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Eton ATV6A 90 Service Manual

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E-TON POWER
ATV6A 90
VIPER 90
SERVICE MANUAL

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Summary of Contents for Eton ATV6A 90

  • Page 1 All manuals and user guides at all-guides.com E-TON POWER ATV6A 90 VIPER 90 SERVICE MANUAL...
  • Page 2 All manuals and user guides at all-guides.com VIPER 90 SERVICE MANUAL 2009 by E-TON POWER TECH CO., LTD. First edition, May 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of E-TON POWER TECH CO., LTD. is expressly prohibited.
  • Page 3 All manuals and user guides at all-guides.com IMPORTANT This manual was produced by the E-TON POWER TECH CO primarily for use by E-TON dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on E-TON machine has a basic understanding of the mechanical ideas and the procedures of machine repair.

  • Page 4: Manual Organization

    All manuals and user guides at all-guides.com HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 5 All manuals and user guides at all-guides.com SYMBOLS The following symbols are not relevant to every machine. SPEC INFO Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Engine Carburetor Chassis Electrical Troubleshooting CHAS CARB TRBL –...

  • Page 6: Table Of Contents

    All manuals and user guides at all-guides.com TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL – TROUBLESHOOTING...

  • Page 7: General Information

    All manuals and user guides at all-guides.com CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 ENGINE SERIAL NUMBER...............1-1 IMPORTANT INFORMATION .................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-2 REPLACEMENT PARTS................1-2 GASKETS, OIL SEALS AND O-RINGS ............1-2 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS............1-4...

  • Page 8: Specifications

    All manuals and user guides at all-guides.com CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS ................2-4 CHASSIS SPECIFICATIONS ................2-11 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-15 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-16 HOW TO USE THE CONVERSION TABLE..........2-18 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-19 ENGINE....................2-19 OIL FLOW DIAGRAMS.................2-21...

  • Page 9: Periodic Checks And Adjustments

    All manuals and user guides at all-guides.com CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART FOR THE..........3-1 EMISSION CONTROL SYSTEM GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 HANDLEBAR, SEAT, FENDERS AND FUEL TANK ........3-3 HANDLEBAR...................3-3 SEAT, FRONT PANEL AND FOOTREST BOARDS......3-4 FRONT FENDER..................3-5 REAR FENDER AND BATTERY.............3-6 FUEL TANK AND FOOTREST BARS.............3-7...

  • Page 10: Engine

    All manuals and user guides at all-guides.com CHAPTER 4 ENGINE ENGINE ......................4-1 EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS ....4-1 ENGINE MOUNTING BOLTS ..............4-2 REMOVING THE ENGINE ................4-3 INSTALLING THE ENGINE...............4-3 CYLINDER HEAD ....................4-4 REMOVING THE CYLINDER HEAD............4-6 CHECKING THE CAMSHAFT SPROCKET..........4-7 CHECKING THE CYL.
  • Page 11 All manuals and user guides at all-guides.com BELT DRIVE ....................4-31 CRANKCASE COVER................4-31 KICKSTARTER..................4-32 INSTALLING THE KICKSTARTER............4-33 V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY.........4-34 DISASSEMBLING THE SECONDARY SHEAVE........4-35 REMOVING THE PRIMARY SHEAVE............4-36 REMOVING THE SECONDARY SHEAVE AND V-BELT......4-36 DISASSEMBLING THE SECONDARY SHEAVE........4-37 CHECKING THE CLUTCH SHOE............4-37 CHECKING THE V-BELT................4-38 CHECKING THE DRIVE PULLEY............4-38...

  • Page 12: Carburetor

    All manuals and user guides at all-guides.com CHAPTER 5 CARBURETOR CARBURETOR....................5-1 DISASSEMBLING THE CARBURETOR...........5-4 CHECKING THE CARBURETOR .............5-4 ASSEMBLING THE CARBURETOR............5-6 INSTALLING THE CARBURETOR ............5-7 MEASURING AND ADJUSTING THE FUEL LEVEL ........5-8...

  • Page 13: Chassis

    All manuals and user guides at all-guides.com CHAPTER 6 CHASSIS FRONT AND REAR WHEELS ..............6-1 FRONT WHEELS ..................6-1 REAR WHEELS ..................6-2 CHECKING THE WHEELS ..............6-3 CHECKING THE FRONT WHEEL HUBS ..........6-3 CHECKING THE REAR WHEEL HUBS..........6-4 INSTALLING THE WHEEL HUBS............6-4 INSTALLING THE FRONT WHEELS............6-5 INSTALLING THE REAR WHEELS............6-5 FRONT BRAKES ..................6-6...
  • Page 14 All manuals and user guides at all-guides.com STEERING SYSTEM ..................6-28 HANDLEBAR................... 6-28 REMOVING THE HANDLEBAR GRIPS..........6-30 REMOVING THE REAR BRAKE SWITCH ..........6-30 CHECKING THE HANDLEBAR ..............6-30 INSTALLING THE HANDLEBAR ............6-31 INSTALLING THE HANDLEBAR GRIPS ..........6-31 INSTALLING THE REAR BRAKE MASTER CYLINDER......6-32 INSTALLING THE FRONT BRAKE LEVER ASSEMBLY......6-32 INSTALLING THE PARKING BRAKE LEVER.........6-33 STEERING STEM ...................6-34...

  • Page 15: Electrical

    All manuals and user guides at all-guides.com CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS................7-1 WIRING DIAGRAM ..................7-2 CHECKING THE SWITCHS ................7-3 CHECKING SWITCH CONTINUITY .............7-4 IGNITION SYSTEM ..................7-5 CIRCUIT DIAGRAM ..................7-5 TROUBLESHOOTING ................7-6 ELECTRIC STARTING SYSTEM ..............7-10 CIRCUIT DIAGRAM ................7-10 STARTING CIRCUIT OPERATION............7-11 TROUBLESHOOTING ................7-12 STARTER MOTOR..................7-14 CHECKING THE STARTER MOTOR .............7-15...

  • Page 16: Troubleshooting

    All manuals and user guides at all-guides.com CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD STARTING ............8-1 FUEL SYSTEM..................8-1 ELECTRICAL SYSTEM................8-1 COMPRESSION SYSTEM................8-2 POOR IDLE SPEED PERFORMANCE ............8-2 POOR IDLE SPEED PERFORMANCE.............8-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE........8-2 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......8-2 FAULTY CLUTCH ...................8-3 ENGINE OPERATES BUT VEHICLE WILL NOT MOVE......8-3 CLUTCH SLIPPING..................8-3...

  • Page 17: Machine Identification

    All manuals and user guides at all-guides.com MACHINE IDENTIFICATION INFO GENERAL INFORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the left side of the frame. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine.

  • Page 18: Important Information

    All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1.Before removal and disassembly add, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. 3. When disassembling always keep mated parts together.

  • Page 19: Lock Washers/Plates And Cotter Pins

    All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible.

  • Page 20: Checking The Connections

    All manuals and user guides at all-guides.com IMPORTANT INFORMATION INFO CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture Dry with an air blower.

  • Page 21: General Specifications

    All manuals and user guides at all-guides.com SPEC SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code Virper 90 Dimensions Overall length 1,500 mm (59.1 in) Overall width 850 mm (33.5 in) Overall height 900 mm (35.4 in) Seat height 680 mm (26.8 in) Wheelbase 930 mm (36.6 in)
  • Page 22 All manuals and user guides at all-guides.com SPEC SPEC GENERAL SPECIFICATIONS Item Standard Fuel Type Unleaded gasoline 92 octane Fuel tank capacity plastic 4.5 L (0.99 lmp gal, 1.19 US gal) Iron 3.6 L (0.79 lmp gal, 0.95 US gal) Fuel reserve amount plastic 1.0 L (0.22 Imp gal, 0.26 US gal)
  • Page 23 All manuals and user guides at all-guides.com SPEC SPEC GENERAL SPECIFICATIONS Item Standard Brake Front brake type Drum brake operation Right hand operation Rear brake type Single disc brake operation Left hand operation Suspension Front suspension Single A-arm / Independent Rear suspension Swing arm Shock absorber...

  • Page 24: Engine Specifications

    All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit 7.00 ~ 7.40 cm 0.05 mm (0.43 ~ 0.45 cu.in) (0.002 in) Cylinder Bore size 47.000 mm 47.10 mm (1.8504 in) (1.8543 in) Taper limit ----...
  • Page 25 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 10.000 ~ 10.015 mm 10.100 mm (0.3937 ~ 0.3943 in) (0.3976 in) Rocker arm shaft outside diameter 9.972 ~ 9.987 mm 9.910 mm (0.3902 in) (0.3926 ~ 0.3932 in)
  • Page 26 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.02 mm...
  • Page 27 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Compressed pressure ---- 73.75 ~ 90.03 N at 25.45 mm installed) (7.52 ~ 9.18 kg, 16.57 ~ 20.23 lb at 1.00 in) ---- 73.75 ~ 90.03 N at 25.45 mm (7.52 ~ 9.18 kg, 16.57 ~ 20.23 lb at 1.00 in) °/...
  • Page 28 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Type ---- Barrel ---- 1.0 × 2.1 mm Dimensions (B × T) (0.0394 × 0.0827in) 0.45 mm End gap (installed) 0.10 ~ 0.25 mm (0.0177in) (0.0039~0.0098in) 0.09 mm...
  • Page 29 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Automatic centrifugal ---- Clutch shoe thickness 4.0 mm (0.1575 in) (0.078 in) 30.5 mm Clutch shoe spring free length ---- Clutch housing inside diameter 107.0 ~107.2 mm 107.5 mm (4.21 ~4.22 in)
  • Page 30 All manuals and user guides at all-guides.com SPEC SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.04 ~ 0.12mm 0.15 mm (0.0016 ~ 0.0047 in) (0.006 in) Outer-rotor-to-oil-pump-housing clearance 0.14 ~ 0.21 mm 0.28 mm (0.0055 ~ 0.0083 in) (0.0110 in)

  • Page 31: Chassis Specifications

    All manuals and user guides at all-guides.com SPEC SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Shock absorber travel 35 mm (1.38 in) ---- Optional spring ---- Rear suspension Shock absorber travel 40 mm (1.57 in) ---- Optional spring ---- Front wheel Type...
  • Page 32 All manuals and user guides at all-guides.com SPEC SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear disc brake Single ---- Type Disc outside diameter × thickness 190.0 × 3.2 mm (7.48 × 0.13 in) 2.7 mm (0.11 in) Brake disk maximum deflection 0.15 mm (0.006 in) Pad thickness inner...

  • Page 33: Electrical Specifications

    All manuals and user guides at all-guides.com SPEC SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 13.0 ° ± 1 ° /1,700 r/min ---- Advanced timing (B.T.D.C.) 28.5 ° ± 1 ° /4,000 r/min ---- Advancer type Electrical (digital)
  • Page 34 All manuals and user guides at all-guides.com SPEC SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh ---- Starter motor Model/manufacturer C1200-A26-9000/SY ---- Output 0.35 kW ---- Armature coil resistance 0.014 ~ 0.019 at 20 °C (68 ° ---- Brush overall length 7.0 mm (0.28 in)

  • Page 35: Tightening Torques

    All manuals and user guides at all-guides.com SPEC SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cover head cylinder Bolt Holder cam shaft Spark plug —...

  • Page 36: Chassis Tightening Torques

    All manuals and user guides at all-guides.com SPEC SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Remarks Nm m · kg ft · lb Engine lower stay and engine 25.3 Engine and frame 25.3 Engine lower stay and frame 25.3 Swingarm pivot shaft and frame...
  • Page 37 All manuals and user guides at all-guides.com SPEC SPEC TIGHTENING TORQUES ® 1. Before tightening the nuts, apply locking agent (LOCTITE ) to rear axle threads. 2. Tighten the inside nut to 60 Nm (6.0 m · kg, 43.4 ft · lb). k ·...

  • Page 38: How To Use The Conversion Table

    All manuals and user guides at all-guides.com HOW TO USE THE CONVERSION TABLE / SPEC SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread in SI and METRIC UNITS.

  • Page 39: Lubrication Points And Lubricant Types

    All manuals and user guides at all-guides.com SPEC SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Lubricant Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Cylinder head stud bolt thread Cylinder head gasket dowel pin Crankshaft pin outside surface Connecting rod...
  • Page 40 All manuals and user guides at all-guides.com SPEC SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant Primary sheave inside, Collar, Solid bush, Secondary fixed inner surface BEL-RAY asembly lube Secondary sheave torque cam ditch BEL-RAY asembly lube Gasket (Cylinder head cover) Sealant Stopper guide (Cylinder head cover) Sealant...

  • Page 41: Oil Flow Diagrams

    All manuals and user guides at all-guides.com SPEC SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 2 - 21...

  • Page 42: Cable Routing

    All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING CABLE ROUTING Front brake cables Fuel overflow Wire harness Rear brake hose Throttle valve hose Rear brake switch lead Throttle cable Carburetor air vent hose Handlebar switch lead Choke cable Oil catch hose Fuel tank breather hose Crankcase breather hose...
  • Page 43 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Pass the front brake cables, throttle cable and choke cable through the hose guide. Fasten the choke cable, handlebar switch lead and rear brake switch lead with a plastic band. Insert the fuel tank breather hose into the hole in the handlebar cover.
  • Page 44 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Brake fuel tube with a clip. Route the parking brake cable under the cross pipe and left of the steering column as shown in the illustration. 2 - 24...
  • Page 45 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Fuel drain hose Wire harness H Ignition coil Rear brake hose A Positive starter motor lead I Rectifier/regulator Throttle cable B Positive battery lead Starter relay C Negative battery lead Battery Parking brake cable Front brake cables...
  • Page 46 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Pass these leads through rear fender. Fasten the wire harness, main switch lead, heater control switch lead and with a plastic band. Fasten the wire harness, negative battery lead and starter motor lead with a plastic band. Fixed the negative battery lead and negative starter motor lead by a bolt.
  • Page 47 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Rear brake switch lead Positive battery lead Rear brake hose Main fuse Front brake cable (right) Negative battery lead Front brake cable (left) Handlebar switch Throttle cable Choke cable Fuel tank breather hose Parking brake cable Battery...
  • Page 48 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Fasten the handlebar switch lead , rear brake switch lead and choke cable with a plastic band. To starter relay. To the frame. Connect the negative battery lead to the battery so that the lead is routed to the side of the battery. Connect the positive battery lead to the battery so that the lead contacts the battery case.
  • Page 49 All manuals and user guides at all-guides.com SPEC SPEC CABLE ROUTING Throttle cable Handlebar switch lead A Ignition coil Rear brake hose Front brake cable (left) Choke cable Front brake cable (right) Rear brake switch lead Parking brake cable Fasten the handlebar switch lead , rear brake switch lead and choke cable with a plastic band.

  • Page 50: Introduction

    All manuals and user guides at all-guides.com INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as to new machines that are being prepared for sale.
  • Page 51 All manuals and user guides at all-guides.com INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY month Whichev- CHECK OR MAINTENANCE er comes ITEM 1300 2500 2500 5000 (mi) (200) (800) (1600) (1600) (3200) hours Check for looseness or damage, and replace if Wheel hub bearings necessary.

  • Page 52: Handlebar, Seat, Fenders And Fuel Tank

    All manuals and user guides at all-guides.com HANDLEBAR, SEAT, FENDERS AND FUEL TANK HANDLEBAR, SEAT, FENDERS AND FUEL TANK HANDLEBAR 14 Nm (1.4 m kg, 10.1 ft • • (x4) 28 Nm (2.8 m kg, 20.3 ft • • Order Job/Part Q’ty Remarks...

  • Page 53: Seat, Front Panel And Footrest Boards

    All manuals and user guides at all-guides.com HANDLEBAR, SEAT, FENDERS AND FUEL TANK SEAT, FRONT PANEL AND FOOTREST BOARDS (x2) (x4) (x2) Order Job/Part Q’ty Remarks Removing the seat, front panel and Remove the parts in the order listed. footrest boards Handlebar Refer to “HANDLEBAR”.

  • Page 54: Front Fender

    All manuals and user guides at all-guides.com HANDLEBAR, SEAT, FENDERS AND FUEL TANK FRONT FENDER 9.0 Nm (0.9 m kg, 6.5 ft 9.0 Nm (0.9 m kg, 6.5 ft • • • • 9.0 Nm (0.9 m kg, 6.5 ft •...

  • Page 55: Rear Fender And Battery

    All manuals and user guides at all-guides.com HANDLEBAR, SEAT, FENDERS AND FUEL TANK REAR FENDER AND BATTERY 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • (x2) Order Job/Part Q’ty Remarks Removing the rear fender and battery Remove the parts in the order listed.

  • Page 56: Fuel Tank And Footrest Bars

    All manuals and user guides at all-guides.com HANDLEBAR, SEAT, FENDERS AND FUEL TANK FUEL TANK AND FOOTREST BARS (x4) 12 Nm (1.2 m kg, 8.7 ft • • (x4) Order Job/Part Q’ty Remarks Removing the fuel tank and footrest Remove the parts in the order listed. bars Seat and front panel Refer to “SEAT AND FRONT PANEL”.

  • Page 57: Engine

    All manuals and user guides at all-guides.com ADJUSTING THE VALVE CLEARANCE ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room tempera- ture. •...
  • Page 58 All manuals and user guides at all-guides.com ADJUSTING THE VALVE CLEARANCE c. Measure the valve clearance using a thick- ness gauge Out of specification Adjust 3. Adjust: • valve clearance a. Loosen the locknut b. Insert a thickness gauge between the adjuster end and the valve end.

  • Page 59: Adjusting The Engine Idling Speed

    All manuals and user guides at all-guides.com ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE ENGINE IDLING SPEED 1. Start the engine and let it warm up for sev- eral minutes. 2. Attach: • engine tachometer (to the spark plug lead) 3.

  • Page 60: Adjusting The Throttle Lever Free Play

    All manuals and user guides at all-guides.com ADJUSTING THE THROTTLE LEVER FREE PLAY ADJUSTING THE THROTTLE LEVER FREE PLAY Engine idling speed should be adjusted prop- erly before adjusting the throttle lever free play. 1. Measure: • throttle lever free play Out of specification Adjust.

  • Page 61: Adjusting The Speed Limiter

    All manuals and user guides at all-guides.com ADJUSTING THE SPEED LIMITER ADJUSTING THE SPEED LIMITER The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi- tion. Screwing in the adjuster stops the engine speed from increasing.

  • Page 62: Checking The Spark Plug

    All manuals and user guides at all-guides.com CHECKING THE SPARK PLUG CHECKING THE SPARK PLUG 1. Remove: • spark plug 2. Check: • spark plug type Incorrect Change. Standard spark plug CR7HSA/NGK 3. Check: • electrode Wear/damage Replace. • insulator Abnormal color Replace.

  • Page 63: Checking The Ignition Timing

    All manuals and user guides at all-guides.com CHECKING THE IGNITION TIMING CHECKING THE IGNITION TIMING Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: • Shroud cap 2. Attach: • engine tachometer •...

  • Page 64: Measuring The Compression Pressure

    All manuals and user guides at all-guides.com MEASURING THE COMPRESSION PRESSURE MEASURING THE COMPRESSION PRESSURE Insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specification Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”. 2.
  • Page 65 All manuals and user guides at all-guides.com MEASURING THE COMPRESSION PRESSURE a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground the spark plug lead before cranking the engine.

  • Page 66: Checking The Engine Oil Level

    All manuals and user guides at all-guides.com CHECKING THE ENGINE OIL LEVEL CHECKING THE ENGINE OIL LEVEL 1. Place the machine on a level surface. 2. Check: • engine oil level Oil level should be between the maximum mark and minimum mark.

  • Page 67: Changing The Engine Oil

    All manuals and user guides at all-guides.com CHANGING THE ENGINE OIL CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt.

  • Page 68: Cleaning The Air Filter Elements

    All manuals and user guides at all-guides.com CLEANING THE AIR FILTER ELEMENTS CLEANING THE AIR FILTER ELEMENTS There is a check hose at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter elements and air fil- ter case.

  • Page 69: Cleaning The Spark Arrester

    All manuals and user guides at all-guides.com CLEANING THE AIR FILTER ELEMENTS/ CLEANING THE SPARK ARRESTER b. Squeeze the excess solvent out of the spo- nge materials and let it dry. N O T I C E Do not twist or wring out the sponge materials. could damage the sponge materials.
  • Page 70 All manuals and user guides at all-guides.com CLEANING THE SPARK ARRESTER c. Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.

  • Page 71: Chassis

    All manuals and user guides at all-guides.com CHECKING THE FRONT BRAKE SHOES/ ADJUSTING THE FRONT BRAKE CHASSIS CHECKING THE FRONT BRAKE SHOES 1. Check: • Upper adjusting bolt • Lower adjusting bolt Replace more than 12 mm (0.47 in) the brake shoes as a set. Refer to “FRONT BRAKES”...

  • Page 72: Adjusting The Parking Brake

    All manuals and user guides at all-guides.com ADJUSTING THE PARKING BRAKE ADJUSTING THE PARKING BRAKE 1. Check: • parking brake cable end length Out of specification Adjust. Parking brake cable end length 53.0 ~ 57.0 mm (2.09 ~ 2.24 in) 2.

  • Page 73: Checking The Rear Brake Fluid Level

    All manuals and user guides at all-guides.com CHECKING THE REAR BRAKE FLUID LEVEL CHECKING THE REAR BRAKE FLUID LEVEL 1. Place the machine on a level surface. When checking the brake fluid level, make sure that the top of the brake master cylinder reser- voir or brake fluid reservoir is horizontal.

  • Page 74: Checking The Rear Brake Pads

    All manuals and user guides at all-guides.com CHECKING THE REAR BRAKE PADS/ CHECKING THE BRAKE HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM CHECKING THE REAR BRAKE PADS 1. Check: • brake pads Wear indicators almost touch the brake disc Replace the brake pads as a set. Refer to “REAR BRAKE”...
  • Page 75 All manuals and user guides at all-guides.com BLEEDING THE HYDRAULIC BRAKE SYSTEM • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.

  • Page 76: Changing The Final Transmission Oil

    All manuals and user guides at all-guides.com CHECKING THE FINAL TRANSMISSION OIL/ ADJUSTING THE DRIVE CHAIN SLACK CHANGING THE FINAL TRANSMISSION OIL 1. Place the machine on a level surface. 2. Place a receptacle under the final transmission case. 3. Remove: •...
  • Page 77 All manuals and user guides at all-guides.com ADJUSTING THE DRIVE CHAIN SLACK 1. Measure: • drive chain slack Out of specification Adjust. Drive chain slack 10 ~ 25 mm (0.39 ~ 0.98 in) 2. Adjust: • drive chain slack The drive chain slack is adjusted by the rota- tion of the rear axle hub.

  • Page 78: Checking The Steering System

    All manuals and user guides at all-guides.com CHECKING THE STEERING SYSTEM CHECKING THE STEERING SYSTEM 1. Place the machine on a level surface. 2. Check: • steering shaft bushings and bearings Move the handlebar up and down, and/or back and forth. Excessive play Replace the steering shaft bushings and or bearings.

  • Page 79: Adjusting The Toe-In

    All manuals and user guides at all-guides.com ADJUSTING THE TOE-IN ADJUSTING THE TOE-IN 1. Place the machine on a level surface. 2. Measure: • toe-in Out of specification Adjust. Toe-in 10 mm (0.40 in) Before measuring the toe-in, make sure that the tire pressure is correct.

  • Page 80: Checking The Front And Rear Shock Absorbers

    All manuals and user guides at all-guides.com ADJUSTING THE TOE-IN/ CHECKING THE FRONT AND REAR SHOCK ABSORBERS a. Mark both tie-rods ends. This reference point will be needed during adjustment. b. Loosen the locknuts (tie-rod end) of both tie-rods. c. The same number of turns should be given to both the right and left tie-rods until the specified toe-in is obtained.

  • Page 81: Adjusting The Shock Absorbers

    All manuals and user guides at all-guides.com ADJUSTING THE SHOCK ABSORBERS ADJUSTING THE SHOCK ABSORBERS WARNING Always adjust the spring preload of both front shock absorbers to the same setting. Uneven adjustment can result in poor han- dling and loss of stability. 1.

  • Page 82: Checking The Tires

    All manuals and user guides at all-guides.com CHECKING THE TIRES CHECKING THE TIRES WARNING This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures. • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs.
  • Page 83 All manuals and user guides at all-guides.com CHECKING THE TIRES 1. Measure: • tire pressure Out of specification Adjust. • The low-pressure tire gauge is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings.

  • Page 84: Checking The Wheels

    All manuals and user guides at all-guides.com CHECKING THE TIRES/ CHECKING THE WHEELS 2. Check: • tire surfaces Wear/damage Replace. Tire wear limit Front and rear: 3 mm (0.12 in) WARNING It is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately.

  • Page 85: Checking And Lubricating The Cables

    All manuals and user guides at all-guides.com CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS, STEERING SHAFT AND STEERING KNUCKLES CHECKING AND LUBRICATING THE CABLES WARNING WARNING A damaged cable sheath may cause corro- sion and interfere with the cable move- ment.

  • Page 86: Electrical System

    All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: •...
  • Page 87 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY Since VRLA (Valve Regulated Lead Acid) batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 88 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% 5. Charge: Charging Ambient temperature 20°C (68°F) •...
  • Page 89 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY • As shown in the following illustration, the open-circuit voltage of an VRLA (Valve Regulated Lead Acid) battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
  • Page 90 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter Measure the open-circuit Leave the battery unused for more than voltage prior to charging. 30 minutes before measuring its open- circuit voltage.
  • Page 91 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit Leave the battery unused for more voltage prior to charging. than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 92 All manuals and user guides at all-guides.com CHECKING AND CHARGING THE BATTERY 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) N O T I C E First, connect the positive battery lead and then the negative battery lead 8.

  • Page 93: Checking The Fuses

    All manuals and user guides at all-guides.com CHECKING THE FUSES CHECKING THE FUSES The following procedure applies to all of the fuses. N O T I C E To avoid a short circuit, always set the main switch to “OFF” when checking or replac- ing a fuse.
  • Page 94 All manuals and user guides at all-guides.com CHECKING THE FUSES Amperage Items Q’ty rating Main Reserve WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

  • Page 95: Engine

    All manuals and user guides at all-guides.com ENGINE ENGINE ENGINE EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS 13 Nm (1.3 m kg, 9.4 ft • • 25 Nm (2.5 m kg, 18 ft • • Order Job/Part Q’ty Remarks Removing the exhaust pipe/muffler, Remove the parts in the order listed.

  • Page 96: Engine Mounting Bolts

    All manuals and user guides at all-guides.com ENGINE ENGINE MOUNTING BOLTS 35 Nm (3.5 m 35 Nm (3.5 m kg, 25.3 ft kg, 25.3 ft • • • • 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the engine mounting...

  • Page 97: Removing The Engine

    All manuals and user guides at all-guides.com ENGINE REMOVING THE ENGINE Remove: • master link • drive chain INSTALLING THE ENGINE 1. Install: • upper engine mounting bolt/nut • lower engine mounting bolt/nut Do not fully tighten the bolts and nuts. 2.

  • Page 98: Cylinder Head

    All manuals and user guides at all-guides.com CYLINDER HEAD CYLINDER HEAD 6 Nm (0.6 m kg, 4.3 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 9 Nm (0.9 m kg, 6.5 ft •...
  • Page 99 All manuals and user guides at all-guides.com CYLINDER HEAD 6 Nm (0.6 m kg, 4.3 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 9 Nm (0.9 m kg, 6.5 ft •...

  • Page 100: Removing The Cylinder Head

    All manuals and user guides at all-guides.com CYLINDER HEAD REMOVING THE CYLINDER HEAD 1. Align: • “T” mark on the rotor (with the stationary pointer on the crank- case) a. Turn the crankshaft clockwise with a wrench. b. Align the “T” mark on the rotor with the stationary pointer on the crankcase.

  • Page 101: Checking The Camshaft Sprocket

    All manuals and user guides at all-guides.com CYLINDER HEAD 3. Remove: cam shaft comp. • head assy. • cyl. Fasten a safety wire to the timing chain to prevent it from falling into crankcase. CHECKING THE CAMSHAFT SPROCKET 1. Check: •...

  • Page 102: Checking The Cylinder Head

    All manuals and user guides at all-guides.com CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads •...

  • Page 103: Installing The Cylinder Head

    All manuals and user guides at all-guides.com CYLINDER HEAD INSTALLING THE CYLINDER HEAD 1. Install: cyl. head assy. 1 • cam shaft comp. • cap, camshaft • washer • • Tighten the nuts in two stages and a crisscross pattern. 2.
  • Page 104 All manuals and user guides at all-guides.com CYLINDER HEAD i. If the marks are aligned, temporarily tighten the camshaft sprocket bolt. If the marks are not aligned, change the meshing position of the camshaft sprocket and timing chain. 3. Install: bolt, flg.

  • Page 105: Camshaft, Rocker Arms And Valves

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES CAMSHAFT, ROCKER ARMS AND VALVES 9 Nm (0.9 m kg, 6.5 ft • • 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the camshaft, rocker Remove the parts in the order listed.

  • Page 106: Removing The Rocker Arms And Camshaft

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • screw, valve adjusting 2. Remove: • shaft in rocker arm • shaft ex rocker arm • intake rocker arm •...

  • Page 107: Checking The Camshaft

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES 2. Remove: • valve cotters Attach a valve spring compressor attachment between the valve spring retainer and the cylinder head to remove the valve cotters. CHECKING THE CAMSHAFT 1.
  • Page 108 All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches Replace or check the lubrica- tion system. 3. Check: • camshaft lobe Excessive wear Replace the camshaft. 4. Measure: •...

  • Page 109: Checking The Valves And Valve Springs

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES CHECKING THE VALVES AND VALVE SPRINGS 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter – valve stem diameter • Out of specification Replace the cylinder head ass'y.
  • Page 110 All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES 2. Check: • valve face Pitting/wear Grind the face. • valve stem end Mushroom shape or diameter larger than the body of the stem Replace. 3. Measure: • margin thickness Out of specification Replace.
  • Page 111 All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES 7. Measure: • valve seat width Out of specification Reface the valve seat. Valve seat width Intake 0.8 ~ 1.1 mm (0.0315 ~ 0.0433 in) <Limit>: 1.6 mm (0.063 in) Exhaust 0.8 ~ 1.1 mm (0.0315 ~ 0.0433 in)
  • Page 112 All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES b. Apply molybdenum disulfide oil to the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound.

  • Page 113: Installing The Valves And Valve Springs

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES 11.Measure: • spring tilt Out of specification Replace. Spring tilt limit Inner 2.0°/1.1 mm(2.0°/0.04 in) INSTALLING THE VALVES AND VALVE SPRINGS 1. Apply: • molybdenum disulfide oil (onto the valve stem and valve stem seal) 2.

  • Page 114: Installing The Camshaft And Rocker Arms

    All manuals and user guides at all-guides.com CAMSHAFT, ROCKER ARMS AND VALVES INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Install: • camshaft comp. Be sure to align the round hole in camshaft sprocket away from the cylinder head. 2. Apply: •...

  • Page 115: Cylinder And Piston

    All manuals and user guides at all-guides.com CYLINDER AND PISTON CYLINDER AND PISTON 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the cylinder and piston Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”.

  • Page 116: Removing The Piston

    All manuals and user guides at all-guides.com CYLINDER AND PISTON REMOVING THE PISTON 1. Remove: • piston pin clips • piston pin • piston • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
  • Page 117 All manuals and user guides at all-guides.com CYLINDER AND PISTON 47.00 ~ 47.01 mm Cylinder bore “C” (1.8504 ~ 1.8508 in) Taper limit “T” 0.05 mm (0.002 in) Out-of-round “R” 0.01 mm (0.0004 in) “C” = maximum of D “T” = maximum of D or D –...

  • Page 118: Checking The Piston Rings

    All manuals and user guides at all-guides.com CYLINDER AND PISTON CHECKING THE PISTON RINGS 1. Measure: • piston ring side clearance Out of specification Replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 119: Checking The Piston Pin

    All manuals and user guides at all-guides.com CYLINDER AND PISTON CHECKING THE PISTON PIN 1. Check: • piston pin Blue discoloration/grooves Replace the piston pin and then check the lubrication system. 2. Measure: • piston pin outside diameter Out of specification Replace the piston pin.

  • Page 120: Installing The Piston

    All manuals and user guides at all-guides.com CYLINDER AND PISTON INSTALLING THE PISTON 1. Install: • piston rings (onto the piston) • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. •...

  • Page 121: Installing The Cylinder

    All manuals and user guides at all-guides.com CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Install: • cylinder Install the cylinder with one hand while com- pressing the piston rings with the other hand. N O T I C E • Be careful not to damage the timing chain damper during installation.

  • Page 122: C.d.i. Magneto

    All manuals and user guides at all-guides.com C.D.I. MAGNETO C.D.I. MAGNETO 5 Nm (0.5 m kg, 3.6 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 55 Nm (5.5 m kg, 39.8 ft •...

  • Page 123: Removing The C.d.i. Magneto Rotor

    All manuals and user guides at all-guides.com C.D.I. MAGNETO REMOVING THE C.D.I. MAGNETO ROTOR 1. Remove: plate washer While holding the C.D.I. magneto rotor with the holding tool , loosen the C.D.I. mag- neto nut . Do not allow the sheave holder to touch the projection on the C.D.I.

  • Page 124: Installing The C.d.i. Magneto Rotor

    All manuals and user guides at all-guides.com C.D.I. MAGNETO INSTALLING THE C.D.I. MAGNETO ROTOR 1. Install: C.D.I. magneto rotor Clean the tapered portion of the crankshaft and the magneto rotor hub. When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft.

  • Page 125: Belt Drive

    All manuals and user guides at all-guides.com BELT DRIVE BELT DRIVE CRANKCASE COVER 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the belt drive Remove the parts in the order listed. Arm comp kick starter Cover L side Dowel pin For installation, reverse the removal pro-...

  • Page 126: Kickstarter

    All manuals and user guides at all-guides.com BELT DRIVE KICKSTARTER Order Job/Part Q’ty Remarks Removing the kickstarter Remove the parts in the order listed. Crankcase, cover Refer to “CRANKCASE COVER “. Refer to “INSTALLING THE KICKSTARTER“. Spring friction start gear Gear comp starter idle Washer Circlip...

  • Page 127: Installing The Kickstarter

    All manuals and user guides at all-guides.com BELT DRIVE INSTALLING THE KICKSTARTER 1. Install: boss kick spindle spindle comp kick start spring kick starter 2. Hook: spring kick starter Hook the spring end on the spindle comp kick start as shown, and hook the other end the projection 3.

  • Page 128: V-Belt, Clutch, Drive And Driven Pulley

    All manuals and user guides at all-guides.com BELT DRIVE V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY 40 Nm (4.0 m kg, 28.9 ft • • 55 Nm (5.5 m kg, 39.8 ft • • Order Job/Part Q’ty Remarks Removing the V-belt, clutch, primary Remove the parts in the order listed.

  • Page 129: Disassembling The Secondary Sheave

    All manuals and user guides at all-guides.com BELT DRIVE DISASSEMBLING THE SECONDARY SHEAVE 55 Nm (5.5 m kg, 39.8 ft 55Nm (5.5m kg, 39.8ft lb) • • Order Job/Part Q’ty Remarks Disassembling the plate sub assy Disassemble the parts in the order listed. drive Nut hex Clutch comp...

  • Page 130: Removing The Primary Sheave

    All manuals and user guides at all-guides.com BELT DRIVE REMOVING THE PRIMARY SHEAVE 1. Remove: primary sheave nut plate washer oneway clutch primary fixed sheave - 1 primary fixed sheave - 2 collar primary sliding sheave While holding the primary fixed sheave with the rotor holding tool , loosen the primary fixed sheave nut.

  • Page 131: Disassembling The Secondary Sheave

    All manuals and user guides at all-guides.com BELT DRIVE 3. Remove: secondary sheave assembly V-belt Remove the V-belt and clutch assembly from the primary sheave side. DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: clutch carrier nut Install the clutch spring holder and clutch spring holder arm onto the secondary sheave...

  • Page 132: Checking The V-Belt

    All manuals and user guides at all-guides.com BELT DRIVE CHECKING THE V-BELT 1. Check: V-belt Cracks/damage/wear Replace. Grease/oil Clean the primary and sec- ondary sheave. 2. Measure: V-belt width Out of specification Replace. V-belt width 18.0 mm (0.709 in) <Limit>: 17.0 mm (0.669 in) CHECKING THE DRIVE PULLEY 1.

  • Page 133: Checking The Piece Slider

    All manuals and user guides at all-guides.com BELT DRIVE CHECKING THE PIECE SLIDER 1. Check: piece slide Damage/wear Replace CHECKING THE DRIVEN PULLEY 1. Check: face comp, driven face comp, movable driven Cracks/damage/wear Replace the face comp, driven and face comp, movable driven as a set.

  • Page 134: Assembling The Primary Sheave

    All manuals and user guides at all-guides.com BELT DRIVE ASSEMBLING THE PRIMARY SHEAVE 1. Clean: face driver face movable drive boss drive face roller weights Use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 2.

  • Page 135: Assembling The Secondary Sheave

    All manuals and user guides at all-guides.com BELT DRIVE ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: face comp, movable driven’s inner surface face comp, driven’s inner surface torque cam groove oil seals bearings (with the recommended lubricant) 2. Install: face comp, movable driven Install the face comp, movable driven onto the face comp, driven with the oil seal guide...

  • Page 136: Installing The Belt Drive

    All manuals and user guides at all-guides.com BELT DRIVE 5. Install: face comp, driven spring clutch comp Attach the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown. Then, compress the spring, and tighten the clutch nut hex INSTALLING THE BELT DRIVE 1.
  • Page 137 All manuals and user guides at all-guides.com BELT DRIVE 2. Install: clutch nut hex 55 Nm (5.5 m kg, 39.8 ft • • While holding the clutch carrier with the rotor holding tool , tighten the clutch carrier nut with the locknut wrench 3.

  • Page 138: Starter Clutch And Starter Motor

    All manuals and user guides at all-guides.com STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 12Nm (1.2m kg, 8.7ft lb) 12 Nm (1.2 m kg, 8.7 ft • • 12Nm (1.2m kg, 8.7ft lb) 12 Nm (1.2 m kg, 8.7 ft •...

  • Page 139: Checking The Starter Wheel Gear

    All manuals and user guides at all-guides.com STARTER CLUTCH AND STARTER MOTOR CHECKING THE STARTER WHEEL GEAR 1. Check: starter wheel gear idle gear Burrs/chips/roughness/wear Replace 2. Check: starter clutch operation a. Install the starter wheel gear onto the idle gear and hold the starter clutch.

  • Page 140: Oil Pump

    All manuals and user guides at all-guides.com OIL PUMP OIL PUMP 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. C.D.I. magneto Refer to “ C.D.I. MAGNETO “ Cover O-ring Oil seal...

  • Page 141: Checking The Oil Pump

    All manuals and user guides at all-guides.com OIL PUMP CHECKING THE OIL PUMP 1. Check: oil pump driven gear Cracks/damage/wear Replace the de- fective part(s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clear- ance oil-pump-housing-to-inner-rotor-and- outer-rotor clearance Out of specification Replace the oil pump.

  • Page 142: Installing The Oil Pump

    All manuals and user guides at all-guides.com OIL PUMP 3. Check: oil pump operation Rough movement Repeat steps (1) and (2) or replace the defective part(s). INSTALLING THE OIL PUMP 1. Install: o-ring oil pump assembly oil pump bolt 12 Nm (1.2 m kg, 8.7 ft •...

  • Page 143: Crankcase And Crankshaft

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Engine Refer to “ ENGINE “. Cylinder head Refer to “CYLINDER HEAD “.

  • Page 144: Separating The Crankcase

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT SEPARATING THE CRANKCASE 1. Remove: • crankcase bolt 2. Remove: • right crankcase Tap on one side of the crankcase with a soft- face hammer . Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces.

  • Page 145: Removing The Crankshaft Assembly

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • crankshaft assembly • timing chain • Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. • The crankshaft assembly cannot be re- moved if the timing chain is attached onto the crankshaft sprocket.

  • Page 146: Checking The Crankshaft And Connecting Rod

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT CHECKING THE CRANKSHAFT AND CON- NECTING ROD 1. Measure: • crankshaft runout Out of specification Replace the crank- shaft, bearing or both. Turn the crankshaft slowly. Maximum crankshaft runout 0.04 mm (0.0016 in) 2.

  • Page 147: Installing The Crankshaft

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT 5. Check: • crankshaft journal Scratches/wear Replace the crank- shaft. INSTALLING THE CRANKSHAFT 1. Install: • crankshaft assembly • crankcase • timing chain N O T I C E To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.

  • Page 148: Assembling The Crankcase

    All manuals and user guides at all-guides.com CRANKCASE AND CRANKSHAFT ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Install: • crankcase gasket (onto the crankcase mating surfaces) 3. Install: • dowel pins •...

  • Page 149: Transmission

    All manuals and user guides at all-guides.com TRANSMISSION TRANSMISSION 10Nm(1.0m kg, 7.2 ft lb) • • 25Nm(2.5m kg, 18.0 ft • • Order Job/Part Q’ty Remarks Removing the lock washer, drive Remove the parts in the order listed. sprocket, and circlip Transmission oil Drain.

  • Page 150: Checking The Transmission

    All manuals and user guides at all-guides.com TRANSMISSION CHECKING THE TRANSMISSION 1. Measure: • counter shaft runout (with a centering device and dial gauge ) Out of specification Replace the counter shaft. Counter shaft runout limit 0.08 mm (0.0031 in) 2.
  • Page 151 All manuals and user guides at all-guides.com CARB CARBURETOR CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Fuel overflow hose Air vent hose Fuel hose Carburetor assembly Plate Plunger assay, starter Spring Manual starter comp Wire, starter For installation, reverse the removal pro-...
  • Page 152 All manuals and user guides at all-guides.com CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.
  • Page 153 All manuals and user guides at all-guides.com CARB CARBURETOR Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. Spring Float pin Float Needle valve Main jet Needle jet holder Needle jet Pilot jet Plug For assembly, reverse the disassembly procedure.

  • Page 154: Disassembling The Carburetor

    All manuals and user guides at all-guides.com CARB CARBURETOR DISASSEMBLING THE CARBURETOR Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1.
  • Page 155 All manuals and user guides at all-guides.com CARB CARBURETOR 4. Check: • piston valve Damage/scratches/wear Replace. • piston valve diaphragm Cracks/tears Replace. 5. Check: • vacuum chamber cover • piston valve spring Cracks/damage Replace. Check: • jet needle • main jet •...

  • Page 156: Assembling The Carburetor

    All manuals and user guides at all-guides.com CARB CARBURETOR 9. Check: • throttle valve movement Sticks Replace. 10. Check: • choke valve movement Sticks Replace. 11. Check: • starter plunger • starter plunger spring Bends/cracks/damage Replace. ASSEMBLING THE CARBURETOR Before assembling the carburetor, make sure to turn out the pilot air screw the same number of times, as noted before disassembly, from the seated position to the set position.

  • Page 157: Installing The Carburetor

    All manuals and user guides at all-guides.com CARB CARBURETOR 2. Install: • float • needle valve • float pin 3. Install: • accelerator pump assembly 4. Install: • piston valve • jet needle • piston valve spring • vacuum chamber cover INSTALLING THE CARBURETOR 1.

  • Page 158: Measuring And Adjusting The Fuel Level

    All manuals and user guides at all-guides.com CARB CARBURETOR MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level Out of specification Adjust. Fuel level (above the float chamber mating surface) 5.0 ~ 6.0 mm (0.20 ~ 0.24 in) a.

  • Page 159: Front And Rear Wheels

    All manuals and user guides at all-guides.com CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 65 Nm (6.5 m kg, 47.0 ft • • (x4) 45 Nm (4.5 m 45 Nm (4.5 m · kg, 32.5 ft · lb) kg, 32.5 ft •...

  • Page 160: Rear Wheels

    All manuals and user guides at all-guides.com CHAS FRONT AND REAR WHEELS REAR WHEELS 45 Nm (4.5 m kg, 32.5 ft • • (x4) 135 Nm (13.5 m kg, 97.6 ft • • Order Job/Part Q’ty Remarks Removing the rear wheels Remove the parts in the order listed.

  • Page 161: Checking The Wheels

    All manuals and user guides at all-guides.com CHAS FRONT AND REAR WHEELS CHECKING THE WHEELS The following procedure applies to both of the front and rear wheels. 1. Check: • wheel 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play Wheel runout limit...

  • Page 162: Checking The Rear Wheel Hubs

    All manuals and user guides at all-guides.com CHAS FRONT AND REAR WHEELS WARNING Eye protection is recommended when using striking tools. c. To install the wheel bearings, reverse the above sequence. Use a socket that matches outside diameter of bearing outer race to drive in bearing.

  • Page 163: Installing The Front Wheels

    All manuals and user guides at all-guides.com CHAS FRONT AND REAR WHEELS INSTALLING THE FRONT WHEELS The following procedure applies to both of the front wheels. 1. Install: • wheel The arrow mark on the tire must point in the direction of rotation of the wheel.

  • Page 164: Front Brakes

    All manuals and user guides at all-guides.com CHAS FRONT BRAKES FRONT BRAKES Order Job/Part Q’ty Remarks Removing the front brakes Remove the parts in the order listed. Refer to “FRONT AND REAR WHEELS”. The following procedure applies to both of the front brakes. Brake shoe Refer to “INSTALLING THE FRONT Front brake cable (drum side)

  • Page 165: Removing The Front Brakes

    All manuals and user guides at all-guides.com CHAS FRONT BRAKES REMOVING THE FRONT BRAKES The following procedure applies to each brake. 1. Remove: • brake camshaft lever • brake camshaft When removing the brake camshaft lever, mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft.

  • Page 166: Checking The Front Brake Drums

    All manuals and user guides at all-guides.com CHAS FRONT BRAKES 2. Check: • brake shoe lining surface Glazed areas Remove. Use coarse sandpaper. After using sandpaper, wipe off the polished particles with a cloth. 3. Measure: • brake shoe lining thickness Out of specification Replace.

  • Page 167: Installing The Front Brakes

    All manuals and user guides at all-guides.com CHAS FRONT BRAKES 2. Check: • brake drum inner surface Oil/scratches Remove. Use a rag soaked in lacquer thinner or solvent. Use an emery cloth (light Scratches and even polishing). INSTALLING THE FRONT BRAKES The following procedure applies to both of the front brakes.
  • Page 168 All manuals and user guides at all-guides.com CHAS FRONT BRAKES 3. Install: • brake shoe plate When installing the brake shoe plate, align the groove of the brake shoe plate with the pro- jection of the steering knuckle. 4. Install: •...

  • Page 169: Rear Axle And Rear Axle Hub

    All manuals and user guides at all-guides.com CHAS REAR AXLE AND REAR AXLE HUB REAR AXLE AND REAR AXLE HUB 170 Nm (17.0 m kg, 123 ft • • 60 Nm (6.0 m · kg, 43.4 ft · lb) 35 Nm (3.5 m kg, 25.3 ft •...
  • Page 170 All manuals and user guides at all-guides.com CHAS REAR AXLE AND REAR AXLE HUB 170 Nm (17.0 m kg, 123 ft • • 60 Nm (6.0 m · kg, 43.4 ft · lb) 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 171: Removing The Rear Axle

    All manuals and user guides at all-guides.com CHAS REAR AXLE AND REAR AXLE HUB REMOVING THE REAR AXLE 1. Place the machine on a level surface. 2. Remove: • nuts • Apply the brake lever so that the rear axle does not turn, when loosening the nut.

  • Page 172: Checking The Rear Axle

    All manuals and user guides at all-guides.com CHAS REAR AXLE AND REAR AXLE HUB CHECKING THE REAR AXLE 1. Check: • rear axle runout Out of specification Replace. WARNING Do not attempt to straighten a bent axle. Rear axle runout limit 1.5 mm (0.06 in) CHECKING THE DRIVEN SPROCKET 1.

  • Page 173: Installing The Rear Axle

    All manuals and user guides at all-guides.com CHAS REAR AXLE AND REAR AXLE HUB INSTALLING THE REAR AXLE 1. Install: • axle clip 2. Tighten: • nut 60 Nm (6.0 m kg, 43.4 ft • • Tighten the nut with rear axle nut wrench specification while holding the rear axle.

  • Page 174: Rear Brake

    All manuals and user guides at all-guides.com CHAS REAR BRAKE REAR BRAKE REAR BRAKE PADS 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. The following procedure applies to both of the rear brake calipers.

  • Page 175: Replacing The Rear Brake Pads

    All manuals and user guides at all-guides.com CHAS REAR BRAKE N O T I C E Disc brake components rarely require dis- assembly. DO NOT: • disassemble components unless abso- lutely necessary; • use solvents on internal brake compo- nents; •...
  • Page 176 All manuals and user guides at all-guides.com CHAS REAR BRAKE c. Tighten the brake caliper bleed screw. 8 Nm (0.8 m kg, 5.8 ft • • d. Install a new brake pad spring and new brake pads. 3. Install: • brake caliper •...

  • Page 177: Rear Brake Master Cylinder

    All manuals and user guides at all-guides.com CHAS REAR BRAKE REAR BRAKE MASTER CYLINDER 14 Nm (1.4 m kg, 10.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 28 Nm (2.8 m kg, 20.3 ft • •...

  • Page 178: Checking The Master Cylinder

    All manuals and user guides at all-guides.com CHAS REAR BRAKE CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder Wear/scratches Replace the brake mas- ter cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air.

  • Page 179: Installing The Rear Brake Master Cylinder

    All manuals and user guides at all-guides.com CHAS REAR BRAKE INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • brake master cylinder Brake master cylinder holder bolt 14 Nm (1.4 m•kg, 10.1 ft•lb) • The “UP” mark on the brake master cylinder bracket should face up.
  • Page 180 All manuals and user guides at all-guides.com CHAS REAR BRAKE 3. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 N O T I C E Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately.

  • Page 181: Rear Brake Caliper

    All manuals and user guides at all-guides.com CHAS REAR BRAKE REAR BRAKE CALIPER 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 182 All manuals and user guides at all-guides.com CHAS REAR BRAKE 16 Nm (1.6 m kg, 11.6 ft • • 8 Nm (0.8 m kg, 6.5 ft • • 25 Nm (2.5 m kg, 18.1 ft • • Order Job/Part Q’ty Remarks Remove the parts in the order listed.

  • Page 183: Removing The Parking Brake Cable

    All manuals and user guides at all-guides.com CHAS REAR BRAKE REMOVING THE PARKING BRAKE CABLE 1. Loosen: • nut • adjusting bolt 2. Disconnect: • parking brake cable (from parking brake lever) 3. Disconnect: • parking brake cable (from rear brake) CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule...

  • Page 184: Installing The Rear Brake Caliper

    All manuals and user guides at all-guides.com CHAS REAR BRAKE INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper assembly • brake caliper mounting bolts Brake caliper mounting bolt 35 Nm (3.5 m•kg, 25.3 ft•lb) • brake hose • copper washers •...
  • Page 185 All manuals and user guides at all-guides.com CHAS REAR BRAKE WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance. • Refill with the same type of brake fluid: mixing brake fluids may result in a harm- ful chemical reaction and lead to poor brake performance.

  • Page 186: Steering System

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR (x2) (x4) (x2) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Handlebar cover Refer to “SEAT, FENDERS AND FUEL TANK” in chapter 3. Handlebar grip Refer to “REMOVING THE HANDLEBAR GRIPS”...
  • Page 187 All manuals and user guides at all-guides.com CHAS STEERING SYSTEM (x2) (x4) (x2) Order Job/Part Q’ty Remarks Upper handlebar holder Refer to “INSTALLING THE HANDLE- Handlebar BAR”. For installation, reverse the removal pro- cedure. 6 - 29...

  • Page 188: Removing The Handlebar Grips

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM REMOVING THE HANDLEBAR GRIPS 1. Remove: • handlebar grips Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. REMOVING THE REAR BRAKE SWITCH 1.

  • Page 189: Installing The Handlebar

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM INSTALLING THE HANDLEBAR 1. Install: • handlebar • upper handlebar holders 14 Nm (1.4 m · kg, 10.1 ft · lb) • Install the handlebar, please align the punch mark the gap at handlebar holder •...

  • Page 190: Installing The Rear Brake Master Cylinder

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • handlebar switch • handlebar grip • brake master cylinder • Installing the rear brake master cylinder, make sure the handlebar switch , handlebar grip , and brake master cylinder are in the...

  • Page 191: Installing The Parking Brake Lever

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM INSTALLING THE PARKING BRAKE LEVER 1. Install: • parking brake lever • parking brake cable • damper • parking brake lever plate • parking brake lever bracket Install the parking brake cable lever, please align punch mark and the gap at parking brake...

  • Page 192: Steering Stem

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM STEERING STEM 35 Nm (3.5 m kg, 25.3 ft • • 35 Nm (3.5 m kg, 25.3 ft • • 55 Nm (5.5 m kg, 39.8 ft • • Order Job/Part Q’ty Remarks...

  • Page 193: Removing The Steering Stem

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM REMOVING THE STEERING STEM 1. Remove: • steering stem When loosening each tie-rod end nut , hold the tie-rod ball joint with a 14-mm wrench CHECKING THE STEERING STEM 1. Check: •...

  • Page 194: Installing The Lower Handlebar Holder

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM INSTALLING THE LOWER HANDLEBAR HOLDER 1. Install: • lower handlebar holder • nuts 35 Nm (3.5 m kg, 25.3 ft • • The lower handlebar holder and steering stem should be set a right angle when assembling. INSTALLING THE STEERING STEM 1.

  • Page 195: Tie-Rods And Steering Knuckles

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM TIE-RODS AND STEERING KNUCKLES 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m kg, 25.3 ft • • 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 196: Removing The Tie-Rods

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM REMOVING THE TIE-RODS The following procedure applies to both of the tie-rods. 1. Remove: • tie-rod When removing the tie-rod, hold each tie-rod ball joint with a 14-mm wrench and then loosen the tie-rod end nut.

  • Page 197: Installing The Tie-Rods

    All manuals and user guides at all-guides.com CHAS STEERING SYSTEM INSTALLING THE TIE-RODS The following procedure applies to both of the tie-rods. 1. Install: • tie-rod 35 Nm (3.5 m kg, 25.3 ft • • • The tie-rod side which must be installed on outside has grooves •...

  • Page 198: Front Arms And Front Shock Absorber Assemblies

    All manuals and user guides at all-guides.com FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 35 Nm (3.5 m • kg, 25.3 ft • Ib) 35 Nm (3.5 m kg, 25.3 ft • •...

  • Page 199: Removing The Front Arms

    All manuals and user guides at all-guides.com FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES REMOVING THE FRONT ARMS 1. Check: • front arm free play a. Check the front arm side play by moving it from side to side. If side play is noticeable, check the bush- ings.

  • Page 200: Checking The Ball Joints

    All manuals and user guides at all-guides.com FRONT ARMS AND FRONT SHOCK ABSORBER CHAS ASSEMBLIES CHECKING THE BALL JOINTS The following procedure applies to both of the front arm ball joints. 1. Check: • ball joint Damage/pitt Replace the front arm. Free pla Replace the front arm.

  • Page 201: Rear Shock Absorber, Swingarm And Drive Chain

    All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN 35 Nm (3.5 m kg, 25.3 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 75 Nm (7.5 m kg, 54.2 ft •...
  • Page 202 All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN 35 Nm (3.5 m kg, 25.3 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 75 Nm (7.5 m kg, 54.2 ft •...

  • Page 203: Rear Shock Absorber, Swingarm And Drive Chain

    All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN REMOVING THE REAR SHOCK ABSORBER 1. Remove: • rear shock absorber lower bolt • rear shock absorber upper bolt While removing the rear shock absorber lower bolt, hold the swingarm so that it does not drop down.

  • Page 204: Checking The Swingarm

    All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN c. Check the swingarm vertical movement by moving it up and down. If vertical movement is tight or rough, or if there is binding, check the spacer, bearings and frame pivot.

  • Page 205: Checking The Drive Chain

    All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section of the drive chain Out of specification Replace the drive chain. 15-link drive chain section limit (maximum) 239.3 mm (9.42 in) •...

  • Page 206: Installing The Drive Sprocket

    All manuals and user guides at all-guides.com REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN 4. Check: • drive chain rollers Damage/wear Replace the drive chain. • drive chain side plates Cracks/damage/wear Replace the drive chain. 5. Lubricate: • drive chain 6.

  • Page 207: Electrical Components

    All manuals and user guides at all-guides.com ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS Main switch Starter relay Brake switch Battery CDI unit Fuse Ignition coil Rectifier/regulator Spark plug C.D.I. magneto Starter motor 7 - 1...

  • Page 208: Wiring Diagram

    All manuals and user guides at all-guides.com ELEC WIRING DIAGRAM 7 - 2...

  • Page 209: Checking The Switchs

    All manuals and user guides at all-guides.com ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES Damage/wear Repair or replace. Check each switch for damage or wear, proper Improperly connected Properly connect. connections, and also for continuity between the Incorrect continuity reading terminals.

  • Page 210: Checking Switch Continuity

    All manuals and user guides at all-guides.com ELEC CHECKING SWITCH CONTINUITY CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. N O T I C E Never insert the tester probes into the cou- pler terminal slots...

  • Page 211: Ignition System

    All manuals and user guides at all-guides.com ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM Main switch C.D.I. magneto Battery Main fuse C.D.I. unit Ignition coil 7 - 5...

  • Page 212: Troubleshooting

    All manuals and user guides at all-guides.com ELEC IGNITION SYSTEM TROUBLESHOOTING 1. Spark plug The ignition system fails to operate (no • Check the condition of the spark plug. spark or intermittent spark). • Check the spark plug type. • Measure the spark plug gap. Check: Refer to “CHECKING THE SPARK PLUG”...
  • Page 213 All manuals and user guides at all-guides.com ELEC IGNITION SYSTEM 2. Ignition spark gap 3. Spark plug cap resistance • Disconnect the spark plug cap from the • Remove the spark plug cap from the spark spark plug. plug lead. •...
  • Page 214 All manuals and user guides at all-guides.com ELEC IGNITION SYSTEM 4. Ignition coil resistance 5. Main switch • Disconnect the ignition coil connectors • Check the main switch for continuity. from the ignition coil terminals. Refer to “CHECKING THE SWITCHES”. •...
  • Page 215 All manuals and user guides at all-guides.com ELEC IGNITION SYSTEM 7. Pickup coil resistance 8. Source coil resistance • Disconnect the C.D.I. magneto coupler • Disconnect the C.D.I. magneto coupler from the wire harness. from the wire harness. • Connect the pocket tester ( ×...

  • Page 216: Electric Starting System

    All manuals and user guides at all-guides.com ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Starter relay Starter motor C.D.I. unit Engine stop switch Start switch Brake switch 7 - 10...

  • Page 217: Starting Circuit Operation

    All manuals and user guides at all-guides.com ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, brake switch. CHECK If the main switch is on and the engine stop switch is in the ON position, the starter motor can be operated only if: •...

  • Page 218: Troubleshooting

    All manuals and user guides at all-guides.com ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse Minimum open-circuit voltage 2.
  • Page 219 All manuals and user guides at all-guides.com ELEC ELECTRIC STARTING SYSTEM 4. Starter relay 6. Brake switch • Disconnect the starter relay coupler from • Check the brake switch for continuity. the coupler. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester ( × 1) and bat- •...

  • Page 220: Starter Motor

    All manuals and user guides at all-guides.com ELEC STARTER MOTOR STARTER MOTOR 12Nm (1.2m kg, 8.7ft lb) 12Nm (1.2m kg, 8.7ft lb) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Ground lead Starter motor For installation, reverse the removal pro-...

  • Page 221: Checking The Starter Motor

    All manuals and user guides at all-guides.com ELEC STARTER MOTOR CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt Clean with 600-grit sandpaper. 2. Measure: • commutator diameter Out of specification Replace the starter motor. Commutator wear limit 19.5 mm (0.77 in) 3.

  • Page 222: Assembling The Starter Motor

    All manuals and user guides at all-guides.com ELEC STARTER MOTOR 5. Measure: • brush length Out of specification Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: • brush spring force Out of specification Replace the brush springs as a set.

  • Page 223: Charging System

    All manuals and user guides at all-guides.com ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM C.D.I. magneto Rectifier/Regulator Battery Main fuse Battery (+) lead Battery (-) lead 7 - 17...
  • Page 224 All manuals and user guides at all-guides.com ELEC CHARGING SYSTEM TROUBLESHOOTING 1. Main fuse The battery is not being charged. • Check the main fuse for continuity. Refer to “CHECKING THE FUSE” in chap- Check: ter 3. 1. main fuse •...

  • Page 225: Troubleshooting

    All manuals and user guides at all-guides.com TRBL STARTING FAILURE/HARD STARTING SHTG TROUBLESHOOTING The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check, adjustment and replacement of parts.

  • Page 226: Compression System

    All manuals and user guides at all-guides.com TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston rings • Loose spark plug • Improperly installed piston ring • Loose cylinder head or cylinder •...

  • Page 227: Faulty Clutch

    All manuals and user guides at all-guides.com FAULTY GEAR SHIFTING/CLUTCH SLIPPING/ TRBL DRAGGING/OVERHEATING SHTG FAULTY CLUTCH ENGINE OPERATES BUT VEHICLE WILL POOR STARTING PERFORMANCE NOT MOVE V-belt • V-belt slips V-belt • Oil or grease on the V-belt • Bent, damaged or worn V-belt •...

  • Page 228: Faulty Brake

    All manuals and user guides at all-guides.com FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION/ TRBL UNSTABLE HANDLING SHTG FAULTY BRAKE POOR BRAKING EFFECT Front drum brake Rear disc brake • Worn brake shoe lining • Worn brake pads • Worn brake drum • Worn disc •...

This manual is also suitable for:

Viper 90

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