Carter Talon 150 DLX Series, Service Manual

Page 1: ...Talon 150 GX FX DLX Series Service Manual...

Page 2: ...d speci cations contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this m...

Page 3: ...ENGINE 9 LUBRICATION SYSTEM 24 FUEL SUPPLY SYSTEM 28 TRANSMISSION COMPONENTS 33 ELECTRICAL STARTING SYSTEM 36 BELT DRIVE CVT MECHANISM 42 CLUTCH 46 REAR TRANSMISSION SYSTEM 51 ELECTRICAL SYSTEM 56 IGN...

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Page 5: ...r front left side of the engine case FUEL AND OIL RECOMMENDATIONS Be sure to use the speci ed fuel and oil FUEL Gasoline should be 85 to 95 octane or higher Unleaded gasoline is recommended ENGINE OIL...

Page 6: ...utput Power 9HP 7500rpm Maximum Torque N m r min 1 8 0 4000 4500 Starting Electric Ignition CDI Lubrication Force Splash Transmission Automatic CVT CAPACITIES Load 1 rider or 90kg 198Ibs Fuel tank 7L...

Page 7: ...EIGHT Dry Weight 155kg 341lbs TIRE PRESSURE Front 2 9Psi 20kPa cm2 0 2kgf cm2 Rear 2 2Psi 15kPa cm2 0 15kgf cm2 WARRANTY Parts Workmanship 6 months The speci cations are subject to change without noti...

Page 8: ...4 LOCATION OF PARTS...

Page 9: ...necessary L Lubricate R Replace MAINTENANCE AND TUNE UP PROCEDURE Descriptions of the servicing procedures for each item in the Periodic Maintenance requirements SPARK PLUG Clean up the carbon around...

Page 10: ...ed and if left unser viced engine damage can occur Check and clean in the following manner Paper Filter Maintenance Remove the air cleaner from its housing Tap lter on a hard object to knock dust from...

Page 11: ...19 0 94 137 5 200 280 20 28 0 144 5 202 5 FUEL SWITCH PETCOCK Periodically clean the petcock externally with grease remover and water Check for any leaks or seeping fuel Replace the petcock if there...

Page 12: ...run for 5 minutes Check oil level on the ller cap stick to assure proper level The cap needs to be screwed in for a proper reading CHASSIS Grease chassis bushings and bearings with grease quarterly to...

Page 13: ...ndicular which is the circularity of the cylinder In the situation without a dial gauge a feeler gauge can be used to make relativity measurement that is to put a new piston into the cylinder and use...

Page 14: ...it should be replaced After replacement check the clearance between the holes of the piston pin and make sure it com plies with the required measurement PISTON RINGS INSPECTION AND SERVICING Inspect...

Page 15: ...elations of the crank connecting rod component CRANKCASE AND CRANKSHAFT REMOVAL Before removing the crankcase and crankshaft follow these procedures Remove the engine Remove the cylinder cover Remove...

Page 16: ...gasket and the dowel pins Remove the crankshaft from the crankcase Take out the cam chain Remove the gasket on the crankcase joint face be careful to not damage the joint face Remove the oil seal from...

Page 17: ...ly when inspecting Service Limit 0 10mm A 90 0 10mm B 105 Examine if there is any loose or unusual sound when the crank journal bearing turns if there is the whole set should be changed After cleaning...

Page 18: ...n the O ring Tighten the cam chain tensioner bolt VALVE MECHANISM INSPECTION AND SERVICING The picture shows the common valve train of a four stroke engine This is a kind of overhead valve train its i...

Page 19: ...at the top dead center and the T symbol or other mark of the magneto ywheel aligns to the crank case mark When adjusting loosen the lock nuts adjust the bolts with a valve adjusting wrench when turned...

Page 20: ...in tensioner by adjusting bolt clockwise Turn the ywheel counterclockwise to make the T mark on the ywheel align with the mark on the crankcase When the hole on the cam chain timing drive chain wheel...

Page 21: ...ain tensioner cover bolt Replace the valve cover gasket and mount the cover Tighten the valve cover positioning bolt ROCKER ARM AND ROCKSHAFT ROCKER ARM AND ROCKSHAFT REMOVAL Remove the camshaft holde...

Page 22: ...ort rocker arm to the rockshaft Apply some oil on the rockshaft before mounting it on CAM CHAIN TENSIONER The chain tensioner must be in good working condition for proper chain tension 1 Cam chain 2 C...

Page 23: ...valve Exhaust valve Inner spring 31 2mm 31 2mm Outer spring 34 1mm 34 1mm Valve and valve spring installation Mount the spring retainer valve guide oil seal After applying oil on the valve stem mount...

Page 24: ...the outer diameter of the valve stem Valve Inlet valve Exhaust valve Service Limit 0 08mm 0 10mm VALVE GUIDE REPLACEMENT Heat the cylinder head to 100 150 C Tap the valve guide out with a valve guide...

Page 25: ...r too narrow it will result in bad contact between the valve and the valve seat and not seal tight At this time it must be reamed with a custom ized valve seat milling cutter The valve seat milling cu...

Page 26: ...t the valve and observe the contact surface on the valve face If the contact position is too high then cut out some of the upper part of the valve seat with a 32 milling cutter to reduce the working f...

Page 27: ...lace between the valve lever and the valve guide VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION After lapping the valve and valve seat the air impermeability of the joint surface should be in spec...

Page 28: ...screen it is pumped by the rotator oil pump some of it goes into the big end of the con necting rod and splashes on the cylinder wall and the small end of the connecting rod the rest goes through some...

Page 29: ...ing Replacing 0 90l 0 75l Start the engine and run for several minutes in the idle position to make sure there is no oil leak ing Stop the engine and inspect if the oil level is proper ROTARY OIL PUMP...

Page 30: ...and remove the oil pump assembly Remove the screws and disassemble the oil pump OIL PUMP INSPECTION Inspect the clearance between the oil pump body and the outer rotator Service Limit 0 12mm Inspect t...

Page 31: ...e oil pump shaft and make sure the oil pump can turn smoothly OIL PUMP INSTALLATION Install the oil pump on the crankcase Before installing ll the oil pump with oil When installing the arrow of the oi...

Page 32: ...e CV carburetor is a constant vacuum carburetor The picture shows the structure of the CV carburetor 1 Gasket set 5 Float chamber set 2 Float valve set 6 Screw set A 3 Needle jet set 7 Screw set B 4 F...

Page 33: ...or VACUUM CHAMBER REMOVAL Remove the body cover Remove the automatic choke lead wire Loosen the fuel drain bolt and drain the fuel in the oat chamber Remove the fuel line and the vacuum pipe Loosen th...

Page 34: ...buretor clamp and remove the carburetor Check the condition of the connection between the two lead wires The choke value should be below 10V If it exceeds the speci c valve it should be replaced When...

Page 35: ...t Install the air adjusting screw and choke adjusting screw and turn them to the proper position ac cording to the noted number of turns while removing Mount the oat valve the oat and the oat pin Tigh...

Page 36: ...ALVE INSTALLATION Mount the vacuum membrane on the carburetor Mount the spring the vacuum membrane cover and the lock bolt The bottom side of the vacuum membrane should be aligned with the carburetor...

Page 37: ...e 15 Bush 3 Drive face boss 16 Spindle bush 4 Movable drive face comp 17 Kick starter spring 5 Weight roller set 18 Special pin 7 Ramp plate 20 Washer 8 Slide piece 21 Washer 9 Starting driven pulley...

Page 38: ...L SPLINE TRANSFERRING STYLE STARTING MECHANISM INSPECTION Inspect if there is any abrasion or damage of the starting spindle Inspect if there is any abrasion or damage of the starting idle shaft Inspe...

Page 39: ...f the crankcase then insert Before installing apply a little grease on the groove of the rotary retaining spring on the idle shaft The rotary retaining spring should be aligned with the speci c groove...

Page 40: ...on Brush Negative Electrode 12 O ring STARTER MOTOR REMOVAL Before removal rst shut off the main switch and disconnect the battery connecting wire Then press the starting button at this time the start...

Page 41: ...ight picture It should be non con ductive If it s not it should be replaced CARBON BRUSH INSPECTION Inspect the insulating condition between the connecting wire terminal and the starter motor case and...

Page 42: ...When installing do not damage the lip of the dust seal Mount the new O ring on the carbon brush base Install armature into starter motor case marking sure not to damage the carbon brushes Tighten mot...

Page 43: ...motor lead wire 16 Key woodruff 10 Clamp 17 Roller 11 Clamp 18 Needle bearing 12 Bolt 19 O ring 13 Nut 20 Screw 15 Dowel pin 21 Bolt REDUCTION GEAR INSPECTION Remove the starting clutch Remove the re...

Page 44: ...brasion or damage on the contact surface between the driving gear and the needle bearing It should be re placed if the surface is damaged Measure the inner diameter of the driving gear It should be re...

Page 45: ...e starter CONTROLLING MECHANISM STARTER RELAY INSPECTION Turn the main switch to the ON position and press down the starting motor button and listen for a click sound If there is it is normal if there...

Page 46: ...pulleys the drive belt pulley and the driven belt pulley whose diameter can be changed and a notched driven belt The driving belt pulley is mounted on the engine crankshaft and the driven belt pulley...

Page 47: ...t pulley is shown in the picture The picture shows the working theory of the driving belt pulley The picture shows the structure of the driven belt pulley The clutch showed in this picture is the auto...

Page 48: ...rive plate with a universal wrench and then remove the nuts and gasket on the drive plate shaft Remove the drive plate Remove the driven belt from the drive plate Remove the movable drive plate the wh...

Page 49: ...easure the outer diameter of the drive plate hubs movable sur face Service Limit 23 94mm DRIVE BELT PULLEY INSTALLATION Apply some grease evenly in the movable drive plate Put the centrifugal rollers...

Page 50: ...ate and the driven belt Hold the clutch friction plate with a multiuse holder and remove the nut Remove the clutch friction plate CLUTCH INSPECTION Inspect if there is any abrasion or damage on the cl...

Page 51: ...connecting piece Remove the clutch centrifugal weight set and the spring CLUTCH INSTALLATION Mount the clutch damper rubber onto the drive plate pin Mount the new clutch weight set and spring on the...

Page 52: ...ate DRIVEN BELT PULLEY INSPECTION Measure the free length of the driven belt pulley spring Service Limit 163 7mm Inspect if there is any abrasion or damage on the driven plate Measure the outer diamet...

Page 53: ...eused Remove the circlip from the driven plate Drive the ball bearing out The removed bearing cannot be reused Apply some grease on the new ball bearing Drive the ball bearing into the driven plate wi...

Page 54: ...he excessive grease Do not get grease on the movable faces of the driven plate Assemble with the clutch and install on the left crankcase TRANSMISSION BELT TRANSMISSION BELT INSPECTION Remove the left...

Page 55: ...ter the engine stops remove the transmission case oil level bolt Observe the oil level the oil level should be parallel with the observing hole When the oil level is too low add until the oil ows from...

Page 56: ...t pulley Drain out the oil in the transmission case Remove the drive sprocket Remove the bolt and remove the transmission case cover Remove the gasket and the dowel pin Remove the nal gear the nal gea...

Page 57: ...the transmission cover Remove the oil seal and drive out the bearing Remove the nal gear shaft bearing Remove the sub shaft bearing Drive in the new ndal gear shaft and bearing When driving in the na...

Page 58: ...e bearing and oil seal on the left crankcase for wear or damage If it is damaged it must then be replaced Remove the oil seal Drive out the nal gear shaft bearing Remove the sub shaft bearing Remove t...

Page 59: ...t sub shaft gear and the nal gear shaft into the left crankcase Mount the nal gear on the nal gear shaft Install the new dowel pin and gasket Install the transmission case cover and bolt Mount the dri...

Page 60: ...ve Fill the new one with oil 2 mm from the top Replace the oil cooler turning counterclockwise En gine MFG suggest that you change your oil and lter after 40 hours of use Electric System CHARGING SYST...

Page 61: ...hs After 2 3 years of regular usage the capacity of the battery will lessen and will need charging Replace with the same type of battery BATTERY REMOVAL Shut down the main switch to make sure no elect...

Page 62: ...near the battery when charging At the beginning or the end of charging turn off the charger rst in order to avoid the connecting part arcing Measure the voltage 30 minutes after charging is nished an...

Page 63: ...e vehicle body Standard value 0 2 0 4 20 C When the actual value is more than the standard value the coil should be replaced GENERATOR REMOVAL AND INSPECTION GENERATOR REMOVAL Remove the cooling fan c...

Page 64: ...r nuts attachinging to the inner wall of the ywheel After the installation is nished start the engine to inspect and adjust the ignition timing REGULATE RECTIFIER MAIN WIRING SUB ELECTRIC CIRCUIT COND...

Page 65: ...100K R Red G Green 5 100K REGULATE RECTIFIER INSPECTION When the main wiring sub electric circuit condition is normal inspect the regulate recti er Check that the regulate recti er plug contacts well...

Page 66: ...tor If the difference is between 3 it indicates correct ignition timing on the contrary if it is off 3 it should be adjusted Slowly increase the engine rpm when the 150 model increases to 5000 r min a...

Page 67: ...urther measurements If it is measured that the CDI component end is abnormal however the terminal voltage of the generator is normal then there is a bad wire or bad connection When both are not normal...

Page 68: ...nd the ignition coil When the main switch is in OFF position it should be conducted and the resistance value of every coil should be the standard value Inspect the resistance value between every CDI c...

Page 69: ...resistance value is in the standard range it is good however indicates the coil is bad Remove the spark plug cap and measure the resistance value of the secondary ignition coil Standard Value 2 4K 20...

Page 70: ...REAR AXLE REMOVAL Disassemble RR Wheel Remove the cotter pins on axle nut RR wheel Remove the axle nut RR Wheel Block up rear end of the machine Remove rear wheel and hub assembly by sliding splines...

Page 71: ...set by the manufacture in the middle the third position Please use round nut wrench as you adjust the position the tension of shock spring increases as you turn to the left and decreases as you turn...

Page 72: ...ease to the lip of the seal If the retention spring is in bad shape replace the seal with a new one SEAT Remove all the nuts and bolts underneath the seat rail Remove Seat STEERING SHAFT Remove nuts s...

Page 73: ...eck the grease of Ball Joint Clean it if its dirty and lled with grease Replace the Steering Knuckle support if the Ball Joint is loose or steering isn t exible TIE ROD Tie rods should be checked for...

Page 74: ...rea between electrodes using a wire feeler gauge This speci cation is 0 025 0 030 b Before installing spark plug coat threads lightly with graphite grease if possible to ensure easy removal next time...

Page 75: ...sen Nut 1 2 Adjust Nut 2 Turn nut clockwise in 1 2 turn increments then turn nut 1 clockwise until nut is tight Follow this procedure until chain is at proper tension REVERSE COMP Check internal parts...

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Page 77: ...NKCASE BODY REPLACEMENT 54 BEARING ON THE TRANSMISSION CASE COVER REPLACEMENT 53 BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING 42 BRAKE PREFORMANCE 6 BREAK IN PROCEDURE 1 CAM CHAIN TENSIONER 18 C...

Page 78: ...NSPECTION 44 DRIVE BELT PULLEY INSTALLATION 45 DRIVE BELT PULLEY REMOVAL 44 DRIVEN BELT PULLEY 48 DRIVEN BELT PULLEY INSPECTION 48 DRIVEN BELT PULLEY INSTALLATION 50 DRIVEN BELT PULLEY REMOVAL 48 DRIV...

Page 79: ...M INSPECTION 62 IGNITION SYSTEM INSPECTION AND SERVICING 62 IGNITION TIME INSPECTION 62 KICK RETURN STARTING MECHANISM 33 LOCATION OF PARTS 4 LUBRICATION SYSTEM INSPECTION AND SERVICING 24 MAIN WIRING...

Page 80: ...R ARM AND ROCKSHAFT INSTALLATION 17 ROCKER ARM AND ROCKSHAFT REMOVAL 17 ROTARY OIL PUMP 25 SEAT 68 SECONDARY IGNITION COIL INSPECTION 65 SERVICE AIR CLEANER 70 SPARK PLUG 5 SPARK PLUG 65 SPARK PLUG 70...

Page 81: ...MPONENTS INSPECTION AND SERVICING 33 TRIGGER WINDING 64 VACUUM CHAMBER INSTALLATION 30 VACUUM CHAMBER REMOVAL 29 VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION 23 VALVE AND VALVE SEAT LAPPING 23 V...