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

E-TON Yukon II Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

E-TON POWER
ATV3U 150
YUKON II (U.S.)
CHALLENGER 150 (EUR)
SERVICE MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Yukon II and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for E-TON Yukon II

Summary of Contents for E-TON Yukon II

  • Page 1 E-TON POWER ATV3U 150 YUKON II (U.S.) CHALLENGER 150 (EUR) SERVICE MANUAL...
  • Page 2 Yukon II & Challenger 150 SERVICE MANUAL 2009 by E-TON POWER TECH CO., LTD. First edition, October 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 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 SPEC machine. INFO Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Engine Carburetor Chassis Electrical CHAS CARB Troubleshooting 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 ..........2-17 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-17 LUBRICATION POINTS AND LUBRICANT TYPES ........

  • Page 9: Periodic Checks And Adjustments

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ...................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ..............3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 RACKS, SEAT, FENDERS AND FUEL TANK ..........3-3 RACKS, SEAT AND FRONT PANEL .............3-3 FRONT FENDER ..................3-4 REAR FENDER, FOOTREST BOARDS BETTERY AND C.D.I UNIT ..3-5...

  • Page 10: Engine

    CHAPTER 4 ENGINE ENGINE ......................4-1 EXHAUST PIPE/MUFFLER, CABLES 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 DISASSEMBLING THE SECONDARY SHEAVE........4-32 REMOVING THE PRIMARY SHEAVE............4-33 REMOVING THE SECONDARY SHEAVE AND V-BELT......4-33 DISASSEMBLING THE SECONDARY SHEAVE........4-34 CHECKING THE CLUTCH SHOE............4-34 CHECKING THE V-BELT................4-34 CHECKING THE DRIVE PULLEY............4-35 CHECKING THE PRIMARY ROLLER WEIGHTS........4-35 CHECKING THE PIECE SLIDER............4-35 CHECKING THE DRIVEN PULLEY............4-35 ASSEMBLING THE PRIMARY SHEAVE..........4-36 ASSEMBLING THE SECONDARY SHEAVE..........4-37...
  • Page 12 CHAPTER 5 CARBURETOR CARBURETOR....................5-1 DISASSEMBLING THE CARBURETOR...........5-4 CHECKING THE CARBURETOR ............. 5-4 ASSEMBLING THE CARBURETOR............5-6 INSTALLING THE CARBURETOR ............5-6 MEASURING AND ADJUSTING THE FUEL LEVEL ........5-7...
  • Page 13 CHAPTER 6 CHASSIS FRONT AND REAR WHEELS ..............FRONT WHEELS ..................REAR WHEELS ..................CHECKING THE WHEELS ..............CHECKING THE FRONT WHEEL HUBS ..........CHECKING THE REAR WHEEL HUBS..........INSTALLING THE WHEEL HUBS............INSTALLING THE FRONT WHEELS............INSTALLING THE REAR WHEELS............FRONT BRAKES ..................
  • Page 14 STEERING SYSTEM ..................6-23 HANDLEBAR................... 6-23 REMOVING THE HANDLEBAR GRIPS..........6-25 REMOVING THE REAR BRAKE SWITCH ..........6-25 CHECKING THE HANDLEBAR ..............6-25 INSTALLING THE HANDLEBAR ............6-26 INSTALLING THE HANDLEBAR GRIPS ..........6-26 INSTALLING THE REAR BRAKE MASTER CYLINDER......6-27 INSTALLING THE FRONT BRAKE LEVER ASSEMBLY......6-27 STEERING STEM ...................6-28 REMOVING THE STEERING STEM ............6-29 CHECKING THE STEERING STEM ............6-29...
  • Page 15 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS................ 7-1 WIRING DIAGRAM ..................7-2 CHECKING SWITCH CONTINUITY .............7-3 CHECKING THE SWITCHES ................7-4 CHECKING THE BULBS AND BULB SOCKETS ..........7-5 TYPES OF BULBS..................7-5 CHECKING THE CONDITION OF THE BULBS........7-6 CHECKING THE CONDITION OF THE BULBS SOCKETS......7-6 IGNITION SYSTEM ..................7-7 CIRCUIT DIAGRAM ..................
  • Page 16 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 front 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

    INFO IMPORTANT INFORMATION LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates and cotter pins. After the bolt or nut 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 →...

  • Page 21: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code YUKON II (U.S.) CHALLENGER 150 (EUR) Dimensions Overall length 1730 mm (68.1 in) Overall width 980 mm (38.6 in) Overall height 1070 mm (42.1 in) Seat height 760 mm (29.9 in) Wheelbase 1115 mm (43.9 in)
  • Page 22 SPEC GENERAL SPECIFICATIONS Item Standard Fuel Type Unleaded gasoline only Fuel tank capacity plastic 6.5 L (1.43 lmp gal, 1.71 US gal) Fuel reserve amount plastic 1.0 L (0.22 Imp gal, 0.26 US gal) Carburetor Type/quantity CVEK-019 x 1/USA CVEK-008 x 1/EUR Manufacturer KEI HIN Spark plug...
  • Page 23 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 Leading arm Rear suspension Swing arm Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Electrical...

  • Page 24: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit 13.7 ~14.1 cm 0.05 mm (0.002 in) Cylinder Bore size 57.400 ~ 57.410 mm 57.50 mm (2.2598 ~ 2.2602 in) (2.2638 in) Taper limit ---- 0.10 mm (0.0039 in) Maximum out-of-round ---- 0.10 mm...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 10.000 ~ 10.018 mm 10.100 mm (0.3937 ~ 0.3944 in) (0.3976 in) Rocker arm shaft outside diameter 9.972 ~ 9.987 mm 9.910 mm (0.3926 ~ 0.3932 in) (0.3902 in) Rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.046 mm...
  • Page 26 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) 0.030 ~ 0.057 mm 0.10 mm (0.0012 ~ 0.0022 in) (0.0039 in) Stem runout limit ---- 0.02 mm (0.0008 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Compressed pressure ---- 82.10 ~ 100.40 N at 29.00 mm installed) (8.37 ~ 10.23 kg, 18.45 ~ 22.56 lb at 1.1417 in) ---- 82.10 ~ 100.40 N at 29.00 mm (8.37 ~ 10.23 kg, 18.45 ~ 22.56 lb at 1.1417 in) °/ Tilt limit...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston rings Top ring Type ---- Barrel ---- 1.00 × 2.30 mm Dimensions (B × T) (0.0394 × 0.0906 in) 0.45 mm End gap (installed) 0.15 ~ 0.30 mm (0.0177in) (0.0059 ~ 0.0118 in) 0.09 mm Side clearance (installed) 0.015 ~ 0.055 mm...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Automatic centrifugal ---- Clutch shoe thickness 4.0 mm 0 mm (0.1575 in) (0.0787 in) 32.0 mm (1.2598 in) Clutch shoe spring free length ---- Clutch housing inside diameter 124.9 ~ 125.1 mm 125.5 mm (4.9173 ~ 4.9252 in) (4.9409 in)
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.00 ~ 0.15mm 0.15 mm (0.0000 ~ 0.0059 in) (0.0059 in) Outer-rotor-to-oil-pump-housing clearance 0.15 ~ 0.21 mm 0.25 mm (0.0059 ~ 0.0083 in) (0.0098 in) Oil-pump-housing to inner-rotor-and-outer- 0.05 ~ 0.10 mm 0.17 mm...

  • Page 31: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Shock absorber travel 50 mm (1.97 in) ---- Fork spring free length 175 mm (6.89 in) Spring rate (K ) 3.0±0.30 kgf/mm (K ) 4.0±0.40 kgf/mm Rear suspension Shock absorber travel 85 mm (3.35 in) ---- Spring free length...
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear disc brake Type Dual cylinder ---- Disc outside diameter × thickness 190.0 mm × 3.5 mm 3.00 mm (7.48 in × 0.14 in) (0.120 in) Brake disk maximum deflection 0.25 mm (0.009 in) Pad thickness inner 6.2 mm (0.24 in) 2.00 mm...

  • Page 33: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 13.0 ° /1,700 r/min ---- Advanced timing (B.T.D.C.) 29.0 ° /4,000 r/min ---- Advancer type Electrical (digital) ---- C.D.I. Magneto model/manufacturer C1120-V30-9000/SHINGYIH ---- 120 ~ 180 Ω...
  • Page 34 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh ---- Starter motor Model/manufacturer C1200-V30-0000/SHINGYIH ---- Output 0.50 kW ---- Armature coil resistance 0.005 ~ 0.007 Ω at 20 °C (68 ° ---- Brush overall length 11.5 mm (0.45 in) 5.5 mm (0.22 in) Spring force...

  • Page 35: Tightening Torques

    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 Exhaust pipe Muffler Bolt 18.0 Cover head cylinder Bolt Holder cam shaft 14.5 Spark plug —...

  • Page 36: Chassis Tightening Torques

    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: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE / 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 38: Lubrication Points And Lubricant Types

    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 Piston pin outside surface...
  • Page 39 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Lubricant Primary sheave inside, Collar, Solid bush, Secondary fixed inner surface BEL-RAY assembly lube Secondary sheave torque cam ditch BEL-RAY assembly lube Gasket (Cylinder head cover) Sealant Stopper guide (Cylinder head cover) Sealant Crankcase mating surfaces Sealant...

  • Page 40: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS Camshaft Crankshaft Oil pump Oil filter 2 - 20...

  • Page 41: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Choke cable (USA/CAN) Fuel filter hose Handlebar switch lead Rear brake hose Rubber tube Rear brake switch lead Front brake cable (left) Bear tube 3 Fuel sender lead Front brake cable (right) Oil catch hose 4 Starter relay lead Throttle cable Crankcase breather hose...
  • Page 42 SPEC CABLE ROUTING 8 Rectifier/regulator lead 9 Tail light lead 10 Buzzer lead Fasten the rear brake switch lead and handlebar switch lead with a plastic band. Insert the fuel tank breather hose into the hole in the handlebar cover. Fasten the wire harness with a plastic band and a clamper pulser cord.
  • Page 43 SPEC CABLE ROUTING Throttle cable Head light lead Battery Choke cable (USA/CAN) Ignition coil Negative battery lead Wire harness Negative starter motor lead Main fuse (on wire harness) Main switch lead Generator lead C.D.I. unit Meter lead 10 Positive battery lead Light controller Reverse switch lead PTC controller...
  • Page 44 SPEC CABLE ROUTING Pass these leads through rear fender. Fasten power supply lead on the wire harness with a plastic band. 2 - 24...
  • Page 45 SPEC CABLE ROUTING Choke cable (USA/CAN) Wire harness Neutral switch lead Rear brake hose C.D.I. unit Rear brake switch lead Fuel tank breather hose Negative battery lead Handlebar switch lead Throttle cable Main fuse (on wire harness) Front brake cable (right) Battery Front brake cable (left) Positive battery lead...
  • Page 46 SPEC CABLE ROUTING Fasten the handlebar switch lead, rear brake switch lead with a plastic band. To the frame. To starter relay. Connect the positive battery lead to the battery so that the lead contacts the battery case. Connect the negative battery lead to the battery so that the lead is routed to the side of the battery. 2 - 26...
  • Page 47 SPEC CABLE ROUTING Throttle cable Front brake cable (left) 4 Light controller Rear brake hose Front brake cable (right) 5 Main switch Choke cable (USA/CAN) 0 Wire harness 6 Meter Oil catch hose 1 Head light lead (left) 7 Rear brake switch Crankcase breather hose Head light lead (right)

  • Page 48: 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 49 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 50: Racks, Seat, Fenders And Fuel Tank

    RACKS, SEAT, FENDERS AND FUEL TANK SEAT, FENDERS AND FUEL TANK RACKS, RACKS, SEAT AND FRONT PANEL 25 Nm (2.5 m kg, 18.1 ft • • 25 Nm (2.5 m kg, 18.1 ft • • Order Job/Part Q’ty Remarks racks, Removing the seat and front Remove the parts in the order listed.

  • Page 51: Front Fender

    RACKS, SEAT, FENDERS AND FUEL TANK FRONT FENDER 9 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. Racks, seat and front panel Refer to “RACKS, SEAT AND FRONT PANEL”.

  • Page 52: Rear Fender, Footrest Boards Bettery And C.d.i Unit

    RACKS, SEAT, FENDERS AND FUEL TANK REAR FENDER, FOOTREST BOARDS BETTERY AND C.D.I UNIT 9 Nm (0.9 m kg, 6.5 ft 9 Nm (0.9 m kg, 6.5 ft • • • • 9 Nm (0.9 m kg, 6.5 ft • •...

  • Page 53: Fuel Tank And Footrest Bars

    RACKS, SEAT, FENDERS AND FUEL TANK FUEL TANK AND FOOTREST BARS 12 Nm (1.2 m kg, 8.7 ft • • (USA) FUEL 25 Nm (2.5 m kg, 18.1 ft Ib) • • Order Job/Part Q’ty Remarks Removing the fuel tank and footrest Remove the parts in the order listed.

  • Page 54: 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 temperatrue. 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 55: Adjusting The Engine Idling Speed

    ADJUSTING THE VALVE CLEARANCE/ ADJUSTING THE ENGINE IDLING SPEED c. Measure the valve clearance using a thick- ness gauge Out of specification → Adjust. 3. Adjust: • valve clearance a. Loosen the locknut b. Insert a thickness gauge between the adjuster end and the valve end.

  • Page 56: Adjusting The Throttle Lever Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE LEVER FREE PLAY 4. Adjust: • engine idling speed a. Turn the throttle stop screw in or out until the specified idling speed is obtained. Idling speed becomes Turning right higher. Idling speed becomes Turning left lower.

  • Page 57: Adjusting The Speed Limiter

    ADJUSTING THE THROTTLE LEVER FREE PLAY/ ADJUSTING THE SPEED LIMITER 2. Adjust: • throttle lever free play a. Pull back the adjuster cover b. Loosen the locknut on the carburetor side. c. Turn the adjuster in or out until the cor- rect free play is obtained.

  • Page 58: Checking The Spark Plug

    ADJUSTING THE SPEED LIMITER/ CHECKING THE SPARK PLUG 2. Adjust: • speed limiter length a. Loosen the locknut b. Turn the adjuster in or out until the speci- fied speed limiter length is obtained. Speed limiter length is Turning in decreased.

  • Page 59: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 4. Clean: • spark plug (with a spark plug cleaner or wire brush) 5. Measure: • spark plug gap Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) 6.

  • Page 60: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. Detach: • timing light • engine tachometer 5. Install: • Shroud cap The ignition timing is not adjustable. MEASURING THE COMPRESSION PRESSURE Insufficient compression pressure will result in a loss of performance. 1.

  • Page 61: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground the spark plug lead before cranking the engine.
  • Page 62 CHECKING THE ENGINE OIL LEVEL a. Warm up the engine for several minutes, and stop it, then wait at least several min- utes for the oil to drain back into the crank- case. WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out.

  • Page 63: 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 64: Cleaning The Air Filter Elements

    CLEANING THE AIR FILTER ELEMENTS CLEANING THE AIR FILTER ELEMENTS 1. Loosen: • bolts / screws 2. Remove: • air filter case cover • seals • air filter element N O T I C E • The engine should never be run without the air filter;...

  • Page 65: Cleaning The Spark Arrester

    CLEANING THE SPARK ARRESTER CLEANING THE SPARK ARRESTER 1. Clean: • spark arrester WARNING • Select a well-ventilated area free of com- bustible materials. • Always let the exhaust system cool before performing this operation. • Do not start the engine when removing (Only U.S.) the tailpipe from muffler.

  • Page 66: Chassis

    CHECKING THE FRONT BRAKE SHOES/ ADJUSTING THE FRONT BRAKE CHASSIS CHECKING THE FRONT BRAKE SHOES 1. Operate the brake: 2. Check: • wear indicator Wear indicators reaches the wear limit line → Replace the brake shoes as a set. Refer to “FRONT BRAKES” in chapter 6. 3.

  • Page 67: 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 68: 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 2.0 mm (0.08 in) 2.
  • Page 69 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 70: 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: • final transmission oil filler cap •...

  • Page 71: Checking The Steering System

    ADJUSTING THE DRIVE CHAIN SLACK/ CHECKING THE STEERING SYSTEM 1. Measure: • drive chain slack Out of specification → Adjust. Drive chain slack 15 ~ 25 mm (0.59 ~ 0.98 in) 2. Adjust: • drive chain slack The drive chain slack is adjusted by the rota- tion of the rear axle hub.

  • Page 72: Adjusting The Toe-In

    CHECKING THE STEERING SYSTEM/ ADJUSTING THE TOE-IN 3. Check: • tie-rod ends Turn the handlebar to the left and/or right until it stops completely, then slightly move the handlebar slightly in the opposite direction. Tie-rod end (s) have vertical play → Replace the tie-rod end(s).
  • Page 73 ADJUSTING THE TOE-IN 3. Adjust: • toe-in WARNING • Be sure that both tie-rods are turned the same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mis- handling and an accident.

  • Page 74: Checking The Front And Rear Shock Absorbers

    CHECKING THE FRONT ANDREAR SHOCK ABSORBERS CHECKING THE FRONT AND REAR SHOCK ABSORBERS 1. Place the machine on a level surface. 2. Check: • damper rod Bends/damage → Replace the front/rear shock absorber assembly. • oil leakage Excessive oil leakage → Replace the front/ rear shock absorber assembly.

  • Page 75: Adjusting The Shock Absorbers

    • 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 76 CHECKING THE TIRES • TIRE PRESSURE 1) Recommended tire pressure Front 25 kPa (0.25 kgf/cm , 3.6 psi) Rear 25 kPa (0.25 kgf/cm , 3.6 psi) 2) Tire pressure below the minimum speci- fication could cause the tire to dislodge from the rim under severe riding condi- tions.

  • Page 77: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS WARNING Uneven or improper tire pressure may ad- versely affect the handling of this machine and may cause loss of control. • Maintain proper tire pressures. • Set tire pressures when the tires are cold. •...

  • Page 78: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS, STEERING SHAFT AND STEERING KNUCKLES CHECKING AND LUBRICATING THE CABLES 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 79: 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 80 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 81 CHECKING AND CHARGING THE BATTERY Example c. Open-circuit voltage = 12.0 V d. Charging time Using 0.9A-charging current about 5 hours. (Normal charging) Or using 4A-charging current about 1 hour. (Quick charging) e. Charge of the battery = 20 ~ 30% 5.
  • Page 82 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 83 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 84 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 85: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 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: •...
  • Page 86 CHECKING THE FUSES b.If the pocket tester indicates “•”, replace the fuse. 3.Replace: • blown fuse a.Set the main switch to “OFF”. b.Install a new fuse of the correct amperage. c.Set on the switches to verify if the electrical circuit is operational. d.If the fuse immediately blows again, check the electrical circuit.

  • Page 87: Engine

    ENGINE ENGINE ENGINE EXHAUST PIPE/MUFFLER, CABLES AND LEADS 13 Nm (1.3 m kg, 9.4 ft • • 25 Nm (2.5 m kg, 18.1 ft • • Order Job/Part Q’ty Remarks Removing the exhaust pipe/muffler, Remove the parts in the order listed. cables and leads Racks, seat, fenders and fuel tank Refer to “RACKS, SEAT, FENDERS AND...

  • Page 88: Engine Mounting Bolts

    ENGINE ENGINE MOUNTING BOLTS 15 Nm (1.5 m kg, 10.8 ft • • 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the engine mounting bolts Remove the parts in the order listed. Exhaust pipe/muffler Refer to “EXHAUST PIPE/MUFFLER, CABLE AND LEADS”...

  • Page 89: Removing The Engine

    ENGINE REMOVING THE ENGINE Remove: • master link • drive chain INSTALLING THE ENGINE 1. Install: • flange bolts/ nuts Do not fully tighten the bolts and nuts. 2. Tighten: • flange bolts/ nuts 1 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 90: 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 91 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 92: 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 93: Checking The Camshaft Sprocket

    CYLINDER HEAD 3. Remove: cam shaft comp • head comp cylinder • 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 →...

  • Page 94: 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 →...
  • Page 95 CYLINDER HEAD 2. Install: • cam shaft comp round h- a. Rotate the camshaft to align the in camshaft sprocket away from t- he cylinder head. b.Turn the crankshaft clockwise with a wrench. c. Align the “T” mark on the rotor with the stationary pointer on the crankcase.
  • Page 96 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) • • lifter comp tensioner WARNING Always use a new gasket.

  • Page 97: 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 98: 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 99: Checking The Camshaft

    CAMSHAFT, ROCKER ARMS AND VALVES 2. Remove: • valve cotters Attach a valve spring compressor and attach- ment 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 →...
  • Page 100 CAMSHAFT, ROCKER ARMS AND VALVES 4. Measure: • rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 10.000 ~ 10.018 mm (0.3937 ~ 0.3944 in) 5. Measure: • rocker arm shaft outside diameter Out of specification → Replace. Rocker arm shaft outside diameter 9.972 ~ 9.987 mm (0.3926 ~ 0.3932 in)

  • Page 101: 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)
  • Page 102 CAMSHAFT, ROCKER ARMS AND VALVES • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. 5. Eliminate: • carbon deposits (from the valve face and valve seat) 6.
  • Page 103 CAMSHAFT, ROCKER ARMS AND VALVES a. Apply a coarse lapping compound to the valve face. N O T I C E Do not let the compound enter the gap between the valve stem and the guide. b. Apply molybdenum disulfide oil to the valve stem.

  • Page 104: Installing The Valves And Valve Springs

    CAMSHAFT, ROCKER ARMS AND VALVES 10.Measure: • compressed spring force Out of specification → Replace. Installed length Compressed spring force Inner spring 33.55 ~ 41.00 N at 26.00 mm (3.42 ~ 4.18 kg, 7.54 ~ 9.21 lb at 1.0236 in) Outer spring 82.10 ~ 100.40 N at 29.00 mm (8.37 ~ 10.23 kg,...

  • Page 105: Installing The Camshaft And Rocker Arms

    CAMSHAFT, ROCKER ARMS AND VALVES 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. N O T I C E Hitting the valve tip with excessive force could damage the valve. INSTALLING THE CAMSHAFT AND ROCKER ARMS 1.

  • Page 106: 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 107: 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 108 CYLINDER AND PISTON 57.000 ~ 57.010 mm Cylinder bore “C” (2.2441 ~ 2.2 4 4 5 in) Taper limit“T” 0.10 mm (0.0039 in) Out-of-round“R” 0.10 mm (0.0039 in) “C” = maximum of D “T” = maximum of D or D –...

  • Page 109: 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 clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 110: 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 14.994 ~ 15.000 mm (0.5903 ~ 0.5904 in)

  • Page 111: Installing The Cylinder

    CYLINDER AND PISTON 2. Position: 120˚ • top ring 120˚ 120˚ • 2nd ring • oil ring Offset the piston ring end gaps as shown. top ring end 2nd ring end side rail spacer side rail 20 mm (0.79 in) or more 3.

  • Page 112: C.d.i. Magneto

    C.D.I. MAGNETO C.D.I. MAGNETO 12 Nm (1.2 m kg, 8.7 ft • • 55 Nm (5.5 m kg, 39.8 ft • • 5 Nm (0.5 m kg, 3.6 ft • • (x2) 12 Nm (1.2 m kg, 8.7 ft • •...

  • Page 113: Removing The C.d.i. Magneto Rotor

    C.D.I. MAGNETO REMOVING THE C.D.I. MAGNETO ROTOR 1. Remove: • nut • plate washer • While holding the C.D.I. magneto rotor with the holding tool , loosen the C.D.I. magneto nut • Do not allow the sheave holder to touch the pro- jection on the C.D.I.

  • Page 114: Belt Drive

    BELT DRIVE BELT DRIVE CRANKCASE COVER 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 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.

  • Page 115: 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 kick spindle...

  • Page 116: 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 on the projection 3.

  • Page 117: V-Belt, Clutch, Drive And Driven Pulley

    BELT DRIVE V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY 55 Nm (5.5 m kg, 39.8 ft • • (x4) (x4) (x3) (x3) 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 118: Disassembling The Secondary Sheave

    BELT DRIVE DISASSEMBLING THE SECONDARY SHEAVE 55 Nm (5.5 m kg, 39.8 ft • • Order Job/Part Q’ty Remarks Disassembling the plate sub assy Disassemble the parts in the order listed. drive Nut lock Plate comp drive Roller clutch Weight set clutch Spring clutch Plate clutch Collar spring...

  • Page 119: Removing The Secondary Sheave And V-Belt

    BELT DRIVE REMOVING THE PRIMARY SHEAVE 1. Remove: • primary sheave nut • washer ratchet kick starter • • face drive • clip boss drive face • face movable drive • While holding the primary fixed sheave with the rotor holding tool , loosen the primary fixed sheave nut.

  • Page 120: Disassembling The Secondary Sheave

    BELT DRIVE 3. Remove: econdary sheave assembly • • V-belt Remove the V-belt and clutch assembly from the primary sheave side. DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: nut lock • Install the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown.

  • Page 121: Checking The Drive Pulley

    BELT DRIVE CHECKING THE DRIVE PULLEY 1. Check: face movable drive • • face driver Cracks/damage/wear → Replace the face movable drive, face driver and V-belt. CHECKING THE PRIMARY ROLLER WEIGHTS The following procedure applies to all of the roller weights. 1.

  • Page 122: Assembling The Primary Sheave

    BELT DRIVE 2. Check: torque cam groove • Damage/wear → Replace the face comp, driven and face comp, movable drive as a set. 3. Check: • guide pin Damage/wear → Replace the face comp, driven and face comp, movable drive as a set.

  • Page 123: Assembling The Secondary Sheave

    BELT DRIVE 3. Install: • piece slide • face movable drive plate ramp • ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: face comp, movable driven’s inner surface • • face comp, driven’s inner surface torque cam groove • • oil seals •...

  • Page 124: Installing The Belt Drive

    BELT DRIVE INSTALLING THE BELT DRIVE 1. Install: • V-belt plate sub assy drive • N O T I C E Do not allow grease to contact the V-belt, secondary sheave assembly. Install the V-belt onto the face comp, driven. 2.

  • Page 125: Starter Clutch And Starter Motor

    STARTER CLUTCH AND STARTER MOTOR STARTER CLUTCH AND STARTER MOTOR 12 Nm (1.2 m kg, 8.7 ft • • 95 Nm (9.5 m kg, 68.7 ft • • (x3) Order Job/Part Q’ty Remarks Removing the starter clutch and Disassemble the parts in the order listed. starter motor Primary sheave Refer to “...

  • Page 126: Checking The Starter Wheel Gear

    STARTER CLUTCH AND STARTER MOTOR CHECKING THE STARTER WHEEL GEAR 1. Check: • gear comp starting clutch • gear starter reduction Burrs/chips/roughness/wear → Replace 2. Check: starter clutch operation • a. Install the starter wheel gear onto the idle gear and hold the starter clutch.

  • Page 127: Oil Pump

    OIL PUMP OIL PUMP 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft 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.

  • Page 128: Removing The Oil Pump

    OIL PUMP REMOVING THE OIL PUMP 1. Remove: • fan cover assy cooling fan composition • • A.C.G generator assy • the right crankcase cover Gear comp starting clutch and flange • starting clutch 4 - 42...

  • Page 129: Checking The Oil Pump

    OIL PUMP flange bolts and separator oil • • oil pump chain and oil pump driven sprocket oil pump assy • • Disassemble the oil pump assy CHECKING THE OIL PUMP 1. Check: sprocket oil pump driven • Cracks/damage/wear → Replace the defective part(s).

  • Page 130: Installing The Oil Pump

    OIL PUMP 2. Measure: • inner-rotor-to-outer-rotor-tip clearance • outer-rotor-to-oil-pump-housing clearance • oil-pump-housing-to-inner-rotor-and-outer- rotor clearance Out of specification → Replace the oil pump. Inner rotor Outer rotor Inner-rotor-to-outer-rotor-tip clear- ance 0.00 ~ 0.15 mm (0.0000~0.0059in) <Limit>: 0.15mm (0.0059 in) Outer-rotor-to-oil-pump-housing clearance 0.15 ~ 0.21 mm (0.0059~0.0083in) <Limit>: 0.25 mm (0.0098 in)

  • Page 131: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 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.

  • Page 132: Separating The Crankcase

    CRANKCASE AND CRANKSHAFT SEPARATING THE CRANKCASE 1. Remove: • crankcase bolt 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 removed moved if the timing chain is attached onto the crankshaft sprocket.

  • Page 133: 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 crankshaft, 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 →...

  • Page 134: Installing The Crankshaft

    CRANKCASE AND CRANKSHAFT INSTALLING THE CRANKSHAFT 1. Install: • crankshaft assembly • crankshaft • 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 135: Transmission

    TRANSMISSION TRANSMISSION 10Nm(1.0m kg, 7.2 ft lb) • • 25Nm(2.5m kg, 18.1 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 136: Shift Shaft

    TRANSMISSION SHIFT SHAFT 7 Nm (0.7 m kg, 5.1 ft • • (x2) 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the shaft comp rod and Remove the parts in the order listed.

  • Page 137: Checking The Shift Fork

    TRANSMISSION CHECKING THE SHIFT FORK 2. Check: • shift fork cam follower • shift fork pawl Bends/damage/scoring/wear → Replace. 3. Check: • shaft gear shift Roll the shaft gear shift on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent shaft gear shift.

  • Page 138: Removing The Gear Set

    TRANSMISSION 2. Measure: • shaft gear shift comp (with a centering device and dial gauge ) Out of specification → Replace the drive shaft. Dirve shaft runout limit 0.08 mm (0.0031 in) 3. Measure: • final shaft runout (with a centering device and dial gauge ) Out of specification →...

  • Page 139: Checking The Gear Set

    TRANSMISSION • relax the bolts and remove the mission cover • remove the plate fixing and sprocket drive from the final shaft comp • remove the knock pins and gasket • pull the shaft gear shifts out and remove the fork shift •...

  • Page 140: Installing The Gear Set

    TRANSMISSION • check the sprocket drive and plate fixing for wear or damage INSTALLING THE GEAR SET • install counter shaft comp • Install the mission cover and final shaft comp together with circlip • install shaft gear shift comp •...
  • Page 141 CARB CARBURETOR CARBURETOR CARBURETOR 13(A) 13(M) Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in the order listed. Tube clip (B) Tube, rubber (A) Tube clip (A) Pipe, bypass Tube, rubber Bear tube comp Three through tube comp Only Europe.
  • Page 142 CARB CARBURETOR (x4) (x4) 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. Plate fixed piston cover (B) Plate fixed piston cover (A) Vacuum piston cover assy...
  • Page 143 CARB CARBURETOR (x4) (x4) Order Job/Part Q’ty Remarks Carb chamber Float pin Float Pilot jet Main jet Needle jet holder Needle jet Needle valve assy For assembly, reverse the disassembly procedure. 5 - 3...
  • Page 144 CARB CARBURETOR DISASSEMBLING THE CARBURETOR Before disassembling the carburetor, make sure to note the number of times the air adjusting screw is turned out from the seated position to its set position. CHECKING THE CARBURETOR 1. Check: • carburetor body •...
  • Page 145 CARB CARBURETOR 4. Check: • piston valve Damage/scratches/wear → Replace. • piston valve diaphragm Cracks/tears → Replace. 5. Check: • plate fixed piston cover (B) • plate fixed piston cover (A) • vacuum piston cover • piston spring Cracks/damage → Replace. 6.
  • Page 146 CARB CARBURETOR 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. N O T I C E •...
  • Page 147 CARB CARBURETOR 2. Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 5 ~ 10 mm (0.20 ~ 0.39 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. MEASURING AND ADJUSTING THE FUEL LEVEL 1.

  • Page 148: Chassis

    CHAS FRONT AND REAR WHEELS CHASSIS FRONT AND REAR WHEELS FRONT WHEELS 80 Nm (8.0 m kg, 57.9 ft • • (x4) 40 Nm (4.0 m 45 Nm (4.5 m · kg, 32.5 ft · lb) kg, 28.9 ft • •...

  • Page 149: Rear Wheels

    CHAS FRONT AND REAR WHEELS REAR WHEELS 80 Nm (8.0 m kg, 57.9 ft • • (x4) 40 Nm (4.0 m 45 Nm (4.5 m · kg, 32.5 ft · lb) kg, 28.9 ft • • Order Job/Part Q’ty Remarks Removing the rear wheels Remove the parts in the order listed.

  • Page 150: 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 151: 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 152: 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 153: Front Brakes

    CHAS FRONT BRAKES FRONT BRAKES 14 Nm (1.4 m kg, 10.1 ft • • 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.

  • Page 154: 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 155: Checking The Front Brake Drums

    CHAS FRONT BRAKES 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. Brake lining thickness 4.0 mm (0.16 in) <Limit>: 1.5 mm (0.06 in) CHECKING THE FRONT BRAKE DRUMS The following procedure applies to each brake.
  • Page 156 CHAS FRONT BRAKES N O T I C E During installation, lightly grease the brake camshaft and the pivot pin. Wipe off the excess grease. 2. Install: • brake camshaft • brake camshaft lever 14 Nm (1.4 m kg, 10.1 ft •...

  • Page 157: 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 • • 30 Nm (3.0 m kg, 21.7 ft • • 55 Nm (5.5 m kg, 39.8 ft • (x4) (x4) (x4) 35 Nm (3.5 m...
  • Page 158 CHAS REAR AXLE AND REAR AXLE HUB 170 Nm (17.0 m kg, 123 ft • • 30 Nm (3.0 m kg, 21.7 ft • • 55 Nm (5.5 m kg, 39.8 ft • (x4) (x4) (x4) 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 159: 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 160: Checking The Brake Disc

    CHAS REAR AXLE AND REAR AXLE HUB CHECKING THE BRAKE DISC 1. Check: • brake disc Galling/damage → Replace. 2. Measure: • brake disc deflection Out of specification → Replace. Brake disc maximum deflection 0.25 mm (0.009 in) • brake disc thickness Out of specification →...

  • Page 161: Rear Brake

    CHAS REAR BRAKE REAR BRAKE CALIPER 30 Nm (3.0 m kg, 21.7 ft • • 28 Nm (2.8 m kg, 20.3 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.

  • Page 162: Checking The Rear Brake Caliper

    CHAS REAR BRAKE CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pads As required Every two years Caliper ass'y Brake hoses Every four years Replace when Brake fluid brakes are disassembled. 1. Check: • brake caliper body Cracks/damage →...
  • Page 163 CHAS REAR BRAKE WARNING Proper brake hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING” in chapter 2. 2. Fill: • brake reservoir Recommended brake fluid DOT 4 N O T I C E Brake fluid may damage painted surfaces or plastic parts.

  • Page 164: 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 165 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. 4. Install: • brake caliper • brake caliper mounting bolts Brake caliper mounting bolt 30 Nm (3.0 m •...

  • Page 166: 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 167: 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 168 CHAS REAR BRAKE 2. Install: • copper washers • brake hose • union bolt 28 Nm (2.8 m kg, 20.3 ft • • • Tighten the union bolt while holding the brake hose as shown. • Turn the handlebar to the left and to the right to check that the brake hose does not touch other parts (throttle cable, wire harness, leads, etc.).
  • Page 169 CHAS REAR BRAKE 4. Air bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Brake fluid level is under the “LOWER” level line → Add the recommended brake fluid to the proper level.

  • Page 170: Steering System

    CHAS STEERING SYSTEM STEERING SYSTEM HANDLEBAR 14 Nm (1.4 m kg, 10.1 ft • • 14 Nm (1.4 m kg, 10.1 ft • • (x4) (x2) 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.
  • Page 171 CHAS STEERING SYSTEM 14 Nm (1.4 m kg, 10.1 ft • • 14 Nm (1.4 m kg, 10.1 ft • • (x4) (x2) 28 Nm (2.8 m kg, 20.3 ft • • Order Job/Part Q’ty Remarks Plastic band Fasten the rear brake switch lead and handlebar switch lead.

  • Page 172: 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 173: Installing The Handlebar

    CHAS STEERING SYSTEM INSTALLING THE HANDLEBAR 1. Install: • handlebar • upper handlebar holders 14 Nm (1.4 m kg, 10.1 ft • • • 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 174: 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 175: Steering Stem

    CHAS STEERING SYSTEM STEERING STEM 25 Nm (2.5 m kg, 18.1 ft • • 35 Nm (3.5 m kg, 25.3 ft • • (X2) 35 Nm (3.5 m kg, 25.3 ft • (X2) (X2) 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 176: 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 177: Installing The Steering Stem

    CHAS STEERING SYSTEM INSTALLING THE STEERING STEM 1. Tighten: • steering stem nut 35 Nm (3.5 m kg, 25.3 ft • • • tie-rod end nut 35 Nm (3.5 m kg, 25.3 ft • • When tightening each tie-rod end nut , hold the tie-rod ball joint with a 14-mm wrench INSTALLING THE LOCK WASHER...

  • Page 178: Tie-Rods And Steering Knuckles

    CHAS STEERING SYSTEM TIE-RODS AND STEERING KNUCKLES 35 Nm (3.5 m kg, 25.3 ft • • 35 Nm (3.5 m kg, 25.3 ft • • 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the tie-rods and steering Remove the parts in the order listed.

  • Page 179: 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 180: 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 181: 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 • • 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the tie-rods and steering Remove the parts in the order listed.

  • Page 182: 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 183: 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/pitting → Replace the front arm. Free play → Replace the front arm. Turns roughly →...

  • Page 184: 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 • • 75 Nm (7.5 m kg, 54.2 ft • • 35 Nm (3.5 m kg, 25.3 ft •...

  • Page 185: Drive Chain

    REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN 35 Nm (3.5 m kg, 25.3 ft • • 75 Nm (7.5 m kg, 54.2 ft • • 35 Nm (3.5 m kg, 25.3 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 186: 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 187: Checking The Swingarm

    REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN 2. Remove: • flange nut • flange bolt • swingarm CHECKING THE SWINGARM 1. Check: • swingarm Bends/cracks/damage → Replace. 2. Check: • flange bolt Roll the axle on a flat surface. Bends →...

  • Page 188: Installing The Drive Sprocket

    REAR SHOCK ABSORBER, SWINGARM AND CHAS DRIVE CHAIN 3. Check: • drive chain rollers Damage/wear → Replace the drive chain. • drive chain side plates Cracks/damage/wear → Replace the drive chain. 4. Lubricate: • drive chain 5. Check: • drive sprocket •...

  • Page 189: Electricalcomponents

    ELEC ELECTRICAL COMPONENTS ELECTRICALCOMPONENTS Main switch Pickup coil/stator assembly Wire harness Battery Rectifier/regulator Starter motor Head light Reverse switch Main fuse Light control unit Neutral switch C.D.I. unit Horn Starter relay Fuel sender PTC controller Tail light Handlebar switch Ignition coil Buzzer Rear brake switch 7 - 1...

  • Page 190: Wiring Diagram

    ELEC WIRING DIAGRAM 7 - 2...

  • Page 191: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUTY CHECKING SWITCH CONTINUITY ∞ Check each switch for continuity with the poc- ket tester. If the continuity reading is incorrect, Pocket tester check the wiring connections and if necessary, replace the switch. Ωx1 NOTICE: Never insert the tester probes into the cou- pler terminal slots.

  • Page 192: 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 Incorrect continuity reading → Replace the the terminals. Refer to “CHECKING SWITCH switch.

  • Page 193: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect.

  • Page 194: Checking The Condition Of The Bulbs Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS 2. Check: • bulb (for continuity) (with the pocket tester) No continuity Replace. TIP: Before checking for continuity, set the pocket tester to “0” and to the “ Ω x 1” range. a. Connect the positive tester probe to termi- and the negative tester probe to ter- minal , and check the continuity.

  • Page 195: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM Main switch C.D.I. magneto Battery Main fuse C.D.I. unit Ignition coil Engine stop switch Neutral switch Reverse switch 7 - 7...

  • Page 196: Troubleshooting

    ELEC IGNITION SYSTEM TROUBLESHOOTING 2. Spark plug The ignition system fails to operate • Check the condition of the spark plug. (no spark or intermittent spark). • Check the spark plug type. • Measure the spark plug gap. Check: Refer to “CHECKING THE SPARK PLUG” in chapter 3.
  • Page 197 ELEC IGNITION SYSTEM 4. Spark plug cap resistance • Connect the pocket tester ( Ω x 1k) to the ignition coil as shown. • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“ Ω x 1k” range) to the spark plug cap as shown.
  • Page 198 ELEC IGNITION SYSTEM 8. Reverse switch 10. Battery • Check the reverse switch for continuity. • Check the condition of the battery. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING AND CHARGING THE • Is the reverse switch OK? BATTERY” in chapter 3. Minimum open-circuit voltage 12.0 V or more at 20°C •...

  • Page 199: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Starter motor Brake light switch Battery Starter switch Main fuse Eng stop switch Starter relay 7 - 11...

  • Page 200: Starting Circuit Out-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON” the starter motor can only operate if at least one of the following conditions is met: • The engine stop switch is ON. •...

  • Page 201: 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 THE Check: BATTERY” in chapter 3. 1. main fuse Minimum open-circuit voltage 2. battery 12.0 V or more at 20°C 3.
  • Page 202 ELEC ELECTRIC STARTING SYSTEM 4. Starter relay 7. Brake light switch • Disconnect the starter relay coupler from • Check the brake light switch for continuity. the coupler. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester ( Ω x 1) and bat- •...

  • Page 203: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR O-ring Armature assembly Starter motor front cover Starter motor rear cover Brush Brush spring Brush wear limit : 6.5 mm Commutator wear limit : 20.5 mm 7 - 15...

  • Page 204: Removing The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR 1. Remove: • seat assy. • helmet box • starter motor CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt Clean with 600-grit sandpaper. 2. Measure: • commutator diameter a Out of specification Replace the starter motor.

  • Page 205: Assembling The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM ASSEMBLING THE STARTER MOTOR 1. Install: • brush set • rubber seal • starter motor front cover 2. Install: • starter motor rear cover 3. Install: • Starter motor bolts 12 Nm (1.2 m • kg) NOTE: When install the starter motor the ground ter- minal a is installed with upper side bolt.

  • Page 206: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM C.D.I. magneto Rectifier/Regulator Battery Main fuse 7 - 18...

  • Page 207: Troubleshooting

    ELEC CHARGING SYSTEM TROUBLESHOOTING 2. Main fuse The battery is not being charged. • Check the fuse for continuity. Refer to “CHECKING THE FUSES” in chap- Check: ter 3. • Is the fuse OK? 1. charging voltage 2. main fuse 3.
  • Page 208 ELEC CHARGING SYSTEM Positive tester probe white Negative tester probe white/Red • Measure the charging coil resistance. Charging coil resistance 0.72 ~ 0.97 Ω at 20°C • Is the charging coil OK? Replace the char- ging coil assembly. 5. Wiring •...

  • Page 209: Lighting System

    ELEC LIGHTING SYSTEM CHECKING SWITCH CONTINUTY LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch Dimmer switch C.D.I. magneto light control unit Rectifier/Regulator Headlight Battery Tail/brake light Main fuse 7 - 21...

  • Page 210: Troubleshooting

    ELEC LIGHTING SYSTEM TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING light, taillight. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1. main fuse 12.0 V or more at 20°C 2.

  • Page 211: Checking The Lighting System

    ELEC LIGHTING SYSTEM CHECKING THE LIGHTING SYSTEM 2. Voltage 1. The headlight fail to come on. • Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light 1. Headlight bulb and socket couplers as shown. •...
  • Page 212 ELEC LIGHTING SYSTEM 2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the tail/brake light bulb and socket OK? Replace the tail/brake light bulb, socket or both.

  • Page 213: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM ail/brake light Main switch Fuel Battery lever meter Fuel Main fuse sender Brake light switch Neutral switch Eng stop switch Reverse switch Horn switch Shift indicator light Horn Buzzer Light control unit 7 - 25...

  • Page 214: Troubleshooting

    ELEC SIGNALING SYSTEM TROUBLESHOOTING 3. Main switch •Any of the following fail to light: buzzer, • Check the main switch for continuity. brake light or an shift indicator light. Refer to “CHECKING THE SWITCHES”. •The horn fails to sound. • Is the main switch OK? Check: 1.

  • Page 215: Checking The Signaling System

    ELEC SIGNALING SYSTEM CHECKING THE SIGNALING SYSTEM 3. Horn 1. The horn fails to sound. • Disconnect the pink connector at the horn 1. Horn switch terminal. • Connect a jumper lead to the horn terminal • Check the horn switch for continuity. and ground the jumper lead.
  • Page 216 ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 2. The tail/brake light fails to come on. • Pull in the brake levers. 1. Tail/brake light bulb and socket • Measure the voltage (DC 12 V) of green/yellow on the tail/brake light cou- •...
  • Page 217 ELEC SIGNALING SYSTEM 2. Fuel level gauge 2. Neutral switch • Set the main switch to “ON”. • Check the neutral switch for continuity. • Move the float up or down. Refer to “CHECKING THE SWITCHES”. • Check that the display segments of the fuel •...
  • Page 218 ELEC SIGNALING SYSTEM The reverse indicator light fails to come on. The forward indicator light fails to come on. 1. Reverse indicator light bulb and socket 1. Forward indicator light bulb and socket • Check the reverse indicator light bulb and •...
  • Page 219 ELEC SIGNALING SYSTEM 7. The bizzer fails to sound. 1. Reverse switch • Check the reverse switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the reverse switch OK? Replace the reverse switch. 2. Voltage • Connect the pocket tester (DC 20 V) to the bizzer connector at the bizzer terminal as shown.

  • Page 220: Auto Choke System

    ELEC AUTO CHOKE SYSTEM AUTO CHOKE SYSTEM CIRCUIT DIAGRAM C.D.I. magneto Rectifier/Regulator C.D.I. unit Start switch PTC control unit Auto choke unit 7 - 32...
  • Page 221 ELEC AUTO CHOKE SYSTEM TROUBLESHOOTING 1. Auto choke unit resistance • Disconnect the auto choke unit coupler The auto choke system fails to operate. from wire harness. • Connect the Pocket tester(Ω × 1) to the Check: Auto choke unit coupler as shown. Positive tester probe brown 1 1.

  • Page 222: 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 ELECTRICAL SYSTEM FUEL SYSTEM...

  • Page 223: Compression System

    TRBL STARTING FAILURE/HARD STARTING/POOR IDLE SPEED SHTG PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE COMPRESSION SYSTEM Piston and piston rings Cylinder and cylinder head • Improperly installed piston ring • Loose spark plug • Worn, fatigued or broken piston ring • Loose cylinder head or cylinder •...

  • Page 224: Faulty Clutch

    FAULTY GEAR SHIFTING/CLUTCH SLIPPING/ TRBL DRAGGING/OVERHEATING SHTG FAULTY CLUTCH POOR STARTING PERFORMANCE ENGINE OPERATES BUT VEHICLE WILL 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 225: 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:

Atv3u 150Challenger 150

Table of Contents

Save PDF