E-TON Sport 150, Service Manual

Page 1: ...SERVICE MANUAL SF3A 150 SPORT 150 E TON POWER Copyright 2008 2009 ETON America all rights reserved w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o...

Page 2: ...nual the actual vehicle shall prevail Specifications are subject to change without notice This manual that contains all data illustration indication and specifications is based on current production i...

Page 3: ...osis The second chapter covers service maintenance information The third to the eleventh chapters cover engine and driving systems The twelfth to fifteenth chapters are contained the parts set of asse...

Page 4: ...ng bolt Engine oil draining bolt Front turn signal light Front light Position light High Low beam Turn signal Horn switch Seat lock Air Cleaner Kick starter pedal Oil level Main stand Front brake leve...

Page 5: ...LT DRIVING SYSTEM KICK STARTER ARM 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 BODY COVER 12 BRAKE 13 STEERING FRONT WHEEL FRONT SHOCK ABSORBER 14 REAR WHEEL S...

Page 6: ...er the damage that caused by not apply with the limited engine oil Limits to use SAE 85W 140 class oil Warranty will not cover the damage that caused by not apply with the limited gear oil Grease SAE...

Page 7: ...et battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist If you swallow i...

Page 8: ...ect on them y Never bend or twist a control cable to prevent stiff control and premature worn out y Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these...

Page 9: ...acturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal y Remove residues of the old gasket or sealant before reinstal...

Page 10: ...ch do not contact with body to prevent from circuit short and create spark y After service completed make sure all connection points is secured Battery positive cable should be connected firstly And t...

Page 11: ...nector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loose y Insert the terminal completely Check if the terminal is covered by the bo...

Page 12: ...es with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied y Secure the rubber boot firmly as applying it on wire harness y Never u...

Page 13: ...test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction y With sand paper to clean rust on connector pins terminals if fou...

Page 14: ...allation and arrangement Vertical below center incline 80 Deceleration equipment Transmission V belt Fuel Used Unleaded 93 95 Speedometer 0 120km hr Cycle Cooling 4 stroke forced air cooled Horn 83 11...

Page 15: ...8 1 2 Gear oil filling bolt 1 8 0 8 1 2 Oil pump bolts 2 6 0 8 1 2 Oil pump drive sprocket nut 1 6 0 8 1 2 Left crankcase cover bolts 7 6 0 8 1 2 Rubber washer attached Camshaft chain tensioner pivot...

Page 16: ...2 10 3 1 3 5 Drum brake arm bolts front rear 2 6 0 8 1 2 Engine suspension bracket bolts 2 10 4 5 5 5 On frame side Engine connection bolt 1 10 4 5 5 5 On engine side Main standard nut 1 10 3 5 4 5 F...

Page 17: ...logged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pum...

Page 18: ...tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel level too low in carburetor 6 Fuel nozzle clogged in carburetor 1 Malfunction of CDI 2 Malfunction of AC alternator 1 Cylinder piston ring...

Page 19: ...f CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation gasket 2 Carburetor lock loose 3 Poor intake gasket 4 Poor carburetor O ring 5 Vacuum hos...

Page 20: ...n 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor...

Page 21: ...ar brake lever pivot Steering shaft bearing Seat lock Speedometer gear Front wheel bearing Side stand shaft Main stand shaft Rear wheel bearing Copyright 2008 2009 ETON America all rights reserved w w...

Page 22: ...pacity 900 c c Engine Oil change 850 c c capacity 100 c c Transmission Gear oil change 90 c c Clearance of throttle valve 2 6 mm m m 7 0 6 0 p a G C T R 7 A g u l p k r a p S F Mark in idling speed Be...

Page 23: ...adjusted and recorded maintenance data periodically by your E TON Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the mont...

Page 24: ...le speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove the strainer cover spring and strainer If there is an accumulation on the screen...

Page 25: ...change Recommended SAE 85W 140 Fuel System Fuel Pipe Remove luggage box side cover center cover body frame cover and pedal as well as front inner box Check all pipes and replace it when they are dete...

Page 26: ...isted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play 2 6 mm Adjustment can be done in either ends Secondary adjustment is conducted...

Page 27: ...h the mark on the crankshaft and camshaft is at TDC position also as same as level of cylinder head top end A single hole on camshaft sprocket is forward to up Piston is at TDC position in the compres...

Page 28: ...he air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttle valve and release it immediately Repeat this for 2 3 times 5 Read engine RPM and valu...

Page 29: ...k plug A7RTC Remove luggage box Remove body side cover Remove spark plug cap Clean dirt around the spark plug hole Remove spark plug Measure spark plug gap Spark plug gap 0 6 0 7 mm Carefully bend gro...

Page 30: ...olt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the per...

Page 31: ...ll nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scratched or leaking Replace damaged and non repairable components Park...

Page 32: ...ransparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until there is no air inside the brake system hoses Caution y In order to maintain...

Page 33: ...e lining bolt Take out the lining Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance It is not necessary to remove brake hose when replacing t...

Page 34: ...rning the front brake adjustment nut if necessary BRAKE CONFIRAMTION Caution y After brake adjustment it has to check the brake operation to make sure the front and rear wheel can be braked y Pull the...

Page 35: ...re surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspection or depth gauge y Replace the tire if tire tread dent or unusual wearing out...

Page 36: ...in proper position Caution NUTS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Chec...

Page 37: ...3 OIL PUMP 3 4 GEAR OIL 3 7 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lubrication Inner passage Connecting rod Oil pump Oil strainer Crankshaft Copyr...

Page 38: ...e and body 0 05 0 10 0 20 Torque value Engine oil drain pl m f g k 5 4 5 3 g u m f g k 7 1 3 1 r e v o c n e e r c s l i o e n i g n E m f g k 2 1 8 0 t l o b n i a r d l i o r a e G Gear oil filling...

Page 39: ...LEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreign Check if the strainer and O ring of th...

Page 40: ...oil pump driver chain Remove oil pump body bolts 2 bolts Oil Pump Disassembly Remove the screw on oil pump cover Disassemble the oil pump as illustration shown Right crankcase Oil pump cover Oil pump...

Page 41: ...face and pump body Limit below 0 2 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Insta...

Page 42: ...oil pump outer cover 2 bolts Install the starting gear and the alternator Refer to chapter 10 2 bolts 2 bolts oil pump driver chain drive gear oil pump outer cover Start drive gear Copyright 2008 200...

Page 43: ...lacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely Install the draining plug and tighten it Make sure if the plug washer is damaged If so replace it wit...

Page 44: ...AUTO BY STARTER 4 7 FLOAT CHAMBER 4 8 INSTALLATION OF CARBURETOR 4 9 IDLE SPEED ADJUSTMENT 4 9 FUEL TANK 4 10 AIR CLEANER 4 11 MECHANISM ILLUSTRATION Carburetor Fuel strainer Fuel tank cap Fuel strain...

Page 45: ...uge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline z Do not bend or twist throttle valve cabl...

Page 46: ...acceleration z Malfunction of ignition system Late ignition timing z Malfunction of ignition system z Malfunction of carburetor Power insufficiency and fuel consuming z Fuel system clogged z Malfunct...

Page 47: ...tor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove screws 2 screws of vacuum chamber cover and the cover Remove compress...

Page 48: ...ompress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm z Note direction as installing the piston set because wrong direction of the piston cab not be installed...

Page 49: ...um diaphragm Check if the vacuum diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation...

Page 50: ...he rich circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing plate screw and then remove the plate and auto by starter from carburetor Valve inspe...

Page 51: ...e seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one z Take care not to damage jets and adju...

Page 52: ...n gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO value fluctuated repeat the procedures described above for adjusting to standar...

Page 53: ...el cover Remove the fuel tank cover Remove the floor panel Disconnect the fuel unit connector Remove the fuel pipe fuel filter Remove the fuel tank bracket Remove the fuel tank Fuel Tank Installation...

Page 54: ...nt Cleaning Remove left side cover 2 screws Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With compressed air to clean dirty around the element Replace it if it is too...

Page 55: ...SUSPENSION BUSHING 5 6 ENGINE SUSPENSION FRAME 5 7 INSTALLATION OF ENGINE 5 8 MECHANISM DIAGRAM 3 5 4 5kgf m 2 4 3 0kgf m 4 5 5 5kgf m 4 5 5 5 kgf m 4 5 5 5kgf m Copyright 2008 2009 ETON America all...

Page 56: ...i c e p S m e t I Replacement 850 c c Engine Oil Capacity Disassemble 900 c c Replacement 90 c c Gear Oil Capacity Disassemble 100 c c Torque Values m f g k 5 5 5 4 e d i s e m a r f t l o b n o i s n...

Page 57: ...Remove the generator connector and pulse generator connector Remove the starter motor wire on the Starter magnetic switch Remove the spark plug cap Auto by start connector Generator connector Starter...

Page 58: ...cleaner guide and remove the air cleaner guide Remove the exhaust muffler Bolts 2 Nuts 2 Remove the rear wheel Nut 1 Remove the air cleaner connection bolts 2 bolts Nut 1 Bolts 2 2 bolts Copyright 20...

Page 59: ...engine Caution Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new ones if so y With a bracket to support the engine to prevent from it dama...

Page 60: ...8mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and drive both the pressing ring and bolt in to press the bushing out Pressing In P...

Page 61: ...d cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of engine suspension frame Engine suspension frame nut Torque Value 4 5 5 5 kgf m Bolt of engine suspens...

Page 62: ...e Top 3 5 4 5kgf m lower 2 4 3 0kgf m Rear wheel axle nut Torque Value 11 0 13 0kgf m z Notice both feet and hands safety for squeezing as engine installation z Do not bent or squeeze each wires or ho...

Page 63: ...6 8 VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLATION 6 13 VALVE CLEARANCE ADJUSTMENT 6 14 MECHANISM DIAGRAM 0 7 1 1 kgf m 0 7...

Page 64: ...0 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 030 0 057 0 100 Outer 35 25 Free length of valve spring Inner 32 410 Valve Valve seat width 1 000 1 600 Torque Value Cylinde...

Page 65: ...r head y Cylinder head gasket leaking or damage y Tilt or crack cylinder surface 3 Piston y Piston ring worn out High compression pressure y Too much carbon deposit on combustion chamber or piston hea...

Page 66: ...ise motion for release adjuster Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sp...

Page 67: ...cker arm shaft so that take it out Remove cam rocker arm Inspection Of Camshaft Holder Check if the camshaft holder cam rocker arm and rock arm shaft for wearing out or damage Caution Measure the cam...

Page 68: ...e rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD REMOVAL Remove double seat luggage box and front center cover Remove the engine refer to Chapter 5 Re...

Page 69: ...emove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface Caution y Do not damage the matching surfaces of cylinder...

Page 70: ...ter Service Limit IN 4 900mm EX 4 900mm Valve guide Caution Special Service Tool 5 0mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 030mm The difference that...

Page 71: ...uide reamer 5 mm If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace...

Page 72: ...ough or uneven surface from valve seat Caution Use 32 cutter to cut a quarter upper part out y Do not let emery enter into between valve stem and valve guide y Clean up the emery after corrected and a...

Page 73: ...urface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve...

Page 74: ...elease the valve compressor Caution Special tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly Caution The closed coils of valve spring should face down...

Page 75: ...ion so that the T mark on the flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other singl...

Page 76: ...ise motion so that the adjuster is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the adjuster hole Tighten the bolt cap of the adjuster ad...

Page 77: ...YLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 MECHANISM DIAGRAM 0 8 1 2kgf m Copyright 2008 2009 ETON America all rights reserve...

Page 78: ...10 0 040 0 100 Piston Piston ring ID of piston pin hole 15 002 15 008 15 040 0 0 0 5 1 n i p n o t s i p f o D O 14 96 Clearance between piston and piston pin 0 002 0 014 0 020 5 1 d n e l l a m s d o...

Page 79: ...chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase Cylinder 2 bolts Cam chain auto adjuster Cam chain gu...

Page 80: ...s the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or Y motion values Then determinate by the max value Service limi...

Page 81: ...clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm Take out the piston rings and place them respective into cylinder below 20m...

Page 82: ...ce between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 56 9mm Compare measured value with service limit to calculate the clearance between piston a...

Page 83: ...ston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston rings can be rotated freely after installed Top groove 2nd groove Oil gro...

Page 84: ...on Caution Install the cam chain plate the cylinder head gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto adjuster 2 bolts y Do not let the opening of piston pi...

Page 85: ...T CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 MECHANISM DIAGRAM 5 0 6 0kgf m 5 0 6 0kgf m 1 0 1 5kgf m 5 0 6 0kgf m Copyright 2008 2009 ETON A...

Page 86: ...ulley 34 000 34 025 34 060 ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 5 0 6 0kgf m Clutch outer nut 5 0 6 0kgf m driving pulley nut 5 0 6 0kgf m Special Service Tools Clutch s...

Page 87: ...with some specified grease on the gear socket shaft Install the friction spring of driving gear onto convex part of the case Install socket return spring and starter shaft as diagram shown Install kic...

Page 88: ...lace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited specification Service Limit 17 5 mm Caution Using special service tool...

Page 89: ...e Torque value 5 0 6 0 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily Slid...

Page 90: ...the driving belt from the pulley Remove sliding pulley set and driving pulley hub from crankshaft Remove tilt plate Remove weight rollers from sliding pulley Crankshaft Driving pulley hub Sliding pul...

Page 91: ...limit 17 40 mm Check the pulley hub if damaged or wear out Replace it if necessary Measure the pulley hub s outer diameter Replace it if exceed the service limit Service limit 23 94 mm Measure the in...

Page 92: ...d torque Torque value 5 0 6 0 kgf m Install left crankcase cover The pulley surface has to be free of grease Clean it with cleaning solvent Make sure that two sides of pulley surfaces have to be free...

Page 93: ...et from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and then remove O ring oil seal seat from sliding pulley Inspection Clutch outer Measure t...

Page 94: ...ven face Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if ne...

Page 95: ...But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location Caution Install the spring snap into groove with pliers y Grea...

Page 96: ...nd then install the new oil seal if necessary y Its sealing end should be forwarded to outside as bearing installation y Install needle bearing with hydraulic presser Install ball bearing by means of...

Page 97: ...by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with special nut wrench Remove the clutch spring co...

Page 98: ...MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANISM 9 6 MECHANISM DIAGRAM driving gear countershaft gear final driving gear final driving shaft countershaft 0 8 1 2 kgf m 0 8...

Page 99: ...taller Torque value Gear box cover 0 8 1 2 kgf m Gear oil drain plug 0 8 1 2 kgf m Gear oil filling bolt 0 8 1 2 kgf m TROUBLE DIAGNOSIS Engine can be started but motorcycle can not be moved z Damaged...

Page 100: ...ing pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft and the gear are wear or damage Check if the final driving shaf...

Page 101: ...aft bearing from left crankcase using following tools Inner type bearing puller Install new driving shaft bearing into left crankcase Tool Press the bearing into cover with C type hydraulic presser or...

Page 102: ...x cover Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a new final driving shaft bearing onto gear box cover Specified to...

Page 103: ...cover and 7 bolts tighten the bolts Torque 0 8 1 2 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left crankshaft cover Install the rear wheel Add gear oil Recomme...

Page 104: ...TARTING CLUTCH 10 5 RIGHT CRANKCASE COVER INSTALLATION 10 8 MOUNTED COIL SET INSTALLATION 10 8 FLY WHEEL INSTALLATION 10 8 MECHANISM DIAGRAM 9 0 10 0kgf m 1 0 1 4kgf m 1 5 2 0kgf m 1 3 1 7kgf m 5 0 6...

Page 105: ...0 2 3 r a e g n e v i r d g n i t r a t s f o D I 0 4 9 7 2 0 8 2 r e v o c h c t u l c g n i t r a t s f o D O Torque value m f g k 0 6 0 5 t u n l e e h w y l F m f g k 7 1 3 1 r e v o c n e e r c...

Page 106: ...s Remove the fan 4 bolts Hold the flywheel with the universal fixture Remove the 10mm nut on the flywheel Special Service Tools Universal Fixture Flywheel Cooling fan Cooling fan shroud Coil Pulse gen...

Page 107: ...emove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase Caution Do not damage the alternator coil 6 bolts Flywheel puller Pulse g...

Page 108: ...d shaft Starting Clutch Inspection Install the starting clutch onto the starting driven gear Hold the starting clutch and turn the starting driven gear The starting driven gear should can be turned in...

Page 109: ...isassembly Remove the hex blots 3 bolts inside the starting clutch Separate the clutch body and the clutch cover Remove the rollers plugs and springs on the one way clutch Check each rollers and plugs...

Page 110: ...niversal fixture Tighten the 22mm anti loosen lock nut and gasket Caution Special service tools Anti loosen lock nut socket Universal fixture Torque value 9 0 10 0kgf m Add adhesive onto the thread of...

Page 111: ...dent of crankcase Caution Install A C generator connector and pulse generator connector FLYWHEEL INSTALLATION Make sure that there is no magnetic powder If so clean up it Align insert on crankshaft wi...

Page 112: ...ust muffler 2 bolts 2 nuts Install the right side cover 3 screws Install the rear center cover 2 screws Add some engine oil according the specified quantity Cooling fan Exhaust muffler Cooling fan shr...

Page 113: ...CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 0 8 1 2 kgf m 0 8 1 2 kgf m 3 5 4 5 kgf m 1 5 2 0 kgf m 0 8 1 2 kgf m 0 7 1 1 kgf m Copyright 2008 2009 ETON Ame...

Page 114: ...clearance of the big end of the connecting rod 0 100 0 350 0 550 Radial clearance of the big end of the connecting rod 0 000 0 008 0 050 Run out 0 1 Torque value Bolts for crankcase 1 5 2 0 kgf m Bol...

Page 115: ...then separate the left and the right crankcases Remove the cam chain Caution Special Service Tools Crankcase remover set 1 hex socket bolt 2 bolts z Never pry out the connection surfaces of crankcase...

Page 116: ...il seal from the left crankcase z Do not damage contact surface of the crankcase z Soap the gasket residues into solvent and the residues will be removed easily z The left and right bearings of cranks...

Page 117: ...d measure run out of the crankshaft with dial gauge Service limit 0 1mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Check if the in...

Page 118: ...bolts Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8...

Page 119: ...left crankcase Press fit the oil seal to specified position with the oil seal installer 19 8 x30 x5 Special service tools the oil seal installer 19 8 x30 x5 Copyright 2008 2009 ETON America all rights...

Page 120: ...UNDER COVER 12 7 REAR FENDER 12 8 Double Seat Front cover Front handle cover Front under fender Under cover Luggage box Rear carrier Left body cover Right side cover Front center cover Rear handle cov...

Page 121: ...y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during assembly Left right side cover Front cover Luggage box Seat R...

Page 122: ...ont handle cover and the rear handle cover Remove the front handle cover Removed the meter connector Installation Install according to the reverse procedure of removal the connector screwh4 screwsh2 C...

Page 123: ...Removal Remove the screws between the front cover and the front inner box Turn left to pull out the bushing hook of main switch cover Remove the main switch cover Remove the 1 bolt of inside the fron...

Page 124: ...e mounting screws of the body cover Remove the mounting screws of the body cover Remove the seat hook wire connector Remove the body cover Installation Install the cover according to the reverse proce...

Page 125: ...Installation Install the luggage box according to the reverse procedure of removal FLOOR PANEL Removal Remove 4 the rear carrier mounting bolts and remove the rear carrier Remove the 4bolts from the...

Page 126: ...floor panel Remove the 4 screws on the front inner fender Remove the 2 screws on the under cover Remove the under cover Installation Install the under cover according to the reverse procedure of remov...

Page 127: ...luggage box and the double seat Remove the left right body cover Remove the 3 bolts on the rear fender then remove the fender Installation Install the rear fender according to the reverse procedure of...

Page 128: ...ID REPLACEMENT AIR BLEED 13 6 BRAKE CALIPER 13 7 BRAKE DISC 13 8 BRAKE MASTER CYLINDER 13 8 DRUM BRAKE DRUM 13 11 BRAKE LING 13 11 BRAKE PANEL 13 12 MECHANISM DIAGRAM Front Disc Brake System 5 0 7 0 k...

Page 129: ...ECHANISM DIAGRAM Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m Copyright 2008 2009 ETON America all rights reserved w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t...

Page 130: ...icity 0 3 0 5 1 0 Master cylinder inner diameter Master pision outer diameter 11 000 11 043 10 957 10 984 ID of front rear brake drums 0 0 1 3 11 055 10 945 1 0 0 0 3 1 OD of front brake disc 130 00 T...

Page 131: ...ake noise z Dirty lining z Deformed brake disc z Poor brake caliper installation z Imbalance brake disc or wheel DRUM BRAKE Poor brake performance z Improper brake adjustment z Worn brake lining z Wor...

Page 132: ...ar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or rubber components when conduct brake system maintenance CAUTION z Do no...

Page 133: ...system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve CAUTION 2 Slowly release the brake lever and wait for a few seconds until it...

Page 134: ...ng firstly and then install the outer brake lining INSTALLATION Install the brake caliper and tighten the attaching bolts securely Torque 3 1 3 5 kgf m CAUTION Tighten the lining guide bolt Torque 1 6...

Page 135: ...d the master cylinder Remove the rubber pad Remove the circ lip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Do not let foreign materials enter into the cyli...

Page 136: ...ring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master cup Install the cir clip CAUTION Install the rubber pad into groove properly z...

Page 137: ...h Connect brake hoses with 2 new washes Tighten the brake hose bolt to the specified torque value Torque value 3 3 3 7 kgf m Make sure the hose is installed correctly CAUTION CAUTION Add specified bra...

Page 138: ...ree points both ends and center If the thickness is less than specified or if it is contaminated by oil or grease replace as a set Service limit Rear 2 0 mm Inhaling dust may cause respiration system...

Page 139: ...return spring and brake cam as well as the oil seal from the brake panel Installation REAR BRAKE PANEL Apply a thin cost of grease between the oil seals on the brake cam shaft Install the brake cam A...

Page 140: ...TION 14 2 TROUBLE DIAGNOSIS 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT SHOCK ABSORBER 14 7 FRONT FORK STEERING COLUMN 14 8 MECHANISM DIAGRAM Copyright 2008 2009 ETON America all rights reserved...

Page 141: ...teering column wrench Bearing remover Inner type bearing remover Attachment 32 35 mm Attachment 42 47 mm Steering column nut wrench Steering column top cone ring nut wrench TROUBLE DIAGNOSIS Hard stee...

Page 142: ...ion cable and handlebar cover seat Remove the rear brake lever nut and screw then take out the rear brake cable Remove the brake lever seat bolt and then remove the seat Do not operate the front brake...

Page 143: ...r and acceleration cable FRONT WHEEL Removal Disc Brake Support body bottom and lift front wheel free of ground Remove the bolts and disconnect speedometer cable from the gear box Remove the wheel axl...

Page 144: ...hex socket bolts and brake disc Remove the left axle ring and dust seal Remove the dust seal on the right side of speedometer gear Remove the bearing with the inner type bearing remover Take out the b...

Page 145: ...install the right bearing onto the seat Caution Tool C type compressor or bearing compressor Disc Brake Apply with some grease inside of the dust bearing Install the dust seal and the front wheel side...

Page 146: ...o specified torque value Torque value 5 0 7 0kgf m Connect the speedometer cable to the speedometer gear box FRONT SHOCK ABSORBER Removal Remove the front fender front lower spoiler front guard and fr...

Page 147: ...front fork Then tighten the bolts Torque value 2 4 3 0kgf m FRONT FORK STEERING COLUMN Removal Firstly remove the handlebar front wheel front brake set and front shock absorbers Remove the steering co...

Page 148: ...n the top cone race to specified torque tighten the race around 1 4 3 8 turn more Torque value 0 2 0 3kgf m Caution Install the steering column nut and lock the top cone race Then tighten the nut Torq...

Page 149: ...5 2 EXHAUST MUFFLER 15 3 REAR WHEEL 15 3 REAR SHOCK ABSORBER 15 4 MECHANISM DIAGRAM 0 8 1 2kgf m 3 0 3 6kgf m 11 0 13 0kgf m 1 0 1 4kgf m 2 4 3 0kgf m 3 5 4 5kgf m Copyright 2008 2009 ETON America all...

Page 150: ...1 4kgf m Exhaust muffler connection bolt 3 0 3 6kgf m TROUBLE DIAGNOSIS Rear wheel wobbling z bend wheel rim z poor tire z loosen wheel shaft Shock absorber too soft z insufficient shock absorber spr...

Page 151: ...ce limit Radial 2 0mm Axial 2 0mm If the wheel rim wobbling out of the specification except resulted from the wheel rim deformation it might be loosen or worn final driving shaft bearing or bend defor...

Page 152: ...bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution Torque values Rear shock absorber lower mount bolt 2 4 3 0 kg...

Page 153: ...FUEL UNIT 16 23 MECHANISM DIAGRAM Spark plug Fuel unit Ignition coil Battery fuse box Main switch Starter magnetic switch Starting Engine stop switch Horn turn signal light high low beam Front stop sw...

Page 154: ...rical device according to the procedure of diagnosis chart z Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high vol...

Page 155: ...ded usage Hot type A8RTC Cold type A6RTC Spark plug Spark plug gap 0 6 0 7 mm Primary 0 21 10 With plug cap 7 6s10 K Ignition coil resistance 20 Secondary Without plug cap 3 1s10 K F Mark Before TDC 1...

Page 156: ...il circuit Poor ignition coil Poor connection of cable and connectors Poor main switch z Secondary coil circuit Poor ignition coil Poor spark plug Poor high tension cable Current leakage in the spark...

Page 157: ...circuit Allowable current leakage Less than 1 mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit z In the current leakage test set the c...

Page 158: ...iluted sulfuric acid is very toxic Once it spreading on clothes skin or eyes it will cause burned or blind In case of being spread flush with great quantity of water immediately and then send to hospi...

Page 159: ...ing ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires z Turn the charger s switch OFF at first before or after charging to prevent from sparks created on t...

Page 160: ...z The replacement battery is aged and does not have enough capacity z Battery used do not have enough electricity or is over charged z The fuse of the ammeter is blown z The ammeter is improperly con...

Page 161: ...ver emblem and the front cover Remove the headlight control unit connector The headlight control unit function When a headlight does not shine the other headlight mandatory can not shine Item wire col...

Page 162: ...r lighting coil Check Remove the 3P connector of the alternator Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8f0 1 20 Replace the alterna...

Page 163: ...ach terminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200 Primary Black yellow green 0 21 10 Green high voltage cable w o cap 3 5K Ignition Co...

Page 164: ...utton or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to black yellow side Min voltage Above 95 V Caution Primary coil check Disconnect...

Page 165: ...lug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution Check Remove body cover Remove the pulse generator connector Measure...

Page 166: ...e pin Remove the power control connector of the Starter magnetic switch Connect an Ohmmeter between the Starter magnetic switch large pins Connect the green yellow wire to battery positive terminal an...

Page 167: ...Remove the starting motor mounting bolts and motor Starting Motor Installation Install the motor in reverse order of removal METER Removal Remove the front handle cover Remove the speedometer cable Re...

Page 168: ...h organic solvent such as gasoline to prevent from damage these components High low beam indicator Turn left signal light Fuel gauge Odometer Speedometer Turn right signal light Tachometer Copyright 2...

Page 169: ...on Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment bolt located under the headlight Caution Do not touch the bulb sur...

Page 170: ...out the bulb and replace it with new one 12V 10W Installation Install the bulb in reverse order of removal Pull out the bulb and replace it with new one 12V 5W Installation Install the bulb in revers...

Page 171: ...the rear luggage box bolts x4 Remove the left right body cover Remove the luggage box bracket and fuel tank bolts x2 bolts x2 right body cover left body cover luggage box bracket fuel tank Copyright...

Page 172: ...ect main switch leads connector Check connector terminals for continuity color Location Red Black LOCK OFF ON Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the main sw...

Page 173: ...tch color Location Black Black Red OFF ON Starting switch color Location Yellow red Green FREE High Low beam switch color Location Black Red White Blue Red Horn switch color Location white green Light...

Page 174: ...ity when operating the brake lever If the switch damaged replace it with new one Horn Remove the front cover Connect the light blue wire on the horn to the battery positive terminal and the green wire...

Page 175: ...harness Turn the main switch ON position Move the float arm in UP DOWN and then check if the fuel unit indication needle is in correct position Caution Float arm position Indicator needle UP full E em...

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