E-TON ATV6A 90 Service Manual
  1. Manuals
  2. Brands
  3. E-TON Manuals
  4. Offroad Vehicle
  5. ATV6A 90
  6. Service manual

E-TON ATV6A 90 Service Manual

Atv
Hide thumbs
Table of Contents

Advertisement

Quick Links

E-TON POWER
ATV6A 90
VIPER 90
SERVICE MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ATV6A 90 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for E-TON ATV6A 90

Summary of Contents for E-TON ATV6A 90

  • Page 1 E-TON POWER ATV6A 90 VIPER 90 SERVICE MANUAL...
  • Page 2 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 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: How To Use This Manual

    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 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 – ELEC SHTG Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE CARBURETOR CHASSIS ELECTRICAL – TROUBLESHOOTING...

  • Page 7: General Information

    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 ..............

  • Page 8: Specifications

    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....................

  • Page 9: Periodic Checks And Adjustments

    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.............

  • Page 10: Engine

    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. HEAD COVER ASSY..........4-7 CHECKING THE TIMING CHAIN GUIDES..........
  • Page 11 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 CHECKING THE PRIMARY ROLLER WEIGHTS........

  • Page 12: Carburetor

    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

    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............
  • Page 14 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 REMOVING THE STEERING STEM ............6-35...

  • Page 15: Electrical

    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..................

  • Page 16: Troubleshooting

    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 POOR STARTING PERFORMANCE............

  • Page 17: Machine Identification

    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. 1 - 1...

  • Page 18: Important Information

    5. Keep all parts away from any source of fire. REPLACEMENT PARTS 1. Use only genuine E-TON parts for all replacements. GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings.

  • Page 19: Lock Washers/Plates And Cotter Pins

    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

    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. Rust/stains Connect and disconnect sev- eral times.

  • Page 21: General Specifications

    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) Minimum ground clearance 120 mm (4.7 in) Minimum turning radius...
  • Page 22 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) lron 0.5 L (0.11 lmp gal, 0.13 US gal) Carburetor...
  • Page 23 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 Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper...

  • Page 24: Engine Specifications

    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 ---- 0.05 mm (0.002 in) Maximum out-of-round ----...
  • Page 25 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) Rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.043 mm...
  • Page 26 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 (0.0008 in) Valve seat width 0.8 ~ 1.1 mm 1.6 mm...
  • Page 27 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) °/ Tilt limit...
  • Page 28 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 Side clearance (installed) 0.015 ~0.055 mm (0.0035in) (0.0006~0.0022in)
  • Page 29 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) (4.23in) 87.9 mm (3.46 in) Compression spring free length...
  • Page 30 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) Oil-pump-housing-to-inner-rotor-and-outer- 0.06 ~ 0.11 mm 0.20 mm...

  • Page 31: Chassis Specifications

    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 Panel wheel ---- 8 x 5.5 AT Rim size...
  • Page 32 SPEC SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear disc brake Type Single ---- 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 3.7 mm (0.15 in) 1.0 mm (0.04 in)

  • Page 33: Electrical Specifications

    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) ---- C.D.I.
  • Page 34 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) 3.5 mm (0.14 in) Spring force...

  • Page 35: Tightening Torques

    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 — Cylinder head (Pipe assy, inlet) Stud bolt Cylinder head (Muffler pipe) Stud bolt...

  • Page 36: Chassis Tightening Torques

    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 54.2 Rear shock absorber and frame 25.3...
  • Page 37 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). · l · e l i 2 - 17...

  • Page 38: How To Use The Conversion Table

    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

    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 Piston outside and ring groove...
  • Page 40 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 Crankcase mating surfaces Sealant...

  • Page 41: Oil Flow Diagrams

    SPEC SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 2 - 21...

  • Page 42: Cable Routing

    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 Air filter case check hose Parking brake cable...
  • Page 43 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. Fasten rear brake hose and throttle cable with a plastic band.
  • Page 44 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 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 Negative starter motor lead Main fuse Front brake cables Air filter case check hose...
  • Page 46 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 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 2 - 27...
  • Page 48 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 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

    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 Every two years replace the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. Since these items require special tools, data and technical skills, have an E-TON dealer perform the service.

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

    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 Removing the handlebar Remove the parts in the order listed. Fuel tank breather hose Handlebar cover When installing the handlebar cover,...

  • Page 53: Seat, Front Panel And Footrest Boards

    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”. Seat Pull back the seat lock lever, than pull up on the rear of the seat.

  • Page 54: Front Fender

    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 • • Order Job/Part Q’ty Remarks Removing the front fender Remove the parts in the order listed.

  • Page 55: Rear Fender And Battery

    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. Handlebar Refer to “HANDLEBAR”.

  • Page 56: Fuel Tank And Footrest Bars

    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

    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. • When the valve clearance is to be mea- sured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 58 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. c.

  • Page 59: Adjusting The Engine Idling Speed

    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. Measure: • engine idling speed Out of specification Adjust.

  • Page 60: Adjusting The Throttle Lever Free Play

    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. Throttle lever free play 1.0 ~ 3.0 mm (0.04 ~ 0.12 in) 2.

  • Page 61: Adjusting The Speed Limiter

    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. 1.

  • Page 62: Checking The Spark Plug

    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. Normal color is a medium-to-light tan color. 4.

  • Page 63: Checking The Ignition Timing

    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 • timing light (to spark plug lead) 3.

  • Page 64: Measuring The Compression Pressure

    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. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 65 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. c.

  • Page 66: Checking The Engine Oil Level

    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. Oil level low Add oil to the proper level. Do not screw the dipstick in when checking the oil level.

  • Page 67: Changing The Engine Oil

    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. 3. Remove: • dipstick • engine oil drain bolt (along with the O-ring, spring and oil filter screen) 4.

  • Page 68: Cleaning The Air Filter Elements

    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. 1.

  • Page 69: Cleaning The Spark Arrester

    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. c.
  • Page 70 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. d.

  • Page 71: Chassis

    CHECKING THE FRONT BRAKE SHOES/ ADJUSTING THE FRONT BRAKE CHASSIS CHECKING THE FRONT BRAKE SHOES 1. Check: • Upper adjusting bolt • Lower adjusting bolt more than 12 mm (0.47 in) Replace the brake shoes as a set. Refer to “FRONT BRAKES” in chapter 6. ADJUSTING THE FRONT BRAKE Before adjusting the front brake, the front brake linings should be checked.

  • Page 72: Adjusting The Parking Brake

    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. Adjust: • parking brake cable end length a.

  • Page 73: Checking The Rear Brake Fluid Level

    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. 2.

  • Page 74: Checking The Rear Brake Pads

    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” in chapter 6. Brake pad wear limit 1.0 mm (0.04 in) 2.
  • Page 75 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

    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: • dipstick • final transmission oil drain plug 4.
  • Page 77 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

    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. Refer to “STEERING SYSTEM”...

  • Page 79: Adjusting The Toe-In

    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. a. Mark both front tire tread centers. b.

  • Page 80: Checking The Front And Rear Shock Absorbers

    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

    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. Adjust: • spring preload a.

  • Page 82: Checking The Tires

    • TIRE CHARACTERISTICS 1) Tire characteristics influence the han- dling of ATVs. The tires listed below have been approved by E-TON POWER TECH Co., Ltd. for this model. If other tire com- binations are used, they can adversely affect your machine’s handling charac- teristics and are therefore not recom- mended.
  • Page 83 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. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 84: Checking The Wheels

    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

    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. An unsafe condition may result so replace a damaged cable as soon as possi- ble.

  • Page 86: Electrical System

    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: • Wear protective eye gear when handling or working near batteries.
  • Page 87 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 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) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery.
  • Page 89 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 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. Connect a charger and Set the charging voltage to 16~ 17V.
  • Page 91 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 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. Check: • battery terminals Dirt ? Clean with a wire brush.

  • Page 93: Checking The Fuses

    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. 1.Remove: •...
  • Page 94 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

    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. breather hose and leads Rear fender Refer to “SEAT, FENDERS AND FUEL...

  • Page 96: Engine Mounting Bolts

    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 Remove the parts in the order listed. bolts Carburetor Refer to “CARBURETOR”...

  • Page 97: Removing The Engine

    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. Tighten: • upper engine mounting nut 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 98: Cylinder Head

    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 • • 11 Nm (1.1 m kg, 8.0 ft •...
  • Page 99 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 • • 11 Nm (1.1 m kg, 8.0 ft •...

  • Page 100: Removing The Cylinder Head

    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

    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: • camshaft sprocket More than 1/4 tooth wear Replace the cam shaft comp.

  • Page 102: Checking The Cylinder Head

    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 • valve seats 2. Check: • cylinder head Damage/scratches Replace.

  • Page 103: Installing The Cylinder Head

    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. Install: • cam shaft comp. round h- a.
  • Page 104 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. (small head) • • tensioner assy. WARNING Always use a new gasket.

  • Page 105: Camshaft, Rocker Arms And Valves

    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. arms and valves Cylinder head Refer to “CYLINDER HEAD”.

  • Page 106: Removing The Rocker Arms And Camshaft

    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 • exhaust rocker arm Remove the rocker arm shafts with the slide hammer bolt and weight 3.

  • Page 107: Checking The Camshaft

    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. Check: • cam lobes Pitting/scratches/blue discoloration Replace.
  • Page 108 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: • rocker arm inside diameter Out of specification Replace.

  • Page 109: Checking The Valves And Valve Springs

    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. Stem-to-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust...
  • Page 110 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. Margin thickness Intake 0.5 ~ 0.9 mm (0.0197 ~ 0.0354 in)
  • Page 111 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) <Limit>: 1.6 mm (0.063 in) a.
  • Page 112 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

    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

    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: • engine oil (onto the rocker arm shafts) 3.

  • Page 115: Cylinder And Piston

    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”. Cylinder Refer to “INSTALLING THE CYLINDER”.

  • Page 116: Removing The Piston

    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 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 – maximum of D or D “R”...

  • Page 118: Checking The Piston Rings

    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

    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. Piston pin outside diameter 12.996 ~ 13.000 mm (0.5117 ~ 0.5118 in) <Limit>: 12.960 mm (0.5102 in)

  • Page 120: Installing The Piston

    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 numbers located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.

  • Page 121: Installing The Cylinder

    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

    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 • • Order Job/Part Q’ty...

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

    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. magneto rotor. 2.

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

    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. 2.

  • Page 125: Belt Drive

    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- cedure.

  • Page 126: Kickstarter

    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 Washer Spindle comp kick start Spring kick starter Boss distance...

  • Page 127: Installing The Kickstarter

    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

    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. and secondary sheave Nut flange / Washer Ratchet kick starter...

  • Page 129: Disassembling The Secondary Sheave

    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 Spring clutch Spring driven face Collar spring...

  • Page 130: Removing The Primary Sheave

    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

    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 as shown.

  • Page 132: Checking The V-Belt

    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

    BELT DRIVE CHECKING THE PIECE SLIDER 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. 2. Check: torque cam groove Damage/wear Replace the face...

  • Page 134: Assembling The Primary Sheave

    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. Install: roller weights boss drive face 3.

  • Page 135: Assembling The Secondary Sheave

    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 3.

  • Page 136: Installing The Belt Drive

    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 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. Install: outer clutch 40 Nm (4.0 m kg, 28.9 ft •...

  • Page 138: Starter Clutch And Starter Motor

    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 • • Order Job/Part Q’ty Remarks Removing the starter clutch and...

  • Page 139: Checking The Starter Wheel Gear

    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. b. When turning the starter wheel gear clock- wise , the starter clutch and the starter wheel gear should engage, otherwise the starter clutch...

  • Page 140: Oil Pump

    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 Dowel pin Oil pump driven gear Dowel pin...

  • Page 141: Checking The Oil Pump

    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. Inner rotor Outer rotor Oil pump housing Inner-rotor-to-outer-rotor-tip clear- ance 0.04 ~ 0.12 mm...

  • Page 142: Installing The Oil Pump

    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

    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 “. Cylinder piston Refer to “CYLINDER AND PISTON “.

  • Page 144: Separating The Crankcase

    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

    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

    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. Measure: • big end side clearance Out of specification Replace the big end bearing, crankshaft pin, or connecting rod.

  • Page 147: Installing The Crankshaft

    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

    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 • timing chain Install the timing chain so it is not visible through the opening in the left crankcase 4.

  • Page 149: Transmission

    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. Refer to “BELT DRIVE “. Crankcase cover Refer to “V-BELT, DRIVE PULLEY Belt drive...

  • Page 150: Checking The Transmission

    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. Measure: • drive shaft runout (with a centering device and dial gauge ) Out of specification Replace the drive shaft.
  • Page 151 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- cedure.
  • Page 152 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. Cover Spring Piston valve...
  • Page 153 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. 5 - 3...
  • Page 154 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. Check: • carburetor body • float chamber Cracks/damage Replace.
  • Page 155 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 • Needle jet holder • Needle jet •...
  • Page 156 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 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. Adjust: • engine idling speed Engine idling speed 1,600 ~ 1,800r/min...
  • Page 158 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. Stand the machine on a level surface. b.
  • Page 159 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 kg, 32.5 ft 45 Nm (4.5 m · kg, 32.5 ft · lb) • •...

  • Page 160: Rear Wheels

    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. Place the machine on a level surface.

  • Page 161: Checking The Wheels

    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 Radial : 2.0 mm (0.08 in)

  • Page 162: Checking The Rear Wheel Hubs

    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. N O T I C E Do not strike the center race or balls of the bearing.

  • Page 163: Installing The Front Wheels

    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. 2. Tighten: •...

  • Page 164: Front Brakes

    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) BRAKES”.

  • Page 165: Removing The Front Brakes

    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

    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. Measuring points Replace the brake shoes as a set if either is found to be worn to the wear limit.

  • Page 167: Installing The Front Brakes

    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 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: • front brake cable (drum side) • brake shoes Check that the brake shoes are properly posi- tioned.

  • Page 169: Rear Axle And Rear Axle Hub

    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 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 • • 55 Nm (5.5 m kg, 39.8 ft •...

  • Page 171: Removing The Rear Axle

    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

    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

    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. 3.

  • Page 174: Rear Brake

    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

    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; • use spent brake fluid for cleaning; (use only clean brake fluid) •...
  • Page 176 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 • brake caliper mounting bolts Brake caliper mounting bolt 35 Nm (3.5 m•kg, 25.3 ft•lb) 4.

  • Page 177: Rear Brake Master Cylinder

    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 • • Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed.

  • Page 178: Checking The Master Cylinder

    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. 2.

  • Page 179: Installing The Rear Brake Master Cylinder

    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. • Install the brake master cylinder so that the gaps between the brake master cylinder and the brake master cylinder bracket are equal.
  • Page 180 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. WARNING • Use only the designated quality brake fluid: other brake fluids may deteriorate the rubber seals, causing leakage and poor brake performance.

  • Page 181: Rear Brake Caliper

    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. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Parking brake cable Disconnect.
  • Page 182 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. Disassembling the rear brake caliper Adjusting bolt Locknut...

  • Page 183: Removing The Parking Brake Cable

    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 Brake pads As required...

  • Page 184: Installing The Rear Brake Caliper

    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 • union bolt Union bolt 28 Nm (2.8 m•kg, 20.3 ft•lb) N O T I C E When installing the brake hose on the...
  • Page 185 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

    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 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

    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. Remove: • rear brake switch Push the fastener when removing the rear brake switch out of the rear brake lever holder.

  • Page 189: Installing The Handlebar

    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 • The upper handlebar holders should be installed with the flange forward N O T I C E...

  • Page 190: Installing The Rear Brake Master Cylinder

    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 positions shown in the illustration.

  • Page 191: Installing The Parking Brake Lever

    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 lever...

  • Page 192: Steering Stem

    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 Removing the steering stem Remove the parts in the order listed.

  • Page 193: Removing The Steering Stem

    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: • steering stem Bends Replace. WARNING Do not attempt to straighten a bent stem;...

  • Page 194: Installing The Lower Handlebar Holder

    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

    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

    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. REMOVING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles.

  • Page 197: Installing The Tie-Rods

    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

    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 • • 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 199: Removing The Front Arms

    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

    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. Turns roug Replace the front arm.

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

    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: Drive Chain

    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 • • 18 Nm (1.8 m kg, 13.0 ft •...

  • Page 203: Removing The Rear Shock Absorber

    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

    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. 2. Remove: •...

  • Page 205: Checking The Drive Chain

    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) • While measuring the 15-link section, push down on the drive chain to increase its ten- sion.

  • Page 206: Installing The Drive Sprocket

    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. Check: • drive sprocket • driven sprocket More than 1/4 tooth wear Replace...

  • Page 207: Electrical Components

    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

    ELEC WIRING DIAGRAM 7 - 2...

  • Page 209: Checking The Switches

    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. Refer to “CHECKING SWITCH CON- Replace the switch.

  • Page 210: Checking Switch Continuity

    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

    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

    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” 1.
  • Page 213 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. • Connect the ignition dynamic spark tester •...
  • Page 214 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”. • Connect the pocket tester ( × 1) to the •...
  • Page 215 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 ( × 100) to the •...

  • Page 216: Electric Starting System

    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

    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

    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. battery 12.0 V or more at 20 °C (68 °F) 3.
  • Page 219 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

    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- cedure.

  • Page 221: Checking The Starter Motor

    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. Measure: • mica undercut Out of specification Scrape the mica to the proper measurement with a hacksaw...

  • Page 222: Assembling The Starter Motor

    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. Brush spring force 1.0~ 3.0 N (102 ~ 306 gf, 3.60 ~ 10.80 oz)

  • Page 223: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM C.D.I. magneto Rectifier/Regulator Battery Main fuse Battery (+) lead Battery (-) lead 7 - 17...
  • Page 224 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 • Is the main fuse OK? 2. battery 3.

  • Page 225: Troubleshooting

    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. STARTING FAILURE/HARD STARTING FUEL SYSTEM ELECTRICAL SYSTEM...

  • Page 226: Compression System

    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 • Worn, fatigued or broken piston ring •...

  • Page 227: Faulty Clutch

    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 • Slipping V-belt Primary sliding sheave •...

  • Page 228: Faulty Brake

    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 • Oily or greasy brake shoe lining •...

This manual is also suitable for:

Viper 90

Table of Contents

Save PDF