SANYANG INDUSTRY CO. JET 4R, Service Manual

Page 1: ......

Page 2: ...sed on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter JET 4 R 50 series are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice SERVICE DEPARTMENT SANYANG INDUSTRY CO LTD ...

Page 3: ...ne and driving systems The eleventh to fourteenth chapters are contained the parts set of assembly body The fifteenth chapter is electrical equipment The sixteenth chapter is wiring diagram The seventeenth chapter is special tool Please see index of content for quick having the special parts and system information All information illustration directions and specifications included in this manual a...

Page 4: ...STEM 3 FUEL SYSTEM 4 ENGINE REMOVAL 5 CYLINDER HEAD CYLINDER PISTON 6 ALTERNATOR 7 V TYPE BELT 8 FINAL DRIVING MECHANISM 9 CRANKCASE SHAFT 10 BODY COVER 11 BRAKE SYSTEM 12 STEERING FRONT WHEEL FRONT SHOCK ABSORBER 13 REAR WHEEL REAR SHOCK ABSORBER 14 ELECTRICAL EQUIPMENT 15 WIRING DIAGRAM 16 SPECIAL TOOL 17 ...

Page 5: ...ge box Ignition switch Rear brake level Side stand Frame number Gear oil filling bolt Gear oil draining bolt Front turn signal light Front light Position light High Low beam Turn signal Horn switch Air Cleaner Kick starter pedal Main stand Front brake level Exhaust muffler Rear turn signal light Engine number ...

Page 6: ...ge box Ignition switch Rear brake level Side stand Frame number Gear oil filling bolt Gear oil draining bolt Front turn signal light Front light Position light High Low beam Turn signal Horn switch Air Cleaner Kick starter pedal Main stand Front brake level Exhaust muffler Rear turn signal light Engine number ...

Page 7: ...owed Engine oil Limits to use SAE SAE 20 JASO FC class engine oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil MAX 2 serial oils Gear oil King Bramax HYPOID GEAR OIL 140 is recommended Grease King Mate G 3 is recommended Locking sealant Apply sealant medium strength sealant should be used unless otherwise specified Oil seal Apply with lubr...

Page 8: ...you get 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 y If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor y Keep electrolyte beyond reach of children Gasoline is highly f...

Page 9: ...engine chassis or brake system to cause a damage y Wash and clean parts with high ignition point solvent and blow dry with compressed air Pay special attention to O rings or oil seals because most cleaning agents have an adverse effect on them z 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 damage...

Page 10: ...facturer 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 reinstallation grind with a grindstone if the contact surface has any damage y The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can go to their connections so that there is...

Page 11: ...ctrical tape or tube if they contact a sharp edge or corner z Route wire harnesses to avoid sharp edges or corners z Avoid the projected ends of bolts and screws z Keep wire harnesses far away from the exhaust pipes and other hot parts z Be sure grommets are seated in their groves properly z After clamping check each harness to be certain that it is not interfered with any moving or sliding parts ...

Page 12: ...ction GEAR Type 2 STROKE ENGINE Clutch Auto Centrifugal clutch Installation and arrangement Vertical below center incline 80 Deceleration equipment Transmission C V T Fuel Used Unleaded 93 95 Speedometer 0 80 km hr Cycle Cooling 4 stroke forced air cooled Horn 80 112 dB A Bore 39 mm Muffler Expansion Pulse Type Stroke 41 4 mm Exhaust Pipe Position and Direction Right side and Backward Cylinder Num...

Page 13: ... 1 2 Pulse generator flange bolt 2 6 0 8 1 2 Flywheel nut 1 10 3 5 4 5 Inlet pipe flange bolt 4 6 0 8 1 2 Oil pump set plate flange bolt 1 6 0 8 1 2 Cooling fan flange bolt 4 6 0 8 1 2 Fan cover flange bolt 3 6 0 8 1 2 Carburetor insulated joint flange bolt 2 6 0 8 1 2 Shroud 1 6 0 8 1 2 Movable drive face nut 1 12 3 5 4 5 Driven pulley plate nut 1 10 5 5 6 5 L crankcase cover flange bolt 10 6 0 8...

Page 14: ... 5kgf m Bolt for rear brake arm 1 6 0 8 1 2kgf m Brake hose bolt 2 10 3 3 3 7kgf m Rear brake arm lever nuts 1 6 0 8 1 2kgf m Brake master cylinder mounting bolts 2 6 1 0 1 4kgf m Speedometer cable locking screw 1 5 0 15 0 3 Main standard nut 1 10 3 5 4 5 Foot starting lever bolt 1 6 1 6 1 8 Air cleaner bolts 2 6 1 0 1 4 The torque values listed in above table are for more important tighten torque...

Page 15: ... 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 clogged 4 Lines in fuel tank evaporation system clogged 5 Malfunction of fuel pump 6 Loosen or damaged fuel pump vacuum hose 7 Fuel filter clogged 1 Malfunction of spark plug 2 Spark plug foul 3 Malfunction of CDI set 4 Malfunc...

Page 16: ... over heat No foul or discoloration Fouled and discoloration No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 1 Malfunction of CDI 2 Malfunction of AC alternator 1 Cylinder piston ring worn out 2 Cylinder gasket leaked 3 Sand hole in compression parts 4 Valve deterioration 5 Crankcase leakage for pre compression 1 Remove...

Page 17: ...omatic fuel 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 Carburetor lock loose 3 Poor intake gasket 4 Poor carburetor O ring 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or short circuit i...

Page 18: ...aged 3 Driving pulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damaged 7 Transmission gear worn out or burned Engine running and misfire as motorcycle initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance 1 Driving belt worn out or deformation 2 Balance weight roller ...

Page 19: ...ATION TROUBLE DIAGNOSIS 1 13 LUBRICATION POINTS Acceleration cable Front rear brake lever pivot Steering shaft bearing Seat lock Speedometer gear Front wheel bearing Side stand shaft Main stand shaft Rear wheel bearing ...

Page 20: ...ion 2 11 Carburetor Idle Speed Adjustment 2 12 Cylinder Compression Pressure Test 2 12 Headlight Adjustment 2 13 General Information Specification Item Jet 4 R 50 series Tire dimension Front 120 60 13 Rear 130 70 12 Tire pressure at cold Only rider Front 2 0 kg cm2 Rear 2 0 kg cm2 Rear brake lever free play 10 20 mm Transmission oil Recommendation Type HYPOID GEAR OIL Oil SAE 140 Quantity 0 12 L R...

Page 21: ...ng I I 19 Emission check in Idling I I 20 Idle speed check I I 21 Fuel lines I I 22 Throttle operation I I 23 Engine bolt tightening I I 24 Engine screw torque I 25 Carbon cleaning for cylinder head cylinder and piston head and exhaust system I Have your scooter checked adjusted periodically by your SYM Authorized Dealer to maintain the scooter at the optimum condition Code I Inspection cleaning a...

Page 22: ...o clean the element Soap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover z Limit to use SAE 20 JASO FC class engine oil otherwise SYM is no responsible for the warranty z Recommended engine oil MAX 2 serial oils Fuel Lines Remove the luggage box Check fuel lines and replace damaged lines if found Install ...

Page 23: ...ction Check the fuel line for leaking Engine Oil Line Remove the body cover Check the engine oil line and replace damaged parts Remove the filling pipe from the oil pump and drain oil into a cleaning container Loosen the clamp under the engine oil tank and then remove the oil pipe Bleed the air inside the oil pump and oil pipe if air found Install the body cover Fuel filter Oil filling pipe Engine...

Page 24: ...ver and then remove the cover Check if the battery terminals are loosened Remove the battery if its terminals are corroded obviously Battery Removal 1 Remove the Negative battery cable at first 2 Then remove the Positive battery cable 3 Remove the battery Clean the rust with steel brush Install the battery in reverse order of removal and apply with grease onto two terminals Caution The electrolyte...

Page 25: ... checked by visual inspection or by a depth gauge z If the tread bend too much replace the tire z If tire wear exceeds limitation replace the tire and check it for un even wear Caution Wear indicator is distributed on average along the wall rubber for check Rear Drum Brake Free Play Measure the free play of the rear brake lever at the end of the lever Free play 10 20 mm 3 8 3 4 in Adjust the free ...

Page 26: ...the brake fluid will spread out if operated the lever Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Place the diaphragm in Operate the brake lever so that brake fluid 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 thi...

Page 27: ...ning replacements refer to chapter 12 Brake pad Wear Disc Brake Type The arrow mark on brake pad is the wear limitation Replace the brake pad if the wear limit mark closed to the edge of brake disc Caution In order to maintain brake power balance the brake lining must be replaced with one set Brake pad replacements refer to chapter 12 Brake pad Brake caliper Brake disc Wear limit mark Arrow ...

Page 28: ...lity and drive ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be repaired Tighten all nuts and bolts Rear Shock Absorber Park the scooter with its main stand Shake the rear wheel side to side to check engine suspension bushing for wear Replace the bushing ...

Page 29: ...ean any dirt on the spark plug seat z Remove the spark plug z Visually inspect the spark plug electrodes for wear z The center electrode should have square edges and side electrode should have a constant thickness Replace the spark plug if there is apparent wear or if the insulator is cracked and or chipped If the spark plug deposits can be removed by sandpaper the spark plug can be reused z Measu...

Page 30: ...move the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is correct Throttle Valve Operation Check if each steering positions are operated in smooth and handle bar if its operation is smooth as the throttle valve wide opening or fully closed Check throttle cable ...

Page 31: ... the required idling and air screw to adjust to specified idle speed Idle speed 1900 100 rpm Cylinder Compression Pressure Test Remove the left body cover and warn up engine Stop the engine and remove the spark plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 1 kg cm2 Probable causes for low compression pr...

Page 32: ...TS BOLTS TIGHTENESS Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely Check all fixing pins snap rings hose pipe clamps and wire holders for security y To adjust the headlight beam follows related regulations y Improper headlight beam adjustment will make in coming driver dazzled or insufficient lightin...

Page 33: ...m 3 1 Precautions In Operation 3 2 Lubricant 3 2 Trouble Shooting 3 2 Oil Pump Removal 3 3 Oil Pump Installation 3 3 Oil Pump Oil Tube Air Bleeding 3 4 Oil Tank 3 5 Lubrication System Diagram Oil pump Oil output tube Oil tube Oil lever switch Oil tank ...

Page 34: ...ted to apply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage Recommended oil MAX 2 oil Oil tank capacity 1 2lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil pumps adjustment too much oil 2 Poor quality oil 3 Applying with poor quality oil Over heat 1 Improperly oil pumps adjustment insufficient oil 2 Poor quality oil 3 Applying with poor quality oil ...

Page 35: ...face is damaged Check if pump body is damaged Check if pump gear is damaged Check for oil leaking Caution The oil pump cannot be disassembled Oil Pump Installation Install the oil pump onto the crankcase Caution Apply with some grease onto oil pump O ring The connection between both oil pump and crankcase has to be installed in position security Tighten the oil pump mounting bolt security Install ...

Page 36: ...ube is full with oil Then install the tube onto oil pump Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted air bleeding operation too Oil Tube Air Bleeding Remove the oil output tube and plug its input connector Bend the oil tube into U shape and fill out new oil into the output tube Connect the oil ...

Page 37: ... fender Refer to chapter 11 Remove the oil input tube from oil pump and then drain oil to a clean container Remove the oil level switch wire coupler of the oil indicator Remove the mounting bolt on the oil tank upper and left side two bolts and then remove the oil tank Installation Install in the reverse order of removal The oil tubes air bleeding after installation Oil level switch coupler 2 bolt...

Page 38: ...3 Lubrication System 3 6 ...

Page 39: ...rottle Valve 4 3 Carburetor Remove 4 4 Auto By Starter 4 4 Float Float Valve Jet 4 6 Float Level Inspection 4 7 Carburetor Installation 4 7 Reed Valve 4 7 Air Cleaner 4 9 Fuel tank Fuel unit Fuel filter Fuel pump Carburetor Throttle valve cable Fuel cap Fuel inlet tube ...

Page 40: ... 50 Ventura diameter 15 mm Idle speed 1900 100 rpm Throttle handle free play 2 6 mm Troubleshooting Engine cannot be started 1 No fuel in fuel tank 2 Fuel can not reach to carburetor 3 Too much fuel in cylinder 4 Clogged air cleaner Stall after started 5 Incorrect idle speed adjustment 6 No spark on the spark plug 7 Low compression pressure 8 Rich mixture 9 Lean mixture 10 Clogged air cleaner 11 I...

Page 41: ... Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve cable Needle clamp Throttle valve spring F...

Page 42: ...ction Connect resistor meter to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the auto by starter Resistance value Max 10Ω at cold engine Caution If the resistance value exceeds the standard a little bit the auto by starter may still in normal However i...

Page 43: ...or to make sure that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor is in short circuit current higher than specification will flow into the PTC Then it will cause the fuel rich circuit close rapidly and difficult to start the scooter Resistance value 10 2...

Page 44: ...n Caution Do not tighten the screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Installation Install the idle jet the needle jet seat and main jet Then install the throttle valve stopper and air screws to their original position according to the marks as removal Adjust the screws if replace with new ...

Page 45: ...ke pipe with bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Connect the automatic by starter connector Install air cleaner cap Conduct following operations y Adjustment of throttle valve cable y Adjustment of oil pump y Adjustment of idle speed Reed Valve Removal Remove the luggage box Remove the carburetor...

Page 46: ... Replace reed valve if necessary Caution Do not bend the reed valve stopper Otherwise it will cause its strength insufficient and rough engine running If the reed valve or its seat is damaged replace with a set Installation Install in the reverse order of removal procedures Check for leaking after installed Carburetor Fuel hose Reed valve stopper Reed valve Reed valve seat ...

Page 47: ... Removal Installation Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner Install in the reverse order of removal procedures 1 screw 2 bolts Hose clamp ...

Page 48: ...5 Engine Removal 5 1 Maintenance Information 5 2 Engine removal 5 3 Engine hanger bracket 5 6 Engine installation 5 6 3 5 4 5kgf m 2 4 3 0kgf m 4 5 5 5kgf m 4 5 5 5kgf m 4 5 5 5kgf m 4 5 5 5kgf m ...

Page 49: ... Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt 4 5 5 5kgf m Engine hanger bracket bolt 4 5 5 5kgf m Rear cushion upper mounting bolts 3 5 4 5kgf m Rear cushion lower mounting bolts 2 4 3 0kgf m Exhaust muffler connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m ...

Page 50: ...ove the oil control cable from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire couplers of auto by starter and ACG Remove the upper parts of the carburetor from its upper side Remove the carburetor heater electric wire Vacuum tube Fuel output tube Wire couplers Spark plug Carburetor upper parts Heater wire Oil tube Control cable ...

Page 51: ...r brake cable from engine rear lower side Remove brake cable from cable clamp Remove air cleaner and rear inner fender mounting screw Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner 1 screw 2 bolts Hose clamp Rear brake cable ...

Page 52: ...ts beside fan cover and exhaust pipe Support the engine and then remove cushion lower mounting bolt Remove engine mounting nut and bolt Each side 1 bolt and 1 nut Remove the engine Engine mounting nut Rear cushion lower mounting bolt Engine mounting bolt 3 bolts Connection nuts ...

Page 53: ...5 5kgf m Engine installation Install in the reverse order of removal procedures Tighten the engine mounting bolts and rear cushion upper lower bolts Torque value Engine hanger bolt 4 5 5 5kgf m Rear cushion upper mounting bolt 3 5 4 5kgf m Rear cushion lower mounting bolt 2 4 3 0kgf m Exhaust muffler connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m Perform the following inspe...

Page 54: ...6 Cylinder Head Cylinder Piston 6 1 Maintenance Information 6 2 Troubleshooting 6 2 Cylinder Head 6 3 Cylinder Piston 6 5 1 6 2 0kgf m 1 1 1 7kgf m ...

Page 55: ...12 008 Piston pin OD 11 994 12 000 Clearance between piston and piston pin 0 002 0 014 Piston ring end gap 0 100 0 250 Piston ID of connecting rod small end 17 005 17 017 ID 39 000 39 015 Cylinder Deformation ID inner diameter OD outer diameter Tighten torque value Cylinder head 1 6 2 0kgf m Spark plug 1 1 1 7kgf m Exhaust pipe connection nut 0 8 1 2kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m...

Page 56: ...and center cover Remove fuel pump tubes Remove spark plug cap Remove fuel pump bracket 2 nuts Remove vacuum tube and oil pump control cable from engine shield Remove fan cover 3 bolts Remove engine shield mounting bolt 1 bolt 3 bolts Engine shield 1 bolt 2 nuts Vacuum tube Fuel output tube Fuel inlet tube ...

Page 57: ...it in which built up in combustion chamber with shown chisel Caution Do not scratch to the interfaces of combustion chamber and cylinder Cylinder Head Inspection Use a straight edge and a feeler gauge to measure the cylinder head for warp Cylinder Head Installation Replace the cylinder head gasket with new one and place the cylinder head onto cylinder Tighten the 4 bolts with diagonal direction an...

Page 58: ...e pry out operation between cylinder and crankcase Or let radiation fan be knocked seriously Piston Removal Place a clean rag onto crankshaft to cover the piston Remove piston pin clip one piece and then push piston pin out the piston Caution y Do not damage or scratch the piston y Do not apply with lateral force to connecting rod y Do not let piston pin snap ring falling into crankcase Piston Rin...

Page 59: ...th the cylinder and the piston Use a straight edge and a feeler gauge to measure the cylinder head for warp In X and Y direction measure the cylinder for worn out as the three levels shown in the figure With the maximal value to decide cylinder wear out condition Measure the OD of piston at the 7 mm from the bottom of the piston Calculate the clearance between piston and cylinder 7mm ...

Page 60: ...on Measure the end gap of each piston ring Caution With the piston push each piston ring into cylinder correctly Connecting Rod Inspection Measure the ID of connecting rod small end Install bearing and piston pin onto connecting rod small end and then check its clearance The ID of piston pinhole The OD of piston pin Clearance ...

Page 61: ...ne and cannot mix with other one Place a cleaning cloth onto the crankcase opening to prevent the piston pin snap ring from falling into the crankcase Apply with two stroke engine oil onto needle bearing and piston pin and install needle bearing into connecting rod small end Install piston and place EX mark of the piston toward to exhaust side and then install the piston pin onto piston and connec...

Page 62: ...ead Tighten torque 1 6 2 0kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut Tighten torque 0 8 1 2kgf m Tighten exhaust pipe mounting bolt Tighten torque 2 4 3 0kgf m Install the removed parts in the reverse order of removal procedures Inspect following item after installation Test engine compression pressure Check for engine noise...

Page 63: ...7 A C Generator 7 1 Maintenance Information 7 2 Generator Removal 7 3 Generator Installation 7 4 3 5 4 5kgf m 0 8 1 2kgf m 0 8 1 2kgf m 0 8 1 2kgf m ...

Page 64: ... the scooter z Please refer to Chapter 15 for the relative A C generator inspection Torque value Flywheel 3 5 4 5kgf m Special Service Tools Flywheel puller Universal holder Coil resistance value for the A C generator Yellow blue Yellow Pink Earth Yellow blue 50 200Ω Yellow 0 2 0 8Ω Pink 0 2 0 8Ω Earth 50 200Ω PS L blue Y Yellow AC generator ...

Page 65: ...bolts and then take out cooling fan cover Remove 4 bolts and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel Remove the flywheel with flywheel puller Special tool 4 bolts 3 Bolts 10mm flanged nut Special tool ...

Page 66: ...ect the generator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove Caution z Clean dirt and metal pieces inside the flywheel z Make sure that there is no foreign material inside the flywheel Install the flywheel Tighten the flywheel 10 mm nut Torque value 3 5 4 5kgf m Install the removed parts in reverse order of removal procedures St...

Page 67: ... 1 Maintenance Information 8 2 Trouble Shooting 8 2 Left Crankcase Cover 8 3 Reassembly Of Kick Starter 8 4 Installation Of The Left Crankcase Cover 8 4 Drive Belt 8 5 Movable Drive Face 8 6 Clutch Driven Pulley 8 10 3 5 4 5kgf m 5 5 6 5kgf m ...

Page 68: ... pulley spring 87 9 OD of driven pulley 33 965 33 985 ID of movable driven face 33 000 ID Inner Diameter OD Outer diameter Torque Values Movable drive face 3 5 4 5kgf m Driven pulley plate 5 5 6 5kgf m Trouble Shooting Engine can be started but motorcycle cannot be moved 1 Worn drive Belt 2 Worn ramp plate 3 Worn or damaged clutch weight 4 Broken driven pulley spring Shudder or misfire when drive ...

Page 69: ...d thrust washer from left crankcase cover Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection of kick Starter Check if starter spindle driven gear for wear or damage Driven gear Thrust washer Friction spring Return spring Starter spindle Snap ring Kick start arm Bolt ...

Page 70: ...r temporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Installation of the Left Crankcase Cover Install the dowel pin and gasket Install the left crankcase cover Install kick start arm Kick starter spindle Convex part Friction spring Width tooth Return spring Driven gear Dowel ...

Page 71: ...ley Remove driven pulley clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Replace the belt if exceeds the service limit Caution y Using the genuine parts for replacement y The surfaces of drive belt or pulley must be free of grease y Clean...

Page 72: ...ghten nut to specified torque value Torque value 5 5 6 5kgf m Movable Drive Face Removal Remove fan cover and fan Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Remove drive face Drive belt Clutch outer Drive shaft Flywheel Nut Clutch driven pulley Drive face Nut Universal holder Drive face ...

Page 73: ...ller is to press movable driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wearing out or damage Replace it if necessary Measure each roller s outer diameter Replace it if exceed the service limit Ramp plate Movable drive face Weight roller Crankshaft Drive face boss Movable drive face Weight roller ...

Page 74: ... service limit Measure the inner diameter of drive face and replace it if it exceed service limit Reassembly Installation Install weight rollers Install ramp plate Apply with some grease to inside of movable drive face and install drive face boss Caution y The drive face has to be free of grease Clean it with cleaning solvent Weight roller Drive face boss Ramp plate Drive face Movable drive face ...

Page 75: ...o crankshaft Install drive face washer and nut Caution y Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to specified torque Torque value 3 5 4 5kgf m Install left crankcase cover Drive belt Universal holder Nut Drive face Flywheel Press down Movable drive face Crankshaft Drive face boss ...

Page 76: ...ompressor onto bench vise and then remove mounting nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven pulley and then remove O ring oil seal seat from sliding pulley Inspection Clutch outer Measure the inner diameter of clutch outer friction face Replace clutc...

Page 77: ...n pulley and the inner diameter of sliding pulley Replace it if exceeds service limit Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent Check if the bearing outer ...

Page 78: ... rubber is damage or deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch weight should not be greased If so replace it Caution y Grease or lubricant will damage the clutch weight and affect the weight s connection capacity Install the spring into groove with p...

Page 79: ...er bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Install new inner bearing Caution 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 hydraulic presser or driver Install snap clip into the groove of drive face Align o...

Page 80: ...utch 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 mounting nut to specified torque with clutch nut wrench Special tool Clutch spring compressor Clutch nut wrench Remove the clutch spring compressor Torque value 3 5 4 5kgf m Install clutch driven pulley and drive belt onto drive shaft...

Page 81: ...embly of Final Driving Mechanism 9 3 Inspection of Final Driving Mechanism 9 6 Bearing Replacement 9 7 Re Assembly of Final Driving Mechanism 9 8 Bearing 6201 Bearing 6203 Bearing 6201 Bearing 6203 Oil seal 17x30x6 Bearing 6004UU 1 0 1 5kgf m 2 4 3 0kgf m 1 0 1 5kgf m Oil seal 27x42x7 ...

Page 82: ...rque Values Mission cover bolt 2 4 3 0kgf m Mission oil drain bolt 1 0 1 5kgf m Mission oil check bolt 1 0 1 5kgf m Troubleshooting Trouble Diagnosis Engine can be started but scooter cannot be moved 1 Damaged drive gear 2 Burnt out or seized drive gear Noise 1 Seized worn or damage gear 2 Worn or loose bearing Gear oil leaks 1 Excessive gear oil 2 Worn or damage oil seal ...

Page 83: ...y Remove gear oil drain bolt and filling bolt Drain gear oil out from gearbox Remove muffler and rear wheel Remove gearbox cover mounting bolts from the clutch side 7 bolts Remove the mission cover from the rear wheel side Rear wheel nut Gear Oil filling bolt Gear Oil draining bolt 7 bolts ...

Page 84: ...st be replaced when removing the drive shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or Outer bearing puller Shaft protector Remove drive shaft oil seal and bearing from left crankcase Oil seal Drive shaft Counter shaft Final shaft Special tool ...

Page 85: ...st be replaced when removing the drive shaft Drive shaft is pulled out with it s bearing then remove the bearing with bearing puller and shaft protector Special tool Multi functional bearing puller or outer bearing puller Shaft protector Remove drive shaft oil seal and bearing from left crankcase Oil seal Drive shaft Counter shaft Final shaft Special tool ...

Page 86: ...sary Check if the final shaft and gear are burn wear or damage and replace it if necessary Check bearings on gearbox cover Rotate each bearing s inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage a...

Page 87: ... used bearings Once bearing removed it has to be replaced with new one Install new bearings into left crankcase Install new bearings into gearbox cover Special tool Bearing driver Apply with grease onto final shaft oil seal Install the oil seal into gearbox cover Special tool Oil seal driver Special tool Special tool Oil seal driver Oil seal Special tool ...

Page 88: ...pecial tool Drive shaft socket oil seal driver 17x30x6 Install 2 dowel pins new gasket Install counter shaft counter shaft side washer and final shaft into the gearbox Install the mission cover and tighten the bolts 7 bolts Torque value 2 4 3 0kgf m Install driven pulley clutch outer belt Install movable drive face drive face and left crankcase cover Install rear wheel Add gear oil Gear oil quanti...

Page 89: ...ankcase Crankshaft 10 1 Maintenance Information 10 2 Troubleshooting 10 2 Crankcase Disassembly 10 3 Crankshaft Removal 10 3 Crankshaft Inspection 10 4 Crankcase Installation 10 5 Apply sealant 0 8 1 2kgf m ...

Page 90: ...sm chapter 8 y When assembling both crankcase and crankshaft it has press the inner ring edge of the crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service tools The old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil seal has to be replaced with new one after assembled the crankcase It...

Page 91: ...al As the diagram show with 2 special bolts to install the specified service tool onto the left crankcase Remove the crankshaft Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with bearing puller Remove the right and left side oil seals Caution Replace the oil seal with new one as removing the crankshaft Right crankcase Outer bearing puller 7 Bolts Shaft protec...

Page 92: ...ing rod big end at X Y directions as diagram show Place the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Check the crankshaft bearing by means of turning it with hand If any noise and bigger clearance are detected replace the bearing with new one Radial 37mm Clearance 70mm A B Clearance Lateral ...

Page 93: ...e Special Tools Bearing driver6204 Install crankshaft onto the left crankcase Install left crankshaft puller and install bush onto crankshaft Screw the left crankshaft puller onto crankshaft Turn the puller in C W direction and then completely screw the puller to bottom Lubricate crankshaft bearing and bearing seat with 2 stroke engine oil Special Tools L Crank shaft puller L Crank shaft install b...

Page 94: ... them Torque value 0 8 1 2kgf m With right crankshaft install bush install new oil seal into the right crankcase Its installation depth is 4mm as the diagram shown With the specified tool to install a new oil seal onto the left crankcase to the depth of 1 mm as the diagram shown Caution Make sure that the crankshaft can be rotated freely after tightening the bolts Install the following components ...

Page 95: ...ANEL 11 8 SIDE COVER 11 9 UNDER COVER 11 10 Handle visor Handle front Top cover Inner box Front cover Under spoiler Front fender Right side cover Left side cover Floor panel Under cover Inner box cover Center cover Battery cover Right body cover Left body cover Rear carrier Inner fender Rear mudguard Rear fender Rear fender mudguard Splash board plate Rear handle cover R rear mirror L rear mirror ...

Page 96: ...sembly operation y Align the buckles on the guards 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 Left right side cover Front cover Luggage box Seat Rear carrier Under cover Front Handle cover Rear handle cover Floor panel Rear fender Tail light Front fender Front center cove...

Page 97: ...Removed the left right turn signal light connectors Remove the front handle cover Remove the speedometer cable Remove the rear handlebar cover 3 screws Removed the rear handle cover Installation Install according to the reverse procedure of removal Caution With the clipper to fix the end section of the handlebar cover Do not pull it forcedly to avoid to breaking the hooks turn signal light connect...

Page 98: ...ove the 1 mounting bolt of front cover from the frame Remove the front under cover 6 mounting screws between the front under cover and the frame Remove the 2 mounting screws between the front cover and the left right side cover bolt 1 Top cover Screws3 2 Screws1 2 ...

Page 99: ...r box Remove the front cover from the frame Installation Install according to the reverse procedure of removal FRONT INNER BOX Removal Remove the 8 mounting screws of front cover from the inner box A Remove the hook screw bolt from the front inner box 1 bolt Front cover screws 4 2 screws 4 2 ...

Page 100: ... inner box Installation Install the inner box A and the front inner box B according to the reverse procedure of removal BODY COVER REAR CENTER COVER REAR FENDER Removal Open the seat Remove 4 bolts in front of the luggage box Remove 2 bolts in rear of the luggage box Remove the luggage box Remove the rear carrier 3 bolts 2 screws 4 bolts 3 bolts 2 bolts Main switch cover ...

Page 101: ...y cover and the frame Remove the left right side 2 mounting bolts under rear of the body cover between the body cover and the frame Remove the rear fender Remove the left right body cover Installation Install the body cover and rear fender according to the reverse procedure of removal 2 screws 2 bolts Bolts1 2 ...

Page 102: ...e seat Remove the 4 bolts from 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 box Remove the luggage box and the double seat Remove the front center cover Remove the 2 bolts between the floor panel and the body cover 4 bolts screws 4 Front center co...

Page 103: ...stall the floor panel according to the reverse procedure of removal SIDE COVER Removal Remove the left right side 2 mounting screws in the front of the side cover Remove the left right side 2 mounting bolts in the rear of the side cover Remove the left right side cover Installation Install the side cover according to the reverse procedure of removal Screws1 2 2 screws Screws1 2 ...

Page 104: ...ove the floor panel Remove the left right side cover Remove the left right side 4 mounting bolts between the under cover and frame Remove the under cover Installation Install the under cover according to the reverse procedure of removal Bolts2 2 ...

Page 105: ...rmation 12 3 Troubleshooting 12 4 Hydraulic Disc Brake 12 5 Disc Brake Air Bleed 12 6 Disc Brake Caliper 12 7 Brake pad replacement 12 7 Brake Disc 12 9 Disc Brake Master Cylinder 12 9 Rear Drum Brake 12 12 Disc Brake System 2 4 3 0kgf m 2 4 3 0kgf m 3 3 3 7kgf m 3 3 3 7kgf m 1 0 1 4kgf m ...

Page 106: ...12 Brake System 12 2 Rear Drum Brake System 0 8 1 2kgf m 11 0 13 0kgf m 0 8 1 2kgf m ...

Page 107: ... not spill brake fluid on the painted surfaces plastic or rubber parts to avoid damage y Check the operation of the brake system before you go Specifications Item Standard mm The thickness of front brake disc 4 0 Front brake disc run out 0 10 brake master cylinder inner diameter 12 700 12 743 brake master cylinder piston outer diameter 12 657 12 684 OD of front brake disc 190 0 ID of rear brake dr...

Page 108: ...y brake lining disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel Drum Brake Poor brake performance 1 Improper brake adjustment 2 Worn brake lining 3 Worn brake drum 4 Worn brake cam 5 Improper brake lining installation 6 Seized brake cable 7 Dirty brake lining 8 Dirty brake ...

Page 109: ...ystem causing brake performance to be reduced or totally lost Connect drain hose to drain valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Close the drain valve and add specified brake fluid into the brake master cylinder Recommended brake fluid WELLRUN DOT 3 brakes fluid Caution To reuse the spent brake fluid will affect brake...

Page 110: ...n carrying out the air bleeding procedure to avoid air enters into the system Slowly release the brake lever and wait for a few seconds until it reaches its top position Repeat the steps 1 and 2 until there is no air bubble at the end of the hose Tightly close the drain valve Make sure the brake fluid is in the UPPER level of the master cylinder and refill the fluid if necessary Cover the cap Drai...

Page 111: ... value 2 4 3 0kgf m Caution y Use M8 x 35 mm flange bolt only y Long bolt will impair the operation of brake disc Use two seal washers and hose bolts to lock the hose and brake caliper in place Torque value 3 3 3 7kgf m Refill up the brake fluid to the reservoir and make necessary air bleeding Brake pad replacement Front brake Loosen the 2 pad guide pin bolts Remove brake caliper Remove the brake ...

Page 112: ...stall the new brake pads onto brake caliper Install the brake pad guide pin bolts Install the brake caliper and tighten the mounting bolts Torque value 2 4 3 0kgf m Tighten the lining guide pin bolts Torque value 1 5 2 0kgf m ...

Page 113: ...limit 0 30 mm Disc Brake Master Cylinder Master Cylinder Removal Caution y Do not let foreign materials enter into the cylinder y The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Remove the leads of brake light switch Drain out the brake fluid Remove the brake lever from the brake master cylinder Remove the brake hose Remove the master cylinder seat...

Page 114: ... y It is necessary to replace the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston 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 cup I...

Page 115: ...en the brake hose bolt to the specified torque value Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Improper routing may damage leads hoses or pipes Caution Kink of brake leads hose or pipe may reduce brake performance Add specified brake fluid and bleed the system Brake hose Master cylinder 2 bolts Washers ...

Page 116: ...drum for damage or wear out and replace it if necessary Measure the inner diameter of brake drum and record the max value Caution y Clean the rust onto the brake drum with 120 sandpaper y Measure the inner diameter of brake drum with micrometer Measure the thickness of brake lining at three points both ends and center If the thickness is less than specified value or if it is contaminated by oil or...

Page 117: ...m after aligning it with the punched point Tighten the bolts and nuts to specified torque Torque value 0 8 1 2kgf m Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated Caution Brake efficiency will be reduced if brake lining is contaminated by oil or grease Install spring onto the brake shoes Install the brake shoes to the brake panel one after ...

Page 118: ...12 Brake System 12 14 Notes ...

Page 119: ...l Front Cushion 13 1 Maintenance Information 13 2 Troubleshooting 13 2 Steering Handle 13 3 Front Wheel 13 5 Front Cushion 13 8 Steering Stem 13 9 4 0 5 0kgf m 2 4 3 0kgf m 1 0 1 2kgf m 2 4 3 0kgf m 5 0 7 0kgf m 1 0 1 4kgf m ...

Page 120: ...aring driver 6201 Troubleshooting Hard To Steer 1 The steering shaft bolt is too tight 2 The steering shaft bearing are damaged 3 The ball and the top cone of the steering shaft are damaged 4 Insufficient tire pressure The Steering Handle Is Tilted 1 Uneven arrangement of the front cushions 2 The front fork is bent 3 The front wheel axle is bent The Front Wheel Wobbling 1 The rim is bent 2 The whe...

Page 121: ...13 Steering Front Wheel Front Cushion 13 3 Steering Handle Removal Remove handle cover and front cover refer to chapter 11 Remove front brake master cylinder disc brake after 2 bolts removed 2 bolts ...

Page 122: ... right handle switch Tighten the screws 2 screws Align the lock pin of the left handle switch with the hole on the handle and then install the left handle switch Tighten the screws 2 screws Check hoses and cords dispose Install all components in reverse order of removal procedures Conduct following adjustment y Oil pump control cable y Throttle operation y Brake lever free play drum brake Handle m...

Page 123: ... front wheel axle nut and then pull out the axle and remove the wheel Inspection Place the axle onto a V block to measure its run out with a dial gauge The dial gauge indicated 1 2 run out Place the wheel on to a rotation seat and turn the wheel to check its bearing free play If the bearing is noisy or its free play is too much replace it Speedometer cable Axle nut Wheel axle Free play Free play ...

Page 124: ... Remove left side dust seal bearing and dist collar Special tools Inner bearing puller Installation Fill out the block of bearing by grease Drive the left bearing dust seal into wheel rim and install the dist collar Install the right bearing and dust seal Caution y Carefully install the bearing in correct and evenly y Bearing outer face should be faced up as bearing installation 5 bolts Dust seal ...

Page 125: ...erformance so the brake lining brake drum and disc must be free of grease Apply with grease onto the left side dust seal Install the left side collar Place the front wheel between the front cushions Caution Align the front cushion groove with the speedometer gear box stopper flange Insert the wheel axle into the wheel and then install the wheel axle nut Tighten the nut to specified torque Torque v...

Page 126: ...lt and the caliper Take out the hose from hose clamp Remove the front cushion upper bolts and the front cushion Installation Align the cover flange with upper level of the cushion clamp and then tighten bolts Torque value 2 4 3 0kgf m Install the removed components in reverse order of removal procedures 2 bolts Hose clamp 4 bolts Brake caliper ...

Page 127: ...tem Push the cone race until to mounted position Caution Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 29 balls Lubricate the top cone race seat with grease Screw the cone race in to top ball bearing seat till touching and then screw out the cane race 1 4 3 8 turns Caution Check the steeri...

Page 128: ... Cushion 13 10 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 0 1 2kgf m Install in reverse order of removal procedures Steering stem mounting nut Top cone race ...

Page 129: ...14 Rear Wheel Rear Cushion 14 1 Maintenance Information 14 2 Troubleshooting 14 2 Rear Wheel 14 3 Rear Cushion 14 5 11 0 13 0kgf m ...

Page 130: ... m Bolts for the brake disc 2 4 3 0kgf m Exhaust pipe connection nut 1 0 1 4kgf m Exhaust muffler mounting bolt 2 4 3 0kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft Cushion too soft 1 Insufficient cushion spring force Poor brake performance 1 Poor brake adjustment 2 Contaminated brake lining 3 Worn brake lining cam 4 Worn brake cam lever 5 Worn brake d...

Page 131: ...haust pipe nut 2 connection nuts Remove exhaust muffler bolt 3 bolts then remove the muffler Remove rear wheel shaft nut and then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Bolts Connection nuts Shaft nut ...

Page 132: ... Brake disc removal install Installation Install the rear wheel and tighten the nut Tighten torque 11 0 13 0kgf m Install exhaust pipe muffler Tighten torque bolt 2 4 3 0kgf m Tighten torque nut 0 8 1 2kgf m Shaft nut 2 nuts 3 bolts ...

Page 133: ...tallation Install the rear cushion Tighten the upper lower mounting bolts to specified torque Torque value Upper mounting bolt 3 5 4 5kgf m Lower mounting bolt 2 4 3 0kgf m Press down the tail of the scooter for several times to check cushion operation Install all components in reverse order of removal procedures Upper mounting bolt Lower mounting bolt ...

Page 134: ...14 Rear Wheel Rear Cushion 14 6 Note ...

Page 135: ...HARGING SYSTEM 16 5 IGNITION SYSTEM 16 11 STARTING SYSTEM 16 14 METER 16 15 LIGHTS BULBS 16 17 SWITCH 16 19 FUEL UNIT 16 22 MECHANISM DIAGRAM Spark Plug AC Generator Fuse Battery IG Coil Fuel Unit Main Switch Reg Rec Comp Horn Resistor Comp Winker Relay CDI Unit Oil Level Switch Thermo Switch Carburetor heater ...

Page 136: ...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 devices when current is passing these devices because this will generate high voltage and the electrical components in the voltage current regulator will be damaged The ignition switch must be turned OFF ...

Page 137: ...ours standard 3A 1 hour fast charging Leak current 1 mA Charging current 2 1 A 5000 rpm Control voltage in charging 14 0 15 0 V 5000 rpm Ignition System Item Specification Model NGK BR8HSA Recommended Spark plug Gap 0 6 0 7 mm Primary coil 0 19 0 23 Ω Ignition coil and resistance Secondary coil 2 8 3 4 KΩ Ignition timing F mark 13 BTDC 1700 rpm ...

Page 138: ...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 ignition coil Poor spark plug Poor high tension cable Current leakage in the spark plug cap z Incorrect ignition timing Poor alternator Improper installation of the pulse sensor Poor C D I Starting System S...

Page 139: ...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 leakage test set the current range at larger scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse z Do not turn the main switc...

Page 140: ...ort connect positive terminal at first and next negative terminal z Electrolyte 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 send to hospital z When clothes is spread by electrolyte it will contact with skin So it must flush with great quantity water to tak...

Page 141: ...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 switch OFF at first before or after charging to prevent from sparks created on the connectors and explosion z To charge a battery must be based on the battery s ampere hour showed on label z Quick charge ...

Page 142: ... 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 have enough electricity or is over charged z The fuse of the ammeter is blown z The ammeter is improperly connected 3 The charging current is normal but the voltage is not z The fuse of the voltmeter is ...

Page 143: ...ured 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 If main wire circuit check is in normal and there is no loose in the pins of voltage regulator connector then measure the resistance between the connector of voltage regulator Voltage Regulator Check Unit Ω Multi meter M...

Page 144: ...r Measure the resistance between the yellow wire on the alternator and frame ground by multi meter Standard 0 8 0 1Ω 20 Replace the alternator lighting coil if the measured value exceeds standard Resistor check Remove the front cover Measure the resistance between the resistor wire green black and frame ground Standard 5Ω 5W 4 5 5 5 green black Standard 7 5Ω 30W 7 0 8 0 pink The check of alternato...

Page 145: ...ion at each terminal of the harness side connector ITEM Measure at Standard at 20C Pulse Generator Blue Yellow green 50 200Ω Primary Black yellow green 0 21Ω 10 Green high voltage cable w o cap 3 5KΩ Ignition Coil Secondary Green high voltage cable w cap 7 12KΩ CDI UNIT spark plug Ignition coil C D I unit Pluser green black yellow Blue yellow green Black green Black green Blue yellow green Black y...

Page 146: ... 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 black yellow side Min voltage Above 95 V Caution Primary coil check Disconnect the primary coil connector and check the resistance between primary coil terminals Standard 0 21Ω 10 Ω at 20 Primary coil i...

Page 147: ...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 Check Remove body cover Remove the pulse generator connector Measure the resistance between blue yellow terminal on engine side and frame ground Standard 140 20Ω 20 Replace the alternator if the meas...

Page 148: ...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 switch large pins Connect the green yellow wire to battery positive terminal and yellow red to battery negative terminal Check the continuity between the Starter magnetic switch large pins If it is n...

Page 149: ...ter motor pinion in reverse order of removal Starter Motor Pinion Inspection y Pinion reduction gear for wear out or damage replace it with new one y Gear journal for wear out or damage replace it with new one Check the pinion for sliding in axial direction smoothly y The pinion sliding in axial direction not in smooth replace it with new one Starter motor pinion ...

Page 150: ...r other damage It may be short circuiting if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces It can be in continuity among the shifter surfaces but both the shifter surface and the shaft cannot be in continuity Starter Motor Re Assembly Installation Re assemble and install t...

Page 151: ...ge between wire and ground Removal Installation Remove luggage box Drain out oil from oil outlet tube Pull up oil level switch and then remove oil level switch from the oil tank Install the oil level switch in reverse order of removal procedures Indicator light up Indicator not light up Short circuit between indicator and oil level switch Malfunction of oil level switch Indicator not light up Indi...

Page 152: ...ns Remove carburetor heater Inspection Carburetor heater resistance 7 10 Ω Remove power filter coupler and thermo switch coupler and then remove power filter and thermo switch Main switch Power filter Fuse 10A Battery Y AC Generator To REG REC G B G B W Y R Thermo switch G Wire pins Carburetor heater Thermo switch coupler Power filter Carburetor heater ...

Page 153: ...ank as installation and then turn the retain plate in clockwise direction until matching to the arrow Inspection 1 Connect the fuel unit coupler Turn the main switch ON Move the float in up and down and make sure that the fuel indicator can be reached to F Full and E Empty positions Conduct the step 2 if the needle on the fuel indicator is not moved 2 Measure the coupler resistance while the float...

Page 154: ...light Meter illuming light Hi beam indicate light Headlight Hi beam Headlight Lo beam Headlight beam switch Winker switch Winker relay Main switch Fuse 10A Battery Right winker indicate light Left winker indicate light Right winker light Left winker light R B GR SB O W L L B GY G ...

Page 155: ...emove 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 Removal Remove the front handle cover Remove the speedometer cable Remove the front cover Remove the power connector of the meter Bolts x2 Meter connector Meter speedometer cable ...

Page 156: ... not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components Odometer Trip kilometer Speedometer Turn Left Signal Indicator High Beam Indicator Fuel meter Turn Right Signal Time meter Fuel Gauge Turn Right Signal Indicator Turn Left Signal Indicator High Beam Indicator Engine Oil Warning Light Speedometer Clock Odometer Trip kilometer ...

Page 157: ...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 located under the headlight Caution z Do not touch the bulb surface with fingers because the bulb will create hot spot so that let it be burnt It has to be package with cloth or wear glove as installing z Wipe the bul...

Page 158: ...f removal Bulbs Replacement of tail light brake light rear turn signal light Remove the 2 screws of the taillight left right turn light lens Remove the tail light assembly Replace the bulbs of the tail light brake light 12V 5W 21W Replace the bulbs of the turn signal light 12V 10W Installation Install the bulb in reverse order of removal the wire connector of the turn signal light tail light brake...

Page 159: ...nect main switch leads connector Check connector terminals for continuity color Location Black Red green green LOCK OFF ON Replacement Remove the main switch connector and fixing bolts bolts x 2 Remove the main switch Install a new main switch and tighten the bolts bolts x2 main switch connector terminals main switch bolts x 2 ...

Page 160: ...cation Yellow red green FREE High Low beam switch passing color Location blue white brown white White green passing Horn switch color Location Black Light green FREE headlight switch starting switch turn signal switch High Low beam switch passing horn switch brown brown white yellow red green headlight switch Starting switch yellow pink yellow brown white Black white Horn switch Light green High L...

Page 161: ...ow wire on the 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 battery positive terminal and the green wire to the battery negative terminal Then the horn should sound Replace it if necessary Sky blue gray turn signal light switch orange ...

Page 162: ...7 5 107 5Ω F full 4 10Ω 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 unit indication needle is in correct position Caution Float arm position Indicator needle UP full E empty DOWN empty F full Installation Install the fuel unit in reverse order of removal Do not damage or bend the float arm as removin...

Page 163: ......

Page 164: ...NO SYM 9020100 PURPOSE REMOVE ONE WAY CLUTCH FIX NUT ITEM BEARING DISASSEMBLER NO SYM 6202Z 6204 PURPOSE REMOVE THE BEARING ITEM UNIVERSAL HOLDER NO SYM 2210100 PURPOSE HOLD THE MDF CLUTCH OUTER ITEM CLUTCHSPRING COMPRESSOR NO SYM 2301000 PURPOSE DISASSEMBLE THE CLUTCH ITEM CLUTCH NUT WRENCH NO SYM 9020200 PURPOSE LOOSE THE CLUTCH NUT ...