SANYANG ATTILA RS-21 EFi 150 Service manual

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SERVICE MANUAL
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This service manual contains the technical data of each component
inspection and repair for the SANYANG ATTILA RS-21 EFi 150 motorcycle.
The manual is shown with illustrations and focused on “Service Procedures”,
“Operation Key Points”, and “Inspection Adjustment” so that provides technician
with service guidelines.
If the style and construction of 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 data, illustration, indication and specifications
is based on current production information. SANYANG reserves the right to
make changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SANYANG.
Service Department
SANYANG Industry Co., LTD.
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Contents
How to Use This Manual
This service manual describes basic information of different system parts
and system inspection & service for SANYANG ATTILA RS-21 EFi 150
motorcycles. In addition, please refer to the manual contents in detailed for
the model you serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance and special service tools
information.
The third to the eleventh chapters cover engine, fuel injection and driving
systems.
The twelfth to fifteenth chapters are contained the parts set of assembly
body.
The sixteenth chapter is electrical equipment.
The seventh chapter is exhaust emission control system.
The eighteenth chapter is for wiring diagram
Please see index of content for quick having the special parts and system
information.
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Contents
Page
Content
Index
1-1 ~ 1-16
General Information / Trouble Diagnosis
1
2-1 ~ 2-16
Service Maintenance Information
2
3-1 ~ 3-8
Lubrication System
3
4-1 ~ 4-38
Fuel System
4
5-1 ~ 5-10
Engine Removal
5
6-1 ~ 6-16
Cylinder Head / Valve
6
7-1 ~ 7-8
Cylinder / Piston
7
8-1 ~ 8-14
“V” Type Belt Driving System / Foot-Starter
8
9-1 ~ 9-6
Final Driving Mechanism
9
10-1 ~ 10-10 Alternator / Starting Clutch
10
11-1 ~ 11-6
11
Crankcase/Crankshaft
12-1 ~ 12-14 Body Cover
12
13-1 ~ 13-10 Brake System
13
14-1 ~ 14-8
Steering/Front Wheel/Suspension
14
15-1 ~ 15-6
Rear Wheel/Suspension
15
16-1 ~ 16-18 Electrical Equipment
16
17-1 ~ 17-8
Exhaust Emission Control System
17
18-1 ~ 18-2
Electrical Diagram
18
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Contents
Model illustration
Battery / fuse
Engine temperature sensor
Spark plug
Winker relay
Crankshaft position sensor
Horn
IG. Coil /
Start relay /
Fuel pump relay
Fuel tank /
Fuel pump
Intake temperature
& MAP sensor
(T-MAP)
Engine control unit
(ECU)
Throttle position sensor (TPS) /
Air by-pass valve /
Fuel injector /
Seat lock
Front winker light
Tail light /
Rear winker light
Headlight
Air cleaner
Gear oil
Inspection plug
Engine number
Engine oil drain plug
Gear oil drain
plug
Light /
Starter switch
Rear
brake
lever
Ignition switch
Front brake
lever
High & Low
beam /
Passing /
Turn signal /
Horn switch
Oil level
Oil strainer
Exhaust
muffler
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Contents
1. General Information/Trouble Diagnosis
Symbols And Marks.................. 1-1
Torque Values (Frame) ........... 1-11
General safety ........................... 1-2
Standard Torque Values for
Reference................................. 1-11
Service Precautions.................. 1-3
Specifications............................ 1-9
Torque Values (Engine) .......... 1-10
Troubles Diagnosis................. 1-12
Parts To Be Greased............... 1-16
Symbols And Marks
Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information is procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Means that serious injury or even death may result if procedures are
Warning
not followed.
Caution
Engine oil
Means that equipment damages may result if procedures are not
followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover
the damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
Grease
King Mate G-3 is recommended. (KING MATE G-3)
Gear oil
King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended.
(SAE 85W-140)
Locking sealant
Apply sealant, medium strength sealant should be used unless
otherwise specified.
Oil seal
Apply with lubricant.
Renew
Replace with a new part before installation.
Brake fluid
Use recommended brake fluid “DOT3” or “WELLRUN” brake fluid.
Special tools
Special service tools.
correct
Meaning correct installation.
wrong
Meaning wrong installation.
Indication
Indication of components.
directions
Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt
cross through the component (invisibility).
1-1
1
This chapter Contents
1. General Information/Trouble Diagnosis
General safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a
closed area. Run your engine in an open area, if
you have to run your engine in a closed area, be
sure to use an extractor.
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no
flame or spark should be allowed in the work
place or where gasoline is being stored.
Caution
Gasoline is highly flammable, and may
explode under some conditions, keep it away
from children.
Used engine oil
Caution
Battery
Caution
• Battery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
• Battery contains sulfuric acid (electrolyte)
which can cause 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
immediately with water, then go to hospital
to see an ophthalmologist.
• 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.
• Keep electrolyte beyond reach of children.
Brake shoe
Do not use an compressed air or a dry brush to
clean components of the brake system, use a
vacuum cleaner or the equivalent to avoid
asbestos dust flying.
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verdict.
We recommend that you wash your hands
with soap and water right after contacting.
Keep the used oil beyond reach of children.
Inhaling asbestos dust may cause disorders
and cancer of the breathing system.
Brake fluid
Caution
Hot components
Caution
Components of the engine and exhaust
system can become extremely hot after
engine running. They remain very hot even
after the engine has been stopped for some
time. When performing service work on these
parts, wear insulated gloves and wait until
cooling off.
1-2
Spilling brake fluid on painted, plastic, or
rubber parts may cause damage to the
parts. Place a clean towel on the
above-mentioned parts for protection when
servicing the brake system. Keep brake fluid
beyond reach of children.
This chapter Contents
1. General Information/Trouble Diagnosis
Service Precautions
• Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts
for SANYANG motorcycle may damage the
motorcycle.
• Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
• Never bend or twist a control cable to prevent
stiff control and premature worn out.
• Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
• When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
• Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
• When servicing this motorcycle, use only
metric tools. Metric bolts, nuts, and screws are
not interchangeable with the English system,
using wrong tools and fasteners may damage
this vehicle.
• Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on
the part's surface may fall into the engine,
chassis, or brake system to cause a damage.
• Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay • Note the reassemble position of the important
components before disassembling them to
special attention to O-rings or oil seals
ensure they will be reassembled in correct
because most cleaning agents have an
dimensions (depth, distance or position).
adverse effect on them.
• Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
This chapter Contents
1. General Information/Trouble Diagnosis
• The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length out side the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
• Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
• 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 enough
room below the enlarged ends for tightening
the clamps.
Groove
• Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
Clamp
Connector
• Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
Boots
• When oil seal is installed, 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 damage
the oil seal.
• The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Manufacturer's name
Both of these examples can result in bearing
damage.
1-4
This chapter Contents
1. General Information/Trouble Diagnosis
• Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
• Before battery removal operation, it has 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.
• Check if positions and operation for installed
parts is in correct and properly.
• After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
And the two posts of battery have to be
greased after connected the cables.
• Make sure service safety each other when
conducting by two persons.
• Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.
• Note that do not let parts fall down.
• If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
capacity
verification
1-5
This chapter Contents
1. General Information/Trouble Diagnosis
• When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
• Before terminal connection, check if the boot is
crack or the terminal is loose.
• Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
• Do not pull the wires as removing a connector
or wires. Hold the connector body.
• Make sure if the connector pins are bent,
extruded or loosen.
• Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
• Wire band and wire harness have to be
• Insert the connector completely.
clamped secured properly.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
• Check if the connector is covered by the twin
connector boot completely and secured
properly.
1-6
• Do not squeeze wires against the weld or its
clamp.
This chapter Contents
1. General Information/Trouble Diagnosis
• Do not let the wire harness contact with
rotating, moving or vibrating components as
routing the harness.
• Keep wire harnesses far away from the hot
parts.
• 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 applied.
• Secure the rubber boot firmly as applying it on
wire harness.
NEVER TOUCH
•
Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
• Route harnesses so that they neither pull too
tight nor have excessive slack.
• Never use wires or harnesses which insulation
has been broken. Wrap electrical tape
around the damaged parts or replace them.
• Never clamp or squeeze the wire harness as
installing other components.
Never clamp or
squeeze the wire
harness
NEVER TOO
TIGHT
1-7
This chapter Contents
1. General Information/Trouble Diagnosis
• Do not let the wire harness been twisted as
installation.
• With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
•
Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
•
Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its measurement
position and the insert
locations of its two probes?
1-8
This chapter Contents
1. General Information/Trouble Diagnosis
Specifications
Overall Length
1933 mm
Overall Width
700 mm
Overall Height
1160 mm
Wheel Base
1335 mm
Curb
WEIGHT
Weight
Front
48 kg
Rear
75 kg
Total
123 kg
Passengers/
Weight
Total
Weight
Two /110 kg
Front
78 kg
Rear
155 kg
Total
233 kg
MODEL
HE15W
Suspension
System
Front
Tire
Specifications
Front
100 / 90-12 (T/L)
Rear
130 / 70 –12 (T/L)
Brake System
Rear
TELESCOPE
UNlT
SWING
Front
DISK (ø 273 mm)
Rear
DISK (ø 200 mm)
PERFOR Max. Speed
MANCE
Climb Ability
Primary
Reduction
Secondary
Reduction Reduction
Clutch
100 km/hr Above
28° Below
BELT
GEAR
Type
4-STROKE ENGINE
Installation and
arrangement
Vertical, below center,
incline 80°
Fuel Used
Unleaded
Speedometer
0 ~ 140 km/hr
Cycle/Cooling
4-stroke/forced air
cooled
Horn
70~90 dB/A
Bore
57.4 mm
Muffler
Expansion & Pulse Type
Stroke
57.8 mm
Exhaust Pipe Position
and Direction
Right side, and
Backward
Number/Arran
gement
Single Cylinder
Lubrication System
Separated-lubrication
Cylinder
ENGINE
SANYANG
Transmission
Exhaust
Concentration
DIMENSION
Maker
Centrifugal, dry type
C.V.T.
Solid
Particulate
-
CO
Below 4 %
HC
Below 2000 ppm
Displacement
149.5 cc
Compression
Ratio
9.6 : 1
Max. HP
12.4 ps / 8500 rpm
Max. Torque
1.15 kg-m / 6500 rpm
E.E.C.
YES
Ignition
C.D.I.
P.C.V.
YES
Starting System
Power & Foot
Catalytic reaction
control system
NO
1-9
This chapter Contents
1. General Information/Trouble Diagnosis
Torque Values (Engine)
Q’ty
Thread Dia.
(mm)
Torque
Value(Kg-m)
Cylinder head bolts
4
6
1.0~1.4
Cylinder head nuts
4
8
2.0~2.4
Cylinder/cylinder head two-ends
bolts
4
8
0.7~1.1
Cylinder head left bolts
4
6
1.0~1.4
Valve adjustment fixing nuts
4
5
0.7~1.1
Cylinder head left cover bolts
2
6
1.0~1.4
Spark plug
1
10
1.0~1.2
Carburetor heat protector
connecting nuts
2
6
0.7~1.1
Engine oil draining plug
1
12
3.5~4.5
Engine oil strainer cap
1
30
1.0~2.0
Gear oil draining plug
1
8
0.8~1.2
Gear oil filling bolt
1
10
1.0~1.4
Oil pump screws
3
3
0.1~0.3
Engine left side cover bolts
8
6
1.0~1.5
Rubber washer attached
Camshaft chain tensioner bolt
1
6
0.35~0.5
Hex socket bolt
Camshaft chain adjuster bolts
1
6
0.8~1.2
Clutch driving plate nut
1
28
5.0~6.0
Clutch outer bracket nut
1
12
5.0~6.0
Driving disk nut
1
12
5.0~6.0
Flywheel nut
1
12
5.0~6.0
One-way clutch tighten bolts
3
6
1.0~1.4
Apply locking sealant
One-way clutch nut
1
22
9.0~10.0
Apply oil to thread
Crankcase bolts/right crank
cover bolt
12
8
1.5~2.0
Gear box cap bolts
7
8
2.0~2.4
Exhaust pipe bolts
2
8
3.0~3.6
Exhaust pipe connection nut
2
7
0.5~1.0
Item
1-10
Remarks
Tighten to crankcase
Apply oil to thread
This chapter Contents
1. General Information/Trouble Diagnosis
Torque Values (Frame)
Q’ty
Thread Dia.
(mm)
Torque
Value(Kg-m)
1
10
4.0~5.0
1
25.4
1.0~2.0
Cone seat for steering rod
1
25.4
0.2~0.3
Front wheel shaft nut
1
12
5.0~7.0
Rear wheel shaft nut
1
16
11.0~13.0
Wheel hub/rim mounting nuts
Speedometer cable locking
screw
Front shock absorber mounting
bolts
Rear shock absorber upper
connection bolt
Rear shock absorber upper
connection bolt
Brake lever bolts
1
5
0.15~0.3
4
8
2.4~3.0
1
10
3.5~4.5
1
8
2.4~3.0
4
6
1.0~1.4
2
4
0.1~0.2
Front brake hose bolts
2
6
1.0~1.4
Front brake air-bleeding valve
2
10
3.0~4.0
Front brake disc mounting bolts
Front brake clipper mounting
bolts
Drum brake arm bolts
(front/rear)
Engine suspension bracket
bolts
Engine connection bolt
1
6
0.7~1.1
4
8
4.0~4.5
2
8
2.9~3.5
2
10
4.5~5.5
On frame side
1
12
5.0~7.0
On engine side
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
Item
Mounting bolt for steering
handlebar
Mounting nut for steering rod
Remarks
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference
Type
5mm bolt、nut
Tighten Torque
0.45~0.60 kgf-m
Type
3mm screw
Tighten Torque
0.05~0.08 kgf-m
6mm bolt、nut
0.80~1.20 kgf-m
4mm screw
0.10~0.15 kgf-m
8mm bolt、nut
1.80~2.50 kgf-m
0.35~0.50 kgf-m
10mm bolt、nut
3.00~4.00 kgf-m
5mm screw
6mm screw、SH nut
0.70~1.10 kgf-m
12mm bolt、nut
5.00~6.00 kgf-m
6mm bolt、nut
1.00~1.40 kgf-m
8mm bolt、nut
2.40~3.00 kgf-m
10mm bolt、nut
3.50~4.50 kgf-m
1-11
This chapter Contents
1. General Information/Trouble Diagnosis
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment
Fault condition
Probable causes
1. No fuel in fuel tank
Loosen carburetor drain bolt to
check if there is gasoline
inside the carburetor
2. Check if the pipes, fuel tank to fuel
injector and intake vacuum, are clogged.
3. Malfunction of fuel pump relay or poor
wire connection
Fuel supplied to fuel
injector sufficient
No fuel is supplied to
fuel injector
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
Remove spark plug, install
it into spark plug cap, and
perform a spark test
against engine ground.
6. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of ECU
Check if spark.
Weak spark, no spark at
all.
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
Perform cylinder
compression pressure
test.
7. Malfunction of main switch
1. Piston ring seized
砂孔
cylinder compression
pressure normal
Low compression
pressure or no pressure.
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Leak in compression parts
Re-start by following the
starting procedures.
1. Malfunction of throttle valve operation
No ignition
There are some signs of
ignition, nut engine can
not be started.
2. Air sucked into intake manifold
3. Incorrect ignition timing
Remove the spark plug
again and check it.
1. Dirt or clogged fuel injector
Dry spark plug
Wet spark plug
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
1-12
This chapter Contents
1. General Information/Trouble Diagnosis
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment
Fault condition
Probable causes
Try gradual acceleration
and check engine speed
1. Air cleaner clogged
2. Poor fuel supply
Engine speed can be
increased.
Engine speed can not
be increased.
3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
5. Fuel injector clogged
Check ignition timing
(Using ignition lamp)
Ignition timing correct
Incorrect ignition timing
1. Malfunction of ECU
2. Malfunction of AC alternator
Check cylinder
compression pressure
(using compression
pressure gauge)
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
Compression pressure
correct
No compression
pressure
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
Check if fuel injector is
clogged
No clogged
Clogged
1. Replace fuel injector
Remove spark plug
No foul or discoloration
Fouled and discoloration
1. Remove dirt
2. Incorrect spark plug heat range
Check if engine over heat
1. Piston and cylinder worn out
2. Injector clogged
Normal
Engine overheat
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
Continually drive in
acceleration or high
speed
5. Ignition timing too advanced
No knock
Knock
1. Too much carbon deposited in
combustion chamber
2. Malfunction of fuel injector
3. Poor fuel quality
4. Ignition timing too advanced
1-13
This chapter Contents
1. General Information/Trouble Diagnosis
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment
Fault condition
Probable causes
Check ignition timing
(using ignition lamp)
Normal
Abnormal
1. Incorrect ignition timing (malfunction of
ECU or AC alternator)
Check If air sucked through
throttle valve gasket
1. Heat insulation gasket to damage
No air sucked
Air sucked
2. Throttle valve lock loose
3. Intake gasket to damage
4. By-pass hose crack
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
1. Spark plug fouled
2. Malfunction of ECU
3. Malfunction of AC generator
Good spark
Poor spark
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
D. Engine runs sluggish (High speed)
Check and adjustment
Fault condition
Probable causes
Check ignition timing
Normal
Abnormal
1. Malfunction of ECU
2. Malfunction of AC alternator
Check for fuel supplying
system in fuel pump
1. Insufficient fuel in fuel tank
Good
Poor
2. Fuel line clogged
3. Restricted fuel tank EEC line
Check if fuel injector is
clogged
No clogged
1-14
Clogged
1. Replace fuel injector
This chapter Contents
1. General Information/Trouble Diagnosis
E. Clutch, driving and driving pulley
FAULT CONDITIONS
PROBABLE CAUSES
1. Drive belt worn out or deformation
2. Ramp plate of movable drive face damaged
Engine can be started but
motorcycle can not be moved.
3. Driving pulley spring broken
4. Clutch weights broken
5. Drive slide-shaft gear groove broken
6. Transmission gear damaged
Engine running and misfire as
motorcycle initial forward moving
or jumping suddenly (rear wheel
rotating as engine in running)
1. Clutch weights spring broken
2. Clutch outer stuck with clutch weights
3. Connection parts in clutch and shaft worn out or
burned
1. Drive belt worn out or deformation
Poor initial driving ( Poor climbing
performance)
2. Weight roller worn out
3. Movable drive face shaft worn out
4. Driven pulley spring deformation
5. Driven pulley shaft worn out
6. Greased in drive belt and driven face.
1-15
This chapter Contents
1. General Information/Trouble Diagnosis
Parts To Be Greased
Acceleration cable/ Front & rear
brake lever pivot
Seat lock
Steering shaft bearing
Speedometer gear/
front wheel bearing
1-16
Side stand pivot
Main stand pivot
Rear wheel bearing
Home page
Contents
2. Maintenance Information
Precautions In Operation .......... 2-1 Spark Plug .................................. 2-8
Periodical Maintenance
Cylinder Compression
Schedule ..................................... 2-2 Pressure...................................... 2-9
Lubrication System.................... 2-3 Driving System ........................... 2-9
Gear Oil ....................................... 2-4 Steering System ....................... 2-10
Fuel System................................ 2-4 Suspension System ................. 2-10
Air Cleaner.................................. 2-5 Disk Brake System (Front/Rear
Disk Brake) ............................... 2-11
Throttle Valve Operation ........... 2-5
Wheel / Tire ............................... 2-13
Crankcase Ventilation ............... 2-6
Battery....................................... 2-14
Valve Clearance Adjustment..... 2-6
Headlamp Adjustment ............. 2-14
Valve Clearance Inspection
And Adjustment ......................... 2-7 Nuts, Bolts Tighteness ............ 2-14
Idle Speed / Exhaust Gas
Special Service Tools
Adjustment ................................. 2-7 Catalogue.................................. 2-15
Ignition System .......................... 2-8
Precautions In Operation
Specification
Fuel Tank Capacity
6100 c.c.
1000 c.c.
800 c.c.
110 c.c.
Transmission Gear oil
100 c.c.
Clearance of throttle valve
2~6 mm
Spark plug
NGK CR8E Gap: 0.8 mm
“F” Mark in idling speed
BTDC 13º / 1600 rpm
Full timing advanced
BTDC 34º / 8000 rpm
Idling speed
1600±100 rpm
Cylinder compression pressure
12 ± 2 kgf/cm²
Valve clearance: IN/EX
0.12 ± 0.02 mm
Front
100/90-12 59J (T/L)
Tire dimension
Rear
130/70-12 59J (T/L)
Single
Front: 1.75 kg/cm² rear : 2.25 kg/cm²
Tire pressure (cold)
Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²
Battery
12V8Ah (MF battery) type: YTX9A-BS (8Hr)
Engine Oil
Capacity
Change
Capacity
Change
2-1
2
This chapter Contents
2. Maintenance Information
Periodical Maintenance Schedule
Maintenance
Code
item
Initial
300KM
1 Month
every1000KM
3 month
every3000KM
6 month
1 year
every6000KM every12000KM
1
☆Air cleaner
I
C
C
R
2
☆2nd air jet cleaner
I
C
C
R
3
☆Fuel filter
I
I
R
4
☆Oil filter
C
C
C
5
☆Engine oil change
R
Replacement for every 1000km
6
Tire pressure
I
7
Battery inspection
I
I
8
Brake & free play check
I
I
9
Steering handle check
I
I
10
Cushion operation check
I
I
11
Every screw tightening check
I
I
12
Gear oil check for leaking
I
I
13
☆Spark plug check or change
I
14
☆Gear oil change
R
I
I
R
Replacement for every 5000km
15
Frame lubrication
16
Exhaust pipe
17
☆Ignition timing
I
I
18
☆Emission check in Idling
A
I
19
☆Throttle operation
I
I
20
☆Engine bolt tightening
I
I
21
☆CVT driving device(belt﹞
I
22
☆CVT driving device(roller)
C
L
I
I
23
Lights/electrical equipment/mutli-meters
I
24
Main/side stands & springs
I
25
Fuel lines
I
I
27
Cam chain
I
I
I
I
28
☆Valve clearance
I
A
29
☆Crankcase vapor control System
I
C
30
☆Crankcase blow-by over-flow pipe
I
31
☆2nd air jet system
I
32
☆vapor control system
33
Throttle body
34
Input signals from EFI ECU
35
R
Replacement for every 2000km
I
C
I
A
I
A
C
I
Sensors of EMS fuel injector
I - Inspection, A-Adjustment R- Replacement C- Cleaning L- Lubrication (The 33rd, 34th, and 35th items are
for the fuel injection system)
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes
first.
Remarks:
1. These marks ”☆” in the schedule are emission control items. According to EPA regulations, these items must be
perform normally periodical maintenance following the user manual instructions.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after
the motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system - Perform maintenance and check when continuous abnormal ignition, misfire, after-burn,
overheating occur.
b. Carbon deposit removal - Remove carbon deposits in cylinder head, piston heads, exhaust system when
power is obvious lower. Than ever
c. Replace worn out pistons, cylinder head.
Note:
2-2
I
I
This chapter Contents
2. Maintenance Information
Lubrication System
Engine Oil Capacity
Caution
•
•
The vehicle must be parked on a level
ground when checking oil capacity.
Run the engine for 3-5 minutes then stop,
wait about 3-5 more minutes allowing
engine oil to settle before checking the oil
level.
Remove dipstick to check the oil level. If oil level
is below the lower limit mark, add oil to the
specified upper limit mark.
Engine Oil change
Shut off the engine and remove dipstick.
Remove the oil drain plug on the bottom-left of
crankcase to drain oil.
After draining out oil, clean oil plug and its gasket
and reinstall. Replace the gasket if it is damaged.
Torque value: 3.5~4.5 kgf-m
Caution
Warm up the engine. This will make the oil
flow out easily.
Add oil to the specified capacity.
Oil Viscosity: SAE 10W-30, or equivalent
recommended using King-Mate serial oil.
Engine oil capacity: Disassembly: 1050cc
Change:
800cc
When checking for oil leak, run the engine at idle
speed for a few minutes, then check oil capacity
with dipstick.
Oil drain plug
Cleaning the oil strainer
Drain oil from engine, remove the strainer cover,
spring and strainer.
If there is an accumulation on the screen, wash it
off with suitable solvent (recommended using
compressed air to cleaning the foreign).
Check O-ring for damage, replace if necessary.
Reinstall strainer, spring, O-ring and strainer
cover.
Torque value: 1.3~1.7 kgf-m
2-3
This chapter Contents
2. Maintenance Information
Gear Oil
Inspection
Check gear oil if leaking.
Park the motorcycle with main stand on flat level
place.
Turn off engine and remove the gear oil draining
plug.
Place a measurement cup under the draining
hole.
Check gear oil if enough.
Replacement
At first, remove the gear oil refilling bolt, and then
remove the draining plug.
Install the draining plug after drained oil out.
Torque value: 0.8~1.2 kgf-m
Gear oil
refilling bolt
Caution
Inspect if washer is in good condition.
Replace it with new one if it was deformed or
damaged.
Fill out specified gear oil from the engine oil filling
opening.
Install the oil filling bolt.
Torque value: 1.0~1.4 kgf-m
Quantity: 100 c.c.
Recommended: King-Mate HYPOID GEAR OIL
(#140)
Gear oil draining plug
Fuel pipes
Fuel System
Fuel Lines
Remove luggage box, rear carrier, body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind
of fire is strictly prohibited as dealing it.
Fuel filter
Fuel filter
Remove luggage box, rear carrier, body covers.
Remove fuel pump and fuel unit assembly.
Check if the fuel filter is clogged, broken. If so,
clean or replace the fuel filter with new one.
Caution
The arrow on the fuel pump and fuel sender
mean the assembly direction of fuel tank,
check if it is in corrective installation.
2-4
This chapter Contents
2. Maintenance Information
Air Cleaner
Air element
Remove the air cleaner cover (6 screws).
Remove the lock plate from the element of air
cleaner.
Check the element if dirt or damaged.
If it dirt, clean it with solvent and then soap it into
cleaning engine oil after cleaned. Finally,
squeeze it.
Replace it with new one if dirt or damaged.
6 screws
Caution
•
Make sure that the air cleaner cover had
been installed properly after installation
because improperly installation will cause
foreign sucking into cylinder.
•
Do not wet the air cleaner as washing the
motorcycle. Or it may effect engine
performance.
Throttle Valve Operation
Have a wide open of throttle valve as handle bar
in any position and release it to let back original
(full closed) position.
Check handle bar if its operation 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
2~6 mm
Adjustment can be done in either ends.
Secondary adjustment is conducted from top
side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.
Rubber boot
Fixing nut
Adjustment nut
2-5
This chapter Contents
2. Maintenance Information
Primary adjustment is conducted from button
side of cable on the throttle body.
Loosen fixing nut, and adjust by turning the
adjustment nut for its free-play.
Tighten the fixing nut, and check acceleration
operation condition after adjusted.
Fixing nut
Adjustment nut
Crankcase Ventilation
Pull out the plug from draining hose to clean
deposits.
Caution
When always riding in rainy area or full
throttle position, maintenance travel must be
shorted. The deposits can be seen in the
transparent section of draining hose.
Crankcase blow-by plug
Valve Clearance Adjustment
Caution
Checks and adjustment must be performed
when engine is cold (below 35℃).
Remove luggage box.
Remove center cover.
Remove cylinder head left cap.
Remove the ignition timing check hole cap on the
cooling fan cover.
With T type wrench, turn crankshaft in clockwise
motion so that 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 up. (Piston is at
TDC position in the compression stroke.)
TDC mark
Caution
The model that equipped with starting
compression pressure reduction system can
not be rotated in counter-clockwise to prevent
from operating compression pressure
reduction function so that valve clearance can
not be measured.
2-6
Ignition
timing
mark
This chapter Contents
2. Maintenance Information
Valve Clearance Inspection And
Adjustment
Check & adjust valve clearance with feeler
gauge.
Valve clearance (IN/EX): 0.12 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
It has to make sure that valve rock-arm is be
adjusted to standard level when adjusting it,
and re-check the valve clearance after
tightened the fixing nut.
Idle Speed / Exhaust Gas
Adjustment
Connect the DATASCAN connector with the body
harness connector.
Turn on main switch and start the motor. Then
the DATASCAN will open to initial window
automatically.
Adjust the Data Scan to data monitor menu.
Caution
•
•
•
Inspection & adjustment for idle speed
have to be performed after all other parts
in engine that needed adjustment have
been adjusted.
Idle speed check and adjustment have to
be done after engine is being warn up to
working temperature 115~130℃. (around
10 minutes)
This inspection & adjustment have to be
done with DATASCAN. Never adjust the
adjustment screw on the throttle body
arbitrarily to prevent from effect fuel
injection precision.
If idle speed and CO have to be adjusted, then
turn the DATASCAN to idle speed & CO
adjustment function window.
Press ”ENTER” key to enter adjustment function.
The cursor “▲, ▼” is for a digit and the “◄, ►” is
for denary scale.
Emission standard:
1600 ± 100rpm
Engine RPM
HC
CO
900 ppm↓
1.5 ± 0.5%
Please refer to chapter 4, fuel system, for the
detailed usage of DATASCAN.
2-7
This chapter Contents
2. Maintenance Information
Ignition System
F mark
Ignition Timing
Caution
C.D.I ignition system is set by manufacturer
so it can not be adjusted.
Ignition timing check procedure is for
checking whether CDI function is in normal or
Ignition
lamp
Remove right side cover.
Remove ignition timing hole cap located on the
cooling fan cap.
Connect tachometer and ignition lamp.
Start engine and set engine idle speed in 1600
rpm, and if the mark aligns with the “F”, then it
means that ignition timing is correct.
Increase engine speed to 8000 rpm to check
ignition timing advance. If the detent aligns with
advance mark “‫”װ‬, then it means ignition timing
advance is in functional.
If not, check CDI set, pulse flywheel, and pulse
generator. Replace these components if
malfunction of these parts are found.
Spark Plug
Appointed spark plug:CR8E (NGK)
Remove trunk.
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it. Tighten the plug by turning 1/2
turn more with plug socket after installed.
Torque value: 1.0~1.2 kgf-m
Connect spark plug cap.
Spark plug
Side electrode
Central electrode
0.8mm
2-8
This chapter Contents
2. Maintenance Information
Cylinder Compression Pressure
Warn up engine and then turn off the engine.
Remove the trunk and the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of stepping the foot-starting lever.
Caution
Rotate the engine until the reading in the
gauge no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Spark plug
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
• Incorrect valve clearance
•
Valve leaking
Cylinder
pressure
gauge
Cylinder head leaking, piston, piston ring and
cylinder worn out
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
•
Driving System
Gear teeth
Drive Belt
Remove left side cover.
Remove mounting bolt located under air cleaner.
Remove 9 bolts of the engine left side cover and
the cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with
the periodical maintenance schedule to replace
it.
Width limit: 18.5mm or more
Clutch Pad
Start the motorcycle and gradually increase
throttle valve openness to check clutch pad
operation.
If the motorcycle moves with shaking, then check
its clutch pad for wearing. Replace it if
necessary.
Width
Clutch pad
Clutch
2-9
This chapter Contents
2. Maintenance Information
Steering System
Caution
Check all wires and cables if they are
interfered with the rotation of steering handle
bar.
Lift the front wheel out of ground.
Turn handle from right to left alternative and
check if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
adjust the handle top bearing.
Suspension System
Warning
•
•
Do not ride the motorcycle with poor shock
absorber.
Looseness, wear or damage shock
absorber will make poor stability and drive
ability.
Front shock absorber
Hold front brake lever and press down the front
shock absorber for several times to check its
operation.
Hold front brake lever and push forward the front
shock absorber for several times to check its
locking status.
Check if it is scratched or 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 scratched or leaking.
Replace damaged and non-repairable
components.
Park the motorcycle with main standard.
Start engine and let the rear wheel rotate after
increased engine rpm. Check engine for any
parts loose or shaking. Also check the engine
suspension bushing for wear out. Replace the
bushing if worn out.
Tighten all nuts and bolts.
2-10
This chapter Contents
2. Maintenance Information
Disk Brake System (Front/Rear Disk
Brake)
Brake metals hose
Brake System Metal Hoses
Make sure the brake metal hoses for corrosion or
leaking oil, and also check brake system for
leaking.
Brake Fluid
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid to UPPER limit. Also check brake
system for leaking if low brake level found.
Master
cylinder
cap
Caution
In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle bar stop.
Do not operate the brake lever after the cap
had been removed. Otherwise, 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.
Lower limit
Screws
Master cylinder cap
Diaphragm plate
Diaphragm
Upper limit
Air Bleed Operation
Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not
release the brake lever.
Bubbles
Draining valve
Added Brake Fluid
Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4
WELL RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent
from damage brake system or reducing brake
performance.
Transparent draining hose
2-11
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2. Maintenance Information
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.
Brake lining
wear limit
Caution
It is not necessary to remove brake hose
when replacing the brake lining.
Brake clipper Brake disc
Remove the brake clipper bolt, and take out the
clipper.
Caution
Do not operate the brake lever after the
clipper removed to avoid clipping the brake
lining.
Brake
clipper bolt
Pry out the brake lining with a flat driver if lining
be clipped.
Remove brake lining bolt.
Take out the lining.
Brake lining
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set.
Bolt
Brake Lamp Switch
The brake lamp switch is to lit up brake lamp as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.
Master
cylinder
Brake lamp
switch
2-12
This chapter Contents
2. Maintenance Information
Wheel / Tire
Check if both front & rear tires’ pressure is in
correct.
Caution
Tire pressure check should be done as cold
tire.
Appointed tire pressure
Tire size
Front tire Rear tire
Load for
1.75
2.25
Tire pressure
single
as cold tire
Load for two
(Kg/cm²)
1.75
2.5
persons
Appointed Tire
Front wheel: 100/90-12 59J (T/L)
Rear wheel: 130/70-12 59J (T/L)
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
inspection or depth gauge.
•Replace the tire if tire tread dent or unusual
wearing out.
•The tire should be replaced if the wear limit
mark “△” is in visible.
Measure tire thread depth from tire central
surface.
Replace the tire if the depth is not come with
following specification:
Front tire: 1.5 mm
Rear tire: 2.0 mm
Caution
The wear limit marks “∆” are located around
the tire wall even for inspection.
Wear limit indicator
“△” mark
2-13
This chapter Contents
2. Maintenance Information
Battery
Battery Removal
Remove right cover. (3 screws)
Battery cables removal:
1. At first, remove the negative “-” cable.
2. Then, remove the positive “+” cable.
3. Remove the battery.
If there is some rust on battery posts, clean it
with steel brush.
Install the battery in the reverse procedures of
removal.
Caution
•
•
If there is rust on the posts very serious,
spray some hot water on the posts.
Then, clean it with steel brush so that
can remove rust for more easily.
Apply some grease on the posts after
rust removed to prevent from rust again.
Headlamp Adjustment
Headlamp adjustment
Remove the front fender.
Turn the headlamp adjustment screw to adjust
headlamp beam height. (C.W. is for increasing
beam height, and C.C.W. is for decreasing beam
height)
Reinstall the front fender.
Caution
•
•
To adjust the headlamp beam follows
related regulations. Do not adjust it
arbitrarily if not necessary.
Improper headlamp beam adjustment will
make in coming driver dazzled or
insufficient lighting.
Nuts, Bolts Tighteness
Perform periodical maintenance in accord with
the Periodical Maintenance Schedule.
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose (pipe)
clamps, and wire holders for security.
2-14
Headlamp adjustment screw
This chapter Contents
2. Maintenance Information
Special Service Tools Catalogue
(ψ22mm)
(ψ30mm)
Name
Alternator fly wheel
remover
Parts no. SYM-3110A01
Name
Presser for crankcase
bushing
Parts no. SYM-1120300-H9A
Name
Valve clearance
adjustment wrench
Parts no. SYM-9001200
Name
Valve clearance adjuster
Parts no. SYM-9001210
Name
Puller/presser for
crankcase bushing
Parts no. SYM-1120310
Name
Valve spring
compressor
Parts no. SYM-1471100
Name
Universal fixer
Parts no. SYM-2210100
Name
Bearing remover (inner
type)
Parts no. SYM-6204002
Name
Puller/presser for
crankcase bushing
Parts no. SYM-1120320
Name
Valve spring
compressor
Parts no. SYM-1471110/20
Name
Clutch spring
compressor
Parts no. SYM-2301000
Name
Bearing remover (outer
type)
Parts no. SYM-6204001
2-15
This chapter Contents
2. Maintenance Information
(6301)
Name
Bearing installer
Parts no. SYM-9610000
Name
Oil seal installer
Parts no. SYM-9125500
Name
Clutch mounting bolt
wrench
Parts no. SYM-9020200
2-16
Bearing installer
Parts no. SYM-9110400
(27*42*7)
Name
(6203/6004UZ)
(6204)
Name
Parts no. SYM-9620000
(20*32*6)
(25*40*8)
Name
Oil seal installer
Parts no. SYM-9121600
Bearing installer ψ
17mm
Name
Oil seal installer
Parts no. SYM-9120200
Valve cap / Oil filter cap
Fuel pressure gauge
Name
wrench
Parts no. SYM-1236100
Parts no. SYM-HT07010
Name
Home page
Contents
3. Lubrication System
Mechanism Illustration .............. 3-1
Oil Pump Disassembly .............. 3-4
Operational Precautions:........... 3-2
Oil Pump Inspection .................. 3-5
Trouble Diagnosis ...................... 3-2
Oil Pump Re-assembly .............. 3-5
Engine Oil ................................... 3-3
Oil Pump Installation ................. 3-6
Cleaning Engine Oil Strainer..... 3-3
Gear Oil....................................... 3-7
Oil Pump Removal ..................... 3-4
Mechanism Illustration
Rock Arm
Forcedly lubrication
Cam Shaft
Scoop lubrication
Inner passage
Connecting rod
Forcedly lubrication
Crankshaft
Oil strainer
Oil pump
3-1
3
This chapter Contents
3. Lubrication System
Operational Precautions:
General Information
z This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.
Specifications
Oil viscosity
Engine oil quantity Disassembly 1000 c.c.
Replacement 800 c.c
Oil viscosity
SAE 10W-30 or equivalent
(Recommended King-Mate
serial oils)
Gear Oil
Disassembly 110 c.c.
Replacement 100 c.c.
Oil viscosity of gear oil
SAE 85W-140
(Recommended King-Mate
gear oil series SYM
HYPOID GEAR OIL)
unit: mm
Items
Inner rotor clearance
Oil pump Clearance between outer rotor and body
Clearance between rotor side and body
Torque value
Engine oil drain plug
Engine oil filter cover
Gear oil drain plug
Gear oil filling bolt
Oil pump connection screw
Standard (mm)
Limit (mm)
-
0.12
-
0.12
0.05~0.10
0.20
3.5~4.5 kgf-m
1.3~1.7 kgf-m
0.8~1.2 kgf-m
1.0~1.4 kgf-m
0.1~0.3 kgf-m
Trouble Diagnosis
Low engine oil level
• Oil leaking
• Valve guide or seat worn out
• Piston ring worn out
Low Oil Pressure
• Low engine oil level
• Clogged in oil strainer, circuits or pipes
• Oil pump damage
3-2
Dirty oil
• No oil change in periodical
• Cylinder head gasket damage
• Piston ring worn out
This chapter Contents
3. Lubrication System
Engine Oil
Turn off engine, and park the motorcycle in flat
surface with main stand. Check oil level with oil
dipstick after 3-5 minutes.
Do not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Replacement
Oil stick
Caution
Drain oil as engine warmed up so that make
sure oil can be drained smoothly and
completely.
Drain plug
Place an oil pan under the motorcycle, and
remove oil strainer cap.
Make sure if the aluminum washer of the
draining bolt is damaged. If so, replace it with
new one.
Install the drain bolt and tighten it.
Torque value: 3.5~4.5 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 foreign.)
Check if the strainer and O-ring of the oil strainer
are broken. Replace with new one if found.
Install the oil strainer and spring.
Install the oil strainer cap and tighten it.
Torque value: 1.3~1.7 kgf-m
Fill out oil to the oil filler. (Oil viscosity SAE
10W-30) (Recommended King-Mate serial oils)
Oil filter cover
Engine oil quantity: Replacement 800 c.c.
After oil replaced, insert ignition key into the
re-set bottom under instrument panel so that the
oil indicator is changed from red to green and set
oil replacement mileage to zero.
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again if within
standard level after 3-5 minutes.
Check if engine oil leaks.
3-3
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3. Lubrication System
Oil Pump Removal
Remove the alternator (refer to chapter 10).
Remove the engine right cover.
Remove the one-way clutch and starting gear
(1 nut).
Make sure that the pump axle can be rotated
freely.
Remove the oil pump cover (2 screws), and then
the oil pump driving gear clamp and the gear.
Remove oil pump body screws (3 screws).
Oil Pump Disassembly
Remove the screws on oil pump cover and
disassemble the pump as illustration shown.
Engine right cover
Starting gear
Starting
clutch
起動離合器組
Right crankcase
cover
Oil pump driving gear
Oil pump body
Oil pump shaft
Outer rotor
Inner rotor
Oil pump cover
Oil pump outer cover
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3. Lubrication System
Oil Pump Inspection
Check the clearance between oil pump body and
outer rotor.
Limit:below 0.12mm
Check clearance between inner and outer rotors.
Limit: below 0.12mm
Check clearance between rotor side face and
pump body.
Limit: below 2.0 mm
Oil Pump Re-assembly
Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner
rotor. Install the driving shaft.
Install the oil pump cover and fixing pin properly
and then tighten screw. (1 screw)
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3. Lubrication System
Install driving gear and clamp.
Caution
Install the oil pump cover and fixing pin
properly.
Oil Pump Installation
Install the oil pump (3 screws).
Caution
The elliptical hole on the driving gear is not
match with the screw hole. Thus, the elliptical
hole has to align with the screw hoe before
tightening it.
3 screws
Install oil pump outer cover (2 bolts).
2 screws
Install the starting gear and the alternator.
(Refer to chapter 10)
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3. Lubrication System
Gear Oil
Oil Level Inspection
Park the motorcycle on flat surface with main
stand.
Turn off engine and remove both engine oil filling
bolt and oil draining plug.
Filling bolt
Remove gear oil filling hole bolt and place a
measurement cup under the draining plug.
Remove the oil draining plug and the pour gear
oil into the measurement cup. Measure the
gear oil quantity if within standard value.
Add specified gear oil if the oil level too low.
(Standard quantity: 110cc. / replacement: 100
cc.)
Draining plug
Gear Oil Replacement
Remove the gear oil filling hole bolt and its
draining plug and then drain oil completely.
Install the draining plug and tighten it (Make sure
if the plug washer is damaged. If so, replace it
with new one.)
Torque Value: 0.8~1.2 kgf-m
Add new gear oil (100 c.c.) from the gear oil
filling hole and then install the gear oil filling hole
bolt after added oil. And then, tighten the bolt.
Torque Value: 1.0~1.4 kgf-m
※Recommended to apply with SYM HYPOID
GEAR OIL (SAE 85W-140)
Start engine and run it for 2~3 minutes.
Turn of f engine and check if oil leaking.
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3. Lubrication System
NOTES:
3-8
Home page
Contents
4. FUEL INJECTION SYSTEM
Mechanism Illustration ...............4-1 Air By-pass Valve......................4-15
EFI System Components............4-2 Fuel Injector...............................4-15
Introduction Of Fuel Control
Fuel Pump..................................4-15
System .........................................4-3
Fuel Tank ...................................4-16
Electronical Fuel Injection
Components & Operation Principle Air Cleaner .................................4-19 4
Introduction .................................4-3
Trouble Diagnosis & Solutions Of
Precautions In Operation ...........4-4 EFi...............................................4-20
Trouble Diagnosis .......................4-5 Error Code Message and Solution
Operation ...................................4-21
Components Description Of Efi.4-9
EFi Data scan Operation Manual
Fuel Lines ..................................4-11 ....................................................4-23
Ignition System .........................4-12 EFi Component Malfunction
Check& Replacement
Crank Position Sensor..............4-13
Procedure (PI Engine)............4-36
Temperature Sensor .................4-14
Mechanism Illustration
Data Scan
(Diagnosisor)
ECU
Hazardous lamp
Battery
Fuel pump & pressure regulator
Engine temperature sensor
Throttle position
sensor (TPS)
Fuel
tank
Ignition coil
Fuel
injector
Vacuum hose
Air by-pass valve
Crankshaft position sensor
Intake temperature &
MAP sensor
(T-MAP)
4-1
This chapter Contents
4. FUEL INJECTION SYSTEM
EFI System Components
Battery voltage
Main switch ON
Throttle position
sensor
Fuel pump
Engine temperature
sensor
Transistor ignition
coil
5V
12V
ECU
Intake temperature
/MAP sensor
Fuel injector
Crankshaft
position sensor
Idle air by-pass
valve
4-2
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4. FUEL INJECTION SYSTEM
Introduction Of Fuel Control System
The engine of this model was based on a 150 c.c. four-stroke & 4-valve SOHC electronic controlled
single cylinder, air-cooler, engine. It adopts a charcoal canister to absorb the fuel vapor generated
through evaporation in the fuel system & crankcase. Then, introducing evapor into combustion
chamber.
Electronic Fuel Injection Device:
This device consists of both the fuel supply system ---fuel tank, electrical fuel pump, fuel filter, and
fuel pump regulator as well and the fuel control system---fuel injector and ECU.
Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel
pressure is kept within 2.5bar by means of the fuel regulator. Then, the injection signal from ECU is
to let fuel inject to cylinder in every crankshaft rotation. In addition, the residual fuel is back to fuel
tank by the fuel regulator. The fuel pump is stalled into the fuel tank so that can reduce noise and
simplify the fuel pipe routing. The electronic controlled ignition & injection system can control fuel
consumption & emission efficiently so that reaches to the purpose of environmental purification.
Fuel delivery way in most of motorcycle’s engines is by carburetor. The absorption capacity of engine
is to create vacuum inside of the carburetor so that fuel is suck into combustion chamber with air.
Therefore, under such operation, air & fuel mixture ratio is decided by flowing air and fuel absorbed
quantity. Thus, the 3 factors, air detective quantity, fuel quantity decision and fuel absorbed quantity,
are conducted inside of the carburetor.
However, as for the fuel injection system, it detects air absorbed quantity and temperature. Thus, the
fuel supply quantity is decided by the default preset in the system computer. Then, fuel is injected out
by the fuel injector. Comparing with carburetor engine, the 3 factors are independent, and can
increase their precision easily so that fuel supply can be much more accurate.
The engine is equipped with a fuel injection of computerized control and its main characters are as
following:
1. The necessary fuel injection quantity is decided by correspondence with engine rotation. And, the
engine also is applied with a good reaction and high accurate throttle valve. (So, fuel injection
quantity and timing are decided by engine RPM and the throttle valve opening.)
2. The decision of fuel injection quantity and injection timing are controlled by a 8-bite highly
accurate micro-computer.
3. The pressure regulator is always to keep the variances of intake manifold and fuel pressures in a
constant value (2.5bar). So, with the change of intake manifold pressure, the fuel injection quantity
can be kept in proper level.
4. The engine can measure the manifold pressure to enrich fuel injection based on high position
level so that enhance driving capacity.
5. The idle speed control system is to provide manifold with the 2nd air to increase idle speed’s
stability and starting capacity.
Electronical Fuel Injection Components & Operation Principle Introduction
The electronic fuel injection components is consists of both the fuel supply system ---fuel tank,
electrical fuel pump, fuel filter, and fuel pump regulator as well and the fuel control system---fuel
injector and ECU.
Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel
pressure is kept within 2.5bar by means of the fuel regulator. Then, the injection signal from ECU is
to let fuel inject to cylinder in every crankshaft rotation (i.e. the fuel supply system is to inject fuel to
cylinder one time. In addition, the residual fuel is back to fuel tank by the fuel regulator through the
fuel return pipe. In order to reduce noise and simplify the fuel pipe routing the fuel pump usually is
designed to install into the fuel tank.
Generally speaking, the electronic controlled ignition & fuel injection system can control fuel
consumption & emission efficiently so that reaches to the purpose of environmental purification.
4-3
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4. FUEL INJECTION SYSTEM
Precautions In Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place
and strictly prohibit flame when working with gasoline.
Cautions
˙ Do not bend or twist throttle valve cable. Damaged cable will make unstable drive ability.
˙ When disassembling fuel system parts, pay attention to O-ring position, replace with new one
as re-assembly.
Specification
Item
Idle speed
1600±100 rpm
Throttle handle free play
2~6 mm
Torque value
Engine temperature sensor: 0.74~0.88 kgf-m
Tool
Special service tools
Vacuum/air pressure pump
Injection system diagnosisor (Data Scan)
4-4
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4. FUEL INJECTION SYSTEM
Trouble Diagnosis
EFI Electrical Circuit Inspection
Turn on the ignition switch.
NG
Does the warning lamp goes on for 2 seconds
and then off?
OK
NG
Battery voltage over 12.5V?
The voltage difference between battery and
ECU is less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the ECU connector.
3. Turn on the ignition switch.
4. With a multi-meter to measure the voltage
between the 17th pin(+) and the 1st pin (-).
5. Make sure the voltage difference between
battery and ECU is less than 0.2V.
The voltage difference between battery and
active components is less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the connectors of the fuel
injector, by-pass valve, and ignition coil.
3. Measure the voltage between battery
negative side and the each connector (1).
4. Make sure the voltage difference between
battery and those active components is
less than 0.2V.
The voltage difference between 5V-sensors is
less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the connectors of throttle valve
position sensor and intake manifold
temperature/pressure sensors.
3. Turn on the ignition switch.
4. Measure the voltage between the
pins(1)(4) of throttle valve position, and the
pins of intake manifold
temperature/pressure sensors (1) (3) is
within 5V±0.2V.
The voltage difference between battery and
fuel pump is less than 0.2V.
1. Turn off the ignition switch.
2. Disconnect the fuel pump connector.
3. With the probes of multi-meter to touch the
positive & negative sides of the fuel pump.
4. Turn on the ignition switch.
5. Record the voltage difference of the fuel
pump within 3 seconds.
6. Make sure the voltage difference between
battery and fuel pump is less than 0.2V.
1.
2.
3.
4.
Burnt Bulb?
Blown fuse?
Battery voltage too low?
Poor wire contact on ECU
circuit?
5. Poor contact on the master
switch?
6. Malfunction of ECU?
1. abnormal charging circuit?
2. Battery cannot be
charged?
3. Short wire circuit?
OK
NG
1. abnormal wire connection?
OK
NG
1. abnormal wire connection ?
OK
NG
1. abnormal wire connection?
2. Malfunction of ECU?
OK
NG
1. abnormal wire connection?
2. Malfunction of relay?
3. Malfunction of ECU?
OK
END
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4. FUEL INJECTION SYSTEM
Engine cannot be started or difficult to start.
Cannot be started or
difficult to start
Does the warning lamp goes
on for 2 seconds and then
off?
NG
1. Check electrical circuit according to
procedure.
OK
NG
Is the warning lamp out of
order?
1. Connect the Data Scan and check
EMS trouble content.
2. Trouble shooting according to the
troubleshooting procedure.
OK
NG
Is the fuel system abnormal?
OK
Is the electrical circuit
abnormal?
NG
1.
2.
3.
4.
5.
6.
7.
8.
No spark on the spark plug?
wet spark plug?
Loosen spark plug cap?
short in RPM sensor?
Loosen high voltage cable?
No connection for the by-pass valve?
abnormal ECU?
Clean the throttle valve body and
ECU does not be set-up?
NG
1.
2.
3.
4.
5.
No valve clearance?
Incorrect ignition timing?
Stuck valve?
worn out cylinder and piston ring?
improperly adjustment of the air
adjustment screw onto the throttle
valve body?
OK
Is the engine abnormal?
OK
END
4-6
1. Low fuel in fuel tank.
2. The fuel pressure of the injector is
lower than 2.5bar.
3. Fuel leaking in pipe?
4. abnormal regulator?
5. Fuel pump pile leaking?
6. abnormal fuel pump?
7. abnormal fuel injector?
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4. FUEL INJECTION SYSTEM
Diagnosis Of Idle Speed Misfire
Idle speed misfire
Does the throttle valve
cable stuck so could
not be set-up?
1. Connect the Data Scan
and check trouble content
2. Troubleshooting
according to the
troubleshooting
procedure.
Connect the Data Scan
and enter into CO
adjustment at idle
menu. Positive value is
for enrichment, and
negative value is for
lean.
Is the CO value in idle
speed out of set up
range? (0.5%~3.0%)
Is fuel enough?
Are the battery wires
loose?
Does the carbon
deposited onto the throttle
valve body?
Replace with
new one for
confirmation
Is the vacuum hose
leaking?
Does the by-pass valve
operate or out of order?
If the idle speed misfire
problem still can not be solved
after check above related EFI
components item by item,
then check if the other
traditional components on the
engine is in abnormal.
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4. FUEL INJECTION SYSTEM
Abnormal CO Correct Value
Idle speed misfire.
Connect the Data Scan
and check trouble content
if there is an abnormal
CO correct value in idle
speed.
Is fuel enough?
Are the battery wires loose?
Is the voltage enough?
Does the throttle valve cable
stuck so could not be
set-up?
Connect the Data
Scan and enter into
the data analysis
menu.
Start the engine and warm it
up to 115℃~125℃. Make
sure whether the engine
RPM, the openness
(75º~90º) of the by-pass
valve, and the fuel injection
time are in normal.
Switch the Data Scan to
CO adjustment at idle
menu. Positive value is
for enrichment, and
negative value is for
lean.
Is the CO value in idle speed
out of set up range?
(0.5%~3.0%)
Is the vacuum hose
leaking?
Keep the engine running for
3~5 minutes and then turn
off the engine after
confirmed engine operation
in normal. Conduct Error
code erasing operation.
If the abnormal co correct
value problem still cannot be
solved after check above
related EFI components item
by item, then check if the
other traditional components
on the engine is in abnormal.
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4. FUEL INJECTION SYSTEM
Components Description Of EFi
ECU (Electronic Control Unit):
• Powered by DC 8~16V, and has 22 terminals connector on the unit.
• The hardware component consists of an 8-bite computer that be its
control center. It contains the functional circuit interface of engine
condition sensing and the driving actuator for the by-pas valve, fuel
injector, and fuel pump, as well as transistor ignition coil.
• Its major software is a monitor strategy operation program that
includes with controlling strategy, MAP and self-diagnosis programs.
Fuel Injector:
• Powered by DC 8~16V, and has 2 terminals connector on the
injector.
• Its major component is the solenoid valve of high resistance driven by
voltage.
• The two terminals are connected to power source and ground
respective. It is controlled by ECU to decide the injection timing, and
the injector pulse width. Working with 4-valve engine, the unique
2-hole designed injector can provide each intake valve with suitable
fuel quantity to reduce HC emission.
Fuel Pump:
• Powered by DC 8~16V, and has 2 terminals connector on the pump.
• The two terminals are connected to power source and ground
respective. The ECU is to control and manage the operation of fuel
pump through electrical power.
• Its major component is a driving fan pump that equipped with a low
electrical consuming DC motor. Powered by 12V voltage and keep
fuel pressure inside the fuel pump in 2.5 bar which can offer 14 liter
fuel per hour.
• The fuel pump is located inside of the fuel tank, and installed a filter in
front of its inlet so that can prevent from foreign materials sucking into
the fuel pump to damage it and the fuel injector.
By-pass Valve for Idle Speed:
• Powered by DC 8~16V, and has 2 terminals connector on the pump.
• The two terminals are connected to power source and ground
respective. The ECU is to control and manage the operation of
by-pass valve through electrical power.
• Its major component is the solenoid valve of high resistance driven by
voltage.
• By means of signals from all sensors, ECU outputs a signal to control
the opening angle of the valve so that can adjust air flowing to the
intake manifold through the by-pass valve, and then correct the idle
speed to have engine in normal operation.
Transistor Ignition Coil:
• Powered by DC 8~16V, and has 2 terminals connector on the coil.
• The two terminals are connected to power source and ground
respective. Its major component is the highly transferred rate
transformer.
• Its ignition timing is controlled by computer program. From the signals
of ignition timing, crank position sensor, throttle valve position sensor,
and engine temperature sensor as well as intake temperature sensor,
and correspondence with engine speed, then the ECU decides the
ignition timing properly by means of controlling of primary current in
ON & OFF operation to create the secondary voltage of
25000~30000V. And then, the voltage trigged the spark plug
ignition. Such kind of ignition system not only can enhance engine
performance to max. but also increase fuel consumption efficiency
and improve emission quality.
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4. FUEL INJECTION SYSTEM
Intake temperature and pressure sensor:
• Powered by 5V DC from ECU. It has 4 terminals on the sensor.
One terminal is for power, and 2 terminals are for signal output.
And, the rest one is for ground.
• The major component of the intake pressure sensor is a variable
transistor IC. Its reference voltage is DC 5V, and output voltage
range is DC 0~5V.
• It is a sensor of combination by both sensing pressure and
temperature, and can measure the absolute pressure and
temperature in intake process. It also conduct fuel injection quantity
correction based on environmental temperature and position level.
Engine temperature sensor:
• Powered by 5V DC from ECU, and has 2 terminals connector on the
sensor. One terminal is for voltage output and the other one for
ground.
• Its major component is the thermistor of negative temperature
coefficient-NTC. (temperature up, resistance down)
• It locates onto the cylinder head. Correspondence with engine
coolant temperature change, it transferred to voltage signal and sent
to ECU to calculate current temperature. Then, the ECU will correct
fuel injection time and ignition timing according to engine warm up
condition.
Throttle Valve Position sensor:
• Powered by 5V DC from ECU, and has 3-terminal connector on the
sensor. One terminal is for power, and one for voltage output, and
then the last one is for ground.
• Its major component is a highly precious variable resistor. The input
voltage range: 5V DC.
• It is located on the side of throttle body. By means of the throttle
valve rotation to cause voltage change in linear, it provides ECU with
current throttle valve openness information. And also, the ECU
conducts the most properly fuel injection and ignition timing
according to the signal.
Throttle Body:
• The throttle body is the air flow adjustment mechanism of the fuel
injection. (Its function is likely the carburetor.)
• The throttle valve shaft is to turn the throttle valve position sensor in
synchronously so the ECU that can detect the throttle valve
openness in time.
• The guide onto the throttle body is connected to the idle speed air
by-pass valve. By means of the ECU to control the idle speed air
by-pass valve, air-flow is adjusted by the valve so that stabilizes idle
speed.
Crank position/rpm sensor:
24-1
24tooth
-1齒
4-10
• It does not need power supply, and has 2-signal terminals connector
on the sensor.
• Its major component is the magnetic pickup coil, and its output
voltage range is ±0.8~100V.
• The air gap between the sensor and flywheel must have .07~1.1mm.
• The magnetic sensor is sent an inductive voltage that is created by
cutting the magnetic field with the rotation gear (24-1 tooth) onto the
flywheel to the ECU. Then, the ECU calculates current engine
speed and crank position based on the voltage so that controls fuel
injection quantity and ignition timing in properly.
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4. FUEL INJECTION SYSTEM
Fuel Lines
Fuel filter
Fuel tank
Fuel injector
Fuel pump & pressure regulator
Vacuum hose
ECU
Battery
System Description:
1. All sensors’ signals sent to the ECU firstly after the electrical fuel pump inside the fuel tank key-on.
Then, ECU controls the fuel pump relay so let the pump operate. If the engine did not start for
2~3 seconds, then the fuel pump will be turned off to save power. The pressure regulator is to
maintain the fuel pressure in 2.5bar, and the fuel injector inject properly fuel quantity according to
running conditions and environmental corrective coefficient. When key-off or engine stopped, the
fuel pump stops operating.
2. The fuel filter is to filter foreign materials so it has to be replaced regularly.
3. Do not let the starting motor keep running when the engine can not be started in smoothly to
cause battery voltage insufficient (under 8V) and the pump will not be operated. The corrective
method is to start the engine by connecting a new battery or with foot-lever.
4-11
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4. FUEL INJECTION SYSTEM
Ignition System
Spark plug
Throttle valve openness
Intake temperature/pressure
Engine temperature
ECU
rpm/TDC
Ignition coil
TDC/ crank
position sensor
ACG/flywheel gear
ring (24-1 tooth)
Diode
1. Principle of operation:
The engine is equipped with a computerized ignition control system that collects signals from
TDC/crankshaft position sensor, throttle position sensor, temperature sensor, and intake
temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite
micro-computer in the system is to control ignition timing properly. The secondary coil creates
25000~30000V high voltage to ignite the spark plug by means of the transistor to open/close
operation of the primary current inside of the computerized system. Such operation not only have
max engine performance output but also increases fuel consumption ratio.
2. Specification
1) Ignition timing: BTDC 13°/1600RPM
2) Spark plug: NGK CR8E
Gap: 0.7~0.8mm
3) ACG
Pulse generator coil: 120+10% Ω (G/W-Y)
4) Ignition coil:
Primary circuit: 0.63 ± 0.03 Ω (20℃)
5) Battery:
Type: YTX9A-BS.8Ah
Capacity: 12V 8Ah
4-12
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4. FUEL INJECTION SYSTEM
Crank Position Sensor
The magnetic field type sensor is to induct a
voltage signal to calculate engine speed with
ACG gear ring (24-1 tooth).
No teeth
There is one tooth in every 15 degree on the
gear ring. But, one of teeth is flatted to be TDC
base.
Flywheel
gear ring
ECU signal
Secondary
voltage
sensor’s signal
Closed
TDC
Ignition
TDC
Time
Description:
The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that
can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have
a stable and normal running engine.
1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance
engine idle speed to prevent from unstable engine running and misfired within initial starting.
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow
according to engine temperature (engine oil temperature) so that have a fast idle speed.
3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with
acceleration operation to provide intake manifold with proper air-flow quantity. Such operation
will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake
manifold increasing, and then to reduce HC emission.
4-13
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4. FUEL INJECTION SYSTEM
Temperature Sensor
Engine temperature sensor
Intake temperature and
pressure sensor
ECU
Engine oil temperature sensor: According to the semiconductor’s variable character, the sensor
detects the change of engine oil and metal wall and then transferred
into a voltage signal sending to the ECU. Then, the ECU corrects fuel
injection and ignition timing.
NTC-Negative Temperature
Coefficient Resistor
Intake temperature and pressure sensor:
4-14
a sensor that is combined both pressure and NTC can
detect the absolute pressure and temperature in the intake
manifold, and then provides the ECU with signal for
adjustment fuel injection quantity based on environmental
temperature and location level.
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4. FUEL INJECTION SYSTEM
Air By-pass Valve
Fuel injector
TPS
ECU
air temperature
engine oil temperature
engine speed
manifold pressure
throttle openness
Air by-pass valve
Description:
The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that
can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have
a stable and normal running engine.
1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance
engine idle speed to prevent from unstable engine running and misfired within initial starting.
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow
according to engine temperature (engine oil temperature) so that have a fast idle speed.
3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with
acceleration operation to provide intake manifold with proper air-flow quantity. Such operation
will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake
manifold increasing, and then to reduce HC emission.
Fuel Injector
The 2-hole fuel injector provides two intake valves with one fuel injection so that can reduce HC
emission. A short mounted nut can lock the fuel injector easily and receive fuel from the fuel pump.
The mounting bracket can limit the fuel injector rotation in left or right motion. The fuel injection
quantity is controlled by the ECU signal. The fuel pressure regulator can keep pressure difference in
between fuel pressure and manifold vacuum around 2.5bar by means of diaphragm and spring.
Therefore, with such operation, the fuel injector can control its fuel injection quantity by injection width
(time) under different engine loads.
Fuel Pump
The electrical fuel pump is powered by battery and controlled by the ECU for on or off. The pump can
output 14 l/h fuel quantity in 2.5 bar.
4-15
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4. FUEL INJECTION SYSTEM
Fuel Tank
Removal of fuel pump/pressure control
valve/fuel sender
Open the seat cushion.
Remove the luggage assembly. (bolt x 4, screw x
1)
Remove the rear carrier. ( bolt x 4)
Remove both the left and right body covers.
(screw x 4)
Remove the rear lamp. (screw x 4)
Fuel cut valve
Disconnect the connectors of fuel pump relay,
diode, and fuel sender.
Remove the fuel cut valve. (screw x 4)
Diode
Removal of fuel pump/fuel sender
Slightly knock the fuel pump mounting plate to let
the plate out of locker.
Remove the mounting plate and the fuel pump
body.
Caution
The fuel pump mounting plate is easily
deformed as removing the plate. Thus, in
order to prevent from fuel leaking, check it in
detailed and replace it with new one if
necessary.
4-16
Relay
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4. FUEL INJECTION SYSTEM
Remove the rubber oil seal.
Installation of the fuel pump and the fuel
sender
Install them in reverse procedure of removal.
Caution
The oil seal of fuel pump can not be omitted,
deformed or damaged.
The ▲ mark must be aligned
Caution
• Do not bent the fuel sender floating arm.
• Do not fill out too much fuel in the tank.
• The ▲ mark must be aligned as installing
the fuel pump mounting plate.
The fuel sender check. (refer to chapter
16-Electrical Equipment)
Removal of fuel tank
Open the seat cushion.
Remove the luggage assembly. (bolt x 4, screw x
1)
Remove the body cover. (screw x 4)
Remove the rear lamp assembly. (screw x 4)
Disconnect the connectors of fuel pump relay,
regulator, and fuel sender.
Remove the fuel pump.
Remove the fuel cut valve.
Bolt x 4
Remove the fuel inlet. (bolt x 2)
Bolt x 2
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4. FUEL INJECTION SYSTEM
Remove the fuel tank mounting bracket. (bolt x 4)
Bolt x 4
Remove the fuel tank.
Loosen the fuel inlet clamper and then remove
the fuel inlet and the connection hose.
Remove all hoses from the pressure regulator.
Installation
Install the fuel tank in reverse procedure of
removal.
Fuel return hose
Pressure regulator
Fuel outlet hose
Fuel inlet hose
To fuel injector
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4. FUEL INJECTION SYSTEM
Air Cleaner
Remove the air cleaner cover. (screw x 6)
Screw x 6
Remove the air cleaner assembly.
Installation:
Install the air cleaner in reverse procedure of
removal.
Application of fuel injection system
diagnosisor
Open the front luggage cover.
Connect the ECU connector and then turn on the
main switch.
Operate the diagnosisor according to its
operation instruction.
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4. FUEL INJECTION SYSTEM
Trouble Diagnosis & Solutions Of EFi
Judgment of Flash Code
When the engine might have problem and also no tester to detect, the problem can be detected by
reading the flash times of CHK lamp on the odometer. And then, the motorcycle is warned what kind
of problem had occurred by means of the solution priority lamp of the tester operation message table,
or the FLASH CODE.
There are descriptions for the two ways below:
To show “the solution priority”
Turn the KEY ON directly, and the CHK lamp goes up for 2 seconds. Then, the CHK lamp will lit up by
3 types for showing the priority of problem solution so that reminds the rider to have the motorcycle
conduct troubleshooting.
The 1st Priority: the CHK lamp lit up by every 0.3 second.
The 2nd Priority: the CHK lamp lit up continuously.
The 3rd Priority: the CHK lamp is not lit up.
Priority
Lit up types
ON
1
0.3 sec
OFF
0.3 sec
ON
2
OFF
ON
3
OFF
To show “FLASH CODE”:
Before turning the KEY ON, wide open the throttle valve. Then, turn the KEY ON, the CHK lamp lit up
for 2 seconds and off. But, the CHK lamp will lit up again after off 3 seconds. In the means time,
close the throttle valve. Finally, it is to determine what problem occurred based on the flash time of
CHK lamp.
Before show up, CHK lamp will lit up for 4 seconds firstly. Then, according to the lamp flash times
(every 0.5 second), the problem will be determined by comparing with the operation message table.
If there has the 2nd problem in the system, the CHK lamp will have flash operation again after its lit
up for 4 seconds.
= lit up
= lit off
Throttle valve 100% on
nd
st
The 2
The 1 problem shown up
0.5 0.5
4
4
0.5 0.5 0.5 0.5 0.5 0.5
4
4 seconds for problem
flash ending
4 seconds for problem flash
starting
4 seconds for problem
flash ending
4 seconds for problem flash
starting
3 seconds for delay
4-20
4
Close the throttle valve
3
Lamp test
Turn on the main switch
2
problem shown up
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4. FUEL INJECTION SYSTEM
Error Code Message and Solution Operation
DTC Solution Flash
Code Priority code
Message
P0217
1
1
Engine
temperature
overheat
P0335
2
2
Crank position
sensor
P1120
2
3
Poor contact of
the throttle
valve sensor
4
Application
malfunction of
the throttle
position sensor
P1121
2
P1122
2
5
Rotation speed
malfunction of
the throttle
position sensor
P0560
1
6
Abnormal
battery voltage
warning
P0110
2
7
Abnormal
intake
temperature
sensor
P0410
2
8
Abnormal air
by-pass valve
Solution Operation
1. Stopping the motorcycle immediately, and solve it
with priority
2. Check if the lubricant system for abnormal?
3. Is the ignition or fuel supply system in normal?
4. Has the engine shown burnt?
5. Make sure if the engine temperature senor is in
normal.
6. Make sure if the connector is in normal.
1. Check if the connection of the crank position sensor
is open-circuit.
2. Check if the air gap between the sensor and gear
tooth is within specification.
3. Check if the crank rotation is run-out.
4. Check if the sensor is in normal according to the
new component replacement procedure.
1. Connect the disgnosisor and reset the throttle valve
position. Make sure if the idle speed position is
within specified range.
2. Make sure if the wire circuit of the throttle valve
position sensor is loosen or short.
3. Check if the openness of idle speed by-pass valve
is within specification. (40~100%)
4. Adjust the idle speed CO value to specified range.
(0.5%~2.0%)
5. If this problem symptom still existing, check if the
throttle position sensor (TPS) is in normal according
to the new component replacement procedure.
1. Make sure if the wire circuit of the throttle valve
position sensor is loosen or short.
2. If this problem symptom still existing, check if the
throttle position sensor (TPS) is in normal according
to the new component replacement procedure.
1. Make sure if the wire circuit of the throttle valve
position sensor is loosen or short.
2. If this problem symptom still existing, check if the
throttle position sensor (TPS) is in normal according
to the new component replacement procedure.
1. Make sure if the battery voltage is too low or high
(below 10V or exceed 16V)
2. Make sure if the ACG generator charging system
circuit is short or abnormal.
3. Make sure if the 15th terminal on the ECU to battery
positive post is short.
4. Make sure if the battery is in normal. Replace it with
new if the battery is out or order.
1. Make sure if the sensor’s resistor is in normal (20℃
2353~2544Ω).
2. Make sure if the sensor’s wire is in open-circuit (the
22th terminal on ECU).
3. Make sure if the sensor is normal according to the
new component replacement procedure.
1. Make sure if the sensor’s resistor is open or short
circuit.
2. Make sure if the sensor’s wire is in open-circuit (the
13th terminal on ECU)
3. Make sure if the by-pass valve is normal according
to the new component replacement procedure.
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4. FUEL INJECTION SYSTEM
DTC
Code
Solution Flash
Priority code
P0505
2
P0251
2
P0350
2
P0230
2
P0219
2
P1560
2
P0700
2
P0115
2
P1561
2
P0650
3
P1410
2
P0105
2
4-22
Message
Solution Operation
1. Check if the openness of idle speed by-pass valve
Application
is within specification. (40~100%)
range abnormal
9
2. Make sure if the idle speed valve openness is in
of the air
normal. (stuck or poor adjustment of air screw)
by-pass valve
3. Make sure if the intake manifold is leaking.
1. Make sure if the fuel injector resistor is within
specification. (14.5 Ω, 20℃)
Abnormal fuel 2. Make sure if the connector or wire is in open-circuit.
10
injector
(the 3rd terminal of ECU)
3. Make sure if the fuel injector power supplied is in
normal. (12~15V)
1. Make sure if the ignition coil resistor is within
specification. (0.63 Ω, 23℃)
2. Make sure if the connector or wire is in open-circuit.
Abnormal
(the 12th terminal of ECU)
11
ignition circuit 3. Make sure if the ignition coil power supplied is in
normal. (12~15V)
4. Make sure if the ignition coil is normal according to
the new component replacement procedure.
1. Make sure if the connector or wire is in open-circuit.
Abnormal fuel
12
2. Replace with new relay to make sure if this
pump relay
abnormal is disappeared.
1. Engine speed exceed safety limit. Decreasing the
Engine
13
speed and then the DTC code disappeared.
over-speeding
2. Check if the CVT belt is broken.
1. Make sure if the 18th terminal of ECU is 5V.
2. Make sure if the sensor’s power voltage is 5V. (The
Abnormal 5V
14
driving voltage
16th & 18th terminals)
3. Replace the ECU and confirm again.
1. If the engine speed is exceed 300rpm as starting, in
order to prevent run-away, the ECU will decrease
engine speed or stop the engine.
High RPM
15 warning for
2. Rider should avoid to starting engine with WOT
suddenly.
starting engine
3. Check if acceleration cable is stuck. Re-set the idle
speed adjustment position.
1. Make sure if the sensor’s resistor is within
Abnormal
specification. (25℃, 10319~11981Ω)
2. Make sure if the sensor’s wire is in open-circuit. (the
engine
16
temperature
9th terminal of ECU)
sensor
3. Make sure if the sensor is normal according to the
new component replacement procedure.
Abnormal
engine
17
temperature
gauge
1. Check if the warning lamp is burnt.
Abnormal
18
2. Check if the warning lamp circuit is open. (the 4th
warning lamp
terminal of ECU)
Adjustment of
19
CO
1. Make sure if the sensor’s voltage is within
specification. (101kpa, 3.925V)
Abnormal MAP 2. Check if the sensor circuit is open. (the 8th terminal
20
sensor
of ECU)
3. Make sure if the sensor is normal according to the
new component replacement procedure.
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4. FUEL INJECTION SYSTEM
EFi Data scan Operation Manual
A. DTC Codes Retrieved by Data Scan
Description:
When a problem comes out, with the Data Scan to diagnosis the problem and solve it.
Method:
1. Stop the engine and do not turn on the ignition switch.
2. Open the front grove cover, and connect the connector on the motorcycle with the Data Scan’s
connector.
3. The menu will show connection and software & hardware versions.
4. Press “Enter” to enter main menu.
5. Move the ▼ ▲ key to “ read DTC” and then press “Enter” key.
6. The menu will show 3 functions, 1) Current problem searching 2) Just occurred problem searching,
and 3) past problem searching, for selection.
7. When selecting the 1) & 2) functions, then it will search the DTC code of current & just occurred
problems.
8. Compare with the DTC code table, and conduct the troubleshooting procedure.
B. EFI Data Scan Introduction
Connector
Main body
LCD monitor
Data transmission
indicator
Connection
cable
Spare keys
Next page
and value
adjustment
key
Enter function
key
Exit function
key
Software card
slot
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4. FUEL INJECTION SYSTEM
C. Data Scan Function Menu
1. P1120: Throttle position sensor
connection problem
2. P0560: Abnormal battery
voltage
3. P0700: Starting speed exceeds
CVT matching speed
1. Problem searching.
2. Just occurred problem
searching,
3. past problem list
The DTC codes
can be erased
only under turn on
the ignition switch
and engine
stopped.
Monitor menu
(1/8)
Engine speed
3700rpm
Intake
temperature
35℃
Engine
With the narrow
mark to adjust
value.
5+1
-103 4+10
6-1
Adjustment range
does not exceed
±75.
Engine speed
4-24
1. Re-set throttle position.
(the command must be
done after adjusting the
idle speed screw or
replacing the throttle
body.)
2. Carbon deposited time
re-set. (the command
must be done after
cleaning the throttle
body or replaced new
one ECU.)
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4. FUEL INJECTION SYSTEM
D. Operation Steps & Menu Function Description
1. Connect the Data Scan’s connector onto the specified signal connector of the EFI system on the
motorcycle.
2. Turn the ignition switch on and then the LCD monitor goes on and show “SANGYANG Motor Co.”
as fig 1.
3. Press the “ENTER” key to continue, the monitor goes show “CONNECTING” as fig 2.
Fig 1
Fig 2
When press “ENTER” key, it shown 2 pages (1/2~2/2) of motorcycle data. To select function menu
with the ◄ ► cursor.
Fig 3
Fig 4
4. In the (2/2) menu, press “ENTER” and then enter into the main menu. (as fig 5)
Then with the ▲▼ cursor to select main menu, and then press “ENTER” to conduct 1~7 function.
Each functions’ menu is described as below:
Fig 5
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4. FUEL INJECTION SYSTEM
When selecting the “1. retrieving DTC code” (LCD background changed into black), and press
“ENTER”, then there have 3 sub-functions can be selected.
Fig 6
With the ▲▼ cursor to select “1. active DTC codes” (LCD background changed into black), press
“ENTER” , and then enter into problem searching menu & verify if problem occurred right now.
The menu will show problem symptom when problem have been detected. Then, conduct
repairing procedure for the problem. However, if there is no DTC codes been shown on the
menu , it means the EFI system is in normal. Press “EXIT” key to back to the main menu.
Fig 7
Fig 8
With the ▲▼ cursor to select “2. occurred DTC codes” (LCD background changed into black),
press “ENTER” , and then enter into problem record menu. (as fig 9)
Fig 9
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4. FUEL INJECTION SYSTEM
To verify if there has problem occurred in past. When the menu record shows the past problem
record, it will show the problem symptom (as fig 10). Then, suggestion to erase the DTC codes.
(please refer to DTC codes Erase on page 28). However, if there is no problem shown on the
menu, it means that there is no problem record in past. Press “EXIT” key to back to the main
menu.
Fig 10
Fig 11
With the ▲▼ cursor to select “3. history DTC codes” (LCD background changed into black), press
“ENTER” , and then enter into problem record menu. (as fig 12)
Fig 12
When the menu record shows the history problem record, it will show the problem symptom (as fig
13). Then, suggestion to erase the DTC codes. (Please refer to DTC codes Erase on page 37).
However, if there is no history problem record shown on the menu, it means that there is no
problem record in history. Press “EXIT” key to back to the main menu.
Fig 13
Fig 14
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4. FUEL INJECTION SYSTEM
Remarks:
a. Current DTC codes: It means that the problem onto EFI system is occurring. When the
problem is solved, the recorded will disappear.
b. Past DTC codes: It means that the problem onto the EFI system just occurred. The DTC
codes are recorded. Even the Current problem are solved and its DTC codes also have been
erased, the DTC codes still be recorded into the past DTC codes until turning off the ignition
switch so that the past DTC codes can be erased.
c. History DTC codes: It means that the problem onto the EFI system had been occurred. So,
the DTC codes were recorded. Unless with command to erase the problem history record, the
problem record will be kept continuously.
5. With the ▲▼ cursor to select “2. DTC Code Erase” (LCD background changed into black), (as fig
15), press “ENTER” key to erase the DTC codes (as fig 15-1, 16, 17). This function can be
conducted only when the ignition switch is turned on and the engine stopped. Press “EXIT” key to
back to the main menu.
Fig 15
Fig 16
Fig 15-1
Fig 17
6. With the ▲▼ cursor to select “3. Data analysis” (LCD background changed into black), (as fig
18), press “ENTER” key to enter into EFI data analysis. There are 8 instantly dynamic data
values shown on the menu. (1/7~7/7) (as fig 19, 20, 21, 22, 23, 24, 25, 26) Select desired
menu with ◄ ► cursor.
◎ As the fig 19 (1/8) shown, the menu provides with 3 set dynamic values of engine rpm, intake
temperature & sensor’s voltage, and engine temperature & sensor’s voltage.
Fig 18
4-28
Fig 19
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4. FUEL INJECTION SYSTEM
◎ As the fig 20 (2/8) shown, the menu provides with 3-set dynamic values of engine rpm,
atmosphere pressure & sensor’s voltage, and throttle valve opening & sensor’s voltage.
◎ As the fig 21 (3/8) shown, the menu provides with 3-set dynamic values of engine rpm, CO
voltage meter, battery voltage, and sensor’s voltage.
Fig 20
Fig 21
Description:
CO voltage meter: it is designed onto the ECU. This model does not has this function.
Battery voltage: it means that the ECU receives voltages from the terminals of power
supply, fuel injector, transistor ignition coil, and fuel pump.
Sensor voltage supply: it means that DC 5V supplied by the ECU and detected voltage.
(standard voltage value: 5V±0.5%)
◎ As the fig 22 (4/8) shown, the menu provides with 4-set dynamic values of engine rpm,
injection timing, ignition timing, and ignition charging timing.
Description:
Injection timing: It means that the fuel injector opening times controlled by the ECU. i.e. the
fuel injection quantity.
ignition angle: It means that the ignition angle (timing) for the engine controlled by the ECU.
ignition charging timing: It means that the charging timing (ignition energy) set by the
ignition transistor.
Fig 22
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4. FUEL INJECTION SYSTEM
◎ As the fig 23 (5/8) shown, the menu provides with 4-set dynamic values of engine rpm, initial
position voltage of throttle valve idle speed, idle speed target value, and idle speed CO
corrective value.
Description:
initial position voltage of throttle valve idle speed: It means that the ECU memorizes the idle
speed voltage from the first time of throttle position sensor. This value can be a reference
for the throttle position sensor damaged.
idle speed target value: It means that the idle speed target value set by the ECU based on
current engine temperature and intake temperature.
idle speed CO corrective value: Based on CO value of the engine emission, it corrects the
air-flow of idle speed air by-pass valve.
Fig 23
◎ As the fig 24 (6/8) shown, the menu provides with 4-set dynamic values of engine rpm,
accumulated running time, PWM output of temperature gauge, and idle speed valve opening.
Description:
accumulated running time: It means that the ECU’s inner timer starts to count the ECU
operation time at every time to turn on the ignition switch, even the engine does not start,
and until turn off the ignition switch.
PWM output of temperature gauge: this model does not has this function.
idle speed valve opening.: It means that the opening of air by-pass valve at current idle
speed.
Fig 24
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4. FUEL INJECTION SYSTEM
◎ As the fig 25 (7/8) shown, the menu provides with 2-set dynamic values of fuel pump
condition and manual TPI initialization.
Description:
Fuel pump condition: It means the ON & OFF condition of current fuel pump.
manual TPI initialization: It means the action status of the manual TPI initialization.
Fig 25
◎ As the fig 26 (8/8) shown, the menu provides with 2-set dynamic values of CO deposit time
and CO deposit time reset value.
Description:
CO deposit time: It means that the ECU inner timer starts to count the engine throttle body
used time.
CO deposit time reset value: It means that the engine inner timer starts to reset the engine
throttle body used time. When you replaced the new one ECU.
Fig 26
7. When you do not want to check the data analysis above, press “EXIT” key to back to the “4. Idle
speed CO adjustment” (LCD background changed into black) ( as fig 26) on the main menu.
Press “ENTER” key to enter into idle speed CO adjustment. (as fig 27) With the ▲▼ and ◄ ►
cursors to adjust the idle speed CO value.
Micro adjustment: Press ▲ for one time then +1, but press ▼ for one time then –1.
Macro adjustment: Press ► for one time then +10, but press ◄ for one time then –10.
After adjustment, press “EXIT” key to back to main menu.
Fig 26
Fig 27
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4. FUEL INJECTION SYSTEM
8. With the ▲▼ cursor to select “5 operation test” function, press “ENTER” key to enter into “5.
re-set/Zero setting command” main function menu. (as fig 28)
Fig 28
With the ▲▼ cursor to select “1. Reset TPI adaption” or “2. Re-set CO deposited time” function.
(as fig 29, 30, 31, 32, 33, 34) (Note: Do not enter this menu if not necessary.)
Description:
1. Reset TPI adaption: After replaced the throttle body with new one or idle speed
adjustment screw had been removed, this command has to be
conducted.
2. Reset CO deposit time: After clean carbon deposition on the throttle body or replaced it,
and replaced the ECU with new one, but without clean or
replaced the throttle body, this command has to be conducted.
Press ENTER key to left this set up function menu.
Fig 29
Fig 30
4-32
Fig 31
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4. FUEL INJECTION SYSTEM
Press ENTER key to left this set up function menu.
Fig 32
Fig 33
Fig 34
9. With the ▲▼ cursor to select “6. Waveform” analysis (as fig 35), press ENTER to enter into the
waveform analysis menu. (as fig 36). 1. engine speed, 2. ignition timing (BTDC), 3. TPS, and 4.
Atmosphere pressure sensor.
Fig 35
Fig 36
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4. FUEL INJECTION SYSTEM
With the ▲▼ cursor to select “1. engine speed (as fig 37), press ENTER to enter into the “engine
speed” menu to check current waveform. There are 3 instantly dynamic data values shown on the
menu. (as fig 38, 39, 40). Select desired menu with ◄ ► cursor.
Fig 37
Fig 38
Fig 39
Fig 40
With the ▲▼ cursor to select “2. ignition timing (BTDC) (as fig 41), press ENTER to enter into the
“ignition timing” menu to check current waveform. (as fig 42). Press EXIT key to left the “ignition
timing” waveform menu.
Fig 41
4-34
Fig 42
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4. FUEL INJECTION SYSTEM
With the ▲▼ cursor to select “3. throttle position sensor (TPS) (as fig 43), press ENTER to enter
into the “3. TPS” menu to check current waveform. (as fig 42). Press EXIT key to left the “TPS”
waveform menu.
Fig 43
Fig 44
With the ▲▼ cursor to select “4. Atmosphere Pressure Sensor (as fig 45), press ENTER to enter
into the “Atmosphere Pressure Sensor” menu to check current waveform. (as fig 46). Press EXIT
key to left the “Atmosphere Pressure Sensor” waveform menu.
Fig 45
Fig 46
10. With the ▲▼ cursor to select “7. Identification” analysis (as fig 47), press ENTER to enter into the
Identification analysis menu. (as fig 48, 49).
Fig 47
Fig 48
11. Here are all operation menus for the EFI Data Scan.
Fig 49
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4. FUEL INJECTION SYSTEM
EFi Component Malfunction Check& Replacement Procedure (PI Engine)
PI (Port Injection) → Intake manifold injection engine
Item
1
Parts No.
Service
Inspection Method
Parts Name schedule
390-002
At least
1. With the Data Scan to check if the
Ignition coil 20000km
ignition coil is malfunction.
life-expecta 2. Erase the DTC codes and replace
ncy
with new one & confirm again. If the
Check it
DTC codes disappear, then the
every
ignition coil is abnormal. Replace it
3000km
with new one.
3. If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one.
4. Before the ignition coil is verified in
abnormal, check the coil resistance
and connector wire for short-circuit.
1. If the ignition coil has to be
changed, erase the DTC codes with
the Data Scan.
2. Turn off ignition switch, and replace
the coil with new one.
3. Turn on ignition switch and make
sure the DTC codes disappear.
1. If the by-pass valve has to be
changed, erase the DTC codes with
the Data Scan.
2. Turn off the ignition switch, and
then replace the valve with new
one.
3. Turn on ignition switch and make
sure the DTC codes disappear.
4. Check idle speed CO and adjust it if
necessary.
2
379-010
By-pass
valve
3
358-016
At least
1. Connect a pressure gauge between 1.
fuel pump & 20000km
the regulator and fuel injector.
2.
regulator
life-expecta 2. Make sure fuel pressure is within
ncy
2.5bar. The pressure is reached
Check it
within 3 seconds after turn on
every
ignition switch.
6000km
3. If the fuel pressure is out of
specification, check if the fuel pipe is
leaking. Is the fuel pump voltage
over 12V?
4. Replace the regulator and confirm
again.
4
366-005
Engine
temperature
sensor
4-36
At least
1. Check if the by-pass valve DTC
20000km
code shown with the Data Scan.
life-expecta 2. Erase the DTC codes and replace
ncy
with new one & confirm again. If the
Check it
DTC codes disappear, then the
every
by-pass valve is abnormal.
3000km
Replace it with new one.
3. If the DTC codes still exist, check if
the wire connector and by-pass
valve resistance are in normal.
4. If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new
one.
Adjustment & replacement procedure
1. Has the DTC code shown with the
At least
Data Scan.
20000km
life-expecta 2. Engine temperature has to be
ncy
reached to room temperature after
Check it
engine stopped for a while.
3. Erase the DTC codes and replace
every
with new one & confirm again. If the
3000km
DTC codes disappear, then the
sensor is abnormal. Replace it
with new one.
4. If the DTC codes still exist, check if
wire connector and sensor’s
resistance are normal.
The oil seal has to be replaced if it
has to replace the regulator.
Oil seal has to be installed onto the
outer cover, and then assemble it
1. If the sensor has to be changed,
erase the DTC codes with the Data
Scan
2. Turn off ignition switch, and
remove connector.
3. Remove the sensor with tools.
4. New component tighten torque is
0.74~0.88kg-m.
5. Connect the connector, and the
Data Scan. Then, turn on ignition
switch.
6. Make sure if the DTC codes are
disappeared.
7. The value of stopped engine
temperature should near to room
temperature.
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4. FUEL INJECTION SYSTEM
Item
5
Parts No.
Parts Name
366-008
Intake
temperature
/pressure
sensor
Service
Inspection Method
schedule
At least
1. Connect the Data Scan as
20000km
inspection. The engine intake
life-expectancy
temperature and pressure should
Check every
close to environmental
3000km
temperature & atmosphere
pressure. (conduct this task after
stopped the engine for a while)
2. If the DTC codes of intake
temperature or pressure shown on
the Data Scan, replace the
pressure sensor firstly with new
one. Make sure if the DTC codes
are disappear. If not, check the
connector wire for short-circuit.
Replace the connector if
necessary.
3. If the DTC codes still exist, replace
the ECU.
4. If the DTC codes are disappear,
install the original pressure sensor
and check it again. If the DTC
codes are disappear, then, replace
the ECU with new one.
At least
1. Please refer to idle speed
20000km
adjustment section for the idle
life-expectancy
speed CO adjustment.
Check every
2. Connect the Data Scan and check
3000km
if the throttle position DTC code
appears.
3. If the code appears, replace the
throttle body to make sure the
code can be erased.
4. If the code disappears, replace the
throttle body.
5. If the code still exists, replace the
ECU with new one. Then, if the
code can be erased, the ECU has
to be replaced.
6
308-008
Throttle
body
7
1. Check if the fuel injector DTC code
337-004
At least
appears.
Fuel injector 20000km
life-expectancy 2. If the code appears, replace a new
Check every
fuel injector for confirmation. If the
3000km
code can be erased, then, replace
the fuel injector.
3. If the code still can not be clear,
check if connector wire is in
short-circuit.
4. If the code still exists, replace the
ECU with new one. Then, if the
code can be erased, the ECU has
to be replaced.
Adjustment & replacement
procedure
Replacement procedure for T-MAP
(intake temperature/pressure
sensor)
1. Turn off the ignition switch.
2. Disconnect the connector of
intake temperature/pressure
sensor. Replace the sensor with
new one.
3. Connect the connector with Data
Scan.
4. Turn on the ignition switch, and
check if the intake temperature/
pressure close to environmental
temperature and atmosphere
pressure with the Data Scan.
5. Erase the DTC codes, and make
sure the problem is solved.
The throttle body replacement
procedure:
1. Install a new throttle body
2. Make sure there is no leaking.
3. Connect the Data Scan and
record carbon accumulated time.
4. Re-set the time with the Data
Scan.
5. Re-set the throttle position data
with the Data Scan.
6. Throttle valve WOT set up. Turn
off ignition switch, and WOT the
throttle valve and hold it. Turn on
the ignition switch and hold for 2
seconds. Release the throttle
valve.
7. Please refer to the idle speed
adjustment section for the idle
speed CO if necessary.
Confirmation or replacement
procedure for the fuel injector:
1. Erase the DTC code with the
Daya Scan.
2. Turn off ignition switch and
disconnect the fuel injector
connector.
3. Connect the connector to a new
fuel injector.
4. Connect the Data Scasn, and turn
on the ignition switch.
5. Make sure the DTC code had
been clear.
6. Please refer to idle speed
adjustment section for idle speed
CO value confirmation.
(Firstly, make sure if the fuel injector
DTC code had been clear, and then
install a new fuel injector.)
4-37
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4. FUEL INJECTION SYSTEM
Item
8
9
Parts No.
Service
Inspection Method
Parts Name
schedule
325-002
At least
1. Connect the Data Scan.
ECU
20000km
2. Record the ECU service time.
life-expectancy
Check every
3000km
Adjustment & replacement
procedure
ECU replacement procedure:
1. Connect the Data Scan onto the
original ECU.
2. Record the ECU service time.
3. Turn off the ignition switch.
4. Replace the ECU with new one.
5. Re-set the ECU service time.
6. Clean the carbon deposition
around the throttle body.
7. Please refer to idle speed
adjustment section for idle speed
CO value confirmation.
Idle speed Check for new 1. Warm up the motorcycle by
1. Warm up the motorcycle by
CO
motorcycle and
running it in 50km/hr for 5 minutes.
running it in 50km/hr for 5
Adjustment every 3000km. 2. Connect the Data Scan.
minutes.
3. Record the idle speed CO value, 2. Connect the Data Scan.
rpm, and carbon deposition
3. Record the idle speed CO value,
accumulated time.
rpm, and carbon deposition
accumulated time.
4. With the Data Scan to adjust the
idle speed CO value to be
0.5%~2.0%.
5. Record the idle speed CO value,
rpm and CO variant value.
6. (The engine temperature has to
be in 115℃~140℃, and intake
temperature to be in 25℃~40℃
as adjusting.)
4-38
Home page
Contents
5. REMOVAL OF ENGINE
Operational Precautions ........... 5-1 Engine Suspension Frame ........ 5-8
Engine Removal ......................... 5-2 Installation Of Engine ................ 5-9
Removal Of Engine
Suspension Bushing .............. 5-7
Operational Precautions
General Information
z Engine must be supported by a bracket or adjustable tool in height.
z The following parts can be serviced with the engine installed on the frame.
1. Throttle valve
2. Driving disk, driving belt, clutch, and transporting disk
3. Final reduction gear mechanism
5
Specification
Item
Specification
Replacement
800 c.c.
Disassemble
1000 c.c.
Replacement
100 c.c.
Disassemble
110 c.c.
Engine Oil Capacity
Gear Oil Capacity
Torque Values
Engine suspension bolt (Frame side)
Engine suspension nut (engine side)
Bolt of rear shock absorber upper connection
Bolt of rear shock absorber lower connection
Bolt of rear brake clipper
Nut of rear wheel axle
Nut of exhaust connection
Bolt of exhaust fixed
Bolt of rear bracket
4.5~5.5 kgf-m
4.5~5.5 kgf-m
3.5~4.5 kgf-m
2.4~3.0 kgf-m
2.9~3.5 kgf-m
11.0~13.0 kgf-m
0.5~1.0 kgf-m
3.0~3.6 kgf-m
3.0~3.6 kgf-m
5-1
This chapter Contents
5. REMOVAL OF ENGINE
Engine Removal
Remove the battery cap (Nut ×3).
Remove the battery negative (-) cable.
Remove the battery positive (+) cable.
Open seat cushion.
Remove the trunk assembly. (bolt x 4, screw x 1)
Remove rear bracket and fuel tank cap.
(hex-socket bolt x 4)
Remove both left & right body covers and central
upper cover set. (screw x 4)
Remove both left & right side covers. (screw x4)
Remove both left & right pedals of rear seat.
(screw x 8)
Remove central cover. (screw x2)
Remove the connector of rear lamp power wire.
Remove the generator power wire and speed
sensor connector.
Remove the starter motor cable on the relay.
5-2
Starter motor cable
This chapter Contents
5. REMOVAL OF ENGINE
Remove the spark plug.
Remove the engine temperature sensor
connector.
Caution
Open the latch located under the temperature
sensor before disconnect it so that the
connector can be pull out and not be
damaged.
Spark plug cap
Remove the by-pass pipe and disconnect circuit
connector.
Temperature sensor
By-pass valve connector
Throttle position
sensor connector
Remove the throttle body lines and throttle body
cables.
Disconnect the connector of throttle position
sensor.
Loosen the clamp of the air cleaner duct, and
then remove the duct.
Remove the fuel injector line and circuit
connectors.
Fuel injector connector
Fuel supply line
5-3
This chapter Contents
5. REMOVAL OF ENGINE
Remove the throttle body and the fuel injector.
(nut x 2)
Nut x2
Loose the strap screw of the air duct on the
engine left side, and then remove the air duct.
Remove the air cleaner bolts. (bolt x 2)
Bolt x 2
The strap screw of the air duct
Remove the front-end nuts of exhaust pipe.
(Nut ×2)
Nut x2
Remove the rear-end bolts of exhaust pipe.
(Bolt ×3)
Remove the exhaust pipe.
Bolt x 3
5-4
This chapter Contents
5. REMOVAL OF ENGINE
Remove the rear brake pipe seat. (bolt x 2)
Remove the rear brake assembly. (bolt x 2)
Bolt x 2
Bolt x 2
Bolt x 2
Remove the front-end nut of rear bracket. (bolt x
2)
Remove the rear wheel axle nut. (nut x 1)
Nut x 1
Remove the rear bracket.
5-5
This chapter Contents
5. REMOVAL OF ENGINE
Engine suspension removal
Remove the rear shock absorber lower bolt.
(bolt x 1)
Bolt x 1
Remove the side hole cap of cooling fan.
Side hole cap
Remove the engine suspension nuts, and then
remove the bolt from the side hole.
Caution
With a bracket to support the engine to
prevent from it damage by falling down as
removing the engine.
Nut x 1
Check if the engine suspension, rear shock
absorber bushing, and cushion rubber for
damage. Replace them with new ones if so.
5-6
This chapter Contents
5. REMOVAL OF ENGINE
Removal Of Engine Suspension
Bushing
If engine suspension frame and the cushion
rubber of rear shock absorber bushing damaged.
Then, with the bushing remover / pressor,
Ø 28mm & Ø 20mm, to press the bushing out,
and replace it with new one.
Engine suspension bushing:
Ø 28mm
Rear shock absorber bushing: Ø 20mm
Pressing out
Place the detent section of the bushing remover
toward the bushing, and drive both the pressing
ring and bolt in to press the bushing out.
Pressing In
Place the flat section of the remover toward the
bushing, and then drive the bushing, pressing
ring, and bolt in to install the bushing.
5-7
This chapter Contents
5. REMOVAL OF ENGINE
Engine Suspension Frame
Removal
Remove the right side bolt of engine suspension
frame.
Engine suspension
bolt (right side)
Remove the left side bolt of engine suspension
frame.
Engine suspension
bolt (left side)
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 engine suspension
frame.
Engine suspension frame nut:
Torque Value: 4.5~5.5 kgf-m
5-8
This chapter Contents
5. REMOVAL OF ENGINE
Installation Of Engine
Check if the bushings of engine suspension
frame and shock absorber for damaged. If so,
replace with new ones.
Install the engine according to the reversing
order of removal.
Caution
z Note both feet and hands safety for
squeezing as engine installation.
z Do not bent or squeeze each wires or
hose.
z Route all cables and wires in accordance
with the routine layout.
Nut x 1
Engine suspension nut:
Torque Value: 4.5~5.5 kgf-m
Rear shock absorber bolt:
Torque Value:
Top: 3.5~4.5 kgf-m
Down: 2.4~3.0 kgf-m
Rear wheel axle nut:
Torque Value: 11.0~13.0 kgf-m
Nut x1
5-9
This chapter Contents
5. REMOVAL OF ENGINE
NOTES:
5-10
Home page
Contents
6. Cylinder Head/Valve
Mechanism Illustration...............6-1
Valve Stem Replacement .......... 6-9
Precautions In Operation...........6-2
Valve Seat Inspection And Service
.................................................. 6-10
Troubleshooting .........................6-3
Cylinder Head Removal .............6-4
Cylinder Head Disassembly ......6-6
Cylinder Head Inspection ..........6-7
Cylinder Head Reassembly .... 6-12
Cylinder Head Installation ...... 6-14
Valve Clearance
Adjustment............................ 6-16
Mechanism Illustration
6
1.0~1.4 kgf-m
0.7~1.1 kgf-m
1.0~1.2kgf-m
0.8~1.2kgf-m
2.0~2.4kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
6-1
This chapter Contents
6. Cylinder Head/Valve
Precautions In Operation
General Information
• This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well
as rocker arm.
• Cylinder head service cannot be carried out when engine is in frame.
Specification
Camshaft
Rocker
arm
Unit: mm
Item
Standard
Limit
Compression pressure
12 ± 2 kg/cm²
-
Intake
25.688
25.290
Exhaust
25.519
25.120
ID of valve rocker arm
12.000~12.015
12.100
OD of valve rocker arm shaft
11.966~11.984
11.910
Intake
4.975~4.990
4.900
Exhaust
4.950~4.975
4.900
5.000~5.012
5.030
Intake
0.010~0.037
0.080
Exhaust
0.025~0.062
0.100
Free length of valve spring
35.000
31.500
Valve seat width
1.000
1.600
-
0.050
Height of cam lobe
OD of valve stem
Guide seat
Valve
Clearance between
valve stem and guide
Connection Flatness of cylinder head
Torque Value
Cylinder head bolt
Cylinder head bolt (LH)
Cylinder head Nut
Sealing bolt of timing chain auto-tensioner
Bolt of timing chain auto-tensioner
Timing gear cover bolts
Spark plug
TOOLS
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-2
1.0~1.4kgf-m
1.0~1.4kgf-m
1.8~2.2kgf-m (apply with oil on bolt thread & seat)
0.8~1.2kgf-m
1.0~1.4kgf-m
0.7~1.1kgf-m (apply with oil on bolt thread & seat)
1.0~1.4kgf-m
This chapter Contents
6. Cylinder Head/Valve
Troubleshooting
Engine performance will be effected by troubles on engine top-end. The troubles usually can be
determinated or by performing cylinder compression test and judging the abnormal noise generated.
Rough Idle
• Low compression pressure
Low compression pressure
1. Valve
z Improper valve adjustment
z Burnt or bended valve
z Improper valve timing
z Valve spring damaged
z Valve carbon
z Poor sealing on valve seat
z Improper spark plug installation
2. Cylinder head
z Cylinder head gasket leaking or damage
z Tilt or crack cylinder surface
3. Piston
z Piston ring worn out
High compression pressure
Too much carbon deposit on combustion chamber or piston head
•
Noise
• Improper valve clearance adjustment
• Burnt valve or damaged valve spring
• Camshaft wear out or damage
• Cam chain wear out or looseness
• Auto-tensioner wear out or damage of cam chain
• Camshaft sprocket wear out
• Rocker arm or rocker arm shaft wear out
White smoke
• Valve guide or valve stem wear out
• Valve stem seal wear out
6-3
This chapter Contents
6. Cylinder Head/Valve
Cylinder Head Removal
Bolt x 2
Remove:
Remove the cooling fan cover. (screw x 2, bolt x
2)
Screw x 2
Remove the right cover of engine. (screw x 4)
Up
Screw x 2
Down
Screw x 2
Remove the left cover of engine. (screw x 4)
Bolt x 1
Remove the left cap bolt of cylinder head (bolt
x2), and then remove the left cap of cylinder
head.
Remove the spark plug.
Bolt x 2
6-4
This chapter Contents
6. Cylinder Head/Valve
Turn the flywheel in counter clockwise motion
with T type wrench until the “T” mark on flywheel
aligned with the mark on the crankcase so that
the hole on the camshaft sprocket is forward up
and piston is at TDC position.
BTDC
Loosen the screw cap of camshaft chain
tensioner and remove O-ring.
With a flat screwdriver to tighten the screw of
camshaft chain tensioner in a clockwise motion
for release tensioner.
Remove the cam sprocket. (bolt x2)
Bolt x 2
Remove the left bolt (bolt x2) of cylinder head
firstly, and then remove the 4 nuts & washers
from the cylinder head top-end.
Pry out the chain and take out the sprocket.
Then, remove the cylinder head.
Nut x 4
Bolt x 2
Caution
•
•
Loosen the nuts diagonally by 2-3
sequences.
Do not let the chain fall into the crankcase
after removed the sprocket.
6-5
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6. Cylinder Head/Valve
Cylinder Head Disassembly
Remove the adjustment hole cap for the EX & IN
valve clearance. (bolt x 6)
Adjustment
hole cap
Firstly, remove the camshaft stopper, and then
drive a 6mm bolt into camshaft. Finally, remove
the camshaft and rocker arm.
Stopper
Camshaft
Use a valve compressor to press the valve
spring.
After removed valve split locks, release the
compressor and then take out spring retainer,
valve spring and valves.
Caution
In order to avoid loosing spring elasticity, do
not press the spring too much. Thus, press
length is based on the valve split locks in
which can be removed.
Special Service Tool: Valve spring compressor
Or with the valve spring remover/installer to
compress the valve spring directly. Then, remove
the valve and valve spring.
Caution
In order to avoid damaging the valve stem
and the cylinder head, in the combustion
chamber place a rag between the valve
spring remover/installer as compressing the
valve spring directly.
Special Service Tool: Valve spring remover/
installer.
6-6
Valve split lock
This chapter Contents
6. Cylinder Head/Valve
Remove valve, valve stem and valve spring.
Cylinder Head Inspection
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 25.29mm
EX: Replacement when less than 25.12mm
Inspect the camshaft bearing for looseness or
wear out. If any, replace whole set of camshaft
and bearing.
Rocker Arm
Measure the cam rocker arm I.D.
Service Limit: Replace when it is less than
12.10 mm.
Rocker Arm Shaft
Measure the active O.D. of the cam rocker arm
shaft and cam rocker arm.
Service Limit: Replace when it is less than
11.91 mm.
Calculate the clearance between the rocker arm
shaft and the rocker arm.
Service Limit: Replace when it is less than
0.10 mm.
6-7
This chapter Contents
6. Cylinder Head/Valve
Remove cylinder head gasket and 2 lock pins.
Remove chain plate.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Lock pin
Caution
•
•
Do not damage the matching surfaces of
cylinder and cylinder head.
Avoid residues of gasket or foreign
materials falling into crankcase as
cleaning.
Chain plate
Cylinder head gasket
Remove valve stem guide seal.
Clean carbon deposits in combustion chamber.
Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of
cylinder head.
Cylinder Head
Check if spark plug and valve holes are crack.
Measure cylinder head wrapage with a
straightedge and flat feeler gauge.
Service limit: 0.5 mm
Valve Spring Free Length
Measure the free length of intake and exhaust
valve springs.
Service limit: 31.5 mm
6-8
This chapter Contents
6. Cylinder Head/Valve
Valve Stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit:
IN→4.90 mm
EX→4.90 mm
Valve Guide
Caution
Before measuring the valve guide, clean
carbon deposits with reamer.
Special Service Tool: 5.0mm valve guide reamer
Measure and record each valve guide inner
diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit:
IN→0.08 mm
EX→0.10 mm
5.0mm valve guide
reamer
Caution
If clearance between valve stem and valve
guide exceeded service limit, check whether
the new clearance that only replaces new
valve guide is within service limit or not. If
so, replace valve guide.
Correct it with reamer after replacement.
If clearance still exceeds service limit after
replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing
valve guide.
Valve Stem Replacement
Heat up cylinder head to 100~150℃ with heated
plate or toaster.
5.0mm valve
guide driver
Caution
•
•
Do not let torch heat cylinder head
directly. Otherwise, the cylinder head may
be deformed as heating it.
Wear on a pair of glove to protect your
hands when operating.
6-9
This chapter Contents
6. Cylinder Head/Valve
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
Tool: Valve guide driver: 5 mm
Caution
•
•
13 mm
(0.15in)
Valve guide driver
5.0mm
Check if new valve guide is deformation
after pressed it in.
When pressing in the new valve guide,
cylinder head still have to be kept in
100~150℃.
Adjust the valve guide driver and let valve guide
height is in 13mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve
guide with reamer.
Caution
•
•
Using cutting oil when correcting valve
guide with a reamer.
Turn the reamer in same direction when it
be inserted or rotated.
Valve guide reamer
5.0mm
Correct valve seat, and clean up all metal
residues from cylinder head.
Tool: Valve guide reamer 5 mm
Valve Seat Inspection And Service
Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other
manual grinding tool.
Caution
•
•
Do not let emery enter into between
valve stem and valve guide.
Clean up the emery after corrected, and
apply with red paint onto contact faces of
valve and valve seat.
Remove the valve and check its contact face.
Caution
•
•
Replace the valve with new one if valve
seal is roughness, wear out, or
incomplete contacted with valve seat.
If the valve and the valve seat still can
not be matched sealing after grinded,
replace it with new one.
6-10
Valve seat
width
This chapter Contents
6. Cylinder Head/Valve
Valve Seat Inspection
If the valve seat is too width, narrow or rough,
correct it.
Valve seat width
Service limit: 1.6 mm
Check the contact condition of valve seat.
Valve Seat Grinding
The worn valve seat has to be grinded with valve
seat chamfer cutter.
Use 45° valve seat chamfer cutter to cut any
rough or uneven surface from valve seat.
Roughness
45°
Caution
After valve guide had been replaced, it has
to be grinded with 45° valve seal chamfer
cutter to correct its seat face.
Use 32° cutter to cut a quarter upper part out.
Old valve seat width
32°
Use 60° cutter to cut a quarter lower part out.
Remove the cutter and check new valve seat.
Old valve seat width
60°
Use 45° cutter to grind the valve seat to specified
width.
1.0mm
Caution
Make sure that all roughness and uneven
faces had been grinded.
Grind valve seat again if necessary.
45°
6-11
This chapter Contents
6. Cylinder Head/Valve
Coat the valve seat surface with red paint.
Install the valve through valve guide until the
valve contacting with valve seat, slightly press
down the valve but do not rotate it so that a seal
track will be created on contact surface.
Contact surface
too high
Old valve seat
width
Caution
The contact surfaces of valve and valve seat
are very important to the valve sealing
capacity.
32°
If the contact surface too high, grind the valve
seat with 32° cutter.
Then, grind the valve seat to specified width.
If the contact surface too low, grind the valve seat
with 60° cutter.
Then, grind the valve seat to specified width.
Contact surface
too low
Old valve seat
width
60°
After the valve seat grinded, coat valve seat
surface with emery and then slightly press the
grinded surface.
Clean up all emery coated onto cylinder and
valve after grinded.
Cylinder Head Reassembly
Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Valve split
locks
Valve stem
oil seal
Spring
retainer
Caution
The closed coils of valve spring should face
down to combustion chamber.
6-12
Valve
Valve spring
This chapter Contents
6. Cylinder Head/Valve
Use valve spring compressor to press valve
spring.
Install valve split locks and release the valve
compressor.
Caution
In order to avoid loosing spring elasticity, do
not press the spring too much. Thus, press
length is based on the valve split locks in
which can be removed.
Special Service Tool: Valve spring compressor
Or with the valve spring remover/installer to
install valve and spring.
Firstly, install valve spring, retainers onto the
valve as assembling.
Caution
In order to avoid damaging the valve stem
and the cylinder head, in the combustion
chamber place a rag between the valve
spring remover/installer as compressing the
valve spring directly.
With the valve spring remover/installer, compress
the valve spring directly. Then, remove the valve
and valve spring.
Special Service Tool: Valve spring remover/
installer.
Tap valve stem to make valve retainer and valve
stem sealing properly.
Caution
Place and hold cylinder head on to working
table and place a rag against onto the valve
so that can prevent damage valve stem and
cylinder head.
6-13
This chapter Contents
6. Cylinder Head/Valve
Install the camshaft onto the cylinder head and
then the rocker arm and the rocker arm shaft.
Lock the lock plate after rotate the rocker arm
shaft to properly position.
EX rocker arm shaft
Lock plate
Caution
There is different shapes on the top-end of
rocker arm shaft. The machined surface on
the rocker arm shaft has to face toward
exhaust side, and then the larger surface
has to align with the bolt hole of cylinder
h d
Cylinder Head Installation
IN rocker arm shaft
Lock pins
Install the lock pins and new cylinder head
gasket onto the cylinder head.
Install the camshaft chain plate.
Chain plate
Cylinder head gasket
Install the cylinder head.
Tighten the 4 nuts onto the cylinder head top-end,
and then the 2 cylinder head mounting bolts on
its side.
Torque value: 2.0~2.4 kgf-m
Nut x 4
Bolt x 2
Caution
This model is equipped with precious 4
valves mechanism so tighten torque can not
be over the limited value and tightening the
bolts diagonally by 2-3 sequences. It can
prevent from cylinder head deformation and
then cause noise or leaking problems so that
effect motorcycle’s performance.
With T type wrench to turn crankshaft in a
clockwise motion so that the “T” mark on the
alternator flywheel aligns with the mark on
crankcase. (piston is at TDC position)
Place the TDC marks of the cam sprocket at
same level of the top-end of cylinder head. The
other single hole of the cam sprocket is in
upward. Then, install the cam chain onto the
cam sprocket.
Install the spark plug and tighten it.
Torque value: 1.0~1.2 kgf-m
6-14
BTDC
This chapter Contents
6. Cylinder Head/Valve
Tighten the cylinder head right side cover. (bolt x
2)
Bolt x 2
With flat screwdriver, turn the cam sprocket
tensioner in counter-clockwise motion so that the
tensioner is pushed out to contact the cam chain
plate tightly. Apply with oil onto a new O-ring
and then install it onto the tensioner hole.
Tighten the bolt cap of the tensioner adjustment
hole.
Caution
The O-ring must be installed into glove.
Install the left-side cover of the engine body. (bolt
x 1)
Bolt x 1
Install the right-side cover of the engine body.
(screw x 4)
Up
Screw x 2
Down
Screw x 2
6-15
This chapter Contents
6. Cylinder Head/Valve
Install the cooling fan cover. (screw x2, bolt x 2)
Bolt x 2
Screw x 2
Valve Clearance Adjustment
Loosen valve clearance adjustment nuts and
bolts located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.12 ± 0.02 mm
EX 0.12 ± 0.02 mm
Install the valve clearance adjustment hole cap.
(bolt x2)
Start the engine after assembly. Remove the
intake valve adjustment hole cap and make sure
that engine oil flows onto the cylinder head.
Stop the engine after confirmed, and then install
the intake valve adjustment hole cap.
Install the seat cushion and the central cover.
Caution
•
•
The cylinder components will be serious
wear out if lubricant did not flow onto the
cylinder head. So it has to be
confirmed.
It has to be in idle speed when conduct
this procedure. Never increase engine
speed in high RPM.
6-16
Intake valve
adjustment hole cap
Home page
Contents
7. Cylinder/Piston
Mechanism Illustration ...............7-1 Piston Removal ...........................7-5
Precautions In Operation ...........7-2 Piston Inspection ........................7-5
Trouble Diagnosis.......................7-2 Piston Ring Installation ..............7-7
Cylinder Removal........................7-3 Piston Installation .......................7-8
Cylinder Inspection.....................7-4 Cylinder Installation....................7-8
Mechanism Illustration
7
0.8~1.2 kgf-m
7-1
This Chapter Contents
7. Cylinder/Piston
Precautions In Operation
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification
Unit: mm
Item
Standard
Limit
57.400~57.410
57.500
Bend/wrapage
-
0.050
Cylindrical roundness
-
0.050
Cylindrical roundness
-
0.050
Top ring
0.025~0.060
0.090
2nd ring
0.015~0.050
0.090
Top ring
0.100~0.250
0.500
2nd ring
0.250~0.400
0.650
Oil ring side
rail
0.200~0.800
-
57.370~57.390
57.300
Lower-end up 9mm
of piston skirt
-
0.010~0.040
0.100
15.002~15.008
15.040
14.994~15.000
14.960
0.002~0.014
0.020
15.016~15.034
15.060
ID
Cylinder
Clearance between
piston rings
Ring-end gap
Piston/Piston
ring
OD of piston
Piston OD measurement position
Clearance between piston and
cylinder
ID of piston pin boss
OD of piston pin
Clearance between piston and piston pin
ID of connecting rod small-end
Trouble Diagnosis
Low Or Unstable Compression Pressure
• Cylinder or piston ring worn out
High Compression Pressure
• Carbon deposit onto the piston & combustion
chamber
Knock or Noise
• Cylinder or piston ring worn out
• Carbon deposits on cylinder head top-side
• Piston pin hole and piston pin wear out
7-2
Smoking in Exhaust Pipe
• Piston or piston ring worn out
• Piston ring installation improperly
• Cylinder or piston damage
Engine Overheat
• Carbon deposits on cylinder head top side
This Chapter Contents
7. Cylinder/Piston
Cylinder Removal
Remove cylinder head. (refer to chapter 6)
Remove 2 bolts and then take out the cam chain
auto-tensioner.
Bolt x 2
Remove cam chain plate.
Remove cylinder.
Remove cylinder gasket and lock pins.
Clean the residues attached onto the matching
surfaces of cylinder and crankcase.
7-3
This Chapter Contents
7. Cylinder/Piston
Cover the holes of crankcase and cam chain with
a piece of cloth.
Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.
Caution
To soap the residues into solvent so that the
residues can be removed more easily.
Cylinder Inspection
Check if the inner diameter of cylinder is worn
out or damaged.
In the 3 positions (top, center and bottom) of
cylinder, measure the X and Y direction values
respective in the cylinder.
Service limit: 57.50 mm
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 positions of X or Y motion
values.) Then, determinate by the max. value.
Service limit:
Real roundness: correct or replace as over
0.05 mm
Cylindrical roundness: correct or replace as
over 0.05 mm
Check Cylinder Wrapage.
Service limit: correct or replace as over 0.05
mm
7-4
Exhaust side
Top
Center
Bottom
Intake side
This Chapter Contents
7. Cylinder/Piston
Piston Removal
Plug crankcase opening with a cleaning cloth to
prevent from piston pin snap ring or other parts
falling into crankcase when disassembling.
Hold another snap ring with pliers.
Push out the piston pin from the side that not
removed the snap ring.
Remove piston rings.
Caution
Pay attention to remove piston rings because
they are fragile.
Disassemble the piston rings.
Check if the piston rings are damaged or its
grooves are worn.
Clean out the carbon deposit around the
piston ring groove.
Piston Inspection
Piston ring
Install the piston rings and then measure
clearance between piston ring and its grooves.
Service Limit:
Top ring: replace if over 0.09 mm
2nd ring: replace if over 0.09 mm
Push in
Piston
Feeler gauge
Take out the piston rings and place them
respective into cylinder below 20mm of cylinder
top. Measure each piston ring gaps.
Caution
Push the piston rings into cylinder with
piston top-end in parallel motion.
Service Limit:
Top ring: replace if over 0.5 mm
2nd ring: replace if over 0.65 mm
Piston rings
7-5
This Chapter Contents
7. Cylinder/Piston
Measure the outer diameter of piston pin.
Service Limit: 14.96 mm
Measure the inner diameter of connecting rod
small end.
Service Limit: 15.06 mm
Measure the inner diameter of piston pin hole.
Service Limit: 15.04 mm
Calculate clearance between piston pin and its
hole.
Service Limit: 0.02 mm
Measure piston outer diameter.
Caution
The measurement position is 10 mm
distance from piston bottom side, and 90° to
piston pin.
Service limit: 57.30 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
7-6
This Chapter Contents
7. Cylinder/Piston
Piston Ring Installation
Clean up piston top, ring groove, and piston shirt.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
•
•
•
Do not damage piston and piston rings as installation.
All marks on the piston rings must be forwarded to up side.
Make sure that all piston rings can be rotated freely after installed.
Top ring
120°
2nd ring
Side
ring
Spacer
Oil ring
Side
ring
Over 20 mm
Top groove
2nd groove
Oil groove
7-7
This Chapter Contents
7. Cylinder/Piston
Piston Installation
Install piston and piston pin, and place the IN
marks on the piston top side forward to intake
valve.
Install new piston pin snap ring.
Caution
•
•
Do not let the opening of piston pin snap ring
align with the opening piston ring.
Place a piece of cloth between piston skirt
section and crankcase in order to prevent
snap ring from falling into crankcase as
operation.
Cylinder Installation
Clean up all residues and foreign materials on
the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
To soap the residues into solvent so that the
residues can be removed more easily.
Install 2 lock pins and new gasket.
Coat engine oil to inside of cylinder, piston and
piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because this will cause the piston and the
piston rings to be damaged.
Install the cam chain plate, the cylinder gasket
and lock pins.
Install cylinder head. (refer to Chapter 6)
Install the cam chain auto-tensioner. (2 bolts)
Bolt x 2
7-8
Home page
Contents
8. V-Belt Driving System/Foot Starter
Mechanism Illustration............... 8-1 Foot Starter ..................................8-3
Maintenance Description ........... 8-2 Driving Belt ..................................8-4
Trouble Diagnosis ...................... 8-2 Sliding Pulley...............................8-6
Left Crankcase Cover................. 8-3 Clutch/Driven Pulley ...................8-9
Mechanism Illustration
5.0~6.0 kgf-m
5.0~6.0 kgf-m
8
5.0~6.0 kgf-m
1.0~1.5 kgf-m
8-1
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Maintenance Description
PRECAUTIONS IN OPERATION
•
Driving pulley, clutch, and driven pulley can be serviced on the motorcycle.
•
Driving belt and driving pulley surface must be free of grease.
Specification
Item
Standard value
Driving belt width
Unit: mm
Limit
18.500
ID of sliding pulley bushing
19.500
27.000~27.021
27.060
OD of sliding pulley hub
26.970~26.990
26.940
OD of weight roller
19.950~20.100
19.500
ID of clutch jacket
130.000~130.200
130.500
4.000~4.100
2.000
128.400
123.400
33.965~33.985
33.940
34.000~34.025
34.060
Thickness of clutch lining
Free length of driving pulley spring
OD of driving pulley
ID of sliding pulley
ID: Inner Diameter
OD: Outer diameter
Torque value
Sliding pulley nut: 5.0~6.0 kgf-m
Clutch jacket nut: 5.0~6.0 kgf-m
driving pulley nut: 5.0~6.0 kgf-m
Special Service Tools
Clutch spring compressor
Bearing puller (inner type)
Clutch mounting nut wrench
Universal fixture
Trouble Diagnosis
Engine can be started but motorcycle can
not be moved
1. Worn driving Belt
2. Worn tilt plate
3. Worn or damaged clutch lining
4. Broken driven pulley
Shudder or misfire when driving
1. Broken clutch lining
2. Worn clutch lining
8-2
Insufficient horsepower or poor high speed
performance
1. Worn driving belt
2. Insufficient spring capacity of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Left Crankcase Cover
Removal of Crankcase Cover
Remove body cover.
Remove foot starter lever. ( bolt x 1)
Remove the outer cover of engine left-side cover.
(screw x 3)
Loosen vent strap on the front-left side of cover,
and then remove the vent.
Remove air cleaner. (bolt x 2)
Remove the engine left-side cover. ( bolt x 8)
Outer cover screw x 3
Foot Starter
Disassembly
Remove snap ring and thrust washer from
engine left-side cover.
Install foot starter lever, rotate the lever slightly
and then remove driving gear and washer.
Remove the lever, foot starter, starter shaft, and
return spring as well as socket.
Inspection
Check if starter shaft, driving gear, socket and
bearing hole for wear or damage. Replace it with
new one if necessary.
Check the return spring and friction spring for
spring force or damaged. Replace it with one if
poor parts found.
Reassembly
Install socket, return spring and starter shaft as
diagram shown.
Install thrust washer and snap ring onto starter
shaft.
Install foot starter lever temporary.
Rotate the lever and then align driving gear with
width-tooth on the starter shaft.
Install the friction of driving gear onto convex part
of the cover.
Installation of the left crankcase cover
Install the left crankcase cover. (8 screws)
Install front vent tube of left cover and tighten the
strap.
Install foot starter lever. (1 bolt)
Tighten the air cleaner. (2 bolts)
Install the body cover.
Starter shaft
Return spring Driving gear
Return
spring
Starter
shaft
Friction
spring
8-3
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Driving Belt
Removal
Remove left crankcase cover.
Hold driving pulley with universal fixture, and
remove nut and clutch jacket.
Universal
fixer
Hold the clutch outer jacket with the universal
fixture, and the remove the nut and the clutch
outer jacket.
Nut
Caution
Using special service tools for tightening or
loosening the nut. Fixed rear wheel or rear
brake only will damage reduction gear system.
Universal
fixer
Push the driving belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove.
Driving belt and clutch at 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 belt if exceeds the service
limit.
Service Limit: 18.5 mm
Caution
•
•
Using the genuine parts for replacement.
The surfaces of driving belt or pulley must
be free of grease.
8-4
Driving belt
Tooth
Width
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Installation
Pull out the driving pulley and then insert the
driving belt into the driving pulley.
Sliding
driven
pulley
Caution
Pull out driving pulley and then insert the
driving belt into the driving pulley so that the
driving belt set can be installed onto sliding
pulley more easily.
Install the clutch set with driving belt onto the
driving shaft.
The other end of belt hook onto the sliding pulley.
Install the clutch outer jacket.
Install the clutch with universal fixture, and then
tighten nut to specified torque value.
Torque value: 5.0~6.0 kgf-m
Clutch jacket
Nut
Universal fixer
Caution
When install the driving belt, if there is a
arrow mark, then the arrow mark must point
to rotation motion. If not, the letters on the
belt must be forwarded to assembly
direction
8-5
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Sliding Pulley
REMOVAL
Remove left crankcase cover.
Hold driving pulley with universal fixture, and
then remove driving pulley nut.
Remove driving pulley.
Universal
fixture
Take out the driving belt from the pulley.
Remove sliding pulley set and driving pulley hub
from crankshaft.
Sliding pulley
Crankshaft
Remove tilt plate.
Sliding
pulley
Remove weight rollers from sliding pulley.
Weight roller
Weight roller
8-6
Driving
pulley hub
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Inspection
The operation of sliding pulley is means of the
weight roller to pressing on it with centrifuge
force. And then the speed is changed by the title
plate rotation. Thus, if weight rollers are wear
out or damage, the centrifuge force will be
effected.
Check if rollers are wear out or damage.
Replace it if necessary.
Measure each roller’s outer diameter. Replace it
if exceed the service limit.
Service limit: 19.50 mm
Weight roller
Check the pulley hub if damaged or wear out.
Replace it if necessary.
Measure the pulley hub’s outer diameter.
Replace it if exceed the service limit.
Service limit: 23.94 mm
Measure the pulley hub’s inner diameter.
Replace it if exceed the service limit.
Service limit: 24.06 mm
Assembly/Installation
Sliding pulley
Pulley hub
Weight roller
Install the weight roller.
Caution
The both ends of weight roller are different.
In order to prolong the roller life span and
prevent abnormal wearing out, install the
closed end onto the sliding pulley in the
movement of CCW.
Closed end
Install the title plate guide boot (3 pieces) onto
the title plate.
Install the title plate.
Guide boot
Tilt plate
8-7
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Apply with grease 4~5 g to inside of driving shaft
hole, and install driving pulley hub.
Caution
The pulley surface has to be free of grease.
Clean it with cleaning solvent.
Pulley surface
Install siding pulley assembly onto crankshaft.
Sliding pulley
Pulley hub
Crankshaft
DRIVING PULLEY INSTALLATION
Press driving belt into pulley groove, and then
press down the up & down sides of the driving
belt to separate it away from the driving pulley
hub.
Press down
Caution
To press down the up & down sides of the
driving belt can avoid to pressing and
damaging the belt when installing the driving
pulley, and also can make sure that the
driving pulley can be tighten.
Driving belt
Install driving pulley, washer and nut.
Caution
Make sure that two sides of pulley surfaces
have to be free of grease. Clean it with
cleaning solvent.
Hold driving pulley with universal fixture.
Tighten nut to specified torque.
Torque value: 5.0~6.0 kgf-m
Install left crankcase cover.
Universal fixture
8-8
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Clutch/Driven Pulley
Special nut wrench
DISASSEMBLY
Remove driving belt and clutch/driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let nut
be installed more easily.
Caution
Do not press the compressor too much.
Hold the clutch spring compressor onto bench
vise, and then remove mounting nut with special
nut wrench.
Release the clutch spring compressor and
remove clutch and spring from driven pulley.
Clutch spring compressor
Remove oil seal from driven pulley.
Oil seal
Remove guide pin, guide pin roller, and sliding
pulley, and then remove O-ring & oil seal seat
from sliding pulley.
Sliding pulley
O-ring
Oil seal
Guide pin
Guide pin
Guide pin
roller
INSPECTION
Clutch jacket
Measure the inner diameter of clutch jacket
friction face. Replace the clutch jacket if exceed
service limit.
Service limit: 130.5 mm
Inner
diameter
Clutch jacket
8-9
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Clutch lining
Measure each clutch lining thickness.
it if exceeds service limit.
Service limit: 2.0 mm
Replace
Clutch lining
Clutch
Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 123.4 mm
Driven pulley
Check following items:
• If both surfaces are damage or wear.
• If guide pin groove is damage or wear.
• Replace damaged or worn components.
• Measure the outer diameter of driven surface
and the inner diameter of driven pulley.
Replace it if exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm
Free length
Driven pulley
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. Also check if bearing outer is installed
properly. Replace it if necessary.
Sliding disc
Guide pin
groove
Needle bearing
Outer ball
bearing
8-10
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Clutch Block Replacement
Remove snap and washer, and the remove
clutch block and spring from driving plate.
Check if spring is damage or insufficient
elasticity.
Spring
Driving
plate
Clutch block
Check if shock absorption rubber is damage or
deformation. Replace it if necessary.
Apply with grease onto setting pins.
Snap ring
Shock absorption
rubber
Setting pin
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 to specified location.
Shock absorption
rubber
Caution
•
Grease or lubricant will damage the clutch
block and effect the block’s connection
capacity.
Clutch block
Install the spring snap into groove with pliers.
Spring
8-11
This Chapter Contents
8. V-Belt Driving System/Foot Starter
Install snap ring and mounting plate onto setting
pin.
Snap ring
REPLACEMENT OF DRIVEN PULLEY BEARING
Remove inner bearing.
Caution
•
•
Oil seal
Outer bearing
If the inner bearing equipped with oil seal
on one side in the driven pulley, then
remove the oil seal firstly.
If the pulley equipped with ball bearing, it
has to remove snap ring and then the
bearing.
Inner needle
bearing
Snap ring
Remove snap ring and then push bearing
forward to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified grease. Recommended to
use the KING MATE G-3.
Install the snap ring and hold the bearing.
Snap
ring
Specified oil
Sealing
end
Outer
bearing
Install a new inner bearing.
Caution
•
•
Sealing end
Its sealing end should be forwarded to
outside as bearing installation.
Install needle bearing with hydraulic
presser. Install ball bearing by means
of hydraulic presser.
Align oil seal lip with bearing, and then install the
new oil seal. (if necessary)
8-12
Inner bearing
This Chapter Contents
8. V-Belt Driving System/Foot Starter
INSTALLATION OF CLUTCH/DRIVEN PULLEY
ASSEMBLY
Install new oil seal and O-ring onto sliding pulley.
Apply with specified grease to lubricate the inside
of sliding pulley.
Oil seal
Specified
grease
O-ring
Install sliding pulley onto driven pulley.
Install guide pin and guide pin roller.
Sliding pulley
O-ring
Oil seal
Guide pin
Guide pin
Guide pin
roller
Install oil socket.
Oil socket
Install driving belt, 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 mounting nut to specified torque with special
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0 kgf-m
Install clutch/driven pulley and driving belt onto
driving shaft.
Mounting nut wrench
Mounting
nut
Clutch spring compressor
8-13
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8. V-Belt Driving System/Foot Starter
NOTES:
8-14
Home page
Contents
9. Final Driving Mechanism
Mechanism Illustration .............. 9-1 Inspection Of Final Driving
Mechanism..................................9-3
Operational precautions............ 9-2
Bearing Replacement.................9-4
Trouble Diagnosis...................... 9-2
Re-Assembly Of Final
Disassembly of Final
Driving Mechanism .................9-6
Driving Mechanism ................. 9-3
Mechanism Illustration
Countershaft
Final driving
shaft
Final driving gear
9
0.8~1.2 kgf-m
Countershaft
gear
Driving gear
2.0~2.4 kgf-m
1.0~1.4 kgf-m
9-1
This Chapter Contents
9. Final Driving Mechanism
Operational precautions
Specification
Application gear oil: 4-stroke lubricant
Recommended oil: KING MATE serial gear oils
Oil quantity: 110 c.c. (100 c.c. when replacing)
Torque value
Gear box cover
Gear oil drain plug
Gear oil filling bolt
2.0~2.4 kgf-m
1.0~1.4 kgf-m
0.8~1.2 kgf-m
Tools
Special service tools
Inner type bearing puller
Outer type bearing puller
Gear box oil seal installer
Gear box bearing installer
Trouble Diagnosis
Engine can be started but motorcycle can
not be moved
• Damaged driving gear
• Burnt out driving gear
• Broken driving belt
Noise
• Worn or burnt gear
• Worn gear
9-2
Gear oil leaks
• Excessive gear oil
• Worn or damage oil seal
This Chapter Contents
9. Final Driving Mechanism
Disassembly of Final Driving
Mechanism
Remove the rear wheel. (refer to chapter 15)
Remove the clutch.
Drain gear oil out from gear box.
Remove gear box cover bolts (7 bolts) and then
remove the cover and the final driving shaft.
Remove gasket and setting pin.
7 bolts
Remove countershaft and gear.
Remove final driving gear and shaft.
Final driving shaft
Countershaft
gear
Final driving
gear
Countershaft
Driving shaft
Inspection Of Final Driving
Mechanism
Check if the countershaft and the gear are wear
out or damage.
Check if the final driving shaft and gear are burn,
wear or damage.
9-3
This Chapter Contents
9. Final Driving Mechanism
Check bearings on gear box and 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 box & cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Caution
• Do not remove the driving shaft from the
cover top side.
• If remove the driving shaft from the gear
box, then its bearing has to be replaced.
Check driving shaft and gear for wear or damage.
Bearing Replacement
Caution
• Never install used bearings. Once bearing
removed, it has to be replaced with new
one.
Remove driving shaft bearing from left crankcase
using following tools:
Inner type bearing puller
Install new driving shaft bearing into left
crankcase.
Special tool:
Press the bearing into cover with C type
hydraulic presser or bearing installer.
9-4
This Chapter Contents
9. Final Driving Mechanism
Press out the driving shaft from the gear box.
Remove oil seal from the gear box.
Remove the driving shaft bearing from the gear
box cover with the inner type bearing puller.
Caution
• Using the bearing protector as pressing
out the driving shaft from the gear box
cover.
Specified tool:
Inner type bearing puller.
If the driving shaft is pulled out with its bearing,
then remove the bearing with bearing puller and
bearing protector.
Special tool:
Multi-functional bearing puller
Bearing protector
Shaft protector
Universal bearing
puller (inner type)
Install a new driving shaft bearing onto gear box
cover.
Then, install the driving shaft.
Specified tool:
Press the bearing in with C type hydraulic
presser or bearing installer.
Install a new final driving shaft bearing onto gear
box cover.
Specified tool:
Press the bearing in with C type hydraulic
presser or the bearing installer.
Apply with some grease onto the lip section of oil
seal and then install the seal.
9-5
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9. Final Driving Mechanism
Re-Assembly Of Final Driving
Mechanism
Install final driving shaft and final driving gear,
countershaft, and countershaft gear.
Final
driving
shaft
Install the setting pins (2 pins) and new gasket.
Setting pins
Apply with grease onto the oil seal lip of final
driving shaft.
Install the gear box cover and 7 bolts. (tighten the
bolts)
Torque: 2.0~2.4 kgf-m
Install the clutch/sliding driving pulley.
Install the driving pulley, belt and left crankshaft
cover.
Install the rear wheel.
Add gear oil.
※Recommended usage: SYM HYPOID GEAR
OIL (SAE 85W-140)
(110 cc: standard capacity)
(100 cc: when replacement)
7 bolts
9-6
Final driving
shaft gear
Counter
shaft
Home page
Contents
10. Alternator/Starting Clutch
Mechanism Illustration .................1
Starting Clutch ........................ 10-5
Precautions in Operation ........10-2
Right Crankcase Cover Installation
.................................................. 10-8
Alternator Removal..................10-3
Alternator Coil Set Removal ...10-4
Right Crankcase Cover
Removal .................................10-4
Mounted Coil Set Installation. 10-8
Flywheel Installation ............... 10-8
Mechanism Illustration
5.0~6.0 kgf-m
9.0~10.0 kgf-m
1.0~1.4 kgf-m
10
0.1~0.3 kgf-m
1.5~2.0 kgf-m
1.3~1.7 kgf-m
10-1
This Chapter Contents
10. Alternator/Starting Clutch
Precautions in Operation
General information
z Refer to chapter 5: Engine removal and installation
z Refer to chapter 1: The troubleshooting and inspection of alternator
z Refer to chapter 16: The service procedures and precaution items of starter motor
Specification
Item
Unit: mm
Service Limit
ID of starting driven gear
32.060
OD of clutch cover
27.940
Torque value:
Flywheel nut
5.0~6.0 kgf-m
Bolt 8mm
1.5~2.0 kgf-m
Oil screen cover
1.3~1.7 kgf-m
Starting clutch mounting bolt
9.0~10.0 kgf-m with oil on the thread
Starting clutch hex socket bolt
1.0~1.4 kgf-m with adhesive
Special service tools
Flywheel puller
Universal fixture
10-2
This Chapter Contents
10. Alternator/Starting Clutch
Alternator Removal
Crankshaft
position sensor
Flywheel
Fan
Fan shroud
Coil
Cable guide
Drain out the engine oil.
Remove the right side cover. ( 4 screws)
Remove the exhaust pipe. (2 bolts, 2 nuts)
Remove the fan shroud. (2 screws)
Remove the cooling fan shroud. (bolt x 2, screw
x 2)
Remove the cooling fan. (4 bolts)
Cooling fan
Hold the flywheel with the universal fixture.
Remove the 10mm nut on the flywheel.
Special Service Tools:
Universal Fixture
Universal fixture
10-3
This Chapter Contents
10. Alternator/Starting Clutch
Remove the flywheel with the flywheel puller.
Special service tools:
Flywheel puller
shaft protector
Caution
Install a shaft protector on the right end of
crankshaft to avoid damaging the crankshaft
before installing the flywheel puller.
Flywheel puller
Crankshaft
position sensor
Alternator Coil Set Removal
Remove the connectors of the alternator and
crankshaft position sensor.
Alternator connector
Cable guide
Remove the 6 bolts for the crankshaft position
sensor, the alternator coil and cable guide.
Then, remove the alternator assembly.
Crankshaft
position
sensor
Caution
Do not damage the alternator coil.
Coil
8 bolts
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
crankcase.
Caution
Do not damage the connection surfaces.
10-4
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10. Alternator/Starting Clutch
Starting Clutch
Starting Clutch Removal
Hold the starting driven gear with the universal
fixture.
Remove the 22mm anti-loosen mounting nut and
gasket.
Special service tools:
Anti-loosen mounting nut socket
Universal fixture
Mounting nut
Caution
The mounting nut is left-turn thread.
Mounting nut socket
Remove the starting driven gear.
Remove starting clutch, starting idle-gear, and
shaft.
Starting Clutch Inspection
Install the starting clutch onto the starting driven
gear.
Hold the starting clutch and turn the starting
driven gear.
The starting driven gear should can be turned in
the motion of C.W. and can not be turned in
C.C.W.
10-5
This Chapter Contents
10. Alternator/Starting Clutch
Check the starting driven gear for wear or
damage.
Measure the ID of the starting driven gear.
Service Limit:
ID: 32.06 mm or less
Check the starting idle gear and shaft for wear or
damage.
Measure the ID of the starting idle gear.
Service Limit:
ID: 10.05 mm or less
Measure the OD of the starting idle gear.
Service Limit:
OD: 9.94 mm or more
Disassembly
Remove the hex blots (3 bolts) inside the starting
clutch.
Separate the clutch body and the clutch cover.
Remove the rollers, plugs, and springs on the
one way clutch.
Check each rollers and plugs for wear or
damage.
Install rollers, plugs and springs.
Plug
Roller
Clutch body
Clutch cover
Measure the OD of the starting clutch cover.
Service Limit:
OD: 27.94 mm or more
10-6
Spring
This Chapter Contents
10. Alternator/Starting Clutch
Installation
Install the components in the reverse procedures
of removal.
Plug
Spring
Caution
Add adhensive onto the thread of hex socket
bolt.
Roller
Torque value: 1.0~1.4 kgf-m
Clutch body
Clutch cover
Starting clutch Installation
Install idle gear shaft and idle gear.
Install starting clutch.
Install the starting driven gear onto the starting
clutch.
Hold the starting driven gear with the universal
fixture.
Tighten the 22mm anti-loosen mounting nut and
gasket.
Caution
Add engine oil onto the thread of mounting
nut.
Special service tools:
Anti-loosen mounting nut socket
Universal fixture.
Torque value: 9.0~10.0 kgf-m
Mounting nut
Mounting nut socket
10-7
This Chapter Contents
10. Alternator/Starting Clutch
Right Crankcase Cover Installation
8 bolts
Install setting pin and new gasket on the
crankcase.
Replace the right crankshaft oil seal of the
crankcase and apply some oil onto the oil seal
lip.
Install right crankcase cover onto the right
crankcase. (8 bolts)
Torque value: 1.5~2.0 kgf-m
Cable guide
Mounted Coil Set Installation
Install the coil set onto right crankcase cover. (2
screws)
Install crankshaft position sensor. (2 screws)
Tighten the cable guide. (2 screws)
Torque: 1.5~2.0 kgf-m
Tie the wire harness hose onto the indent of
crankcase.
Crankshaft
position
sensor
Caution
Make sure that the wire harness is placed
under the crankshaft position sensor.
Coil
Crankshaft position
sensor connector
Connect the connectors of alternator and
crankshaft position sensor.
Alternator connector
Flywheel Installation
Make sure that there is no magnetic powder.
so, clean up it.
Align insert on crankshaft with the flywheel
groove, and then install the flywheel.
Hold the flywheel with flywheel holder, and
tighten its nut.
Torque value: 5.0~6.0 kgf-m
Special service tool:
Universal fixture
10-8
Universal fixture
If
This Chapter Contents
10. Alternator/Starting Clutch
Install the cooling fan. (4 bolts)
Cooling fan
Install the cooling fan shroud. ( 3 screws)
Install the rear bracket mounting bolts. (2 bolts)
Install the exhaust pipe. (2 bolts, 2 nuts)
Install the right side cover. (4 screws)
Add some engine oil according to specified
quantity.
10-9
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10. Alternator/Starting Clutch
NOTES:
10-10
Home page
Contents
11. Crankcase/Crankshaft
Mechanism Illustration ............11-1
Disassembly Of Crankcase ..... 11-3
Operational precautions..........11-2
Crankshaft Inspection.............. 11-4
Trouble diagnosis ....................11-2
Assembly Of Crankcase .......... 11-5
Mechanism Illustration
1.5~2.0 kgf-m
1.0~1.4 kgf-m
11
0.7~1.0 kgf-m
0.8~1.2 kgf-m
0.8~1.2 kgf-m
3.5~4.5 kgf-m
11-1
This Chapter Contents
11. Crankcase/Crankshaft
Operational precautions
General Information
• This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft
can be serviced.
• Complete following operations before disassembling crankcase.
•
Engine
Chapter 5
Cylinder head
Chapter 6
Cylinder/ piston
Chapter 7
V-belt Drive pulley
Chapter 8
Alternator/Foot Starting Clutch
Chapter 10
Start motor
Chapter 16
If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have to
replaced.
Specification
Unit: mm
Item
Standard
Limit
Left, right clearance of the big end of the connecting rod
0.100~0.300
0.550
Right angle clearance of the big end of the connecting rod
0.000~0.008
0.050
─
0.100
Run-out
Torque value
Bolts for crankcase
Bolts for cylinder/cylinder head
Engine oil draining plug
Bolts for cam chain tensioner
Special Service Tools
Crankcase remover/set
Crankshaft installation puller
Inner type bearing puller
Outer type bearing puller
Bearing pressing tools
Oil seal pressing tools
Trouble diagnosis
Engine noise
• Loose crankshaft bearing
• Loose crankshaft pin bearing
• Wear piston pin or piston pin hole
11-2
:
:
:
:
1.5~2.0 kgf-m
0.7~1.0 kgf-m
3.5~4.5 kgf-m
0.8~1.2 kgf-m
This Chapter Contents
11. Crankcase/Crankshaft
Disassembly Of Crankcase
Remove the cam chain tensioner (hex socket
bolt x 1) from the left crankcase side.
Remove the 2 bolts from the right side of
crankcase, and then remove the right crankcase.
Hex-socket bolt x 1
Screw x 2
Remove the crankshaft from the left crankcase.
Remove the cam chain.
Remove the gasket and setting pin. (2 bolts)
Scrape gasket residues off the crankcase contact
surface.
Caution
•
•
•
Check if the right & left bearings are
press-in the crankshaft.
Do not damage contact surface of the
crankcase.
Soap the gasket residues into solvent and
the residues will be removed easily.
Remove oil seal from the left crankcase side.
11-3
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11. Crankcase/Crankshaft
Crankshaft Inspection
Measure left and right clearance of connecting
rod big end.
Service limit: Replace when it is more than
0.55 mm
Measure the radical clearance of the big end at
the vertical 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
60 mm
Bearing Inspection
Rotate the bearing with fingers and make sure
the bearing can be rotated smoothly and quietly.
Check if the inner ring is connected onto the
crankshaft tightly.
Replace crankshaft as a set when noise or
looseness is detected.
90 mm
Clearance
Clearance
曲軸軸承
11-4
This Chapter Contents
11. Crankcase/Crankshaft
Assembly Of Crankcase
Install cam chain into the chain hole of the left
crankcase, and then split out the cam chain.
Caution
Do not damage the cam chain as installing
the crankshaft.
Install crankshaft into the left crankcase and then
install two dowel pins and new crankcase gasket.
Dowel pins
Install the right crankcase and tighten the
crankcase bolts. (2 bolts)
Torque value: 1.5~2.0 kgf-m
2 bolts
Install the cam chain tensioner.
Install a new O-ring onto the mounting bolt of the
chain tensioner.
Apply some oil on the O-ring and tighten the bolt.
Torque value: 0.8~1.2 kgf-m
Hex-socket bolt
Caution
The O-ring must be installed into the bolt’s
groove.
11-5
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11. Crankcase/Crankshaft
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: the oil seal installer
(25x37x6)
11-6
Home page
Contents
12. Body Cover
Mechanism Illustration ............ 12-1 Luggage Box ............................12-8
Maintenance Information ........ 12-2 Rear Carrier ..............................12-9
Front Cover............................... 12-3 Body Cover .............................12-10
Handlebar Cover ...................... 12-4 Left & Right Side-Foot Plates 12-11
Front Fender............................. 12-5 Left & Right Side-Covers.......12-11
Front Under Spoiler ................. 12-6 Floor Panel..............................12-12
Inner Box .................................. 12-7 Rear Fender ............................12-13
Center Cover ............................ 12-8
Mechanism Illustration
Seat
Luggage box
Handlebar side
cover (RH)
Handlebar rear cover
Rear Carrier
Right body
cover
Right side cover
12
Center body
cover
Handlebar cover
Left-body
cover
Center cover
Handlebar side
cover (LH)
Right foot
plate
Tail light
set
Battery
cover
Left foot plate
Inner rear
fender
Front cover
Rear
fender
Left side cover
Floor panel
Front fender
Inner box
Front under
spoiler
Foot mat
Under Cover
12-1
This Chapter Contents
12. Body Cover
Maintenance Information
Body covers disassemble sequence:
Handlebar Rear
Cover
Handlebar Left/right
side cover
Handlebar front
cover
Front cover
Center cover
Front fender
Luggage box & seat
Front under Spoiler
Rear carrier
Inner box
Body cover
Left/Right foot
plates
Rear fender /
Tail light set
Left/right
side-covers
Inner rear fender
Floor Panel
Under Cover
•
•
•
•
•
Be careful not to damage various covers in disassembly or re-assembly operation.
Never injure hooks molded on the body covers in disassembly or re-assembly operation.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the guard and the covers during assembly.
12-2
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12. Body Cover
Front Cover
Removal
Remove the 4 mounting screws from the top-end
of front luggage box.
Screw x 4
Remove the upper screw (screw x 1) from the
front fender.
Screw x 1
Remove the lower screw (screw x 1) from the
front fender.
Screw x 1
Remove the front lamp wire connector and then
the front fender.
Installation
Install according to the reverse procedure of
removal.
12-3
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12. Body Cover
Handlebar Cover
Screw x 5
Removal
Remove the handlebar rear cover (screw x 5).
Disconnect the wire connectors of left & right
switches.
Remove the handlebar rear cover.
Caution
•
Open the hooks on the two end-section
of the handlebar cover as removing the
cover. The, remove the handlebar cover.
Do not pull it forcedly to avoid to breaking
the hooks.
Remove the front cover, and odometer wire
connector.
Remove the odometer cable.
Remove the handlebar front cover and odometer
set. (screw x 4)
Screw x 4
Odometer cable
Remove the odometer cover. (screw x 3)
Disassemble the odometer cover and the
odometer set. (screw x 2)
Installation
Install according to the reverse procedure of
removal.
12-4
Switch wire connector
This Chapter Contents
12. Body Cover
Front Fender
Removal
Remove the front guard screws. (left & right x 2)
Left & right screws x 2
Remove the front guard.
Installation
Install according to the reverse procedure of
removal.
12-5
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12. Body Cover
Front Under Spoiler
Remove the inner box screw (left & right each
side x 3), the mounting bolts (2 bolts) of foot plate,
and 1 screw on the left & right each side of side
cover.
Remove the screw (screw x 4) from the top-end
of front under spoiler.
Screw on each side x 3
Removal
Remove the front fender, front brake system, and
odometer cable, as well as the front wheel.
Bolt x 2
Screw x 4
Bend the frame hook slightly straight on the front
under spoiler, and then remove it.
Installation
Install according to the reverse procedure of
removal.
Frame hook
12-6
This Chapter Contents
12. Body Cover
Removal
Remove the front under spoiler firstly.
Remove the inner box screw (left & right each
side x 3), the mounting bolts (2 bolts) of foot plate,
and 1 screw on the left & right each side of side
cover.
Screw on each side x 3
Inner Box
Bolt x 2
Remove the inner nut of the inner box.
Nut x 1
ECU connector
Bend out all wire strap.
Disconnect the wire connector of ECU, and the
diagnosis connector.
Remove the screw (screw x 4) from the top-end
of front under spoiler.
Diagnosis connector
Take out the front luggage.
Installation
Install according to the reverse procedure of
removal.
12-7
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12. Body Cover
Center Cover
Removal
Remove the 1 upper screw inside of the luggage
box.
Remove the lower 2-screws in front of the center
cover.
Take out the center cover.
Installation
Install according to the reverse procedure of
removal.
Bolt x 2
Luggage Box
Bolt x 2
Removal
Open the seat.
Remove the 1 upper screw inside of the front
luggage box.
Remove the 2 mounting nuts and 2 bolts of the
luggage box.
Nut x 1
Lift the luggage box up by pushing the luggage
box & seat upward.
Installation
Install according to the reverse procedure of
removal.
12-8
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12. Body Cover
Rear Carrier
Bolt x 4
Removal
Remove the hex-socket bolts (bolt x 4) of the rear
carrier.
Caution
Do not open the fuel tank cap as removing
the bolts so that prevent from bolts falling
into the fuel tank.
Open the fuel tank cap with key.
Take out the fuel/vapor separator.
Remove the rear carrier.
Fuel/vapor separator
Installation
Install according to the reverse procedure of
removal.
12-9
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12. Body Cover
Body Cover
Removal
Remove the rear carrier, luggage box and seat
firstly.
Remove the body cover mounting screw. (2
screws on each side)
Screws on each side
Gently split out the body cover a little bit with
hands and then lift the cover up slightly. Then,
remove the seat locker cable.
Remove the body cover.
Installation
Install according to the reverse procedure of
removal.
12-10
Seat locker
cable
This Chapter Contents
12. Body Cover
Left & Right Side-Foot Plates
Bolt x 1
Removal
Remove the foot connection screws & bolt. ( 3
screws & 1 bolt on left & right each side)
Screw x 3
Remove the rear connection screws. (1 screw on
left & right each side)
Installation
Install according to the reverse procedure of
removal.
Screw x 1
Left & Right Side-Covers
2 screws on left & right each side
Remove the mounting screws. (2 screws on left
& right each side)
Pull out the side-cover backward so that the front
clipper can be separated.
Remove the side-covers.
Installation
Install according to the reverse procedure of
removal.
12-11
This Chapter Contents
12. Body Cover
Floor Panel
Bolt x2
Removal
• Remove the center cover, luggage box, body
side covers, and body cover firstly.
• Remove the front mounting bolts (bolt x 2) of
the floor panel.
Remove the battery cover. (screw x 3)
Screw x 3
Remove the battery bracket (screw x 2) and
power cables.
Take out the battery.
Remove the bottom mounting screws from the
floor panel, and then the floor panel.
Installation
Install according to the reverse procedure of
removal.
12-12
Screw x 1
This Chapter Contents
12. Body Cover
Rear Fender
Removal
Remove the upper bolts (bolt x 2) from the rear
fender.
Bolt x 2
Remove the left & right side bolt (1 bolt on each
side) from the rear fender.
Remove the rear turning signal lamp wire, and
then the rear fender.
Installation
Install according to the reverse procedure of
removal.
1 bolt on left & right each side
12-13
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12. Body Cover
NOTES:
12-14
Home page
Contents
13. Brake
Front Disc Brake System ........ 13-1
Rear Disc Brake System.......... 13-2
Precautions in Operation ........ 13-3
Trouble Diognosis ................... 13-4
Hydraulic Brake System
Inspection .............................. 13-5
Brake Fluid Replacement /
Air-Bleed ................................13-6
Brake Caliper............................13-7
Brake Disc ................................13-8
Brake Master Cylinder .............13-8
Front Disc Brake System
3.5 kgf-m
13
0.55 kgf-m
1.8 kgf-m
4.5 kgf-m
13-1
This Chapter Contents
13. Brake
Rear Disc Brake System
3.5 kgf-m
0.55 kgf-m
4.5 kgf-m
13-2
This Chapter Contents
13. Brake
Precautions in Operation
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air
hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
•
•
•
•
•
The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before you go.
Specifications
Unit: mm
Item
Standard
Limit
4.000
2.500
0.100 or less
0.300
Master cylinder inner diameter
11.000~11.043
11.055
ID of master cylinder piston
10.957~10.984
10.945
Diameter of front disc
273.000
─
Diameter of rear disc
200.000
─
Thickness of front disc brake lining
5.100
2.000
Thickness of rear disc brake lining
5.100
2.000
The thickness of front brake disc
Front brake disc eccentricity
Torque values
Brake hose bolt
3.50 kgf-m
Bolt for brake caliper
3.30 kgf-m
Brake lining pin bolt
1.80 kgf-m
Cap of Brake lining pin bolt
1.00 kgf-m
Air-bleed valve
0.55 kgf-m
13-3
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13. Brake
Trouble Diognosis
Soft brake lever
1. Air inside the hydraulic system
2. Hydraulic system leaking
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disc
7. Low brake fluid
8. Blocked brake pipe
9. Warp/bent brake disc
10. Bent brake lever
Uneven brake
Dirty brake lining/disc
Poor wheel alignment
Clogged brake hose
Deformed or warped brake disc
Restricted brake hose and fittings
Hard operation of brake lever
1. Blocked brake system
2. Poor brake caliper
3. Blocked brake pipe
4. Seized/worn master cylinder piston
5. Bent brake lever
Brake noise
Dirty lining
Deformed brake disc
Poor brake caliper installation
Imbalance brake disc or wheel
13-4
Tight brake
Dirty brake lining/disc
Poor wheel alignment
Deformed or warped brake disc
This Chapter Contents
13. Brake
Hydraulic Brake System Inspection
Hose connection
Inspection
Visual inspect for brake fluid leaking or damage.
Check if brake hose connection loosen with
wrench and turn the handlebar from right to left
motion or press down the shock absorber to
check if there is something is interfered with the
brake system or brake components.
Operate the brake system and check the brake
lining. Check the front brake from front side,
and replace the brake lining with new one when
the brake lining wear limitation groove reaches to
the brake disc.
Brake lining
wear limitation
groove
Brake caliper Brake disc
Park the motorcycle on a flat ground and check
its brake fluid level.
Recommended brake fluid: WELL RUN (DOT
3) brake fluid
CAUTION
z
z
z
The fluid level will not be correct if parking
the motorcycle in title or just parking. It
has to waiting for around 3~5 minutes.
Never use faked brake fluid to prevent from
chemical reaction.
It has to apply with same brand brake fluid
to sure the brake performance.
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 rubber
components when conduct brake system
maintenance.
Lower
level
Master cylinder
Mounting seat
Punch
point
CAUTION
z
Do not over the upper level when adding
brake fluid and avoid to spilling brake fluid
on painted surfaces, plastic or rubber
components to result in their damages.
Split ring
“UP” mark
13-5
This Chapter Contents
13. Brake
Remove the master cylinder cap and diaphragm.
Add good quality brake fluid and it has to add
same brand brake fluid into the master cylinder.
Clean dirty brake disc.
CAUTION
The dirty brake lining or disc will reduce the
brake performance. The mixed
non-compatible brake fluid will reduce brake
performance. Foreign materials will block the
system causing brake performance to be
reduced or totally lost.
Screw
Master cylinder
Diaphragm plate
MAX.
Diaphragm
MIN.
Brake Fluid Replacement/Air-Bleed
Connect drain hose to drain valve.
Open the drain valve on the caliper and hold and
release the brake lever alternatively until the old
brake fluid is entirely drained out. Close the
drain valve and add specified brake fluid into the
brake master cylinder.
Drain valve
CAUTION
To reuse the spent brake fluid will effect brake
performance.
Connect one end of transparent hose to the drain
valve, and put the other end into a container.
Open the drain valve around 1/4 turns, and at the
same time hold the brake lever until the there is
no air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air 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.
Bubble
Drain valve
CAUTION
z
z
Do not release the brake lever before the
drain valve is closed.
Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air entering into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose. Tightly close the
drain valve.
4. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the fluid
if necessary.
5. Cover the cap.
13-6
Transparent draining hose
This Chapter Contents
13. Brake
Brake Caliper
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hoses.
Bolts x 2
CAUTION
•
•
Do not spill brake fluid on painted surfaces.
The exhaust pipe has to be removed
before remove the rear brake caliper.
Remove the bolt cap, and loosen the lining guide
bolt.
Remove two caliper bolts and the caliper.
INSTALLATION
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.3 kgf-m
Front brake caliper
CAUTION
•
•
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of brake
disc.
Tighten the lining guide bolt.
Torque: 1.8 kgf-m
Install the bolt cap.
Torque: 1.0 kgf-m
Rear brake caliper
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.5 kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
13-7
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13. Brake
Brake Disc
Inspection
Visually check the brake disc for wear or break.
Measure the thickness of the disc at several
places. Replace the disc if it has exceeded the
service limit.
Allowable limit: 2.0 mm
Brake
disc
Micrometer
Remove the brake disc from wheel.
Check the disc for deformation and bend.
Allowable limit: 0.30 mm
CAUTION
•
•
Do not let grease touch to the brake disc
that will cause brake performance.
Do not clean the brake lining with air gun
because the lining is contained asbestos.
Operator should wear mask & glove and
use vacuum cleaner to clean the brake
lining.
Brake Master Cylinder
Removal
CAUTION
Do not let foreign materials enter into the
cylinder.
Master
cylinder
CAUTION
The whole set of master cylinder, piston,
spring, diaphragm and clip should be
replaced after removal.
Remove the front and rear handlebar guards.
Remove the leads of brake lamp switch.
Drain out the brake fluid.
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder seat and the master
cylinder.
Remove the rubber pad.
Remove the clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Brake
hose
Clip
Rubber
washer
Piston
Spring
Master
cylinder
13-8
This Chapter Contents
13. Brake
Inspection
Check the master cylinder for damage or scratch.
Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit: 11.055 mm
Master
cylinder
Dial
gauge
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit: 10.945 mm
Piston
Micrometer
Assembly
CAUTION
•
•
It is necessary to replace the whole set
comprising piston, spring, piston cup, and
clip.
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.
Install the clip.
Rubber
boot
Sub-rubber
washer
clip
Piston
Main rubber
washer
Spring
Master
cylinder
CAUTION
•
•
Never install cup lip in the opposite
direction.
Make sure the clip is seated securely in the
groove.
Install the rubber pad into groove properly.
13-9
This Chapter Contents
13. Brake
INSTALLATION
Place the master cylinder onto handlebar, and
install the split ring and bolts. The “UP” mark on
the split ring should face upward.
Align the split ring on the master cylinder seat
with the alignment point on the handlebar.
Tighten the upper bolt of the seat to specified
torque value, and then tighten lower bolt to the
same specified torque value.
Master cylinder
Punch
point
Split ring
“UP” mark
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 sure the hose is installed correctly.
Sealing washer
CAUTION
Improper routing may damage leads, hoses
or pipes.
Hose bolt
Brake hose
CAUTION
Kink of brake leads, hose or pipe may
reduce brake performance.
Add specified brake fluid and bleed the system
and conduct the air-bleeding job for the system.
13-10
Mounting
seat
Home page
Contents
14. Steering/Front Wheel/Front Shock Absorber
Mechanism Illustration.............14-1
Front Wheel............................... 14-4
Precautions in Operation .........14-2
Front shock absorber .............. 14-7
Trouble diagnosis.....................14-2
Front fork/steering column...... 14-7
Steering Handlebar...................14-3
Mechanism Illustration
4.0~5.0 kgf-m
1.0~2.0 kgf-m
0.2~0.3 kgf-m
14
2.4~3.0 kgf-m
3.1~3.5 kgf-m
5.0~7.0 kgf-m
14-1
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Precautions in Operation
General Information
• Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take
care not to rotate body in reverse.
• Be careful not to allow oil or grease get on brake drum or linings.
Torque values
Front wheel axle
5.0~7.0 kgf-m
Steering handlebar nut
4.0~5.0 kgf-m
Steering column top cone sliding ring
0.2~0.3 kgf-m
Steering column lock nut
1.0~2.0 kgf-m
Speedometer cable nut
Front shock absorber: Upper nut
0.15~0.3 kgf-m
2.4~3.0 kgf-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 nut wrench
Trouble diagnosis
Hard steering stem
• Over tightening of steering stem lock nut
• Damaged steering stem steel ball and
steering stem bearing seat
• Insufficient tire pressure
Steering stem off center
• Uneven left/right cushion
• Bend fork
• Bent front wheel/tire offset
14-2
Front wheel wobbling
• Bent wheel rim
• Loose wheel axle nut
• Poor wheel or wearing
• Too much clearance on wheel bearing
Soft front suspension
• Front shock absorber spring worn out
• Oil leaking on cushion oil ring
Front suspension noise
• Bent shock absorber linkage
• Loosen shock absorber nut
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Steering Handlebar
Master cylinder
REMOVAL
Remove handlebar front & rear cover and the
front cover (refer to chapter 12).
Disc Brake
Remove the 2 bolts of the brake master cylinder,
and then take out the master cylinder and the
split ring.
Caution
Do not operate the front brake lever to avoid
to pressing out the brake lining when
removing the master cylinder.
Mounting
seat
Bolts
Remove throttle handlebar housing screw and
then remove the handlebar, throttle cable, and
handlebar upper housing & under housing.
Screw
Remove the mounting bolt of the rear brake
cylinder. (bolt x 2)
Take out rear brake cylinder.
Bolts x 2
With a wrench to hold the handlebar bolt and
then remove the nut.
Take out the handlebar after removed the bolt.
Installation
Install the handlebar according to the reverse
procedure of removal.
Apply with some grease onto the handlebar
moving parts when installing the throttle
handlebar housing, throttle handlebar, and
throttle cable.
Bolt
Nut
14-3
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Front Wheel
Removal
Support body bottom and lift front wheel free of
ground.
Remove the screw, and disconnect speedometer
cable from the gear box.
Speedometer
cable
Remove the wheel axle nut and pull out the axle.
Then, remove the front wheel.
Caution
Do not operate the front brake lever to avoid
to pressing out the brake lining when
removing the master cylinder.
Wheel axle
nut
Inspection
Wheel axle
Set the axle in V-blocks and measure the run-out.
Service limit: 0.2 mm
Wheel axle
Wheel Rim
Place the wheel onto a rotated bracket.
Turn the wheel with hand and measure its
wobble value with a dial gauge.
Service limit:
Radial : 2.0 mm
Axial
: 2.0 mm
14-4
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Disassembly
Remove the left axle ring and dust seal.
Remove the dust seal on the right side of
speedometer gear.
Remove the bearing with the inner type bearing
remover.
Take out the bearing spacer and then remove the
other bearing.
Tool:
Inner type bearing remover.
Bearing
Wheel side
collar
Bearing
Speedometer
gear dust
seal
Dust seal
Bearing bushing
Bearing Inspection
Turn the inner race of bearing with fingers. The
bearing should be turn smoothly. Also check if
the outer collar is tightly connected to the wheel
hub.
If the bearing do not turn smoothly, or if they are
too loose in the races, or damaged, then, remove
and replace the bearings with new ones.
Clearance
Clearance
Caution
The bearing must be replaced in pair.
Installation
Install the bearing according to the reverse
procedure of removal.
Apply some grease into the bearing seat of the
wheel hub.
Install the left bearing onto the seat.
Install the bearing spacer and then install the
right bearing onto the seat.
14-5
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Caution
Do not install used bearing and replace the
bearing once it has been removed.
Do not the bearing in tile motion when
installing.
Tool:
C-type compressor or bearing compressor.
Both samples will damage bearing
Align the flange part on the speedometer gear
with the slot of wheel hub, and then install the
speedometer gear box.
Caution
Contaminated brake lining will reduce brake
performance so the brake lining, brake drum
and disc must be free of grease.
Place the front wheel between the front shock
absorbers.
Align the flange part on the speedometer gear
with the slot of shock absorber stopper.
Stopper
Brake panel
slot
Install the front wheel axle from right shock
absorber side.
Install the wheel axle nut, and tighten it to
specified torque value.
Torque value: 5.0~7.0 kgf-m
Connect the speedometer cable to the
speedometer gear box.
Wheel axle nut
14-6
Speedometer cable
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
Front shock absorber
Removal
Remove the front fender, front under spoiler, front
cover, and front wheel as well as front brake
components.
Remove the brake fluid hose clipper or cable
guide on the left shock absorber. (bolt x 1)
As for disc brake, remove the cable guide on the
right shock absorber. (bolt x 1)
Brake
fluid hose
clipper
Remove the top connection bolt of the right
shock absorber. (bolt x 4)
Remove the shock absorber from the front fork.
Bolts
Shock absorbers
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 absorber onto the front fork. Then,
tighten the nut.
Torque value: 2.4~3.0 kgf-m
Front fork/steering column
Removal
Firstly, remove the handlebar, front wheel, front
brake set, and front shock absorbers.
Remove the steering lock nut.
Remove the top cone race, and then remove the
steering column.
Steering lock
nut
Caution
Place the steering column bearing balls into a
parts container to avoid to missing or
shortage.
Steering top
cone race
14-7
This Chapter Contents
14. Steering/Front Wheel/Front Shock Absorber
With a plastic hammer to tap the steering ball
race slightly, and then remove the top ball
bearing race.
Remove the lower-end cone bearing race on the
frame with a punch.
Caution
Do not damage the frame and the steering
race.
Installation
Install a new top-cone bearing race onto the top
of steering column.
And then, push the lower-cone bearing seat from
bottom until to locking position.
Lower ball bearing
race
Balls
Lower
cone-race
Caution
Top
cone-race
Do not let the ball bearing in title motion as
installation.
Apply with some grease onto the top & bottom
bearing balls, and then install the balls into
bearing race.
Press in a new lower cone-race onto the steering
column, and lubricate it with grease.
Install the steering column.
Lubricate the top-cone race with grease.
Drive the cone-race into the steering column until
contact 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: 0.2~0.3 kgf-m
Balls
Top ball bearing
race
Steering lock
nut
Return 1/2 turns
Locking to
1/4~3/8 turns
Caution
Do not tighten the top cone race too tight to
prevent from damage the ball bearing seat
when tightening the top cone race.
Install the steering lock nut and lock the top cone
race. Then, tighten the nut.
Torque value: 1.0~2.0 kgf-m
Install the bearing seat according to the reverse
procedure of removal.
Steering lock
nut
Top cone-race
Steering
column nut
Caution
Check the steering column if it can be turned
freely and no clearance in vertical motion.
Top
cone-race
14-8
Contents
Home page
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Mechanism Illustration............. 15-1
Rear Wheel ................................ 15-3
Precautions in Operation ......... 15-2
Rear Carrier ............................... 15-4
Trouble Diagnosis .................... 15-2
Rear Shock Absorber ............... 15-6
Exhaust Pipe ............................. 15-3
Mechanism Illustration
3.5~4.5 kgf-m
2.4~3.0 kgf-m
0.55 kgf-m
3.5 kgf-m
15
4.5 kgf-m
15-1
This Chapter Contents
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Precautions in Operation
General Information
As for the wheel removal, service, and installation procedures, please refer to the service manual of
high speed tire.
Specification
Unit: mm
Items
Standard
Limit
Radial
-
2.0
Axial
-
2.0
4.0
2.0
238.6
233.6
Wheel wobbling
Thickness of rear brake lining
Free length of rear shock absorber
Torque values
Rear axle nut
10.0~12.0 kgf-m
Rear brake caliper bolt
2.9~3.5 kgf-m
Rear shock absorber upper mount bolt
3.5~4.5 kgf-m
Rear shock absorber lower mount bolt
2.4~3.0 kgf-m
Exhaust pipe connection nut
1.0~1.2 kgf-m
Exhaust pipe connection bolt
3.2~3.8 kgf-m
Trouble Diagnosis
Rear wheel wobbling
• bend wheel rim
• poor tire
• loosen wheel shaft
Shock absorber too soft
• insufficient shock absorber
spring force
15-2
Braking Noise
• worn brake lining
• brake drum deformation
• improperly brake panel
installation
• unparalleled brake drum or
wheel unparallel.
Poor brake performance
• Poor brake adjustment
• contaminated brake lining
• worn brake lining
• Air inside of the brake
hose/pipe
• greased brake disc
• Clogged brake pipe
• Bent brake pipe
• Insufficient brake fluid
This Chapter Contents
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Exhaust Muffler
Nuts x 2
Removal
Remove the front-end nut of the exhaust muffler.
(nut x 2)
Remove the bolts. (bolts x 3)
Remove the exhaust muffler.
Installation
Install the exhaust muffler according to the
reverse procedure of removal.
Caution
Replace the exhaust muffler gasket if it is
broken or deformed.
Torque value:
Exhaust muffler connection bolt: 3.2~3.8 kgf-m
Exhaust muffler connection nut: 1.0~1.2 kgf-m
Bolts x 3
Rear Wheel
INSPECTION
Measure wheel rim wobbling.
Service limit:
Radial: 2.0 mm
Axial: 2.0 mm
• If the wheel rim wobbling out of the
specification, except resulted from the wheel
rim deformation, it might be loosen or worn
final driving shaft bearing or bend, deformed
driving shaft.
Removal
Remove the rear brake pipe mounting seat.
(bolt x 2)
Remove the rear brake assembly. (bolt x 2)
Bolt x 2
15-3
This Chapter Contents
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Remove the front bolt from the rear carrier.
(bolt x 2)
Remove the rear wheel axle nut. (nut x 1)
Bolt x 2
Nut x 1
Remove the rear fork.
Remove the rear wheel.
Caution
Never hold the brake lever as caliper was
removed so that prevent from pushing out
the brake pad.
Rear Fork
Bearing
Turn the inner ring of bearing onto the fork with
hand. The bearing should be turned smoothly &
quietly.
Check the match condition of both bearing and
arm.
Replace it if turning is not smooth or in noisy.
15-4
Clearance
Clearance
This Chapter Contents
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Replacement of Rear Wheel Bearing
Remove the outer bearing from the fork.
With inner type bearing puller to remove bearing.
Remove inner oil seal.
Caution
Bearing
Oil seal
Do not use the used oil seal.
Install a new bearing onto the fork with C-press
or bearing presser.
Install oil seal and bearing bushing onto the fork.
Installation
Install rear wheel.
Install bearing bushing onto the fork.
Install the fork onto the rear wheel axle.
Install the bearing bushing and washer onto the
fork.
Tighten the rear wheel axle nut.
Install the brake caliper, and then tighten caliper
bolt & pipe mounting bracket.
Install the exhaust pipe, and then tighten its bolt
and but.
Install body covers according to the reverse
procedure of removal.
Torque value:
Rear axle nut
Rear brake caliper bolt
Exhaust pipe connection bolt
Exhaust pipe connection nut
Brake pipe clipper
10.0~12.0 kgf-m
2.9~3.5 kgf-m
3.2~3.8 kgf-m
1.0~1.2 kgf-m
Caution
Pay attention to on the installation direction
of the rear carrier axle ring. The small end
of inner & outer axle rings have to forward to
arm bearing.
Bolt x 3
15-5
This Chapter Contents
15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Rear Shock Absorber
Removal
Remove the luggage box. (bolt x4, screw x1)
Remove the body cover. (screw x 4)
Remove the air cleaner. (bolt x2)
Remove the under bolt of the rear shock
absorber. (bolt x 1)
Remove the upper bolt 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
The rear shock absorber has to be replaced
with one set and can not be replaced by
unauthorized persons. Otherwise, it might
damage the rubber bushing and
construction.
Torque values
Rear shock absorber lower mount bolt:
2.4~3.0 kgf-m
Rear shock absorber upper mount bolt:
3.5~4.5 kgf-m
15-6
Bolt x 1
Bolt x 1
Contents
Home page
16. Electrical Equipment
Precautions In Operation .........16-1 Starting System ........................ 16-9
Trouble diagnosis .....................16-2 Meter........................................ 16-11
Battery........................................16-2 Lamp/Bulb............................... 16-13
Charging system.......................16-3 Main switch/Horn.................... 16-15
Current Leakage Test ...............16-4 Fuel Pump ............................... 16-18
Ignition System .........................16-7
Precautions In Operation
•
•
•
•
•
•
•
•
•
•
When remove the battery, the disconnection sequence of cable terminals shall be strictly
observed.
Spark plug heat range/model and tighten torque.
Ignition plug.
Headlamp adjustment.
Removal and installation of alternator.
MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water.
Battery must be taken out from scooter when charging the battery. But do not open the battery
caps.
Do not quick charge the battery unless in emergency.
A voltmeter must be used when checking battery charging condition.
Starting motor can be removed directly from engine.
Specification
Charging System
Items
Battery
Specification
Capacity
12V8Ah
Charging rate
STD: 0.16A/5hrs, emergency charging: 16A/0.5hrs
Leaking current
Less 1mA
Charging current
4.8A/1600 rpm
Voltage controlled by regulator
14.5±0.5V/2000 rpm
16
16-1
This Chapter Contents
16. Electrical Equipment
Trouble diagnosis
No power supply
• Dead battery
• Disconnect battery cable
• Fuse burned out
• Faulty ignition switch
Low voltage
Weak battery
• Loose battery connection
• Charging system failure
• Voltage-current regulator failure
•
Starter motor does not work
• The fuse is blown
• The battery is not fully charge
• Poor main switch
• Poor starter switch
• The front and rear brake switches do not
operate correctly
• Starter relay is out of work
• The ignition coil is poorly connected, open or
short-circuited
• The starter motor is out of work
Battery
Removal
Remove the rubber carpet.
Remove the battery cap. (screw x 3)
Remove the battery mounting bracket. (bolt x 2)
Firstly, remove the negative(-) post, and remove
the positive (+) post.
Remove the battery.
Voltage Inspection
Measure the voltage with a digital voltage meter.
Voltage Value:
Fully charged: 13.0~13.2V at 20℃
undercharged: less 12.3V at 20℃
16-2
Intermittent power supply
• Loose charging system connection
• Loose battery cables
• Loose connection or short-circuit in discharging
system
• Loose connection or short-circuit in lighting
system
Charging system failure
• burn Fuse
• Loose, broken or shorted wire or wire
connection
• Faulty voltage regulator
• Faulty alternator
Weak starter motor
• Poor charging system
• The battery is not fully charged
• Poor connection in the windings
• The motor gear is jammed by foreign material
Starter motor is working, but engine does not
crank
• Poor starter motor pinion
• The starter motor run in reverse direction
• Poor battery
This Chapter Contents
16. Electrical Equipment
Charging system
Charging wire circuit
Main switch
Green Black
Red
Pink
Yellow
Fuse
20A
Battery
Regulator
Alternator
Charging
Connect the battery charger’s positive (+)
terminal to battery’s positive (+) post.
Connect the battery charger’s positive (-)
terminal to battery’s positive (-) post.
Charging current
Charging time
Standard
Max
0.9A
16.0A
5~10H
1H
Warning
• Strictly keep flames away from a charging
battery.
• The charging ON/OFF is controlled by the
charger’s switch. Do not control the
charging by battery jump wires.
Caution
• Quick charge a battery should be used only
in an emergency.
• Make sure the current and charging time of
above description.
• The battery will be damaged by too much
current or too rush charging.
After installing the battery, coat the terminals with
clean grease.
16-3
This Chapter Contents
16. Electrical Equipment
Current Leakage Test
Current Leakage Inspection
Turn the main switch to OFF position, and
remove the negative cable terminal (-) from the
battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal (as
shown on left diagram).
Caution
•
•
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.
Do not turn the main switch to ON position
during test.
Battery (-) terminal
Ground
wire
If the leaked current exceeds the specified value,
it 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.
Charging Voltage/Current Inspection
Caution
•
•
Before conducting the inspection, be sure
that the battery is fully charged. Use a fully
charged battery having a voltage larger than
13.0 V. If undercharged, the current changes
dramatically.
While starting the engine, the starter motor
draws large amount of current from the
battery. Thus, do not start the engine with
battery.
After the engine is warmed up, replace original
battery with a fully charged battery.
Connect a digital voltmeter to the battery
terminals.
Connect an ammeter between both ends of the
main fuse.
Caution
When the probe is reversibly connected, use
a voltmeter having an indication that the
current flows from the positive or the negative
direction and the measurement should be at
zero, ammeter at one direction only.
16-4
Digital meter
Ammeter
Fuse connector
This Chapter Contents
16. Electrical Equipment
Caution
•
•
•
Main switch
Do not use short-circuit cable.
It is possible to measure the current by
connecting an ammeter between the
battery positive terminal and the cable
position terminal, however, while the starter
motor is activated, the surge current of the
motor draws from the battery may damage
the ammeter. Use the foot lever to start the
engine.
The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing through.
It may damage the ammeter.
Connect DATDSCAN, and switch to data
analysis menu.
Turn on the headlamp to high beam and start the
engine.
Accelerate the engine gradually to the specified
revolution per minute and measure the charging
voltage/current.
Charging Current: 4.8A/1600 rpm
Control Charging Voltage:
14.0±0.5 V / 2000 rpm
Caution
To replace the old battery, use a new battery
with the same current and voltage.
The following problems are related to the
charging system, follow the instructions provided
in the checking list to correct it if any one of the
problems takes place.
(1) The charging voltage can not exceed the
voltage between two battery terminals and
the charging current is in the discharging
direction.
(2) The charging voltage and current are too
much higher than the standard values.
The following problems are not related to the
charging system; correct it if any by following
steps indicate in the checking list.
(1) The standard charging voltage and current
can only reach when the revolution of the
engine exceeds the specified rpm.
- Bulbs used exceed their rate and
consume too much power.
- The replacement battery is aged and
does not have enough capacity.
(2) The charging voltage is normal, but the
current is not.
- The replacement battery is aged and
does not have enough capacity.
- Battery used do not have enough
electricity or is over charged.
- The fuse of the ammeter is blown.
- The ammeter is improperly connected.
(3) The charging current is normal, but the
voltage is not.
- The fuse of the voltmeter is blown.
Engine rpm
16-5
This Chapter Contents
16. Electrical Equipment
REGULATOR INSPECTION
Remove the rear carrier. (refer to chapter 12,
section 8)
Remove the body cover. (refer to chapter 12,
section 8)
Disconnect the 3P connector of the regulator.
Item
Main switch
connection wire
Battery
connection wire
Measurement
point
Standard Value
R~B
Battery voltage
(ON)
R~G
Battery voltage
Check the parts onto the abnormal wire circuit if
the measured values are not within standards.
If the parts is OK, then it is the wire circuit
abnormal.
Replace the regulator if both checks are OK.
CHARGING COIL INSPECTION
Caution
The coil need not be removed from engine
as conduct this test.
Regulator
At the alternator side from the regulator
connector, measure the resistor between pink
and yellow wires.
Standard value: 0.16~0.8Ω
16-6
This Chapter Contents
16. Electrical Equipment
Ignition System
Ignition System Circuit
Blue /
white
Blue /
yellow
Pulse
generator
Green/
white
Spark plug
Ignition
coil
Main switch
Black
Battery
Red
Make the following inspection at each terminal of the harness side connector.
ITEM
Crank position sensor
Primary
Ignition Coil
Secondary
Measure at:
result
Green / whiteblue / yellow
120±10% Ω
Black / white-red
0.63Ω
Black / whitehigh voltage cable
2.9MΩ
Ignition coil
Remove the luggage box.
Remove the ignition coil connector and the spark
plug cap.
Measure the resistor between the terminals of
ignition coil primary circuit.
Standard value: 0.63Ω
Remove the spark plug cap from the spark plug
wire, and measure the resistor between the spark
plug wire and primary circuit terminal (black/
white).
Standard value: without cap 2.95 MΩ
16-7
This Chapter Contents
16. Electrical Equipment
Replacement
Remove the mounting bolt of ignition coil if
necessary, and replace the ignition coil.
Ignition coil
Spark plug
CRANK POSITION SENSOR INSPECTION
Disconnect the pulse generator connector,
measure the resistor between terminals from
green/white to blue/yellow wires.
Standard value: 120±10%Ω
16-8
This Chapter Contents
16. Electrical Equipment
Starting System
Starting Circuit
Engine switch
Battery
Main fuse 20A
Red
Main fuse 10A
Rear brake switch
Starting
switch
Starting relay
Yellow /
red
Starting Relay Inspection
Turn main switch to "on", and operate the brake
lever. Then press starting button to check if there
a click sound. It is normal if there is a click
sound.
Green /
yellow
Starting motor
Negative (-)
Positive (+)
Remove the luggage assembly.
Disconnect the battery negative (-) terminal.
Remove the battery positive (+) connection and
starting motor wires from the starting relay large
pin.
Remove the power control connector of the
starting relay.
Connect a Ohmmeter between the starting relay
large pins.
Connect the green/yellow wire to battery positive
(+) terminal, and the green/yellow wire to battery
negative (-) terminal.
Check the continuity between the starting relay
large pins.
If it is not continuity, then replace the starting
relay.
16-9
This Chapter Contents
16. Electrical Equipment
STARTING MOTOR REMOVAL
Remove the luggage. (chapter 12, section 6)
Remove the air cleaner. (chapter 4, section 10)
Remove the battery negative terminal.
Remove the battery positive terminal and the
starting motor wire from the big terminal of
starting relay.
Remove the starting motor mounting bolts and
the motor.
Remove the starting motor mounting bolts and
the motor.
Starting Motor Installation
Install the motor and other components in
reverse procedure of removal.
16-10
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16. Electrical Equipment
Meter
Removal
Remove the front cover. (chapter 12, section 4)
Remove the power connector of the instrument
panel.
Remove the rear cover of the handlebar. (chapter
12, section 3)
Remove the odometer cable.
速度錶導線
Remove the turn signal lamp relay.
16-11
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16. Electrical Equipment
Remove the front cover of handlebar. (chapter 12,
section 3)
Remove the instrument panel assembly.
(screw x 4)
Disassemble the instrument seat and the
instrument. (screw x 2)
Instrument Panel Installation
Install the panel in reverse procedure of removal.
16-12
Screw x 4
Screw x 4
This Chapter Contents
16. Electrical Equipment
Lamp/Bulb
Headlamp Bulb Replacement
Remove the front fender. (chapter 12, section 4)
Disconnect the headlamp wire connector, and
then remove the rubber boot.
Press down the bulb spring locker and then
remove the locker with turning it in CCW motion.
Replace the bulb with new one if necessary.
Caution
•
•
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.
Wipe the bulb with cloth to prevent from
damaged if the bulb be touched by hands.
Install the bulb in reverse order of removal.
Connect power to check if the bulb has been
installed properly after installation.
Please conduct the headlamp beam adjustment
job if replace the headlamp bulb.
Front Turn Signal Lamp Bulb Replacement
Remove the lamp cover of the turn signal lamp.
(screw x 2)
Replace the bulb with new one.
16-13
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16. Electrical Equipment
Rear Turning Signal Lamp Replacement
Pry out the lamp cover from the preset slot onto
the lower parts of cover.
Check if the bulb is burnt or damage, and replace
it if necessary.
Connect power to check if the bulb has been
installed properly after installation.
Preset slot
Tail Lamp/Brake Lamp Replacement
Remove the outer cover of the tail & rear turning
signal lamps. (screw x 2)
Check if the bulb is burnt or damage, and replace
it if necessary.
Connect power to check if the bulb has been
installed properly after installation.
Screw x 2
16-14
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16. Electrical Equipment
Main switch/Horn
Main Switch
Inspection
Remove front fender. (chapter 12, section 4)
Disconnect main switch leads connector.
Check connector terminals for continuity.
BAT1
BAT2
ON
●
●
Wire color
Red
Black
LOCK
OFF
Replacement
Remove the handlebar bolt. (bolt x 1)
Bolt x 1
Remove the handlebar assembly.
Remove the main switch connector and bolts.
(bolts x 3)
Remove the main switch.
Install a new main switch and tighten the bolts.
(bolts x 3)
Bolts x 3
16-15
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16. Electrical Equipment
Handlebar switch
Remove the rear handlebar cover. (chapter 12,
section 3)
Disconnect the connector of the handlebar
switch.
Check the continuity of follow pins listed below
columns.
Starting switch
ST
E
Starting
motor switch
FREE
●
●
Wire color Yellow/ Red
Green
Headlamp switch
CI
TL
HL
●
●
●
●
●
Black
brown
Brown/
white
●
Wire
color
Headlamp switch
High/Low beam switch
LO
HL
HI
●
●
PASS
●
●
PASSING
●
●
●
●
Wire color
White
Brown/
white
Blue
Black
16-16
Hi/Lo beam switch
This Chapter Contents
16. Electrical Equipment
Turn signal lamp switch
FROM R
N
Turn signal lamp switch
R
WR
●
●
●
●
L
PUSH OFF
FROM L
Wire color
Light
blue
●
●
●
●
Gray
Orange
Horn switch
Horn
Remove the front fender.
Connect 12V power to the 2 pins on the horn.
Then, the horn should sound.
Replace it if necessary.
Brake lamp switch
The circuit of black wire and the green/yellow
wire on the brake lamp switch should be in
continuity when operating the brake lever.
If the switch damaged, replace it with new one.
Brake lamp switch
16-17
This Chapter Contents
16. Electrical Equipment
Fuel Pump
Removal
Open the seat cushion.
Remove the luggage box assembly. (Chapter 12,
section 6)
Remove the rear carrier. (Chapter 12, section 8)
Remove the left & right side body covers.
(Chapter 12, section 8)
Disconnect the fuel pump and the wires & pipes
around the filler opining. (screw x 4)
With special service tools to loosen the mounting
plate by in CCW motion.
Take out the fuel pump.
Caution
• Gasoline is a very low ignition point & high
evaporative material. Thus, it is has to
strictly prohibit flame or spark as operation.
• Gasoline or its evaporation is harmful to
human skin so always avoid to contact with
gasoline. Quickly clean or flush it if skin
contacted.
• Keep the clearness inside of the fuel tank
and prevent from foreign materials falling
into the tank.
Caution
Do not damage or bend the float arm as
removing.
The resistance values are listed below when the
float arm in F and E positions.
Float arm position
Resistance value
E (empty)
97.5~107.5 Ω
F (full)
4~10 Ω
Connect the fuel gauge sender to the main
harness.
Turn the main switch “ON”.
Move the float arm in UP & DOWN, and then
check if the fuel gauge indication needle is in
correct position.
Caution
Fuel gauge
UP
(full)
Turn on the turn signal lamp to make sure
battery is in good condition before this test.
Float arm position
UP (full)
DOWN (empty)
16-18
Indicator needle
F (full)
E (empty)
DOWN
(empty)
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Contents
17. Emission Control System
Periodical Maintenance
Information/Emission Standard
.................................................17-1
Fuel Evaporative Emission
Control System (E.E.C.)....... 17-3
Precautions for ensuring within
emission standard .................17-1
Ignition System ...................... 17-6
Names Of Mechanisms In The
Emission Control System .....17-2
Function Of Mechanisms In The
Emission Control System .....17-2
Crankcase blow-by system ... 17-5
Inspection Items..................... 17-7
Countermeasure For
Emission Pollutants Not
Within Standard As In Idle
Speed (4-Stroke Engine)........ 17-8
Periodical Maintenance Information/Emission Standard
Please conduct periodical inspection, adjustment or service to ensure best performance in
SYM authorized dealers or service centers.
Note 1: Clean or replace the air cleaner element more often when the motorcycle is operated on
dusty roads or in the Heavily- polluted environment.
Note 2: Maintenance should be performed more often if the motorcycle is frequently operated in high
speed and after the motorcycle has accumulated a higher mileage.
Precautions for ensuring within emission standard
1. Fuel usage: Limited to use unleaded gasoline.
2. Oil usage: Limited to use 4-stroke engine oil.
3. Perform the periodical maintenance in accordance with the periodical maintenance schedule.
(refer to the periodical maintenance schedule)
4. Per the emission control system, strictly limited to be adjusted or replaced arbitrarily (such as
spark plug usage, idle speed adjustment, ignition timing, as carburetor adjustment).
5. Cautions:
•
Since the malfunction of ignition, charging, and fuel systems are effected the catalytic converter
very much, please have your motorcycle to SYM authorized dealers or service centers to
conduct adjustment or service.
Thus, it has to replace parts with SYM genuine parts and conduct by SYM authorized dealers or
service centers if the motorcycle needs to replace one of the emission control system parts.
17
17-1
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17. Emission Control System
Names Of Mechanisms In The Emission Control System
Four-Stroke engine model:
1. Catalyst converter (C.A.T.A.→Catalyst Converter)
2. Evaporative Emission Control System (E.E.C. → Evaporative Emission Control System)
3. Positive Crankcase Ventilation System (P.C.V. → Positive Crankcase Ventilation System)
Function Of Mechanisms In The Emission Control System
General:
The emission control strategy of this model was formulated basing on a four-stroke & 4-valve SOHC
electronic controlled single cylinder engine. It adopts a charcoal canister to absorb the fuel vapor
generated through evaporation in the fuel system. Then, introducing vapor into combustion
chamber.
Electronic Fuel Injection Device:
This device consists of both the fuel supply system --- fuel tank, electrical fuel pump, fuel filter, and
fuel pump regulator as well and the fuel control system --- fuel injector and ECU.
Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel
pressure is kept within 2.5 kg/cm2 by means of the fuel regulator. Then, the injection signal from
ECU is to let fuel inject to cylinder in every crankshaft rotation. In addition, the residual fuel is back to
fuel tank by the fuel regulator.
The fuel pump is stalled into the fuel tank so that can reduce noise and simplify the fuel pipe routing.
The electronic controlled ignition & injection system can control fuel consumption & emission
efficiently so that reaches to the purpose of environmental purification.
Engine refinements:
Four Valves designed combustion chamber, together with optimum compression ratio, ignition timing,
intake and exhaust timing, have all contributed to maximize the intake/exhaust efficiency and
combustion efficiency.
Secondary air introducing system:
System
Device
Components
4-valve
combustion
chamber
Purpose & function
The semi-circular combustion chamber is
designed to balancing the air stream to achieve
the combustion stability.
Combustion
system
Combustion
chamber
EEC system
Charcoal
Evaporative
emission control canister Purge
control valve
system
A canister is used to absorb vapor from fuel
tank and to introduce it into carburetor at an
opportune timing.
PCV system
Crankcase
blow-by
introducing
device
To introduce blow-by into combustion chamber
via a separator for burning then discharging.
17-2
Vapor separator
This Chapter Contents
17. Emission Control System
Fuel Evaporative Emission Control System (E.E.C.)
1.
Construction:
• Reduce HC to pollute air.
• To absorber fuel vapor and saving fuel consumption.
Fuel hose
Fuel vapor separator
Fuel cap (closed type)
Fuel tank
Vacuum hose
Injector
Vapor hose
Blow-by
return hose
Vapor purge
control solenoid
Air filter
Flesh air
Fuel
Fuel vapor
Vacuum
Flesh air inlet
Active carbon
canister
Engine
2.
Principle of operation:
1. Vapor generated in fuel tank and fuel system through evaporation is contained in the confined
system to prevent it from escaping into the atmosphere, at the same time, the vapor will be
introduced into a charcoal canister where the hydrocarbon in the vapor will be absorbed by
active carbon.
2. When engine is running, the negative pressure of intake opens the purge line, breaks HC off
from active carbon and then sucks it into engine together with air from bottom of the canister.
3. The canister can be used repeatedly without reducing its performance because of the
system's purge function.
3.
Trouble Diagnosis:
Fuel can not flow to carburetor
1. No fuel in the fuel tank
2. loosen vacuum hose of the fuel pump
3. plugged hose in the system
4.
Cautions:
1. Do not exceed the reed valve of the fuel filler when filling out fuel.
2. Do not have rush acceleration or running in high speed when applying the spare fuel.
17-3
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17. Emission Control System
Service Methods for the E.E.C. system
1. Visual check:
1) Check the outside of canister for damage.
2) Check all hoses for breakage.
2.
Leak test:
1) Disconnect the P.C.V. hose, and connect a T-type hose connector to a pressure gauge and a
pressure source as shown below:
Fuel tank
Pressure gauge
Pressure
source
Active carbon
canister
Plugged
2) Plug canister vent.
3) Apply 100 mmAq into pressure source inlet then plug it. The pressure at the gauge should not
drop to below 10 mmAq within 10 seconds.
3.
P.C.V. Function Test:
1) Disconnect the hose of connection to the active carbon canister, and then connect a T-type
hose connector to pressure source as shown below:
Pressure
gauge
To engine vacuum
Pressure
source
To air filter
P.C.V.
2) Apply 100 mmAq into pressure source inlet as engine stopped then plug it. The pressure at
the gauge should not drop to below 10 mmAq within 10 seconds.
17-4
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17. Emission Control System
Crankcase blow-by system
1.
Construction:
Blow-by draining hose
Fuel vapor separator
Draining
hose
Injector
Air cleaner
Crankcase
Fresh air
Mixture
Blow-by
Engine oil
2.
Piston
Principle of operation:
• Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor
separator by engine vacuum.
• Drill a hole in the air cleaner and install a vapor separator, so that blow-by from crankcase will
flow through a cylinder check valve and then separated by the separator.
• The separated vapor will be sucked into combustion chamber by engine negative pressure to
be burned again instead of discharging into atmosphere. Drain liquidized fuel in the drain pipe
periodically.
3.
Service Methods
Visual check
• Remove drain plug to drain the fuel when fuel level on the drain pipe reaches 80 % full.
• Check connecting hose for damage and looseness.
17-5
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17. Emission Control System
Ignition System
1. CONSTRUCTION:
Spark plug
Throttle valve openness
Intake temperature/pressure
Engine temperature
ECU
RPM/TDC
Ignition coil
TDC/crankshaft
position sensor
Flywheel gearing
(24-1 tooth)
Diode
2. Principle of operation:
The engine is equipped with a computerized ignition control system that collects signals from
TDC/crankshaft position sensor, throttle position sensor, temperature sensor, and intake
temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite chip
of ECU in the system is to control ignition timing properly. The secondary coil creates
25000~30000V high voltage to ignite the spark plug by means of the transistor to open/close
operation of the primary current inside of the computerized system.
3. SPECIFICATION
1) Ignition timing: BTDC 13°/1600RPM
2) Spark plug: NGK CR8E
Gap: 0.7~0.8mm
3) A.C.G.
Pulse coil resistor: 120+10% Ω (G/W-Y)
4) Ignition coil
Primary circuit: 0.63 ± 0.03 Ω (20℃)
5) Battery
Type: TYX9A-BS.8Ah
Capacity: 12V 8Ah
17-6
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17. Emission Control System
Inspection Items
Fuel Evaporation Control System:
1. Visual inspect the carbon canister and hoses for damage.
2. leaking check.
3. function test of the purge control solenoid valve.
Crankcase Blow-by Control System:
1. Visual inspect the carbon canister and hoses for damage.
2. leaking check.
3. Drain hose check.
Catalyst Converter:
1. Check if exhaust emission is within standard.
2. Remove the exhaust pipe and shake it slightly to check if noise.
Fuel Supply System:
1. Clean the air filter.
2. Check the air filter.
3. Make sure the fuel pressure supplied from the fuel pump.
4. Adjust CO/HC values at idle speed. (Engine rpm should be within specification)
Emission test items
CO
HC
Emission standard
4.50% or less
9000 ppm or less
Ignition system:
• Spark plug check and replacement.
• High voltage coil check and replacement.
17-7
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17. Emission Control System
Countermeasure For Emission Pollutants Not Within Standard As In Idle
Speed (4-Stroke Engine)
Conduct periodical inspection
(check one time for 1500 km /
6 months)
Test exhaust contents at idling
(note 1)
Adjustment the fuel injection
system controller (note 2)
Clean the fuel injector
Keep the CO value in 1.5~
4.5% (note 3) by adjusting the
ECU.
Replace the fuel injector
Clean the carbon deposit in
cylinder and combustion
chamber.
Check piston rings for seized
or leaking.
Clean or replace the muffler.
Inspect other related
mechanism on the engine.
Note 1: test it according to the idling test procedure.
Note 2: Adjustment the idle adjustment screw. Set the engine rpm in specified speed, and test CO,
HC at idling. And then adjust the air adjustment screw at the same time to let CO value to
be 1.5~4.5%.
Note 3: If the values still can not be reached to specification after adjusted the fuel injection system
controller, then clean or replace it with new one according to the replacement procedures.
17-8
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Contents
18. Wiring Diagram
HE15W Wiring Diagram
18
18-1
Home page
18. Wiring Diagram
NOTES:
18-2
Contents