Explorer Patriot 430 Service Manual

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SERVICE MANUAL

PATRIOT 430

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Page 1 SERVICE MANUAL PATRIOT 430...
Page 2 Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the ATV, EXP PATRIOT 430 ATV, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.
Page 3: General Information
HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for EXP PATRIOT 430 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
Page 4 SERIAL NUMBER Frame number: Engine number: Home page Contents - 3 -...
Page 5 CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-6 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14 V BELT DRIVING SYSTEM 9-1 ~ 9-12 FINAL DRIVING MECHANISM...
Page 6 1. Symbols and Marks 2. General Safety 3. Service Precautions 4. Specifications 1-16 5. Torque Values 1-17 6. Troubles Diagnosis 1-19 7. Lubrication Points 1-24 1. Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed.
Page 7 2. General Safety Carbon monoxide If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.
Page 8 Brake pad Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum cleaner or the equivalent to avoid dust flying. Caution Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system Brake fluid Caution Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts.
Page 9 3. Service Precautions Always use with EXP genuine parts and recommended oils. Using non-designed parts for EXP ATV may damage the ATV. Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged. When servicing this ATV, use only metric tools.
Page 10 Never bend or twist a control cable to prevent unsmooth control and premature worn out. Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.
Page 11 The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.
Page 12 Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage. The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.
Page 13 Lubricate the rotation face with specified lubricant on the lubrication points before assembling. Check if positions and operation for installed parts is in correct and properly. Make sure service safety for each other when conducting by two persons. Do not let parts fall down. Before battery removal operation, it has to remove the battery negative ) cable firstly.
Page 14 After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables. Make sure that the battery post caps are located in properly after the battery posts had been serviced.
Page 15 When separating a connector, it locker has to Insert the terminal completely, unlocked it first. Then, conduct the service Check if the terminal is covered by the boot. Do not let boot open facing up. Do not pull the wires as removing a connector or wires. Hold the connector body. Make sure if the connector pins are bent, extruded or loosen.
Page 16 Before terminal connection, check if the boot is crack or the terminal is loose. Secure wires and wire harnesses to the frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.
Page 17 Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. Keep wire harnesses far away from the hot parts. Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws.
Page 18 Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied. Secure the rubber boot firmly as applying it on wire harness. Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the damaged parts or replace them.
Page 19 Do not let the wire harness been twisted as installation. Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering position. Before operating a test instrument, operator should read the operation manual of the instrument.
Page 20 With sand paper to clean rust on connector pins/terminals if found.And then conduct connection operation later. - 19 -...
Page 21: Lubrication System
4.Specifications MAKER MODEL Overall Length 2160 mm Front Double arm Suspension System Overall Width 1200 mm Rear Double arm Overall Height 1180 mm Front 25×8-12(off road) Tire Specifications 25×10-12(off Wheel Base 1294 mm Rear road) Front 965 mm Steel/Aluminum Wheel tread Rear 914 mm Front...
Page 22 5. Torque The torque values listed in table are for more important tighten torque values. Please see standard values for not listed in the table. Engine Torque Thread Dia. Tor Value Item Q’ty Remarks (mm) (N-m) Cylinder stud bolt 10~14 Cylinder head nut 36~40 Cylinder head right bolt...
Page 23 Frame Torque Thread Dia. Tor Value Item Q’ty Remarks (mm) (N-m) Handlebar upper holder bolt Steering shaft nut Steering tie-rod nut Knuckle nut Steering shaft holder bolt Front wheel nut Front axle castle nut Rear axle castle nut Rear wheel nut Engine hanger nut Drive gear bolt Driven gear nut...
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Page 28 7. Lubrication Points - 27 -...
Page 29 Acceleration cable/F ront&rear lever pivot Drive shaft Speedometer gear GREASE Wheel bearing GREASE - 28 -...
Page 30: Table Of Contents
1. Technical Date 2. Periodical Maintenance Schedule 3. Fuel Hoses 4. Throttle Cable 5. Air Cleaner 6. Spark Plug 7. Valve Clearance 8. Carburetor Idle Speed Adjustment 9. Ignition System 10. Cylinder Compression Pressure 11. Drive Belt 12. Brake System (Disk Brake) 2-10 13.
Page 31: Technical Date
1. Technical Date Fuel Tank Capacity 15000 c.c. Capacity 3500 c.c. Engine Oil Change 3200 c.c. Capacity 150c.c Front differential oil Change 130c.c Capacity 130 c.c. Rear gear box oil Change 110 c.c. Engine + radiator 2200 c.c. Capacity of coolant Reservoir upper 800 c.c.
Page 32: Periodical Maintenance Schedule
2. Periodical Maintenance Schedule 1.st 300KM 1 Month or 3 month or 6 month or 1 year or Maintenance Item 1,000KM 3,000KM 6000KM 12,000KM Code Air cleaner Fuel filter Oil filter Replacement for every 1000 km Engine oil change Tire pressure Checking before every riding Battery inspection Brake fluid &...
Page 33: Fuel Hoses
3.Fuel Hoses Remove the fuel tank cover. Loosen 5 screws and 4 bolts, Remove the tank cover Check all lines, and replace it when they are deterioration, damage or leaking Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Page 34: Spark Plug
6. Spark Plug Recommended spark plug : NGK-R-CR7E Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Spark plug gap 0.8 mm Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it.
Page 35: Valve Clearance
7. Valve Clearance Caution Checks and adjustment must be performed when the engine temperature is below 35 . Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket aligns with cylinder head mark so that piston is placed at TDC position in compression stroke.
Page 36: Carburetor Idle Speed Adjustment
8. Carburetor Idle Speed Adjustment Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle Ignition cable speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Park the ATV with main stand and warm up engine.
Page 37: Ignition System
9. Ignition System Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking CDI unit whether CDI function is in normal or not. Connect tachometer and ignition light. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “H”...
Page 38: Drive Belt
Clamp strips 11. Drive Belt Loosen the 2 clamp strips of right crankcase cover, and then remove the right crankcase cover vapor hose. Remove 14 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord 14bolts with the periodical maintenance schedule to...
Page 39: Brake System (Disk Brake)
12. Brake System (Disk Brake) Brake System Hose Make sure the brake hoses contain no corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
Page 40: Brake Light Switch/Starting Inhibitor
Brake Lining Wear The indent mark on brake lining is the wear limitation. Replace the brake lining pad if the wear limit mark closed to the edge of brake disc. Caution To check front brake lining must be remove front wheel first. It is not necessary to remove brake hose when replacing the brake lining.
Page 41: Headlight Beam Distance
14. Headlight Beam Distance Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high. Caution To adjust the headlight beam follows related regulations. Ad ju s t s c r e w Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.
Page 42: Steering Handle
17. Steering Handle Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. 18.
Page 43: Special Tools List
20. Special Tools List PARTS NO:440649 PARTS NO:440650 PARTS NAME: Extension puller /Remover PARTS NAME: Bushing(924739) Remover PARTS NO:440651 PARTS NO:440652 PARTS NAME: Bearing(924384) Remover PARTS NAME: Bearing(924182) Remover PARTS NO:440653 PARTS NO:440654 PARTS NAME: Bearing(924382) Remover PARTS NAME: Transmission Shaft Remover PARTS NO:440655 PARTS NO:440656...
Page 44 PARTS NO:440657 PARTS NO:440658 PARTS NAME: Crank Shaft Holder PARTS NAME: Starter (924136)Holder PARTS NO:440659 PARTS NO:440660 PARTS NAME: Flywheel Remover PARTS NAME: Chain Wheel(924360) Installer Washer(924718) Installer PARTS NO:440661 PARTS NO:440662 PARTS NAME: Piston & Rod Connecting PARTS NAME: Cylinder Head Valve Gap Holder Adjuster PARTS NO:440663...
Page 45 PARTS NO:440665 PARTS NO:440666 PARTS NAME: Idler Gear(924187) Puller PARTS NAME: Gear Driven (924146) Holder PARTS NO:440667 PARTS NO:440668 PARTS NAME: Cylinder Head Valve and Spring PARTS NAME: Universal Joint Head Installer /Remover (924646)Installer PARTS NO:440669 PARTS NO:440670 PARTS NAME: Chain Wheel (924360) Remover PARTS NAME: Engine oil filter(924153) Washer(924718) Remover Installer/Remove - 44 -...
Page 46 1. Mechanism Diagram 2. Precautions in Operation 3. Troubleshooting 4. Engine Oil 5. Engine Oil Strainer Clean 6. Oil pump 1.Mechanism Diagram 2.Precautions in Operation General Information This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 3500 c.c.
Page 47 3.Troubleshooting Low engine oil level Oil leaking Valve guide or seat worn out Piston ring worn out Low oil pressure Low engine oil level Clogged in strainer, circuits or pipes Oil pump damage Dirty oil No oil change in periodical Cylinder head gasket damage Piston ring worn out - 46 -...
Page 48: Engine Oil
4.Engine Oil Turn off engine, and park the ATV in flat surface Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. Oil Change Caution Drain oil as engine warmed up so that makes sure...
Page 49: Oil Pump
One way clutch 6.Oil Pump Oil Pump Removal Remove the one way clutch. Remove the clutch shoe. Remove the snap ring. Remove the washer. Remove the oil pump driver gear. Caution The clutch shoe nut has left-hand threads. Snap ring Remove the snap ring.
Page 50 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body.
Page 51 Tighten the oil pump screw. Oil Pump Installation Install the oil pump, and then tighten 3 screws. Torque 1.0 kgf-m Make sure that oil pump shaft can be rotated freely. Install the washer. Install the pin. Install the oil driven gear. Install the washer.
Page 52 1. Mechanism Diagram 2. Precautions in Operation 3. Trouble Shooting 4. Carburetor Remove / Install 5. Air Cut-Off Valve 6. Throttle Valve 7. Float Chamber 8. Adjustment of Idle Speed 9. Fuel Tank 4-10 10. Air Cleaner 4-11 1. Mechanism Diagram 2.
Page 53 Do not bend off throttle cable. Damaged throttle cable will make unstable drivability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one after re-assembly There is a drain screw in the float chamber for draining residual gasoline. Do not disassemble air-cut valve arbitrarily.
Page 54: Trouble Shooting
3. Trouble Shooting Mixture too lean Poor engine start Clogged fuel injector No fuel in fuel tank Vacuum piston stick and closed Clogged fuel tube Malfunction of float valve Too much fuel in cylinder Fuel level too low in float chamber No spark from spark plug(malfunction of Clogged fuel tank cap vent ignition system )
Page 55: Carburetor Remove / Install
4. Carburetor Remove / Install Removal Remove the fuel tank. Loose the carburetor clamp screws Clamp Clamp Loosen the carburetor side cap 3 screws. Remove cap. Disconnect the throttle cable. Remove the starter cable. Remove the carburetor. Installation Install in reverse order of removal procedures. Start cable 5.
Page 56 Remove air vent hoses. Remove fuel hose. Remove vacuum hose. Remove air cut-off valve cover 2 screws, spring and valve. Inspection Check the valve is in normal. If the valve is in normal, it will restrict 2 screws air-flow. If air-flow is no restricting, replace carburetor assembly.
Page 57: Throttle Valve
6. Throttle Valve 2 screws Disassembly Remove carburetor top comp. Remove the spring, holder, needle set.jet and piston valve. Remove the cable adjuster assy. Cable adjuster assy - 56 -...
Page 58: Float Chamber
7. Float chamger Disassembly Remove 4 mounting screws and remove float chamber cover. 4 screws Remove the screw, float pin, float and float valve. Float Screw Inspection Check float valve and valve seat for Float valve damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
Page 59 Disassembly Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution Be care not to damage jets and air adjustment screw. Before removing adjustment screw, turn it all the way down and note the number of turns.
Page 60: Adjustment Of Idle Speed
8. Adjustment of Idle Speed Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the ATV to perform the adjustments.
Page 61: Fuel Tank
9. Fuel Tank Fuel unit removal Open the seat. Remove the center cover above fuel tank. Remove left side cover Remove fuel unit (4 bolts). 4 bolts Caution Do not bend the float arm of fuel unit Do not fill out too much fuel to fuel tank. Fuel unit inspection (Refer to electrical equipment chapter 17).
Page 62: Air Cleaner
10. Air Cleaner Removal Loosen the clamp of air cleaner and carburetor, and then remove the vapor hose. Clamp Remove the air cleaner (3bolts). Installation Install the tank in the reverse order of removal. Cleaning air cleaner element Remove the air cleaner cover (4 catch hooks).
Page 63 1. Precautions in Operation 2. Removal of Engine 3. Engine Installation 4. Engine Disassembly 5-10 1. Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable. Engine shall be removal in the conditions of necessary repair or adjustment only. The following parts can be serviced as engine mounted on frame: Carburetor.
Page 64 2. Removal of Engine Remove the seat. Remove battery negative post (-). Remove battery positive (+) post. Remove side cover and the footrest (refer chapter 13). Negative(-) Positive(+) Remove starter motor wire. Starter motor wire Remove the spark plug cap. Disconnect A.C.
Page 65 Remove 2 nuts, and then remove exhaust pipe. 2 Nuts Remove 2 bolts, and then remove the exhaust muffler. Remove the fuel hose Fuel hose Remove the air cleaner. Air cleaner - 64 -...
Page 66 Remove the carburetor. Remove the gearshift lever. Remove the gearshift mud. Remove the speedometer cable. - 65 -...
Page 67 Remove the front and rear tube. Remove coolant inlet hoses. Water hoses clamp Remove coolant outlet hose and by-pass pipe. Outlet hose By-pass pipe Remove 2 bolts and remove the front differential plate Plate 2 bolts - 66 -...
Page 68: Engine Installation
Remove the front differential 2 bolts. Remove the rear differential 3 bolts. 3 bolts Remove the engine mounting bolts and nuts. 3 screws Remove the engine from the left side. 3.Engine installation - 67 -...
Page 69: Engine Removal
Remove the engine in the reverse order of engine removal. Caution The engine mounting nuts are self-locking once the nut was been removed it is no longer of any use. Be sure to use new nuts. For every time engine installation and tighten them Torque value 70 N-m - 68 -...
Page 70 Torque value Front differential and rear gear box flange coupling bolt: 83 N-m Plate 3 bolts Install the new gasket Install muffler. Pay attention don’t damage the connector. Tighten the exhaust pipe nuts specified torque. 25 N-m Connector bolt: - 69 -...
Page 71 Muffler mounting bolt: 12 N-m. Tighten the muffler bolts specified torque. 29 N-m - 70 -...
Page 72: Engine Disassembly
4.Engine Disassembly Remove starter motor wire. Remove the spark plug cap. Remove the thermostat. Remove the spring bolt and remove the cam chain pensioner adjuster assy. Remove the engine oil pipe bolts. - 71 -...
Page 73 Remove the recoil starter. Remove the valve timing check plug. Turn the crankshaft and let the”T.D.C line”on The rotor with index mark. - 72 -...
Page 74: Mechanism Diagram
1. Mechanism Diagram 2. Precautions in Operation 3. Troubleshooting 4. Cylinder Head Removal 5. Cylinder Head Inspection 6. Valve Stem Replacement 6-10 7. Valve Seat Inspection and Service 6-11 8. Cylinder Head Reassembly 6-13 9. Cylinder Head Installation 6-14 10. Valve Clearance Adjustment 6-16 1.
Page 75: Precautions In Operation
2.Precautions in Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. - 74 -...
Page 76 Specification Item Standard Limit Compression pressure 10±2.5 kg/cm2 Intake 33.442 33.392 Camshaft Height of cam lobe Exhaust 33.327 33.277 ID of valve rocker arm 12~12.018 12.080 Rocker arm OD of valve rocker arm shaft 11.966~11.984 11.936 Intake 4.975~4.990 4.900 OD of valve stem Exhaust 4.950~4.975 4.900...
Page 77: Troubleshooting
3.Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage Valve carbon deposit.
Page 78: Cylinder Head Removal
2 nuts 4. Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove Thermostat bolts the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.
Page 79 Remove cylinder head cover,and hole bolts(3 bolts) 3 bolts 3 bolts Remove fix stand for spindle cam (6 bolt) 6 bolts Remove cam sprocket bolts and then remove The sprocket by prying chain out. 1 bolts Remove cam chain tensioner and hole bolt. 2 bolts Cam shafts Remove cam shafts.
Page 80 Remove the 4 cylinder head mounting bolts from cylinder head right side, and then remove 4 bolts and washers from cylinder head upper side. Remove the cylinder head. 4 bolts Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Gasket Clean up residues from the matching surfaces of cylinder and cylinder head.
Page 81: Cylinder Head Inspection
Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. 5. Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
Page 82 Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is more than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm. Service Limit: Replace when it is more than 11.936 mm.
Page 83 5.0mm valve guide reamer Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
Page 84: Valve Stem Replacement
6. Valve Stem Replacement Valve guide driver 5.0mm Heat up cylinder head to 100~150 with heated plate or toaster. Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed when heating it. Wear on a pair of glove to protect your hands when operating.
Page 85: Valve Seat Inspection And Service
7. Valve Seat Inspection and Service Clean up all carbon deposits on intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
Page 86 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Use 45° cutter to grind the valve seat to specified width. Caution Make sure that all roughness and uneven faces had been ground. Grind valve seat again if necessary.
Page 87: Cylinder Head Reassembly
After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. 8. Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide.
Page 88: Cylinder Head Installation
Gasket 9. Cylinder Head Installation Clean up all residues and foreign materials from the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of Dowel pins Chain guide cylinder and cylinder head.
Page 89 Install cam chain to sprocket and align the timing mark on the sprocket with that of cylinder Timing mark head. Align sprocket bolt hole with camshaft 2 bolts bolt hole. Tighten the sprocket mounting bolts. Caution Make sure timing marks are matched. Install the lock washer so that it is covering the locating pin.
Page 90: Valve Clearance Adjustment
Spark plug Install and tighten spark plug Torque value: 1.0~2.0kgf-m Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.
Page 91 1. Mechanism Diagram 2. Precautions in Operation 3. Trouble Shooting 4. Cylinder and Piston Removal 5. Piston Ring Installation 6. Piston Installation 7. Cylinder Installation 1. Mechanism Diagram...
Page 92: Trouble Shooting
2. Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit mm Item Standard Limit 86.022~86.052 86.100 Cylinder Bend 0.050 Clearance Top ring 0.004~0.075 0.011 between piston ring 0.02~0.055 0.090 rings Top ring...
Page 93: Cylinder And Piston Removal
4. Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
Page 94 Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm 2nd ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. Caution Pay attention to remove piston rings because they are fragile.
Page 95: Piston Ring Installation
Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 20.065mm Measure the inner diameter of piston pin hole. Service Limit: 20.02 mm Calculate clearance between piston pin and its hole.
Page 96 Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings in installation. All marks on the piston rings must be forwarded to up side. Make sure that all piston rings can be rotated freely after installed.
Page 97: Piston Installation
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily. 6.
Page 98 Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
Page 99 1. Mechanism Diagram 2. Precautions in Operation 3. Trouble Shooting 4. Cylinder and Piston Removal 5. Piston Ring Installation 6. Piston Installation 7. Cylinder Installation 1. Mechanism Diagram...
Page 100: Trouble Shooting
2. Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit mm Item Standard Limit 86.022~86.052 86.100 Cylinder Bend 0.050 Clearance Top ring 0.004~0.075 0.011 between piston ring 0.02~0.055 0.090 rings Top ring...
Page 101: Cylinder And Piston Removal
4. Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
Page 102 Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm 2nd ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. Caution Pay attention to remove piston rings because they are fragile.
Page 103: Piston Ring Installation
Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 20.065mm Measure the inner diameter of piston pin hole. Service Limit: 20.02 mm Calculate clearance between piston pin and its hole.
Page 104 Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings in installation. All marks on the piston rings must be forwarded to up side. Make sure that all piston rings can be rotated freely after installed.
Page 105: Piston Installation
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily. 6.
Page 106 Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
Page 107 1. Mechanism 2. Maintenance Description 3. Troubleshooting 4. Clutch Cover 5. Drive Belt 6. Drive Face 7. Clutch Outer/Driven Pulley 8-10 1. Mechanism Diagram...
Page 108: Maintenance Description
2. Maintenance Description Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Drive belt and drive pulley must be free of grease. Specification Item Standard value Limit Driving belt width 28.500 mm 27.000 mm OD of movable drive face boss 26.946~26.980 mm...
Page 109: Clutch Cover
Clamp strips 4.Clutch Cover Clutch cover removal Release the 2 clamp strips of clutch cover ducts , and then remove the ducts. Remove clutch cover. (14 bolts) Remove 2 dowel pin and gasket. 14 bolts Clutch cover install Install left clutch cover in the reverse procedures of removal.
Page 110 Clutch over inspection Check bearing on clutch cover. Rotate bearing’s Inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly. If bearing rotation is uneven, noising, or loose Bearing mounted, then replace it.
Page 111: Drive Belt
holder Universal 5. Drive Belt Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool universal holder holder Universal Hold clutch outer with universal holder, and remove nut, and clutch outer. Caution Using special service tools for tightening or loosening the nut.
Page 112 Driven face Installation Caution Pull out driven face to avoid it closing. Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.
Page 113: Drive Face
Universal holder 6. Drive Face Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive Movable drive face face boss from crankshaft. Drive face boss Remove ramp plate.
Page 114 Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter.
Page 115 With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Press down Driven pulley installation(By 2 screw) Press drive belt into pulley groove, and then pull the belt onto drive shaft.
Page 116: Clutch Outer/Driven Pulley
7. Clutch Outer/Driven Pulley Disassembly Remove drive belt, and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much. Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool.
Page 117 Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 225 mm Free length Driven pulley Check following items: If both surfaces are damaged or worn. Driven face If guide pin groove is damaged or worn Replace damaged or worn components.
Page 118 Installation of Clutch OUTER/Driven Oil seal Pulley Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. O-ring Specified grease Movable driven Install the movable driven face onto driven face face.
Page 119 Transmission system Remove Remove the driven output rear shaft and front shaft. Separate the driven output rear shaft and front shaft. Remove the c-ring from the universal joint assy. Remove the driven output front shaft with a chisel. Remove the joint parts. Using a vise let the driven output rear shaft held in movable.
Page 120 Unlock the nut with a chisel. Remove the nut. Remove the bearing by tapping with the hammer and tool. Remove the universal joint assy Remove the parts. Rear universal joint disassembly. Remove the c-ring from the universal joint assy.
Page 121 Remove the parts. Using a vise held the driven output rear shaft and remove the nut. When reassemble with a new nut. Unlock the nut with a chisel. Must be replaced the new bearing and oil seal when reassembly Remove the NTT form Driven output front shaft.
Page 122 Disassembly the bevel gear. Unlock the nut with a chisel. Using a vise held the driven output front shaft and remove the nut. Remove the washer driven bevel gear and bearing. Remove the parts. Replace the new nut for reassemble. Must be replaced the new bearing and oil seal for reassemble.
Page 123 Inspection: Check the bearing and joint surface. If any defects(damage, wear or scuffing) replace the bearings and joint assy. Install the parts as show. Insert the bearing to the joint and turning the joint. If excessive play is noted, must be replace the new bearing.
Page 124 Reassembly driven output rear shaft. Before reassembly thoroughly clean all parts with solvent. Using a vise hold the bevel gear. Tighten the new nut to the specified torque. Torque: 100N-m (10kgf-m) Stake the nut with a punch. Apply gease to the bearing and seal lip.
Page 125 Apply grease to the oil seal lip. Install the oil seal to the joint yoke. (The oil seal lip should be positioned joint yoke side.) Using a vise hold the driven output rear shaft. Tighten new nut to the specified torque. Torque: 100N-m (10kgf-m) Stake the nut with a punch.
Page 126 Fehle Tooth contact: face contact 80% up Using the tool to install the bearings and joint. Reassemble the universal joint. When the tooth contact and backlash have been adjusted or checked. Tool: 440668 Install the new c-ring by tapping and hammer.(copper) Using the new c-ring for reassembly.
Page 127 FINAL ASSEMBLY After adjusting tooth contact correctly, remove the front and rear output shafts and drive bevel gear. Clean off any dye or paste from the gear teeth, and lubricate the teeth with engine oil. Tighten the drive bevel gear nut and rear out put shaft nut to the specified torque.
Page 128 ENGINE REASSEMBLY NOTE: When reassembly the engine pay attention, apply engine oil to sliding parts and running parts before re-assembling. CAUTION Be sure keep the drive belt, drive face and driven face away from any greasy matter. Install the output shaft assembly with a plastic mallet.
Page 129 DRIVE TRAIN Install the rear and front out put shaft. Install the C-ring. NOTE: Must fit the pins on the bearing into the groove of the crankcase. TRANSFER/GEARSHIFT Install the transfer related parts. Install the spacer spring, shaft and reverse idle gear.
Page 130 7. Mechanism Diagram 10-1 8. Precautions in Operation 10-2 9. Left Crankcase Cover Removal 10-3 10. A.C.G. Set removal 10-3 11. Left Cover Bearing 10-3 12. Flywheel Removal 10-4 13. Starting Clutch 10-5 14. Flywheel Installation 10-7 15. A.C.G. Set Installation 10-8 16.
Page 131: Precautions In Operation
2. Precautions in Operation General information Refer to chapter 17: The troubleshooting and inspection of alternator Refer to chapter 17: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear OD of starting clutch gear 52.548~52.445 Torque...
Page 132: Left Crankcase Cover Removal
15 bolts 3. Left Crankcase Cover Removal Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump (2 bolts). Remove 15 bolts from the left crankcase cover. Remove the left crankcase cover. Remove dowel pin and gasket.
Page 133: Flywheel Removal
Check the oil seal for wear or damage. Replace Oil seal it if necessary. Install a new one bearing (16005) by bearing driver. Bearing 6. Flywheel Removal Flywheel nut Remove left crankcase cover. Remove starter reduction gear and shaft. Pull out flywheel with A.C.G.
Page 134: Starting Clutch
7. Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 29 mm OD: 52.54 mm Check the starting reduction gear and shaft for wear or damage.
Page 135 One way clutch removal Remove starting driven gear. Starting driven gea 6 socket bolts Remove 6 socket bolts, and then remove one way clutch. One way clutch Starting driven gear 6 socket bolts One way clutch Installation Install the components in the reverse procedures of removal.
Page 136: Flywheel Installation
Install starting driven gear. Starting driven gear Groove 8. Flywheel Installation Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Torque vale: 10.0~12.0kgf-m Special tool: Universal Holder Install reduction gear shaft and reduction gear.
Page 137: Set Installation
Wire 3 bolts 9. A.C.G. Set Installation Install the A.C.G. coil set onto right crankcase cover (3 screws). Install pulse generator (3 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator.
Page 138 15 bolts Install left crankcase cover (15 screws). Install the dowel pin, new gasket and water pump cover onto left crankcase cover. Water pump bolts...
Page 139 L CASE R CASE...
Page 140 Oil seal Remove the oil seal with the special tool. Oil seal remover 440656 Install the oil seal with the special tool. Bearing installer set 440655 CAUTION Change the new oil seal to prevent oil leakage. NOTE: Be sure the stamped mark on the oil seal faces outside.
Page 141 BEARING REASEMBLY Install the bearing. NOTE: Be sure The sealed cover of the bearing must face outside. Install the chuck, Bearing NOTE: When installing the Bearing chuck,apply a small quantity of Loctite 262TM (Thread locker) to the screws.
Page 142 DRIVE BELT COVER Remove the snap ring with the snap ring pliers. NOTE: If any damage the bearing,replace the new one. Remove the bearing. REASSEMBLY Install the bearing. Install the snap ring with snap ring pliers.
Page 143 L CRANK CASE COVER Remove the oil pressure valve When installing the oil valve, tighten it to the specified torque. Oil pressure value:25N M(2.5kgf-m) Using an shaped tool to check the oil pressure valve operation. If the piston does not operate, replace the new one.
Page 144 Remove the oil seal. REASSEMBLY Install the bearing. Apply grease to the bearing, O-ring and oil seal lip. Install the oil seal. NOTE: When installing the oil seals, be sure the stamped mark on the oil seal faces outside. Apply a small quantity of Loctite 262 (Thread locker) to the screws and install the bearing retainer.
Page 145: Recoil Starter
Recoil starter DISASSEMBLY After removing the nut, take out the recoil starter related parts from the housing. WARNING When removing the plastics disc. Wear eye and hand protection, because the spring may quickly unwind and caus e an injury.
Page 146 REASSEMBLY Hook the spiral spring end with the recoil starter case. WARNING Wear eye and hand protector when reassembly the reel, because the spring may quickly unwind and cause an injury. Apply grease to the spiral spring. Turn the starter rope on the reel properly. Engage the part of the reel with the spiral spring end...
Page 147 CRANKSHAFT Mounting the crankshaft in the crankcase. NOTE: Use the front fork oil seal installer as an attachment. Front fork oil seal installer 440655 Apply a small quantity of Loctite 262 (Thread locker) to the thread and install and the gearshift cam stopper.
Page 148 Apply Loctite 510 (Flange sealant) to the mating surface of the left crankcase. L CASE R CASE...
Page 149 Assemble the crankcase within few minutes. NOTE: After crankcase screws have been tightened, check if crankshaft rotate smoothly. Fit the clamp to the bolt. Check the each shaft rotates smoothly after the crankcase bolts have been tightend. OIL PUMP Install the oil pump. Install the washer and pin.
Page 150 OIL PUMP DRIVE GEAR Install the pin. Install the oil pump drive gear and washer. Apply lock tail to the oil pump drive gear bolt. NOTE: Flange side of the gear is positioned inside. Tighten the oil pump drive gear bolt to the specified torque.
Page 151 Install the one way clutch outside. Install the clutch housing. OUTSIDE The one way clutch outside facing must on the shaft outside. NEUTRAL SWITCH Install the springs and switch contacts. Install the neutral switch. CLUTCH CASE Install the dowel pins and put the new gasket. Tighten the clutch case bolts.
Page 152 FIXED DRIVE FACE Install the fixed drive face. MOVABLE DRIVE/DRIVEN FACE AND DRIVE BELT Install the drive belt,between the movable driven face and fixed driven face by tapping with a plastic mallet. CAUTION The drive belt contact surface of the driven face should be thoroughly cleaned.
Page 153 Tighten the movable drive face nut to the specified torque with the special tool. Movable drive face nut: 115 N-m(11.5 kgf-m) Rotor holder 440666 NOTE: Turn the fixed drive face until the belt is seated in and both the drive and driven faces check the belt without slip.
Page 154 WATER PUMP GEAR Install the pin. Install the water pump chain to the two water pump gears as shon. Install the water pump gears with special tool. Install the wash. Bearing installer set 440660 Install the water pump gears and tighe the nut. NOTE: Make sure the crankshaft can turning smoothly.
Page 155 GENERATOR Install the key. Install the one way clutch and generator rotor sets. caution Be sure the one way clutch on the crankshaft is fitted into the generator rotor properly. Tighten the generator rotor nut to the specified torque with the special tool. Generator rotor nut:160 N-m(16.0 kgf-m) Rotor holder 440664 Install the output drive gear by installing the...
Page 156 GEARSHIFT Install the cam driven gear. Reassrmble the gearshift shaft. Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear. STARTER DRIVEN GEAR/IDLE GEAR Install the starter idle gear and driver gear. LEFT CRANKCASE COVER Install the dowel pins and put the new gasket.
Page 157 Tighten the left crankcase cover bolt. NOTE: Fit the clamp to the bolt. SPEEDOMETER GEARBOX Fit a new gasket and install the speedometer gearbox. WATER PUMP Check the water pump shaft position with water pump gear shat. Apply engine oil on the O-ring of water pump. Install water pump.
Page 158 STARTER CUP Apply engine oil to the O-ring and lip of the oil seal. Install the starter cup. Tighten the starter cup nut by using a suitable bar. Starter cup nut: 35 N-m(3.5 kgf-m) Cup, Starter installer 440658...
Page 159: Water Pump Impeller 1 7
General Information Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. Refill the radiator with distilled water or specified additives.
Page 160 Trouble Diagnosis The engine temperature is too high The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to close. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The filler cap of the radiator malfunction. The engine temperature is too low The water thermometer and the temperature sensor malfunction.
Page 163: System Test
System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low. The specified pressure shall be maintained at Pressure tester Filler cap...
Page 164 Check reserve tank Remove the front center cover, and then Upper remove reserve tank filler cap. Check the liquid level in the front fender right side. Add coolant to proper level if too low. Reinstall the reserve tank filler cap. Lower Caution The reserve tank liquid level cannot too high,...
Page 165 Loosen the radiator 4 bolts. Remove coolant upper side pipes. 4 bolts Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and Collant outlet pipe cooling fan. Disassembly Loosen the 4 bolts from the fan duct, and then remove the fan duct.
Page 166: Water Pump
Water Pump Check water pump seal / cooling system divulges inspection Disassembles the refrigerant drain bolt, overflows little buckles the actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
Page 167 Thermostat Temperature sensor Please refer to chapter 17 for inspection of temperature sensor. By-pass pipe Removal Drain out the coolant. Remove the thermostat set. (2 bolts) 2 bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.
Page 168 1. Mechanism Diagram 13-1 2. Maintenance 13-2 3. Front handle cover / Meter cover 13-3 4. Front center cover 13-4 5. Upper center cover 13-4 6. Footrest 13-5 7. R/L side cover 13-5 8. Front fender 13-6 9. Rear fender 13-7 10.
Page 169: Maintenance
2. Maintenance Disassemble sequence: Be careful not to damage various covers in assembly or disassembly operation. Never injure hooks molded on the body covers. Align the buckles on the guards with slot on the covers. Make sure that each hook is properly installed during the assembly. Never compact forcefully or hammer the guard and the covers during assembly.
Page 170: Front Handle Cover / Meter Cover
3. Front handle cover / Meter 4 screws cover Remove Remove 4 screws from meter cover ,and then remove front handle cover. Loosen 2 bolts from meter stay. 2 bolts Remove couplers of meter. 4 screws Disassembly Remove 4 screws and 2 nuts. Installation Install in reverse order of removal procedures.
Page 171: Front Center Cover
4. Front center cover Remove Loosen 3 screws from the front center cover. Please disassemble first then push the cap upward, and then remove front center cover. Installation Install in reverse order of removal 3 screws procedures 5. Fuel tank cover Remove Remove seat.
Page 172: Footrest
6. Footrest cover Remove Loosen the 4 bolts, which connect the footrest, these 4 bolts just between footrests. Loosen the 6 bolts connect with front fender both side, also loosen 5 bolts connect with rear fender both side, and then remove footrest cover.
Page 173: Front Fender
8. Front fender Remove Remove the seat. Remove front center cover, and then loosen 4 screws of fuel tank cover. Loosen the screws which connect to footrest and side cover, (each side 9 screws) Loosen the 4 screws, which connect the front fender right and left side, then remove front winker and headlight coupler, Remove head lamp stay bolts(each side 2...
Page 174: Rear Fender
9. Rear fender Remove the seat. Loose screws which connect to footrest and side cover.(each side 6 screws) Remove fuse box, starter relay, battery and C.D.I on rear fender. Caution Loose battery screw from polar side, never connect polar and negative with any electric Polar object.
Page 175: Front Bumper Cover
10. Front bumper cover Remove Loosen 4 bolts from the rear carrier. Remove the front bumper cover Installation Install in reverse order of removal procedures. Caution Please put the shift lever in the “N” position bracket that welded in the frame when take off the body cover and running the engine in”N”position Warning It will be very dangerous if not follow this process that the engine gear will...
Page 176 2. Maintenance Description 14-2 3. Trouble Diagnosis 14-3 4. Front Wheel 14-4 5. Front Wheel Hub 14-4 6. Disk Brake System Inspection 14-7 7. Adding Brake Fluid 14-8 8. Brake fluid replacement / Air-bleed 14-9 9. Front Brake Caliper 14-10 10.
Page 177: Maintenance Description
2. Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
Page 178: Trouble Diagnosis
3. Trouble Diagnosis Soft brake lever Hard operation of brake lever 1. Air inside the hydraulic system 1. Blocked brake system 2. Hydraulic system leaking 2. Poor brake caliper 3. Worn master piston 3. Blocked brake pipe 4. Worn brake pad 4.
Page 179: Front Wheel
4. Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, and then remove front wheels. Installation Install the front wheel and tighten the nuts. 4 nuts Torque: 50 N-m 5.
Page 180 Remove 4 socket bolts, and then remove the brake disk from wheel hub. 4 bolts Inspection Install the front brake disk to the wheel hub. Install wheel hub and brake disk on to knuckle. Install wheel hub washer and tighten the wheel hub nut.
Page 181: Disk Brake System Inspection
6.Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Page 182: Adding Brake Fluid
Master cylinder 7. Adding Brake Fluid Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
Page 183: Brake Fluid Replacement / Air-Bleed
8. Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.
Page 184: Front Brake Caliper
9. Front Brake Caliper Removal Brake hose bolt Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Inspection Make sure the brake linings condition.
Page 185: Brake Disk
10. Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 3.5 mm Remove the brake disk from wheel hub. Check the disk for deformation and bend.
Page 186 Remove the rubber boot. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Master Cylinder 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 directions.
Page 187 Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to 2 washers Brake light switch brake light switch, then install the brake stopper at last.
Page 188 17. Mechanism Diagram 15-1 18. Operation Precautions 15-2 19. Trouble Diagnosis 15-2 20. Steering Handle 15-3 21. Steering Shaft 15-5 22. Steering Tie-Rod 15-6 23. Knuckle 15-7 24. Front Cushion 15-8 25. Suspension Arm 15-9 26. Toe-In 15-10 1. Mechanism Diagram...
Page 189: Trouble Diagnosis
2. Operational Precautions Torque Handlebar upper holder bolt 24 N-m Steering shaft holder bolt 23 N-m Steering shaft nut 84 N-m Steering tie-rod nut 40 N-m Knuckle nut 50 N-m Tie rod lock nut 40 N-m Suspension arm nut 70 N-m Front cushion mounting nut 45 N-m 3.
Page 190: Steering Handle
4. Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter Loosen the socket bolts for the front brake master cylinder, and remove front brake master cylinder. Caution Do not let foreign materials enter into the cylinder.
Page 191 Loosen 2 screws, and then remove handle left switch and choke cable. 2 screws Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. Installation Install in reverse order of removal procedures. Torque: Handlebar holder bolt 24 N-m 4 socket bolts...
Page 192: Steering Shaft
5. Steering Shaft Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod. Steering shaft nut Remove the cotter pin below steering shaft, and remove steering shaft nut and washer. Cotter pin Steering shaft nut Bend out the steering shaft holder nut fixed plate. Loosen 2 bolts, and then remove steering shaft holder, nut fixed plate, pressed plate and steering shaft.
Page 193: Steering Tie-Rod
Cotter pin 6. Steering Tie-Rod Remove Remove cotter pin and tie-rod nut from steering shaft side. Tie-rod nuts Remove cotter pin and tie-rod nut from wheel side. Tie-rod nuts Cotter pin Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration.
Page 194: Knuckle
7. Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Tie-rod Remove cotter pin and tie-rod nut, remove tie rod. Cotter pin Remove cotter pin and ball joint nut. Remove upper and under ball joints by ball joint driver.
Page 195: Front Cushion
8. Front Cushion Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion upper bolt nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque: Front cushion nut 45 N-m...
Page 196: Suspension Arm
9. Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Loosen upper suspension arm nuts, remove swing arm bolts. Remove upper suspension arm. Suspension arm nuts and bolts Loosen under suspension arm nuts, remove swing arm bolts.
Page 197: Toe-In
10. Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels turn 180 degree, so the marks on the tires are aligned with the axle center height.
Page 198 1. Mechanism Diagram 16-1 2. Maintenance Description 16-2 3. Trouble Diagnosis 16-3 4. Rear Wheel 16-4 5. Rear Wheel Axle 16-5 6. Disk Brake System Inspection 16-6 7. Adding Brake Fluid 16-7 8. Brake Fluid Replacement / Air-Bleed 16-8 9. Rear Brake Caliper 16-9 10.
Page 199: Maintenance Description
2. Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
Page 200: Trouble Diagnosis
3. Trouble Diagnosis Soft brake lever Air inside the hydraulic system Hydraulic system leaking Worn master piston Worn brake pad Poor brake caliper Worn brake lining/disk Low brake fluid Blocked brake hose Warp/bent brake disk Bent brake lever Hard operation of brake leve Blocked brake system Poor brake caliper Blocked brake pipe...
Page 201: Rear Wheel
4. Rear Wheel Removal Raise the rear wheels off ground by placing a jack or other support under the frame. 4 nuts Remove the rear wheel nuts, and the remove rear wheel. Installation Install the rear wheel and tighten the nuts. Torque: 50 N-m...
Page 202: Rear Wheel Axle
5. Rear Wheel Axle Remove cotter pin, rear wheel axle connecter nut and washer. Wheel hub nut Cotter pin Installation Install wheel shaft connecter washet and tighten the wheel shaft connecter nut. Torque:100 N-m Install cotter pin. Remove rear wheel knuckle 2 bolts.(R/L) Installation Install rear wheel knuckle and tighten the bolts.
Page 203: Disk Brake System Inspection
6. Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
Page 204: Adding Brake Fluid
7.Adding Brake Fluid Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the Fluid cup brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
Page 205: Brake Fluid Replacement / Air-Bleed
8. Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake Air-bleed valve fluid into the brake master cylinder.
Page 206: Rear Brake Caliper
9. Rear Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Brake hose bolt Remove two caliper bolts and the caliper. Inspection Make sure the brake linings condition.
Page 207: Brake Disk
10. Brake Disk Removal Removal the rear wheel. Removal the rear wheel knuckle. Removal the rear wheel axle. Removal the cushion 4 bolts. 4 bolts Removal the rear arm upper 1 bolts.(R/L) Installation Install the rear arm upper and tighten the bolt. Torque: 70 N-m Removal the rear arm lower 2 bolts.(R/L) Installation...
Page 208 Removal the stabilizer bar 4 bolts. Installation Install the stabilizer bar and tighten the bolts. Torque: 28 N-m Removal the rear brake disk 4 bolts. Installation 4 bolts Install the rear brake disk and tighten the bolts. Torque: 25 N-m Removal the rear differential 3 bolts.
Page 209: Rear Brake Master Cylinder
Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 3.5 mm Remove the brake disk from rear differential. Check the disk for deformation and bend.
Page 210 Right footrest side – rear brake master cylinder Place a container under the brake master cylinder, remove fluid hose clamp, and drain out the brake fluid. Loosen the brake hose bolt and finally remove the brake hose. Remove the E type clip, and remove brake push rod pin.
Page 211 Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 10.945 mm Foot brake 18.845 mm Master Cylinder Assembly Caution It is necessary to replace the whole set comprising piston, spring, piston cup, and cir clip. Make sure there is no dust on all components before assembling.
Page 212 Right footrest side – rear brake master cylinder Install the master cylinder bolts and the master cylinder. Install brake push rod to the brake pedal, and install pin and E type clip. Caution To adjustment brake pedal, you must be remove push rod pin first.
Page 213: Rear Cushion
12. Rear Cushion Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Remove rear cushion upper bolt, and then remove rear cushion. Installation Install rear cushion, and install rear cushion upper bolt. Install rear cushion under bolt, and install nut. Tighten the rear cushion upper bolt and under nut to the specified torque value.
Page 214 1. Mechanism Diagram 17-1 2. Maintenance Date 17-2 3. Technical Specification 17-2 4. Trouble Diagnosis 17-3 5. Battery 17-4 6. Charging System 17-5 7. Ignition System 17-8 8. Starting System 17-10 9. Meters 17-12 10. Light / Bulb 17-13 11. Switch / Horn 17-16 12.
Page 215: Maintenance Date
2. Maintenance Data Operational precaution When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.
Page 216: Trouble Diagnosis
4. Trouble Diagnosis No voltage Charging system does not operate Battery discharged properly The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage The battery is not fully charged Engine does not crank smoothly Poor contact...
Page 217: Battery
5. Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove Clamp battery. Voltage Check Use the digital voltmeter to check the voltage of the battery.
Page 218: Charging System
6. Charging System Charging circuit Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal. Caution In the current leakage test, set the current range at the largest scale, then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter...
Page 219 Inspection on Charging Voltage Connect a tachometer Turn on the headlight to high beam and start the engine. Accelerate the engine to the specified revolution per minute and measure the charging voltage. Specified Charging Current: 1.2 A / 6000 rpm Control Charging Voltage: 14.5 + 0.5 V / 2000 rpm Caution...
Page 220 Inspection on regulator rectifier Remove the seat, side cover L. Disconnect three couplers of the regulator Rectifier Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Connection R – B Battery voltage (ON) Battery connection...
Page 221: Ignition System
7. Ignition System Ignition circuit diagram C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result Main switch turn to B ~ W/B Battery voltage “ON”position Pulse generator G/W ~ L/Y...
Page 222 Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Standard resistance: 2.9 ±10% Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.
Page 223: Starting System
8. Starting System Starting circuit diagram Inspection on starter relay Open the main switch. Press the brake. Starter relay Push down the starter switch. If a sound of .”Looh Looh”. is heard, it indicates the relay function normally. Remove the seat. Disconnect the negative cable terminal of the battery.
Page 224 Removal of Starter motor Negative Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. Loosen the lock bolts and remove the starter motor. Starter motor cable Installation of Starter motor Install in reverse order of removal procedures.
Page 225: Meters
9. Meter 4 screws Removal Remove 4 screws from meter cover ,and then remove front handle cover. Loosen 2 bolts from meter stay. 2 bolts Remove couplers of meter. 4 screws Remove 4 screws and 2 nuts, and then remove speedometer.
Page 226: Light / Bulb
10. Light / Bulb Replacing Bulb for Headlight Remove waterproof cover for the headlight. Remove bulb setting hook. Take out the bulb connector and the bulb. Replace with new bulb if necessary. (Hight light H1 12V 55W) (Low light H7 12V 55W) Caution Never touch the bulb with finger, which will create a heat point.
Page 227 Replacing the Front winker light Bulb Pull out the front winker light bulb seat. 2 screws Replace with new front winker light bulb. (12V 10W) Replacing Bulb of Position Light Pull out the position light bulb seat. Replace with new position light bulb. (12V 5W)
Page 228 Replacing Bulb of Taillight and Rear Winker Light Turn the taillight and rear winker light bulb connectors by CCW. Replace with new taillight bulb. (12V 16W) Replacing Bulb of License Light Turn the license light bulb connectors by CCW. Replace with new license light bulb. Replace with new license ight bulb.
Page 229: Switch / Horn
11. Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: Replacement of main switch Disconnect the coupler of the main switch. Push out the main switch. Align the main switch stopper with the meter cover groove, and install main switch.
Page 230 Headlight Switch Head light switch Winker switch Winker switch Horn switch Horn switch Hazard switch Hazard switch...
Page 231 Front Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity.
Page 232: Fuel Unit
12. Fuel Unit Remove the seat. Remove the fuel tank cap. Remove the upper center cover and front fender (refer chapter 13). Disconnect the coupler of the fuel unit. Remove the fuel unit (4 bolts). Caution Great care shall be taken not to damage or bend the float arm of the gauge.
Page 233: Cooling Fan Thermo Switch
13. Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
Page 234: Thermo Unit
14. Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Thermo unit Caution Wear gloves and goggles when performing this test. Caution Engine oil should be used as a heating medium as the test temperature must be higher than 100 .