TGB Blade 525 Service Manual
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TGB Blade 525 Service Manual

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BLADE 500/525
SERVICE MANUAL
TAIWAN GOLDEN BEE CO.,LTD.
PDF created with pdfFactory Pro trial version
www.pdffactory.com

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Keith
August 6, 2025

Hi can u tell me what the part that has two hose coming down to it from rad as it was full of gray gunge thick but that ment to have water in it but thick gunge instead so was wondering what this does thank u.

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Summary of Contents for TGB Blade 525

  • Page 1 BLADE 500/525 SERVICE MANUAL TAIWAN GOLDEN BEE CO.,LTD. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the ATV, BLADE 525/500, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3: General Information

    HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for BLADE 525/500 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Homepage CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-7 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-14 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14 “V”...
  • Page 5 Home page Contents SERIAL NUMBER Frame number Engine number PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 6 Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Torque Values ........1-10 General Safety ........1-2 Troubles Diagnosis......1-12 Service Precautions ......1-3 Lubrication Points ......1-17 Specifications ........1-9 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    To this chapter contents 1. GENERAL INFORMATION General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have ‧...

  • Page 8: Service Precautions

    1. GENERAL INFORMATION Service Precautions ● ● Never bend or twist a control cable to prevent Always use with TGB genuine parts and recommended oils. Using non-designed parts for unsmooth control and premature worn out. TGB ATV may damage the ATV.
  • Page 9 To this chapter contents 1. GENERAL INFORMATION ● The length of bolts and screws for assemblies, ● Remove residues of the old gasket or sealant cover plates or boxes is different from one another, before reinstallation, grind with a grindstone if be sure they are correctly installed.
  • Page 10 To this chapter contents 1. GENERAL INFORMATION ● Lubricate the rotation face with specified ● After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. ●...
  • Page 11 To this chapter contents 1. GENERAL INFORMATION ● When separating a connector, it locker has to be ● Insert the terminal completely. unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. ●...
  • Page 12 To this chapter contents 1. GENERAL INFORMATION ● Do not let the wire harness contact with rotating, ● Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.
  • Page 13 To this chapter contents 1. GENERAL INFORMATION ● Do not let the wire harness been twisted as ● With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust ● Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

  • Page 14: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER MODEL Overall Length 2155 mm Suspension Front Double arm Overall Width 1170 mm System Rear Unit Swing Overall Height 1205 mm Front 25X8-12 Tire Specifications Wheel Base 1300 mm Rear 25X10-12 Front 930 mm Aluminum / Steel...

  • Page 15: Torque Values

    1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw...
  • Page 16 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks 2.40 Handlebar upper holder bolt 5.00 Steering shaft nut 5.00 Steering tie-rod nut 5.00 Knuckle nut 3.40 Steering shaft holder bolt 3.60 Tie rod lock nut 4.00 Handlebar under holder nut...

  • Page 17: Troubles Diagnosis

    To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside ● No fuel in fuel tank the carburetor ●...
  • Page 18 To this chapter 1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed ● Air cleaner clogged ● Poor fuel supply Engine speed can not be Engine speed can be ●...
  • Page 19 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) ● Normal Abnormal Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good Poor...
  • Page 20 To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley FAULT CONDITIONS PROBABLE CAUSES ● Drive belt worn out or deformation ● Ramp plate of movable drive face damaged Engine can be started but ● Driving pulley spring broken motorcycle can not be moved.
  • Page 21 1. GENERAL INFORMATION G. Loss power Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand ● Brake dragging ● Drive chain too tight Spin freely Abnormal ● Damaged wheel bearing ● Wheel bearing needs lubrication Check tire pressure ●...

  • Page 22: Lubrication Points

    To this chapter contents 1. GENERAL INFORMATION Lubrication Points Acceleration cable/ Front & rear brake lever pivot Speedometer gear Wheel bearing 1-17 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 23 To this chapter contents 1. GENERAL INFORMATION Note: 1-18 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 24 Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ···················· 2-1 Brake System (Disk Brake) ················· 2-8 Periodical Maintenance Schedule ······ 2-2 Brake Light Switch/Starting Inhibitor Switch ··················································· 2-9 Fuel Lines ············································· 2-3 Headlight Beam Distance ···················· 2-10 Acceleration Operation ······················· 2-3 Clutch Disc Wear ·································...

  • Page 25: Periodical Maintenance Schedule

    R ~ Replacement T ~ Tighten Have your ATV checked, adjusted, and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

  • Page 26: Fuel Lines

    To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines Fuel tank Remove the seat . Loosen 2 screws and 2 bolts Carbureto 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 27: Valve Clearance

    To this chapter contents 2. MAINTENANCE INFORMATION 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. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.

  • Page 28: Carburetor Idle Speed Adjustment

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

  • Page 29: Ignition System

    To this chapter contents 2. MAINTENANCE INFORMATION 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 whether CDI function is in normal or not. Connect tachometer and ignition light.

  • Page 30: Drive Belt

    To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Clamp strips Loosen the 2 clamp strips of clutch cover, and then remove the clutch cover vapor hose. Remove 14 bolts of the clutch cover. 14bolts Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.

  • Page 31: Brake System (Disk Brake)

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

  • Page 32: Brake Light Switch/Starting Inhibitor

    To this chapter contents 2. MAINTENANCE INFORMATION Brake Lining Wear Front brake The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark Lining closed to the edge of brake disc. Caution ●...

  • Page 33: Headlight Beam Distance

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

  • Page 34: Steering Handle

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

  • Page 35: Special Tools List

    2. MAINTENANCE INFORMATION Special Tools List PARTS NO. : 440649 PARTS NO. : 440650 PARTS NAME : EXTENSION PULLER / PARTS NAME : BUSHING(924739) REMOVER REMOVER PARTS NO. : 440651 PARTS NO. : 440652 PARTS NAME : BEARING(924384) PARTS NAME : BEARING(924384) REMOVER φ15 REMOVER φ20 PARTS NO.
  • Page 36 2. MAINTENANCE INFORMATION 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) &...
  • Page 37 2. MAINTENANCE INFORMATION PARTS NO. : 440665 PARTS NO. : 440666 PARTS NAME : IDLER GEAR (924187) PARTS NAME : GEAR DRIVEN PULLER (924146) HOLDER PARTS NO. : 440667 PARTS NO. : 440668 PARTS NAME : CYLINDER HEAD VALVE PARTS NAME : UNIVERSAL JOINT HEAD (924646) AND SPRING INSTALLER/REMOVER INSTALLER...
  • Page 38 3. LUBRICATION SYSTEM Mechanism Diagram ······························ 3-1 Engine Oil ··············································· 3-3 Precautions in Operation ······················ 3-2 Engine Oil Strainer Clean ······················ 3-3 Troubleshooting ···································· 3-2 Oil Pump ················································· 3-4 Mechanism Diagram PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 39: Precautions In Operation

    3. LUBRICATION SYSTEM 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. Filter change:3200 c.c. Change: 3000 c.c. Oil viscosity SAE 10W-40 Items Standard (mm) Limit (mm) Inner rotor clearance...

  • Page 40: Engine Oil

    3. LUBRICATION SYSTEM 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.

  • Page 41: Oil Pump

    3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal One way clutch 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. Remove the snap ring.
  • Page 42 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body.
  • Page 43 3. LUBRICATION SYSTEM Tighten the oil pump screw. Oil Pump Installation Install the oil pump, and then tighten 3 screws. Torque value：1.0kgf-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 44 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 45: Fuel System

    4. FUEL SYSTEM Mechanism Diagram ......4-1 Throttle Valve ........4-6 Precautions in Operation..... 4-2 Float Chamber........4-7 Trouble Diagnosis ........ 4-3 Adjustment of Idle Speed ....4-9 Carburetor Remove / Install ....4-4 Fuel Tank ..........4-10 Air Cut-Off Valve ........4-5 Air Cleaner..........4-11 Mechanism Diagram PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 46: Precautions In Operation

    4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions ● Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. ●...

  • Page 47: Trouble Diagnosis

    4. FUEL SYSTEM Trouble Diagnosis 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 ●...

  • Page 48: Carburetor Remove / Install

    4. FUEL SYSTEM 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. Disconnect the starter cable. Remove the carburetor. Installation Install in reverse order of removal procedures.

  • Page 49: Air Cut-Off Valve

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

  • Page 50: Throttle Valve

    4. FUEL SYSTEM Throttle Valve Disassembly 2 screws Remove carburetor top comp. Remove the spring，holder，needle set.jet and piston valve. Remove the cable adjuster assy. Cable adjuster assy PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 51: Float Chamber

    4. FUEL SYSTEM Float Chamber Disassembly Remove 4 mounting screws and remove float chamber cover. 4 screws Remove the screw, float pin, float and float valve. Float Screw Float valve Float Inspection Check float valve and valve seat for damage, blocking.
  • Page 52 4. FUEL SYSTEM Remove main jet, needle jet holder, needle jet, Main jet slow jet and air adjustment screw. Slow jet Starter jet Cautions T ake care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns.

  • Page 53: Adjustment Of Idle Speed

    4. FUEL SYSTEM Parking brake Adjustment of Idle Speed Caution ● Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. ●...

  • Page 54: Fuel Tank

    4. FUEL SYSTEM Fuel Tank Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter 13) Disconnect fuel unit coupler. 4 bolts Remove fuel unit (4 bolts).

  • Page 55: Air Cleaner

    4. FUEL SYSTEM Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Clamp Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the regulator. Remove the air cleaner (5 bolts).
  • Page 56 4. FUEL SYSTEM Notes: 4-12 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 57: Engine Removal

    5. ENGINE REMOVAL Precautions in Operation ..... 5-1 Engine Disassembly......5-10 Removal of Engine ....... 5-2 Front differential set oil...... 5-12 Engine Installation ........ 5-7 Final gear set oil ......... 5-13 Precautions in Operation General Information ● The engine has to be supported with special service tools that can be lifted or adjustable. ●...
  • Page 58 5. ENGINE REMOVAL Engine Removal Before taking the engine out of the frame. Clean and wash the engine using A steam cleaner. Engine removal is explained in the following. Steps. Reinstall the engine by reversing the removal procedure. ‧Before removal the engine. Drain engine oil ‧Remove the seat.
  • Page 59 5. ENGINE REMOVAL Remove the gearshift lever. Remove the fuel hose and vacuum hose. Fuel pipe Vacuum pipe Remove the air cleaner. Air cleaner Remove the carburetor. Carburetor PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 60 5. ENGINE REMOVAL Remove the speedometer cable. Remove the gearshift mud. Remove the connector of lead wire. Remove the signal generator lead wire connector and generator lead wire connector. Remove the spark plug cap. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 61 5. ENGINE REMOVAL Remove the right footrest. Remove the brake pedal. Remove the L and R muffler. Remove the exhaust pipe. Remove the front and rear tube PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 62 5. ENGINE REMOVAL Remove the front and rear shaft bolts. Remove the engine mounting bolts and nuts. Remove the engine mounting bracket. Remove the engine bolsters. Remove the flange bolts and take down engine bolster. Remove the engine from the right side. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 63 5. ENGINE REMOVAL Engine installation 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：...
  • Page 64 5. ENGINE REMOVAL Torque valve: Engine mounting bracket bolt 26 N-m (2.6kgf-m,or 19lb-ft) Apply sealant to the screw. Apply sealant to the propeller shaft flange coupling bolts. Tighten them to the standard torque. Apply sealant to the front propeller shaft flange coupling bolts. Tighten them to the standard torque.
  • Page 65 5. ENGINE REMOVAL Exhaust pipe nut: Connector bolt: Muffler mounting bolt: 25N-m (2.5kgf-m, 16.5lb-ft) Apply to the muffler mounting bolt to the muffler sealant fixed bolts and tighten them. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 66 5. ENGINE REMOVAL 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. 5-10 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 67 5. ENGINE REMOVAL Remove the engine oil pipe bolts. 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. 5-11 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 68 5. ENGINE REMOVAL 5-12 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 69 5. ENGINE REMOVAL Front differential set oil Caution Be sure the differential set temperature below 35 SAE#90 hypoid gear oil Oil standard: Oil capacity: 300c.c. Remove the under cover. Place an oil pan below the differential set case. Drain nut Remove drain bolt, filler nut and drain oil out.
  • Page 70 5. ENGINE REMOVAL Final gear set oil Remove the final gear set under cover. Place an oil pan below the case of final gear set. Remove the drain blot. Remove the filler cap Drain oil nut. Tighten the drain blot. Remove the oil check bolt.
  • Page 71 5. ENGINE REMOVAL Note： 5- 14 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 72: Cylinder Head/Valve

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

  • Page 73: Precautions In Operation

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

  • Page 74: Troubleshooting

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

  • Page 75: Cylinder Head Removal

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Removal Remove engine. (Refer to chapter 5) 2 Nuts Remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove the thermostat. Thermostat bolts Remove hole bolt and spring for the cam chain tensioner.
  • Page 76 To this chapter contents 6. CYLINDER HEAD/VAL Remove cylinder head cover, and hole bolts(3 bolts) 3 bolts 6 bolts Remove fix stand for spindle .cam (6 bolts). Remove cam sprocket bolts and then remove Chain tensioner thesprocket by prying chain out. 1 bolt 1 bolts Remove cam chain tensioner and hole bolt.
  • Page 77 To this chapter contents 6. CYLINDER HEAD/VALVE Remove the 4 cylinder head mounting bolts from 4 Nuts cylinder head right side, and then remove 4 bolts and washers from cylinder head upper side. Remove the cylinder head. 4 bolts Gasket Remove cylinder head gasket and 2 dowel pins.

  • Page 78: Cylinder Head Inspection

    To this chapter contents 6. CYLINDER HEAD/VALVE Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. Cylinder Head Inspection Check if spark plug and valve holes are cracked.
  • Page 79 To this chapter contents 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
  • Page 80 To this chapter contents 6. CYLINDER HEAD/VALVE Valve guide Caution 5.0 mm valve guide reamer Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve...

  • Page 81: Valve Stem Replacement

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

  • Page 82: Valve Seat Inspection And Service

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution ●...
  • Page 83 To this chapter contents 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.

  • Page 84: Cylinder Head Reassembly

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

  • Page 85: Cylinder Head Installation

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
  • Page 86 To this chapter contents 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the Timing mark timing mark on the sprocket with that of cylinder head. 2 bolts Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution Make sure timing marks are matched.

  • Page 87: Valve Clearance Adjustment

    To this chapter contents 6. CYLINDER HEAD/VALVE 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 88: Cylinder/Piston

    Home page Contents 7. CYLINDER/PISTON Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7 Cylinder Installation ························· 7-7 Trouble Diagnosis································ 7-2 Cylinder and Piston Removal ············· 7-3 Mechanism Diagram PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 89: Precautions In Operation

    7. CYLINDER/PISTON Precautions in Operation General Information Specification Unit：mm Item Standard Limit 93.022~93.052 93.100 Cylinder Bend 0.050 Top ring 0.04~0.075 0.011 Clearance between piston rings ring 0.02~0.055 0.090 Top ring 0.150~0.300 0.500 Piston/ Ring-end gap ring 0.300~0.450 0.650 Piston ring Oil ring side rail 0.200~0.700 OD of piston (2...

  • Page 90: Cylinder And Piston Removal

    To this chapter contents 7. CYLINDER/PISTON Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. 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 91 To this chapter contents 7. CYLINDER/PISTON Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn.
  • Page 92 To this chapter contents 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 21.960 mm Measure the inner diameter of connecting rod small end. Service Limit: 22.065 mm Measure the inner diameter of piston pin hole. Service Limit: 22.020 mm Calculate clearance between piston pin and its hole.

  • Page 93: Piston Ring Installation

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

  • Page 94: Piston Installation

    To this chapter contents 7. CYLINDER/PISTON Clean up all residues and foreign materials on the matching surface of crankcase. attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily.
  • Page 95 To this chapter contents 7. CYLINDER/PISTON Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。...
  • Page 96 Home page Contents 8. V-BELT DRIVING SYSTEM Mechanism Diagram ··························· 8-1 Drive Belt ·············································· 8-5 Maintenance Description ···················· 8-2 Drive Face············································· 8-7 Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley·················· 8-10 ························· 8-3 Clutch Cover Mechanism Diagram PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 97: Maintenance Description

    Torque value Special Service Tools ● Drive face nut: 10~12kgf-m Clutch spring compressor: ● Clutch outer nut: 10~12.0kgf-m Inner bearing puller: TGB- ● Drive plate nut: 10~12kgf-m Clutch nut wrench 27 x 15 mm: TGB- Universal holder: TGB- Bearing driver:...

  • Page 98: Clutch Cover

    To this chapter contents 8. V-BELT DRIVING SYSTEM 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 99 To this chapter contents 8. V-BELT DRIVING SYSTEM 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 100: Drive Belt

    To this chapter contents 8. V-BELT DRIVING SYSTEM Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool：universal holder Hold clutch outer with universal holder, and Universal holder remove nut, and clutch outer.
  • Page 101 To this chapter contents 8. V-BELT DRIVING SYSTEM Installation Driven face 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 102: Drive Face

    To this chapter contents 8. V-BELT DRIVING SYSTEM Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face Movable drive face boss from crankshaft.
  • Page 103 To this chapter contents 8. V-BELT DRIVING SYSTEM Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged.
  • Page 104 To this chapter contents 8. V-BELT DRIVING SYSTEM With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Driven pulley installation(By 2 screw) Press drive belt into pulley groove, and then pull...

  • Page 105: Clutch Outer/Driven Pulley

    To this chapter contents 8. V-BELT DRIVING SYSTEM Clutch Outer/Driven Pulley Clutch nut wrench 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.
  • Page 106 To this chapter contents 8. V-BELT DRIVING SYSTEM 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. If guide pin groove is damaged or worn.
  • Page 107 8. V-BELT DRIVING SYSTEM Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face. Movable driven face Guide pin Install the guide pin and guide pin roller.
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  • Page 109: Final Driving Mechanism

    9. FINAL DRIVING MECHANISM 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.
  • Page 110 9. FINAL DRIVING MECHANISM 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-rings from the universal joint assy. PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 111 9. FINAL DRIVING MECHANISM 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 from Driven output front shaft PDF created with pdfFactory Pro trial version...
  • Page 112 9. FINAL DRIVING MECHANISM 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 fro reassemble. Must be replaced the new bearing and oil seal for reassemble.
  • Page 113 9. FINAL DRIVING MECHANISM Inspection: Check the bearings 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 114 9. FINAL DRIVING MECHANISM 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, 73lb-ft) Stake the nut with a punch. Apply grease to the bearing and seal lip.
  • Page 115 9. FINAL DRIVING MECHANISM 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 the new nut to the specified torque. Torque: 100N-m (10kgf-m, 73lb-ft) Stake the nut with a punch.
  • Page 116 9. FINAL DRIVING MECHANISM ○ 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 117 9. FINAL DRIVING MECHANISM FINAL ASSEMBLY l After adjusting tooth contact correctly, remove the Front and rear output shafts and drive bevel gear. l Clean off any dye or paste from the gear teeth, and lubricate the teeth with engine oil. l Tighten the drive bevel gear nut and rear out put Shaft nut to the specified torque.
  • Page 118 9. FINAL DRIVING MECHANISM 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. l Install the output shaft assembly with a plastic mallet.
  • Page 119 9. FINAL DRIVING MECHANISM DRIVE TRAIN l Install the rear and front out put shaft. l 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. Install the washer.
  • Page 120 9. FINAL DRIVING MECHANISM Note: 9-12 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 121: Alternator/ Starting Clutch

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

  • Page 122: Precautions In Operation

    10. ALTERNATOR/STARTING CLUTCH 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...

  • Page 123: Right Crankcase Cover Removal

    10. ALTERNATOR/STARTING CLUTCH Left Crankcase Cover Removal 15 bolts 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 124: Flywheel Removal

    10. ALTERNATOR/STARTING CLUTCH Check the oil seal for wear or damage. Oil seal Replace it if necessary. Install a new one bearing (16005) by bearing driver. Bearing Flywheel Removal Remove left crankcase cover. Flywheel nut Remove starter reduction gear and shaft. Pull out flywheel with A.C.G.

  • Page 125: Starting Clutch

    10. ALTERNATOR/STARTING CLUTCH 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: 52.54mm Check the starting reduction gear and shaft for wear or damage.
  • Page 126 10. ALTERNATOR/STARTING CLUTCH One way clutch removal Remove starting driven gear. Starting driven gea Remove 6 socket bolts, and then remove one way clutch. 6 socket bolts One way clutch Starting driven gear One way clutch Installation 6 socket bolts Install the components in the reverse procedures of removal.

  • Page 127: Flywheel Installation

    10. ALTERNATOR/STARTING CLUTCH Install starting driven gear. Starting driven gear Flywheel Installation Align the key on crankshaft with the flywheel groove, and Groove then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Flywheel nut not to be reused should be replaced when disassembled Torque value:16~18kgf-m...

  • Page 128: Set Installation

    10. ALTERNATOR/STARTING CLUTCH A.C.G. Set Installation Wire 3 bolts 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. Make sure that the wire harness is placed under pulse generator.
  • Page 129 10. ALTERNATOR/STARTING CLUTCH Install left crankcase cover (15 screws). Install the dowel pin, new gasket and water pump cover 15 bolts onto left crankcase cover. Water pump bolts Install the water pipe. Install the recoil starter assy.(4 bolts). 10-9 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 130 10. ALTERNATOR/STARTING CLUTCH Note: 10-10 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 131 11. CRANKSHAFT / CRANKCASE L CASE R CASE 11-1 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 132 11. CRANKSHAFT / CRANKCASE Oil SEAL l Remove the oil seal with the special tool. Oil seal remover 440656 l 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 133 11. CRANKSHAFT / CRANKCASE BEARING REASEMBLY l 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 262 (Thread locker) to the screws. 11-3 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 134 11. CRANKSHAFT / CRANKCASE DRIVE BELT COVER l Remove the snap ring with the snap ring pliers. NOTE: If any damage the bearing,replace the new one. Remove the bearing. REASSEMBLY l Install the bearing. l Install the snap ring with snap ring pliers. 11-4 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 135 11. CRANKSHAFT / CRANKCASE L CRANK CASE COVER l Remove the oil pressure valve When installing the oil valve ,tighten it to the specified Torque. Oil pressure value:25N．M(2.5kgf-m,17lb-ft) Using an shaped tool to check the oil pressure valve Operation. If the piston does not operate, replace the new one.
  • Page 136 11. CRANKSHAFT / CRANKCASE l Remove the oil seal. REASSEMBLY Install the bearing. l Apply Grease to the bearing,O-ring and Oil seal lip. l Install the oil seal. NOTE: When installing the oil seals, be sure the stamped mark on the oil seal faces outside. l Apply a small quantity of Loctite 262 (Thread locker) to the screws and install the bearing retainer.
  • Page 137 11. CRANKSHAFT / CRANKCASE Recoil starter ③ ⑤ ④ ① ② ① Nut ② Ratchet set ③ Reel ④ Spiral spring ⑤ Rope DISASSEMBLY After removing the nut, take out the recoil starter related Ratchet parts from the housing. Ratchet guide Friction plate WARNING Spacer...
  • Page 138 11. CRANKSHAFT / CRANKCASE REASSEMBLY l Hook the spiral spring end ① with the recoil starter case. ① 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. ②...
  • Page 139 11. CRANKSHAFT / CRANKCASE CRANKSHAFT l 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 140 11. CRANKSHAFT / CRANKCASE l Apply Loctite 510 (Flange sealant) to the mating surface of the left crankcase. L CASE R CASE 11-10 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 141 11. CRANKSHAFT / CRANKCASE l Assemble the crankcase within few minutes. NOTE: l After crankcase screws have been tightened, check if crankshaft rotate smoothly. l Fit the clamp to the bolt. l Check the each shaft rotates smoothly after the crankcase bolts have been tightend.
  • Page 142 11. CRANKSHAFT / CRANKCASE OIL PUMP DRIVE GEAR l Install the pin. l Install the oil pump drive gear and washer. l 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 143 11. CRANKSHAFT / CRANKCASE l Install the one way clutch outside. l Install the clutch housing. “OUTSIDE” The one way clutch outside facing must on the shaft outside. NEUTRAL SWITCH l Install the springs and switch contacts. l Install the neutral switch. CLUTCH CASE Install the dowel pins and put the new gasket.
  • Page 144 11. CRANKSHAFT / CRANKCASE AIR DEFECTOR&FIXED DRIVE FACE l Install the air defector. l Install the fixed drive face. MOVABLE DRIVE/DRIVEN FACE AND DRIVE BELT l 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 145 11. CRANKSHAFT / CRANKCASE l 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,85 lb-ft) 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 146 11. CRANKSHAFT / CRANKCASE WATER PUMP GEAR l Install the pin. l 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 l Install the water pump gears and tighe the nut NOTE: Make sure the crankshaft can turning smoothly.
  • Page 147 11. CRANKSHAFT / CRANKCASE GENERATOR l 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.
  • Page 148 11. CRANKSHAFT / CRANKCASE GEARSHIFT l Install the cam driven gear. l Reassemble the gearshift shaft. l Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear. STARTER DRIVEN GEAR/IDLE GEAR l Install the starter idle gear and driver gear. LEFT CRANKCASE COVER l Install the dowel pins and put the new gasket.
  • Page 149 11. CRANKSHAFT / CRANKCASE l 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 l Check the water pump shaft position with water pump gear shat.
  • Page 150 11. CRANKSHAFT / CRANKCASE STARTER CUP l Apply engine oil to the O-ring and lip of the oil seal. l Install the starter cup. Tighten the starter cup nut by using a suitable bar. Starter cup nut: 35 N．M( 3.5 kgf- m, 25 lb-ft) Cup, Starter installer 440658 11-20 PDF created with pdfFactory Pro trial version...

  • Page 151: Cooling System

    Boiling point Pressurized: 125.6 Torque Value For water pump impeller 1.0~1.4kgf-m Tools Requirement Special tools Water pump bearing driver (6901): TGB-440640 Water pump oil seal driver (Inner): TGB-440641 Water pump mechanical seal driver: TGB-440642 Inner bearing puller: TGB-440645 Trouble Diagnosis...
  • Page 152 To this chapter contents 12. COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.
  • Page 153 To this chapter contents 12. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12→0V)? temperature gauge over 3 checks? E-2.

  • Page 154: System Test

    ● Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unclear trade mark refrigerant. Coolant recommended: TGB Bramax radiator agent. Concentration: 50% 12-4 PDF created with pdfFactory Pro trial version...
  • Page 155 To this chapter contents 12. COOLING SYSTEM Check reserve tank ● Remove the front center cover, and then remove reserve tank filler cap. ● Check the liquid level in the front fender right side. Add coolant to proper level if too low. ●...
  • Page 156 To this chapter contents 12. COOLING SYSTEM Loosen the radiator 4 bolts. Remove Coolant inlet pipe coolant upper side pipes. 4 bolts Remove coolant outlet pipe. coolant outlet pipe Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. thermo switch Disassembly Loosen the 4 bolts from the fan duct, and then...

  • Page 157: Water Pump

    12. COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection ● Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. ● Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 158 To this chapter contents 12. COOLING SYSTEM 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.
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  • Page 160: Body Cover

    13. BODY COVER Mechanism Diagram 13-1 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 161 13. BODY COVER Maintenance Body covers dissemble sequence Fuel tank cover Right and left foot board Right and left foot board Right and left front internal fender Right and left front shock mount, front bumper Front air inlet plate Right and left head lamp support, body cover Rear body cover Front protector rear protector...
  • Page 162 13. BODY COVER Remove seat Remove 2 bolts from battery fixed Remove cable and battery fixed Remove 1 screw and take off shift lever Remove fuel cap Remove 4 screws，and then remove fuel tank cover Installation Install in reverse order of removal procedures. 13-3 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 163 13. BODY COVER Remove screws from right or left foot board (each side 4 screws) Remove screws from right or left foot board (each side 8 screws) Remove M6 bolts from right or left foot board remove right or left foot board (each side 3 bolts) Remove bolts from right or left front internal fender (each side 5 bolts)，and then remove right or left front internal fender...
  • Page 164 13. BODY COVER Remove screws from front bumper (each side 3 screws) Remove head lamp couplers，and then remove front bumper Remove bolts from right and left head lamp support (each side 2 bolts) Remove bolts from front air inlet plate (each side 2 bolts) ，and then remove front air inlet plate Remove bolts from front body cover (each side 1 bolts)
  • Page 165 13. BODY COVER Remove lock cap Remove power source couplers，and then remove front body cover Remove bolts (each side 1 bolts) Remove 2 couplers Installation Install in reverse order of removal procedures. 13-6 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 166 13. BODY COVER Remove 1 couplers and 1 nut from starting motor relay，and then remove starting motor relay Remove 1 bolts from rear body covert Remove 1 nut from bear reflector assembly (each side 1 bolts) Remove number-plate lamp couplers 、rear lamp assembly couplers (L/R) and turn signal lamp couplers (L/R) Installation...
  • Page 167 13. BODY COVER Remove screws from rear body covert (each side 2 screws) ，and then remove rear body covert Remove 2 bolts from front protector Remove 2 bolts from front protector，and then remove front protector Remove bolts from bear protector (each side 1 bolts) Installation Install in reverse order of removal procedures.
  • Page 168 13. BODY COVER Remove bolts from bear protector (each side 1 bolts)，and then remove bear protector Remove bolts from upper bracket assembly (each side 2 bolts) Remove speedometer assembly couplers，and then remove upper bracket assembly Installation Install in reverse order of removal procedures. 13-9 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 169 13. BODY COVER 13-10 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 170: Troubles Diagnosis

    Home page Contents 14. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid ···························· 14-8 Mechanism Diagram···························14-1 Maintenance Description ···················14-2 Brake fluid replacement / Air-bleed ·· 14-9 Trouble Diagnosis ······························14-3 Front Brake Caliper···························· 14-10 Brake Disk ·········································· 14-11 Front Wheel·········································14-4 Front Brake Master Cylinder ············· 14-11 Front Wheel Hub·································14-4 Disk Brake System Inspection ··········14-7 Mechanism Diagram...

  • Page 171: Maintenance Description

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. ●...

  • Page 172: Trouble Diagnosis

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

  • Page 173: Front Wheel

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. 4 screws Remove the front wheel nuts, and then remove front wheels.
  • Page 174 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove 4 socket bolts, and then remove the 4 bolts brake disk from wheel hub. Installation 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 175: Disk Brake System Inspection

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

  • Page 176: Adding Brake Fluid

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

  • Page 177: Brake Fluid Replacement / Air-Bleed

    o this chapter contents 14. FRONT BRAKE & FRONT WHEEL 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.

  • Page 178: Front Brake Caliper

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Front 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. Remove two caliper bolts and the caliper.

  • Page 179: Brake Disk

    To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 180 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Cir clip Remove the piston and the spring. Rubber boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
  • Page 181 To this chapter contents 14. FRONT BRAKE & FRONT WHEEL Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake Brake light switch Brake lever bolt light switch.
  • Page 182 Home page Contents 15. STEERING / FRONT SUSPENSION Mechanism Diagram ··························15-1 Steering Tie-Rod ································ 15-6 Operational Precautions ····················15-2 Knuckle ··············································· 15-7 Trouble Diagnosis ······························15-2 Front Cushion ···································· 15-8 Steering Handle ··································15-3 Suspension Arm ································ 15-9 Steering Shaft ·····································15-5 Toe-In ·················································· 15-10 Mechanism Diagram 300~350 kgf-cm 300~350 kgf-cm...
  • Page 183 To this chapter contents 15. STEERING / FRONT SUSPENSION Operational Precautions Torque Values Handlebar upper holder bolt 300~350 kgf-cm Steering shaft holder bolt 300~350 kgf-cm Steering shaft nut 250~350 kgf-cm Steering tie-rod nut 250~350 kgf-cm Knuckle nut kgf-cm Tie rod lock nut 450~550 kgf-cm Suspension arm nut 450~550 kgf-cm...
  • Page 184 To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Handle Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter Handle protect cover Loosen the socket bolts for the front brake master brocket bolts cylinder, and remove front brake master cylinder.
  • Page 185 To this chapter contents 15. STEERING / FRONT SUSPENSION Loosen 2 screws, and then remove handle left switch and choke hosing. 2 screws 4 socket bolts Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. Remove 2 nuts to remove handle under holder and meter bracket.

  • Page 186: Steering Shaft

    To this chapter contents 15. STEERING / FRONT SUSPENSION 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 steering shaft, and below remove steering shaft nut and washer. Cotter pin Bend out the steering shaft holder nut fixed plate.
  • Page 187 To this chapter contents 15. STEERING / FRONT SUSPENSION Steering Tie-Rod Remove Remove cotter pin and tie-rod nut from steering shaft side. Remove cotter pin and tie-rod nut from wheel side. Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage , wear or deterioration.
  • Page 188 To this chapter contents 15. STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Tie-rod Remove cotter pin and tie-rod nut, remove tie rod. Cotter pin Universal holder Remove cotter pin and ball joint nut. Remove upper and under ball joints by ball joint driver.
  • Page 189 To this chapter contents 15. STEERING / FRONT SUSPENSION Front Cushion Remove Remove front cushion under bolt nut, and remove the bolt. Remove front cushion upper bolt nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque value: Front cushion nut 4.6kgf-m...
  • Page 190 To this chapter contents 15. STEERING / FRONT SUSPENSION Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Suspension arm nuts and bolts Loosen upper arm nuts, remove swing suspension arm bolts. Remove upper s arm.
  • Page 191 To this chapter contents 15. STEERING / FRONT SUSPENSION Toe-In When repair or disassemble steering system parts, must to adjustment the toe-in. Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height.
  • Page 192 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake fluid replacement / Air-bleed ·· 16-9 Mechanism Diagram···························16-1 Maintenance Description ···················16-2 Rear Brake Caliper ····························· 16-10 Trouble Diagnosis ······························16-3 Brake Disk ·········································· 16-11 Rear Wheel ··········································16-4 Rear Brake Master Cylinder ·············· 16-11 Disk Brake System Inspection ··········16-5 Rear Cushion······································...

  • Page 193: Maintenance Description

    Brake lever nut 1.00kgf-m Rear cushion mounting bolt Air-bleed valve 0.50kgf-m 4.6kgf-m 9.2kgf-m Swing arm pivot bolt 2.40kgf-m Rear wheel nut Special tools Inner bearing puller: TGB-440645 Rear axle bearing driver (6007LLU): TGB-440640 16-2 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 194: Trouble Diagnosis

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

  • Page 195: Rear Wheel

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

  • Page 196: Disk Brake System Inspection

    16. REAR BRAKE & REAR WHEEL & REAR CUSHION 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 197: Rear Wheel Axle

    16. REAR BRAKE & REAR HEEL & REAR CUSHION Rear Wheel Axle Remove rear wheel housing 4 bolts. Escape rear wheel housing from rear fork assy. Remove tow ball mount 4 bolts (2 bolts each side) 16-6 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 198 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Remove rear axle housing 4 bolts. Remove rear axle housing Inspection Check bearings on rear wheel axle bearing seat. Rotate each 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 bearing seat.

  • Page 199: Adding Brake Fluid

    16. REAR BRAKE & REAR WHEEL & REAR CUSHION Fluid cup 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 200: Brake Fluid Replacement / Air-Bleed

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Air-bleed valve 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.

  • Page 201: Rear Brake Caliper

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

  • Page 202: Brake Disk

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 203 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 13.954 mm Foot brake 15.850 mm Master Cylinder Assembly Caution ●...
  • Page 204 To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION 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 clip. Caution To adjustment brake pedal, you must be removed push rod pin fist.

  • Page 205: Rear Cushion

    To this chapter contents 16. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Cushion Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Rear cushion under bolt Remove rear cushion upper bolt, and then remove rear cushion.
  • Page 206 PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 207: Mechanism Diagram

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

  • Page 208: Maintenance Data

    To this chapter contents 17. ELECTRICAL SYSTEM Maintenance Data Operational precaution ● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) ● The model of the spark plug and the tightening torque. ●...
  • Page 209 To this chapter contents 17. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate ● Battery discharged properly ● The cable disconnected ● Burnt fuse ● The fuse is blown ● Poor contact, open or short circuit ● Improper operation of the main switch ●...

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