E-TON sport 50, Service Manual

Page 1: ...SERVICE MANUAL SPORT 50 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: ...f the motorcycle are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice This manual that contains all...

Page 3: ...ection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance The third to the eleventh chapters cover engine and driving syste...

Page 4: ...VAL 5 CYLINDER HEAD VALVE 6 CYLINDER PISTON 7 V TYPE BELT DRIVING SYSTEM KICK STARTER ARM STARTER CLUTCH 8 FINAL DRIVING MECHANISM 9 A C GENERATOR STARTING CLUTCH 10 CRANKCASE CRANKSHAFT 11 BODY COVER...

Page 5: ...LER NO SYM 1130000 PURPOSE INSTALL CRANKCASE ITEM OUTER BEARING PULLER NO SYM 6204010 PURPOSE REMOVE THE BEARING ITEM ACG FLYWHEEL PULLER NO SYM 3110A00 PURPOSE REMOVE ACG FLYWHEEL ITEM LOCK NUT PULLE...

Page 6: ...ITEM CLUTCHSPRING COMPRESSOR NO SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH ITEM CLUTCH NUT WRENCH NO SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT ITEM GY6 STARTER GEAR PULLER NO SYM 2822100 GY6 PURPOSE RE...

Page 7: ...cleaner Gear oil filling bolt Oil level Tail light Front turn signal light Fuel tank Fuel unit Turn signal horn switch Head light Position light Rear turn signal light Engine oil draining bolt Igniti...

Page 8: ...pment damages may result if procedures are not followed Engine oil Limits to use SAE 10W 30 API SH CD class oil Warranty will not cover the damage that caused by not apply with the limited engine oil...

Page 9: ...se serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediate...

Page 10: ...tion to O rings or oil seals because most cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent stiff control and premature worn out y Rubber parts may become...

Page 11: ...d fill the groove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damag...

Page 12: ...s to remove the battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark y After service completed make sure all connecti...

Page 13: ...y Check if any wire loose y Check if the connector is covered by the twin connector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loos...

Page 14: ...ther pull too tight nor have excessive slack y Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be appl...

Page 15: ...adjacent or surrounding parts in all steering positions y Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the i...

Page 16: ...y Reduction GEAR Type 4 STROKE ENGINE Clutch Centrifugal type Installation and arrangement Vertical below center incline 80 Deceleration equipment Transmission C V T Fuel Used Petrol Speedometer 0 50...

Page 17: ...1 2 Oil pump drive sprocket nuts 1 6 0 8 1 2 Left crankcase cover bolts 10 6 0 8 1 2 Cylinder head cover bolts 4 6 0 8 1 2 Camshaft chain tensioner pivot 1 6 0 8 1 2 Hex socket bolt Camshaft chain adj...

Page 18: ...ake disc mounting bolts 4 10 4 0 4 5 Front brake clipper mounting bolts 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 conne...

Page 19: ...w the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clog...

Page 20: ...tion No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 5 Fuel level too low in carburetor 6 Fuel nozzle clogged in carburet...

Page 21: ...uel cup Check if carburetor clogged 1 Incorrect ignition timing malfunction of CDI or AC alternator 1 Rich mixture loosen the screw 2 Lean mixture tighten the screw 1 Poor heat insulation gasket 2 Car...

Page 22: ...ion 2 Driving disk damaged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged Engine running and misfire as motorcycle initial for...

Page 23: ...N TROUBLE DIAGNOSIS E TON 1 16 LUBRICATION POINTS Acceleration cable Front rear brake lever pivot Steering shaft bearing Seat lock Speedometer gear Front wheel bearing Side stand shaft Main stand shaf...

Page 24: ...NUTS BOLTS TIGHTEN 2 15 PRECAUTIONS IN OPERATION Specification Main 5200 c c Fuel Tank Capacity auxiliary 1500 c c capacity 850 c c Engine Oil change 750 c c capacity 110 c c Transmission Gear oil ch...

Page 25: ...system I Code I Inspection cleaning and adjustment R Replacement C Cleaning replaced if necessary L Lubrication Have your motorcycle checked adjusted and recorded maintenance data periodically by your...

Page 26: ...y Disassembly 850cc Change 750cc When checking for oil leak run the engine at idle speed for a few minutes then check oil capacity with dipstick Cleaning the oil strainer Drain oil from engine remove...

Page 27: ...stall the oil filling bolt Torque value 1 0 1 5 kgf m Quantity 90 c c Recommended SAE 85W 140 Fuel System Fuel Pipe Remove luggage box rear center cover body cover and rear fender as well as front inn...

Page 28: ...is smooth Check throttle valve cable and replace it if deteriorated twisted or damaged Lubricate the cable if operation is not smooth Measure handle bar free play in its flange part Free play 2 6 mm A...

Page 29: ...mark T on the generator flywheel aligns with 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...

Page 30: ...st sampling muffler of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within standard 4 Slightly accelerate the throttl...

Page 31: ...e these components if malfunction of these parts are found SPARK PLUG Appointed spark plug TORCH A7RC Remove luggage box Remove center cover Remove spark plug cap Clean dirt around the spark plug hole...

Page 32: ...n chamber or piston head DRIVING SYSTEM DRIVING BELT Remove left side cover Remove mounting bolt located under air cleaner Remove 9 bolts of the engine left crankcase Remove the left crankcase cover C...

Page 33: ...r leaking Replace damaged and non repairable components Tighten all nuts and bolts Rear Shock absorber Press down the rear shock absorber for several times to check its operation Check if it is scratc...

Page 34: ...uid contents inside the brake system hoses AIR BLEED OPERATION Connect a transparent hose to draining valve Hold the brake lever and open air bleeding valve Perform this operation alternative until th...

Page 35: ...n Pry out the brake lining with a flat driver if lining be clipped Remove brake lining bolt Take out the lining Caution Never mix or use dirty brake fluid to prevent from damage brake system or reduci...

Page 36: ...Free play 10 20 mm Adjust the free play by turning 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...

Page 37: ...Check if tire surface is ticked with nails stones or other materials Check if tire surface or wall for crack or damaged and replace it if necessary The tire tread depth can be checked by visual inspe...

Page 38: ...nt screw after the beam height 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 fra...

Page 39: ...TIONS 3 2 TROUBLE DIAGNOSIS 3 2 ENGINE OIL 3 3 CLEANING ENGINE OIL STRAINER 3 3 OIL PUMP 3 4 GEAR OIL 3 7 MECHANISM DIAGRAM Valve rocker arm Camshaft Scoop lubrication Forcedly lubrication Forcedly lu...

Page 40: ...Limit Inner rotor clearance 0 12 Clearance between outer rotor and body 0 12 Oil pump Clearance between rotor side face and body 0 05 0 10 0 20 Torque value Engine oil drain plug 1 0 1 5kgf m Engine o...

Page 41: ...tighten it Torque value 1 0 1 5 kgf m CLEANING ENGINE OIL STRAINER Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer recommended using compressed air to clean dirty foreig...

Page 42: ...to chapter10 Remove the engine right crankcase cover Make sure that the pump axle can be rotated freely Remove the oil pump driving gear nut Remove oil pump body bolts 3 bolts Remove the oil pump pin...

Page 43: ...ow 0 12 mm Check clearance between rotor side face and pump body Limit below 0 2 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Insert the drive shaft into the inner rotor I...

Page 44: ...e 2 O rings Install the oil pump pin Install the oil pump Install the oil pump body bolts 3 bolts Install the oil pump driving gear nut Install the alternator refer to chapter10 Install the engine rig...

Page 45: ...the oil level too low Standard quantity 110 cc Replacement 100 cc Gear Oil Replacement Remove the gear oil filling bolt and its draining plug and then drain oil completely Install the draining plug a...

Page 46: ...ROUBLE DIAGNOSIS 4 3 CARBURETOR REMOVAL 4 4 VACUUM CHAMBER 4 4 ACCELERATE PUMP 4 6 AUTO BY STARTER 4 7 FLOAT CHAMBER 4 8 INSTALLATION OF CARBURETOR 4 9 IDLE SPEED ADJUSTMENT 4 9 FUEL TANK 4 10 AIR CLE...

Page 47: ...l service tools Vacuum air pressure pump General service tools Fuel level gauge Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit...

Page 48: ...dle speed z Malfunction of carburetor z Dirty fuel Intermittently misfire as acceleration z Malfunction of ignition system Late ignition timing z Malfunction of ignition system z Malfunction of carbur...

Page 49: ...ase the clamp strip of air cleaner Release the clamp strip of carburetor isolator Take the carburetor out VACUUM CHAMBER Removal Loosen drain screw and drain out residual fuel in float chamber Remove...

Page 50: ...piston Cautions Install vacuum piston to carburetor body Install compress spring Install vacuum chamber cover and tighten 2 screws Do not damage vacuum diaphragm z Note direction as installing the pis...

Page 51: ...arm from the carburetor Remove 3 mounting screws and remove the float chamber cover Remove 3 mounting screws and remove the float chamber cover Installation Install the valve as reverse order of remo...

Page 52: ...t clogged Connect battery posts 12V to starter s connectors After 5 minutes test the rich circuit with compressed air If air flow through the circuit then replace the starter Removal Remove fixing pla...

Page 53: ...or body passages with compressed air In case of worn out or dirt the float needle valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or...

Page 54: ...screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rpm and CO...

Page 55: ...der of removal Cautions Fuel Tank Removal Open the seat Remove the rear carrier 3 bolts Remove the luggage box and the double seat 4 bolts Remove the left right body cover Disconnect the fuel unit con...

Page 56: ...eaner Installation Install the air cleaner in the reverse order of removal Air Cleaner Element Cleaning Remove the air cleaner cover 7 screws Remove the air cleaner element 2 screws With compressed ai...

Page 57: ...DIAGRAM 5 1 OPERATIONAL PRECAUTIONS 5 2 ENGINE REMOVAL 5 3 REMOVAL OF ENGINE 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...

Page 58: ...k driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Specification Disassemble 800 c c Engine Oil Capacity Replacement 750 c c Disassemble 110 c c Gear Oil Capaci...

Page 59: ...ody cover Remove the power connector of auto by start Remove the generator connector and pulse generator connector Remove the starter motor wire on the Starter magnetic switch Remove the spark plug ca...

Page 60: ...nd throttle valve cable from the carburetor Loose the strap screw of the air cleaner guide and remove the air cleaner guide Remove the exhaust muffler Bolts 2 Nuts 2 Remove the rear wheel Nut 1 Remove...

Page 61: ...Remove the engine suspension nut and bolt engine side and then remove the engine Caution Check if the engine suspension rear shock absorber bushing and cushion rubber for damage Replace them with new...

Page 62: ...ress the bushing out and replace it with new one Engine suspension bushing 28mm Rear shock absorber bushing 20mm Pressing out Place the detent section of the bushing remover toward the bushing and dri...

Page 63: ...move the left side bolt of engine suspension frame Check if the engine suspension frame bushing and cushion rubber for damage If so replace with new ones Installation Tighten the bolts and nuts of eng...

Page 64: ...suspension nut Torque Value 4 5 5 5kgf m Rear shock absorber bolt Torque Value Top 3 5 4 5kgf m lower 2 4 3 0kgf m Rear wheel axle nut Torque Value 11 0 13 0kgf m y Notice both feet and hands safety f...

Page 65: ...NDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD INSPECTION 6 8 VALVE SEAT INSPECTION AND SERVICE 6 10 CYLINDER HEAD REASSEMBLY 6 12 CYLINDER HEAD INSTALLATION 6 13 CAMSHAFT INSTALLAT...

Page 66: ...0 10 015 10 10 Rocker arm OD of valve rocker arm shaft 9 972 9 987 9 910 Intake 4 975 4 99 4 90 OD of valve stem Exhaust 4 955 4 97 4 90 ID of Guide 5 000 5 015 5 030 Intake 0 010 0 037 0 080 Clearanc...

Page 67: ...on y Poor sealing on valve seat y Improper spark plug installation 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder surface 3 Piston y Piston ring worn out High compre...

Page 68: ...chain adjuster in a counter clockwise 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 s...

Page 69: ...t and bearing Disassembly Of Camshaft Holder With a 5 mm bolt to screw in the cam rocker arm shaft so that take it out Remove cam rocker arm Inspection Of Camshaft Holder Check if the camshaft holder...

Page 70: ...vice Limit Replace when it is above 9 910 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is above 0 10 mm CYLINDER HEAD REMOVAL Remove double...

Page 71: ...alve spring and valves Caution Special Service Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder he...

Page 72: ...lve stem in valve guide and measure record the valve stem outer diameter Service Limit IN 4 900mm EX 4 900mm Valve guide Caution Special Service Tool 5 0mm valve guide reamer Measure and record each v...

Page 73: ...seat and clean up all metal residues from cylinder head Special tool Valve guide reamer 5 mm If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that...

Page 74: ...ve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough 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 v...

Page 75: ...hat a seal track will be created on contact surface Caution If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat with 45 cutter to specified width If the conta...

Page 76: ...alve spring compressor to press valve spring Install valve split locks and release the valve compressor Caution Special tool valve spring compressor Tap valve stem to make valve retainer and valve ste...

Page 77: ...er arm shaft Caution With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of t...

Page 78: ...tment nut Standard Value IN EX 0 06 0 02mm Turn the cam chain adjuster in clockwise motion so that the adjuster is pushed out to contact the cam chain plate tightly Tighten the bolt cap of the adjuste...

Page 79: ...1 MECHANISM DIAGRAM 7 1 PRECAUTIONS IN OPERATION 7 2 TROUBLE DIAGNOSIS 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7 5 PISTON RING INSTALLATION 7 7 PISTON INSTALLATION 7 8 CYLINDER INSTALLATION 7 8 MECHA...

Page 80: ...0 025 0 040 0 100 Piston Piston ring ID of piston pin hole 13 002 13 008 13 040 OD of piston pin 12 994 13 000 12 980 Clearance between piston and piston pin 0 002 0 014 0 018 ID of connecting rod sm...

Page 81: ...to chapter 6 Remove 2 bolts and then take out the cam chain auto adjuster Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surf...

Page 82: ...ctive in the cylinder Service limit 39 047mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom pos...

Page 83: ...the carbon in piston ring grooves Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09mm 2nd ring replace if over 0 09mm...

Page 84: ...he inner diameter of piston pin hole Service Limit 13 040mm Calculate clearance between piston pin and its hole Service Limit 0 02mm Measure piston outer diameter Caution Service limit 38 970mm Compar...

Page 85: ...lace the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all pist...

Page 86: ...g piston into cylinder Press piston rings in one by one as installation Caution Install the cam chain plate the cylinder head gasket and lock pins Install cylinder head refer to Chapter 6 Install the...

Page 87: ...UTCH 8 1 MECHANISM DIAGRAM 8 1 MAINTENANCE DESCRIPTION 8 2 TROUBLE DIAGNOSIS 8 2 LEFT CRANKCASE COVER 8 3 KICK STARTER ARM 8 3 DRIVING BELT 8 4 SLIDING PULLEY 8 6 CLUTCH DRIVEN PULLEY 8 9 MECHANISM DI...

Page 88: ...OD of driven pulley 33 965 33 985 33 940 ID of sliding pulley 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 drivin...

Page 89: ...ne if poor parts found Reassembly Apply with some specified grease on the gear shaft Install the friction spring of driving gear onto convex part of the case cover Install return spring and starter sh...

Page 90: ...same time Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram shown Replace the driving belt if it exceed maintenance limited spec...

Page 91: ...e clutch with universal fixture and then tighten nut to specified torque value Torque value 3 5 4 5 kgf m Caution Pull out driving pulley and then insert the driving belt into the driving pulley so th...

Page 92: ...ley Remove the sliding pulley fixing nut and remove the driving belt from the sliding pulley Remove the driving belt from the sliding pulley Remove the limited speed bush Remove the bush and remove th...

Page 93: ...ers are wear out or damage Replace it if necessary Measure each rollers outer diameter Replace it if exceed the service limit Service limit 15 57 mm Measure the inner diameter of the sliding pulley Se...

Page 94: ...ut Caution Hold driving pulley with universal fixture Tighten nut to specified 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...

Page 95: ...clutch spring compressor and remove clutch and spring from driven pulley Remove socket from driven pulley Remove oil seal from driven pulley Remove guide pin guide pin roller and sliding pulley and th...

Page 96: ...ts Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94mm Inner diameter 34 06mm Driven Pulley...

Page 97: ...f necessary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push...

Page 98: ...bearing Install a new inner bearing Caution Align oil seal lip with bearing and then install the new oil seal if necessary y Its sealing end should be forwarded to outside as bearing installation y In...

Page 99: ...n pulley spring and clutch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the...

Page 100: ...9 1 OPERATIONAL PRECAUTIONS 9 2 TROUBLE DIAGNOSIS 9 2 DISASSEMBLY OF FINAL DRIVING MECHANISM 9 3 INSPECTION OF FINAL DRIVING MECHANISM 9 3 BEARING REPLACEMENT 9 4 RE ASSEMBLY OF FINAL DRIVING MECHANI...

Page 101: ...ng puller Outer type bearing puller Gear box oil seal installer Gear box bearing installer Torque value Gear box cover 2 6 3 0 kgf m Gear oil drain plug 1 0 1 5 kgf m Gear oil filling bolt 1 0 1 5 kgf...

Page 102: ...box cover and the final driving shaft Remove gasket and setting pin Remove countershaft and gear Remove final driving gear and shaft INSPECTION OF FINAL DRIVING MECHANISM Check if the countershaft an...

Page 103: ...or damage and replace it if necessary Check driving shaft and gear for wear or damage BEARING REPLACEMENT Caution Remove driving shaft bearing from left crankcase using following tools Inner type bea...

Page 104: ...er Bearing protector Install a new driving shaft bearing onto crankcase Then install the driving shaft Specified tool Press the bearing in with C type hydraulic presser or bearing installer Install a...

Page 105: ...oil seal lip of final driving shaft Install the gear box cover and 7 bolts tighten the bolts Torque 2 6 3 0 kgf m Install the clutch sliding driving pulley Install the driving pulley belt and left cr...

Page 106: ...STALLATION 10 4 FLY WHEEL INSTALLATION 10 4 PRECAUTIONS IN OPERATION General information y Refer to chapter 5 Engine removal and installation y Refer to chapter 1 The troubleshooting and inspection of...

Page 107: ...lts 2 nuts Remove the fan shroud 4 bolts 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 Coolin...

Page 108: ...Caution RIGHT CRANKCASE COVER REMOVAL Remove the right crankcase cover 8 bolts Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and cr...

Page 109: ...cover 2 bolts Install pulse generator 2 bolts Torque 0 8 1 2kgf m Tie the wire harness hose onto the indent of crankcase Install A C generator connector and pulse generator connector FLYWHEEL INSTALLA...

Page 110: ...5 Install the cooling fan 4 bolts Install the cooling fan shroud 4 bolts Install the exhaust muffler 2 bolts 2 nuts Add some engine oil according the specified quantity Exhaust muffler Cooling fan sh...

Page 111: ...RANKSHAFT 11 1 MECHANISM DIAGRAM 11 1 OPERATIONAL PRECAUTIONS 11 2 TROUBLE DIAGNOSIS 11 2 DISASSEMBLY OF CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 5 ASSEMBLY OF CRANKCASE 11 6 MECHANISM DIAGRAM 1 5 2 0...

Page 112: ...eplaced Specification Unit mm Item Standard Limit Left right 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 Ru...

Page 113: ...crankcase Drive the screw of the crankcase remover set into the crankcase and then separate the left and the right crankcases Remove the cam chain Caution Special Service Tools Crankcase remover set z...

Page 114: ...s 2 Scrape gasket residues off the crankcase contact surface Caution Remove oil seal from the left crankcase z Do not damage contact surface of the crankcase z Soap the gasket residues into solvent an...

Page 115: ...ical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers...

Page 116: ...rankcase gasket Install the right crankcase and tighten the crankcase bolts 1 bolts Torque value 0 8 1 2 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain...

Page 117: ...11 7 Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x37x6 Special service tools th...

Page 118: ...COVER 12 10 LUGGAGE BOX 12 10 FLOOR PANEL 12 10 Front center cover Front handle cover Frame number cover Left body cover Inner box A Double Seat Rear carrier Luggage box Floor panel Front cover Rear...

Page 119: ...s with slot on the covers 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 Battery cover Luggage box S...

Page 120: ...and the frame Removed the left right turn signal light connectors Remove the front handle cover Remove the speedometer cable Remove the handlebar rear cover 2 screws Removed the brake switch connector...

Page 121: ...x A Remove the 2 mounting screws between the front cover and the inner box Remove the 1 mounting bolt of front cover from the frame Remove the headlight wire connector and then remove the front cover...

Page 122: ...move the 4 mounting screws between the front under cover and the inner box B Remove the 2 mounting bolts between the front under cover and frame Remove the 2 mounting screws between the front under co...

Page 123: ...ng screws of front cover from the inner box A Remove the screw on the front inner box Remove the front cover Remove the screw on the main switch Remove the main switch cover Remove the 4 screws betwee...

Page 124: ...under cover and the inner box B Remove the front inner box A and the front inner box B Remove the screw between the inner box A and the inner box B Remove the front inner box A Remove the front inner...

Page 125: ...the seat Remove the luggage box 4 bolts Remove the rear carrier 3 bolts Remove the 2 mounting bolts of the rear fender Remove the 2 mounting screws between the body cover and the floor panel Remove t...

Page 126: ...r fender and the left right body cover Remove the 2 screws between the rear fender and the rear center cover Remove the rear fender Remove the rear center cover Remove the left right body cover Instal...

Page 127: ...the luggage box Remove the luggage box and the double seat Installation Install the luggage box according to the reverse procedure of removal FLOOR PANEL Removal Remove the 4 bolts from the luggage bo...

Page 128: ...C BRAKE SYSTEM INSPECTION 13 5 BRAKE FLUID REPLACEMENT AIR BLEED 13 6 BRAKE CALIPER 13 7 BRAKE DISK 13 8 BRAKE MASTER CYLINDER 13 8 DRUM BRAKE DRUM 13 11 BRAKE LING 13 11 BRAKE PANEL 13 12 MECHANISM D...

Page 129: ...13 BRAKE E TON 13 2 Rear Drum Brake System 0 8 1 2 kgf m 0 8 1 2 kgf m...

Page 130: ...go Specifications Unit mm Item Standard Limit The thickness of front brake disk 3 50 2 00 Front brake disk eccentricity 0 15 0 30 Master cylinder inner diameter 25 40 ID of front rear brake drums 130...

Page 131: ...ake z Dirty brake pad disk z Poor wheel alignment z Deformed or warped brake disk Brake noise z Dirty pad z Deformed brake disk z Poor brake caliper installation z Imbalance brake disk or wheel DRUM B...

Page 132: ...luid WELLRUN DOT 3 brake fluid CAUTION Brake Fluid Add Turn the handlebar to let the master cylinder in horizontal position before removed the master cylinder cap Place a rag onto painting plastic or...

Page 133: ...bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the brake lever and open the drain valve around 1 4 turns and then close the valve CA...

Page 134: ...e pad Compress the brake caliper at first as installation Install the inner brake pad firstly and then install the outer brake pad INSTALLATION Install the brake caliper and tighten the attaching bolt...

Page 135: ...e brake master cylinder Remove the brake hose Remove the master cylinder seat and the master cylinder Remove the rubber pad Remove the circlip Remove the piston and the spring Clean the master cylinde...

Page 136: ...cup and then install the cup onto the piston Install the larger end of the spring onto the master cylinder The master cup s cavity should be face inside of master cylinder when installing the master...

Page 137: ...orque value Install the brake lever and connect leads to brake lamp switch Connect brake hoses with 2 new washes Tighten the brake hose bolt to the specified torque value Torque value 3 5 kgf m Make s...

Page 138: ...E PAD Inspection Measure the thickness of the brake pad at three 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...

Page 139: ...tallation Slightly grind the brake pad surfaces with sand paper to clean the surfaces Caution BRAKE PANEL Removal Remove the brake arm bolt and then remove the brake arm wear indicator brake return sp...

Page 140: ...ner gear of wear indicator and the mark on the brake arm with the indent gear of brake cam and then install it Tighten the bolts and nuts to specified torque Torque 0 8 1 2 kgf m REAR BRAKE PANEL Appl...

Page 141: ...SM DIAGRAM 14 1 PRECAUTIONS IN OPERATION 14 2 TROUBLE DIAGNOSIS 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT SHOCK ABSORBER 14 8 FRONT FORK STEERING COLUMN 14 8 MECHANISM DIAGRAM 3 1 3 5kgf m 1 0...

Page 142: ...0kgf m Tools Special service tools Steering 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 nu...

Page 143: ...d then remove the handlebar acceleration 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 th...

Page 144: ...moving parts when installing the acceleration handlebar seat acceleration handlebar and acceleration cable FRONT WHEEL Removal Support body bottom and lift front wheel free of ground Remove the bolts...

Page 145: ...h a dial gauge Service limit Radial 2 0 mm Axial 2 0 mm Disassembly Remove 3 hex socket bolts and brake disc Remove the left axle ring and dust seal Remove the dust seal on the right side of speedomet...

Page 146: ...wheel hub Install the left bearing onto the seat Install the bearing spacer and then install the right bearing onto the seat Caution Tool C type compressor or bearing compressor Apply with some grease...

Page 147: ...the flange part on the speedometer gear with the slot of shock absorber stopper Install the front wheel axle from right shock absorber side Install the wheel axle nut and tighten it to specified torq...

Page 148: ...rk Installation Install the shock absorbers according to the reverse procedure of removal Align the shock absorber top edge with the top end level of the front fork when installing the front shock abs...

Page 149: ...with the top bearing seat no clearance Note return 1 2 turn and then tighten 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...

Page 150: ...15 1 MECHANISM DIAGRAM 15 1 PRECAUTIONS IN OPERATION 15 2 TROUBLE DIAGNOSIS 15 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...

Page 151: ...ck absorber lower mount bolt 2 4 3 0kgf m Exhaust muffler connection nut 1 0 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...

Page 152: ...tion nut 1 0 1 4kgf m REAR WHEEL Inspection Measure wheel rim wobbling Service limit Radial 2 0mm Axial 2 0mm If the wheel rim wobbling out of the specification except resulted from the wheel rim defo...

Page 153: ...r bolt x 1 Remove the upper nut of the rear shock absorber bolt x 1 Remove the rear shock absorber Installation Install the rear shock absorber according to the reverse procedure of removal Caution To...

Page 154: ...6 11 STARTING SYSTEM 16 14 METER 16 15 LIGHTS BULBS 16 17 MAIN SWITCH HORN 16 19 FUEL UNIT 16 22 MECHANISM DIAGRAM Spark plug Alternator Fuel unit Ignition coil Battery fuse box C D I Main switch REG...

Page 155: ...lyte and then charged to prolong the battery s life span z Please check electrical device according to the procedure of diagnosis chart z Do not disconnect and connect the connector of electrical devi...

Page 156: ...tage controlled by regulator 14 5 0 5 V Resistor Resistance 20 5W5 4 5 5 5 Ignition System Item Specification Standard TORCH D7RC Recommended usage Hot type TORCH D8RC Cold type TORCH D6RC Spark plug...

Page 157: ...C D I z alternator is out of work Engine does not crank smoothly z Primary coil circuit Poor ignition coil Poor connection of cable and connectors Poor main switch z Secondary coil circuit Poor igniti...

Page 158: ...t may indicate a short 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...

Page 159: ...ectrolyte diluted 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 se...

Page 160: ...clean grease z Strictly keep flames away from a charging battery z The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires z Turn the charger s swit...

Page 161: ...battery is aged and does not have enough capacity 2 The charging voltage is normal but the current is not z The replacement battery is aged and does not have enough capacity z Battery used do not hav...

Page 162: ...sistance If the measured value is abnormal check the abnormal wire circuit If components are good it could be a poor wire circuit If all items are in good condition then replace the voltage regulator...

Page 163: ...rnator Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 1 20 Replace the alternator lighting coil if the measured value exceeds standard...

Page 164: ...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 Coil Secondary Gr...

Page 165: ...y terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to b...

Page 166: ...d and the measured value is exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary Pulse generator Caution...

Page 167: ...ositive connection and starting motor wires from the starter magnetic switch large pin Remove the power control connector of the Starter magnetic switch Connect a Ohmmeter between the Starter magnetic...

Page 168: ...inal Remove the luggage box Remove the starting motor power wire Remove the starting motor mounting bolts and motor Starting Motor Installation Install the motor in reverse order of removal METER Remo...

Page 169: ...screws Take out the meter Caution Installation Install the meter in reverse order of removal Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these compo...

Page 170: ...if the bulb has been installed properly after installation Please conduct the headlight beam adjustment job if replace the headlight bulb The headlight beam adjustment Loosen the adjustment bolt loca...

Page 171: ...place it with new one 12V 5W Installation Install the bulb in reverse order of removal Bulbs Replacement of tail light brake light rear turn signal light Remove the seat and luggage box Bolts x4 Remov...

Page 172: ...tch Check Remove the headlight connector and the front cover Disconnect main switch leads connector Check connector terminals for continuity color Location Black Red green green OFF ON LOCK Replacemen...

Page 173: ...elow columns Engine stop switch color Location Black Black Red Starting switch color Location Yellow red green FREE Horn switch color Location Black Light green FREE turn signal switch horn switch Hor...

Page 174: ...brake light switch should be in continuity 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 batte...

Page 175: ...position Resistance value E empty 97 5 107 5 F full 4 10 DOWN empty Connect the fuel unit to the main harness Turn the main switch ON position Move the float arm in UP DOWN and then check if the fuel...

Page 176: ......

Page 177: ...itch and lines I I 15 Throttle valve operation and cable I I 16 Engine bolts and nuts I I 17 Cylinder head cylinder and piston I 18 Exhaust system cleaning carbon I 19 Cam Chain ignition time I I 20 V...