HER CHEE ATV-600 Service Manual
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HER CHEE ATV-600 Service Manual

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SERVICE MANUAL
ATV-600
Aug, 2011
HER CHEE INDUSTRIAL CO., LTD.

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Summary of Contents for HER CHEE ATV-600

  • Page 1 SERVICE MANUAL ATV-600 Aug, 2011 HER CHEE INDUSTRIAL CO., LTD.
  • Page 2 It is highly recommended that a qualified mechanic, regardless of technical level, should study the service manual in full before attempting service on ATV-600 All the data and diagrams provided in this service manual are valid at the time of publication.

  • Page 3: General Information

    HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for ADLY ATV-600. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 CONTENTS Index Chapter 1 GENERAL INFORMATION Chapter 2 MAINTENANCE INFORMATION Chapter 3 LUBRICATION SYSTEM Chapter 4 FUEL SYSTEM Chapter 5 ENGINE REMOVAL Chapter 6 CYLINDER HEAD/VALVE Chapter 7 CYLINDER/PISTON Chapter 8 V BELT DRIVING SYSTEM Chapter 9 TRANSMISSION Chapter 10 WHEEL, DRIVE SHAFT &...
  • Page 5 Ch. 1 GENERAL INFORMATION Vehicle Identification Number Frame Number: ＊ The frame serial number is engraved on lower front right side of the frame, which is under the front differential box. VIN Plate ＊ The VIN (Vehicle Identification Number) is attached to the lower front right side of frame behind the radiator.
  • Page 6 Ch. 1 GENERAL INFORMATION Symbols and Marks ………………………1-1 Specifications …………………………..1-9 General Safety ……………………………...1-2 Locking Torque ………………………..1-10 Attention on operation ...………………….1-4 Troubles Diagnosis …………………...1-12 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed.
  • Page 7 Ch. 1 GENERAL INFORMATION General Safety Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Gasoline is highly flammable, and may explode under some conditions, keep it away from children.
  • Page 8 Ch. 1 GENERAL INFORMATION Used engine oil Caution Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.
  • Page 9 Ch. 1 GENERAL INFORMATION Attention on Operation  All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item when dismounted.  Locking of all screws, nuts, cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks.
  • Page 10 Ch. 1 GENERAL INFORMATION Attention on Operation  Certified lubricants in cans shall be used on all the elements to be lubricated.  After assembly, performance of all elements shall be duly checked and the locking shall be duly verified. ...
  • Page 11 Ch. 1 GENERAL INFORMATION  Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.  The tool should be pressed against two (inner and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race).
  • Page 12 Ch. 1 GENERAL INFORMATION  When separating a connector, it locker has to Insert the terminal completely, unlocked it first. Then, conduct the service Check if the terminal is covered by the boot. Do not let boot open facing up. ...
  • Page 13 Ch. 1 GENERAL INFORMATION  Definition of signs: The sign given in the Service Manual shall refer to the operation methods and observation. OIL: Lubrication by designated lubricant. GREASE: Lubrication by grease Special Tool: Parts on which special tools shall be used General Tool: General tools shall be used New: Replace by new items after dismounting Attention...
  • Page 14 Ch. 1 GENERAL INFORMATION Specifications MODEL ATV-600 OVERALL 2150 mm GEARS L / H / N / R / P LENGTH OVERALL 1280 mm FRONT DRIVE 4x4 with Differential Lock WIDTH OVERALL 1250 mm REAR DRIVE Shaft drive HEIGHT 3.0L...
  • Page 15 Ch. 1 GENERAL INFORMATION Locking Torque The standard locking torque shall apply in case of no specification. Standard Torque： Type Torque (kg-m) Type Torque (kg-m) 5 mm bolt, nut 0.45~0.6 5 mm screw 0.35~0.5 6 mm bolt, nut 0.8~1.2 6 mm screw, SH nut 0.7~ 1.1 8 mm bolt, nut 1.8~2.5...
  • Page 16 Ch. 1 GENERAL INFORMATION Chassis： Locking Position Dia. (mm) Torque (kg-m) Remark Handlebar upper holder bolt Steering shaft bottom nut Ball joint fixed nut Steering shaft holder bolt Front axle lock nut Rear axle lock nut Engine hanger nut Drive gear bolt Driven gear nut Front / Rear suspension arm bolt Front / Rear suspension arm nut...
  • Page 17 Ch. 1 GENERAL INFORMATION 1-12...
  • Page 18 Ch. 1 GENERAL INFORMATION 1-13...
  • Page 19 Ch. 1 GENERAL INFORMATION 1-14...
  • Page 20 Ch. 1 GENERAL INFORMATION 1-15...
  • Page 21 Ch. 1 GENERAL INFORMATION 1-16...

  • Page 22: Maintenance Information

    Ch. 2 MAINTENANCE INFORMATION Periodical Maintenance Schedule Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your ATV checked, adjusted, and recorded maintenance data periodically by your ADLY 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 23: Fuel Lines

    Ch. 2 MAINTENANCE INFORMATION Fuel Lines Remove the seat. Loosen 2 screws and 2 bolts Remove the tank cover. Check all lines, and replace the lines when they are deteriorated, damaged or leaking. Warning  Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

  • Page 24: Spark Plug

    Ch. 2 MAINTENANCE INFORMATION Spark Plug Recommended spark plug: CR8E Remove the spark plug cap. Clean the dirt around the spark plug hole. Remove the spark plug. Measure the spark plug gap. Spark plug gap: 0.8~0.9 mm Carefully bend ground electrode of the plug to adjust the gap if necessary.
  • Page 25 Ch. 2 MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Caution  Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted.  Idle speed check and adjustment have to be done after engine being warmed up.
  • Page 26 Ch. 2 MAINTENANCE INFORMATION Ignition System Caution  Full transistor ignition system is setup by the manufacturer so it cannot be adjusted.  Ignition timing check procedure is for checking whether ignition function is in normal or not. Connect tachometer and ignition light. Start engine.

  • Page 27: Drive Belt

    Ch. 2 MAINTENANCE INFORMATION Drive Belt Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover ventilation pipe. Remove 17 bolts. Remove the left crankcase cover. Check if the belt is cracked or worn out. Replace the belt if necessary or in accordance with the periodical maintenance schedule to replace it.

  • Page 28: Front Differential

    Ch. 2 MAINTENANCE INFORMATION Front Differential Check the front differential for abnormal noise or unsmooth rotation. Caution * Do not attempt to disassemble the Front Differential. * Please exchange the whole assembly if necessary. Gear oil drain bolt Oil Exchange and Refill ...

  • Page 29: Brake System

    Ch. 2 MAINTENANCE INFORMATION Brake System Brake System Hose Check the brake hoses for corrosion or oil leaking. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found.

  • Page 30: Brake Light Switch

    Ch. 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 31 Ch. 2 MAINTENANCE INFORMATION Headlight Beam Distance Turn on main switch. Turn the headlight adjusting screw to adjust headlight beam height. Caution * To adjust the headlight beam follows related regulations. * Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting. Adjust Bolts Clutch Weight Run the ATV and increase throttle valve opening...
  • Page 32 Ch. 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 off 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 33 Ch. 2 MAINTENANCE INFORMATION Special Tool List NAME Rocker arm pin puller NAME Tappet adjusting wrench NAME Tappet adjusting wrench SYM-1445100 SYM-9001200 SYM-1472100 Valve cotter remove & AC.G. Flywheel puller NAME Tappet adjuster NAME NAME assembly tool SYM-2301000-HMA SYM-1471110/20 SYM-3110000-HMA NAME BEVEL GEAR Houshing NAME...
  • Page 34 Ch. 2 MAINTENANCE INFORMATION NAME Driveshaft BRG. 6328 NAME OUTPUT SHAFT OIL NAME OUTPUT SHAFT OIL driver SEAL 42*52*7 SEAL 38*52*7 SYM-9100500-REA A6328 SYM-9120900-REA SYM-9120800-REA NAME Water pump oil seal driver NAME WATER PUMP BRG. NAME Water pump mechanical 6001 driver seal driver SYM-9120200-REA SYM-6001300-REA...

  • Page 35: Lubrication System

    Ch. 3 LUBRICATION SYSTEM Mechanism Diagram......3-1 Engine Oil Strainer Clean......3-4 Precautions in Operation......3-3 Oil Filter Unit .........3-5 Troubleshooting ........3-3 Oil Pump..........3-6 Engine Oil..........3-4 Mechanism Diagram...
  • Page 36 Ch. 3 LUBRICATION SYSTEM...
  • Page 37 Ch. 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 capacity Dis-assembly: 3000 c.c. Replacement: 2400 c.c. Replacement with oil filter replaced: 2700 c.c. Oil viscosity SAE10W-30 (Recommend JASO MA Grade engine oil) Gear Box Oil...

  • Page 38: Engine Oil

    Ch. 3 LUBRICATION SYSTEM Engine Oil Turn off engine，and park the ATV in flat surface. Check oil level with oil dipstick. Do not screw the dipstick into engine as checking. If oil level is nearly low level，fill out recommended oil to upper level Oil change caution ...
  • Page 39 Ch. 3 LUBRICATION SYSTEM Oil Filter Unit Remove the oil filter unit with special tool. Install the oil filter unit by hand. Apply some grease around the O-ring thread area to ensure the sealing. Lock the oil filter unit with special tool. Torque value 1.3-1.7 kgf-m...

  • Page 40: Oil Pump

    Ch. 3 LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove the recoil starter and the AC Generator. Remove the cir clip and take out the oil pump sprocket. Make sure that pump shaft can be rotated freely. Remove 3 screws on the oil pump，and then remove the oil pump.

  • Page 41: Oil Pump Inspection

    Ch. 3 LUBRICATION SYSTEM Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover. Remove the oil pump shaft roller and shaft. Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors.
  • Page 42 Ch. 3 LUBRICATION SYSTEM Tighten the oil pump screw. Oil Pump Installation Install the oil pump and then tighten screws. Torque value 0.1-0.3kgf-m Make sure that oil pump shaft can be rotated freely. Install the oil pump sprocket and then install cir clip onto oil pump shaft.
  • Page 43 Ch. 3 LUBRICATION SYSTEM Notes:...

  • Page 44: Fuel System

    Ch. 4 FUEL SYSTEM Mechanism Diagram......4-1 Vacuum Chamber........4-6 Precautions in Operation...... 4-2 Float Chamber........4-7 Trouble Diagnosis......... 4-3 Adjustment of idle Speed...... 4-9 Carburetor Removal / Installation…..4-4 Fuel Tank..........4-10 Air Cut-off Valve........4-5 Air Cleaner..........4-11 Mechanism Diagram Fuel Strainer...
  • Page 45  re-assembly There is a drain screw in the float chamber for draining residual gasoline.  Do not disassemble air cut valve arbitrarily.  Specification Item ATV-600 Carburetor diameter 36 mm I.D. number AM4A Fuel level 17 mm Main injector...
  • Page 46 Ch. 4 FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean   No fuel in fuel tank Clogged fuel injector   Clogged fuel tube Vacuum piston stick and closed   Too much fuel in cylinder Malfunction of float valve ...
  • Page 47 Ch. 4 FUEL SYSTEM Carburetor Removal / Installation Removal Remove the fuel tank. Turn the fuel valve lever to OFF position. Remove 1 screw from throttle lever cap then remove throttle lever cap. Loosen throttle cable adjustment nut and remove throttle cable Remove the idle adjustment wire.
  • Page 48 Ch. 4 FUEL SYSTEM Air Cut-Off Valve Disassembly Remove 2 screws. Remove air cut-off valve cover spring and valve. 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 49 Ch. 4 FUEL SYSTEM Vacuum Chamber Disassembly Removal Loosen drain screw and drain out residual fuel in float chamber. Remove screws (4 screws) of vacuum chamber cover and the cover. Remove compress spring and vacuum piston. Remove fuel needle seat spring and injector needle.

  • Page 50: Float Chamber

    Ch. 4 FUEL SYSTEM Float Chamber Disassembly Remove 4 mounting screws and remove float chamber cover. Remove the float pin float and float valve. Inspection Check the float valve and valve seat for damager blocking. Check float valve for wearing and check valve seat face for wear dirt.
  • Page 51 Ch. 4 FUEL SYSTEM Remove main jet needle jet holder needle jet slow jet and air adjustment screw. Caution  Be careful not to damage jets and adjust screw.  Before removing air adjustment screw, turn it all the way down and note the number of turns.
  • Page 52 Ch. 4 FUEL SYSTEM Adjustment of Idle Speed Caution  Air screw was set at factory so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation.  The parking brake is located on the right hand lever and must be used to stop the ATV to perform the adjustments.

  • Page 53: Fuel Tank

    Ch. 4 FUEL SYSTEM Fuel Tank Ground wire Fuel tank removal Open the seat. Remove the front cover and front top center cover. Remove the side covers and lower side covers. Remove the front fender. Remove fuel gauge wire and ground wire from tank.

  • Page 54: Air Cleaner

    Ch. 4 FUEL SYSTEM Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor and then remove the vapor hose. Loosen the clamp strip of air cleaner and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts). Installation Install the tank in the reverse order of removal.
  • Page 55 Ch. 4 FUEL SYSTEM Remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry. Caution * Never use gasoline or acid organized solvent to clean the element. Filter element Soap the element into cleaning engine oil and then squeeze it out.
  • Page 56 Ch. 4 FUEL SYSTEM Notes : 4-13...

  • Page 57: Engine Removal

    Ch. 5 ENGINE REMOVAL Precautions in Operation……………… 5-1 Engine Installation………….………….. 5-6 Engine Removal………………….…..5-2 Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable.  The following parts can be serviced as engine being mounted on frame: ...

  • Page 58: Engine Removal

    Ch. 5 ENGINE REMOVAL Engine Removal Remove the seat. Remove the battery negative terminal (-). Remove the battery positive (+) terminal. Remove front fender and the footrest (refer chapter 13). Remove the starter motor wire. Remove the spark plug cap. Disconnect A.
  • Page 59 Ch. 5 ENGINE REMOVAL Remove the front left and rear left tires. Remove the idle speed adjustment nut. Remove 2 bolts on the muffler. Remove the muffler. Idle speed adjust screw Remove the throttle cable. Remove 2 nuts and 1 bolt. Remove the exhaust pipe.
  • Page 60 Ch. 5 ENGINE REMOVAL Remove 2 manifold clamps. Remove the carburetor. Remove 4 bolts. Remove the air cleaner. Remove 1 bolt under the seat and 1 bolt on top of left CVT cover. Loose the fix bolt for muffler joint which is located on top of left CVT cover.
  • Page 61 Ch. 5 ENGINE REMOVAL Remove the coolant drain bolt and drain out coolant. Remove the coolant inlet pipe from the water pump cover and the outlet pipe from the thermostat cover. Remove the PCV pipe. Remove 2 bolts. Remove the starter motor. Remove 3 bolts on the front propeller shaft connector.

  • Page 62: Engine Installation

    Ch. 5 ENGINE REMOVAL Remove the foot brake pedal. Remove the coolant reserve tank. Remove the front and rear side engine hanger mounting nuts and bolts. Remove left side engine hanger ， and then remove engine from left side. Engine Installation Check the bush of engine hanger parts for any damage.
  • Page 63 Ch. 5 ENGINE REMOVAL NOTE:...
  • Page 64 Ch. 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 Troubleshooting ........6-3 Cylinder Head Reassembly....6-13 Cylinder Head Removal......6-4 Cylinder Head Installation....6-14 Cylinder Head Inspection......6-7 Valve Clearance Adjustment....6-16 Mechanism Diagram...
  • Page 65 Ch. 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 66 Ch. 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. Valve ...

  • Page 67: Cylinder Head Removal

    Ch. 6 CYLINDER HEAD & VALVE Cylinder Head Removal Remove the engine from the frame. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 2 thermostat bolts and then remove the thermostat. Remove the bolt and spring of the cam chain tensioner.
  • Page 68 Ch. 6 CYLINDER HEAD & VALVE Remove the side cover mounting blots of cylinder head，and then remove the side cover. Remove left crankcase cover and turn the drive face. Align the timing mark on the cam sprocket with that of cylinder head to make the piston at TDC position.
  • Page 69 Ch. 6 CYLINDER HEAD & VALVE Remove the 2 cylinder head mounting bolts from cylinder head right side and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. Remove cylinder head gasket and 2 dowel pins. Remove chain guide.

  • Page 70: Cylinder Head Inspection

    Ch. 6 CYLINDER HEAD & VALVE Remove the valve stem seals. Clean carbon deposits in the 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 71: Valve Spring Free Length

    Ch. 6 CYLINDER HEAD & VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged Service Limit: Replace if more than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.

  • Page 72: Valve Guide

    Ch. 6 CYLINDER HEAD & VALVE Valve guide Caution Before measuring the valve guide，clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
  • Page 73 Ch. 6 CYLINDER HEAD & VALVE Valve Stem Replacement Heat up cylinder head to 100-150 ℃ with heated plate. Caution  Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. Wear on a pair of glove to protect your hands when operating.
  • Page 74 Ch. 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 75 Ch. 6 CYLINDER HEAD & VALVE Use 60∘cutter to cut the quarter lower parts out. Remove the cutter and check the new valve seat. Use 45∘cutter to grind the valve seat to specified width. Caution  Make sure that all roughness and uneven faces had been ground.

  • Page 76: Cylinder Head Reassembly

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

  • Page 77: Cylinder Head Installation

    Ch. 6 CYLINDER HEAD & VALVE Cylinder Head Installation 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 ...
  • Page 78 Ch. 6 CYLINDER HEAD & VALVE Install cam chain on to sprocket and align the timing mark on the sprocket with the two sprocket bolt holes and the lower bolt hole of the cylinder side cover. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts.

  • Page 79: Valve Clearance Adjustment

    Ch. 6 CYLINDER HEAD & VALVE Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder 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...
  • Page 80 Ch. 6 CYLINDER HEAD & VALVE Notes: 6-17...
  • Page 81 Ch. 7 PISTON & CYLINDER Mechanism Diagram......7-1 Piston Ring Installation......7-6 Precautions in Operation......7-2 Piston Installation........7-7 Trouble Diagnosis.........7-2 Cylinder Installation......7-7 Cylinder and Piston Removal…….…...7-3 Mechanism Diagram...
  • Page 82 Ch. 7 PISTON & CYLINDER Precautions in Operation General Information  Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Item Standard Limit 92.00 92.100 Cylinder Bend 0.050 Clearance between piston Top ring 0.015-0.050 0.090 rings 0.015-0.050...
  • Page 83 Ch. 7 PISTON & CYLINDER Cylinder and Piston Removal Remove the cylinder head (refer to chapter 6). Remove the coolant hose from cylinder. Remove the cylinder Cover the holes of crankcase and cam chain with a piece of cloth to prevent foreign material falling into the crankcase.
  • Page 84 Ch. 7 PISTON & CYLINDER Check cylinder if warp. Service limit: 0 05 mm Measure the 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 85 Ch. 7 PISTON & CYLINDER Measure the outer diameter of piston pin. Service Limit: 16 .96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit:17 02 mm Calculate clearance between piston pin and its hole.

  • Page 86: Cylinder/Piston

    Ch. 7 PISTON & CYLINDER 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 87: Piston Installation

    Ch. 7 PISTON & CYLINDER Clean up all residues and foreign materials on the contact surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution  Wet the residues into solvent so that the residues can be removed more easily.

  • Page 88: Cylinder Installation

    Ch. 7 PISTON & CYLINDER Cylinder Installation Install dowel pins and new gasket 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.
  • Page 89 Ch. 7 PISTON & CYLINDER Notes:...
  • Page 90 Ch. 8 V-BELT DRIVING SYSTEM Mechanism Diagram........ 8-1 Drive Belt..........8-3 Maintenance Description......8-2 Drive Plate..........8-4 Trouble Diagnosis........8-2 Movable Drive Face Disassembly..8-6 Left Crankcase Cover.......8-3 Driven Pulley Disassembly.....8-13 Mechanism Diagram...
  • Page 91 Ch. 8 V-BELT DRIVING SYSTEM Maintenance Description Precautions in Operation General Information  Drive face clutch outer and driven pulley can be serviced on the vehicle. ， ，  Drive belt and drive pulley must be free of any grease. Specification Item Standard value...

  • Page 92: Left Crankcase Cover

    Ch. 8 V-BELT DRIVING SYSTEM Left Crankcase Cover Left crankcase cover removal Release 2 clamp strips of left crankcase cover ducts and then remove the ducts. ， Remove left crankcase cover cap. Remove left crankcase cover bolts (17bolts). Remove 2 dowel pin and gasket Left crankcase cover installation Install left crankcase cover in the reverse procedure of removal.
  • Page 93 Ch. 8 V-BELT DRIVING SYSTEM Loosen 1nut from the driven pulley with Special tool. Tool name: Universal holder Tool NO: SYM-2210100 Remove the drive pulley and belt. Inspection Check the drive belt for crack or wear. Replace it if necessary. Measure the width of drive belt as diagram shown.
  • Page 94 Ch. 8 V-BELT DRIVING SYSTEM Loosen 10 bolts from the clutch cover. Remove the clutch cover. Remove the clutch outer. One-way Clutch Inspection Check each roller for wear or damage. Hold the clutch outer and turning the one way clutch for right side.
  • Page 95 Ch. 8 V-BELT DRIVING SYSTEM Movable Drive Face Disassembly Loosen 4 bolts form the drive face. Remove the drive face plate Remove the drive face plate Remove the ramp plate and weight roller (8pcs). Inspection The weight rollers are to press movable drive face by means of centrifuge force.
  • Page 96 Ch. 8 V-BELT DRIVING SYSTEM Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face boss, and replace it if it exceed service limit. Service limit: 35.950 mm Measure the inner diameter of movable drive face, and replace it if it exceed service limit.
  • Page 97 Ch. 8 V-BELT DRIVING SYSTEM Left crankcase cover inspection Remove cir clip with inner cir clip pliers Check bearing on left crankcase 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.
  • Page 98 Ch. 8 V-BELT DRIVING SYSTEM Bearing installation Install the bearing 6302 with special tool Tool name: L COVER FR BRG. 6302 bearing IN. puller with air Tool NO. : SYM-9615000-REA A6302 Put the caller and nut. Install the bearing with air or head tool.
  • Page 99 Ch. 8 V-BELT DRIVING SYSTEM Make sure the bearing code and put the bearing. Install the bearing 6006 with special tool Tool name: L COVER FR BRG. 6006 bearing driver Tool NO. : SYM-9615010-REA 6006 Knock the bearing to the objected position. Install the cir clip.
  • Page 100 Ch. 8 V-BELT DRIVING SYSTEM Drive plate Disassembly Remove 5 E-ring from drive plate. Remove the spring plate and centrifugal clutch plate. Remove 5 springs from the drive plate Check if spring is damaged or insufficient elasticity. Remove 5 clutch weights. Check if spring is damaged or insufficient elasticity.
  • Page 101 Ch. 8 V-BELT DRIVING SYSTEM Service limit: 3.0 mm Apply grease onto setting pins. Install the spring into groove with pliers. Install new clutch weight onto setting pin and then push to the specified location. Apply with grease onto setting pins. Caution ...
  • Page 102 Ch. 8 V-BELT DRIVING SYSTEM plate. Install 5 e-ring in the drive plate. Driven Pulley Disassembly Disassemble the driven pulley with special tool. Apply special tool compressor onto the pulley 8-13...
  • Page 103 Ch. 8 V-BELT DRIVING SYSTEM Remove cir clip with pliers. Loosen the special tools nut Remove the driven pulley collar and 4 roller guides. Remove the movable driven face. 8-14...
  • Page 104 Ch. 8 V-BELT DRIVING SYSTEM Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 119.5 mm Driven pulley Check following items:  If both surfaces are damaged or worn.  If guide pin groove is damaged or worn. Replace damaged or worn components.
  • Page 105 Ch. 8 V-BELT DRIVING SYSTEM Installation Use the driven face assy. expander to expand the driven face assy. Put the drive belt into the driven face assy. and hold it tight by hand. Special Tool Tool number: SYM-2321000-REA Tool name: Driven Face Assy. Expander Put the driven face assy.

  • Page 106: Transmission

    Ch. 9 TRANSMISSION Mechanism Diagram.........9-1 Transmission Inspection....9-6 Precautions in operation......9-2 Bearing Replacement......9-8 Trouble Diagnosis........9-2 Transmission Reassembly....9-11 Transmission Disassembly.....9-3 Mechanism Diagram...
  • Page 107 Ch. 9 TRANSMISSION Precautions in Operation Specification Item Standard value Limit(mm) OD of shift fork shaft 13.984-14.000 mm 13.966 mm ID of shift fork 14.000-14.016 mm 14.034 mm Shift fork claw thickness 5.930-6.000 mm 5.730 mm Torque value Gear oil drain bolt 1.1-1.5kgf-m Gear oil fill bolt 3.5-4.5kgf-m...

  • Page 108: Transmission Disassembly

    Ch. 9 TRANSMISSION Transmission Disassembly Remove gear change lever (2 bolts). Remove the gear change lever. Remove 2 c clips from brake pedal. Remove brake spring & stop switch spring Remove brake penal. Remove the front and rear propeller shaft. Remove the engine from the frame before performing the transmission disassembly.
  • Page 109 Ch. 9 TRANSMISSION Remove the front and rear output shaft covers. Remove 13 bolts from the right crankcase. Remove the right crankcase from the left crankcase. Remove the counter shaft, shift fork and the shift drum.
  • Page 110 Ch. 9 TRANSMISSION Remove the drive shaft bearing setting plate (1 bolt). Remove the drive shaft. Remove the output shaft. Caution  Do not remove the drive shaft from the crankcase if unnecessary.  When removing the drive shaft from the crankcase，then the bearing has to be replaced.
  • Page 111 Ch. 9 TRANSMISSION Transmission Inspection Check the shift spindle for any wear or damage. Check if the shift drum is worn or damaged. Check if the shift fork and shaft is worn or damaged. Measure the outer diameter of shift fork shaft. Replace it if it exceed service limit.
  • Page 112 Ch. 9 TRANSMISSION Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn wear ， or damage. Check bearings on the left and right crankcase. Rotate each bearing’s inner ring by fingers. Check if the bearings can be rotated smoothly and silently and also check if the bearing outer ring is mounted on gear tightly.

  • Page 113: Bearing Replacement

    Ch. 9 TRANSMISSION Bearing Replacement Caution  Never install used bearings. Once bearing removed it has to be replaced with new one. ， Left crankcase side Remove the drive shaft and bearing from the left crankcase. Remove the drive shaft bearing from the shaft by outer bearing puller.
  • Page 114 Ch. 9 TRANSMISSION Install the park gear cir-clip by using cir-clip installer. Special tool: Tool number SYM-9060200-R EA Tool name Park gear cir-clip installer Right crankcase side Remove the final shaft bearing on the right crankcase with inner bearing puller. Special tool: Tool number SYM –...
  • Page 115 Ch. 9 TRANSMISSION Install the final shaft bearing with the bearing driver. Special tool: Tool number SYM-2343110-REA 6307 Tool name Final shaft bearing driver Install the counter shaft bearing with the bearing driver. Install the drive shaft needle bearing with the bearing driver.
  • Page 116 Ch. 9 TRANSMISSION Transmission Reassembly Install the reverse shaft onto the left crankcase. Install the counter shaft and gearshift fork. Install the shift drum. Rotate the shift drum and make sure it can rotate smoothly. Install the final shaft onto the right crankcase. Put the same numbers of shim，...
  • Page 117 Ch. 9 TRANSMISSION Install the bevel gear housing Put the same numbers of shim which were ， removed during removal on the bevel gear ， housing. Install the bevel gear. Lock the nut by using final shaft stopper. Special tool: Tool number SYM-2343100-REA Tool name: Final shaft stopper.
  • Page 118 Ch. 9 TRANSMISSION Install the change lever arm. Keep the level mark on the change lever arm horizontal. 9-13...
  • Page 119 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Mechanism Diagram........10-1 Wheel Drive Shaft Inspection....10-7 Trouble Diagnosis........10-2 Repair Pack........... 10-8 Wheel Drive Shaft Removal....... 10-3 Wheel Drive Shaft Assembly..... 10-10 Wheel Drive Shaft Disassembly....10-4 Front and Rear Drive Shaft....10-14 Mechanism Diagram Rear propeller shaft Rear axle gearbox...
  • Page 120 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Trouble Diagnosis Engine can be started but vehicle cannot move.  Damaged wheel driveshaft  Damaged propeller shaft  Damaged front differential or rear axle gearbox Noise  Worn or burnt driveshaft  Worn or burnt steel ball ...
  • Page 121 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Wheel Drive Shaft Removal Front wheel drive shaft removal Remove the front wheel. Remove the front brake caliper and disk. Remove the tie-rod. Remove the knuckle body. Remove the wheel drive shaft with special tool. Rear wheel drive shaft removal Remove the rear wheel.
  • Page 122 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Wheel Drive Shaft Disassembly Universal Joint disassembly Open the boot band clip with scrapper. Remove the rubber boot bands. Remove the UJ rubber boot. Disassemble the wheel drive shaft UJ assembly with rubber hammer & special tool. Tools name: Wheel driveshaft assembly seat Tools number: SYM-4423000-REA Caution...
  • Page 123 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Remove 6 steel balls from UJ assembly outer race. Tools name：Wheel drive shaft assembly seat. Tools number：SYM-4423500-REA Remove the inner race and cage from the outer race. Clean the inner race，outer race，steel balls and cage.
  • Page 124 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Remove the inner cir-clip with screw drive. Disassemble DOJ assembly. Clean the DOJ assembly. Remove the cir-clip from the drive shaft. Remove the steel balls from cage. 10-6...
  • Page 125 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Wheel Drive Shaft Inspection Clean all spare parts. Check the surface of these parts for wear or scratch. Replace DOJ or UJ assembly if any stepped scratch is found. Check the inside surface of UJ outer race. Replace UJ assembly if it is damaged.
  • Page 126 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Repair Pack Check if DOJ & UJ boot is damaged Replace DOJ or UJ assembly if it is damaged. Remove the DOJ & UJ boot. Remove the DOJ & UJ cage. Remove the DOJ & UJ boot. 10-8...
  • Page 127 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Disassemble and clean all spare parts. Check if there is any corrosion on the surface of these parts. Replace DOJ or UJ assembly if any damaged part is found. Clean the DOJ & UJ cage. Unpack DOJ Repair Pack.
  • Page 128 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Wheel Drive Shaft Assembly DOJ assembly Assemble the DOJ boot. Assemble 6 steel balls, inner race and cage then drive shaft into the assembly. Assemble exit cir-clip onto drive shaft. Grease into the DOJ outer race. Caution ...
  • Page 129 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Install the wheel drive shaft and cir-clip into DOJ outer race. Install DOJ boot outside band. Install DOJ boot. Pull and open DOJ boot Pressure balancing that make it inside and external. Deduct DOJ band closely with rubber hammer. 10-11...
  • Page 130 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT UJ assembly Assemble universal joint and UJ boot and Pour into the grease. Pour grease into the UJ boot inside. Caution  Please use the grease of the repair pack. Using other oil may cause the part to be damaged.
  • Page 131 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Install UJ boot. Pull and open DOJ boot to balance the inside and outside pressure. Install band with rubber hammer. 10-13...
  • Page 132 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Front and Rear Drive Shaft Rubber Boot Front Drive Shaft Remove Loosen 3 bolts from the front drive shaft connector. Push the rubber boot on the drive shaft to engine and loose it. Pull the shaft connector to front and then remove the drive shaft.
  • Page 133 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Remove the rear side exit cir-clip. Remove propeller shaft and rubber boots. Drive shaft inspection Check if the spur gear has is damaged or not. Please replace new parts if it has split or damaged.
  • Page 134 Ch. 10 WHEEL DRIVE SHAFT/PROPELLER SHAFT Check if the propeller shaft rubber boot is damaged or not. Propeller shaft installation Install in the reverse order of removal procedures. 10-16...
  • Page 135 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Mechanism Diagram......11-1 Recoil Starter Cover Removal....11-5 Precautions in Operation....11-2 One Way Clutch Installation....11-7 Right Crankcase Cover Removal….. 11-3 Flywheel Installation......11-8 A.C. Generator Removal....11-3 A.C. Generator Installation....11-9 Flywheel Removal......11-4 Right Crankcase Cover Installation ..11-9 One Way Clutch Removal....
  • Page 136 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Precautions in Operation General information • Refertochapter18: The troubleshooting and inspection of alternator • Refertochapter18: The service procedures and precaution items of starter motor Item Standard value(mm) Limit(mm) ID of starting clutch gear 27.026-27.045 27.050 OD of starting clutch gear 45.192-45.283 45.183 Specification...
  • Page 137 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Right Crankcase Cover Removal Remove the left footrest. Drain the engine oil and coolant，and then remove coolant hoses. Remove 5 bolts from the recoil starter cover. Remove the recoil starter cover and gasket. Remove the water pump cover (5 bolts ) A.C.
  • Page 138 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Flywheel Removal Remove the A. C. Generator flywheel with special tool. Tool name: A. C. G. flywheel puller Tool number: SYM-3110000-HMA Starting Clutch Gear Inspection Remove the starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear.
  • Page 139 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Check each roller for wear or damage. Install the starting clutch driven gear onto one way clutch. Hold the flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely，but not C.W direction. Recoil Starter Cover Removal Loosen bolt on the ratchet cover then remove ratchet cover.
  • Page 140 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Remove the 2 springs from the ratchet cover. Do not remove the volute spring from the recoil starter cover unless the spring is broken. If the volute spring is removed from the recoil starter cover, it should be replaced with a new one. Remove the starter grip rubber.
  • Page 141 Ch. 11 A.C.GENERATOR/STARTING CLUTCH One Way Clutch Installation Install the components in the reverse Procedures of removal. Caution  Tape a tightening tape onto the thread of hexagon bolt. Torque value： 1.0~1.4 kg-m Install the starting driven gear. 11-7...
  • Page 142 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Flywheel Installation Install the reduction gear shaft and reduction gear. Assemble the starting driven gear of the flywheel. Align the key on crankshaft with the flywheel groove， and then install the flywheel. Install the flywheel onto crank shaft. 11-8...
  • Page 143 Ch. 11 A.C.GENERATOR/STARTING CLUTCH A.C. Generator Installation Install the A.C. Generator stator set onto right crankcase cover (3 screws). Install the pulse generator (2 screws). Tie the wire harness securely onto the in dent of crankcase. Caution  Make sure that the wire harness is placed under pulse generator.
  • Page 144 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Install the water pump cover (5 bolts) Assemble the gasket. Assemble the starter cover on the right crankcase cover. 11-10...
  • Page 145 Ch. 11 A.C.GENERATOR/STARTING CLUTCH Note： 11-11...

  • Page 146: Crankcase / Crankshaft

    Ch. 12 CRANKCASE/CRANKSHAFT Mechanism Diagram......12-1 Crankcase Disassembly.....12-3 General Information.......12-2 Crankshaft Inspection......12-5 Trouble Diagnosis.........12-2 Crankcase Assembly......12-6 Mechanism Diagram 12-1...
  • Page 147 Ch. 12 CRANKCASE/CRANKSHAFT General Information Operational precautions  This Section concerns disassembly of the crankcase for repair purpose.  Remove following components before disassembling crankcase. －Engine remove Section 5 －Cylinder head Section 6 －Cylinder and piston Section 7 －Drive face and driven pulley Section 8 －AC generator/Start one way clutch Section 10...

  • Page 148: Crankcase Disassembly

    Ch. 12 CRANKCASE/CRANKSHAFT Crankcase Disassembly Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the cam chain tensioner. Loosen 2 bolts on the left crankcase. Loosen 13 bolts on the right crankcase. Place left crankcase downward and right crankcase up.
  • Page 149 Ch. 12 CRANKCASE/CRANKSHAFT Remove balance shaft from left crankcase. Remove crankshaft from left crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution  Do not damage the contact face of the gasket. It is better to moisten the gasket residue for easy scrapping.

  • Page 150: Crankshaft Inspection

    Ch. 12 CRANKCASE/CRANKSHAFT Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm Place the crankshaft on a V-block, measure run-out of the crankshaft.

  • Page 151: Crankcase Assembly

    Ch. 12 CRANKCASE/CRANKSHAFT Check balance Shaft bearing Check bearings on right and left crankcase. Rotate each bearings inner ring with fingers. Check if bearings can be turned in smooth and silent，and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven，noising，or loose bearing mounted，then replace it.
  • Page 152 Ch. 12 CRANKCASE/CRANKSHAFT Install 2 dowel pins and new gasket. Install the left crankcase onto the right crankcase. Tighten 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m 12-7...
  • Page 153 Ch. 12 CRANKCASE/CRANKSHAFT Clean the crankshaft. Apply a layer of grease on the lip of oil seal ， Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. By oil seal driver (27x42x7) ，...

  • Page 154: Cooling System

    Ch. 13 COOLING SYSTEM General Information........13-1 Radiator ………………......13-6 Trouble Diagnosis……......13-2 Water Pump ………….......13-8 System Test ……........13-5 Thermostat …………......13-9 General Information Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.
  • Page 155 Ch. 13 COOLING SYSTEM Trouble Diagnosis The engine temperature is too high The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to close. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The radiator filler cap of the radiator malfunction.
  • Page 156 Ch. 13 COOLING SYSTEM Trouble Diagnosis The temperature indicated is too high A. Stop and waiting for the engine is completely A1.Refill the radiator with cooled down, open cap Water leaking problem coolant then check for Water leaking problem to check the capacity of any leakage? coolant in radiator.
  • Page 157 Ch. 13 COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 E-1.Measure thermal switch Replace thermal switch rpm and inspect cooling to confirm voltage be fan was operating after changed (12→0V)? the temperature gauge over 3 checks? E-2.Connect cooling fan F. Confirm the cooling fan terminals with battery Replace cooling fan was convulsion?

  • Page 158: System Test

    Ch. 13 COOLING SYSTEM System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low.
  • Page 159 Ch. 13 COOLING SYSTEM Remove the front center cover, and then remove UPPER reserve tank filler cap. Check the liquid level in the front fender right side. Add coolant to proper level if too low. Reinstall the reserve tank filler cap. Caution ...
  • Page 160 Ch. 13 COOLING SYSTEM Loosen the radiator 4 bolts. Remove coolant upper side pipes. Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. collant outlet pipe Disassembly Loosen the 4 bolts from the fan duct, and then remove the fan duct.

  • Page 161: Water Pump

    Ch. 13 COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection Disassembles the refrigerant drain bolt, overflows little buckles the actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 162 Ch. 13 COOLING SYSTEM Thermostat Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.
  • Page 163 Ch. 13 COOLING SYSTEM NOTES: 13-10...

  • Page 164: Body Cover

    Ch. 14 BODY COVER Mechanism Diagram......14-1 Footrest cover ….….……..….……. 14-6 Maintenance ………………....14.2 Front cover ……..…………..…….. 14-7 Meter cover ……………………………... 14-3 Head light cover…………….………. 14-7 Maintenance cover/Fuel tank cover… 14-4 Rear cover …………………...………..14.8 R/L side cover …………………..…. 14-5 Tail light cover……………….…..….. 14-9 Mechanism Diagram 14-1...

  • Page 165: Fuel Tank Cover

    Ch. 14 BODY COVER Maintenance Disassemble sequence: R/L footrest Seat Front cover Meter cover Head light cover Maintenance cover Rear cover Fuel tank cover Tail light cover R/L side cover Be careful not to damage various covers in assembly or disassembly operation. Never injure hooks molded on the body covers.
  • Page 166 Ch. 14 BODY COVER Meter cover Remove Remove2 screws from meter cover, and then remove meter cove. Loosen 3 nuts from meter stay. Remove couplers of meter. Installation Install in reverse order of removal procedures 14-3...
  • Page 167 Ch. 14 BODY COVER Maintenance cover Remove Loosen 2 screws from the front cover. Remove maintenance cover. Installation Install in reverse order of removal procedure Fuel tank cover Remove Remove seat. Loosen2 screws, and then remove fuel tank cover. Installation Install in reverse order of removal procedures 14-4...
  • Page 168 Ch. 14 BODY COVER R/L side cover 1 Bolt Remove Loosen the 1 bolt, and then remove fuel valve cap. Loosen 6 bolts on left side cover, and then remove side cover. Right side cover removal procedure is similar to the left side cover.
  • Page 169 Ch. 14 BODY COVER Footrest cover Remove Loosen the 5 bolts, which connect the footrest, these 5 bolts just between footrests. 5 bolts Loosen 5 bolts connect with front cover both side, also loosen 5 bolts connect with rear cover both side, and then remove footrest cover.
  • Page 170 Ch. 14 BODY COVER Front Cover Remove Remove the seat. Remove maintenance cover, and then loosen 2 bolts of fuel tank cover. Loosen 4 screws which connect to head light cover. 2 Screws Remove 2 bolts and take off shift lever. 2 Bolts Loosen the 2 bolts, which connect the front cover right and left side, then remove front...
  • Page 171 Ch. 14 BODY COVER Rear cover Remove the seat. Loose all bolts which connect to footrest and side cover. There are 6 bolts on the left side cover and 7 bolts on the right side cover. Loosen 2 screws the screws which connect to fixed plate.
  • Page 172 Ch. 14 BODY COVER Tail light cover Remove Loosen 6 bolts from the rear carrier. Lossen the 8 screw from the rear cover. Loosen 2 screws the screws which connect to fixed plate. Remove Tail light cover. Installation Install in reverse order of removal procedures. Caution ...
  • Page 173 Ch. 14 BODY COVER NOTE: 14-10...
  • Page 174 Ch. 1 FRONT BRAKE & FRONT WHEEL Mechanism Diagram ………..…..…... 15-1 Adding Brake Fluid…………………... 15-7 Maintenance Description……….……15-2 Brake fluid replacement / Air-bleed...15-8 Trouble Diagnosis ……………..…. 15-3 Front Brake Caliper…………….……. 15-9 Front Wheel ……………………..15-4 Brake Disk………………………..…...15-10 Front Wheel Hub …………..……...…. 15-4 Front Brake Master Cylinder ……... 15-10 Disk Brake System Inspection……..
  • Page 175 Ch. 1 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 176 Ch. 1 FRONT BRAKE & FRONT WHEEL Trouble Diagnosis Soft brake lever Hard operation of brake lever  Air inside the hydraulic system  Blocked brake system  Hydraulic system leaking  Poor brake caliper   Worn master piston Blocked brake pipe ...

  • Page 177: Front Wheel

    Ch. 1 FRONT BRAKE & FRONT WHEEL Front Wheel Removal Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, and then remove front wheels. Installation Install the front wheel and tighten the nuts. Torque: 5.0 kg-m Front Wheel Hub Removal...
  • Page 178 Ch. 1 FRONT BRAKE & FRONT WHEEL Inspection Install the front brake disk to the wheel hub. Install wheel hub and brake disk on to knuckle. Install wheel hub washer and tighten the wheel hub nut. Torque: 10 kg-m Install cotter pin. Install front brake caliper.
  • Page 179 Ch. 1 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 180 Ch. 1 FRONT BRAKE & FRONT WHEEL 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 181 Ch. 1 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. Close the drain valve and add specified brake fluid into the brake master cylinder.

  • Page 182: Front Brake Caliper

    Ch. 1 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 183: Front Brake Master Cylinder

    Ch. 1 FRONT BRAKE & FRONT WHEEL Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 3.5 mm Remove the brake disk from wheel hub.
  • Page 184 Ch. 1 FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Remove the piston and the spring. Clean the master cylinder with recommended brake fluid. Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary.
  • Page 185 Ch. 1 FRONT BRAKE & FRONT WHEEL Master Cylinder Installation 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 light switch, then install the brake stopper at last. Connect brake hoses with 2 new washers.
  • Page 186 Ch. 16 STEERING / FRONT SUSPENSION Mechanism Diagram ………..……...….16-1 Steering Tie-Rod ………..………..………16-6 Operation Precautions ……………...…16-2 Knuckle ………………..…………..………16-7 Trouble Diagnosis ………………...……16-2 Front Cushion …………..………..………16-8 Steering Handle ……………..….……….16-3 Suspension Arm ………..………..………16-9 Steering Shaft ……………….…..………16-5 Toe-In ……………………………………..16-10 Mechanism Diagram 16-1...
  • Page 187 Ch. 16 STEERING / FRONT SUSPENSION Operational Precautions Torque: Handlebar upper holder bolt 2.3 kg-m Steering shaft holder bolt 5.0 kg-m Steering shaft bottom nut 5.5 kg-m Steering tie-rod nut 4.0 kg-m Knuckle nut 5.0 kg-m Tie rod lock nut 4.0 kg-m Suspension arm nut 4.5 kg-m...
  • Page 188 Ch. 16 STEERING / FRONT SUSPENSION Steering Handle Removal Remove the handle cover, meter set, handle protect cover. (Refer to Chapter13) Loosen the socket bolts for the front brake master cylinder, and remove front brake master cylinder. Cautions  Do not let foreign materials enter into the cylinder.
  • Page 189 Ch. 16 STEERING / FRONT SUSPENSION Loosen 2 screws, and then remove handle left switch and choke cable. Remove switch wire band. Remove handle mounting bolt, and then remove the handle upper holder, handle. Installation Install in reverse order of removal procedures. Torque: Handlebar holder bolt 2.3 kg-m 16-4...

  • Page 190: Steering Shaft

    Ch. 16 STEERING / FRONT SUSPENSION Steering Shaft Remove Remove cotter pins, and loosen right and left steering tie-rod nuts. Remove tie-rod. Tie-rod nut Remove the cotter pin below steering shaft, and remove steering shaft nut and washer. Bend out the steering shaft holder nut fixed plate. Loosen 2 bolts, and then remove steering shaft holder, nut fixed plate, pressed plate and steering shaft.
  • Page 191 Ch. 16 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. Tie-rod nuts Cotter pin Inspect the ball joint rubbers for damage, wear or deterioration.
  • Page 192 Ch. 16 STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Remove cotter pin and tie-rod nut, remove tie rod. Ball Joint Remove cotter pin and ball joint nut. Tie-rod nuts Cotter pin Remove upper and under ball joints by ball joint driver.
  • Page 193 Ch. 16 STEERING / FRONT SUSPENSION Front Cushion Remove Remove front cushion lower nut, then remove the bolt. Remove front cushion upper nut, and remove the bolt and cushion. Installation Install in reverse order of removal procedures. Torque: Front cushion nut: 4.5 kg-m 16-8...
  • Page 194 Ch. 16 STEERING / FRONT SUSPENSION Suspension Arm Remove Remove front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Loosen upper suspension arm nuts, remove swing arm bolts. Remove upper suspension arm. Loosen under suspension arm nuts, remove swing arm bolts.
  • Page 195 Ch. 16 STEERING / FRONT SUSPENSION Toe-In Cautions  During tie rod adjustment it is very important Cautions that the following precautions be taken when  tightening tie rod end jam nuts. If the rod end Due to the critical nature of the procedures is positioned incorrectly it will not pivot, and we recommends steering component repair may break.
  • Page 196 Ch. 16 STEERING / FRONT SUSPENSION NOTE: 16-11...

  • Page 197: Rear Brake / Wheel / Suspension

    Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Mechanism Diagram …………………..17-1 Adding Brake Fluid …………………….17-7 Maintenance Description …………….17-2 Brake Fluid Replacement / Air-Bleed .17-8 Trouble Diagnosis ……………………..17-3 Rear Brake Caliper ……………………..17-9 Rear Wheel ……………………………...17-4 Rear Cushion ……..…………………...17-10 Rear Wheel Axle ……………………….17-5 Rear Brake Master Cylinder ………...17-11 Disk Brake System Inspection ………17-6 Brake disk…………...………………….17-13 Mechanism Diagram 17-1...
  • Page 198 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Maintenance Description Operational precautions Cautions  The brake caliper can be removed without removing the hydraulic system. After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system. ...
  • Page 199 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Trouble Diagnosis Soft brake lever Uneven brake   Air inside the hydraulic system Dirty brake lining/disk   Hydraulic system leaking Poor wheel alignment   Worn master piston Clogged brake hose ...
  • Page 200 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Rear Wheel Removal Raise the rear wheels off ground by placing a jack or other support under the frame. Remove the rear wheel nuts, and the remove rear wheel. Installation Install the rear wheel and tighten the nuts. Torque: 5.0 kg-m 17-4...
  • Page 201 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Rear Wheel Axle Remove cotter pin, rear wheel axle connecter nut and washer. Installation Install wheel shaft connecter washer and tighten the wheel shaft connecter nut. Torque: 12.0 kg-m Install cotter pin. Remove rear wheel knuckle 2 bolts.(R/L) Cotter pin Wheel hub...
  • Page 202 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION 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.
  • Page 203 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION 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 204: Rear Brake Caliper

    Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Brake fluid replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.
  • Page 205 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Cautions  Do not spill brake fluid on painted surfaces. Brake hose bolt Remove two caliper bolts and the caliper.
  • Page 206 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Removal Support the frame. Loosen rear cushion under bolt nut, and remove rear cushion under bolt. Remove rear cushion upper bolt, and then remove rear cushion. Installation Install rear cushion, and install rear cushion upper bolt.

  • Page 207: Rear Brake Master Cylinder

    Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Rear Brake Master Cylinder Master Cylinder Removal Cautions  Do not let foreign materials enter into the brake fluid reservoir.  The whole set of master cylinder, piston, spring, diaphragm and cir-clip should be replaced as a set.
  • Page 208 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Right footrest side – rear brake master cylinder Lock nut Install the master cylinder bolts and the master cylinder. R-clip Adjust nut Install brake push rod to the brake pedal, and install pin and R clip. Cautions ...
  • Page 209 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Brake Disk Removal Removal the rear wheel. Removal the rear wheel knuckle. Removal the rear wheel axle. Removal the cushion 4 bolts. Removal the rear arm upper 2 bolts.(R/L) 4-bolts Installation Install the rear arm upper and tighten the bolt. Torque: 4.5 kg-m 2-bolts Removal the rear arm lower 2 bolts.(R/L)
  • Page 210 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Removal 4 bolts which fix the stabilizer bar. Installation Install the stabilizer bar and tighten the bolts. Torque: 2.8 kg-m Removal 4 bolts fix the rear brake disk. Installation Install the rear brake disk and tighten the bolts. Torque: 2.5 kg-m Removal the rear differential 3 bolts.
  • Page 211 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 4 mm Remove the brake disk from rear differential.
  • Page 212 Ch. 17 REAR BRAKE / WHEEL / SUSPENSION NOTE: 17-16...

  • Page 213: Spark Plug

    Ch. 18 ELECTRICAL EQUIPMEMNT Maintenance Date …………………..…. 18-1 Meter ………..….…..……….….. 18-12 Technical Specification ……….……... 18-2 Light / Bulb……………..…………... 18-16 Trouble Diagnosis ………………...……18-3 Switch / Horn ………………….…...…18-17 Battery ………………………..…………. 18-4 Fuel Unit ……………………….………18-19 Charging System ……………..……….. 18-5 Cooling Fan Switch ………….………18-20 Ignition System ……………………..….
  • Page 214 Ch. 18 ELECTRICAL EQUIPMEMNT Technical Specification Charging system Description Specification Capacity 12V18Ah Battery Charging rate 1.4A / 5 ~ 10 hours (standard) hour 6A / 0.5(fast charging) Leak current < 1mA Charging current 1.2 A / 1500rpm Control voltage in charging 14.5 + 0.5 V / 1500rpm Ignition system Description...
  • Page 215 Ch. 18 ELECTRICAL EQUIPMEMNT 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 ...
  • Page 216 Ch. 18 ELECTRICAL EQUIPMEMNT Battery Removal CLAM Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery. Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 217: Charging System

    Ch. 18 ELECTRICAL EQUIPMEMNT Charging System Charging circuit Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal. Caution ...
  • Page 218 Ch. 18 ELECTRICAL EQUIPMEMNT Inspection on Charging Voltage Caution  Before conducting the inspection, make sure that the battery is fully charged. If undercharged, the current changes dramatically. Use a fully charged battery having a voltage larger than 13.0 V While starting the engine, the starter motor draws large amount of current from the battery.
  • Page 219 Ch. 18 ELECTRICAL EQUIPMEMNT Inspection on regulator rectifier Remove the seat, side cover L. Disconnect three couplers of the regulator Rectifier Inspection the rectifier coupler to the wire harness passes the condition. Item Check Standard Value Points Main switch B – G Battery Connection voltage(ON)
  • Page 220 Ch. 18 ELECTRICAL EQUIPMEMNT IGNITION SYSTEM Ignition Circuit Diagram C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result Main switch turn to “ON” position G ~ W/B Battery voltage 480 ~ 550Ω...
  • Page 221 Ch. 18 ELECTRICAL EQUIPMEMNT Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Standard resistance: 2.8Ω±15% Measure the resistance between the spark plug and the primary winding.

  • Page 222: Starting System

    Ch. 18 ELECTRICAL EQUIPMEMNT Starting System Starting circuit diagram Inspection on starter relay The starter relay is located under the seat behind the battery. Open the main switch. Press the brake. Push down the starter switch. Disconnect the negative cable terminal of the battery.
  • Page 223 Ch. 18 ELECTRICAL EQUIPMEMNT Removal of Starter motor Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Θ ♁ Remove starter motor cable. Loosen the lock bolts and remove the starter motor. Installation of Starter motor Install in reverse order of removal procedures.
  • Page 224 Ch. 18 ELECTRICAL EQUIPMEMNT Meter Removal Remove 2 screws behind the meter cover, and then remove speedometer cover. Loosen 3 bolts from meter stay. Remove couplers of meter. Meter Function and setup 18-12...
  • Page 225 Ch. 18 ELECTRICAL EQUIPMEMNT 18-13...
  • Page 226 Ch. 18 ELECTRICAL EQUIPMEMNT 18-14...
  • Page 227 Ch. 18 ELECTRICAL EQUIPMEMNT METER 18-15...
  • Page 228 Ch. 18 ELECTRICAL EQUIPMEMNT Light / Bulb Replacing Bulb for Headlight Remove waterproof cover for the headlight. Remove bulb socket. Take out the bulb connector and the bulb. Replace with new bulb if necessary. (Hight Beam H1 12V 55W) (Low Beam H7 12V 55W) Caution ...
  • Page 229 Ch. 18 ELECTRICAL EQUIPMEMNT Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: Handle switches Disconnect the coupler of handle from front fender left side. Check the continuity between two points as indicated in the table below.
  • Page 230 Ch. 18 ELECTRICAL EQUIPMEMNT Horn Remove the horn under front fender. Apply 12 V power source to two terminals of the horn, the horn should sound. Replace the horn if necessary. Winker Switch Hazard switch 2W/4W/LOCK switch 18-18...
  • Page 231 Ch. 18 ELECTRICAL EQUIPMEMNT Fuel Unit Remove the seat. Remove the fuel tank cap. Remove the upper center cover and front fender (refer chapter 13). Disconnect the coupler of the fuel unit. Remove the fuel unit (4 bolts). Caution  Great care shall be taken not to damage or bend the float arm of the gauge.
  • Page 232 Ch. 18 ELECTRICAL EQUIPMEMNT Cooling Fan Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
  • Page 233 Ch. 18 ELECTRICAL EQUIPMEMNT Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Thermo unit Caution Wear gloves and goggles when performing  this test. Caution ...
  • Page 234 Ch. 18 ELECTRICAL EQUIPMEMNT NOTE: 18-22...

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