TGB EST 1000 Service Manual
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TGB EST 1000 Service Manual

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EST 1000
SERVICE MANUAL
TAIWAN GOLDEN BEE CO.,LTD.

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  • Page 1 EST 1000 SERVICE MANUAL TAIWAN GOLDEN BEE CO.,LTD.
  • Page 2 This service manual contains the technical data of each component inspection and repairs for the Blade 1000. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the Blade 1000 are different from that of the photos, pictures shown in this manual, the actual...
  • Page 3 1. GENERAL INFORMATION PAGE CONTENT GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM FUEL INJECTION SYSTEM ENGINE ASSEMBLY ENGINE TOP END ENGINE BOTTOM END TRANSMISSION BEAR BOX CONTINUOUSLY VARIABLE TRANSMISSION DRIVE SYSTEM STEERING SYSTEM & SUSPENSION ELECTRIC POWER STEERING BRAKE SYSTEM &...
  • Page 4 1. GENERAL INFORMATION SERIAL NUMBER Frame Number and Engine Number TST*000001*...
  • Page 5 2. MAINTENANCE INFORMATION Precautions in Operation ······················ 2-1 Brake System (Disk Brake) ················· 2-8 Periodical Maintenance Schedule ·········2-2 Brake Light Switch/Starting Inhibitor Fuel Lines ············································· 2-3 Switch ·················································· 2-9 Acceleration Operation ························· 2-3 Headlight Beam Distance ···················· 2-10 Clutch Disc Wear ································· 2-10 Air Cleaner············································...
  • Page 6 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 7 2. MAINTENANCE INFORMATION Fuel Lines Check all lines, and replace it when they are deterioration, damage or leaking. For removal, refer to chapter 4 Fuel Pump. Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it. Acceleration Operation Have a wide open of throttle valve as handle in any position and release it to let back original...

  • Page 8: Valve Clearance

    2. MAINTENANCE INFORMATION Valve Clearance Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove front fender, top cover and air cleaner. Remove cylinder head cover. Turn camshaft bolt in C.W. direction and let the Printing mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.
  • Page 9 2. MAINTENANCE INFORMATION Ignition System For ignition system, refer to chapter 5 electric system. Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove the top cover. Remove the side cover. Remove any one of the spark plug cap and spark plug.
  • Page 10 2. MAINTENANCE INFORMATION Drive Belt Remove side cover. Remove footrest. Remove bolts of the clutch cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace Width limit: 31.0 mm or above PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 11: Brake System

    2. MAINTENANCE INFORMATION Brake System 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. Also check brake system for leaking if low brake level found.
  • Page 12 2. MAINTENANCE INFORMATION Brake Lining Wear The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc. Caution ● To check front brake lining must be remove front wheel first.
  • Page 13 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 14 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. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then check the handle top bearing.
  • Page 15 2. MAINTENANCE INFORMATION 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 φ15 PARTS NAME : BEARING(924384) REMOVER φ20 PARTS NO.
  • Page 16 2. MAINTENANCE INFORMATION PARTS NO. : 440667 PARTS NO. : 440671 PARTS NAME : CYLINDER HEAD VALVE AND PARTS NAME : WET CLUTCH SCREW NUT SPRING INSTALLER/REMOVER FIXER PARTS NO. : 560001 PARTS NO. : 560002 PARTS NAME : FLYWHEELREMOVER PARTS NAME : FLYWHEEL INSTALLER PARTS NO.
  • Page 17 2. MAINTENANCE INFORMATION PARTS NO. : 560007 PARTS NO. : 560008 PARTS NAME : DRIVEN PULLEY EXTEND TOOL PARTS NAME : BEARING REMOVER (W/ FOR REMOVE BELT 440649 Ø20 mm) PARTS NO. : 560009 PARTS NO. : 560010 PARTS NAME : DEAR DIFF. NEEDLE BEARING PARTS NAME : REAR DIFF.
  • Page 18 2. MAINTENANCE INFORMATION PARTS NO. : 560013 PARTS NO. : 560014 PARTS NAME : PLAIN BEARING INSTALLER PARTS NAME : PLAIN BEARING REMOVER (RIGHT CRANKCASE) (RIGHT CRANKCASE PARTS NO. : 560015 PARTS NO. : 560016 PARTS NAME : CRANKCASE COVER LH PARTS NAME : CRANKCASE COVER LH PLAIN BEARING INSTALLER PLAIN BEARING REMOVER...
  • Page 19 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 Overhaul: 2300 c.c. Filter change: 1800 c.c. Change: 2000 c.c. Oil viscosity SAE 10W-40 Items Standard (mm) Limit (mm) Inner rotor clearance...

  • Page 20: Oil Filter Change

    3.LUBRICATION SYSTEM Oil Level Verification NOTE: Strictly follow this procedure, otherwise wrong oil level may be indicated. ▪ Ensure vehicle is on a level surface. ▪ Start engine and let idle for a few minutes. ▪ Stop engine, wait a few minutes to allow oil to flow down to crankcase then check oil level.
  • Page 21 3.LUBRICATION SYSTEM CAUTION Never use the gasket ring a second time. Always replace by a new one. ▪ Replace oil filter. ▪ Refill engine with recommended engine oil. ▪ Oil change capacity with filter: 2.0 L. ▪ After filling, check the oil level with dipstick. ▪...
  • Page 22 3.LUBRICATION SYSTEM ▪ If the engine oil pressure is out of specifications, check the points described in troubleshooting section. ▪ Removal oil pressure gauge and adapter hose. NOTE: To remove adapter hose from oil pressure gauge, use the disconnect tool. ▪...
  • Page 23 3.LUBRICATION SYSTEM OIL PRESSURE SWITCH Oil Pressure Switch Activation ▪ Oil pressure switch works when engine oil pressure is between 20 and 40 kPa. ▪ To check the function of the oil pressure switch, an oil pressure test has to be performed.
  • Page 24 3.LUBRICATION SYSTEM Removal ▪ Remove the bolts and the ACG cover. ▪ Pull out the oil pressure valve and washer. Inspection ▪ Inspect pressure valve housing, O-ring and valve for scoring or other damages. ▪ Clean bore and thread in the magneto housing from metal shavings and other contamination.
  • Page 25 3.LUBRICATION SYSTEM OIL PUMP The oil pump is located on the engine CVT side (behind cover). Removal ▪ Drain engine oil. ▪ Remove parts to access the CVT cover. ▪ Remove the CVT cover. ▪ Remove CVT assembly. ▪ Remove crankcase cover LH. ▪...
  • Page 26 3.LUBRICATION SYSTEM ▪ Using a feeler gauge, measure the clearance of inner and outer rotors as shown. ▪ If clearance of inner and outer rotors exceeds the tolerance, replace oil pump shaft assembly. Ensure to also check oil pump cover. If damaged, replace the complete oil pump assembly.
  • Page 27 3.LUBRICATION SYSTEM ENGINE OIL STRAINER ▪ The engine oil strainer is located between both crankcase halves. ▪ Usually the strainer no needs to clean. ▪ During engine over hall, it will clean after separate the crankcase half. ▪ Remove the retaining bolts and pull the oil strainer out.
  • Page 28 4-1. FUEL SYSTEM FUEL TANK AND FUEL PUMP 4-1-1...

  • Page 29: Fuel System

    4-1. FUEL SYSTEM FUEL TANK AND FUEL PUMP GENERAL WARNING Fuel is flammable and explosive under certain conditions. Ensure work area is well ventilated. Do not smoke or allow open flames or sparks in the vicinity. WARNING Always disconnect battery prior to working on the fuel system. WARNING Torque wrench tightening specifications must strictly be adhered to.

  • Page 30: Fuel Pump Assembly

    4-1. FUEL SYSTEM SYSTEM DESCRIPTION Fuel Tank Vent System ▪ The fuel tank is equipped with a vent system that ensures the fuel tank remains at ambient pressure. ▪ Air can enter the fuel tank at all times through the fuel tank vent valve. This prevents negative pressure within the fuel tank, which could cause fuel starvation.
  • Page 31 4-1. FUEL SYSTEM INSPECTION FUEL PUMP PRESSURE TEST The pressure test will show the available pressure at the fuel pump outlet. It validates the pressure regulator, the fuel pump and tests for leaks in the system. NOTE: Diagnose a fuel system problem. 1.

  • Page 32: Fuel Hose Replacement

    4-1. FUEL SYSTEM FUEL HOSE AND CLAMP Fuel Hose Replacement When replacing fuel hoses, be sure to use hoses and clamps from TGB parts department. This will ensure continued proper and safe operation. WARNING Use of fuel lines other than those recommended by TGB may compromise fuel system integrity.

  • Page 33: Fuel Tank Installation

    4-1. FUEL SYSTEM Fuel Tank Inspection ▪ Inspect fuel tank for nay damages or cracks which may result in fuel leaks. ▪ Inspect tank and protector attachment points for damages. ▪ Inspect protector for damages. ▪ If cracks, gouges or other damages, which may lead to a fuel, leak, or damages to attachment points that could prevent the tank from being secure are found, replace fuel tank.
  • Page 34 4-1. FUEL SYSTEM ▪ If battery voltage is now read, check fuel pump ground circuit between fuel pump connector and ECU connector. ▪ If battery voltage is still not read, check fuel pump: - Fuse. - Power circuit. - Wiring and connectors. Fuel Pump Resistance Test 1.
  • Page 35 4-1. FUEL SYSTEM Fuel Pump Installation Forward For installation, reverse the removal procedure. CAUTION Manipulate fuel pump with care. 1. Install a NEW gasket ring. 2. Place gasket ring so that it is located between pump and tank mounting surface. 3.
  • Page 36 4-1. FUEL SYSTEM FUEL GAUGE METER The fuel gauge meter is a float actuated variable resistance type that is part of the fuel pump. Fuel Gauge Meter Resistance Test 1. Disconnect the fuel pump connector. ① 2. Use multimeter measure the resistance of the gauge meter..
  • Page 37 4-1. FUEL SYSTEM FUEL TANK VENT VALVE Fuel tank Vent Valve Test Test for Normal Operation 1. Disconnect vent hose from fuel tank vent valve. 2. Connect the VACCUM /PRESSURE PUMP and a short piece of hose to the fuel tank vent valve.
  • Page 38 4-1. FUEL SYSTEM TROUBLESHOOTING FUEL SYSTEM DIAGNOSTIC FLOW CHART Fuel pump does not run Activate electric system to Fuel pump runs for 2 enable fuel pump sec. then stop Check fuse. Install fuel pressure gauge Check fuel pump reley. on fuel pressure line Rapair or replace if necessary Activate electric system to...

  • Page 39: Table Of Contents

    4-2. FUEL INJECTION SYSTEM Fuel Injection System Components………..1 EFI system components inspection…..…..12 Precautions in servicing……………………..2 Sensor circuit mal. troubleshooting………24 General………………………………………..2 Fault diagnosis………………………..….…45 Integrated fault diagnosis program. …...…48 Connector/coupler……………….…….…….3 Fuse……………………………….…….…….3 Fault diagnosis note……………….…….…49 ECU/various sensors…………………..……3 Use diagnosis tool..………………….…..…52 Electrical circuit inspection procedure. ……4 Troubleshooting table…………………..…60 Parts location………………………………...8 Comprehensive maintenance list…….……61...

  • Page 40: Precautions In Servicing

    4-2. FUEL INJECTION SYSTEM PRECAUTIONS IN SERVICING When handling the Fuel Injection component parts or servicing the Fuel Injection system, observe the following points for the safety of the system. GENERAL Be sure to relieve the fuel pressure while the engine is OFF. Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control.

  • Page 41: Connector/Coupler

    4-2. FUEL INJECTION SYSTEM CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt. • With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.

  • Page 42: Electrical Circuit Inspection Procedure

    4-2. FUEL INJECTION SYSTEM • Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to the ECU or sensors may result. • Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result. ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.
  • Page 43 4-2. FUEL INJECTION SYSTEM CONTINUITY CHECK • Measure resistance across coupler B (between A and C in the figure). • If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 44 4-2. FUEL INJECTION SYSTEM SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 45 4-2. FUEL INJECTION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number Starter valve vacuum difference Idle speed 1250+/- 100 rpm Throttle grip free play 2~4 mm Ω Fuel injector resistance Manifold absolute pressure at idle 420 +/- 30 mm Hg Fuel pressure at idle 300 kPa TORQUE VALUES...

  • Page 46: Parts Location

    4-2. FUEL INJECTION SYSTEM PARTS LOCATION Shift level Oil pressure switch Fuse box Coolant sensor DC. Power outlet Headlight relay EPS controller Regulator Ignition coil AC.Generator Speed sensor Winch switch O2 sensor Hazard control Main switch Winker relay Horn Rear Brake switch Front Brake switch 4-2-8...

  • Page 47: Wiring Diagram

    4-2. FUEL INJECTION SYSTEM WIRING DIAGRAM With EPS 4-2-9...
  • Page 48 4-2. FUEL INJECTION SYSTEM Without EPS 4-2-10...

  • Page 49: Ecu Terminal

    4-2. FUEL INJECTION SYSTEM ECU TERMINAL HARNESS ECU PLUG Wire Wire Circuit Note Circuit Note Code Color Code Color VSENS Sensor voltage Br/W Blank Gr/R SGND2 Signal ground Blank W/Br Throttle position sensor Br/L Key SW voltage Blank CAN_H Diagnosis Tool Blank Gear B Engine Check...

  • Page 50: Efi System Components Inspection

    4-2. FUEL INJECTION SYSTEM EFI SYSTEM COMPONENTS INSPECTION T-MAP SENSOR • Turn the ignition OFF. • Disconnect the T-MAP sensor 4P connector. • Check for loose or poor contact on the MAP sensor connector. • Connect the T-MAP sensor connector. •...
  • Page 51 4-2. FUEL INJECTION SYSTEM ECT SENSOR INSPECTION • Turn the ignition switch OFF. • Disconnect ECT sensor 2P connector. • Check for loose or poor contact on the ECT sensor connector. • Connect the ECT sensor connector. • Turn the ignition switch ON. •...
  • Page 52 4-2. FUEL INJECTION SYSTEM REMOVAL / INSTALLATION • Disconnect the ECT sensor 2P connector from the sensor • Remove the ECT sensor. • Install the new ECT sensor. TORQUE: 120 kgf/cm • Connect the ECT sensor 2P connector. Standard: RESISTANCE TEMPERATURE(℃) TOL.
  • Page 53 4-2. FUEL INJECTION SYSTEM TP SENSOR INSPECTION • Turn the ignition switch OFF. • Disconnect the TP sensor 3P connector. • Check for loose or poor contact on the TP sensor connector. • Connect the TP sensor connector. • Start the engine and check the MIL light. •...
  • Page 54 4-2. FUEL INJECTION SYSTEM VEHICLE SPEED SENSOR • Turn the ignition switch OFF. • Disconnect the vehicle speed sensor 3P connector. • Check for loose or poor contact on the vehicle speed sensor connector. • Connect the vehicle speed sensor 3P connector. •...
  • Page 55 4-2. FUEL INJECTION SYSTEM INJECTOR • Turn the ignition switch OFF. • Disconnect the injector 2P connector. • Check for loose or poor contact on the injector 2P connector. • Connect the injector 2P connector. • Turn the ignition switch ON. •...
  • Page 56 4-2. FUEL INJECTION SYSTEM INSPECTION • Start the engine and let it idle. • Confirm the injector operating sounds with a sounding rod or stethoscope. • If the injector does not operate, replace the injector. REMOVAL • Disconnect the injector 2P connector. •...
  • Page 57 4-2. FUEL INJECTION SYSTEM CRANK POSITION SENSOR • Turn the ignition switch OFF. • Disconnect the crank position sensor 2P connector. • Check for loose or poor contact on the crank position sensor 2P connector. • Connect the crank position sensor 2P connector. •...
  • Page 58 4-2. FUEL INJECTION SYSTEM IGNITION COIL • Turn the ignition switch OFF. • Disconnect the ignition coil 2P connector. • Check for loose or poor contact on the ignition coil 2P connector. • Connect the ignition coil 2P connector. • Turn the starter motor more than 10 seconds and then check that the MIL light.
  • Page 59 4-2. FUEL INJECTION SYSTEM THROTTLE BODY REMOVAL NOTE: • Before disconnecting the fuel hose, release the fuel pressure by loosening the clamp. • Always replace the clamp when the fuel hose is removed or loosened. DISASSEMBLY • Disconnect the TP sensor, T-MAP sensor and ISC sensor connector from the throttle •...
  • Page 60 4-2. FUEL INJECTION SYSTEM ROLL OVER SENSOR INSPECTION • Remove the seat set. • Turn the ignition switch ON and measure the voltage between the following terminals of the Roll Over sensor connector with the connector connected. TERMINAL STANDARD 4~5V 1~1.5V B-C (65 3.9V~4.3V...
  • Page 61 4-2. FUEL INJECTION SYSTEM O2 Sensor Functional Description: ● Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply pins for heater; for a heater control pin; signal for a grounding pin; O2 for a signal pin. ●...
  • Page 62 4-2. FUEL INJECTION SYSTEM REMOVAL / INSTALLATION • Remove the seat set. • Disconnect the ECU 48P connectors. POWER INPUT LINE • Turn the ignition switch ON. • Measure the voltage between the ECU and ground. • There should be battery voltage. •...
  • Page 63 4-2. FUEL INJECTION SYSTEM SENSOR CIRCUIT TROUBLESHOOTING CPS SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Metal particles or foreign material being The signal does not reach ECU for 3 sec. or more, after receiving the starter signal. stuck on the CPS sensor and rotor tip •...
  • Page 64 4-2. FUEL INJECTION SYSTEM Are the resistance and continuity OK? YES Go to next step 2 NO Replace CPS sensor with new one 7) After repairing the trouble, clear the DTC using Diagnosis Tool. Step 2 1) Crank the engine a few seconds with the starter motor, and measure the CPS sensor peak voltage at the coupler.
  • Page 65 4-2. FUEL INJECTION SYSTEM TMAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Clogged vacuum passage between throttle T-MAP sensor voltage low or high (0.1 V Sensor voltage < 4.8 V) body and T-MAP sensor • Air being drawn from vacuum passage NOTE: Note that atmospheric pressure varies between throttle body and T-MAP sensor...
  • Page 66 4-2. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to next step 2 • Loose or poor contacts on the ECU coupler terminal 1 or 27 • Open or short circuit in the Yellow/Black wire or Gray/Red wire 8) After repairing the trouble, clear the DTC using Diagnosis tool.
  • Page 67 4-2. FUEL INJECTION SYSTEM TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • TP sensor maladjusted Output voltage is not within the following • TP sensor circuit open or short range. • TP sensor malfunction Difference between actual throttle opening •...
  • Page 68 4-2. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to next step 2 • Loose or poor contacts on the ECU coupler (terminal 1 or 27) • Open or short circuit in the Yellow/Black wire or Gray/Red wire Step 1 (When sensor voltage is higher than specified) 1) Loosen and lift up the fuel tank.
  • Page 69 4-2. FUEL INJECTION SYSTEM 4) Disconnect the TP sensor coupler. 5) Check the continuity between W/Br wire and ground. 6) Also, check the continuity between W/Br wire and Gr/R wire C. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 70 4-2. FUEL INJECTION SYSTEM Are the continuity and resistance OK? YES Go to step 3 • Reset the TP sensor position correctly. • Replace the new TP sensor (throttle body). 7) After repairing the trouble, clear the DTC using Diagnosis tool. Step 3 1) Connect the TP sensor coupler.
  • Page 71 4-2. FUEL INJECTION SYSTEM ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • ECT sensor circuit open or short Output voltage is not within the following • ECT sensor malfunction range. • ECU malfunction 0.1 Sensor voltage < 4.6 V Sensor voltage is higher than specified •...
  • Page 72 4-2. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to step 2 • Loose or poor contacts on the ECU coupler (terminal 42 or 27) • Open or short circuit in the Y/R wire or Gr/R wire Step 1 (When sensor voltage is higher than specified) 1) Turn the ignition switch OFF.
  • Page 73 4-2. FUEL INJECTION SYSTEM 6) Connect the ECT sensor coupler. 7) Turn the ignition switch ON. 8) Measure the voltage between Y/R wire and ground. Output voltage: 0.1 – 4.6 V (+ Y/R – - Ground) Are the continuity and voltage OK? Go to step 2 Y/R wire shorted to ground.
  • Page 74 4-2. FUEL INJECTION SYSTEM IGNITION SYSTEM MALFUNCTION TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and check that the fuse is not blown and the battery is fully charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
  • Page 75 4-2. FUEL INJECTION SYSTEM Step 3 1) Measure the ignition coil primary peak voltage. NOTE: This inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage OK? Go to step 4 Go to step 5 Step 4 1) Check the plug caps for poor contacts.
  • Page 76 4-2. FUEL INJECTION SYSTEM FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Injector circuit open or short CPS signals produced but fuel injector • Injector malfunction signal is interrupted continuous by 4 times • ECU malfunction or more. Step 1 1) Turn the ignition switch OFF.
  • Page 77 4-2. FUEL INJECTION SYSTEM NOTE: Injector voltage can be detected only 3 seconds after ignition switch is turned ON. Is the voltage OK? • L/G wire open or shorted to ground, or poor 47 connection (cylinder side) • If wire and connection are OK, intermittent trouble or faulty ECU.
  • Page 78 4-2. FUEL INJECTION SYSTEM Fuel Pump RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Fuel pump relay circuit open or short No voltage is applied to fuel pump although • Fuel pump relay malfunction fuel pump relay is turned ON, or voltage is •...
  • Page 79 4-2. FUEL INJECTION SYSTEM ROLL OVEWR SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • TO sensor circuit open or short The sensor voltage should be the following • TO sensor malfunction for 2 sec. and more, after ignition switch is •...
  • Page 80 4-2. FUEL INJECTION SYSTEM Step 1 (When sensor voltage is higher than specified) 1) Remove the seat set. 2) Turn the ignition switch OFF. 3) Check the Roll over sensor coupler for loose or poor contacts. If OK, then check the Roll over sensor lead wire continuity.
  • Page 81 4-2. FUEL INJECTION SYSTEM Is the continuity OK? Go to step 2 Y/B or Pu/B wire open or Pu/B wire shorted to ground 10) After repairing the trouble, clear the DTC using Diagnosis tool. Step 2 1) Connect the Roll over sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler.
  • Page 82 4-2. FUEL INJECTION SYSTEM IDLE SPEED CONTROLLER CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • ISC malfunction The operation voltage does not reach the • ISC circuit open or short ISC. • ISC motor malfunction ECU does not receive communication signal from the ISC.
  • Page 83 4-2. FUEL INJECTION SYSTEM ISC continuity: ∞ Ω (Infinity) (Terminal – Ground) • Measure the resistance between A-D and B-C as below • The standard are all follow 50±5Ω. Is the resistance OK? •Br/B, G/B, Y/B and B/Y wire open or shorted to ground, or poor 28, 39, 40 and 41 connection •...

  • Page 84: Fault Diagnosis

    4-2. FUEL INJECTION SYSTEM Fault Diagnosis EFI Circuit inspection 4-2-46...
  • Page 85 4-2. FUEL INJECTION SYSTEM Can not Start the engine or difficult to start inspection 4-2-47...
  • Page 86 4-2. FUEL INJECTION SYSTEM Idle flameout diagnosis 4-2-48...

  • Page 87: Integrated Fault Diagnosis Program

    4-2. FUEL INJECTION SYSTEM Integrated Fault Diagnosis Program 4-2-49...

  • Page 88: Fault Diagnosis Note

    4-2. FUEL INJECTION SYSTEM Fault Diagnosis Note When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or can not start engine, MIL light at the dashboard will be lighting, to inform drivers to carry out maintenance. Overhaul, the diagnosis tool can be used for troubleshooting.
  • Page 89 4-2. FUEL INJECTION SYSTEM Fault Code And The Sensors Of The Table No. Fault codes Fault Description XXXXX Un define B2225 Tilt switch diagnosis ( short circuit to battery B2226 Tilt switch diagnosis ( _Open circuit) short circuit to ground P0000 No DTC Sensor heater diagnosis #0 (...

  • Page 90: Use Diagnosis Tool

    4-2. FUEL INJECTION SYSTEM P0485 Cooling fan diagnosis ( _Open circuit) short circuit to ground P0562 Battery voltage diagnosis (Voltage too low) P0563 Battery voltage diagnosis (Voltage too high) P0608 Reference voltage diagnosis ( short circuit to battery P0609 Reference voltage diagnosis ( _Open circuit) short circuit to ground P0615...
  • Page 91 Method of Use: 1. Connected to the diagnostic connector for diagnosis tool. NACS→TGB interface→Transfer Cable→TGB 3 pin/6 pin Diagnosis Cable→Vehicle. 2. When the IG of the motorcycle is on, the system starts to run, entering into boot screen. 3. Key ON and the diagnosis display screen appeared the words connection.
  • Page 92 4-2. FUEL INJECTION SYSTEM 2. Diagnostic Trouble Code 3. Live Data 4. Actuator 5. Special Function Press ▲▼ button to choose one function. 1. Vehicle Info Move the cursor to ”Vehicle Info” and press ENTER to see the content This is the page of “Vehicle Info”, press ▲▼ button to view all vehicle info. 2.
  • Page 93 4-2. FUEL INJECTION SYSTEM Move the cursor to ”Current” and press “ENTER” to continue After entering the page, press ▲▼ to view all the Diagnostic Trouble Code. After viewing the Diagnostic Trouble Code, press ESC to return to the previous page. Move the cursor to “History”...
  • Page 94 4-2. FUEL INJECTION SYSTEM ★ NOTE: not all ECU support this function. Numerical analysis of images (1 / 3), the waveform can be displayed as shown in the following items: Freeze Data (01/03) Number of data Engine speed Throttle valve volt Intake pressure MAP Freeze Data (02/03) Engine temp...
  • Page 95 4-2. FUEL INJECTION SYSTEM Move the cursor to “Erase DTC” item and press ENTER to EARSE ALL DIAGNOSTIC TROUBLE CODE DIRECTLY! When you see the following picture on the screen, the Diagnostic Trouble Code erasure is completed. Press ESC button back to the main menu. 3.
  • Page 96 4-2. FUEL INJECTION SYSTEM 4. Actuator Move the cursor to “Activator” and press ENTER to see the content (To perform this function, IG must be ON and engine stop running.) This is the page after entering the “Activator” function Take one activation function for example: move the cursor to “Ignition coil” item and press ENTER to continue.
  • Page 97 4-2. FUEL INJECTION SYSTEM 5. Special Function Move the cursor to “Special Function” and press ENTER to view the content There are two items under “Special Function”: “Reset TPS” and “Reset Adaptive”. Move the cursor to “Reset TPS” and press ENTER. Then you will see the following picture, which means the RESET is completed.

  • Page 98: Troubleshooting Table

    4-2. FUEL INJECTION SYSTEM Troubleshooting Table 4-2-60...

  • Page 99: Comprehensive Maintenance List

    4-2. FUEL INJECTION SYSTEM Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation. 2. Spare parts, according to the "EFI System components description" implementation. Comprehensive Maintenance List Maintenanc Testing Procedures Test items Determine benchmarks Fault reasons e Project •...
  • Page 100 4-2. FUEL INJECTION SYSTEM • Main switch ON but • Injector state • ECU fault not start engine when start • Investigation the injector it’s leaking fuel? • Start engines again or use for the diagnosis tool of output function •...
  • Page 101 5-1. ENGINE ASSEMBLY Engine Removal and Installation·············· 5-1 Cooling System········································5-9 ·····································5-3 ·····························5-21 Air Intake System AC Generator System ········································5-5 Exhaust System ENGINE REMOVAL AND INSTALLATION WARNING To avoid potential burns, let engine and exhaust system cool down before servicing. During assembly/installation, use the torque Values and service products as in the exploded view. Clean thread before applying a thread locker.

  • Page 102: Engine Installation

    5-1. ENGINE ASSEMBLY Lifting and Remove the Engine 1. Remove four bolts on the rear output drive shafts connecting plate. 2. Remove the front and rear engine support bolts. Remove front output drive shaft bolts. 3. Carefully backward the engine and gearbox then raise the front of engine to separate front output drive shaft from engine.
  • Page 103 5-1. ENGINE ASSEMBLY AIR INTAKE SYSTEM...
  • Page 104 5-1. ENGINE ASSEMBLY GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean thread before applying a thread locker. WARNING Never modify the air intake system. Otherwise, engine performance degradation or damage can occur. The engine is calibrated to operate specifically with these components. AIR CLEANER ELEMENT Air Filter Element Replacement 1.
  • Page 105 5-1. ENGINE ASSEMBLY EXHAUST SYSTEM...

  • Page 106: Muffler Removal

    5-1. ENGINE ASSEMBLY GENERAL WARNING To avoid potential burns, never touch exhaust system components immediately after the engine has been run because these components are very hot. Let engine and exhaust system cool down before performing any servicing. During assembly/installation, use the torque values and service products as in the exploded view. Clean thread before applying a thread locker.
  • Page 107 5-1. ENGINE ASSEMBLY EXHAUST PIPE Exhaust Pipe Removal 1. Remove seat and seat steady. 2. Remove LH side cover, inner fender and the heat isolation. 3. Remove O2 sensor and exhaust pipe from vehicle. 4. Remove the Muffler. CAUTION: Do not damage the O2 sensor connecting wire. “Y”...
  • Page 108 5-1. ENGINE ASSEMBLY COOLING SYSTEM RADIATOR WATER PUMP...

  • Page 109: Thermostat Removal

    5-1. ENGINE ASSEMBLY COOLING SYSTEM GENERAL WARNING Never start engine without coolant. Some engine parts such as the rotary seal on the water pump shaft can be damaged. During assembly/installation, use the torque values and service products as in the exploded view. Clean thread before applying a thread locker.

  • Page 110: Thermostat Installation

    5-1. ENGINE ASSEMBLY 8. Pull hoses from thermostat housing to remove thermostat. Thermostat Test ▪ To check thermostat, put it in water and heat the water. THERMOSTAT OPENING TEMPERATURE STARTS TO OPEN FULLY OPEN 65 ℃ 88 ℃ ▪ Replace thermostat if it does not begin to open at specified temperature.

  • Page 111: Radiator Removal

    5-1. ENGINE ASSEMBLY Radiator Removal 1. Install a large hose pincher on both radiator hoses. 2. Lift front of vehicle to extend suspension. 3. Remove the following parts from the radiator: - Radiator inlet hose (LH upper) - Radiator outlet hose (RH lower). - Radiator mounting screws (2 at top of radiator).
  • Page 112 5-1. ENGINE ASSEMBLY Relay Operation test (Radiator Cooling Fan) The easiest way to check the relay is to remove it and bypass it using a jumper. If the radiator-cooling fan is activated, replace the relay. See illustration to find where to bypass the relay.
  • Page 113 5-1. ENGINE ASSEMBLY Radiator Cooling Fan Fuse Location The fuse is located in the fuse box under the seat set. Radiator Cooling Fan Test Connect the 12VDC to cooling fan connector, if fan turns on; check CTS, wiring harness and connectors.
  • Page 114 5-1. ENGINE ASSEMBLY Radiator Cooling Fan Removal 1. Disconnect fan motor electrical connector. 2. Remove 4 fan retaining screws. 3. Remove the radiator fan. Radiator Cooling Fan Installation For the installation, reverse the removal procedure. WATER PUMP HOUSING It is located on the engine ACG side. Water Pump Housing Removal WARNING To avoid potential burns, do not remove...
  • Page 115 5-1. ENGINE ASSEMBLY WATER PUMP IMPELLER Water Pump Impeller removal 1. Remove water housing. 2. Unscrew impeller. NOTICE: Water pump shaft and impeller have right hand threads. Remove by turning counterclockwise and install by turning clockwise. TORQUE: 220~250 kgf.cm Water Pump Impeller Inspection Check impeller for cracks or other damage.
  • Page 116 5-1. ENGINE ASSEMBLY 6. Remove oil seal from crankcase by pulling screws with pliers. 7. Check water pump shaft axial play. If not adequate, engine must be disassembled to replace the water pump shaft. 8. Clean oil seal seat. Rotary Seal and Oil Seal Installation Oil Seal Apply engine oil on water pump shaft.
  • Page 117 5-1. ENGINE ASSEMBLY 7. Pull water pump shaft in proper position until the rotary seal is flush with the end of water pump shaft threads. NOTICE: Ensure that the water pump shaft is properly adjusted with rotary seal. NOTICE: Ensure that the water pump shaft moves freely while pushing it toward the crankcase.
  • Page 118 5-1. ENGINE ASSEMBLY Water Pump Shaft/Seal Removal (Disassembled Engine) 1. Remove the water pump housing and impeller. 2. Remove the circlip retaining the driven gear on water pump shaft. 3. Remove water pump driven gear, needle pin and thrust washer. 4.
  • Page 119 5-1. ENGINE ASSEMBLY NOTE: For installation use the torque values specified in the exploded view. NOTICE: Always replace rotary seal and water pump shaft together. Also install a NEW oil seal (behind rotary seal) at the same time. NOTE: Never use oil in the press fit area of the oil seal and rotary seal. ▪...
  • Page 120 5-1. ENGINE ASSEMBLY AC GENERATOR SYSTEM 5-20...
  • Page 121 5-1. ENGINE ASSEMBLY GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean thread before applying a thread locker. W ARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 122 5-1. ENGINE ASSEMBLY STATOR Stator Static test: Continuity 1. Disconnect the ACG connector. 2. Install the ACG DIAGNOSTIC HARNESS on ACG connector. 3. Set multimeter to Ω. 4. Connect multimeter between YELLOW wires. 5. Read resistance. RESISTANCE 20 ℃ TERMIINAL 1 and 2 0.15 –...
  • Page 123 5-1. ENGINE ASSEMBLY 6. Read voltage as per following table. TEST ENGINE TERMINAL VOLTAGE SPEED 1 and 2 10 – 25 VAC 4000 RPM 1 and 3 2 and 3 7. If voltage is lower than specification, replace stator. 8. Re-plug connectors properly. Stator Removal ▪...
  • Page 124 5-1. ENGINE ASSEMBLY NOTE: Use grease to place protector on crankshaft end prior to screw on the ACG puller. Screw ACG puller bolt to remove rotor. Rotor Inspection ▪ Check inner side of rotor for scratches or other damage. ▪ Check keyway of the rotor for wear or damages.
  • Page 125 5-1. ENGINE ASSEMBLY UNIDIRECTIONAL CLUTCH Unidirectional Clutch Removal ▪ Remove ACG cover. ▪ Loosen thrust plate screws located inside rotor. ▪ Remove rotor (refer to ROTOR above). ▪ Remove starting clutch gear. ▪ Remove thrust plate screws and thrust plate. Unidirectional clutch inspection ▪...
  • Page 126 5-1. ENGINE ASSEMBLY STARTING CLUTCH GEAR Starting clutch Gear Removal ▪ Remove ROTOR. ▪ Pull starting clutch gear out of the rotor. Starting Clutch Gear Inspection ▪ Inspect gear, especially teeth and unidirectional collar, for wear and other damage. ▪ Check needle bearing condition. Replace starting clutch gear if necessary.
  • Page 127 5-2. ENGINE TOP END TOP END INTAKE MANIFOLD 5-2-1...
  • Page 128 5-2. ENGINE TOP END CYLINDER HEAD 5-2-2...
  • Page 129 5-2. ENGINE TOP END CYLINDERS AND PISTONS 5-2-3...

  • Page 130: Engine Top End

    5-2. ENGINE TOP END GENERAL ▪ Special references are made in the text for procedures, which are different for front cylinder and rear cylinder. ▪ When diagnosing an engine problem, always perform a cylinder leak test. ▪ Always place the vehicle on level surface. NOTE: Even though the following procedures do not require the engine removal.
  • Page 131 5-2. ENGINE TOP END PROCEDURES INTAKE MANIFOLD Intake Manifold Removal 1. Remove upper and both side covers. 2. Remove four mounting bolts of air cleaner. 3. Loosen clamp of intake adapter 4. Raise air cleaner and using needle-nose pliers loosen and disconnect two air hoses, then pull up and remove the air cleaner.

  • Page 132: Rocker Arm Removal

    5-2. ENGINE TOP END CYLINDER HEAD COVER Cylinder Head Cover Removal ▪ Remove the bolts of cylinder head cover. ▪ Remove cover and gasket. ▪ Repeat at the procedure for the other cylinder head cover if required. Cylinder Head Cover Inspection Check the gasket on the cover if it is brittle, cracked or hard.

  • Page 133: Rocker Arm Installation

    5-2. ENGINE TOP END Rocker Arm Shaft ▪ Clean the oil hole of rocker arm shaft. ▪ Check for scored friction surface; if so, replace parts. Rocker Arm Installation NOTE: Use the same procedure for exhaust and intake rocker arm. ▪...

  • Page 134: Cylinder Head Removal

    5-2. ENGINE TOP END CYLINDER HEAD Cylinder Head Removal ▪ The removal procedure is the same for both cylinder heads. ▪ Drain coolant and remove the hoses.. NOTE: Before removing cylinder head, blow out remaining coolant by air pressure. During cylinder head removal, the remaining coolant in cylinder head could overflow into engine and a little quantity of coolant could drop into the...

  • Page 135: Cylinder Head Installation

    5-2. ENGINE TOP END Cylinder head Installation For installation, reverse the removal procedure. NOTE: Never invert front and rear cylinder heads. ▪ Ensure dowel pins and key are in place. NOTICE: Timing chain guide (fixed) has to be fixed between cylinder and cylinder head. ▪...

  • Page 136: Camshaft Inspection

    5-2. ENGINE TOP END Camshaft Inspection ▪ Check each lobe and bearing journal of camshaft for scoring, scuffing, cracks or other signs of wear. ▪ Using a micrometer measure camshaft journal diameter and lobe height. ▪ Replace parts that are not within specifications.

  • Page 137: Camshaft Installation

    5-2. ENGINE TOP END Camshaft Installation ▪ For installation, reverse the removal procedure. NOTICE: Do not invert the camshaft during assembly. Any mix-up of the components will lead to engine damage. ▪ Tighten the camshaft retaining bolts with specified torque. TORQUE: 1.0~1.2 kgf.m VALVE SPRING Valve Spring Removal...
  • Page 138 5-2. ENGINE TOP END Valve Spring Installation ▪ For installation, reverse the removal procedure. ▪ To ease installation of cotters, apply oil or grease on them so that they remain in place while releasing the spring. NOTE: Valve cotter must be properly engaged in valve stem grooves.
  • Page 139 5-2. ENGINE TOP END VALVE OUT OF ROUND Valve Stem and Valve Guide Clearance ▪ Using a micrometer and a small gauge measure valve stem and valve guide in three places. NOTE: Clean valve guide to remove carbon deposits before measuring. ▪...
  • Page 140 5-2. ENGINE TOP END Valve Face and Seat ▪ Check valve face and seat for burning or pittings and replace valve or cylinder head if there are signs of damage. ▪ Ensure to seat valves properly. Apply some lapping compound to valve face and work valve on its seat with a lapping tool.

  • Page 141: Cylinder Removal

    5-2. ENGINE TOP END CYLINDER Cylinder Removal ▪ Remove chain tensioner. ▪ Remove timing gear. ▪ Remove the camshaft ▪ Remove the nuts at cylinder ▪ Remove the cylinder head. ▪ Pull out the cylinder ▪ Discard cylinder base gaskets. Cylinder Inspection ▪...

  • Page 142: Cylinder Installation

    5-2. ENGINE TOP END Cylinder Installation ▪ For installation, reverse the removal procedure. NOTICE: Always replace cylinder base gasket before installing the cylinder. NOTE: Ensure the front and rear cylinder installation correct, the timing chain adjuster should face to the backside of cylinder. Wrong install direction will lose the function of chain adjuster and cause timing chain damage.
  • Page 143 5-2. ENGINE TOP END Piston Inspection ▪ Inspect piston for scoring, cracking or other damages. Replace piston and piston rings if necessary. ▪ Using a micrometer. Measure piston pin. ▪ The measured dimension should be as described in the following tables. If not, replace piston.

  • Page 144: Piston Installation

    5-2. ENGINE TOP END ▪ Measure piston pun. See the following illustration for the proper measurement positions. ▪ Replace piton pin if diameter is out of specifications. ▪ Measure inside diameter of connecting rod small end bushing. ▪ Replace connecting rod if diameter of connecting rod small end is out of specifications.
  • Page 145 5-2. ENGINE TOP END PISTON RINGS Ring Removal ▪ Remove the piston. Ring Inspection Ring/Piston Groove Clearance ▪ Using a feeler gauge measure each ring/piston groove clearance. If the clearance is too large, the piston and the piston rings should be replaced. ▪...
  • Page 146 5-2. ENGINE TOP END Ring Installation ▪ For installation, reverse the removal procedure. NOTE: First install spring and then ring of oil scraper ring. ▪ Install the oil scraper ring first, then the lower compression ring with the open edge facing up, then the upper compression ring with the word “R”...
  • Page 147 5-2. ENGINE TOP END TIMING CHAIN 5-2-21...
  • Page 148 5-2. ENGINE TOP END GENERAL During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 149 5-2. ENGINE TOP END TIMING CHAIN TENSIONERS Timing Chain Tensioner Removal ▪ Make sure the respective cylinder is set to TDC ignition. ▪ Carefully unscrew chain tensioner plug and release spring tension. CAUTION Tensioner is spring loaded. ▪ Remove O-ring, spring and chain tensioner plunger.
  • Page 150 5-2. ENGINE TOP END NOTE: Install the new gasket of chain tensioner. NOTICE: Improper adjustment of the timing chain will lead to severe engine damage. ▪ Fit the spring on one side into the slot of the plug and on the other side into the plunger. NOTE: Turn spring only clockwise in order to fit the spring end into the notch of the plunger and to avoid loosening the plunger during spring...
  • Page 151 5-2. ENGINE TOP END Timing Gear Installation ▪ For installation, reverse the removal procedure. ▪ Clean mating surface and threads of camshaft prior installing timing gear. ▪ Crankshaft must be set to TDC position before install the timing chain. NOTICE: Crankshaft and camshaft must be locked at TDC ignition position to place timing gear and timing chain in the proper position.
  • Page 152 5-2. ENGINE TOP END Camshaft Timing Cylinder (front) ▪ Turn rear cylinder to TDC ignition. ▪ Using a 14 mm Allen key, turn crankshaft 450° clockwise, until marks on magneto flywheel and magneto cover are aligned. NOTE: At TDC ignition, the printed marks on the camshaft have to be parallel to cylinder head base as per following illustration.

  • Page 153: Timing Chain

    5-2. ENGINE TOP END TIMING CHAIN The engine is equipped two timing chains. One of timing chain is located on engine ACG side behind the magneto cover. The second timing chain is located on engine PTO side behind the PTO cover. Timing Chain Removal (ACG Side) ▪...
  • Page 154 5-2. ENGINE TOP END Timing Chain Inspection ▪ Inspection is the same for both timing chains. ▪ Check timing chain on timing gear for excessive radial play. ▪ Check chain condition for wear and teeth condition. ▪ If chain is excessively worn or damaged, replace it as a set (timing gear and timing chain).
  • Page 155 5-3. ENGINE BOTTOM END BOTTOM END ENGINE DRIVE SHAFT 5-3-1...
  • Page 156 5-3. ENGINE BOTTOM END CRANKCASE CRANKSHAFT 5-3-2...
  • Page 157 5-3. ENGINE BOTTOM END WATER PUMP, OIL PUMP 5-3-3...
  • Page 158 5-3. ENGINE BOTTOM END BOTTOM END GENERAL ▪ During assembly/installation, use the torque values and service products as in the exploded views. ▪ Clean threads before applying a thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced with new ones where...
  • Page 159 5-3. ENGINE BOTTOM END Engine Drive Inspection ▪ Replace oil seals and/or O-ring if they are brittle, hard or damaged. ▪ Check drive shaft bearings for contamination and/or metal shavings. Check if bearing turn freely and smoothly. Replace if necessary. ▪...
  • Page 160 5-3. ENGINE BOTTOM END ▪ Remove oil seal with a small flat screwdriver. NOTICE: Avoid scoring surface with tool. Vent Backboard Oil Seal Inspection Check oil seal running surface of crankshaft CVT side for grooves. Replace if necessary. CVT Vent Backboard Oil Seal Installation ▪...
  • Page 161 5-3. ENGINE BOTTOM END NOTE: Measure plain bearing inside diameter and compare to crankshaft journal diameter. ▪ Replace if the measurement is out of specification. PLAIN BEARING INSDIE DIAMETER (CVT BACKBOARD) Plain Bearing Replacement (CVT Vent Backboard Cover) Plain Bearing Removal NOICTE: Unless otherwise instructed.
  • Page 162 5-3. ENGINE BOTTOM END NOTE: Wrong oil bore position will stop oil supply to plain bearings and will damage the engine. NOTICE: The partition of the plain bearings must be positioned near to oil bore in counterclockwise direction. CVT Vent Backboard Installation ▪...

  • Page 163: Crankcase Disassembly

    5-3. ENGINE BOTTOM END Drive Gear Installation ▪ For installation, reverse the removal procedure. ▪ Adequately oil the ball bearing of the breather gear. CRANKCASE Crankcase Disassembly 1. Drain the following system: 1.1 Cooling system 1.2 Engine oil. 1.3 Gearbox oil. 2.

  • Page 164: Crankcase Inspection

    5-3. ENGINE BOTTOM END 11. Remove the following parts: - Oil filter. - Oil cooler. - Oil pump drive gear. NOTE: Oil pump removal from crankcase is not necessary, but recommended to see condition of oil pump. 12. Remove electric starter. NOTE: Before splitting the crankcase, measure crankshaft axial play.
  • Page 165 5-3. ENGINE BOTTOM END MAIN BEARING INSIDE DIAMETER (CVT/ACG) Plain Bearing Replacement (Main) Plain Bearing Removal NOTICE: Always use a press for removal of plain bearings. ▪ Remove plain bearings with the PLAIN BEARING REMOVER/INSTALLER ▪ Carefully push the plain bearings out, from the crankcase half inside towards the outside.

  • Page 166: Crankcase Assembly

    5-3. ENGINE BOTTOM END NOTE: Mark position of oil bore on crankcase half. Align mark on plain bearing remover/installer with mark on crankcase half. NOTE: Wrong oil bore position will stop oil supply to plain bearings and will cause engine damage.
  • Page 167 5-3. ENGINE BOTTOM END Connecting Rod Big End Axial Play ▪ Using a feeler gauge, measure distance between butting face of connecting rods and crankshaft counterweight. Connecting Rod Big End Radial Play NOTE: Prior to remove connecting rod from the crankshaft, mark big end halves together to ensure a correct reinstallation (cranked surface fits in only one position).

  • Page 168: Crankshaft Assembly

    5-3. ENGINE BOTTOM END Crankshaft Assembly ▪ For assembly, reverse the disassembly procedure. Pay attention to following details. ▪ Put plain bearings correctly in place and clean the split surface on both sides (cracked area) carefully with compressed air. NOTE: Oil the plain bearing surface of the connecting rod and crank pin before installation.
  • Page 169 5-4. TRANSMISSION GEARBOX TRANSMISSION GEARBOX 5-4-1...
  • Page 170 5-4. TRANSMISSION GEARBOX GENERAL During assembly/installation, use the torque values and service products as in the exploded views. Clean threads before applying a thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 171 5-4. TRANSMISSION GEARBOX PROCEDURES VSS (VEHICLE SPEED SENSOR) VSS Location ▪ The vehicle speed sensor is located on the right housing of the gearbox. ▪ To reach the VSS, remove the following parts: - Passenger seat. - RH side cover. VSS Wire identification COLOR FUNCTION...
  • Page 172 5-4. TRANSMISSION GEARBOX VSS Removal ▪ Remove RH side cover ▪ Remove VSS retaining bolts. ▪ Turn sensor and pull it out of the gearbox right cover. VSS Installation ▪ For installation, reverse the removal procedure. Apply GREASE on VSS O-ring. GEAR SWITCH To reach the VSS, remove the following parts: - Passenger seat.
  • Page 173 5-4. TRANSMISSION GEARBOX Gear Switch Removal ▪ Disconnect the gear switch connector. ▪ Remove LH side cover. ▪ Drain the engine oil and gearbox oil. ▪ Remove the CVT assembly. ▪ Remove two bolts and replace gear switch. Gear Switch Installation For installation, reverse the removal procedure.
  • Page 174 5-4. TRANSMISSION GEARBOX Gearbox Bearings NOTE: Always support gearbox housings properly when ball bearings are removed. Housing damages mat occur if this procedure is not performed correctly. ▪ Check if ball bearings turn freely and smoothly. ▪ Check all bearings, bearing points, tooth flanks and taper grooves.
  • Page 175 5-4. TRANSMISSION GEARBOX Gear Camshaft Comp. ▪ Check all the gear tooth wear, cracks or other damage. ▪ Replace if necessary Parking Gear ▪ Check the gear tooth wear, cracks or other damage. ▪ Replace if necessary. Output Secondary gear shaft and 17 tooth Gear ▪...
  • Page 176 5-4. TRANSMISSION GEARBOX SHIFT LEVER 5-4-8...

  • Page 177: Shift Lever

    5-4. TRANSMISSION GEARBOX SHIFT LEVER ▪.before performing any servicing on the transmission linkage system, be sure the transmission lever is on NEUTRAL position and the parking brake is applied. ▪ During assembly/installation, use the torque values and services products as in the exploded view.
  • Page 178 5-4. TRANSMISSION GEARBOX SHIFT ROD Shift Rod Adjustment 1. Place shift lever in NEUTRAL position. NOTICE ： Move vehicle back and forth to ensure gearbox is seat in neutral position. 2. Secure vehicle using parking brake. 3. Remove side cover. 4.
  • Page 179 5-4. TRANSMISSION GEARBOX 4. Remove shift plate nut and bolt. 5. Remove shift plate. Shift Plate Inspection - Check shift plate for: - Cracks. - Bending. - Spline condition. Shift Plate Installation ▪ The installation is the reverse of the removal procedure.
  • Page 180 5-5. CONTINUOUSLY VARIABLE TRANSMISSION CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 5-5-1 PDF created with pdfFactory Pro trial version www.pdffactory.com...
  • Page 181 To perform the following instructions, it is not Any drive pulley repairs must be performed necessary to remove engine. by an authorized TGB dealer. ▪ This CVT is lubrication free. Never lubricate Subcomponent installation and assembly any components except drive pulley one-way tolerance require strict adherence to procedure detailed.
  • Page 182 5-5. CONTINUOUSLY VARIABLE TRANSMISSION CVT Draining If water is present in CVT, it can be drained as follows: 1. Remove drain bolt. 2. Let water drain from CVT. 3. Reinstall drain bolt. NOTICE: If any debris entered the CVT, CVT must be cleaned and inspected.
  • Page 183 5-5. CONTINUOUSLY VARIABLE TRANSMISSION ▪ Using special tool to loose and remove the drive pulley assembly. ▪ Prior to removing the drive pulley., mark sliding sheave and governor cup to ensure correct indexation at reinstallation. NOTICE: Do not lean the tool hook on the slider shoe guides.
  • Page 184 5-5. CONTINUOUSLY VARIABLE TRANSMISSION GOVERNOR CUP REMOVEAL ▪ Using special tool #560017 loose and remove the governor cup. NOTICE: During removal, press and hold the governor cup. Centrifugal lever Replacement Removal ▪ Loosen and remove the bolts and nuts on the centrifugal lever.
  • Page 185 5-5. CONTINUOUSLY VARIABLE TRANSMISSION TUNER HAFT COVER INSTALLATION ▪ For installation, reverse the removal order. ▪ Install the spring. ▪ Align the mark at the mounting area as shown. ▪ Install the special tool and using compress machine press the tuner cover to the position. ▪...
  • Page 186 5-5. CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY Driven Pulley Removal ▪ Remove DRIVE BELT. ▪ Using the DRIVEN CLUTCH HOLDER, hold the driven pulley and loosen the driven pulley screw. NOTE: Do not unscrew the driven pulley screw completely. ▪ Apply axial pressure with your hand on driven pulley and maintain during screw removal.
  • Page 187 5-5. CONTINUOUSLY VARIABLE TRANSMISSION ▪ Press the special tool #560019 down and remove the two C-clips. ▪ ▪ Lightly lift up the compress machine and remove the cam. ▪ Disassemble the cam, spring, spring seat and outer haft sheave. Slider Shoe Replacement ▪...
  • Page 188 5-5. CONTINUOUSLY VARIABLE TRANSMISSION ▪ Using rubber hammer push out the slider shoe. ▪ Replace and install new slider shoe. CAUTION The slider shoe have two side, the flat side should toward the center. ▪ Tighten the screws and washer. TORQUE: 25~35 kgf.cm 5-5-9...
  • Page 189 5-5. CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY ASSEMBLY For assemble the driven pulley, the sequence as follow: ▪ Install the spring seat into the outer haft sheave. NOTE: The hole of spring seat should align the center hole of outer haft sheave. ▪...
  • Page 190 5-5. CONTINUOUSLY VARIABLE TRANSMISSION ▪ Using special tool #560019 and compress machine on the cam and push down. CAUTION During push down, you should counter-clockwise turn the outer haft sheave to let the spline of cam align to the shaft. NOTE: If the spline not aligns the shaft, the cam can not push down.
  • Page 191 6. DRIVE SYSTEM FRONT DRIVE (FRONT DIFFERENTIAL) PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 192: Drive System

    6. DRIVE SYSTEM DRIVE SYSTEM FRONT DRIVE GENERAL During assemble/installation, use torque values and service products as in the exploded views. Clean threads before applying thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 193 6. DRIVE SYSTEM FRONT DRIVE SHAFT Front Drive Shaft Removal ▪ Lift and support vehicle. ▪ Remove the wheel hub. ▪ Remove the knuckle. ▪ Strongly pull drive shaft out of differential. ▪ Discard the stop ring at the end of the shaft. Front Drive Shaft Inspection ▪...
  • Page 194 6. DRIVE SYSTEM Drive Shaft Boot Installation ▪ For installation, reverse the removal procedure. ▪ Install new circlip. ▪ Pack bearing area with grease. NOTE: Do not use or add other grease. ▪ Install new drive shaft clamps. FRONT DIFFERENTIAL Front differential Removal Caution Be sure the differential set temperature below...
  • Page 195 6. DRIVE SYSTEM Front Differential Disassembly Unscrew the differential housing bolts then separate half housings. Pinion Gear ▪ Remove and discard oil seal. ▪ Unscrew the pinion nut. Front Differential Adjustment Using special tool to adjust the cable. Adjust the suitable length by the rotate the nuts Front Differential Installation For installation, reverse the removal procedure.
  • Page 196 6. DRIVE SYSTEM REAR DRIVE (REAR DIFFERENTIAL) PDF created with pdfFactory Pro trial version www.pdffactory.com...

  • Page 197: Rear Drive

    6. DRIVE SYSTEM REAR DRIVE GENERAL During assemble/installation, use torque values and service products as in the exploded views. Clean threads before applying thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.

  • Page 198: Rear Drive Shaft Installation

    6. DRIVE SYSTEM REAR DRIVE SHAFT Rear Drive Shaft Removal ▪ Lift and support vehicle. ▪ Remove the wheel hub. ▪ Remove the knuckle. ▪ Strongly pull drive shaft out of differential. ▪ Discard the stop ring at the end of the shaft. Rear Drive Shaft Inspection ▪...
  • Page 199 6. DRIVE SYSTEM Drive Shaft Boot Installation ▪ For installation, reverse the removal procedure. ▪ Install new circlip. ▪ Pack bearing area with grease. NOTE: Do not use or add other grease. ▪ Install new drive shaft clamps. REAR DIFFERENTIAL Rear differential Removal Caution Be sure the differential set temperature below...
  • Page 200 6. DRIVE SYSTEM Rear Differential Disassembly Unscrew the differential housing bolts then separate half housings. Rear Differential Adjustment Using special tool to adjust the cable. Adjust the suitable length by the rotate the nuts Rear Differential Installation For installation, reverse the removal procedure. Fill the gear oil and tighten the bolt.
  • Page 201 7-1. STEERING SYSTEM AND SUSPENSION STEERING SYSTEM EPS MODEL 7-1-1...
  • Page 202 7-1. STEERING AND SUSPENSION NON EPS MODEL 7-1-2...
  • Page 203 7-1. STEERING SYSTEM AND SUSPENSION STEERING SYSTEM GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 204 7-1. STEERING AND SUSPENSION PROCEDURES HANDLEBAR COVER Handlebar Cover Removal 1. Loosen six screws on the dashboard cover. 2. Remove the two screws on the both rear mirror bracket. 3. Remove the top cover screws and pull out the cover from the handlebar. Handlebar Cover Inspection Check covers for cracks or other damages.
  • Page 205 7-1. STEERING SYSTEM AND SUSPENSION Handlebar Removal 1. Remove handlebar cover. NOTE: Remove handlebar grips, throttle lever, brake lever and switch only if the handlebar is defective and requires replacement. 2. Remove four bolts from the dashboard bracket. 3. Remove the dashboard. 4.
  • Page 206 7-1. STEERING AND SUSPENSION Steering Shaft Removal (without EPS) 1. Remove handlebar cover. 2. Remove dashboard support. 3. Loosen handlebar mounting bolts and remove handlebar. 4. Remove the body top cover. 5. Remove steering shaft bracket and bolts. 6. Remove the inner fender. 7.Remove the cotter pin and castle nut at the arm plate.
  • Page 207 7-1. STEERING SYSTEM AND SUSPENSION WHEEL AND TIRE TIRES GENERAL WARNING WARNING Do not rotate tires. The front and rear tires have a different size. Respect direction of Torque wrench tightening specifications rotation when applicable. must strictly be adhered to. Castle Nut TIRE PRESSURE Torque: 950-1200 kgf-cm...
  • Page 208 7-1. STEERING AND SUSPENSION FRONT SUSPENSION 7-1-8...
  • Page 209 7-1. STEERING SYSTEM AND SUSPENSION FRONT SUSPENSION GENERAL ▪ The procedure explained below is the same for the RH and LH sides unless otherwise noted. ▪ During assembly/installation, use the torque values and service products as in the exploded view. ▪...
  • Page 210 7-1. STEERING AND SUSPENSION - Seizing or binding condition except at extreme end of either stroke. - Oil leakage. - A gurgling noise, after completing one full compression and extension stroke. ▪ Replace if any faults are present. Shock Absorber Installation For installation, reverse the removal procedure.
  • Page 211 7-1. STEERING SYSTEM AND SUSPENSION UPPER A ARM Upper A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove fasteners retaining brake hose to vehicle. 4. Remove and discard cotter pin retaining ball joint.
  • Page 212 7-1. STEERING AND SUSPENSION REAR SUSPENSION 7-1-12...
  • Page 213 7-1. STEERING SYSTEM AND SUSPENSION REAR SUSPENSION GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying a thread locker.
  • Page 214 7-1. STEERING AND SUSPENSION - Seizing or binding condition except at extreme end of either stroke. - Oil leakage. - A gurgling noise, after completing one full compression and extension stroke. ▪ Replace if any faults are present. Shock Absorber Installation For installation, reverse the removal procedure.
  • Page 215 7-1. STEERING SYSTEM AND SUSPENSION UPPER A ARM Upper A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove bolts and nuts securing A arm to frame. 4. Remove bolts and nut securing upper knuckle.
  • Page 216 7-1. STEERING AND SUSPENSION LOWER A ARM Lower A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove bolts and nuts securing A arm to frame. 4. Remove bolts and nut securing lower knuckle.
  • Page 217 7-2. ELECTRIC POWER STEERING EPS (Electric Power Steering) 7-2-1...
  • Page 218 7-2. ELECTRIC POWER STEERING (EPS) Electric Power Steering When electrical system is under high load GENERAL (battery not at full charge, operating the vehicle During assembly/installation, use the torque for prolonged periods of time at slow speed and values and service products as in the exploded low RPM which, requires higher power steering view.
  • Page 219 7-2. ELECTRIC POWER STEERING The internal protection system decreases the Steering Torque Sensor assistance level available to protect its The steering column is connected to the shaft electronic board. The normal assistance level on the EPS unit. A small area of the EPS shaft will return when riding conditions are back to is magnetized.
  • Page 220 7-2. ELECTRIC POWER STEERING How to View EPS Mode Selection 1. To view the active EPS assist mode, press MODE button from the dashboard and move to EPS select page, the EPS page will blinking then press the RESET button to engage the EPS assist.
  • Page 221 7-2. ELECTRIC POWER STEERING SYSTEM DESCRIPTION (COMPONENTS) EPS Unit ▪ The EPS unit is a self-contained unit that includes the steering gear, the EPS module, the EPS motor and the torque sensor. ▪ The EPS module provides DC power to the motor.
  • Page 222 7-2. ELECTRIC POWER STEERING TROUBLESHOOTING LOW POWER STEERING ASSIST NO POWER STEERING 1. Low battery voltage. 1. EPS malfunction. - Check battery terminals. Clean, repair, - If the CHECK ENGINE light is on and a EPS replace or tighten as required. FAULT message is visible in the dashboard, - Test battery voltage.
  • Page 223 7-2. ELECTRIC POWER STEERING EPS unit Power Fuse Test A 40 A EPS fuse located at the right side under the passenger seat in the EPS fuse box provides power for the EPS motor. 1. To remove fuse box cover, simultaneously squeeze tabs inwards on each end of fuse box cover as you pull upward on the cover.
  • Page 224 7-2. ELECTRIC POWER STEERING EPS unit Input Voltage Test (Power Side) ① ③ 1. Disconnect the EPS power connector. 2. Test for 12 VDC EPS motor power at pin as per following table. ② EPS power connector pin 1 + Battery GND The voltage should be battery voltage ▪...
  • Page 225 7-2. ELECTRIC POWER STEERING EPS Unit Ground Circuit Test 1. Disconnect the EPS ground connector (GDN) 2. Test for continuity between PINS to battery ground. EPS GND connector pin A + Battery GND EPS GND connector pin B+ Battery GND The voltage should be Continuity (close to 0 Ω...
  • Page 226 7-2. ELECTRIC POWER STEERING PS System Load Test If the charging system cannot sustain normal voltage when the EPS is operating, EPS may be greatly reduced or nonexistent. Carry out the following steps. 1. Connect the red lead of voltmeter set to VDC to the EPS fuse box battery terminal.
  • Page 227 7-2. ELECTRIC POWER STEERING EPS Unit Current Test 1. Connect vehicle to the latest BUS software. 2. Click on the Rear Data button. 3. Choose the Monitoring page tab. 4. At the bottom of the Monitoring page, choose the EPS tab. 5.
  • Page 228 7-2. ELECTRIC POWER STEERING EPS Unit Removal Remove the following items: • Both internal fender. • The front bumper. • Disconnect the wiring of headlamp and power source. • The front cover. • The inlet tube. ▪ Loose the handle steering lock nut. ▪...
  • Page 229 7-2. ELECTRIC POWER STEERING Loose the clamp of anti-dust rubber. Lift up and dismounting the EPS unit. Take out the EPS unit from the left side of vehicle. NOTE: Be careful do not damage the cable of torque sensor. Remove the four bolts ① and the bracket ②. ②...
  • Page 230 7-2. ELECTRIC POWER STEERING Steering lower Bearing Seat Refer to the picture for install new bearing and seal into the bearing seat then assemble the bearing seat assembly. ① Steering Pad. ② Bearing Seat ③ Oil Seal ④ Bearing x 2 ⑤...
  • Page 231 7-2. ELECTRIC POWER STEERING Fuse Removal Simultaneously squeeze tabs inwards on each end of fuse box cover as you pull downward on the cover. Replace the damage fuse. Installation Install the control in the reverse order of removal. 7-2-15...
  • Page 232 7-3. BRAKE SYSTEM AND BODY COVER BRAKE FRONT BRAKE 7-3-1...
  • Page 233 7-3. BRAKE SYSTEM AND BODY COVER REAR BRAKE 7-3-2...
  • Page 234 7-3. BRAKE SYSTEM AND BODY COVER BRAKE SPECIFICATIONS FRONT BRAKES Item Standard Service Limit Bake Pad Thickness 1 mm Brake Disc Thickness 4.75 mm 4.24 mm Brake Disc Run out 0.254 mm Caliper Piston Diameter 30.12 mm 30.07 mm Caliper Bore Diameter 30.28 mm 30.33 mm REAR BRAKES...
  • Page 235 7-3. BRAKE SYSTEM AND BODY COVER BRAKE SYSTEM SERVICE NOTES Disc brake systems are lightweight, low maintenance and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.
  • Page 236 7-3. BRAKE SYSTEM AND BODY COVER BRAKE LIGHT SWITCH Brake Light Switch Location There are two brake light switches, which located on the brake liquid distributor, one at front and other at LH rear. Brake Light Switch Continuity Test 1. Disconnect brake light switch connector. 2.
  • Page 237 7-3. BRAKE SYSTEM AND BODY COVER MASTER CYLINDER Master Cylinder Removal (Hand Brake) 1. Drain brake system. 2. Remove master cylinder. 3. Unscrew brake hose from master cylinder. Master Cylinder Removal (Pedal Brake) 4. Disconnect master cylinder rod from brake pedal.
  • Page 238 7-3. BRAKE SYSTEM AND BODY COVER CALIPER Caliper Removal 1. Safety lift and support the vehicle. 2. Remove wheels. 3. If caliper is removed from vehicle for replacement: 3.1 Drain brake system. 3.2Unscrew brake hose from caliper. 4. Remove fasteners retaining brake hose to knuckle.
  • Page 239 7-3. BRAKE SYSTEM AND BODY COVER BRAKE PADS Brake Pads Replacement 1. Remove caliper from knuckle. 2. Remove brake pad pins from caliper. 3. Remove brake pads. 4. Clean pistons end using brake cleaner. 5. Push caliper pistons inward. NOTE: To avoid damaging pistons, use an old pad to push it into the caliper using a C-clamp.
  • Page 240 7-3. BRAKE SYSTEM AND BODY COVER BODY FRONT BUMPER TOP COVER, SIDE COVER, FOOTREST 7-3-9...
  • Page 241 7-3. BRAKE SYSTEM AND BODY COVER FRONT COVER REAR COVER 7-3-10...
  • Page 242 7-3. BRAKE SYSTEM AND BODY COVER REMOVAL Top Cover ▪ Unscrew the jam nut. ▪ Unscrew and remove the shift gear lever holder. ▪ Remove the four bolts at front and two bolts at rear of the top cover as shown. Side Cover ▪...
  • Page 243 7-3. BRAKE SYSTEM AND BODY COVER Front Bumper Comp. ▪ Disconnect front lamp connector. ▪ Remove the four retaining bolts on the front side. ▪ Remove the four retaining bolts on the backside. Footrest ▪ Remove both side footrest-connecting bolts as shown.
  • Page 244 7-3. BRAKE SYSTEM AND BODY COVER Inner Fender ▪ Remove the five retaining screws and inner fender as shown. Front Cover ▪ Disconnect DC supply connector. ▪ Remove two front cover retaining bolts and take out the front cover. Rear Cover ▪...
  • Page 245 7-3. BRAKE SYSTEM AND BODY COVER ▪ Disconnect rear light lamp connector. ▪ Remove both side reflector retaining nuts. ▪ Remove two retaining screws on the inside of rear cover. ▪ Remove the fuel hose clamp from the fuel filler assembly and detach the hose.
  • Page 246 7-3. BRAKE SYSTEM AND BODY COVER ▪ Loosen the fuel tank breath hose retaining clip and remove the hose. ▪ Remove the rear cover together with rear bumper and fender side rail. Skid Plate ▪ Remove retaining bolts and plate from the bottom of the frame.
  • Page 247 7-3. BRAKE SYSTEM AND BODY COVER ▪ Install passing beam headlight three mounting screws. ▪ Adjust the suitable aiming height of lamp. ▪ Install driving beam headlight three mounting screws. ▪ Adjust the suitable aiming height of lamp. ▪ Install the winker/position/daytime running lamp five mounting screws.

  • Page 248: Electric System

    8-1. ELECTRIC SYSTEM Mechanism Diagram Shift lever Oil pressure switch Fuse box Coolant sensor DC. Power outlet Headlight relay EPS controller Regulator Ignition coil AC.Generator Speed sensor Winch switch Hazard control Main switch Winker relay Horn Rear Brake switch Front brake 8-1-1...
  • Page 249 8-1. ELECTRIC SYSTEM ELECTRIC SYSTEM IGNITION SYSTEM GENERAL WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced. Hoses, cables or locking ties removed during a procedure must be reinstalled as per factory standards.
  • Page 250 8-1. ELECTRIC SYSTEM ENGINE WILL NOT START (ENGINE TURNS OVER) 1. Fouled or defective spark plug. - Replace. 2. Defective CPS. - Check operation of CPS and replace if necessary.. 3. Defective trigger wheel. - Check. 4. Defective ignition circuit. - Check fuse of fuse box, ignition coil and wiring condition.
  • Page 251 8-1. ELECTRIC SYSTEM IGNITION SYSTEM FUSE MAXI FUSE EPS Model ▪ Remove the seat. ▪ Remove the isolate shield. ▪ Push inward from the both side and lift up the cap. ▪ Check the fuse condition, replace if necessary. MAXI ESP：40 A, Green MAXI FUSE：30 A, Pink Charged：30 A, Pink...
  • Page 252 8-1. ELECTRIC SYSTEM IGNITION SWITCH Ignition Switch Quick Test ▪ Turn ignition switch to ON position. ▪ If dashboard turns on (assuming it works), the ignition switch is good. ▪ If dashboard does not turn on, check the following: - Battery. - Fuses (main fuse, fan, headlight, brake light) - ECU is properly powered.
  • Page 253 8-1. ELECTRIC SYSTEM Ignition Coil Ground Circuit Continuity Test Pin 1 and ECM Pin 1 and ECM Ignition Coil Resistance Test An ignition coil with good resistance measurement can still be faulty. Voltage leak can occur at high voltage level that is not detectable with an ohmmeter.
  • Page 254 8-1. ELECTRIC SYSTEM SPARK PLUG Troubleshooting Fouled Spark Plug Fouling of the spark plug is indicated by irregular running of the engine, decreased engine speed due to misfiring, reduced performance, and increased fuel consumption. This is due to a loss of compression. Other possible cause are : prolonged idling or low speed riding, a clogged air filter, incorrect fuel, defective ignition system, incorrect spark plug...
  • Page 255 8-1. ELECTRIC SYSTEM CHARGING SYSTEM GENERAL SYSTEM DESCRIPTION The purpose of the charging system is to keep the battery at a fuel state of charge and to provide the electrical system with the required electrical power for normal vehicle operation. AC Generator The AC generator is the primary source of electrical energy.
  • Page 256 8-1. ELECTRIC SYSTEM 2. Increase engine RPM and read voltage. If voltage is above specification, replace voltage rectifier. If voltage is below specification, check stator output and wiring harness prior to concluding that voltage rectifier is defective. Output Voltage Test 1.

  • Page 257: Battery Load Test

    8-1. ELECTRIC SYSTEM BATTERY Battery Voltage Test (No Load Applied) NOTE: A voltage test is carried out on a battery without discharging current. It is the simplest and most commonly used. However, be aware that the voltage test can be good; while the battery does not have enough power to crank the engine .A load test gives a more accurate condition of the battery.

  • Page 258: Battery Cleaning

    8-1. ELECTRIC SYSTEM Battery Cleaning Clean the battery rack, cables and battery posts using a solution of baking soda and water. Remove corrosion (if so) from battery cable terminals and battery posts using a firm wire brush. Rinse with clear water and dry well. Battery Storage If the battery is in storage or used infrequently, disconnect the battery cables to eliminate drain...
  • Page 259 8-1. ELECTRIC SYSTEM STARTING SYSTEM GENERAL WARNING Torque wrench tightening specifications must be strictly adhered to. Locking devices when removed (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pins, etc.) must be replaced. Hoses, cables or locking ties removed during a procedure must be reinstalled as per factory standards.
  • Page 260 8-1. ELECTRIC SYSTEM ENGINE DOES NOT CRANK AND GAUGE DOES NOT TURN ON 1. Burnt main fuse. - Check fuse. 2. Burnt ignition fuse - Check fuse. 3. Defective or discharged battery - Test battery. 4. Defective ignition switch or circuit. - Check ignition switch.
  • Page 261 8-1. ELECTRIC SYSTEM Starter Relay Operational Test 1. Disconnect both terminals from the starter relay. 2. Connect pin 1 to the positive battery terminal. 3. Momentarily connect pin 2 to the chassis ground. If starter runs, carry out the STARTER RELAY INPUT VOLTAGE TEST.
  • Page 262 8-1. ELECTRIC SYSTEM ELECTRIC STARTER Starter Operation Test Using booster cables, carefully supply current from a 12 volt battery directly to the starter. Connect the Black (-) cable first, then connect the remaining jumper cable from the battery then to the starter. If starter turns, test other starting system components.
  • Page 263 8-1. ELECTRIC SYSTEM CAUTION When connecting the RED (=) cable to the starter motor, make sure the battery cables are disconnected. TORQUE: 6 Nm. First connect RED(=) cable to battery then connect BLACK(-) cable. Connect battery cables. WARNING Always connect RED (+) cable first and BLACK (-) cable last.
  • Page 264 8-1. ELECTRIC SYSTEM LIGHTS, SPEEODEMETER AND ACCESSORIES GENERAL NOTICE: it is recommended to always disconnect the battery when replacing any electric or electronic parts. Always disconnect battery exactly in the specified order, black (-) cable first. TROUBLESHOOTING DIAGNOSTIC IMPORTANT: When troubleshooting an electronic system fault, check battery condition, cables and connections first.
  • Page 265 8-1. ELECTRIC SYSTEM HEADLIGHTS Headlight Wire Identification Headlight Relay 12 volt input from fuse (headlight power) = Yellow/Black. 12 volt input from ignition switch (relay winding input) = Yellow/Blue. 12 volt output to headlights low beam and low/high beam switch = Green. Relay winding ground (from ECU ) = Orange/Black.
  • Page 266 8-1. ELECTRIC SYSTEM ▪ Disconnect the wiring connector. ▪ Counter clockwise then remove the bulb. Installation ▪ For installation, reverse the removal procedure. TAILLIGHTS/BRAKE LIGHTS Brake Light Switch ▪ Disconnect the front brake switch connector. ▪ Press the right brake lever and check continuity of brake switch connector.
  • Page 267 8-1. ELECTRIC SYSTEM TURN SIGNAL LAMP Turn Signal ▪ Disconnect the wiring of turn signal connector. ▪ Press the left brake lever or pedal then check continuity of brake switch connector. ▪ Replace if necessary. Replacement ▪ Remove five screws of turn signal lamp. ▪...
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