caliper for any leaks. • Check the brake pads for wear or damage and replace if necessary. 6.
  • Page 92 2. Attach brake caliper (1). 3. Attach: • Hub and rotor (4) • Washer (3) • Castle nut (2) • Cotter pin () 4. Attach: • Front wheel (1) secure with lug nuts (2) • Dust proof cover (3)
  • Page 93 Section 6 Front shock absorber and Front wheel fork and Front Differential 1. Left upper A-arm 2. Ball joint 8. Cotter pin 14. Front shock 3. Spring circlip 9. Left lower A-arm 15. Lock nut M10x1.25 4. Right upper A-arm 10.
  • Page 94 Section 6 Front shock absorber and Front wheel fork and Front Differential 1. Front differential assembly 2. Right case 3. Left case 4. Clutch toper gear wheel 5. Seal 6. Differential speed outer 7. Bolt M10x18 8. Bolt M8x20 9. Bolt M8x25 10.

  • Page 95: (I) Disassembly

    (I) Disassembly of front shock absorber and front wheel fork: These instructions are for one side of the unit only. CAUTION: Before starting disassembly make sure you have completely drain the oil from the front differential. 1. Place container under drain bolt (1) and let drain completely.
  • Page 96 5. Remove • Upper A-arm (1) from frame • Lower A-arm (2) from frame. 6. Remove • Front differential case (1)
  • Page 97 Remove M6 bolts (2) and electric motor comp.() Use force on the end bearing to dislodge the drive assembly (3).
  • Page 98 One side only Upper A-arm Front differential axle Protective plate Washer Castle nut Hub and rotor Knuckle Lower A-arm Front differential (II) Installation of front shock absorber and front wheel fork- These directions are as- sembly for one side on the unit only. 1.
  • Page 99 4. Attach the upper A-arm (1) to the frame. 5. Install the front shock absorber (1) to the frame (2) and the top of the upper A-arm (3). 6. Attach the front differential axle to the front differential. 7. Attach the steering knuckle (1) to the lower (2) and upper (3) A-arms, secure with castle nut and cotter pin (a) 8.

  • Page 100: Chapter Iv Electric Appliance

    Chapter IV Electric Appliance Section 1 Electric Assembly 1. CDI ignition unit 2. Starting motor relay 3. 30A fuse 4. Nut M6 5. Zip tie 6. Zip tie 7. Ignition coil 8. Bolt M6x20 9. Stop lamp switch assembly 0. Battery 11.

  • Page 102: Section 2 Inspect Switch

    Section 2 Inspect switch (I) Inspect kill switch Make certain the wire end is on the pocket mul- timeter. If there are any problems replace the switch Pocket multimeter • Turn the multimeter to “O” • Turn the multimeter to “Ωx1” when inspecting the circuit •...
  • Page 103 Section 3 Check Lamp (headlight) Check the headlight condition 1. Remove the headlight bulb CAUTION: Pay attention to support the lamp. Do not pull the lead wire, otherwise it will brake. WARNING: When the headlight illuminates, remove your hand from the lamp, it will be very hot. Do not touch until it has cooled down.

  • Page 104: Section 4 Troubleshooting The Ignition System Failure

    Section 4 Troubleshooting Ignition System failure If the ignition system does not work (No spark) Check: 1. Spark plug 5. Main switch 2. Spark plug gap 3. Resistance of ignition coil and wire 4. Engine stop switch Power spark tester: Ignition tester: Pocket multimeter: •...
  • Page 105 2. Ignition spark clearance • Remove the spark plug • Connect as shown in figure (1) Spark testing instrument (2) Spark plug cap (3) Spark plug • Turn the main switch to the “ON” position • Check the ignition spark clearance •...

  • Page 106: Section 5 Running Starting Circuit

    Section 5 Running of Starting circuit The starting circuit of this vehicle including starting motor, cut-off relay, rear brake switch and neutral switch. If the main switch is in position, the starting motor could be operated only at the following conditions: •...

  • Page 107: Section 6 Troubleshooting Electric Starting System

    Section 6 Troubleshooting electric starting system If starting motor does not work • Check . Fuse 6. Main switch 2. Battery 7. Neutral switch 3. Starting motor 8. Rear brake switch 4. Cut-off relay 9. Starting switch 5. Starting relay 10.
  • Page 108 No rotation Repair or replace starting motor Operation 4. Power off relay • Remove relay from cable • Connect portable multitester (Ωx1) and bat- tery (12V) to end of wire on relay Battery end (-) - yellow/white wire end () Battery end (-) - red/white wire end (2) Battery end (-) - red/black wire end (3) •...
  • Page 109 FAIL 6. Main switch Refer to “Check system” Replace main switch PASS 7. Neutral switch FAIL Refer to “Check system” Replace neutral switch PASS FAIL 8. Rear brake switch Refer to “Check system” Replace rear brake switch PASS 9. Starting switch FAIL Refer to “Check system”...

  • Page 110: Section 7 Battery Will Not Hold Charge

    Section 7 Battery will not hold charge Check: 1. Safety 4. Stator coil 2. Battery 5. Coupling of circuit 3. Charging voltage (entire charging system) • Remove parts before maintenance Coil techometer ) Cushion Engine tachometer • Repair with special tools Pocket multimeter 1.
  • Page 111 • Start engine and accelerate to 2000r/m Charging Voltage: 14-15V at 2000r/m Use fully charged battery Specification met Out of specification 4. Resistance value for stator coil • Remove the lighting coil of AC magneto • Connect pocket multimeter to stator coil (Ωx1) Pocket multimeter (+) - white terminal 1 Pocket multimeter (-) - white terminal 2...

  • Page 112: Section 8 Troubleshooting

    Section 8 Troubleshooting If the headlight or taillight is out Check: 1. Safety 4. Lamp switch 2. Battery 5. Coupling of wires 3. Main switch (entire lighting sys- tem) Pocket multimeter: P/N • Remove the following parts before starting YU-03112 90890-03112 troubleshooting maintenance ) Cushion 2) Front luggage carrier...
  • Page 113 4. Change lamps FAIL Refer to “Inspection of switch” PASS If the lamp switch fails, replace the switch on left handle 5. Coupling of wires • Check the wire coupling for entire lighting system Refer to “Diagram” Poor coupling PASS Connect whole lighting system correctly Check the returning condition of each lighting system.

  • Page 114: Section 9 Inspection Of Lighting System

    Section 9 Inspection of Lighting System (II) If headlight is out No electricity 1. Bulb and socket • Check if the bulb and socket are correct Replace bulb and socket PASS 2. Voltage • Connect the pocket tester (DC 20V) to the headlight Multimeter (+) - green terminal (1) or yel- low terminal (2)
  • Page 115 (II) If taillight is out No electricity 1. Bulb and socket • Check if the bulb and socket are correct Replace bulb and socket PASS 2. Voltage • Connect the pocket tester (DC 20V) to the taillight terminal Multimeter (+) - blue terminal (1) Multimeter (-) - black terminal (2) •...

  • Page 116: Section 10 Troubleshooting

    Section 10 Troubleshooting (I) If indicator lamp is out Check: 1. Safety 4. Coupling of wires 2. Battery (whole signal system) 3. Front switch • Remove the following parts before trouble- shooting Picket multimeter ) Seat 2) Front frame 3) Front pedal •...
  • Page 117 3. Main switch FAIL Refer to “Inspection of switch” PASS Replace main switch 4. Coupling of wires • Check the coupling of whole signal system Poor connection wires Refer to “Diagram of wires” Connect it correctly PASS Check the condition of each signal system Refer to “Inspection of signal system”...

  • Page 118: Section 11 Inspection Of Signal System

    Section 11 Inspection of Signal System No electricity (I) If the neutral indicator lamp is out 1. Bulb and socket Replace bulb and socket •Check if the bulb and socket circuit B are correct. PASS No electricity 2. Neutral switch Replace neutral switch •...
  • Page 119 (II) If the reverse indicator lamp is out No electricity 1. Bulb and socket • Check if the bulb and socket are in good Replace bulb and socket condition. PASS No electricity 2. Reverse switch Replace reverse switch • Refer to “Inspection of switch” PASS 3.
  • Page 120 (III) If the HB indicator light is out No electricity 1. Bulb and socket •Check if the bulb and socket circuit B are Replace bulb and socket correct. PASS No electricity 2. High or low beam switch • Refer to “Inspection of switch” Replace handlerbar switch (left) PASS 3.

  • Page 121: Chapter V Engine

    Chapter V Engine Section I Disassembly of Engine (I) Remove the engine from ATV . Remove • Cushion • Front luggage carrier • Front bumper • Front fender • Rear luggage carrier • Rear fender The disassembling method refers to “Fender, fuel tank disassembly”...
  • Page 122 5. Disconnect gearshift linkage from engine. 6. Wire and hose ) Remove • Spark plug cap • CDI magneto wire (1) • Reverse switch wire (2) • Neutral switch wire (3) • Air pipe (4) 7. Disassembly of engine ) Remove •...

  • Page 123: (Ii) Disassembly Of Engine

    (II) Disassembly of engine . Remove • Hand starting unit (1) 45. Remove • Starting lever cap (1) • Starting lever (2) CAUTION: • Before untying the knot (3) , pull out the rope long enough to tie a knot to avoid to be pulled into the cap 46.
  • Page 124 2. Remove • Shifter linkage rod (1) Pay attention not to lose washer 3. Remove • Cam sprocket cover (1) 4. Remove • Spark plug (1) • Upper valve cap (intake) (2) • Lower valve cap (exhaust) (3)
  • Page 125 5. Remove • Chain tensioner (2) CAUTION: Before removing the chain tensioner, loosen the screw (1) first. 6. Remove • Bolt () • Timing sprocket (2) CAUTION: • When loosening the bolt, it is needed to fix the hand starting ratchet (4) •...
  • Page 126 9. Remove • Cylinder body assembly (2) • Cylinder gasket (3) • Dowel pin (4) • O-ring (5) 0. Remove • Circlip () • Piston pin (2) • Piston unit (3) CAUTION: • Before disassembling the piston pin circlip, cover the crankcase with a clean cloth to avoid the circlip suddenly dropping into the case.
  • Page 127 • Nut (4) securing Primary yoke (5) 2. Remove • Primary output shaft (1) • Shims (2) • Internal yoke for tension spring (3) • Tension spring (4) 3. Remove • Starting ratchet (1) CAUTION: Fix the starting ratchet with special tool, and loosen the bolt on the starting ratchet.
  • Page 128 6. Remove • Flywheel; (1) CAUTION: Disassemble the flywheel with a puller. 7. Remove • Gasket of left crankcase cover (1) • Dowel pin • Intermediate gear shaft (3) key way • Washer • Duplex intermediate gear (5) • Oil pump protective plate (6) •...
  • Page 129 2. Remove • Forward/Reverse shifter linkage (1) • Seal (2) • Snap ring (3) • Washer (4) • Shifter (5) • Shifter guide (6) •Shifter fork (7) 22. Remove • Washer • Forward/Reverse output shaft (1) • Drive chain (2) •...
  • Page 130 25. Remove • CVT cover () • Clutch support bracket (2) • Secondary clutch (3) • Primary clutch (4) • Primary clutch sleeve (5) • V-belt (6) • CVT rear cover (7)
  • Page 131 26. Remove • Clutch cover () • gasket (2) 27. Remove • Seal () • Snap ring (2) • Output Shaft (3) 28. Remove • Lock nut (1) • One way clutch bearing (2) • Clutch (3) 40. Remove • Stop plate (2) •...
  • Page 132 42. Remove • Rocker shaft (1) • Air intake and exhaust rocker (2) CAUTION: • Screw the slip hammer assy into rocker shaft, then pull out the rocker. 43. Remove • Valve lock clip (1) CAUTION: • Disassemble the valve lock clip with valve spring compressing device.

  • Page 133: Section 2 Inspection And Maintenance Of Engine

    Section 2 Inspection and Maintenance of Engine . Cylinder cover ) Clean • Carbon deposit Use circular scraper () CAUTION: Please do not use sharp tool to avoid scraping • Nut of spark plug • Valve seat ring • Bottom face of cylinder 2) Measure •...
  • Page 134 3) Measure • Rod part run-out of valve rod Replace it if unqualified 4) Measure • Clearance between valve rod and valve guide pipe Clearance=[A]-[B] Inner diameter of valve guide pipe [A] Valve rod diameter [B] Replace the valve or valve guide pipe if unqualified.
  • Page 135 3) Install • Circlip () • Valve guide pipe (2) Use the installing and disassembling device of valve guide pipe 4) Ream the inner diameter of valve guide pipe to get proper valve rod clearance. CAUTION: Regrind the valve race after installing valve guide pipe 4.
  • Page 136 • Press the valve on the valve race through valve guide pipe to leave clear trace on the valve. • Remove the valve from cylinder cover • When the valve contacts with valve race, the reddle is marked on the valve from valve race.
  • Page 137 The contacting part [B] is in the middle of valve face. But the width is too narrow Result Reamer assy of valve rale USE Reamer 45˚ Get unified contacting width .0mm (0.04in) The contacting part [C] is too narrow, and on the upper edge of valve face Result Reamer assy of valve rale...
  • Page 138 • Paint molybdenum disulfide oil on the valve rod part. • Place the valve in to the cylinder cover • Rotate the valve to grind in with seat fully on the valve face, then clean the dirt • Repeat procedure until the contacting width of valve face and valve seat CAUTION: In order to get the best grinding quality, you...
  • Page 139 2) Measure • Installing pressure of valve spring If unqualified, replace the inner and outer spring totally. 6. Seal check of valve 1) Installation of valve Lubricate • Valve rod part () • Valve rod oil seal (2) Install • Valve spring seat (1) (lower part) •...
  • Page 140 CAUTION: Must install the long pitch end of all valve spring upward 2) Check the valve seal If there is leakage on the valve face, repair again and regrind or replace the valve and regrind. Inspecting procedure of valve seal •...
  • Page 141 8. Valve rocker and rocker shaft 1) Check • Rocker hole • Contacting surface with distribution cam If ever worn, replace it 2) Check • Rocker shaft surface Replace or check lubrication if there are dents, scratches, or discoloration 3) Measure •...
  • Page 142 • Subtract the outer diameter of rocker shaft from inner diameter of valve rocker hole to calculate clearance. Clearance between rocker hole and shaft= (a) - (b) Inner diameter of valve rocker hole (a) Outer diameter of rocker shaft (b) Replace a set if unqualified 9.
  • Page 143 2) Check Flexibility of chain tensioner Checking procedure • Press the tensioner pushing rod lightly with finger, and rotate it clockwise with thin screwdriver to screw it in. • Press the pushing rod lightly with finger and remove screwdriver, then the pushing rod screws out stably •...
  • Page 144 If out of specification, hone or replace the cylinder and piston (replace in a set) If out of specification, replace the piston and piston ring as a set at the same time. •Calculate the mating cylinder clearance with the following formulas Mating cylinder clearance=“C”-“P”...
  • Page 145 Clearance between piston ring and ring groove Standard Limit First 0.03~0.07mm 0.2mm Ring (0.001~0.003 in) (0.005in) Second 0.02~0.06mm 0.2mm Ring (0.008~0.024in) (0.005in) 2) Measurement: • Closed clearance of piston ring • Install the piston ring to the cylinder, pull forward about 20mm (0.8in), then pull the pis- ton ring with piston top to make it vertical with cylinder wall.
  • Page 146 Main points of reassembly of crankshaft: The oil traces on crankshaft (1) and crank pin (2) should be connected correctly, the position of two oil traces should be within 1mm (0.04 in) 17. Driving gear of balance shaft and gear of balance shaft Inspection: •...
  • Page 147 • Inspection • Bolt (1) (overrunning clutch) • Loosen then replace with new one and apply fastening agent CAUTION: Fastening torgue of bolt (overrunning clutch) is 30Nm(3.0m·kg22yd·pound) Apply the fastening agent on the bolt 19. Main clutch Clutch case 1) Inspection: •...
  • Page 148 22. Shift fork and fork shaft 1) Inspection: • Fork Connecting surface to gear and shift cam If worn, scraped, bent, or damaged, replace it. 2) Inspection • Fork shaft (Roll the fork shaft on a plane) If bent replace it. WARNING: Never attempt to straighten a bent fork shaft 3) Inspection...
  • Page 149 27. Bearing and oil seal ) Inspection • Bearing If jammed in operation or there are pits and damage, replace it. 2) Inspection • Oil seal If damaged or worn replace it. 28. Circlip and washer Inspection: • Circlip • Washer If damaged, loose, or bent, replace it.
  • Page 150 30. Hand operated mechanism ) Inspection • Inspection () If cracked, bent, or damaged, replace it. • Driving jaw (2) • Compressing Spring (3) • Torsion spring (4) (Driving jaw position) Wear/cracks/damage, replace it. 2) Inspection: • Rolling spring (1) (Starting) Wear/cracks/damage, replace it.
  • Page 151 4) Inspection • Reverse fork (1) If wear/abrasion/bend/damage is found on the surface connecting with connecting jaw and reverse operating shaft, replace it. • Compressing spring (2) If the elasticity is lost, or worn, replace it • Steel ball (3) If wear, damage, or scratch marks are found, replace it.

  • Page 152: Section 3 Assembly And Adjustment Of Engine

    Section 3 Assembly and Adjustment of Engine 1. Crank connecting rod 2. Balanced initiative gear 11. Seal ring sheath 3. Buffer spring 12. Seal ring 4. Pin 13. Nut M16 5. Initiative gear clamp plate 14. Balanced shaft 6. Circlip 15.
  • Page 153 Shift gear mechanism 14. Driven gear 1. Main shaft 5. Pin 2. Seal o-ring 6. Cirlcip 3. Bearing 17. Rolled needle bearing 4. Bearing 18. Gearshift arm comp 5. Collar sheath 19. Fuel seal 6. Oil seal 20. Washer 7. Seal o-ring 2.
  • Page 154 Clutch . Outer cover 2. Cintrifugal clutch 3. Bearing seat outer cover 4. Bearing 16010 5. Fuel seal SD32x66x8 6. Circlip 75.5 7. Circlip 49 8. Bearing seat seal cushion 9. Flange bolt mx 0. One way machine 11. Nut M22 12.
  • Page 155 (III) Assembly of left crankcase Output mechanism 10. Screw bushing 18. Nut 1. Output gear 11. Irregular left hand nut 19. Rear cover 2. Forward gear assy 12. Output shaft 20. O-ring 3. Reverse gear 3. Washer 21. Bolt M8x15 4.
  • Page 156 Electric starting system . Circlip 2 10. Spring cover 2. Washer 11. Spring 3. Wheel axle 12. Timing chain 4. Double wheel 13. Up guide plate assembly 5. Woodruff key 14. Magneto rotor 6. Washer 15. Magneto stator 7. Electric starting gear assy 16.
  • Page 157 (V) Assembly of cylinder head Cylinder cover assembly 1. Locking nut 12. Bolt M6x12 2. Adjusting screw 13. Locking plate 3. Throttle arm 4. Clamp plate 4. Arm axle 1 15. Rolling bearing 6005-RS/C3 5. Valve locking 16. Driving pin 6.
  • Page 158 Cylinder head  25. O-ring . Cylinder head cover assem- 13. Screw M8x45-10.9 26. Screw M6x18-06025 4. Washer 8 29. Chain tensioner 2. Steel wire circlip 15. Sprocket wheel cover assy 30. Tensioner washer 3. Valve guide tube 16. Oil shield assembly 31.
  • Page 159 Cylinder head 2 7. Piston ring 2 1. Cylinder body assembly 8. Oil ring subassembly 2. Screw M6 x 25-10.9 9. Circlip 3. Cylinder body gasket 0. Piston 4. Locating pin 99530-14016 . Piston Pin 5. O-ring 12. Double end bolt 6.

  • Page 160: (I) Installation

    Installation • Attach gear and shaft to bracket using circlip.
  • Page 161 • Mount bracket (4) to crankcase (5) using M8 bolts (3). Torque of bolt: 23Nm (17ft.lbs) • Install internal drive gear (1). • Install reverse shaft (9) using circlip (6), seal (5), and washer (4).
  • Page 162 • Install oil screen (1) using M6 bolts(2). Torque of bolts: 10Nm (7ft.lbs) • Mount balanced shaft (3)
  • Page 163 • Attach shifting fork (1) to gear. • Install crank chain (2). • Install crankshaft (1). • Attach right crankcase (5) to left crankcase (4)using silicon as sealent.
  • Page 164 • Outside of right crankcase • Attach clutch plates to right crankcase using one- way bearing.
  • Page 165 •Use gasket (1) when installing cover (2). •Use circlip (4) to hold in bearing. • Mount cover (2) using M8 bolts(3). Torque of bolts: 23Nm (17ft.lbs)
  • Page 166 •Make sure pieces are used in this order. • Mount rear cover (1) using M10 bolts Torque of bolts 45Nm (33ft.lbs). • Make sure to use all shims (2), four on each side. • Mount u-joint using M12 nut. Torque of nut: 80Nm (59ft.lbs)
  • Page 167 • Install universal joint (1) using circlips (2). • Mount oil pump gear (3) using M6 bolts (4) Torque of bolts: 10Nm(7ft.lbs) • Install timing chain guard (5). • Install timing chain (6), make sure to feed chain (6) onto sprocket (7).
  • Page 168 • Mount gear (3) in crankcase. • Install pin (2) and spring (1) in gear (3). • Install piston (6) using piston pin (5) and clips (7). • Install piston rings (4) on piston (6).
  • Page 169 • Install gearshift connector (1) assembly to crankcase. • Mount starter motor (2) using M8 bolts (3). • Mount cylinder (5)using base gasket (4).
  • Page 170 • Valve, inner spring, outer spring, valve locking clips • Install camshaft (1) using bracket (3) and M6 bolts (2). Torque of bolts: 10Nm (7ft.lbs)
  • Page 171 • Install rocker arms (1) in cylinder head (2). • Install cylinder head (2) using M10 bolts (3). Torque ob bolts: 45Nm (33ft.lbs) • Attach valve covers (5) using M6 bolts (4). Torque of bolts: 10Nm (7ft.lbs)
  • Page 172 Mount intake manifold (1) using M6 bolts(2). • Torque of bolts: 10Nm (7ft.lbs) • Mount timing sprocket (3) using bracket and M8 bolts (4). Torque of bolts: 23Nm (17ft.lbs) • Attach timing chain cover using M8 bolts. Torque of bolts: 23Nm (17ft.lbs)
  • Page 173 • Mount chain tensioner (4) using M6 bolts (3). Torqure of bolts: 10Nm (7ft.lbs) • Install spring (2) using M10 bolt (1). Torque of bolts: 45Nm (33ft.lbs) • Install flywheel gear (5) on crankshaft. • Make sure to use a gasket (6) when installing left crankcas cover.
  • Page 174 • Mount left crankcase cover (1) using M10 bolts (2). Torque bolts:45Nm (33ft.lbs) • Mount recoil ratchet (3) to crankcase cover (2). • Attach pull starter (5) using M8 bolts (4). Torque of bolts: 23Nm (17ft.lbs)
  • Page 175 • Install oil filter (1) below pullstarter. • Install inside right crankcase cover (2).
  • Page 176 • Install drive (2) and driven pulleys (). • Install holding plate (4) using M8 bolts (3). • Install right crankcase cover (5) using M8 bolts (6). Torque of bolts: 10Nm (7ft.lbs)

  • Page 177: (I) Starting Trouble/Difficulty

    Chapter VI Vehicle Ordinary Trouble and it’s judgement Trouble • Wrong spark plug heat value CAUTION: • Inefficient spark plug cap Please refer to relevant contents for the in- spection, adjustment and replacement of (2) Ignition coil parts. • Coil is damaged (I) Starting trouble/difficulty •...
  • Page 178 (2) Piston and piston ring (1) Carburetor • Improper piston ring installation • Wrong needle valve position • Piston rings are worn and out of elasticity • Main jet is clogged or loose • Piston rings are damaged • Fuel is polluted •...
  • Page 179 (4) Driving system (2) Fuel System • Claw of gear end is down • Main jet of carburetor is damaged • Improper fuel level (V) Clutch slips • Core of air filter is clogged () Clutch • Improper adjustment of clamp plate release (3) Cylinder system rod clearance of clutch •...
  • Page 180 • Improper installation of steering 2. Bulb is off pillar bearings • Incorrect bulb • Holding seat of steering pillar or • Battery failure sealing ring is damaged • Rectifier failure • Rod is bent • Improper connection of ground wire •...

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