HER CHEE 2002 ATV-320 U Service Manual
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HER CHEE 2002 ATV-320 U Service Manual

High power liquid cooled engine
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SERVICE MANUAL
ATV-320 S/U
2002/24
JUNE 30, 2007
High Power Liquid Cooled Engine
HER CHEE INDUSTRIAL CO., LTD.

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  • Page 1 SERVICE MANUAL ATV-320 S/U 2002/24 JUNE 30, 2007 High Power Liquid Cooled Engine HER CHEE INDUSTRIAL CO., LTD.
  • Page 2 Foreword This service manual contains information on servicing ATV-320(S/U) This manual is written for use as a guideline only. It is recommended that any mechanic, with or without sufficient experience, thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual.

  • Page 3: Table Of Contents

    CONTENTS General Information & Lubrication General Information --------------------------------------- Information for Preparation ------------------------------ Lubrication --------------------------------------------------- Chapter 1 Engine, Transmission & Gear Engine Removal & Installation ------------------------- Cylinder Head & Valve ----------------------------------- Cylinder & Piston ------------------------------------------ I-20 Crankcase & Crankshaft --------------------------------- I-27 Cooling System -------------------------------------------- I-33 Transmission &...

  • Page 4: General Information

    General Information MODEL IDENTIFICATION Engine No. Frame No. The frame serial number is stamped on the The engine serial number is stamped on the lower front right side of frame. upper rear right crankcase. Carburetor Identification No. VIN No. The VIN (Vehicle Identification Number) is The carburetor identification number is attached to the lower front right side of frame stamped on the right side of the carburetor.

  • Page 5: Information For Preparation

    Information for Preparation ATTENTION ON OPERATION All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item when dismounted. Locking of all screws, nuts, cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks.
  • Page 6 Information for Preparation ATTENTION ON OPERATION Certified lubricants in cans shall be used on all the elements to be lubricated. After assembly, performance of all elements shall be duly checked and the locking shall be duly verified. In case of an operation is performed by over 2 people, the assignment shall be conducted in coordination and safety shall be the first priority.

  • Page 7: Lubrication

    Lubrication GENERAL The maintenance of the oil pump and engine oil can be done with the engine install in the frame. When removing and install the oil pump, use care not to allow dust or dirt to enter the engine and oil line.

  • Page 8: Engine Oil

    Engine Oil OIL LEVEL Warm up the engine. Stop the engine and park the vehicle on level ground. Check the oil level through the oil window. Min. Level If the level is near the lower of the window, fill to the middle level with the recommended engine oil.

  • Page 9: Oil Pump

    Oil Pump OIL PUMP REMOVAL Remove the right crankcase cover. Bolt Remove the flywheel and starter idle and driven gears. Remove the attaching bolt and oil separator cover. Remove the circlip, then remove the oil pump drive chain and driven sprocket. Remove the two oil pump mounting bolts and Oil Separator Cover remove the oil separator and oil pump.

  • Page 10: Chapter 1 Engine, Transmission & Gear

    Chapter 1 Engine, Transmission & Gear Contents Engine Removal & Installation Cylinder Head & Valve Cylinder & Piston Crankcase & Crankshaft Cooling System Transmission & Gear GENERAL SAFETY WARNING If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in a closed area.
  • Page 11 Chapter 1 Engine, Transmission & Gear Engine Removal/Installation GENERAL A floor jack or other adjustable support is required to support and maneuver the engine. SPECIFICATION Engine dry weight 32 kg (72 lb) Oil capacity Engine 1.0 liter (1.06 US qt.) at disassembly 0.8 liter (0.85 US qt.) at change Transmission 0.6 liter (0.74 US qt.) at disassembly...
  • Page 12 Chapter 1 Engine, Transmission & Gear Engine Removal & Installation ENGINE REMOVAL Park the vehicle on the level ground and pull parking lever to park the vehicle. Disconnect the battery ground (-) cable. Remove left and right floor panel and step bar. Remove foot brake pedal.
  • Page 13 Chapter 1 Engine, Transmission & Gear ENGINE INSTALLATION Move the engine into the frame Insert the front engine bracket to correct position then insert the bolts. Insert all other engine mounting bolts and tighten the nuts by following steps. A. Rear lower engine mount Torque value: 40 –...
  • Page 14 Chapter 1 Engine, Transmission & Gear Cylinder Head Cover...
  • Page 15 Chapter 1 Engine, Transmission & Gear Cylinder Head...
  • Page 16 Chapter 1 Engine, Transmission & Gear Camshaft / Valve / Cam...
  • Page 17 Chapter 1 Engine, Transmission & Gear Cylinder Head/Valves Service Information GENERAL This section covers maintenance of the cylinder head, valves, camshaft and rocker arms. SPECIFICATION Service Limit Item Standard mm (in) mm (in) 34.590-34.34.700 (1.3618-1.3661) 34.54 (1.3598) Camshaft Cam height 34.460-34.680 (1.3567-1.3654) 34.41(1.3547) Rocker arm I.D.
  • Page 18 Chapter 1 Engine, Transmission & Gear Troubleshooting Engine top problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing noises with a sounding rod or stethoscope. Low Compression ◦ Valves — Incorrect valve adjustment —...

  • Page 19: Cylinder Head Cover

    Chapter 1 Engine, Transmission & Gear Cylinder Head Cover Blow-by tube CYLINDER HEAD COVER REMOVAL Remove blow-by hose on cylinder head cover. Remove four cylinder head cover bolts. Head cover bolts Camshaft CAMSHAFT REMOVAL Remove the cam chain adjuster sealing bolt and spring.
  • Page 20 Chapter 1 Engine, Transmission & Gear Rocker Arm ROCKER ARM REMOVAL Remove rocker arm/cam shaft bearing holder plate mounting bolt and holder plate. Remove rocker arm shaft by using a M6 bolt screw in shaft then pull out the shaft. Remove rocker arm.
  • Page 21 Chapter 1 Engine, Transmission & Gear Cylinder Head CYLINDER HEAD REMOVAL Remove the thermostat housing bolt and thermostat housing from the cylinder head. Remove the cam chain adjuster sealing bolt and spring. Remove the two cam sprocket holder bolts. Thermostat housing bolt Derail the cam chain from the cam sprocket teeth and remove the cam sprocket.
  • Page 22 Chapter 1 Engine, Transmission & Gear CYLINDER HEAD DISASSEMBLY Compress the valve spring and remove the valve cotters, retainers, springs, spring seat and valves. CAUTION 。To prevent loss of tension, do not compress the valve springs more than necessary to remove the cotters.
  • Page 23 Chapter 1 Engine, Transmission & Gear VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs. Service Limit: Inner (IN, EX): 27.5 mm (1.08 in) Outer (IN, EX): 30.4 mm ( 1.20 in) VALVE STEM Inspect each valve for bending, burning, or abnormal stem wear.
  • Page 24 Chapter 1 Engine, Transmission & Gear NOTE 。If the stem-to guide clearance exceeds the Valve stem seal service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guide as necessary and to fit. If the stem-to-guide clearance exceeds the service limits with new guide, replace the valve also.
  • Page 25 Chapter 1 Engine, Transmission & Gear CAUTION 。To prevent loss of tension, do not compress the valve spring more than necessary. Tap the valve stems gently with a plastic hammer to firmly seat the cotters. CAUTION 。Support the cylinder head above the working bench surface to prevent possible valve damage.
  • Page 26 Chapter 1 Engine, Transmission & Gear CAMSHAFT INSTALLATION Remove the timing hole (oil filling) cap from the right crankcase cover. Turn the drive pulley counterclockwise and align the “T” mark on the flywheel with the index mark on the right crankcase cover. Insert the camshaft into camshaft holding house and turn down the intake and exhaust lobe.
  • Page 27 Chapter 1 Engine, Transmission & Gear VALVE CLEARANCE NOTE ◦ Inspect and adjust valve clearance while the engine is cold (below 35 ℃/95℉). Remove the cylinder head cover. Remove the left crankcase recoil cover. Remove the timing hole plug (oil filling plug) from the right crankcase cover.
  • Page 28 Chapter 1 Engine, Transmission & Gear CYLINDER HEAD COVER INSTALLATION Check the cylinder head cover seal for any buckle or broken. Replace a new one if necessary. Coating engine oil on seal face before install. Install the cylinder head cover to cylinder and tighten four 6mm head cover bolts crisscross pattern in two or more steps.
  • Page 29 Chapter 1 Engine, Transmission & Gear Cylinder/Piston/Crankshaft I-20...
  • Page 30 Chapter 1 Engine, Transmission & Gear Cylinder/Piston/Crankshaft Service Information GENERAL 。It is recommended to remove the engine from frame body for cylinder and piston service. 。If the crankshaft bearing, oil pump drive sprocket or timing sprocket need to replacement, the crankshaft assembly must be replaced.
  • Page 31 Chapter 1 Engine, Transmission & Gear Cylinder CYLINDER REMOVE Remove the cylinder head. Disconnect the water hose from the cylinder. Remove the cam chain guide. Remove the cylinder base bolt and cylinder. Remove the cylinder gasket and dowel pins. Place rags in the crankcase openings. Clean off any gasket material from the cylinder surface of the crankcase.
  • Page 32 Chapter 1 Engine, Transmission & Gear Piston PISTON REMOVE Place clean shop towels in the crankcase opening to keep the piston pin clips or other parts from falling into the crankcase. Remove the piston pin clips with pliers. Pull the piston pin out of the piston and remove the piston.
  • Page 33 Chapter 1 Engine, Transmission & Gear CAUTION ◦ Piston rings are easily broken; take care not to damage them during removal. Insert each piston ring into the cylinder 20 mm (0.75 in) in from the bottom. To ensure that it’s square in the bore, use a piston to push it in.
  • Page 34 Chapter 1 Engine, Transmission & Gear PISTON RING INSTALLATION Clean the piston head, ring lands and skirts. Carefully install the piston rings onto the piston. Marking Stagger the ring end gaps as shown. NOTE ◦ Be careful not to damage the piston rings during assembly.
  • Page 35 Chapter 1 Engine, Transmission & Gear CYLINDER INSTALLATION Install the cam chain adjuster base onto the cylinder with a new gasket. Tighten the two adjuster base bolts. Torque: 8 – 12 N.m (6 – 9 ft.lb) Coat the cylinder bore, piston and piston rings with fresh engine oil.
  • Page 36 Chapter 1 Engine, Transmission & Gear Crankcase I-27...
  • Page 37 Chapter 1 Engine, Transmission & Gear Crankcase CEANKCASE SEPARATION Remove the cam chain adjuster by removing the bolt. Remove the cam chain. Remove the nine crankcase attaching bolts. Remove the crankcase with the left side crankcase down and remove the right crankcase.
  • Page 38 Chapter 1 Engine, Transmission & Gear CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge. Service Limit: 0.05 mm (0.002 in) Set the crankshaft on a stand or in V blocks and using a dial indicator to read run out at the points shown.
  • Page 39 Chapter 1 Engine, Transmission & Gear Install the oil pipe into the right crankcase and secure it with the bolt. Install the crankshaft into the left crankcase being careful not to damage the oil seal. Install the dowel pins and a new gasket. Place the crankcase over the crankshaft and onto the left crankcase.
  • Page 40 Chapter 1 Engine, Transmission & Gear Right Crankcase Cover I-31...
  • Page 41 Chapter 1 Engine, Transmission & Gear Right Crankcase REMOVAL Drain the coolant by disconnected coolant tube. Remove oil tube. Drain the engine oil thru oil filter cover or oil draining bolt. Remove right case mounting bolts. Remove right crankcase. Remove the crankcase gasket and dowel pins. Oil draining bolt IMSPECTION Remove water pump cover and inspect the...

  • Page 42: Cooling System

    Chapter 1 Engine, Transmission & Gear Cooling system I-33...
  • Page 43 Chapter 1 Engine, Transmission & Gear Cooling System Service Information GRENERAL WARNING ◦ Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine must be cool before servicing the cooling system. ◎...

  • Page 44: Coolant Replacement

    Chapter 1 Engine, Transmission & Gear System Testing COOLING SYSTEM LEAK TEST Remove the front luggage rack. Remove the radiator cap. Install special plug (radiator cap) and hose pincher on overflow hose. Pressurize all system through coolant reservoir to 103 kPa (15 PSI). Repair or replace components if system will not hold the specified pressure for at least six seconds.
  • Page 45 Chapter 1 Engine, Transmission & Gear Check the level of coolant in the reserve tank and fill to the correct level if the level is low. Install the front light fender (280AS) or front fender assy. (280AU). Max. Min. Radiator INSPECTION Inspect the radiator soldered joints and seams for leaks.
  • Page 46 Chapter 1 Engine, Transmission & Gear Thermostat REMOVAL Disconnect the thermo sensor wire connector from the housing. Drain the coolant Remove the thermostat housing from the cylinder head by removing the mounting bolt. Remove the cover attaching bolts and separate the thermostat housing.
  • Page 47 Chapter 1 Engine, Transmission & Gear Left Crankcase Cover I-38...
  • Page 48 Chapter 1 Engine, Transmission & Gear Drive Pulley/Clutch/Driven Pulley Service Information GENERAL 。 The drive pulley, clutch and driven pulley can be service with the engine installed. 。 Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATION ITEM STANDARD mm (in)

  • Page 49: Drive Belt

    Chapter 1 Engine, Transmission & Gear Left Crankcase Cover REMOVAL/INSTALLATION Remove left foot bar. Remove front and rear air tube on left crankcase. Remove the crankcase cover attaching bolts and remove the crankcase cover, dowel pins and gasket. Inspect the gasket for crankcase cover and replace it if necessary.

  • Page 50: Drive Pulley

    Chapter 1 Engine, Transmission & Gear INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 23.0 mm (0.9055 in) Min. 23 mm INSTALLATION Lay the drive belt on the driven pulley. Squeeze the driven pulley to widen its faces then set the drive belt on the drive pulley face collar.
  • Page 51 Chapter 1 Engine, Transmission & Gear INSPECTION Check the face seal for wear or damage. Replace the face seal with a new one if necessary. Check each roller for wear or damage. Min.22.4mm Measure the weight roller O.D. Service Limit: 22.4 mm (0.8819 in) Measure the moveable drive face bushing I.D.
  • Page 52 Chapter 1 Engine, Transmission & Gear ASSEMBLY Lubricate the inside of the moveable drive face with grease then install the weight rollers. NOTE 。 Use 25-30g of grease and apply to the inside of the moveable drive face evenly. Specified grease: Lithium based grease Install the ramp plate.
  • Page 53 Chapter 1 Engine, Transmission & Gear Clutch/Driven Pulley REMOVAL Remove the left crankcase cover, drive pulley face and drive belt. Hold the clutch outer with drive pulley holder and remove the drive pulley nut and clutch outer. Remove the driven pulley/clutch assembly. INSPECTION Check the clutch outer for wear or damage.
  • Page 54 Chapter 1 Engine, Transmission & Gear Transmission I-45...
  • Page 55 Chapter 1 Engine, Transmission & Gear Transmission Service Information SPECIFICATION Specified gear oil: SAE 85W/90 or equivalant Oil capacity: 0.5 liter (0.52 US qt.) at change 0.6 liter (0.63 US qt.) at disassembly TORQUE VALUES Transmission case cover 6 mm 8-12 N.m (6-9 ft.lb) 8 mm 20-24 N.m (14-18 ft.lb)
  • Page 56 Chapter 1 Engine, Transmission & Gear Gearbox DISASSEMBLY Drain the gear oil by loosen drain bolt. Remove drive sprocket. Remove shaft lever. Loosen eight gearbox attaching bolts. Remove right side gearbox cover, dowel pins and gasket. Remove gear shaft arm. Remove shift rod guide rod.
  • Page 57 Chapter 1 Engine, Transmission & Gear INSPECTION Inspect drive shaft, main shaft and final gear set Final Gear for abnormal wear or broken teeth. Main Shaft Driver Shaft Inspect gear shaft arm for abnormal wear or broken teeth. Check oil seal for broken or damage, replace it if necessary.
  • Page 58 Chapter 1 Engine, Transmission & Gear INSTALLATION Install gear set to gear case. NOTE ◦ Do not forget install main shaft washer. Install shaft drum. Install gear shaft fork. Install gear shift arm. NOTE ◦ Aligned shift forks to shift drum groove, gear shift arm to shift drum and shift drum retainer in correct position.
  • Page 59 Chapter 2 Fuel System & Carburetion Contents Carburetor Fuel Tank Air Cleaner Exhaust System Service Information GENERAL The fuel system comprises a petrol tank from which petrol is fed by gravity to the float chamber of the Mikuni carburetor. A vacuum control tap with build-in gauze filter is located beneath the rear end of the fuel tank.
  • Page 60 Chapter 2 Fuel System & Carburetion Troubleshooting Engine cranks but won’t start Poor performance and fuel economy ◦ No fuel in tank ◦ No fuel to carburetor ◦ Clogged fuel system ◦ Engine flooded with fuel ◦ Faulty ignition system ◦...

  • Page 61: Chapter 2 Fuel System & Carburetion Carburetor

    Chapter 2 Fuel System & Carburetion CARBURETOR II-3...
  • Page 62 Chapter 2 Fuel System & Carburetion Carburetor CARBURETOR REMOVAL Loosen the air filter tube and intake manifold Throttle cable hook bands. Disconnect the throttle cable on carburetor side. Remove the choke cable with choke piston. Leave the throttle cable and choke cable on vehicle.
  • Page 63 Chapter 2 Fuel System & Carburetion Float/Float valve/Jets DISASSEMBLY Remove the four chamber screws and the float chamber. Choke jet Remove the main jet, needle jet holder, idle jet Main jet Idle jet and choke jet. Remove the float pin, float and float valve. Float pin FLOAT VALVE INSPECTION Inspect the float valve for grooves and nicks.
  • Page 64 Chapter 2 Fuel System & Carburetion CARBURETOR INSTALLATION Tighten the drain screw. Connect the drain tube to the carburetor. Install the throttle cable. Install the choke cable with choke piston. Install the carburetor aligning the tab on the carburetor with the groove in the intake manifold and tighten the band screw.

  • Page 65: Fuel Tank

    Chapter 2 Fuel System & Carburetion FUEL TANK II-7...
  • Page 66 Chapter 2 Fuel System & Carburetion Fuel Tank REMOVAL WARNING ◦ Do not smoke or allow flames or spark in the work area. Remove the seat. Remove the front fender. Remove fuel tank to frame mounting bolts. Disconnect the fuel tube and vacuum tube on fuel valve.
  • Page 67 Chapter 2 Fuel System & Carburetion INSPECTION Check the petrol gauge seal for damage or deterioration and replace if necessary. Use a ohmmeter connect to gauge terminal to check the ohm reading from upper to lower float level of petrol gauge. Ohm reading: 10 Ω...

  • Page 68: Air Cleaner

    Chapter 2 Fuel System & Carburetion AIR CLEANER ASSEMBLY II-10...
  • Page 69 Chapter 2 Fuel System & Carburetion Air Cleaner Assembly REMOVAL Remove the seat. Loosen the air cleaner case to air camber connecting tube band. Tube Band Remove the four air cleaner case mounting bolts and remove the air cleaner case. INSPECTION AND CLEAN OUT Disconnect the air filter assembly mounting clamp.

  • Page 70: Exhaust System

    Chapter 2 Fuel System & Carburetion EXHAUST SYSTEM II-12...
  • Page 71 Chapter 2 Fuel System & Carburetion Exhaust System REMOVAL Disconnect the shaft selecting rod nut. Loosen exhaust pipe front section to cylinder head mounting nuts. Loosen muffler silencer hanger mounting bolts. Pull back the muffler assembly for removal. Bend the exhaust pipe front section to release pipe springs.

  • Page 72: Chapter 3 Ignition And Starting System

    Chapter 3 Ignition and Starting System Ignition System Service Information GENERAL ◦ Ignition timing cannot be adjusted since the ignition control module is factory present. ◦ A continuity check can usually be made without removing the parts from the vehicle. Simply disconnect the wires and use a continuity tester or ohmmeter at the terminals.

  • Page 73: Ignition Coil

    Chapter 3 Ignition and Starting System Ignition Coil INSPECTION Disconnect the ignition coil primary wires and measure the resistance between the terminals. Resistance: 0.1 – 0.3 Ω Remove the spark plug cap from the spark plug and measure the resistance between the ignition coil primary terminal and spark plug cap.
  • Page 74 Chapter 3 Ignition and Starting System Capacitive Discharge Ignition - C.D.I. GENERAL The CDI unit was located on front right of frame, about the right front shock absorber. There are three electrical connectors for the CDI: the two-pin connector and a four-pin connector on CDI body and a four-pin gear position coupler.

  • Page 75: Starting System

    Chapter 3 Ignition and Starting System Starting System Service Information SPECIFICATION ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0-12.5 mm (0.47-0.49in) 6.5 mm (0.26 in) Starter motor brush spring tension 680-920 g (1.49-2.03 lb) 680 g (1.49 lb) TROUBLESHOOTING Starter won’t turn ◦...

  • Page 76: Starter Relay

    Chapter 3 Ignition and Starting System Starter Relay GENERAL The relay coil is normal if you hear a click when starter button is depressed with the ignition switch ON and brake lever pressed. Starter switch REMOVAL/INSPECTION Remove the seat. Disconnect the negative battery cable from the battery.

  • Page 77: Starter Motor

    Chapter 3 Ignition and Starting System Starter Motor REMOVAL Remove the negative battery cable from the battery. Disconnect the starter cable from the starter motor. Remove the two mounting bolts then remove the starter motor. INSTALLATION NOTE ◦ Before installing the starter motor, check the operation by connecting the starter motor wire to the starter relay.

  • Page 78: Recoil Backup Starting System

    Chapter 3 Ignition and Starting System Recoil Backup Starting System III-7...
  • Page 79 Chapter 3 Ignition and Starting System Recoil Backup Starting System CHECK NOTE ◦ Pull the recoil haft rapidly to have enough kinetic energy for engine starting. Park the vehicle on a level ground. Put the gear shaft to “Neutral”. Turn the ignition switch “ON”. Pressed the brake lever then pull the recoil haft.

  • Page 80: Chapter 4 Frame & Cover

    Chapter 4 Frame & Cover GENERAL INFORMATION This Chapter covers the procedures necessary to remove and install the body panels and other body parts. Since many service and repair operations on this vehicle require remove of the panels and/or other parts, the procedure are grouped here and referred to from other Chapter. In the case of damage to the panels or other parts, it is usually necessary to remove the broken component and replace it with a new (or used) one.
  • Page 81 Chapter 4 Frame & Cover FRAME BODY-320S IV-2...
  • Page 82 Chapter 4 Frame & Cover FRAME BODY-320U IV-3...
  • Page 83 Chapter 4 Frame & Cover BODY COVER& SEAT-320S IV-4...
  • Page 84 Chapter 4 Frame & Cover BODY COVER& SEAT-320U IV-5...
  • Page 85 Chapter 4 Frame & Cover REAR FENDERS REMOVAL Remove the seat by flip back the latch level and lift the back end of seat. Remove left and right floor panels. Flip Remove rear carrier. Disconnect tail light and L/R indicator light connector.
  • Page 86 Chapter 4 Frame & Cover FRONT FENDER REMOVAL 320S NOTE ◦ The aid of an assistant will be required when removing front panel. Remove L/R floor panel. Remove front fascia and disconnect headlight wire. Disconnect indicator light and main switch wire. Remove L/R side cover and front to rear joint bolts.
  • Page 87 Chapter 4 Frame & Cover 320U Remove L/R floor panel. Remove front carrier (optional accessory). Disconnect headlight, indicator light and main switch connector. Remove shaft nob and shaft rod plate fixing bolts. Remove two fender to frame mounting bolts Remove four bumper cover to bumper and headlight to bumper mounting bolts.
  • Page 88 Chapter 4 Frame & Cover FRONT/REAR CARRIER (320U ONLY) FRONT CARRIER REMOVAL Loosen two carrier to bumper mounting bolts. Loosen two carrier to cover fixed pole bolts. Remove the front carrier. INSTALLATION Install the front carrier in the reverse order of removal.
  • Page 89 Chapter 4 Frame & Cover FRONT BUMPER REMOVAL Remove the front carrier. Remove four bumper mounting bolts. Remove the front bumper. NOTE ◦ Attached all four bolts first, and after aligned the bumper, then tighten the bolts. INSTALLATION Install the front bumper in the reverse order of removal.

  • Page 90: Handlebar & Steering

    Chapter 5 Wheels, Tires & Brakes Contents Handlebar & Steering Front & Rear Wheel Suspension System Hydraulic Brake Service Information Specification ITEM STANDARD mm (in) SERVICE LIMIT mm (in) Axle round out 0.2 (0.008) Radial 2.0 (0.08) Rim round out Axial 2.0 (0.08) Torque Values...
  • Page 91 Chapter 5 Wheels, Tires & Brakes HANDLE BAR...
  • Page 92 Chapter 5 Wheels, Tires & Brakes STEERING...
  • Page 93 Chapter 5 Wheels, Tires & Brakes Handlebar REMOVAL Remove the speedometer assembly mounting screws. Loosen L/R hand brake master cylinder holder mounting bolts and remove brake cylinder from handlebar. Loosen L handle switch mounting bolts and remove switch from handlebar. Disconnect brake switch wire, overdrive switch wire, throttle and choke cable.
  • Page 94 Chapter 5 Wheels, Tires & Brakes Steering STEERING SHAFT REMOVE Remove the front fender. NOTE ◦ Raise the front frame and secure with stable stand for easily working. Remove the handlebar. Remove tie rod end nuts on steering shaft side. Remove the steering shaft nut.
  • Page 95 Chapter 5 Wheels, Tires & Brakes FRONT & REAR WHEEL...
  • Page 96 Chapter 5 Wheels, Tires & Brakes Front & Rear Wheel WHEEL REMOVAL NOTE ◦ Use a hydraulic jacket for easily serving. Use parking brake to locked rear wheel. Slightly loosen wheel nuts. Raise the frame to let wheel leave ground. Loosen and remove wheel nuts then remove wheel.
  • Page 97 Chapter 5 Wheels, Tires & Brakes HUB REMOVAL Remove the wheel. Remove the hub to axle mounting nut cotter pin. Loosen the hub to axle mounting nut and remove nut and plane washer. Remove the hub from axle. INSPECTION Front hub Check oil seal for broken or damage, replace it if necessary.
  • Page 98 Chapter 5 Wheels, Tires & Brakes FRONT SUSPENSION...
  • Page 99 Chapter 5 Wheels, Tires & Brakes REAR SUSPENSION & SWING ARM SUB ASS'Y V-10...

  • Page 100: Front Suspension

    Chapter 5 Wheels, Tires & Brakes Front Suspension A-arm REMOVAL CAUTION ◦ Support the vehicle frame steady when servicing or inspecting. Remove front tire. Remove tie rod end on knuckle. Remove upper and lower ball joint on knuckle and apart the knuckle with brake clipper from ball joint.

  • Page 101: Rear Suspension

    Chapter 5 Wheels, Tires & Brakes Rear Suspension SWING ARM REMOVAL CAUTION ◦ Support the vehicle frame steady when servicing or inspecting. Remove L and R foot pad and rear tires. Disconnect drive chain and remove the chain Remove rear shock absorber mounting bolts both upper and lower then remove shock from axle.
  • Page 102 Chapter 5 Wheels, Tires & Brakes REAR WHEEL AXLE RMOVAL Loosen brake disk flange tighten nuts and remove the nuts. Remove brake disk flange assembly. Push wheel axle to right side and remove axle with rear sprocket assembly from axle holder. Remove rear sprocket assembly from axle.
  • Page 103 Chapter 5 Wheels, Tires & Brakes HYDRAULIC BRAKE SYSTEM V-14...
  • Page 104 Chapter 5 Wheels, Tires & Brakes BRAKE CALIPER V-15...

  • Page 105: Service Information

    Chapter 5 Wheels, Tires & Brakes Service Information GENERAL ◦ The brake calipers can be removed without disconnecting the hydraulic system. ◦ Bleed the hydraulic system if it has been disassembled or if the brake feels spongy. ◦ Do not allow foreign material to enter the system when filling the reservoir. ◦...
  • Page 106 Chapter 5 Wheels, Tires & Brakes Brake Fluid Replacement/Bleeding BRAKE FLUID DRAINING WARNING ◦ A contaminated brake disc or pads reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. CAUTION ◦ Do not allow foreign material to enter the system when filling the reservoir.
  • Page 107 Chapter 5 Wheels, Tires & Brakes BRAKE FLUID FILLING/BLEEDING Fill the reservoir with DOT-3 or DOT-4 brake fluid from a sealed container. CAUTION ◦ Do not mix different types of fluid. They are not compatible. Connect a commercially available brake bleeder to the bleed valve.
  • Page 108 Chapter 5 Wheels, Tires & Brakes BRAKE FLUID FILLING/BLEEDING If a brake bleeder is not available, perform the following procedure: Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
  • Page 109 Chapter 5 Wheels, Tires & Brakes BRAKE PAD REPLACEMENT WARNING ◦ Never blow out brake dust with compressed air and don’t inhale it. NOTE ◦ Always replace the brake pads in pair to assure even disc pressure. FRONT BRAKE PADS Remove the front wheel.
  • Page 110 Chapter 5 Wheels, Tires & Brakes REAR BRAKE PADS Remove the caliper mounting bolts and remove caliper from rear swing arm. Push caliper piston back into the caliper bore to provide enough room for remove pads. Remove the inner pad first then outer pad. NOTE ◦...
  • Page 111 Chapter 5 Wheels, Tires & Brakes REMOVAL AND INSTALLATION Front disc removal/installation Remove the wheel hub. Remove the disc retaining bolts on hub. Installation is the reverse of removal. Tighten the disc retaining bolts. Torque: 43 N.m (31 ft.lb) NOTE ◦...

  • Page 112: Parking Brake

    Chapter 5 Wheels, Tires & Brakes Parking Brake ADJUSTMENT Park the vehicle on a level ground. Pull the parking lever to left side. Loosen the parking brake adjust bolt fixing nut and then turn in the adjust bolt until you can feel it touch the piston wall.
  • Page 113 Chapter 6 Alternator/Electrical Equipment Contents Alternator & Starting Motor Battery Lights & Horn Wire Diagram Alternator/Starter Clutch Service Information GENERAL ◦ The alternator and starter clutch can be serviced with the engine installed in the frame. SPECIFICATION ITEM STANDARD mm (in) SERVICE LIMIT mm (in) Starter driven gear I.D.

  • Page 114: Alternator & Starter Gear

    Chapter 6 Alternator/Electrical Equipment Alternator & Starter Gear VI-2...
  • Page 115 Chapter 6 Alternator/Electrical Equipment Right Crankcase Cover REMOVAL Remove right foot pad. Drain the coolant by disconnecting the water hoses of the water pump. Remove the two pipe bolts, two 8 mm oil pipe bolts, 12 mm oil pipe bolt and washer, then remove the pipe.
  • Page 116 Chapter 6 Alternator/Electrical Equipment STATOR REMOVAL Remove the wire grommet from the groove in the cover. Remove the breather plate and ignition pulse generator. Remove the three stator attaching bolts and stator. FLYWHEEL REMOVAL Remove the oil orifice from the end of the crankshaft.
  • Page 117 Chapter 6 Alternator/Electrical Equipment Starter Gear STARTER IDLE/DRIVEN GEAR REMOVAL Remove the starter idle gear. Remove the set plate. Remove the starter driven gear and idle gear shaft. STARTER GEAR INSPECTION Inspect the starter driven gear for wear or damage. Measure the starter driven gear I.D.

  • Page 118: Starter Clutch

    Chapter 6 Alternator/Electrical Equipment Starter Clutch DISASSEMBLY Remove the hex socket bolts using an impact driver and 6 mm socket bit. Measure the one way clutch outer I.D. Service Limit: 58.98 mm (2.322in) ASSEMBLY Install the one way clutch into the one way clutch outer.
  • Page 119 Chapter 6 Alternator/Electrical Equipment FLYWHEEL INSTALLATION Install starter gear to crankshaft, apply some grease onto crankshaft for easily insert. Install starter gear holding plate by slight raise the starter gear and insert the holding plate. Fasten the holding plate tighten blot. Wipe off oil and grease from the tapered section of the crankshaft and flywheel.
  • Page 120 Chapter 6 Alternator/Electrical Equipment STATOR INSTALLATION Install the stator on the right crankcase cover with the three bolts. Install the ignition pulse generator and breather plate with two bolts. Install the wire grommet in its groove in the cover securely. NOTE ◦...
  • Page 121 Chapter 6 Alternator/Electrical Equipment CAUTION ◦ The 8 mm oil pipe bolt for the cylinder head cover side is black because its oil hole differs from the oil pipe bolt for the right crankcase cover side. ◦ Install the oil pipe bolts in the correct position. ◦...

  • Page 122: Electrical Equipment

    Chapter 6 Alternator/Electrical Equipment Electrical Equipment Service Information GENERAL INFORMATION ◦ The machines covered by this manual are equipped with a 12 volt electrical system. The components include a three-phase permanent magnet alternator and a regulator/rectifier unit. The regulator/ rectifier unit maintains the charging system output within the specified range to prevent overcharging and converts the AC (alternating current) output of the alternator to DC (direct current) to power the lights and other components and to charge the battery.
  • Page 123 Chapter 6 Alternator/Electrical Equipment Headlight BULB REPLACEMENT Remove headlight panel. (280AS only) Disconnect the headlight coupler. Remove headlight bulb rubber dust seal. Bulb Socket Remove the bulb socket. Remove the clip and replace the headlight bulb. CAUTION Dust Seal ◦ Do not put finger prints on the headlight bulb, they may create hot sports on the bulb.
  • Page 124 Chapter 6 Alternator/Electrical Equipment Regulator/Rectifier GENERAL Regulator/rectifier was located on left front side of front fender. The regulator/rectifier unit maintains the charging system output within the specified range to prevent overcharging and converts the AC (alternating current) output of the alternator to DC (direct current) to power the lights and other components and to charge the battery.

  • Page 125: Wire Diagram

    Chapter 6 Alternator/Electrical Equipment Wire Diagram VI-13...

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