Sym Quad Lander 600 Service Manual
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Sym Quad Lander 600 Service Manual

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FOREWORD
CONTENTS
HOW TO USE THIS MANUAL
SERIAL NUMBER
Quad Lander 600
SERVICE MANUAL
20101103

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Table of Contents
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Summary of Contents for Sym Quad Lander 600

  • Page 1 FOREWORD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Quad Lander 600 SERVICE MANUAL 20101103...
  • Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment”, providing technician with service guidelines. If the style and construction of the ATV, Quad Lander 600, are different from the photos, pictures shown in this manual, the actual vehicle shall prevail.
  • Page 3 Homepage Contents HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG Quad Lander 600ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 Homepage CONTENTS Page Content Index 1-1 ~ 1-17 GENERAL INFORMATION 2-1 ~ 2-17 MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-13 FUEL SYSTEM 5-1 ~ 5-6 ENGINE REMOVAL 6-1 ~ 6-17 CYLINDER HEAD/ VALVE 7-1 ~ 7-8 CYLINDER/ PISTON 8-1 ~ 8-17 “V”...
  • Page 5 Home page Contents SERIAL NUMBER Frame number Engine number...
  • Page 6 Homepage Contents 1. GENERAL INFORMATION Symbols and Marks......1-1 Torque Values ........1-10 General Safety ........1-2 Troubles Diagnosis......1-12 Service Precautions ......1-3 Lubrication Points ......1-17 Specifications ........1-9 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
  • Page 7 To this chapter contents 1. GENERAL INFORMATION General Safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have •...
  • Page 8 To this chapter contents 1. GENERAL INFORMATION Service Precautions Always use with SANYANG genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-designed parts for unsmooth control and premature worn out. SANYANG ATV may damage the ATV. Rubber parts may become deteriorated when old, Special tools are designed for remove and install and prone to be damaged by solvent and oil.
  • Page 9 To this chapter contents 1. GENERAL INFORMATION The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if the another, be sure they are correctly installed. In contact surface has any damage.
  • Page 10 To this chapter contents 1. GENERAL INFORMATION Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.
  • Page 11 To this chapter contents 1. GENERAL INFORMATION When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the boot covers the terminal. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated...
  • Page 12 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.
  • Page 13 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness been twisted as With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering...
  • Page 14 To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL UA60A-6 Overall Length 2110 mm Front Double arm Suspension System Overall Width 1150 mm Rear Double arm Overall Height 1220 mm Front AT25x8-12 (off road) Tire Specifications Wheel Base 1300 mm Rear AT25x10-12 (off road)
  • Page 15 To this chapter contents To this chapter contents 1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type...

  • Page 16: Table Of Contents

    To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks 2.40 Handlebar upper holder bolt Steering shaft nut 5.00 5.00 Steering tie-rod nut 5.00 Knuckle nut Steering shaft holder bolt 3.40 3.60 Tie rod lock nut 4.00 Handlebar under holder nut...
  • Page 17 To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside No fuel in fuel tank the carburetor Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.
  • Page 18 To this chapter contents 1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Engine speed can be Engine speed cannot be Lines in fuel tank evaporation system increased.
  • Page 19 To this chapter contents 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the airscrew of carburetor Good...
  • Page 20 To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS Drive belt worn out or deformation Ramp plate of movable drive face damaged Engine can be started but Driving pulley spring broken motorcycle can not be moved. Clutch weights broken Drive slide-shaft gear groove broken Transmission gear damaged...
  • Page 21 To this chapter contents 1. GENERAL INFORMATION G. Loss power Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand Brake dragging Spin freely Abnormal Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication Check tire pressure Normal Abnormal...
  • Page 22 To this chapter contents 1. GENERAL INFORMATION Lubrication Points Acceleration cable/ Front & rear brake/ Lever Pivot Wheel bearing 1-17...
  • Page 23 Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ···················· 2-1 Front Differential ·································· 2-8 Periodical Maintenance Schedule ······ 2-2 Rear Axle Gearbox······························· 2-8 Fuel Lines ············································· 2-3 Brake System ······································· 2-9 Acceleration Operation ······················· 2-3 Brake Light Switch······························· 2-10 Air Cleaner············································...

  • Page 24: Periodical Maintenance Schedule

    C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM 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 25: Fuel Lines

    To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines Fuel tank Remove the seat. Loosen 2 screws and 2 bolts Remove the tank cover. Fuel hose Check all lines, and replace the lines when they are deteriorated, damaged or leaking. Fuel filter Carburetor Warning...

  • Page 26: Spark Plug

    To this chapter contents 2. MAINTENANCE INFORMATION Spark Plug Ground electrode Recommended spark plug: CR8E Remove the spark plug cap. Central electrode Clean the dirt around the spark plug hole. Remove the spark plug. Measure the spark plug gap. Spark plug gap：0.8 mm Carefully bend ground electrode of the plug to adjust the gap if necessary.

  • Page 27: Carburetor Idle Speed Adjustment

    To this chapter contents 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition coil 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 28: Ignition System

    To this chapter contents 2. MAINTENANCE INFORMATION Ignition System Full transistor igniter 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.

  • Page 29: Drive Belt

    To this chapter contents 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. 9 bolts 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 30: Front Differential

    To this chapter contents 2. MAINTENANCE INFORMATION Front Differential 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. Differential control unit 2 bolts Rear axle gearbox Rear Axle Gearbox...

  • Page 31: Brake System

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

  • Page 32: Brake Light Switch

    To this chapter contents 2. MAINTENANCE INFORMATION Brake Lining Wear Front brake The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark Lining closed to the edge of brake disc. Caution To check front brake lining must be remove Brake lining wear front wheel first.

  • Page 33: Headlight Beam Distance

    To this chapter contents 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.

  • Page 34: Steering Handle

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

  • Page 35: Special Tools List

    SYM-2301000-HMA SYM-1471110/20 SYM-3110000-HMA KNUCKLE BODY BRG. NAME NAME Drive shaft puller NAME Driveshaft BRG. 6228 driver 6006 driver SYM-2341120-REA SYM-5024000-REA 6006 SYM-2341110-REA 6228 WHEEL DRIVE SHAFT Countershaft OIL SEAL BEVEL GEAR HOUSHING NAME NAME NAME BRG 6306 driver BALL SET tool...
  • Page 36 Water pump mechanical seal NAME Water pump oil seal driver NAME NAME driver driver SYM-9120200-REA SYM-6001300-REA A6001 SYM-1721700-H9A CLUTCH COVER BRG. 6207 NAME NAME NAME Lock nut driver R COVER OIL SEAL GUIDE driver SYM-9610000- REA A6207 SYM-1133000-REA SYM-9020100 2-14...
  • Page 37 To this chapter contents 2. MAINTENANCE INFORMATION Outer bearing puller NAME Inner bearing puller NAME Inner bearing puller NAME SYM-6204002 SYM-6204022 SYM-6204001 NAME Universal holder NAME Clutch nut wrench NAME Crankcase tool SYM-2210100 SYM-9020200 SYM-1120000-ALL (55mm) (55mm) NAME Rear axle nut wrench...
  • Page 38 2. MAINTENANCE INFORMATION MAIN BRG. UP/LWR PULLEY DRIVEN FACE NAME NAME NAME 40*44*20 driver 41*44*4 OIL SEAL GUIDE SYM-9100110-REA SYM-9100400 G5A ADA SYM-9121100-REA ENG L COVER RADIAL BALL FINAL SHAFT BRG 6307 PULLEY DRIVEN FACE NAME NAME NAME BRG. 6006 driver...
  • Page 39 To this chapter contents 2. MAINTENANCE INFORMATION L COVER FR. BRG. 6302 MAIN BRG. UP/LWR NAME NAME NAME Drive plate fixer 40*44*20 assemble tool driver SYM-9100100-REA SYM-9615000-REA 6302 SYM-2230000-REA NAME NAME NAME NAME NAME NAME NAME NAME NAME 2-17...
  • Page 40 Home page Contents 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 41 To this chapter contents 3. LUBRICATION SYSTEM Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Oil Route Spray Lubrication Con-Rod Spray Lubrication...

  • Page 42: Precautions In Operation

    SAE 10W-30 (Recommended King serial oils) Rear axle gear oil replacement: 100c.c. Front differential gear oil replacement: 200c.c. Gear oil viscosity SAE 80 or 90 (Recommended SYM Hypoid gear oil) Items Standard (mm) Limit (mm) Inner rotor clearance 0.15 0.20...

  • Page 43: Engine Oil

    To this chapter contents 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.

  • Page 44: Oil Filter Unit

    Oil Filter Unit Drain bolt Remove the oil filter unit with special tool. Special Service Tool: Tool No: SYM-1445100 Install the oil filter unit by hand. Lock the oil filter unit with special tool. Special Service Tool: Tool No: SYM-1445100...

  • Page 45: Oil Pump

    To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove the recoil starter and the AC Generator. (Refer to chapter 10) 。 Remove the cir clip and take out the oil pump sprocket. Cir Clip Make sure that pump shaft can be rotated freely. Remove 3 screws on the oil pump, and then remove the oil pump.
  • Page 46 To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Pins...
  • Page 47 To this chapter contents 3. LUBRICATION SYSTEM 1 screw Tighten the oil pump screw. Roller 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. 3 screws Install the oil pump sprocket, and then install cir clip onto oil pump shaft.
  • Page 48 To this chapter contents 3. LUBRICATION SYSTEM Notes:...
  • Page 49 Home page Contents 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 ........

  • Page 50: Precautions In Operation

    To this chapter contents 4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.

  • Page 51: Trouble Diagnosis

    To this chapter contents 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 No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system )

  • Page 52: Carburetor Removal / Installation

    To this chapter contents 4. FUEL SYSTEM Carburetor Removal / Installation Removal Remove the fuel tank. Turn the fuel valve lever on off. fuel valve lever throttle cable Remove 1 screw from throttle lever cap them 1 screw remove throttle lever cap. Loosen throttle cable adjustment nut and remove throttle cable adjustment nut...

  • Page 53: Air Cut-Off Valve

    To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve Disassembly Remove 2 screws. 2 screws Remove air cut-off valve cover, spring and valve. Air cut-off valve Cover O-ring Spring 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 54: Vacuum Chamber

    To this chapter contents 4. FUEL SYSTEM Vacuum Chamber vacuum chamber cover Disassembly Removal Loosen drain screw, and drain out residual fuel in float chamber. Remove screws (4 screws) of vacuum chamber cover and the cover. 4 bolts Remove compress spring and vacuum piston. Spring Remove fuel needle seat, spring, and injector needle...

  • Page 55: Float Chamber

    To this chapter contents 4. FUEL SYSTEM Float Chamber Disassembly Remove 4 mounting screws and remove float chamber cover. 4 Screws Float valve Remove the float pin, float and float valve. Float Inspection Check float valve and valve seat for damage, blocking.
  • Page 56 To this chapter contents 4. FUEL SYSTEM Remove main jet, needle jet holder, needle jet, Needle jet holder Needle jet slow jet and air adjustment screw. Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns.

  • Page 57: Adjustment Of Idle Speed

    To this chapter contents 4. FUEL SYSTEM Adjustment of Idle Speed Parking brake Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the ATV to perform the adjustments.

  • Page 58: Fuel Tank

    To this chapter contents 4. FUEL SYSTEM Fuel Tank Fuel unit 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 unit wire from tank. (Covers remove please refer chapter remove 2 fuel tubes from fuel valve.

  • Page 59: Air Cleaner

    To this chapter contents 4. FUEL SYSTEM Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Clamp Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts).
  • Page 60 To this chapter contents 4. FUEL SYSTEM Remove the air cleaner element. 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. Soap the element into cleaning engine oil and then squeeze it out.
  • Page 61 To this chapter contents 4. FUEL SYSTEM Notes: 4-13...
  • Page 62 Home page Contents 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: Carburetor Drive pulley, drive belt, clutch, and movable drive face assembly.
  • Page 63 To this chapter contents 5. ENGINE REMOVAL Engine Removal Negative Remove the seat. Remove the battery negative terminal (-). Remove the battery positive (+) terminal. Remove front fender and the footrest (refer chapter 13). Positive Remove the starter motor wire. Starter motor wire Remove the spark plug cap.
  • Page 64 To this chapter contents 5. ENGINE REMOVAL Remove the front left and rear left tires. Remove the idle speed adjustment nut. Idle speed adjustment nut Remove 2 bolt on the muffler. Remove the muffler. Remove the throttle cable. Remove 2 nuts and 1 bolt. Remove the exhaust pipe.
  • Page 65 To this chapter contents 5. ENGINE REMOVAL Remove 2 manifold clamps. Remove the carburetor. Manifold clamps Remove 4 bolts. Remove the air cleaner. 4 bolts Remove 2 bolts. Remove the muffler. 2 bolts Remove 2 nuts and 1 bolt. Remove the exhaust pipe. 2 nuts Bolt...
  • Page 66 To this chapter contents 5. ENGINE REMOVAL Remove the coolant drain bolt and drain out PCV pipe coolant. Remove the coolant inlet pipe from the water pump cover and the outlet pipe from the thermostat cover. Remove the PCV pipe. Coolant pipe Remove 2 bolts.
  • Page 67 To this chapter contents 5. ENGINE REMOVAL Remove the rear brake pedal. Remove the coolant reserve tank. 2 bolts Remove the front and rear side engine hanger mounting nuts and bolts. Remove left side engine hanger, and then remove engine by left side. Engine Installation Check the bush of engine hanger parts for any damage.
  • Page 68 Home page Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10 Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11 Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13 Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-14 Cylinder Head Inspection···················...

  • Page 69: Precautions In Operation

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

  • Page 70: Troubleshooting

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

  • Page 71: Cylinder Head Removal

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Removal 2 nuts Remove the engine from the frame. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Thermostat bolts Remove 2 thermostat bolts and then remove the thermostat. Remove the bolt and spring of the cam chain tensioner.
  • Page 72 Cam sprocket disk Loosen 2 bolts from the cam sprocket. Remove the cam sprocket disk and washer. Remove the cam sprocket. Special Service Tool: Cam shafts Tool no: SYM-1445100 TOOL number: rocker arm and camshaft puller Rocker arm shaft and camshaft puller...
  • Page 73 In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Tool no: SYM-1471110/20-4v Valve cotter remove TOOL number: valve cotter remove & and assembly tool assembly tool...

  • Page 74: Cylinder Head Inspection

    To this chapter contents 6. CYLINDER HEAD/VALVE Remove the valve stem seals. 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.
  • Page 75 To this chapter contents 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
  • Page 76 To this chapter contents 6. CYLINDER HEAD/VALVE Valve guide Caution 5.0 mm valve guide reamer Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve...

  • Page 77: Valve Stem Replacement

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

  • Page 78: Valve Seat Inspection And Service

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 79 To this chapter contents 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.

  • Page 80: Cylinder Head Reassembly

    To this chapter contents 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 Valve spring retainer Lubricate the valve stem with engine oil, and then Valve stem seal...

  • Page 81: Cylinder Head Installation

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
  • Page 82 To this chapter contents 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the 2 bolts Timing mark 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.

  • Page 83: Valve Clearance Adjustment

    To this chapter contents 6. CYLINDER HEAD/VALVE Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder 4 bolts Install and tighten spark plug Torque value: 1.0~2.0kgf-m Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that vehicle performance be...
  • Page 84 To this chapter contents 6. CYLINDER HEAD/VALVE Notes: 6-17...
  • Page 85 Home page Contents 7. CYLINDER/PISTON 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 1.0~1.4kgf-m 0.8~1.2kgf-m...

  • Page 86: Precautions In Operation

    To this chapter contents 7. CYLINDER/PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. UA25A Specification Unit：mm Item Standard Limit 92.00 92.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring...

  • Page 87: Cylinder And Piston Removal

    To this chapter contents 7. CYLINDER/PISTON 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 88 To this chapter contents 7. CYLINDER/PISTON 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 89 To this chapter contents 7. CYLINDER/PISTON 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 90: Piston Ring Installation

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

  • Page 91: Piston Installation

    To this chapter contents 7. CYLINDER/PISTON 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 92 To this chapter contents 7. CYLINDER/PISTON Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。...
  • Page 93 Home page Contents 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 5.0~6.0kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m...

  • Page 94: Maintenance Description

    Weight of weight roller 19.700~20.300 19.200 Torque value Special Service Tools Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000 Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002 Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200 Universal holder:...

  • Page 95: Left Crankcase Cover

    Left crankcase cover installation Install left crankcase cover in the reverse procedure of removal. SYM-2211000-REA Drive Belt Loosen 1nut from the drive face with Special tool. Tool name: Movable Drive Face Holder Tool NO: SYM-2211000-REA Remove the movable drive face.

  • Page 96: Drive Plate

    8. V-BELT DRIVING SYSTEM Loosen 1nut from the driven pulley with Special SYM-2210100 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.
  • Page 97 Check each roller for wear or damage. Hold the clutch outer and turning the one way clutch for right side. Loosen the drive plate nut with special tool. SYM-2230000-REA Remove the drive plate. Tool name: drive plate holder Tool NO: SYM-2230000-REA...

  • Page 98: Movable Drive Face Disassembly

    To this chapter contents 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 99 To this chapter contents 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, Movable drive face and replace it if it exceed service limit.
  • Page 100 If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Remove the bearing 6302 with inner bearing SYM-6204025 puller. Tools number: SYM-6204025 Tools name: INNER BEARING PULLER. Remove the bearing 6006 with inner bearing SYM-6204025 puller. Tools number: SYM-6204025...
  • Page 101 Bearing installation SYM-9615000-REA A6302 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. SYM-9615000-REA A6302 caller Air tool Install the bearing with air or head tool.
  • Page 102 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 SYM-9615010-REA 6006 Knock the bearing to the objected position. Install the cir clip.
  • Page 103 To this chapter contents 8. V-BELT DRIVING SYSTEM Drive plate Disassembly Remove 5 e-ring from drive plate. Remove the spring plate and centrifugal clutch centrifugal clutch plate. e-ring Spring Remove 5 springs from the drive plate Check if spring is damaged or insufficient elasticity.
  • Page 104 To this chapter contents 8. V-BELT DRIVING SYSTEM Measure each clutch weight thickness. Replace it if exceeds service limit. 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.

  • Page 105: Driven Pulley Disassembly

    To this chapter contents 8. V-BELT DRIVING SYSTEM Install the spring plate and centrifugal clutch 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 Special tool compressor 8-13...
  • Page 106 To this chapter contents 8. V-BELT DRIVING SYSTEM Remove cir clip with pliers. Cir clip Loosen the special tools nut Remove the driven pulley collar and 4 roller guides. 4 roller guides Drive pulley collar Remove the movable driven face. 8-14...
  • Page 107 To this chapter contents 8. V-BELT DRIVING SYSTEM Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 119.5 mm Free length Driven pulley Check following items: If both surfaces are damaged or worn. If guide pin groove is damaged or worn.
  • Page 108 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 Driven Face Assy. Put the driven face assy. onto the drive shaft.
  • Page 109 To this chapter contents 8. V-BELT DRIVING SYSTEM Notes: 8-17...
  • Page 110 Home page Contents 9. Transmission Mechanism Diagram ··························· 9-1 Transmission Inspection··················· 9-7 Precautions in operation ···················· 9-2 Bearing Replacement ························ 9-9 Trouble Diagnosis ······························· 9-2 Transmission Reassembly················ 9-12 Transmission Disassembly ················ 9-3 Mechanism Diagram Needle Bearing HK2220C Drive shaft Radial Ball Bearing 6228 Shift Drum Counter Shaft Reverse Shaft...

  • Page 111: Precautions In Operation

    Gear oil drain bolt 1.1~1.5kgf-m Gear oil fill bolt 3.5~4.5kgf-m Tools Special tools Bearing driver (6228): SYM-2341110-REA A6228 Bearing driver (6307): SYM-2343110-REA 6307 Bearing driver (2220): SYM-9100400-REA 2220 Bearing driver (6307): SYM-2346000-REA A6307 Final shaft gear stopper: SYM-2343100-REA Needle bearing driver (HK2016):...

  • Page 112: Transmission Disassembly

    To this chapter contents 9. Transmission Transmission Disassembly Remove gear change lever (2 bolts). Remove the gear change lever. 2 bolts Remove 2 c clips from brake pedal. Concave marks Remove brake spring & stop switch spring Remove brake penal. Shift drum Gearshift spindle Remove the front and rear propeller shaft.
  • Page 113 To this chapter contents 9. TRANSMISSION Remove the front and rear output shaft covers. 4 bolts Remove 13 bolts from the right crankcase. Remove the right crankcase from the left crankcase. Shift drum Shift fork Remove the counter shaft, shift fork and the shift drum.
  • Page 114 Remove the reverse shaft and the output shaft. Reverse shaft Output shaft Final gear stopper Remove the bevel gear with the final shaft stopper. Special tool: Tool number：SYM-2343100-REA Tool name：Final shaft stopper. Remove 4 bolts. Bevel gear housing Shim Remove the shims from the bevel gear housing.
  • Page 115 To this chapter contents 9. TRANSMISSION Remove the drive shaft bearing setting plate (1 bolt). Bearing setting plate Remove the drive shaft. Drive shaft bearing Remove the output shaft. Output shaft Caution Bearing Do not remove the drive shaft from the crankcase if unnecessary.

  • Page 116: Transmission Inspection

    To this chapter contents 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 117 To this chapter contents 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. Drive shaft bearing Balance shaft bearing Rotate each bearing’s inner ring by fingers.

  • Page 118: Bearing Replacement

    Remove the drive shaft bearing from the shaft by outer bearing puller. Replace the drive shaft bearing with new one by bearing driver. Special tool: Tool number：SYM-2341110-REA A6228 Tool name：Bearing driver (6228) Bearing driver Remove the cir-clip and the park gear. Park gear...
  • Page 119 To this chapter contents 9. TRANSMISSION Install the park gear cir-clip by using cir-clip Park gear cir-clip installer installer. Special tool: Tool number：SYM-9060200-REA Tool name：Park gear cir-clip installer Cir-clip Park gear Inner bearing puller Right crankcase side Remove the final shaft bearing on the right crankcase with inner bearing puller.
  • Page 120 To this chapter contents 9. Transmission Bearing driver 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. Special tool: Tool number：SYM- Tool name：Counter shaft bearing driver...

  • Page 121: Transmission Reassembly

    To this chapter contents 9. TRANSMISSION Reverse shaft Transmission Reassembly Install the reverse shaft onto the left crankcase. Drive shaft Install the counter shaft and gearshift fork. Shift drum Gearshift fork Counter shaft Install the shift drum. Rotate the shift drum and make sure it can rotate smoothly.
  • Page 122 Shim Final gear stopper Install the bevel gear. Lock the nut by using final shaft stopper. Special tool: Tool number：SYM-2343100-REA Tool name：Final shaft stopper. Bevel gear Reassemble the right and left crankcase. Concave marks Install the gearshift spindle. Align the concave marks on the shift gear and the shift drum gear.
  • Page 123 To this chapter contents 9. TRANSMISSION Install the change lever arm. Change lever arm Keep the level mark on the change lever arm horizontal. Level mark 9-14...
  • Page 124 Home page Contents 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 Propeller Shaft·····10-14 Mechanism Diagram Rear Propeller Shaft Front Differential...

  • Page 125: Trouble Diagnosis

    To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Trouble Diagnosis Engine can be started but vehicle cannot move. Damaged wheel drive shaft Damaged propeller shaft Damaged front differential or rear axle gear box Noise Worn or burnt drive shaft Worn or burnt steel ball Worn or burnt gear Gear oil leaks...

  • Page 126: Wheel Drive Shaft Removal

    To this chapter contents 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 127: Wheel Drive Shaft Disassembly

    Remove the UJ rubber boot. Disassemble the wheel drive shaft UJ assembly SYM-4423000-REA with rubber hammer & special tool. Tools name：Wheel driveshaft assembly seat Tools number：SYM-4423000-REA Caution Do not disassemble UJ assembly by using the steel hammer. Rubber hammer 10-4...
  • Page 128 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Remove 6 steel balls from UJ assembly outer SYM-4423500-REA 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 129 To this chapter contents 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 130: Wheel Drive Shaft Inspection

    To this chapter contents 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 131: Repair Pack

    To this chapter contents 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 &...
  • Page 132 To this chapter contents 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 133: Wheel Drive Shaft Assembly

    To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Wheel Drive Shaft Assembly DOJ assembly Drive shaft Assemble the DOJ boot. DOJ boot Assemble 6 steel balls, inner race and cage then drive shaft into the assembly. Inner race Drive shaft DOJ cage 6 Steel balls Assemble exit cir-clip onto drive shaft.
  • Page 134 To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Install the wheel drive shaft and cir-clip into DOJ outer race. Install DOJ boot outside band. Small band Install DOJ boot. Large band Pull and open DOJ boot Pressure balancing that make it inside and external.
  • Page 135 To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Grease UJ assembly Pour Assemble universal joint and UJ boot and into the grease. Pour grease into the UJ boot inside. Inside band Caution Please use the grease of the repair pack. Using other oil may cause the part to be damaged.
  • Page 136 To this chapter contents 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 137: Front And Rear Propeller Shaft

    To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Front and Rear Propeller Shaft Remove Loosen 3 bolts from the front propeller connector. Disassemble the engine and propeller connector. Spring Remove the front propeller shaft connector Propeller shaft connector Propeller shaft Remove the front propeller shaft connector, spring, spring pin and shaft.
  • Page 138 To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Remove the rear side exit cir-clip. Cir-clip Remove propeller shaft and rubber boots. Rubber boot Drive shaft inspection Spur gear Check if the spur gear has is damaged or not. Please replace new parts if it has split or damaged.
  • Page 139 To this chapter contents 10. WHEEL DRIVE SHAFT/PROPELLER SHAFT Check if the propeller shaft rubber boot is Rubber boot damaged or not. Propeller shaft installation Install in the reverse order of removal procedures. 10-16...
  • Page 140 Home page Contents 11. A.C. GENERATOR/ST ARTING CLUTCH Mechanism Diagram ··························· 11-1 Recoil Starter Cover Removal ··········· 11-5 Precautions in Operation ··················· 11-2 Starter One-way Clutch Installation ·· 11-6 Right Crankcase Cover Removal ······ 11-3 Flywheel Installation··························· 11-7 A.C. Generator Removal····················· 11-3 A.C.

  • Page 141: Precautions In Operation

    27.026~27.045 27.050 OD of starting clutch gear 45.192~45.283 45.183 Torque value Flywheel nut 5.0~6.0kgf-m Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive 8 mm bolts 0.8~1.2kgf-m 12 mm bolts 1.0~1.4kgf-m Tools Special tools A.C.G. flywheel puller: SYM-3110000-HMA Universal holder: SYM-2210100 11-2...

  • Page 142: Right Crankcase Cover Removal

    To this chapter contents 11. A.C. GENERATO R/STARTING CLUTCH Right Crankcase Cover Removal Water pump cover 5 bolts 5 bolts 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.

  • Page 143: Flywheel Removal

    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 144: Recoil Starter Cover Removal

    To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH Check each roller for wear or damage. Recoil Starter Cover Removal Loosen bolt on the ratchet cover then remove ratchet cover. Starter ratchet Remove the starter ratchets from the ratchet cover. 2 springs Remove the 2 springs from the ratchet cover.

  • Page 145: Starter One-Way Clutch Installation

    To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH 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 146: Flywheel Installation

    To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH Rotate the inner part of the starter one-way clutch to make sure it is installed correctly and works properly. Starting reduction gear Starter one-way clutch Install the starting reduction gear first and then install the starting driven gear to the crankshaft.

  • Page 147: A.c. Generator Installation

    To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH Screw in the three flywheel bolts evenly Torque value: 1.0~1.4kgf-m. Rotate the flywheel to make sure it is installed well and works properly. 2 bolts 3 bolts A.C. Generator Installation Install the A.C. Generator stator set onto right crankcase cover (3 screws).
  • Page 148 To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH Remove the water pump cover. Install the right crankcase cover onto the crankcase. Note: Align the water pump shaft indent with the oil pump shaft. Assemble the connector bolt and starter pulley on the right crankcase cover.
  • Page 149 To this chapter contents 11. A.C. GENERATOR/STARTING CLUTCH Note: 11-10...
  • Page 150 Home page Contents 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 1.0~1.4kgf-m Eng. Oil drain bolt 3.5~4.5kgf-m 12-1...

  • Page 151: General Information

    Bolts for crankcase 0.8~1.2kgf-m Engine oil drain bolt 3.5~4.5kgf-m Cylinder stud bolt 1.0~1.4kgf-m Tools Special tools Crankcase Main Bearing Install Tool: SYM-9100100-REA Trouble Diagnosis Engine noise Loose crankshaft bearing Loose crankshaft pin bearing Worn out piston pin and pin hole 12-2...

  • Page 152: Crankcase Disassembly

    To this chapter contents 12. CRANKCASE / CRANKSHAFT Crankcase Disassembly Cam Chain Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the cam chain tensioner. Cam chain setting plate 2 bolts Loosen 2 bolts on the left crankcase.
  • Page 153 To this chapter contents 12. CRANKCASE / CRANKSHAFT Remove balance shaft from left crankcase. Balance shaft 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 154: Crankshaft Inspection

    To this chapter contents 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 point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.

  • Page 155: Crankcase Assembly

    If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Special tool: Tool number：SYM-6204024 Tool name：Inner bearing puller bearing driver Crankcase Assembly Install the crankshaft to the left crankcase. Install the balance shaft to the left crankcase.
  • Page 156 To this chapter contents 12. CRANKCASE / CRANKSHAFT Install the transmission mechanism to the left crankcase. Install the dowel pins and new crankcase gasket. Install the right crankcase to the left crankcase. Tighten 13 bolts on the right crankcase. Tighten 2 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m Install the tensioner and tighten the pivot bolt.
  • Page 157 To this chapter contents 12. CRANKCASE / CRANKSHAFT Notes: 12-8...
  • Page 158 Home page Contents 13. COOLING SYSTEM Mechanism Diagram ··························13-1 System Test········································ 13-5 General Information ···························13-2 Radiator ·············································· 13-6 Trouble Diagnosis ······························13-2 Water Pump ········································ 13-8 Cooling System Troubleshooting ·····13-3 Thermostat ········································· 13-13 Mechanism Diagram Radiator filler cap Reserve tank By-pass pipe To cylinder head Coolant outlet pipe Radiator...

  • Page 159: General Information

    For water pump impeller 1.0~1.4kgf-m Tools Requirement Special tools Water pump bearing driver (6901): SYM-9100100 Water pump oil seal driver (Inner): SYM-9120500-H9A Water pump mechanical seal driver: SYM-1721700-H9A Inner bearing puller: SYM-6204020 Trouble Diagnosis The engine temperature is too high...

  • Page 160: Cooling System Troubleshooting

    To this chapter contents 13. COOLING SYSTEM Cooling System Troubleshooting The temperature indication is too high A. Stop and wait for the A1.Fill the radiator with coolant engine completely cool and inspect for any leakage. Coolant leaking problem down, open filler cap and check the capacity of coolant in the radiator is enough or not.
  • Page 161 To this chapter contents 13. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12→0V)? temperature gauge over 3 checks? E-2.

  • Page 162: System Test

    Stop the engine. Add coolant to proper level if necessary. Screw and tighten up the radiator filler cap. Caution In order to avoid the water tank rusting, please do not use the unidentified coolant. Coolant recommended: SYM Bramax radiator agent. Concentration: 50% 13-5...

  • Page 163: Radiator

    To this chapter contents 13. COOLING SYSTEM Check reserve tank Remove the front center cover, and then remove reserve tank filler cap. Check the liquid level in the front fender right Upper side. Add coolant to proper level if too low. Reinstall the reserve tank filler cap.
  • Page 164 To this chapter contents 13. COOLING SYSTEM Disconnect the couplers for the thermo switch. Coolant inlet pipe Remove the radiator inner hose clamp, water hose, fan motor, and then remove radiator and cooling fan. Thermo switch Loosen the radiator 4 bolts and remove the 4 bolts radiator tank.

  • Page 165: Water Pump

    To this chapter contents 13. COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection Disassembles the coolant drain bolt, overflow some coolant, check if the coolant has the oil pollution or not. Turn off the oil filler plug, check if the engine oil becomes milky white or not.
  • Page 166 If the bearing does not rotate smoothly or produces a noise, replace it with new one. Special tool: Tool number：SYM-6204024 Tool name：Inner bearing puller Check any wear and damage of the mechanical seal and inside seal.
  • Page 167 SYM-6001300-REA A6001 Take the bearing on the special tool. Put the special tool cap on the right crankcase. Special tools: Tool number：SYM-6001300-REA A6001 Tool name：Water pump bearing 6001 inner puller. Assemble the bearing for the crankcase with SYM-6001300-REA special tool.
  • Page 168 To this chapter contents 13. COOLING SYSTEM Mount the water pump shaft to the right crankcase cover. Install the seal washer into the impeller. Caution Washer must be replaced together with the mechanical seal. Water pump shaft Install the impeller onto the water pump shaft and tighten.
  • Page 169 To this chapter contents 13. COOLING SYSTEM Install the impeller onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m Caution The impeller is left thread. Install the dowel pin and right cover gasket. Water pump rotor The rotation water pump impeller, causes the water pump drive shaft scoop channel, aligns the oil pump drive shaft flange, install the right crankcase.

  • Page 170: Thermostat

    To this chapter contents 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) 2 Bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.
  • Page 171 To this chapter contents 13. COOLING SYSTEM NOTES: 13-14...
  • Page 172 Home page Contents 14. BODY COVER Mechanism Diagram ·····························14-1 Front Fender········································· 14-4 Maintenance ··········································14-2 Footrest ················································ 14-5 Front Carrier··········································14-3 Rear Carrier ·········································· 14-6 Fuel Tank Cover····································14-3 Rear Fender·········································· 14-6 Mechanism Diagram Front carrier Front fender Meter cover Front top cover Headlight Right side cover Front grille...

  • Page 173: Maintenance

    To this chapter contents 14. BODY COVER Maintenance Body covers disassemble sequence: Maintenance Cover Front Bumper Cover Rear Carrier Front Top Cover Front Low Bumper Rear Center Up Cover Fuel Tank Cover R/L Inner Protector Tail Light Low Cover Front Carrier Front Grille Rear fender R/L Side Covers...

  • Page 174: Front Carrier

    To this chapter contents 14. BODY COVER Front Carrier Removal Loosen 6 bolts from the front carrier. Remove the front carrier. Installation Install in the reverse order of removal procedures. 6 bolts Fuel Tank Cover Removal Remove the maintenance cover. Remove the front top cover.

  • Page 175: Front Fender

    To this chapter contents 14. BODY COVER Front Fender 4 bolts Removal Remove the seat. Remove the maintenance cover and front top cover. Remove the fuel tank cap and fuel tank cover. Remove the right and left side covers. Remove 4 screws from footrest. 4 screws Remove 4 screws from the right and left inner protectors.

  • Page 176: Footrest

    To this chapter contents 14. BODY COVER Footrest Removal Remove right and left foot peg bolts (each side 2 bolts). Remove the foot pegs. 2 bolts Remove 2 bolts from the right and left footrests. 2 bolts Remove 4 screws from the rear part of the footrest.

  • Page 177: Rear Carrier

    To this chapter contents 14. BODY COVER Rear Carrier 2 Bolts Removal Loosen 4 bolts from the rear carrier. Remove the rear carrier. Installation 2 Bolts In stall in the reverse order of removal procedures. Rear Fender Rear center up cover Remove the rear carrier.
  • Page 178 To this chapter contents 14. BODY COVER Disconnect the full transistor igniter, 2WD/ 4WD Full transistor igniter control unit and battery open control unit. 2WD/ 4WD control unit Battery open control unit Remove the rear fender. Installation Install in the reverse order of removal procedures. 14-7...
  • Page 179 To this chapter contents 14. BODY COVER NOTES: 14-8...
  • Page 180 Home page Contents 15. FRONT BRAKE & FRONT WHEEL Mechanism Diagram ·····························15-1 Adding Brake Fluid ······························ 15-6 Maintenance Description ·····················15-2 Brake Fluid Replacement / Air-bleed·· 15-6 Trouble Diagnosis ································15-3 Front Brake Caliper······························ 15-8 Front Wheel ···········································15-4 Brake Disk ············································ 15-9 Front Wheel Hub ···································15-4 Front Brake Master Cylinder···············...

  • Page 181: Maintenance Description

    To this chapter contents 15. 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. Do not remove brake caliper before removing the hydraulic system.

  • Page 182: Trouble Diagnosis

    To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Trouble Diagnosis Soft brake lever Hard steering 1. Air inside the hydraulic system 1. Faulty tire 2. Hydraulic system leaking 2. Insufficient tire pressure 3. Worn master piston 4. Worn brake pad 5.

  • Page 183: Front Wheel

    To this chapter contents 15. 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 4 nuts from the front wheel. Remove the front wheel. 4 nuts Installation Install the front wheel and tighten the nuts.

  • Page 184: Disk Brake System Inspection

    To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Wheel hub Inspection Check disk & hub for wear or damage, and replace it if necessary. Installation Install the front wheel disk and hub. Brake disk Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam...

  • Page 185: Adding Brake Fluid

    To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Adding Brake Fluid Before removing the brake fluid reservoir, turn the handle to make the brake fluid reservoir become horizontal, and then remove the brake fluid reservoir. Before serving the brake system, cover the surface of the painted or the rubber parts by the rags.
  • Page 186 To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Air-bleed valve Open the drain valve around 1/4 turns, and at the same time hold the brake lever until the there is no air bubble in the drain hose and also feeling resistance on the brake lever.

  • Page 187: Front Brake Caliper

    To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Front Brake Caliper Brake hose bolt Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill the brake fluid on painted surfaces. Remove two caliper bolts and the caliper.

  • Page 188: Brake Disk

    To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Brake Disk Brake disk Inspection Visually check the brake disk for wear or spoilage. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 189 To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Remove the rubber boot. Remove the cir clip. Cir clip Remove the piston and the spring. Rubber boot Clean the master cylinder with recommended Piston brake fluid. Piston cup Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch.
  • Page 190 To this chapter contents 15. 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. 2 socket bolts Install the brake lever, and connect leads to brake Brake lever bolt light switch.
  • Page 191 To this chapter contents 15. FRONT BRAKE & FRONT WHEEL Notes: 15-12...
  • Page 192 Home page Contents 16. STEERING / FRONT SUSPENSION Mechanism Diagram ······················16-1 Knuckle·············································· 16-7 Precautions in Operation ··············16-2 Knuckle Disassembly ······················· 16-8 Trouble Diagnosis ·························16-2 Knuckle Assembly ···························· 16-9 Steering Handle ·····························16-3 Front Cushion ··································· 16-11 Steering Shaft ································16-4 Suspension Arm ······························· 16-12 Steering Tie-Rod ····························16-6 Toe-In ·················································...

  • Page 193: Handlebar Upper Holder Bolt

    To this chapter contents 16. STEERING / FRONT SUSPENSION Precautions in Operation Torque Values 2.4kgf-m Handlebar upper holder bolt 4.0kgf-m Handlebar under holder nut 3.4kgf-m Steering shaft holder bolt 5.0kgf-m Steering shaft nut 5.0kgf-m Steering tie-rod nut 5.0kgf-m Knuckle nut 3.6kgf-m Tie rod lock nut 5.0kgf-m...

  • Page 194: Steering Handle

    To this chapter contents 16. STEERING / FRONT SUSPENSION Steering Handle Handle wire Removal Remove the handle cover, meter set, handle protect cover and front fender. (Refer to chapter Remove the handle wire band. 2 brocket bolts Loosen the socket bolts from the rear brake master cylinder, and remove front brake master cylinder.

  • Page 195: Steering Shaft

    To this chapter contents 16. STEERING / FRONT SUSPENSION Remove the handle mounting bolt, and then remove the handle upper holder, handle. Remove 2 nuts to remove handle under holder and meter bracket. Installation Install in the reverse order of removal procedures. Torque value: 4.0kgf-m Handlebar under holder nut...
  • Page 196 To this chapter contents 16. STEERING / FRONT SUSPENSION Loosen 2 bolts, and then remove steering shaft holder, nut fixed plate, pressed plate and steering shaft. Inspection Check oil rings for wear or damage, and replace it if necessary. Measure the holder inner diameter. Maximum limit: Ø39.5 mm 2 bolts Oil rings...

  • Page 197: Steering Tie-Rod

    To this chapter contents 16. STEERING / FRONT SUSPENSION Steering Tie-Rod Tie-rod nuts Removal Remove the cotter pin and the tie-rod nut from the steering shaft side. Cotter pin Tie-rod Remove the cotter pin and the tie-rod nut from the wheel side.

  • Page 198: Knuckle

    To this chapter contents 16. STEERING / FRONT SUSPENSION Knuckle Remove Remove front wheel, front brake caliper, front wheel hub and brake disk. Remove 2 bolts from front brake caliper them remove front brake caliper 2 bolts Remove cotter pin and nut, remove front brake disk.

  • Page 199: Knuckle Disassembly

    To this chapter contents 16. STEERING / FRONT SUSPENSION Remove cotter pin and tie-rod nut, remove tie rod SYM-5325800-REA with special tool. Tools number: SYM-5325800-REA Tools name: ball joint driver Remove the knuckle body. Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking.

  • Page 200: Knuckle Assembly

    Assemble bearing 6006uu by special tool in the knuckle then lock the nut. SYM-5024000- REA A6006 Install the bearing with special tool & air tool. Tools number: SYM-5024000- REA A6006 SYM-5024000- REA A6006 Tools name: wheel knuckle body bearing 6006 in puller with air.
  • Page 201 SYM-9123200- REA Oil seal Install oil seal into the knuckle body with hammer. Hamme SYM-9123200- REA Tools number: SYM-9123200- REA Tools name: wheel knuckle body seal 40*55*8 in driver. Assemble oil seal 40*50*6.5 by special tool. SYM-9123000- REA Oil seal Install oil seal into the knuckle body with hammer.

  • Page 202: Front Cushion

    To this chapter contents 16. STEERING / FRONT SUSPENSION Front Cushion Removal Remove the front cushion under bolt nut, and remove the bolt. Remove the front cushion upper bolt nut, and remove the bolt and the cushion. Bolt Installation Install in the reverse order of removal procedures. Torque value: Front cushion nut 4.6kgf-m...

  • Page 203: Suspension Arm

    To this chapter contents 16. STEERING / FRONT SUSPENSION Suspension Arm Suspension arm nuts Removal Remove the front wheel, wheel hub, and brake caliper, brake disk, tie-rod, knuckle and front cushion. Loosen upper suspension arm nuts. Remove swing arm bolts. Loosen 1 bolt from under suspension arm cover and then remove the cover.

  • Page 204: Toe-In

    To this chapter contents 16. STEERING / FRONT SUSPENSION Toe-In After repair or disassembly of the steering system parts, adjustment of toe-in is required. Keep the vehicle on level ground and the front wheels facing forward. Mark the centers of the tires to indicate the axle center height.
  • Page 205 Home page Contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Mechanism Diagram ··························· 17-1 Suspension Arm ································· 17-10 Maintenance Description···················· 17-2 Disk Brake System Inspection··········· 17-11 Trouble Diagnosis······························· 17-3 Adding Brake Fluid ····························· 17-12 Rear Wheel··········································· 17-4 Brake Fluid Replacement / Air-bleed· 17-13 Rear Wheel Connecter ························...

  • Page 206: Rear Axle Castle Nut

    Rear wheel axle nut 9.20kgf-m Brake lever nut 1.00kgf-m Rear 4.6kgf-m cushion mounting bolt Air-bleed valve 0.50kgf-m 9.2kgf-m Swing arm pivot bolt 2.40kgf-m Rear wheel nut Special tools Inner bearing puller: SYM-6204022 Rear axle bearing driver (6007LLU): SYM-9100100 RA1 A3017 17-2...

  • Page 207: Trouble Diagnosis

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Trouble Diagnosis Soft brake lever Vibration or Wobble 1. Air inside the hydraulic system 1. Axle is not tightened well 2. Hydraulic system leaking 2. Bent rim 3.

  • Page 208: Rear Wheel

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Removal Raise the rear wheels off the ground by placing a jack or other support under the frame. Remove the rear wheel nuts, and then remove rear wheels.

  • Page 209: Rear Wheel Hub

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Wheel Hub 2 nuts Remove Loosen 2 nuts then 2 flange bolts 2 bolts Remove the rear wheel hub. Wheel Hub Disassembly 4 washer seals Remove 4 washer seals & 2 callers from rear wheel hub.
  • Page 210 Inner cir clip pliers Cir clip in 55 Remove the 2 bearing from rear wheel hub with special tool. Tools number: SYM-6204025 Tools name: inner bearing outer puller. SYM-6204025 Remove the 4 oiled from rear wheel hub with special tool.
  • Page 211 Install 2 bearing 6006uu into the rear wheel hub SYM-5024000- REA A6006 with special tool. Tools number: SYM-5024000- REA A6006 Tools name: wheel knuckle body bearing 6006 in puller with air or head tool. Bearing 6006uu Assembly oil seal 40*50*6.5 by special tool...
  • Page 212 Inner cir clip pliers Cir clip in 55 Assembly oil seal 40*55*8 by special tool SYM-9123200-REA Tools number: SYM-9123200- REA Tools name: wheel knuckle body seal 40*55*8 in driver. Oil SEAL 40*50*6.5 Install the oil seal with special tool & hammer SYM-9123000-REA Oil SEAL 40*50*6.5...

  • Page 213: Rear Cushion

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Cushion Removal Remove the rear wheels. Remove the rear wheel connecter. Loosen 2 bolts from the rear cushion. Remove the rear cushion. Installation Install rear cushion, and install rear cushion upper bolt.

  • Page 214: Suspension Arm

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Suspension Arm 2 bolts Removal Remove the rear wheel, wheel hub and rear cushion. Loosen upper suspension arm nuts. Remove swing arm bolts. Bolt Loosen 2 bolts from under suspension arm cover and then remove the cover.

  • Page 215: Disk Brake System Inspection

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts.

  • Page 216: Adding Brake Fluid

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Fluid cup Adding Brake Fluid Before removing the brake fluid reservoir, turn the handle to make the brake fluid reservoir become horizontal, and then remove the brake fluid reservoir.

  • Page 217: Air-Bleed Valve

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake Fluid Replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out.

  • Page 218: Rear Brake Caliper

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Rear Brake Caliper Brake hose bolt 2 bolts Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces.

  • Page 219: Brake Disk

    To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit.
  • Page 220 To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder Hose clamp Place a container under the brake master cylinder, remove fluid hose clamp, and drain out the brake fluid.
  • Page 221 To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Allowable limit: Hand brake 13.954 mm Foot brake 15.850 mm Master Cylinder Assembly Caution It is necessary to replace the whole set...
  • Page 222 To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Right footrest side – rear brake master cylinder Hose clamp Install the master cylinder bolts and the master cylinder. 2 bolts Install brake push rod to the brake pedal, and Lock nut Adjustment nut install pin and E type clip.
  • Page 223 To this chapter contents 17. REAR BRAKE & REAR WHEEL & REAR CUSHION Notes: 17-19...
  • Page 224 Home page Contents 18. ELECTRICAL SYSTEM Mechanism Diagram ·····························18-1 Starting System ······································ 18-10 Maintenance Data··································18-2 Meters ······················································ 18-12 Technical Specification ························18-2 Light / Bulb ·············································· 18-13 Trouble Diagnosis·································18-3 Switch / Horn··········································· 18-16 Battery····················································18-4 Cooling Fan Thermo Switch ·················· 18-19 Charging System···································18-5 Thermo Unit·············································...

  • Page 225: Maintenance Data

    To this chapter contents 18. ELECTRICAL SYSTEM Maintenance Data Operational precaution When removing the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal then the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.

  • Page 226: Trouble Diagnosis

    To this chapter contents 18. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate Battery discharged properly The cable disconnected Burned fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage...
  • Page 227 To this chapter contents 18. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove the battery. Clamp Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 228: Charging System

    To this chapter contents 18. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Black Yellow Yellow Fuse 20A Yellow Battery Regulator rectifier AC. Generator 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.
  • Page 229 To this chapter contents 18. ELECTRICAL SYSTEM Inspection on Charging Voltage Connect a tachometer. Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...
  • Page 230 To this chapter contents 18. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3-pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Battery voltage R –...

  • Page 231: Ignition System

    To this chapter contents 18. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram Black Shift Gear Control Unit Full Transistor Ignition Unit Green White Yellow Blue G/W L/Y Fuse 15A Ignition Coil Main fuse Spark Plug Battery Main switch Pulse Generator Full Transistor Ignition Unit Disconnect connectors of the full transistor ignition unit.
  • Page 232 To this chapter contents 18. ELECTRICAL SYSTEM 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: 2.8 ± 10% Ω Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.
  • Page 233 To this chapter contents 18. ELECTRICAL SYSTEM Starting System Starting circuit diagram Shift gear control unit Fuse 15A BR/Y Main switch Main fuse Brake switch Battery Change switch Starter relay Starter motor Black Green White Starter switch Yellow Brown Brake light Inspection on starter relay Open the main switch.
  • Page 234 To this chapter contents 18. ELECTRICAL SYSTEM Removal of Starter motor Negative Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. Starter motor cable Loosen the lock bolts and remove the starter motor.
  • Page 235 To this chapter contents 18. ELECTRICAL SYSTEM Meters Meter set couplers Removal Remove the front fender. Remove couplers of meter and main switch couplers. Main switch coupler Remove 4 bolts from meter stay. 4 bolts Remove 3 screws and speedometer cable. Disassemble speedometer cover and speedometer.
  • Page 236 To this chapter contents 18. ELECTRICAL SYSTEM Light / Bulb 2 screws Headlight bulb replacement Remove 2 screws for the headlight cover, and remove the cover. Adjusting screw Remove the rubber boot. Rubber boot Press the bulb setting hook. Hook Remove the bulb connector and the bulb.
  • Page 237 To this chapter contents 18. ELECTRICAL SYSTEM Front winker light bulb replacement 2 screws Remove 2 screws from the winker light cover. Remove the winker light cover. Replace with new front winker light bulb. (12V 21W) Position light bulb Replacing Bulb of Position Light Pull out the position light bulb seat.
  • Page 238 To this chapter contents 18. ELECTRICAL SYSTEM Replacing Bulb of Taillight and Rear Taillight bulb Winker Light Remove 2 screws. Remove the taillight cover. 2 screws Replace with new taillight bulb. (12V 5W/21W) Remove 2 screws. Remove the rear winker light cover. 2 screws Pull out the rear winker bulb.
  • Page 239 To this chapter contents 18. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position Main switch coupler Wire Color Black Replacement of main switch Disconnect the coupler of the main switch.
  • Page 240 To this chapter contents 18. ELECTRICAL SYSTEM Headlight Switch Headlight switch BAT3 Position ● White Wire color White Blue Brown / Black Winker switch Winker switch Hazard switch Position N PUSH OFF Brown / Wire color Pink Black White Horn switch Horn switch BAT3 Position...
  • Page 241 To this chapter contents 18. ELECTRICAL SYSTEM Front Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch Brake light switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity.

  • Page 242: Cooling Fan Thermo Switch

    To this chapter contents 18. ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
  • Page 243 To this chapter contents 18. ELECTRICAL SYSTEM Thermo unit Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2 Caution Wear gloves and goggles when performing this test.
  • Page 244 To this chapter contents 18. ELECTRICAL SYSTEM Notes: 18-21...
  • Page 245 Homepage Contents 19. ELECTRICAL DIAGRAM 19-1...
  • Page 246 Homepage Contents 19. ELECTRICAL DIAGRAM Note: 19-2...

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