SANYANG | MAXSYM 400i | Service manual | SANYANG MAXSYM 400i Service manual

SANYANG MAXSYM 400i Service manual
MAXSYM 400i
SERVICE MANUAL
FOREWORD
CONTENTS
HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATION
20120303
Homepage
Contents
Foreword
This service manual contains the technical data of each component inspection
and repair for the Sanyang MAXSYM 400i scooter. 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, MAXSYM 400i, are different
from that of the photos, pictures shown in this manual, the actual vehicle shall
prevail. Specifications are subject to change without notice.
Service Department
Sanyang Industry Co., LTD.
Homepage
Contents
How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for Sanyang MAXSYM 400i scooter. 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 information.
Th third to the twelfth chapter covers the engine and driving systems.
The thirteenth to the sixteenth is contained the parts set of assembly body.
The seventeenth chapter is electrical equipment.
The eighteenth chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and
“Mechanism Illustration” in the PDF version, and can be access to these items
by clicking on the buttons.
If user wants to look for the content of each chapter, selecting the words of
each chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, on the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back
the homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the
content. In addition, there is a “To this Chapter Contents” button at the second
page of each content so that clicking the button can back to the contents of this
chapter.
Homepage
Contents
Contents
Page
Content
Index
1-1 ~ 1-16
General Information
1
2-1 ~ 2-16
Maintenance Information
2
3-1 ~ 3-6
Lubrication System
3
4-1 ~ 4-58
Fuel Injection System
4
5-1 ~ 5-4
Engine Removal
5
6-1 ~ 6-16
Cylinder Head / Valve
6
7-1 ~ 7-8
Cylinder / Piston
7
8-1 ~ 8-14
V-Belt Drive System
8
9-1 ~ 9-8
Final Drive Mechanism
9
10-1 ~ 10-4
AC Generator / Starting Clutch
10
11-1 ~ 11-8
Crankshaft / Crankcase
11
12-1 ~ 12-12
Cooling System
12
13-1 ~ 13-16
Body Cover
13
14-1 ~ 14-12
Brake System
14
15-1 ~ 15-11
Steering / Front Wheel / Front Cushion
15
16-1 ~ 16-6
Muffler / Rear Wheel / Rear Cushion
16
17-1 ~ 17-22
Electrical System
17
18-1 ~ 18-2
Wiring Diagram
18
Contents
Home page
Mechanism Illustration
Start / engine stop switch
Front winker
Luggage box
Fuel tank /
fuel pump
Dimmer / winker / horn
seat open / pass switch
Main switch
Coolant filler cap
Taillight /
rear winker
Headlight
Air cleaner
Reserve tank
cap
Main stand
Side stand
Back mirror
Front brake lever
Rear brake lever
Engine number
Muffler
Homepage
Contents
1. General Information
Symbols and Marks····························1-1
Torque Values ···································· 1-10
General Safety ····································1-2
Troubleshooting································· 1-12
Before Servicing·································1-3
Lubrication Points ····························· 1-16
Specifications ·····································1-9
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service is needed. If
supplemental information is needed for these symbols and marks, explanations will be added in the text
instead of using the symbols or marks.
Warning
Caution
Means that serious injury or loss of life may happen if procedures are not
correctly followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil.
Engine 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
Locking sealant
King Mate G-3 is recommended.
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 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
To this chapter contents
1. General Information
General Safety
Carbon Monoxide
Before you start the engine, make sure the place
is well ventilated. Never start the engine in an
unventilated place. If you have to start the engine
in an unventilated place, an exhaust fume
extractor is needed.
Caution
Exhaust fume contains toxic gas which may
cause one to lose consciousness and even result
in loss of life.
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 the
children.
Used Engine Oil
Caution
Prolonged contact with the used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified yet. We recommend that
you wash your hands with soap right after
contacting. Keep the used oil beyond reach of the
children.
Hot Components
Caution
Components of the engine and exhaust system
can be extremely hot after engine running. They
remain very hot even after the engine has been
stopped for a period of time. Before performing
service work on these parts, wear the heat
insulation gloves or wait until the temperature
drops.
1-2
Battery
Caution
‧ Battery emits explosive gases; flame is strictly
prohibited. Keep the place well ventilated
when the battery is being charged.
‧ Battery contains sulfuric acid (electrolyte)
which can cause serious burns, be careful not
to spill it on your skin or eyes. If you get
battery fluid on your skin, flush it off with water
immediately. If you get battery fluid in your
eyes, flush it off immediately with water and
go to hospital to see an ophthalmologist
doctor.
‧ If you swallow the battery fluid by mistake,
drink a lot of water or milk, and take some
laxative such as Epsom salts or vegetable oil
and then go to see a doctor.
‧ Keep the battery and battery fluid beyond
reach of the children.
Brake Shoes
Do not use compressed air or brush to clean the
components of the brake system. Use a vacuum
cleaner or the equivalent to avoid dust drifting in
the air.
Caution
Inhaling brake shoes dust may cause disease or
even cancer of the respiratory system.
Brake Fluid
Caution
Brake fluid spilled on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the top of the parts for protection
when servicing the brake system. Keep the brake
fluid beyond reach of the children.
To this chapter contents
1. General Information
Before Servicing
Always use SANYANG genuine parts and
recommended oil. Using improper parts may
cause damage to or destruction of the vehicle.
Special tools are designed for removal and
installation of component parts without
damaging them. Using wrong tools may result
in parts damage.
When servicing this vehicle, use only metric
tools. Metric bolts, nuts, and screws are not
interchangeable with the Britain system, using
wrong tools and fasteners may damage this
vehicle.
Clean the outside of the parts or the cover
before removing it from the vehicle. Otherwise,
dirt and deposit accumulated on the part's
surface may fall into the engine, chassis, or
brake system to cause damage.
Wash and clean parts with high flash point
solvent, and then blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most of the cleaning agents have bad
effect on them.
Never bend or twist control cables to avoid
unsmooth control and premature worn out.
Rubber parts may become deteriorated when
old, and be damaged by solvent and oil easily.
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.
Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
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
To this chapter contents
1. General Information
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, and 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
To this chapter contents
1. General Information
Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
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.
Check if positions and operation for installed
parts is in correct and properly.
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.
If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
Note that do not let parts fall down.
Capacity
verification
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.
1-5
To this chapter contents
1. General Information
When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
Do not pull the wires as removing a connector
or wires. Hold the connector body.
Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
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.
Make sure if the connector pins are bent,
extruded or loosen.
Wire band and wire harness have to be
clamped secured properly.
Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
Do not squeeze wires against the weld or its
clamp.
Check if the connector is covered by the twin
connector boot completely and secured
properly.
Before terminal connection, check if the boot is
crack or the terminal is loose.
1-6
To this chapter contents
1. General Information
Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
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.
Keep wire harnesses far away from the hot
parts.
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.
Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
Route harnesses so that they neither pull too
tight nor have excessive slack.
Never clamp or squeeze the wire harness as
installing other components.
Never clamp or
squeeze the wire
harness
Never too tight
1-7
To this chapter contents
1. General Information
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
To this chapter contents
1. General Information
Specifications
Overall Length
2270 mm
Overall Width
825 mm
Overall Height
1410 mm
Wheel Base
1555 mm
Weight
Curb
Weight
Front
94 kg
Rear
135 kg
Total
229 kg
Passengers/Weight
Cylinder
Total
Weight
Engine
SANYANG
Two / 150 kg
Front
131 kg
Rear
248 kg
Total
379 kg
MODEL
Suspension
System
Tire
Specifications
Brake System
Performance
Reduction
LX40A1-6 / F
Front
TELESCOPIC FORK
Rear
UNlT SWING
Front
120 / 70-15 56S
Rear
160 / 60-14 65H
Front
DOUBLE DISK
(ø 275 mm)
Rear
DISK (ø 275 mm)
Max. Speed
>152 km/hr
Climb Ability
<24°°
Primary
Reduction
Secondary
Reduction
Belt
Gear
Type
4-STROKE ENGINE
Clutch
Centrifugal, dry type
Installation and
arrangement
Vertical, below
center, incline 80°
Transmission
CVT
Fuel
Above 92 unleaded
Speedometer
0 ~ 180 km/hr
Cycle/ Cooling
4-stroke/
Liquid-cooled
Horn
93~112 dB/A
Bore
Ø 83.0 mm
Muffler
Stroke
73.8 mm
Exhaust Pipe Position and
Direction
Number/Arrange
ment
SINGLE CYLINDER
Lubrication System
Expansion & Pulse
Type
Right side, and
Backward
Forced circulation &
splashing
Exhaust
Concentration
Dimension
MAKER
Displacement
399 cc
CO
<2.0 g/km
Compression Ratio
10.6 : 1
HC
<0.3 g/km
Max. HP
33.3 ps / 7000 rpm
NOx
<0.15 g/km
Max. Torque
3.52 kg-m / 5500 rpm
E.E.C.
-
Ignition
Full transistor ignition
P.C.V.
√
Starting System
Electrical starter
Catalytic reaction control
system
√
1-9
To this chapter contents
1. General Information
Torque Values
The torque values listed in below are for more important tightening torque values. Please see standard
values for those not listed in the table.
Standard Torque Values for Reference
Type
5 mm bolt、nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
12 mm bolt、nut
Tighten Torque
0.45~0.6kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
Type
5 mm screw
6 mm screw、SH nut
6 mm bolt、nut
8 mm bolt、nut
10 mm bolt、nut
Tighten Torque
0.35~0.5kgf-m
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
Engine Torque Values
Item
Cylinder stud bolt
Cylinder head nut
Cylinder head right bolt
Cylinder head side cover bolt
Cylinder head cover bolt
Cylinder head stud bolt (inlet pipe)
Cylinder head stud bolt (EX. pipe)
Air inject pipe bolt
Air inject reed valve bolt
Tappet adjustment screw nut
Spark plug
Camshaft Chain Tensioner bolt
Carburetor insulator bolt
Oil pump screw
Water pump impeller
Engine left cover bolt
Engine oil draining bolt
Engine oil strainer cap
Mission draining bolt
Mission filling bolt
Clutch driving plate nut
Clutch outer nut
Drive face nut
ACG. Flywheel nut
Crankcase bolt
Mission case bolt
Muffler mounting bolt
Muffler mounting nut
1-10
Q’ty Thread Dia. (mm) Torque Value(kgf-m)
4
4
2
2
4
2
2
4
2
4
1
2
2
2
1
9
1
1
1
1
1
1
1
1
7
7
3
2
10
8
8
6
6
6
8
6
3
5
10
6
6
3
7
6
12
30
8
10
28
14
14
14
6
8
10
8
1.0~1.4
3.6~4.0
2.0~2.4
1.0~1.4
1.0~1.4
1.0~1.4
2.4~3.0
1.0~1.4
0.07~0.09
0.7~1.1
1.0~1.2
1.0~1.4
0.7~1.1
0.1~0.3
1.0~1.4
1.1~1.5
3.5~4.5
1.3~1.7
0.8~1.2
1.0~1.4
5.0~6.0
5.0~6.0
8.5~10.5
5.0~6.0
0.8~1.2
2.6~3.0
3.2 ~3.8
1.0 ~1.2
Remarks
Apply oil to thread
To this chapter contents
1. General Information
Frame Torque Values
Item
Mounting bolt for steering handle
post
Lock nut for steering stem
Q’ty Thread Dia. (mm) Torque Value (Kg-m)
Remarks
1
10
4.0~5.0
1
BC1
1.0~2.0
Steering top cone race
1
BC1
2.0~3.0
Front wheel axle nut
1
12
5.0~7.0
Rear wheel axle nut
1
16
11.0~13.0
Front cushion mounting bolt
4
10
3.5~4.5
Rear cushion upper connection bolt
1
10
3.5~4.5
Rear cushion under connection bolt
1
8
2.4~3.0
Rear fork mounting bolt
2
10
4.0~5.0
Brake hose bolt
2
10
3.0~4.0
Brake air-bleeding valve
1
6
0.8~1.0
Front brake disc mounting bolt
5
8
4.0~4.5
Rear brake disc mounting bolt
5
8
4.0~4.5
Brake clipper mounting bolt
2
8
2.9~3.5
Engine hanger link bolt
2
12
7.5~9.5
On frame side
Engine hanger link nut
1
12
7.5~9.5
On engine side
Main standard nut
1
10
4.0~5.0
Air cleaner bolts
2
6
1.0~1.4
1-11
To this chapter contents
1. General Information
Troubleshooting
A. Engine cannot be started or
difficult to be started
Check and adjustment
Fault condition
Probable causes
Press the fuel injector feed pipe and confirm
whether there is fuel in the feed pipe
The fuel supply to the fuel injector is
sufficient
The fuel injector is not
1. Check the fuel amount in the fuel tank
2. Check if the fuel pipe and the vacuum
tube are blocked or not
3. Malfunction of fuel pump relay or wiring
4. Malfunction of fuel pump
5. The fuel strainer is blocked or not
Check the spark plug ignition
condition
1. Malfunction of spark plug
2. Spark plug contamination
Sparks
Week sparks or no spark
3. Malfunction of ECU
4. Malfunction of the AC Generator
5. Ignition coil is in open or short circuit
Perform cylinder compression
pressure test
6. Malfunction of main switch
1. Piston ring seized
Normal cylinder compression pressure
Low or no compression
pressure
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leakage
Restart the engine
No ignition
5. Sand hole in the compression parts
With signs of ignition but
the engine cannot be
started
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
Remove and check the
spark plug
Dry spark plug
1-12
Wet spark plug
1. Contaminated or clogged fuel injector
2. Malfunction of throttle valve operation
3. Malfunction of fuel pressure regulator
To this chapter contents
1. General Information
B. Engine runs sluggish (Speed
does not pick up, lack of power)
Check and adjustment
Fault condition
Probable causes
Accelerate gradually and
check engine RPM
Engine RPM can be
increased
Engine RPM cannot be
increased
1.
2.
3.
4.
Clogged air cleaner
Poor fuel supply
Clogged exhaust pipe
Clogged fuel injector
Check ignition timing
(Using ignition lamp)
Correct ignition timing
Incorrect ignition
timing
1. Malfunction of ECU
2. Malfunction of AC Generator
Check cylinder
compression pressure
(using compression
Normal compression pressure
Abnormal compression
pressure
Check if the fuel
injector is clogged or
Not clogged
Clogged
1.
2.
3.
4.
5.
Worn out cylinder or piston ring
Cylinder gasket leakage
Sand hole in compression parts
Valve deterioration
Jammed piston ring
1. Replace the fuel injector
Remove and check the
spark plug
No contamination or
discoloration
Contaminated or
Check if the engine is
over heated
Normal
Engine overheated
1. Remove the dirt
2. Incorrect spark plug heat range
1.
2.
3.
4.
Worn out piston or cylinder
Abnormal fuel injector
Poor fuel quality
Carbon deposit in the combustion
chamber
Continually drive in
acceleration or high
speed
No knocking
Knocking
1. Carbon deposit in the combustion
chamber
2. Malfunction of fuel injector
3. Poor fuel quality
4. Abnormal ignition timing
1-13
To this chapter contents
1. General Information
C. Engine runs sluggish (especially
in low speed and idling)
Check and adjustment
Fault condition
Probable causes
Check ignition timing
(using ignition lamp)
Normal
1. Incorrect ignition timing
(malfunction of ECU or AC
Abnormal
Check for any air sucked in through
the throttle body insulator gasket
1. Abnormal throttle body insulator gasket.
2. Abnormal throttle body installation
Air sucked in
No air sucked in
3. Abnormal inlet pipe gasket
4. Damaged ABV pipe
Remove the spark plug
and check the spark
condition
Good spark
Poor spark
1.
2.
3.
4.
5.
Contaminated spark plug
Malfunction of ECU
Malfunction of AC Generator
Malfunction of ignition coil
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.
2.
Malfunction of ECU
Malfunction of AC Generator
Check the fuel pump
supply condition
Good
Poor
1. Insufficient fuel in the fuel tank
2. Pressed or clogged fuel pipe
Check if fuel injector
clogged
Normal
1-14
Clogged
1. Replace the fuel injector
To this chapter contents
1. General Information
E. CLUTCH AND DRIVING PULLEY
FAULT CONDITION
PROBABLE CAUSES
Engine can be started but the
vehicle cannot run
1.
2.
3.
4.
5.
6.
Engine shuts down or trembles
when the vehicle is running
(rear wheel rotates during
engine idling).
Poor initial driving (poor
climbing performance)
Worn out or damaged drive belt
Damaged movable drive face
Damaged driven face spring
Broken clutch weight
Broken drive shaft groove
Worn out or damaged transmission
gear
1. Broken clutch spring
2. Clutch outer stuck with clutch weights
3. Connection parts between clutch and shaft worn
out or burned
1.
2.
3.
4.
5.
Worn or deformed drive belt
Worn weight roller
Worn driven face
Deformed driven face spring
Grease on drive belt or drive / driven
1-15
To this chapter contents
1. General Information
Lubrication Points
Acceleration cable/
Front & rear brake lever pivot
Seat locker
Steering stem bearing
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
Cylinder Compression Pressure ········ 2-8
Periodical Maintenance Schedule ······ 2-2
Drive Belt ·············································· 2-8
Engine Oil············································· 2-3
Steering Handle Top Bearing·············· 2-9
Engine Oil Strainer Clean···················· 2-3
Cushion ················································ 2-9
Gear Oil················································· 2-4
Disk Brake System······························· 2-10
Fuel Lines / Cable ································ 2-4
Brake Light Switch / Start Switch······· 2-12
Air Cleaner ··········································· 2-5
Wheel / Tire··········································· 2-12
P.C.V. System ······································ 2-6
Battery ·················································· 2-13
Valve Clearance ··································· 2-6
Nuts, Bolts Tightness ·························· 2-13
Spark Plug············································ 2-7
Special Tools List ································ 2-14
Precautions in Operation
Model
Fuel Tank Capacity
Engine Oil
Transmission
Gear oil
LX40A1-6 / F
14,200±500 c.c.
capacity
change (with oil filter
replaced)
2,000 c.c.
change
1,800 c.c.
capacity
350 c.c.
change
330 c.c.
Capacity of
coolant
1,900 c.c.
Engine + radiator
1400 c.c.
Reservoir upper
350 c.c.
Clearance of throttle valve
Spark plug
2~6 mm
CR8E (gap:0.6~0.7 mm)
Timing advance idle speed
BTDC 10º / 1,550 rpm
Idling speed
1,550±100 rpm
Cylinder compression pressure
12.5 ± 2 kgf/cm²
IN
0.10±0.02 mm
EX
0.12±0.02 mm
Tire dimension
Front
120/70-15 56S
Tire dimension
Rear
160/60-14 65H
Tire pressure
(cold)
single
Front: 2.00 kg/cm²
Rear: 2.25 kg/cm²
Load 90 Kg (full load)
Front: 2.00 kg/cm²
Rear: 2.50 kg/cm²
Valve clearance
Battery
12V11.2Ah (MF battery) / TTZ14S
2-1
2
To this chapter contents
2. Maintenance Information
Periodical Maintenance Schedule
No
item
1
2
3
☆Air cleaner element
☆Fuel filter
☆Oil filter (paper)
4
5
☆Oil filter screen
☆Engine oil change
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Tire pressure
Battery inspection
Brake free play check
Steering handle check
Cushion operation check
Every screw tightening check
Gear oil check for leaking
☆Spark plug check or change
☆Gear oil change
Frame lubrication
Exhaust pipe
☆Ignition timing
☆Emission check in Idling
☆Throttle operation
☆Engine bolt tightening
☆CVT driving device(belt﹞
☆CVT driving device(roller)
Lights/electrical equipment/multi-meters
Main/side stands & springs
Fuel lines
Cam chain
☆Valve clearance
☆Crankcase evaporative control system
☆Evaporative control system
Lines & connections in cooling system
Coolant reservoir
Coolant
ECU input voltage
EFi sensor coupler
1 month
every
1,000KM
I
First replacement
at 1000 km
I
First replacement
at 1000 km
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
3 months
every
5,000KM
C
6 months
every
10,000KM
R
I
1 year
every
15,000KM
R
Second replacement at 20,000km
Further replacement every 20,000km
Cleaning every 10,000km
Second replacement at 5,000km
Further replacement every 5,000km
I
I
I
I
I
I
I
I
I
I
R
Replacement for every 10,000 km
L
L
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
R
I
I
I
I
I
I
I
I
I
I
C
I
I
I
I
I
R
I
I
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1,000 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
performed normally periodical maintenance following the user manual instructions. They are prohibited to be
adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.
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.
c. Replace worn out pistons, cylinder head.
2-2
To this chapter contents
2. Maintenance Information
Engine Oil
Turn off engine, and park the vehicle in a flat
surface with main stand.
Check oil level with oil dipstick
Do not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that to make
sure oil can be drained smoothly and
completely.
Place an oil pan under the vehicle, and remove oil
drain bolt.
After draining, make sure washer can be re-used.
Install oil drain bolt.
Torque value: 3.5~4.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-40)
Recommended using King serial oil.
Engine oil capacity:
Disassembly - 2000c.c.
Replacement (oil filter replaced) - 1900c.c.
Replacement – 1800c.c.
Install dipstick, start the engine for running several
minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Engine Oil Strainer Clean
Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value:
:1.3~1.7kgf-m
2-3
To this chapter contents
2. Maintenance Information
Gear Oil
Oil inspection bolt
Oil level inspection
Park the vehicle on a flat surface with main stand.
Turn off the engine.
Gear Oil Change
Remove oil inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after draining.
Torque value: 0.8~1.2kgf-m
Add gear oil to specified quantity from the
inspection hole.
Install the inspection bolt.
Torque value: 1.0~1.4kgf-m
Gear Oil Quantity: 330 c.c. when replacing it.
Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
Fuel Lines / Cable
Remove luggage box.
Remove rear carrier.
Remove body covers.
Check all lines, and replace it when they are
deteriorated, damaged or leaking.
Warning
2~6 mm
Gasoline is a low ignition material so any kind
of fire is strictly prohibited as dealing it.
Acceleration 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 acceleration 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.
Rubber
Adjustment can be done in either end.
Secondary adjustment is conducted from top side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.
Adjustment nut
2-4
To this chapter contents
2. Maintenance Information
Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
Adjustment nut
Air Cleaner
Air Cleaner Element
Remove 6 screws from the air cleaner cover.
6 screws
Remove the air cleaner element.
Caution
The air cleaner element is made of paper so
do not soap it into water or wash it with water.
2-5
To this chapter contents
2. Maintenance Information
P.C.V. system
Remove the plug from lower of the breather
chamber hose.
Release the dry internal deposit.
Every 5,000 kilometers release oil
Caution
In releases the breather chamber hose in the
transparent section is worthy of looking at as
any deposit
In the multi-rain or the accelerator in the
situation rides, must reduce the maintenance
traveling schedule
In releases the breather chamber hose in the
transparent section is worthy of looking at as
any deposit
Valve Clearance
Caution
Checks and adjustment must be performed
when the engine temperature is below 35℃.
Remove luggage box.
Remove cylinder head cover & side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket aligns with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to
prevent from camshaft bolt looseness.
Valve clearance inspection and adjustment:
Check & adjust valve clearance with feeler gauge.
Valve clearance (IN):
:0.10±0.02 mm.
Valve clearance (EX):
:0.15±0.02 mm.
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened
the fixing nut.
Special tool: Tappet adjuster
SYM-9001200-08
SYM-9001200-09
SYM-9001200-10
Special tool: Tappet adjuster wrench
SYM-9001200
2-6
Breather chamber hose
To this chapter contents
2. Maintenance Information
Spark Plug
Recommended spark plug: CR8E
Remove luggage box
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.6~0.7 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.
Tighten torque: 1.0~1.2kgf-m
Connect spark plug cap
Spark plug
Ground electrode
Central electrode
0.6~0.7mm
2-7
To this chapter contents
2. Maintenance Information
Cylinder Compression Pressure
Warm up engine.
Turn off the engine.
Remove luggage box and central cover
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
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 cap
Compression pressure:
:12.5±2 Kg/cm²
Check following items if the pressure is too low:
Incorrect valve clearance.
Valve leaking.
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.
Compression gauge
Drive Belt
Remove mounting bolt located under air cleaner.
Remove 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: 22.5 mm or above
Clutch Disc Wear
Run the motorcycle and increase throttle valve
opening gradually to check clutch operation.
If the motorcycle is in forward moving and shaking,
check clutch disc condition then replace it.
Teeth
Width
Clutch lining
Clutch weight
2-8
To this chapter contents
2. Maintenance Information
Steering Handle Top Bearing
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.
Cushion
Caution
Do not ride the motorcycle with poor cushion.
Looseness, wear or damage cushion will
make poor stability and drive-ability.
Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damaged.
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Park motorcycle with main stand.
Turn the rear wheel forcefully and check if engine
bracket bushing worn out
Replace the bushing if looseness found.
Tighten all nuts and bolts.
2-9
To this chapter contents
2. Maintenance Information
Disk Brake System
Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.
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.
Caution
In order to maintain brake fluid in the
reservoir in horizontal position, do not remove
the cap until handle 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.
Operate the brake lever so that brake fluid fulfilled
inside the brake system hoses.
Master cylinder cap
Diaphragm
Added Brake Fluid
Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.
LOWER
Brake
Fluid
Caution
Never mix or use dirty brake fluid to prevent
from damaging brake system or reducing brake
performance.
Air Bleeding 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.
Air bubble
Drain valve
Caution
Before closing the air bleeding valve, do not
release the brake lever.
Transparent hose
2-10
To this chapter contents
2. Maintenance Information
Brake Lining Wear
Lining
The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limitation mark
closed to the edge of brake disc.
Caution
It is not necessary to remove brake hose when
replacing the brake lining.
Brake caliper
Remove the brake clipper bolt, and take out the
clipper.
Brake disk
2 bolts
Caution
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
Pry out the brake lining with a flat driver if lining is
clipped.
Remove 2 cotter pins
Cotter pins
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set.
Remove the brake pad shafts and pads.
2-11
To this chapter contents
2. Maintenance Information
Brake Light Switch / Start Switch
The brake light switch is to light up brake lamp as
brake applied.
Make sure that starter motor can be operated only
under brake applying.
Wheel / Tire
Caution
Tire pressure check should be done as cold
engine.。
Appointed tire pressure
Tire size
Load for
Tire pressure as
under 90 Kg
cold engine
(Kg/cm²)
Full loaded
Front tire Rear tire
2.00
2.25
2.00
2.50
Check if tire surface is stuck with nails, stones or
other materials.
Check if front and rear tires’ pressure is in normal.
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
2-12
Stop switch
To this chapter contents
2. Maintenance Information
Battery
Open the inner box lid.
Loosen screw & remove the battery cover
Battery cable remove:
:
1. Disconnect the cable negative terminal (-),
2. then the cable positive terminal (+)
3. Remove the battery from the motorcycle.。
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.
Nuts, Bolts Tightness
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.
2-13
To this chapter contents
2. Maintenance Information
Special Tools List
NAME
NO
NAME
NO
NAME
NO
NAME
NO
2-14
Valve rocker arm shaft
disassemble tool
SYM-1445100-01
Clutch spring compressor
SYM-2301000-L4A
Crank Shift Oil Seal Driver
35*55*7
SYM-9120900-L4A
Inner bearing puller
SYM-6204022
NAME
NO
NAME
NO
NAME
NO
NAME
NO
L/Cover Radial Ball Brg 6006
Drive
SYM-9615010-REA 6006
Tappet adjusting wrench
SYM-9001200
PULLEY DRIVEN FACE
OPENER
SYM-2321000-REA
Inner Bearing Driver
SYM-6204024
NAME
NO
NAME
NO
NAME
NO
NAME
NO
Valve cotter remove &
assembly tool
SYM-1471110/20
Oil seal driver 45*65*10
SYM-9125500-L4A
Drive Shaft 25*40*7 Oil Seal
Drive
SYM-9120200-L4A
Outer bearing puller
SYM-6204010
To this chapter contents
2. Maintenance Information
NAME
NO
NAME
NO
Driven pulley bearing installer NAME Drive shaft bearing installer
SYM-9100600-L4A DPB
Clutch nut wrench
SYM-9020200
NO
NAME
NO
NAME
Final shaft bearing installer
NAME
NO
SYM-9615000-L4A A6206
NO
NAME
NO
Water pump seal driver
SYM-9120500-L4A
NAME
NO
SYM-9100420-A6305
Universal holder
SYM-2210100
Water pump bearing installer
SYM-1923100-L4A A6203
NAME
NO
Counter shaft bearing driver
SYM-9610000-L4A N1820
NAME AC.G. FLYWHEEL PULLER
NO
NAME
NO
SYM-3110000-HMA
Balance shaft bearing installer
SYM-1333200-L4A A6304
Water pump mechanical seal NAME Water pump mechanical
driver
bearing driver N1010
SYM-1721700-H9A
NO
SYM-9100100-L4A
2-15
To this chapter contents
2. Maintenance Information
NAME
NO
NAME
NO
NAME
NO
2-16
Crankshaft bearing install /
remove tool
SYM-9100310-L4A
Vacuum pressure gauge
SYM-HT07011
NAME
NO
NAME
NO
Crankshaft bearing install tool
SYM-9100310-L4A
Cylinder pressure gauge
SYM-HT07008
NAME
NO
NAME
NO
Fuel pressure gauge
SYM-HT07010
Vehicle circuit test tool kit
SYM-HE170008
Vehicle circuit test harness kit NAME EFi System Diagnostic tool
Multi-meter
SYM-HE170008-01
SYM-HE07007-01
NO
Contents
Homepage
3. Lubrication System
Precautions in Operations ........... 3-1
Oil Pump Inspection...................... 3-4
Troubleshooting............................ 3-1
Oil Pump Reassembly................... 3-4
Engine Oil ...................................... 3-2
Oil Pump Installation..................... 3-5
Oil Pump Removal ........................ 3-3
Gear Oil .......................................... 3-6
Oil Pump Disassembly ................. 3-3
Precautions in Operation
‧ This chapter contains maintenance operation for the engine oil pump and gear oil replacement.
SAE
Specifications
Engine oil quantity
Gear oil
Oil
Disassembly : 2000 c.c.
Change (with oil filter replaced) :
1900 c.c.
Change :
1800 c.c.
Disassembly: 350 c.c.
Change:
330 c.c.
Oil viscosity SEA 10W-40
(Recommended King serial oils)
Gear oil viscosity SEA 85W-140
(Recommended SYM Hypoid
gear oils)
Gear oil
Items
Inner rotor clearance
Oil pump Clearance between outer rotor and body
Clearance between rotor side and body
Torque value oil strainer
1.3~1.7 Kgf-m
Gear oil drain plug
1.1~1.4 Kgf-m
Gear oil inspection bolt
1.1~1.4 Kgf-m
Oil pump connection bolt
0.8~1.2 Kgf-m
Standard (mm)
Limit (mm)
0.15
0.20
0.15~0.20
0.25
0.04~0.09
0.12
Troubleshooting
Low engine oil level
.Oil leaking
.Valve guide or seat worn out
.Piston ring worn out
Dirty oil
.No oil change in periodical
.Cylinder head gasket damage
.Piston ring worn out
Low oil pressure
.Low engine oil level
.Clogged in oil strainer, circuits or pipes
.Oil pump damage
3-1
To this chapter contents
3. Lubrication System
Engine Oil
Turn off engine, and park the vehicle in a flat
surface with main stand.
Check oil level with oil dipstick
Do not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that to
make sure oil can be drained smoothly and
completely.
Place an oil pan under the vehicle, and remove
oil drain bolt.
After draining, make sure washer can be
re-used. Install oil drain bolt.
Torque value: 1.1~1.5 Kgf-m
Fill out engine oil (oil viscosity SEA 10W-40).
Recommended using King serial oil.
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Engine Oil Strainer Clean
Drain engine oil.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value: 1.3~1.7 Kgf-m
Add oil to crankcase (oil viscosity SAE 10W-40)
Recommended using King serial oil.
3-2
Drain bolt
To this chapter contents
3. Lubrication System
Oil Pump Removal
Remove generator and starting gear.
Remove the oil separator (bolt x 2).
Oil separator
Remove snap ring and take out oil pump driving
chain and sprocket.
Torque value: 0.8~1.2 Kg-m
Make sure that pump shaft can be rotated freely.
Remove 3 bolts on the oil pump, and then
remove oil pump.
BOLT×
×3
Oil Pump Disassembly
Remove the screws on oil pump cover and
disassemble the pump as illustration shown.
3-3
To this chapter contents
3. Lubrication System
Oil Pump Inspection
Check the clearance between oil pump body
and outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer
rotors.
Limit: 0.20 mm
Check clearance between rotor side face and
pump body
Limit: 0.12 mm
Oil Pump Reassembly
Install inner and outer rotors into the pump body
Align the indent on driving shaft with that of the
inner rotor.
Install the driving shaft.
Install fixing pin.
3-4
PIN
To this chapter contents
3. Lubrication System
Install the oil pump cover and fixing pin properly
SCREW×
×1
Tighten screw
Make sure that oil pump shaft can be rotated
freely.
Oil Pump Installation
Install the oil pump, and then tighten bolts.
Torque value: 0.8~1.2 Kg-m
Make sure that oil pump shaft can be rotated
freely.
Install oil pump driving chain and sprocket, and
then install snap ring onto oil pump shaft.
Install starting gear and generator.
3-5
To this chapter contents
3. Lubrication System
Gear Oil
Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off the engine and remove oil inspection
bolt.
Gear oil Inspection Bolt
Gear lubrication oil quantity has to be measured
with measurement device.
If oil level is too low, add gear oil.
Recommended using King serial oils.
Install oil inspection bolt.
Torque value: 1.0~1.4 Kgf-m
Gear oil
drain plug
Gear Oil Change
Remove oil level inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after draining.
Torque value: 1.0~1.4 Kgf-m
Make sure that the drain plug washer can be
reused.
Add oil to specified quantity from the inspection
hole.
Gear Oil Quantity: 330 c.c. when replacing it.
Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off the engine and make sure that oil level
is in correct level.
Make sure that no oil leaking.
3-6
Home page
Contents
4. Fuel Injection System
EFi System Components····················· 4-1
Integrated Troubleshooting Procedure
······························································· 4-36
EFi System Vehicle Configuration ····· 4-2
Air Cleaner ············································ 4-39
EFi System Operation ························· 4-3
EFi System Introduction······················ 4-4
EFi System Diagnosis Methods ·········· 4-40
Fuel System·········································· 4-5
Check Light Flault Codes Differentiation
······························································· 4-41
Ignition System ···································· 4-6
Fault Code And Sensors Table ··········· 4-42
Sensors / Drivers ································· 4-7
Precautions in Operation ···················· 4-13
Fault Code and Check Light Flashing
Lighting Identification Table ··············· 4-43
EFi System Components Description 4-14
EFi System Diagnostic Tool - V70 ······ 4-44
EFi System Circuit ······························· 4-30
Diagnostic Tool Note ··························· 4-45
ECU Pin Configuration ························ 4-31
Troubleshooting Table························· 4-57
Troubleshooting ·································· 4-32
Comprehensive Maintenance List ······ 4-58
EFi System Components
Fuel
pump
Diagnostic tool
Ignition coil
AISV
EFi Check light
TPS
Roll over
sensor
TA
Sensor
Injector
O2
Sensor
Power
relay
ISC
(Stepper motor)
MAP
Sensor
TW
Sensor
Battery
ECU
CPS
4-1
4
To this chapter contents
4. Fuel Injection System
EFi System Vehicle Configuration
Right
TPS
ISC
Injector
MAP Sensor
ECU
CPS
O2 Sensor
TW Sensor
Left
EFi Check light
Rollover sensor
Diagnostic coupler
Test switch
4-2
TA Sensor
AISV
Fuel pump
To this chapter contents
4. Fuel Injection System
EFi System Operation
Crankshaft Position
Sensor
CPS
Manifold Absolute
Pressure Sensor
MAP
INJECTOR
Throttle Position
Sensor
Engine Coolant
Temperature Sensor
O2 Sensor
TPS
TW
(ECU)
IGN COIL
Engine Control
Unit
FUEL PUMP
LAMBDA
CHECK LIGHT
Roll Over Sensor
K/S
AISV
Intake Air
Temperature Sensor
TA
ISC
Battery Voltage
Air Injection
Solenoid Valve
Idle Speed Control
Valve
(Stepper motor)
VBATT
Tuning tools
Diagnostic tool
4-3
To this chapter contents
4. Fuel Injection System
EFi System Introduction
Based on 4-stroke SOHC engine, displacement 400 c.c. electronically controlled fuel injection, fuel vapor
absorbed by activated carbon canister. The engine burns off the blow-by fuel-gas in the crankcase
through the fuel-air separating device. The O2 sensor enhances the efficiency of the catalytic converter,
by dynamically controlling the Fuel/Air ratio.
Electronic Fuel Injection Devices
Consist of fuel supply devices: fuel tank, fuel pump, fuel filter and fuel pressure regulator.
And fuel control devices: fuel injector and ECU.
The fuel is pumped from electrical fuel pump in the fuel tank, to the injector on the inlet pipe. The fuel
pressure regulator keeps the fuel pressure around 294±6kPa. The signals from ECU enable the injector to
spray fuel into the combustion chamber once every two crankshaft revolutions. The excessive fuel flows
back to the fuel tank through the fuel pressure regulator. Fuel pump is placed within the tank to reduce the
working noise, and the complicity of fuel pipes. Electronically controlled ignition and injection system
effectively reduce the fuel consumption rate and pollution.
In the traditional gasoline engine, the carburetor supplies the fuel. The process is done by the engine
vacuum and the negative pressure in the carburetor by mixing fuel and air. Under this condition, three
major processes are done simultaneously in the carburetor:
1. Air quantity measurement.
2. Fuel quantity determination.
3. Mixing of fuel and air.
Electronic Fuel Injection System distributes the three major processes to three different devices:
1. MAP / TA sensor measures the air quantity and temperature and sends the signal to ECU as a
reference.
2. ECU determines the amount of fuel to be injected, according to the default A/F rate.
3. ECU enables the injector to spray appropriate fuel amount. The independence of these three functions
will raise the accuracy of the whole process.
EFi engine uses computer-programmed fuel injection, the main features are:
1. The quantity of fuel injected is decided according the condition of the engine. The engine RPM, and
throttle position determines the fuel quantity and injection time-length. This throttle-controlled fuel
injection is better responding and more accurate.
2. The quantity of fuel injection, and the determination of injection time length, are all controlled by 16-bit
microcomputer.
3. The fuel pressure regulator maintains a 294±6 kPa pressure difference between intake pipe and fuel
pipe, raising the accuracy of fuel injection.
4. By measuring the air pressure of intake pipe, this system gives the vehicle better accommodation to the
environment.
5. Idle air by-pass system supplies fuel and air to stabilize the idle running, and cold starting.
6. O2 sensor feeds back the signal to minimize the exhaust pollution.
4-4
To this chapter contents
4. Fuel Injection System
Fuel System
Fuel pump
Injector
ECU
Fuel pump
relay
Power relay
Battery
System Description
1. After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the
fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in
order to save electricity.
Fuel pressure regulator maintains fuel pressure at 294 ± 6kPa (about 3 kg / cm²). According to the
operating conditions and environmental compensation coefficient, appropriate fuel will be injected. After
Key-off or engine stopped operating, the fuel pump stops running.
2. Fuel impurities filtered by the fuel filter should be cleaned regularly.
3. When the engine can not be started, do not keep start motor running continuously which may lead to
lack of battery power (less than 10 V) and the fuel pump will not be able to operate. The correct way is
to use a new battery.
Injector
Eight-hole type injector provides two intake valves fuel injection quantity, enhances the effect of fuel
atomization, and reduces HC emissions. Short-type injector cap can easily fix the injector, receive the fuel
from the fuel pump, and limit injector rotation sliding. The signals from ECU control the fuel pressure
regulator, using the diaphragm and spring to maintain the fuel pressure in 294 ± 6kPa (about 3 kg / cm²),
and determine the fuel injection quantity by adjusting injection time width under different engine
conditions.
Fuel Pump
Electrical fuel pump is placed inside the fuel tank, powered by the battery and controlled by ECU.
Fuel pressure: 294 ± 6kPa (about 3 kg / cm²)
4-5
To this chapter contents
4. Fuel Injection System
Ignition System
Intake air temperature
Manifold absolute pressure
Engine coolant temperature
ECU
Throttle position
Ignition coil
Spark plug
Oxygen content
ACG/ Flywheel Gear
(23+1 Long teeth)
Crankshaft
position
sensor
Power relay
Battery
REG. REC.
Principle
The computer programmed ignition system receives the signals from the Crankshaft position sensor,
Throttle position sensor, O2 Sensor, MAP sensor, Intake air temperature sensor, Engine coolant
temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines the appropriate
ignition timing, controls the ignition coil and triggers the spark plug. This way can not only make the
engine achieve the maximum power output, but also help improve fuel consumption rate.
Specifications
1.
2.
3.
4.
5.
Ignition timing: BTDC 10 ° / 1550RPM
Spark plug: NGK CR8E Clearance: 0.6 to 0.7 mm
ACG crankshaft position sensor coil resistance: 80 ~ 160 Ω (Green / White - Blue / Yellow)
Ignition coil primary circuit resistance: 2.8 Ω ± 15% (20 º C) (Red / Yellow - Black / Yellow)
Battery Type / Capacity: TTZ14S / 12V 11.2Ah
4-6
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4. Fuel Injection System
Sensors / Drivers
Crankshaft Position Sensor (CPS)
Crankshaft position
sensor
Flywheel
Description
The magnetic field type sensor generates a voltage
signal to calculate engine speed with ACG gear ring
(18-1 tooth).
There is one tooth every 20 degree on the gear ring.
But, one of the teeth is blank for the TDC calculating
base.
4-7
To this chapter contents
4. Fuel Injection System
Manifold Absolute Pressure (MAP) / Engine Water Temperature (TW) / Intake Air
Temperature (TA) Sensors
ECU
MAP Sensor
TA Sensor
TW Sensor
Engine water temperature / Intake air temperature sensor:
Use the variable resistor of negative temperature coefficient (thermistor) to sense the outside temperature.
The electrical resistance value goes down when the temperature rises. On the contrary, the electrical
resistance value becomes higher when the temperature falls. Sensors provide the temperature of the
engine coolant and intake air to ECU to determine the injection and ignition timing.
5V
Manifold absolute pressure sensor:
Manifold absolute pressure sensor (MAP Sensor) uses the piezoresistive resistor composed of silicon
diaphragm, forming the Wheatstone bridge circuit to measure the atmospheric pressure and the intake
manifold pressure, which are both transmitted to ECU for reference of engine control.
Inlet
pressure
sensor
Output voltage
Working voltage (5V)
Inlet pressure (kPa)
4-8
Output voltage
To this chapter contents
4. Fuel Injection System
O2 Sensor
Power relay
O2 Sensor
ECU
Battery
O2 Sensor
3
Output voltage
4
1.
2.
3.
4.
1
Ceramics tube
Electrode
Emissions
Atmosphere
2
Rich ← 14.7 → Lean
Function
O2 Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts
the air-fuel ratio by changing the fuel injection time. If the proportion of oxygen is too low, it means the rich
air-fuel mixture with higher HC & CO concentration in the exhaust gas. If the proportion of oxygen is too
high, it means the lean air-fuel mixture with higher temperature and higher NOx concentration.
1. O2 Sensor outputs feedback signal to ECU which keeps the air-fuel mixture near the stoichometric ratio
approximately 14.6 and forms the closed loop control system.
2. When the air-fuel mixture is near the stoichometic ratio, CO / HC / NOx are converted most efficiently.
3. O2 Sensor heater resistance: 6.7 ~ 10.5 Ω
4. O2 Sensor amendment in the voltage value: between 100 ~ 900 mV
4-9
To this chapter contents
4. Fuel Injection System
Throttle Position Sensor (TPS)
ECU
TPS
Battery
TPS
EC
U
5V
VC
6
E
Voltage
VTA
TPS output voltage
4
2
0
50
100
150
Throttle valve opening angle
Basic Principle
TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value
change, determining the throttle position.
Function
TPS determines the throttle valve position and sends signal to ECU as reference of engine control.
4-10
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4. Fuel Injection System
Idle Speed Control Valve (ISC stepper motor)
ISC
ECU
Battery
+Va
-Va
+Vb
-Vb
N
N
S
N
S
Vb
S
Step
Va
Function
ECU controls ISC stepper motor to adjust the bypass intake air quantity and stabilized the idle speed.
4-11
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4. Fuel Injection System
Air Injection Solenoid Valve (AISV)
Function
AISV introduces appropriate air quantity to reduce pollutant emission.
Basic Principle
When the engine RPM and throttle opening are higher than the default value, ECU controls AISV opening
or closure.
Fresh air
AISV
Reed valve
Power relay
ECU
Battery
Power relay
Air Injection
Solenoid Valve
ECU
4-12
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4. Fuel Injection System
Precautions in Operation
General information
Warning
●
●
Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and flame is
strictly prohibited when working with gasoline.
Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to prevent
fuel from splashing.
Cautions
●
●
Do not bend or twist the throttle cable. Damaged cable will lead to unstable driving.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly.
Specification
Item
Specifications
Idle RPM
1550±100 rpm
Throttle handle free play
2~6 mm
Fuel pressure
294±6kPa (about 3.0kg/cm²)
Torque value
Engine Temperature sensor
O2 Sensor
0.74~0.88 kgf-m
3.6~4.6 kgf-m
Special Tools
Vacuum Gauge
Fuel Pressure Gauge
EFi System Diagnostic Scanner
Fuel Pipe Pliers
4-13
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4. Fuel Injection System
EFi System Components Description
ECU (Electronic Control Unit)
Functional Description:
●
●
●
Powered by DC 8~16V, and has 33-pin socket on the unit.
The hardware component consists of a 16-bit microcomputer that is its
control center. It contains the functional circuit interface of engine
condition sensing and the driving actuator for the fuel injector, fuel
pump, as well as ignition coil.
Its major software is a monitor strategy operation program that
includes controlling strategy and self-diagnosis programs.
Testing Procedures:
1. Connect the diagnostic scanner to the diagnostic coupler on the
vehicle.
2. Key-on but not to start engine, confirm ECU and the diagnostic
scanner can be connected or not.
3. Diagnostic scanner will automatically display Version "certification" of
the screen.
4. Confirm the application model, version is correct or not.
5. Check if the fault codes exist.
6. Remove the fault codes.
7. Start engine and check the parameters which shown on the diagnostic
scanner.
Detection judge:
●
Fault codes can be read and cleaned, and the fault codes will not
appear again after re-start.
Treatment of abnormal phenomena:
1. Disconnected→
First, check whether the cartridge is correct and
ECU is normal or not.
2. Unable to start→ ECU or relevant parts abnormal. Re-confirm after the
replacement of abnormal parts.
3. Fault codes appear→ ECU or relevant parts abnormal. Troubleshoot
and re-confirm.
4-14
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4. Fuel Injection System
Throttle Body
Functional Description:
●
●
●
Throttle body is the inlet air flow regulating device (similar to the
carburetor).
Throttle valve pivot drives the throttle position sensor synchronously
and makes ECU detect the throttle opening immediately.
Throttle valve positioning screw has been adjusted and marked on the
production line. Readjustment is not suggested.
Treatment of abnormal phenomena:
●
●
If all fuel injection associated components identified no adverse, and
other traditional engine components are also normal, the engine is still
not smooth, please confirm whether the throttle body coke serious.
If coke serious, please clean throttle body, and then adjust the injection
system.
Throttle positioning screw
4-15
To this chapter contents
4. Fuel Injection System
MAP Sensor
Functional Description:
Powered by 5V DC from ECU. It has 3-pin sockets on the sensor. One
terminal is for power, and 1 terminal 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 by sensing pressure, and can measure the absolute
pressure in intake process. It also conducts fuel injection quantity
correction based on environmental position level.
Pin
Wire color
Function
Left
Yellow / Black 5V voltage input
center
Black / Red
Signal output
Right
Green / Red Ground
●
Testing Procedures:
Y/B
B/R
G/R
1. Inlet pressure sensor connector to properly (using the probe tool).
2. Open the main switch, but not to start engine.
3. Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor
voltage.
4. Confirmed working voltage:
● Voltage meter negative access to the inlet pressure sensor third pin
(Green / Red).
● Voltage meter positive access to the inlet pressure sensor first pin
(Yellow / Black).
5. Confirmed plains output voltage values:
● Voltage meter negative access to the inlet pressure sensor third pin
(Green / Red).
● Voltage meter positive access to the inlet pressure sensor second
pin (Black / Red)
Cautions
Working voltage measurement
●
Attentions to the tools required close to the probe wire waterproof
apron penetrate skin and internal terminal before measurements to
the correct value.
Detection judge:
●
Working voltage value: 5.0±0.1V
●
Plains output voltage values: 2.87±0.03V (Conditions: In the plains
101.3 kPa Measurement)
Cautions
●
●
Output voltage measurement
plains
Treatment of abnormal phenomena:
●
●
●
●
4-16
The higher the altitude, the measurement value to the lower voltage.
Sea-level atmospheric pressure = 1Atm = 101.3kPa = 760mmHg =
1013mbar
Inlet pressure sensor damaged, or poor contact couplers.
Check whether the abnormal wire harness lines.
Inlet pressure sensor anomaly, the proposed replacement of the
sensor to measure the output voltage.
ECU anomaly, the proposed replacement of the ECU to measure the
working voltage.
To this chapter contents
4. Fuel Injection System
TA Sensor
Functional Description:
Use ECU DC 5V power supply provided, has the two-pin coupler, a
voltage output pin; another one for a grounding pin.
● Its main component is a negative temperature coefficient (resistance
temperature rise smaller) thermistor.
● Installed in the air cleaner on the intake temperature sensor within the
resistance, with the induction to the temperature change, and
converted into voltage signals sent to the ECU then calculated the
temperature and, in accordance with the ECU temperature and state
amendments injection time and ignition angle.
Testing Procedures:
Resistance Value Measurement:
● Dismantled inlet temperature sensor connector.
● Use of the "Ohmmeter" Ohm stalls, inspection sensor resistance.
Detection judge:
Resistance value and the temperature between relationships as follows
Temperature (℃)
Resistance value (KΩ)
-20
18.8 ± 2.4
40
1.136 ± 0.1
100
0.1553 ± 0.007
Treatment of abnormal phenomena:
●
●
●
Temperature sensor damaged or connector poor contact.
Check whether the abnormal wire harness lines.
Temperature sensor anomaly, the proposed replacement of the
temperature sensor.
Resistance value measurement
4-17
To this chapter contents
4. Fuel Injection System
TPS
Functional Description:
Use ECU provided DC 5V power supply, has the three-pin coupler, one
for the power supply pin; one for a voltage output pin; one for a
grounding pin.
Its main component is a sophisticated type of variable resistor.
Installed on the throttle body beside the throttle through (the
accelerator) rotates, the output of linear voltage signal provided ECU
perception and judgment then throttle position (opening), and in this
signal with have the most appropriate fuel injection and ignition timing
control.
●
●
●
W/BR
Y/B
Pins
Upper
Center
Under
G/R
Wire color
White / Brown
Yellow / Black
Green / Red
Function
Signal output
5V voltage input
Ground
Testing Procedures:
Working voltage measurement
1. Sensor connected properly (using the probe tool), or can be removed
connector to voltage measurements (direct measurement).
2. Opened the main switch, but do not to start engine.
3. Use "voltage meter" DC stalls (DCV) to check sensor voltage.
4. Confirmed working voltage:
● Voltage meter negative access to the inlet pressure sensor third pin
(Green / Red).
● Voltage meter positive access to the inlet pressure sensor first pin
(Yellow / Black).
5. Throttle output signal recognition (using the probe tool)
● Voltage meter negative access to the sensor third pin (Green / Red).
● Voltage meter positive access to the sensor first pin (white / Brown).
● Measurements were full throttle at full throttle closed the values of
the output voltage.
Cautions
●
TPS output voltage – throttle fully
closed
TPS output voltage – throttle fully
opened
4-18
Attentions to the tools required close to the probe wire waterproof
apron penetrate skin and internal terminal before measurements to
the correct value.
Detection judge:
●
Working voltage value: 5.0±0.1V
●
TPS output voltage – throttle fully closed : 0.6±0.02V
●
TPS output voltage – throttle fully opened: 3.78±0.26V
To this chapter contents
4. Fuel Injection System
Also, can be used for diagnosis tool confirm to the throttle output signal.
1. Connected to the "diagnosis tool", and open the main switch, but not to
start engine.
2. "Diagnosis tool" screen switches to a "data analysis (01 / 03)" screen.
3. Rotations throttle and check voltages.
Throttle output signal
measurement
Treatment of abnormal phenomena:
Throttle sensor damage or connector poor contact.
Check whether the abnormal wire harness lines.
Throttle sensor anomaly, the proposed replacement of the throttle
sensor to measure the voltage.
●
●
●
Warning
●
Throttle sensor prohibited removed from the throttle body to do any
testing.
4-19
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4. Fuel Injection System
TW Sensor
Functional Description:
●
●
●
Powered by 5V DC from ECU. It has the two-pin socket on the sensor.
One terminal is for power output, and 1 terminal are for ground.
Its main component is a negative temperature coefficient (resistance
temperature rise smaller) thermistor.
Installed in the cylinder head, the engine temperature sensor
resistance, with the induction to the temperature change, and
converted into voltage signals sent to the ECU was calculated engine
temperature, ECU accordance with the engine warm up to amendment
the injection time and ignition angle.
Testing Procedures:
●
●
Dismantled engine temperature sensor.
Use of the "meter" Ohm stalls, inspection sensor resistance.
Detection judge:
Resistance value and the temperature between relationships as follows:
Temperature (℃)
Resistance value (KΩ)
-20
18.8 ± 2.4
40
1.136 ± 0.1
100
0.1553 ± 0.007
Resistivity measurements
Treatment of abnormal phenomena:
●
●
●
4-20
Temperature sensor damaged or couplers to poor contact.
Check whether the abnormal wire harness lines.
Temperature sensor anomaly, the proposed replacement of the
temperature sensor.
To this chapter contents
4. Fuel Injection System
O2 Sensor
Functional Description:
●
●
●
G/R
Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply
pins for heater; for a heater control pin; signal for a grounding pin; O2
for a signal pin.
O2 Sensor output feedback signal to the ECU fuel ratio control in the
vicinity of 14.5 ~ 14.7, a closed-loop fuel control.
When the air-fuel ratio control in the near equivalent, CO / HC / Nox to
have the highest conversion efficiency.
L/O
Testing Procedures:
R/O
R/Y
1. Voltage confirmed:
● Removed O2 Sensor and the wire harness between the coupler.
● Open the main switch, but not to start engine.
● Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor
voltage.
● Confirmed working voltage:
Voltage meter negative access to the wire harness sensor coupler
2nd pin (Red / Orange).
Voltage meter positive access to the wire harness sensor coupler
first pin (Red / Yellow).
Confirmed working voltage
B
GR
2. Resistance Confirmation:
Remove O2 Sensor and the wire harness between the coupler.
● Use of the "meter" Ohm stalls, Measurement O2 Sensor heater
resistance.
● Measurement resistance value
Ohm meter negative access to the O2 sensor coupler 2nd pin
(White).
Ohm meter negative access to the O2 sensor coupler first pin
(White).
●
W
W
Resistance Confirmation
4-21
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4. Fuel Injection System
Numerical voltage changes that
the situation.
1. Used the diagnosis tool to confirm of O2 sensor work situations:
● Connected the "diagnosis tool" to diagnosis coupler and open the
main switch to start the engine.
● Engine to be completely warm-up (idling state operation "5 minutes"
above).
● Screen will switch to the diagnosis tool of "DATA STREAM 01/01"
screen, select " O2 Sensor" project, and switches to a wave of
images, turn the throttle engine speed to about 4500 rpm,
Observation O2 Sensor actuator circumstances.
● Observation O2 Sensor voltage values that the situation changes.
Detection judge:
●
●
●
Working voltage value: above 10V
Resistance value: 6.7~10.5Ω
O2 Sensor amendment in the voltage value of between 100 ~ 900 mV
beating; representatives pollution closed-loop control system to normal,
if contrary to maintain a fixed value for abnormalities.
Treatment of abnormal phenomena:
●
●
●
4-22
O2 sensor damaged, heater damaged or couplers to poor contact.
Check whether the abnormal wire harness lines.
O2 Sensor anomaly, the proposed replacement of the O2 Sensor,and
measurements again.
To this chapter contents
4. Fuel Injection System
Roll over sensor
Functional Description:
●
●
●
Control power of the power relay coil, has the three-pin socket.
When vehicles tilt angle greater than 65 degrees, roll over sensor will
be the implementation of ECU system power off. At this point once
again to restart the engine, the need to re-open a main switch.
This as a safety device, when the dumping of vehicles, be cut off
power supply of ECU, and engine stop.
Testing Procedures:
●
●
Because of the roll over sensor for the electronic control agencies, not
against removed after a single measurement.
Normal state, after power is turned on the main switch, measurement
of ECU power relays red / yellow line to the Green Line (ground), the
power supply voltage measurement can determine whether it is normal
for the roll over sensor.
Detection judge:
Voltage: Supply voltage = Battery voltage
Treatment of abnormal phenomena:
Vehicle state vertical, power relays or ECU without electricity supply.
● Roll over sensor internal short circuit or open circuit, or coupler bad
contact.
● Check whether the abnormal wire harness lines.
● Roll over sensor anomaly, the proposed replacement of the roll over
sensor.
4-23
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4. Fuel Injection System
ISC (stepper motor):
:
Functional Description:
●
●
●
Use ECU provided power, has the four-pin socket.
4-pin coupler for the two motor coils of the power supply and
grounding wire, grounding ECU power through the control and
management of the stepper motor actuators.
If it’s mainly low-power DC motors, drives idle speed control valve
(ISC) of the movement to adjust the idle air flow channel size, control
of idle speed of the engine in the cold or hot.
Testing Procedures 1:
Resistance Confirmation:
Idle Air Control Valve will be demolished down coupler (directly in the
body, can also measure).
● Use of the "meter" Ohm stalls (Ω), measurement of the two step
motor coil resistance values.
A phase: ISCAP and ISCAN
B phase: ISCBP and ISCBN
●
ISCBP
Inspection of the actuation (testing can only be on engine, not a single
test):
● Closure of the main switch.
● Use hand to touch Idle Air Control Valve body.
● Open the main switch.
● Feeling the Idle Air Control Valve Actuation.
ISCBN
ISCAP
ISCAN
ISC PINS
Cautions
●
Dynamic checking for Idle Air Control valve, can only be tested on
the engine, not a single test.
Detection judge:
A phase measurement of the
resistance value
1. Resistance value:
A phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)
B phase: 80 ± 10Ω (Environmental conditions: 15 ~ 25 ℃)
2. Actuator inspection:
In the above steps Idle Air Control Valve (ISC) Idling motor actuator
control of inspection, ISC will be slightly vibration or "… da… da…"
continuous sound.
Treatment of abnormal phenomena:
●
●
●
B phase measurement of the
resistance value
4-24
Idle air control valve damage, or poor coupler contact.
Check whether the abnormal wire harness lines.
Idle Air Control Valve anomaly, the proposed replacement of the Idle
Air Control Valve, further inspection of its actuator.
To this chapter contents
4. Fuel Injection System
Fuel Pump
Functional Description:
Powered by DC 8~16V, and has four-pin socket 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 294±6kpa (about 3 kg / cm2).
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.
Testing Procedures 1:
Fuel pump working voltage confirmed:
Fuel pump coupler to properly (using the probe tool), or can be
removed coupler working voltage measurements (direct
measurement).
● Open the main switch, but not to start engine.
● Use "voltage meter" DC stalls (DCV) to check fuel pump voltage.
● Confirmed working voltage:
Voltage meter negative access to the wire harness fuel pump coupler
2nd pin (Green).
Voltage meter positive access to the wire harness fuel pump coupler
first pin (Black / Purple).
●
Cautions
Confirmed working voltage
●
Conducting fuel pump voltage measurement, if the main switch to
open three seconds after the engine did not started, the ECU will
automatically cut off the fuel pump power supply.
Detection judge 1:
1. Working voltage value: Above 10V
2. Resistance value: 1.5±0.5Ω
3. Fuel pressure: 294±6kPa (about 3kg/cm2)
4-25
To this chapter contents
4. Fuel Injection System
Testing Procedures 3:
Fuel pressure measurement:
● Use fuel pressure gauge, connected in series between the injector
and the fuel tank.
Cautions
●
In the implementation of the fuel pressure measurement, will go to
the demolition of the fuel hose, such as: injector or fuel pump hose,
hydraulic measurements after, be sure to confirm whether there is a
leakage of fuel situation in order to avoid danger.
Fuel system pressure
measurement
Detection judge 3:
1. Fuel pressure: 294±6kPa (about 3kg/cm2)
Treatment of abnormal phenomena:
Fuel pressure measurement
demolition - injector
Fuel pressure measurement
demolition - fuel pump
4-26
1.
2.
3.
4.
Fuel pump damages internal coil break, or coupler bad contact.
Fuel filter blockage.
Fuel pump anomaly, the proposed replacement of the fuel pump.
Fuel unit anomaly, the proposed replacement of the fuel unit.
To this chapter contents
4. Fuel Injection System
Fuel Injector
Functional Description:
Powered by DC 8~16V, and has two-pin socket on the injector.
Its major component is the solenoid valve of high resistance driven by
electronic current.
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.
●
●
●
Testing Procedures:
1. Resistance Confirmation:
Use of the "meter" Ohm stalls (Ω), measurement of the injector
resistance value.
2. Injector injection state examination:
● Removed the injector fixed bolt and removed the injector from intake
manifold, but not removal of harness coupler.
● Injector and injector cap tightly by hands, fuel spills should not be
the case.
● Key-on and start the engine, injector injection state examination.
Injector resistance confirmation
Detection judge:
1. Between the two pin resistance values: 10.5±0.53Ω
2. injection state:
● Fuel atomizing good, with a clear scattering angle → judged as
normal.
● Injection-state such as water, no obvious scattering angle → found
abnormal.
Treatment of abnormal phenomena:
Injection-state atomizing good
1. Injector abnormal, the proposed replacement of the new one injector.
2. Injection-state abnormal, for the following reasons:
● Injector obstructive→ the proposed replacement of the new one
injector.
● Fuel pressure shortage → confirmed hydraulic pressure, the
proposed replacement fuel pump to confirm.
Warning
●
Injection-state unusual
●
Gasoline is lower ignited explosive materials, in the ventilation
premises operations, and prohibited fire.
In the inspection injector fuel injection state, the outflow of gasoline,
and the application of appropriate collection containers, so as to
avoid danger.
4-27
To this chapter contents
4. Fuel Injection System
Transistor ignition coil
Functional Description:
●
●
●
Use 8 ~ 16V DC power supply, has the two-pin socket.
Two-pin socket for the power supply and grounding. Its main
components for the high conversion ratio transformer.
Through computer programs when the ignition is controlled, from
ignition timing (TDC) / crank position sensor, the throttle valve position
sensor, engine temperature sensor, the inlet pressure sensor and O2
Sensor, issued by the signal, with the engine Speed through the ECU
to determine the appropriate ignition is, by the current of a crystal
intermittent control, a 25000-30000 volts of secondary hypertension,
flashover triggered spark plug, this approach will not only enable the
engine to achieve maximum output function, also help to improve the
efficiency of fuel consumption and pollution improvements.
Testing Procedures:
First circuit coil resistance
measurement
Resistance Confirmation:
● Removed coil first circuit plugs on the ignition coil (Red / Yellow &
Black / Yellow).
● Use of the "meter" Ohm stalls (Ω), measurement of the ignition coil
resistance value.
Detection judge:
●
Ignition coil primary circuit: 2.8Ω±15% (20ºC)
Treatment of abnormal phenomena:
1. Ignition coil internal coil disconnection damaged, or plugs bad contact.
2. Ignition coil ignition is not abnormal, proposes to replace the ignition
coil.
Crankshaft position sensor
Functional Description:
●
●
●
●
Do not need for an external power supply, has two-pin of signal plug.
Constitutes a major change in its reluctance induction coil.
The spacing of flywheel and sensor should be 0.7 to 1.1 mm.
Magnetic induction sensor is the use of flywheel on the Gear (18-1
tooth) rotary cutting induction coil changes in the magnetic field sensor
with the inductive voltage signal for ECU judgment, calculated at the
engine speed and crankshaft position, and with a most appropriate
time of fuel injection and ignition control.
Testing Procedures:
Resistance Confirmation:
● Removed crankshaft position sensor coupler (Blue / Yellow & Green /
White).
● Use of the "meter" Ohm stalls (Ω), measurement of the crankshaft
position sensor resistance value.
Detection judge:
●
Measurement resistance value
Resistance value: 80~160Ω(20ºC)
Treatment of abnormal phenomena:
1. Sensor internal coil interrupted damaged, or coupler bad contact.
2. Check whether the abnormal wire harness lines.
3. Sensor coil anomaly, the proposed replacement of the new one.
4-28
To this chapter contents
4. Fuel Injection System
AISV
Functional Description:
●
●
●
Control power, has two-pin socket, one for the power supply pin, one
for grounding pin.
Secondary air injection solenoid valve at the Idle (3500 rpm below)
actuator.
At Idling, ECU control solenoid valve by the grounding circuit to be
moving or closing.
Testing Procedures:
Resistance Confirmation:
● Use of the "meter" Ohm stalls (Ω), measurement of the secondary air
injection solenoid valve resistance value.
Detection judge:
Resistance value = 26 ± 2.6Ω (20℃)
Treatment of abnormal phenomena:
●
●
●
Secondary air injection solenoid valve internal short circuit or open
circuit, or coupler bad contact.
Check whether the abnormal wire harness lines.
Secondary air injection solenoid valve anomaly, the proposed
replacement of the new one.
4-29
To this chapter contents
4. Fuel Injection System
EFi System Circuit
4-30
To this chapter contents
4. Fuel Injection System
ECU Pin Configuration
(ON ECU)
ECU Pin Note
Pin NO.
Pin code
Wire color
Note
1
2
IGP
LG
R/Y
G
IGNITION POWER
LOGIC GROUND
3
4
HEGO
SG
L/O
G/R
O2 SENSOR
SENSOR GROUND
5
6
TH
VCC
W/BR
Y/B
7
BATT
R
BATTERY
8
9
PG1
G
POWER GROUND1
10
11
PG2
IG
G
B/Y
POWER GROUND2
IGNITION COIL
12
CRK-P
L/Y
CRANK PULSE SENSOR
13
14
TA
G/BR
AIR TEMP. SENSOR
15
16
TEST
INJ
P/W
L/G
TEST SW
INJECTOR
17
18
MIL
Y/G
MULTI INDICATOR LAMP
19
FLPR
O/W
FUEL PUMP RELAY
20
ISCBP
G/B
IDLE SPEED CONTROL +B
21
ISCAP
L/B
IDLE SPEED CONTROL +A
22
HEGO HT
R/O
O2 SENSOR HEATER
23
CRK-M
G/W
CRANK PULSE SENSOR GND
24
25
TW
-
R/GR
-
WATER TEMP. SENSOR
-
26
27
ROLL
PM
Y/P
B/R
ROLL OVER SENSOR
MANIFOLD PRESSURE SENSOR
28
SOL
O/L
AISV
29
30
K-LINE
W/G
DIAGNOSTIC TOOL
31
ICSBN
B/W
IDLE SPEED CONTROL -B
32
ISCAN
BR/B
IDLE SPEED CONTROL -A
33
RPM
B/Y
THROTTLE POSITION SENSOR
SENSOR POWER OUTPUT (+5V)
RPM SIGNAL
4-31
To this chapter contents
4. Fuel Injection System
Troubleshooting
EFi Circuit inspection
Main switch on
NG
Warning lights extinguished after 2 seconds?
switch?
OK
6. ECU fault?
NG
Battery voltage above 12.5V?
1. Bulbs broken?
2. Fuse broken?
3. Battery voltage is too low?
4. ECU Power line bad contact?
5. Poor contact the main power
1. Charging line anomaly?
2. Unable electrical storage
batteries?
3. Short-circuit leakage?
Battery voltage & ECU of voltage less than 0.2 V?
1. Main switch OFF
2. Removed ECU coupler
3. Main switch ON
4. Use voltage meter measurement of the power-pin
voltage difference
5. Confirmed ECU and battery supply voltage
differential pressure within the 0.2 V voltage
OK
NG
1. Lines anomaly?
OK
Battery voltage – drive parts voltage of less than 0.2
V?
1. Main switch OFF
2. Removed the injector, fuel pump, O2 sensor, roll
over sensor, ignition coil couplers
3. Measurement of the voltage between the couplers
and ground of the voltage difference
4. Confirmed voltage difference and battery voltage
of 0.2 V gap within?
NG
1. Lines anomaly?
OK
ECU 5V voltage - sensor voltage of less than 0.2 V?
1. Main switch OFF
2. Use probe inserted throttle sensor, engine
temperature sensor, the inlet pressure sensor
power connector
NG
1. Lines anomaly?
2. ECU anomaly?
NG
1. Lines anomaly?
2. Relay fault?
3. ECU anomaly?
3. Main switch ON
4. Use voltage meter measurement of the sensor
connector voltage
OK
5. Voltage standard value: 5.0±0.1V
Battery voltage - fuel pump voltage of less than 0.2
V?
1. Main switch OFF
2. Removed fuel pump power coupler
3. Potential probe then pumped two-pin connector
4. Main switch ON
5. Pumped in three second record supply voltage
OK
values
6. Confirmed pump and battery supply voltage
differential pressure within the 0.2 V voltage
End
4-32
To this chapter contents
4. Fuel Injection System
Can not Start the engine or difficult to start inspection
Difficulties or can not to start engine
NG
Warning lights extinguished after 2
seconds?
1. Inspection process in accordance with
circuit inspection
OK
NG
Display warning lights Fault Code?
1. Use diagnosis tool to view EMS fault
content
2. In accordance with Troubleshooting
procedures on troubleshooting
OK
1. Fuel tank inadequate?
2. Fuel injector pressure-less than 294 ±
6kpr?
NG
Is Fuel system anomaly?
OK
NG
Is Circuit anomaly?
Circuit
corrosion short circuit?
NG
OK
1. Spark plug there sparks?
2. Spark plug humid?
3. Spark plug cover loose?
4. Crankshaft position sensor Short
5. The high-voltage power lines loose?
6. ECU anomaly?
7. Leaking oxygen sensor connector
OK
Is Engine anomaly?
3. Pipeline fuel spills?
4. Pressure Regulating Valve anomaly?
5. Fuel pump pipe leakage?
6. Fuel pump anomaly?
7. Fuel injector anomaly?
1. Without valve clearance?
2. Valve timing, is not correct?
3. Valve jam?
4. Cylinder and piston ring wear?
5. Throttle adjustment screw adjustment
of the air improper?
End
4-33
To this chapter contents
4. Fuel Injection System
Idle flameout diagnosis
Idle flameout
Throttle line is not too
jammed to revert to full
closure?
1. Link diagnosis tool to
view EFI fault content
2. In accordance with
Troubleshooting
procedures on
troubleshooting
Idle CO value is set beyond
the scope of (1.5% ~
2.5%)?
Gasoline whether
enough?
Throttle body whether
coke serious?
Whether loose battery
connecter?
Idle Air Control Valve
Actuation whether or
failure?
EFi system more relevant
institutions, each recognized by the
detection, if still unable to rule out
the idling flameout problem, it is
recommended that engine checks
whether there are other traditional
institutions abnormal.
4-34
To this chapter contents
4. Fuel Injection System
CO value revised anomaly
O2 Sensor equipped with the system, in principle, not adjusted CO LLLvalue; such as CO value deviated from the
normal range, check O2 Sensor and other agencies anomaly.
Idle flameout
Link diagnosis tool to view EFI fault
content, its Idle CO value amend
anomalies
Gasoline whether enough?
Throttle line is not too jammed to
revert to full closure?
Connect with the
diagnosis tool, into to
view data steam
screen.
Start engine and warm-to 70 º C ~
95 º C, confirmed engine speed, idle
control valve and fuel injection
timing, oxygen sensor is abnormal?
Whether loose battery connecter?
Voltage is adequacy?
Idle CO value is set beyond the
scope of (1.5% ~ 2.5%)?
Idle functioning of 3 ~ 5 minutes, to
confirm the engine is running
normally after engine flame out,
eliminating fault code operations?
EFi system more relevant
institutions, each recognized by the
detection, if still unable to rule out
the idling flameout problem, it is
recommended that engine checks
whether there are other traditional
institutions abnormal.
4-35
To this chapter contents
4. Fuel Injection System
Integrated Troubleshooting Procedure
Checking,
adjusting
Project
Detection of
maintenance projects
and steps
Battery
voltage
●
Use meter direct
measurement
battery voltage
● Use diagnosis
tool detection
battery voltage
Fault reasons
Fault status
determination
Battery voltage
is 10 V above?
● Diagnosis tool
show whether
the voltage of 10
V above?
●
NO
Battery electricity
Battery connector
loose
● Harness circuit
opening
● ECU coupler not
connected properly
●
●
Parts specifications
●
Diagnosis tool
display voltage
required to
achieve more
than 10 V
●
The sensor
detection
methods and
specifications,
please refer to
repair manual
YES
Diagnosis
fault code
inspection
Use of the
diagnosis tool
detection fault
code
● Elimination of
fault codes, and
then start engine
●
Diagnostic tool
● TPS fault
show whether or
● ETS fault
not a fault code?
● CPS fault
YES ● MAP fault
● Fault Code
cleared after
● O2 sensor fault
show again?
● ROS fault
● ECU fault
●
NO
Fuel
quantity and
fuel
pressure
● Removed the
●
●
●
●
injector on the
intake manifold,
but not removal of
harness coupler.
(Injector and
injector cap tightly
by hands, fuel
spills should not
be the case)
Start the engine
Examine whether
injector fuel
injection
Between the tank
and injector
installation the
pressure gauge
check fuel
pressure
adequacy
Injector whether
injection?
● Injector spray
angle is normal?
● Fuel pressure
enough?
●
NO
●
●
●
less than fuel tank
Injector fault
Fuel pump relay
fault
● Fuel pump fault
● ECU fault
● Fuel pump filter
obstructive
●
Pressure fuel
specifications:
Open the main
switch three
seconds after
but not start
engine →more
than 250 kPa
Idle →
294±6kPa
● Injector
resistance
specifications:
11.7±0.6Ω
Spark plug fault
Roll over sensor
fault
● ECU fault
● Ignition coil fault
● Crankshaft position
sensor fault
●
YES
Ignition
situation
●
Removed the
spark plug from
the cylinder
head, but then
power lines still
ring
● Start the engine
● check spark plug
Examine
whether the
spark plug
ignition?
● Check spark
plug sparks
strength is
normal?
●
sparks
YES
Continued next page
4-36
●
●
NO
Spark plug
specifications:
NGK-CR8E
To this chapter contents
4. Fuel Injection System
Continued from previous page
YES
Closed-loop
systems for
mobility
● Observation
O2
senslor voltage
changes (Standed
motorcycle so that
engine speed
refueling between
4500 to 5500 rpm
●
O2 sensor
voltage is
maintained in a
long time within
a certain range
beating
O2 sensor fault
ECU fault
●
O2 sensor
voltage beating
specifications:
100 ~ 900 mV
from the two
groups within
the interactive
beating
Valve clearance is
not normal
● Intake system leak
●
Manifold
pressure
Specifications:
32~38 kPa
●
●
NG
YES
Engine
vacuum
●
Use diagnosis
tool to detect of
the manifold
pressure
●
Diagnosis tool
manifold
pressure for
compliance with
specifications?
●
NG
YES
Normal starting
Finish
Can not starting or starting difficulties
In traditional engine overhaul way to
maintenance
l
4-37
To this chapter contents
4. Fuel Injection System
Remove fuel pump/fuel unit
Remove side cover.
Remove rear carrier
Remove rear body cover.
Remove floor panel.
Remove under cover.
(Refer to chapter 14)
Remove fuel pump lines coupler.
Release the fuel tube folder, removed the fuel tube.
Remove the fuel tank fixed bolts (Bolt × 2 on both
sides), remove the fuel tank.
Remove / Install fuel pump and fuel unit
Remove fuel pump fixed bolts (Bolt × 6), remove fuel
pump.
Install In the anti-demolition order.
Fuel pump
coupler
Bolt × 2
Pressure Regulating Valve
Cautions
Then remove fuel pump, fuel in fuel tank
internal to confirm not excessive.
Then install fuel pump and fuel unit, attention
direction.
Confirm whether the fuel filter dirt,
obstructive.
Fuel pump installation, to confirm whether it
is normal to the fuel out (the pressure about 3
kg/cm2).
4-38
Fuel filter
To this chapter contents
4. Fuel Injection System
Air Cleaner
Clean air cleaner element
Bolt × 6
Air catheter fixed bolts × 1
Remove air cleaner cover (bolt×8).
Remove air cleaner filter (bolt×6).
Use compressed air to remove the adhesion of dirt,
if not too much dirt cleared, please new
replacement.
Cautions
●
Air cleaner filter for paper products, must not
soak or cleaning by water.
Install air cleaner element
Install In the anti-demolition order.
Cautions
●
Air cleaner filter and air filter cover should be
covered formation is the installation, not to
skew a seam, resulting dust, foreign body
aspiration in the engine.
4-39
To this chapter contents
4. Fuel Injection System
EFi System Diagnosis Methods
When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or
can not start engine, warning light at the meter will be lighting, to inform drivers to carry out maintenance.
Overhaul, the diagnosis tool can be used for troubleshooting (refer to diagnosis tool use guide), or
manually by the meter warning light inspection revealed that the fault codes (refer to checking signal fault
codes discriminate method), the two methods for maintenance.
If the fault has been ruled out or repaired after the inspection light will be extinguished, but ECU fault
code will be recorded, so the need to get rid of fault codes. If a fault exists, this system has two kinds of
methods to eliminate fault codes respectively in the diagnosis tool removal and manual removal.
Using diagnostic tool for overhaul
Diagnosis tool will connect to the motorcycle for coupler diagnosis, according to the use of diagnostic tool
testing methods, when belong fuel injection system fault or parts fault, according to the diagnosis tool of
the fault code display messages do describe parts of the inspection testing maintenance and replacement
parts. When after the maintenance, the need to get rid of fault codes (Please refer to detailed steps
diagnosis tool of instructions), or fault code will always be stored in the ECU.
Manual inspection
Use of cross-wiring (wire or paper clips, etc.) to cross-Joints Test Switch for grounding, in the meter of
this check light are flashing, it means that the injection system or parts of abnormal situations, but not in
the diagnosis tool can be - for the detection, inspection can enjoy for a long time flashing lights flashing
and the short period of time to inform the cause of the malfunction (refer to check light fault information
fault code table).
Test switch coupler
Diagnostic tool coupler
Diagnostic tool coupler and test switch coupler plant
4-40
To this chapter contents
4. Fuel Injection System
Check Light Fault Codes Differentiation
Check light flashing mode
If problem without diagnosis tool to be detected, it can be cross-access the test switch coupler, the
motorcycle from the CHK lights flashing signal interpretation, and then the basis for the diagnosis of
dynamic information tables on the priorities of light, and prompts you to the motorcycle to the emergence
of some warning, or FLASH CODE is to determine what kind of fault, and exclusion.
1
1
1
1
0.5
1
3
Fault code 22
0.5
Unit: second
1
6
Fault code 12
Continuous repeated
Fault Code manual removal procedure:
When there is without diagnosis tool, can be manually cleared Fault Code, the implementation of the
following steps:
1. Main switch OFF
2. Cross-access the test switch for interconnection access, and without opening up (cross-access
movement must indeed).
3. Full throttle and do not open up.
4. Main switch ON
5. Described above, the No. 3 with the No. 4 movements continued liberalization of 5 seconds later, about
5 seconds after inspections at carnivals "flash twice" to complete the removal of fault code.
6. Then remove the cross-wiring.
Test switch
Cross-access
Not to cross-access
Throtrtle
Full throttle
Full throttle closed
At least 5 seconds
Main
switch
ON
OF
F
OF
F
Lighting
Check
light
Not lit
Lighting
2nd inspection lights flash
Not lit
4-41
To this chapter contents
4. Fuel Injection System
Fault Code and Sensors Table
No.
Fault
codes
Fault Description
Parts Inspection
1
0120
Throttle position sensor fault
TP Sensor and wire
2
0105
Manifold absolute pressure sensor fault
MAP sensor and wire
3
0115
Engine temperature sensor fault (water)
TW Sensor and wire
4
0195
Engine oil temperature sensor fault (oil)
Engine temperature sensor and wire
5
0110
Intake air temperature sensor fault
TA Sensor and wire
6
1630
Roll over sensor fault
Roll over sensor and wire
7
0130
O2 sensor fault
O2 Sensor and wire
8
0201
INJ #1 fault
Injector and wire
9
0351
IG #1 fault
Ignition coil and wire
10
0230
Fuel pump fault
Fuel pump and wire
11
0135
O2 sensor heater fault
O2 Sensor and wire
12
1505
ISC Idle speed control motor fault
ISC stepper motor and wire
13
1410
Exhaust 2nd air control solenoid valve fault
AISV and wire
14
0335
Crankshaft position sensor fault
Crankshaft position sensor and wire
15
1205
MAP wire fault
MAP sensor and wire
16
0603
EEPROM fault
EEPROM
4-42
To this chapter contents
4. Fuel Injection System
Fault Code and Check Light Flashing Lighting Identification Table
No.
Fault
codes
1
0120
2
0105
3
0115
4
0195
5
0110
6
1630
7
0130
8
0201
9
0351
10
0230
11
0135
12
1505
13
1410
14
0335
15
1205
16
0603
Check Check light flashing
Parts Inspection
light
state
Throttle position sensor fault
Lighting
Throttle position sensor and wire
long 0,short 6
Fault detection procedures Please refer to the "EFI System components description" throttle position sensor
(TPS) chapter
Fault Description
MAP sensorand wire
Manifold Absolute Pressure sensor fault lighting
long 0,short 9
Fault detection procedures Please refer to the "EFI System components description" manifold Absolute
Pressure sensor (MAP) chapter
Engine temperature sensor fault (water) lighting
Engine temperature sensor and wire
long 1,short 2
Fault detection procedures Please refer to the "EFI System components description" engine temperature
sensor (WPS) chapter.
Engine temperature sensor and wire
Engine oil temperature sensor fault (oil) lighting
long 1,short 1
The current reservation
Intake temperature sensor fault
lighting
Intake temperature sensorand wire
long 1,short 3
Fault detection procedures Please refer to the "EFI System components description" intake temperature
sensor (TAS) chapter.
Roll over sensor fault
lighting
Roll over sensor and wire
long 1,short 5
Fault detection procedures Please refer to the "EFI System components description" Roll over sensor chapter.
O2 sensor fault
lighting
long 1,short 7
O2 Sensorand wire
Fault detection procedures Please refer to the "EFI System components description" O2 sensor chapter.
INJ #1 fault
lighting
long 3,short 3
Injector and wire
Fault detection procedures Please refer to the "EFI System components description" fuel injector chapter.
IG #1 fault
lighting
long 3,short 7
Ignition coil and wire
Fault detection procedures to adhere to the traditional way
Fuel pump fault
lighting
long 4,short 1
Fuel pump and wire
Fault detection procedures Please refer to the "EFI System components description" fuel pump chapter.
O2 sensor heater fault
lighting
long 4,short 5
O2 Sensorand wire
Fault detection procedures Please refer to the "EFI System components description" O2 Sensor chapter.
ISC motor fault
lighting
Step motor and wire
long 4,short 9
Fault detection procedures Please refer to the "EFI System components description" idle speed control valve
(ISC) chapter.
nd
nd
Exhaust 2 air solenoid valve fault
lighting
2 air control valve and wire
long 5,short 4
nd
Fault detection procedures Please refer to the "EFI System components description" 2 air solenoid valve
chapter.
Crankshaft position sensor fault
lighting
Crankshaft position sensor and wire
long 6,short 6
Fault detection procedures Please refer to the "EFI System components description" Crankshaft position
sensor chapter.
Manifold absolute pressure sensor
PM wire fault
lighting
long 6, short 8
and wire
Fault detection procedures Please refer to the "EFI System components description" Manifold absolute
pressure sensor (MAP) chapter.
EEPROM fault
Not lit
EEPROM
long –,short –
This fault Please direct replacement ECU
4-43
To this chapter contents
4. Fuel Injection System
EFi System Diagnostic Tool - V70
Cable connector
LCD
monitor
Link cable
Information
transmission indicator
Function
set Button
Button to turn the
pages, and numerical
adjustment
Leave
button
Executive
Function button
Digital
button
Software cartridge slots
Software
cartridge
Note:
●
●
When problems occurred, can be used for diagnosis tool of the fault is detected, and exclusion.
In addition to testing, troubleshooting, another of the operation can be carried out data analysis-type
monitor.
Method of Use:
1. Maintain engine flameout state, do not open main switch.
2. Opened the luggage box lighting light cover (screw x2), connected to the diagnostic connector for
diagnosis tool.
3. Then open the main switch and the diagnosis tool power switch after diagnosis display screen
appeared the words connection.
4. Press the "ENTER" button into the main screen (there are 6 major functions: ECU ID, DATA STREAM,
FREEZED DATA, TROUBLE CODE, ERASE TB CODE and CO ADAPTION)
5. Use ▲, ▼ select button under the function, press the "ENTER" button access into various functions.
Example: select "DATA STREAM," by the "ENTER" button, the screen showed that the existing fault
codes; indicates no fault "system is OK."
6. Press "EXIT" button to leave of the various functions.
7. Must to close the main switch or power switch of the diagnosis tool after, and then can removal of
diagnosis tool coupler.
4-44
To this chapter contents
4. Fuel Injection System
Diagnostic Tool Use Note
Diagnosis of connectivity
1. For the diagnostic tool coupler access to the
motorcycle injection system diagnostic signal
coupler.
2. main switch ON.
3. Open the diagnosis left power switch, which turn
on the LCD screen, the screen brightness
adjustment knob to the appropriate brightness.
4. SYM and cartridge content display on screen
(such as icon), by the beginning of the
implementation of any button.
5. Display diagnostic software release; press the
"ENTER" button to the implementation.
Test switch
coupler
Diagnostic coupler
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4. Fuel Injection System
Options main functional areas:
1. ECU ID
2. DATA STREAM
3. FREEZED DATA
4. TROUBLE CODE
5. ERASE TB CODE
6. CO ADAPTION
Use "▲" "▼" button, select mobile anti-white subtitles implementation of the project, and then press the
"ENTER" key to the implementation.
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4. Fuel Injection System
1. ECU ID
In the directory functions used "▲" "▼" button, select ECU ID project, press the "ENTER" buttom to
the implementation of information systems function.
ECU ID containing two functions:
1-1. ECU ID Datas
1-2. ECU Pin Assign
1-1. ECU ID Datas
Use "▲" "▼" button, select ECU ID projects, press the "ENTER" buttom to the implementation.
A total of 2 page, use "◄ left" and "right ►" button, view ECU information.
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4. Fuel Injection System
1-2. ECU Pin Assign
Use "▲" "▼" button, select the ECU pin project, and press the "ENTER" button to the
implementation of the ECU pin functions.
ECU pin assign total of 5 pages that can be used "◄ left" and "right ►" button, view the page
note.
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4. Fuel Injection System
2. DATA STREAM
In the directory functions used "▲" "▼" button, select "DATA STREAM" project, press the "ENTER"
key to the implementation.
A total of 3 pages, are able to use "◄ left" and "right ►" button, view injection system information.
On the any screen, press the "EXIT" button, the function can return to the directory screen.
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4. Fuel Injection System
Data stream (1/3)
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
● Engine SPD--RPM (Idle:1550~1750) →Engine idle speed
● FAULT NO.-------(Normal:0) →Fault code number
● BATT. VOLT---V (Above 12V) →Battery voltage
● FUEL PUMP--------(Idle:ON) →Fuel pump actuator state
● MAP-----------kPa (Idle:32~38kPa) →Manifold pressure
● TPS position-----% (Idle:﹤ 1.5%) →Throttle opening
● TPS position---V (Idle:0.58~0.62) →Throttle sensor voltage
● O2 SENSOR---mV (Idle:50~200mV) →O2 sensor voltage
● O2 HEATER--------(Idle:﹥ 3500rpm=ON) →O2 heater actuator state
● ENGINE TEMP-ºC (Stable:85~95ºC) →Engine temperature (cooling water temperature)
In the "DATA STREAM" of the screen use "▲" "▼" button to move the left side of the project "→"
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use "◄ left" and "right ►" button, can transform View wave numerical size.
Numerical analysis of images (1 / 3), the waveform can be displayed as shown in the following items:
Engine SPD
BATT. VOLT
MAP
TPS position %
TPS position Voltage
O2 SENSOR Voltage
ENGINE TEMP
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4. Fuel Injection System
Data stream (2/3)
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
● BARO-----------kPa (Above 98kPa) →Atmospheric pressure
● Intake Air---------ºC (Outside Temp.) →Intake air temperature
● 2nd AIR VALVE-----V (Idle:ON) →Secondary air solenoid valve actuator state
● INJECT TIME---mS(Idle:1~3mS) →Injection time
● IGN. ANGLE-----------(Idle:12~14) →Ignition timing
● STEP MOTOR -----→Idle air control valve step motor actuator state
● CRANKSHAFT ---------(Idle:CW) →Crankshaft functioning direction
● TEST TERMINAL-(Idle:OPEN) →Test terminal state
● IDLE SET----------RPM (=1650 RPM) →Idle speed goal set value
● ISC STEP--------------(Idle:75~95) →Idle Air Control Valve stepper motor learning step
In the "DATA STREAM" of the screen use "▲" "▼" button to move the left side of the project "→"
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use "◄ left" and "right ►" button, can transform View wave numerical size.
Numerical analysis of images (2 / 3), the waveform can be displayed as shown in the following items:
BARO
Intaje Air
INJECT TIME
IGN. ANGLE
IDLE SET
ISC STEP
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4. Fuel Injection System
Data stream (3/3)
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
● LEARNED STEP--------------(Set by ECU) →Idle Air Control Valve stepper motor learning
step
In the "DATA STREAM" of the screen use "▲" "▼" button to move the left side of the project "→"
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use "◄ left" and "right ►" button, can transform View wave numerical size.
Numerical analysis of images (3 / 3), the waveform can be displayed as shown in the following items:
LEARNED STEP NO.
4-52
To this chapter contents
4. Fuel Injection System
3. FREEZED DATA
Objective: When a sensor fault, the EMS system will record all the parameters of fault signals, in
order to facilitate fault diagnosis.
In the directory functions used "▲" "▼" button, select "FREEZED DATA" project, press the "ENTER"
key to the implementation.
Only one page, at any screen, press the "EXIT" button, the function can return to the directory screen.
In the "FREEZED DATA" of the screen use "▲" "▼" button to move the left side of the project "→"
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use "◄ left" and "right ►" button, can transform View wave numerical size.
4-53
To this chapter contents
4. Fuel Injection System
4. TROUBLE CODE
In the functional directory select "TROUBLE CODE" project, press the "ENTER" button
implementation, the message began to read fault.
Fault Code: electronic injection system that had happened fault of the message (whether or not
completion of repair).
Without any fault is that showing "System is OK".
Press the "EXIT" button, the function can return to the directory screen.
If the system has faulty code, that is showing the fault code, that can be used "◄ left" and "right ►" or
"▲" "▼" button to select the fault code (selected before the code "" tags) that, press the "ENTER"
button, the code can be read descriptions and fault handling.
Fault code in the note and treatment of the pages, if the first one page did End, they can press the
"▲" "▼" button to turn the pages to read all content.
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To this chapter contents
4. Fuel Injection System
5. ERASE TB CODE
In the directory functions used "▲" "▼" button, select "ERASE TB CODE" project, press the "ENTER"
key to the implementation.
Conditions: The main switch "ON", or in the engine running state, the fault code can be removed.
Fault code removed, namely showing the "ERASE TB SUCC.!".
Press the "EXIT" button, the function can return to the directory screen.
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To this chapter contents
4. Fuel Injection System
6. CO ADAPTION
In the directory functions used "▲" "▼" button, select "CO ADAPTION" project, press the "ENTER"
button into the CO adjustment screen.
Use "◄ left" and "right ►" or "▲" "▼" button, CO value can be adjusted.
CO ADAPT: CO adjusted value.
CO Read: CO read-back value.
Press the "EXIT" button, the function can return to the directory screen.
4-56
To this chapter contents
4. Fuel Injection System
Troubleshooting Table
Test items
Power
voltage
Fuel
press.
Can’t start
Difficult to
start
Abnormal
phenomena
Start
state
Comprehensive testing program
Without
idle
Idle
state
Parts
closedFault
loop
Ignition Engine Injection
Code
control Detection
state
state
vacuum
system
Idle not
smooth
RPM NG
Acceleration
Flameout
Engine
temp.
sensor
Throttle
position
sensor
ˇ
CO NG
Not smooth
Inability
and slow
Idle
flameout
ECU
Acceleratio
n flameout
Related spare parts
Roll over
Fuel pump
sensor
Ignition
coil
Inlet pipe
Injector
O2 sensor
Secondary
air
Fuel pump injection
solenoid
valve
Fuel
pressure
Spark plug
adjustment
valve
Cylinder
head
Security
unit
Fuel pump
relay
Fuel
Inlet
pressure
pressure
adjustment
sensor
valve
Main
switch
Fuel filter
Power
relay
Battery
Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation.
2. Spare parts, according to the "EFI System components description" implementation.
4-57
To this chapter contents
4. Fuel Injection System
Comprehensive Maintenance List
No.
1
Maintenance
Project
Testing Procedures
Test items
● Battery voltage
Power and ● Use meter direct
measurement battery voltage
voltage
Determine benchmarks
● Battery voltage = 10V Above
●
●
●
●
Battery electricity
Battery connector loose
Harness circuit opening
ECU coupler not connected
properly
● Open the main
switch, but do not to
start the engine of
pressure
● Pressure in idle
● Rotating throttle,
situation of pressure
changes
● Open main switch, but do not
start the engine of pressure:
= 250kPa (Stable value)
●
●
●
●
●
●
Fuel not enough
Security switch not disarm
Fuel pump relay fault
Fuel pump fault
Injector fault
ECU fault
● Spark plug
specifications
● Whether the spark
plug ignition
● Spark plug sparks
whether it is normal
strength
● Specifications: NGK-CR8H
● Ignition conditions:
With traditional engines found
ways
●
●
●
●
●
Spark plug fault
Roll over sensor fault
ECU No. 5 pin fault
Ignition coil fault
Crankshaft position sensor
fault
● Use diagnosis tool detection
of battery voltage
2
3
4
5
6
7
● Use fuel pressure gauge,
connected in series between
the injector and the Pressure
Regulating Valve
● Main switch ON, but not
start engine
● Check fuel pressure
● Start engine (idle)
● Check change of the fuel
pressure
● throttle several rotation
● check to the change of fuel
pressure again
Ignition state ● The spark plug removed from
the cylinder head, but the
power lines still ring
● Start engines or use for the
diagnosis tool of output View
spark plug ignition conditions
Fuel
pressure
Engine
vacuum
● Diagnosis tool to detect the
use of
● Idle state:
pressure = 294±6kPa
(Beating situation from top to
bottom)
● rotation throttle moment:
pressure = 294±6kPa (Slightly
beating)
● Manifold pressure of ● Manifold pressure
diagnosis tool
=32~38kPa
● The injector removed from ● Open the main
the throttle body, but not
switch, but did not
start engine the
dismantle pipeline
injection situation
● Main switch ON, but not
start engine
● Injector state when
● Investigation the injector it’s
start
leaking fuel?
● Once again start engines or
use for the diagnosis tool of
output function
● Check injector fuel injection
and the injection situation
● Stable condition,
Closed - ● Use of diagnostic tool
observation O2 Sensor
sensor voltage
loop control
voltage changes
variation (Idle
system
continued 5 minutes
later to
measurement)
Injection
state
● Not started, injector not
leaking fuel
● In started, the injection state
must show fan shape
● Valve clearance abnormal
● Intake system leak
● Security unit is configured
not disarm
● Fuel pump relay fault
● Fuel pump fault
● Injector fault
● ECU fault
● Idle stable condition: O2
● O2 Sensor fault
Sensor voltage = 50 ~ 200mV ● ECU fault
(Show from top to bottom
beating phenomenon)
● Diagnosis tool of the ● Without any residual Fault
Fault Code ● Use of the diagnosis tool
existing fault-detection code
fault code is it can be
Code
Detection
or historical Fault Code
● Elimination of the
implementation of fault
codes, check can be
eliminated
● Once again start engine
● Check fault is it happen
again
Fault reasons
eliminated
● If residual Fault Code,
● Start again, the fault
according to the "Fault Code
is it will happen again
Maintenance Form"
implementation of
troubleshooting
● throttle position sensor fault
● Engine temperature sensor
fault
● Intake temperature sensor
fault
● Manifold pressure sensor
fault
● O2 Sensor fault
● Crankshaft position sensor
fault
● ECU fault
● Roll over sensor fault
Notes: 1.Fuel pressure gauge connected between the fuel tank and injector, open the main switch to
repeatedly shut down, fuel system makes pressure stability.
2. Injector and injector cap tightly by hands, fuel spills should not be the case
4-58
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Contents
5. Engine Removal
L
Precautions in Operation ......................5-1
Engine Installation .............................5-4
Removal of Engine.................................5-2
Precautions in Operation
The engine has to be supported with special service tools that can be lifted or adjustable.
The following parts can be serviced as engine mounted on frame.
Carburetor.
Cylinder head, cylinder, and piston.
Driving pulley, driving belt, clutch, and driving disc assembly.
Final gear reduction mechanism.
Specification
Item
Engine oil capacity
Capacity
Replacement
1800 c.c.
Disassembly (oil
filter replaced)
1900 c.c.
Disassembly
2000 c.c.
Replacement
330 c.c.
Disassembly
350 c.c.
Engine & radiator
1400 c.c.
Gear oil capacity
Coolant capacity
Reservoir
Total
350 c.c.
as indicator shown
1750 c.c.
Torque Value
Engine mounting bolt
Engine hanger bolt
Rear shock absorber connection bolt (under)
Engine hanger stopper nut
Engine bracket nut
4.0~5.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
1.8~2.2kgf-m
4.0~5.0kgf-m
5-1
To this chapter contents
5. Engine Removal
Removal of Engine
Disconnect the seat dampers.
Remove the air box cover.
Disconnect the air temperature sensor coupler.
Remove the air box.
Air temperature sensor coupler
Disconnect the starter motor wire.
Starter motor wire
Remove the spark plug cap.
Spark plug cap
5-2
To this chapter contents
5. Engine Removal
Remove fuel pipe, vacuum tube and throttle valve
wire from the throttle body.
Disconnect the EFi system coupler.
Remove water hose from water pump.
Remove the thermo-sensor wires.
Water hose
l
Water pump
Remove the muffler (3 bolts, 2 nuts).
Bolt X3
5-3
To this chapter contents
5. Engine Removal
Remove the parking brake cable.
Remove the rear brake caliper (2 bolts).
Rear right cushion bolt
Caution
Do not operate brake lever after the caliper is
removed to avoid clipping the brake pad.
Remove the mounting bolt of rear right cushion.
Bolts X2
Remove the mounting bolt of rear left cushion.
Rear left cushion bolt
Remove the engine hanger lock nut.
Remove the engine hanger axle.
Remove the engine.
Engine Installation
Check if the bushings of engine suspension parts
and shock absorber for damage.
Install engine in the reverse procedures of
removal.
Caution
˙Pay attention of foot & hand safety as engine
installation to avoid hurting.
˙Do not bend or twist wires.
˙Cables wires have to be routed in
accordance with normal layout.
Engine Mounting Bolt:
Torque value: 4.0~5.0 kgf-m
Rear shock absorber bolt:
Torque value: UPPER: 3.5~4.5 kgf-m
LOWER: 2.4~3.0 kgf-m
5-4
Home page
Contents
6. Cylinder Head / Valve
Mechanism Diagram····························6-1
Valve Stem Replacement ··················· 6-10
Precautions in Operation ····················6-2
Valve Seat Inspection and Service ···· 6-11
Troubleshooting ··································6-3
Cylinder Head Reassembly················ 6-13
Cylinder Head Removal·······················6-4
Cylinder Head Installation·················· 6-14
Cylinder Head Disassembly················6-6
Valve Clearance Adjustment·············· 6-16
Cylinder Head Inspection····················6-8
Mechanism Diagram
1.0~1.4 kgf-m
1.0~1.4 kgf-m
2.0~2.4 kgf-m
3.6~4.0 kgf-m
1.0~1.2 kgf-m
1.0~1.4 kgf-m
0.7~1.1 kgf-m
6-1
6
To this chapter contents
6. Cylinder Head / Valve
Precautions in Operation
This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
Remove the engine from the frame before repairing the cylinder head.
Specification
Item
Standard
Limit
12+/2 kg/cm2
---
Intake
30.800~30.920
3.075
Exhaust
30.411~30.531
30.26
ID of valve rocker arm
12.000~12.018
12.10
OD of valve rocker arm shaft
11.966~11.984
11.910
Intake
4.975~4.990
4.900
Exhaust
4.955~4.970
4.900
5.000~5.012
5.030
Intake
0.010~0.037
0.080
Exhaust
0.030~0.057
0.100
Free length of valve spring
35.000
31.500
Valve seat width
1.000
1.6
---
0.05
Compression pressure
Camshaft
Rocker
arm
Valve
Height of cam lobe
OD of valve stem
Guide seat
Clearance between
valve stem and guide
Tilt angle of cylinder head
Torque Value
Cylinder head bolt (LH)
Cylinder head Nut
Sealing bolt of cam chain auto-tensioner
Bolt of cam chain auto-tensioner
Cam sprocket cover bolts
Cam sprocket bolt
6-2
2.0~2.4 kg-m
2.0~2.4 kg-m
0.8~1.2 kg-m
1.2~1.6 kg-m
0.8~1.2 kg-m
1.0~1.2 kg-m
To this chapter contents
6. Cylinder Head / Valve
Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure
1. Valve
Improper valve adjustment
Burnt or bent valve
Improper valve timing
Valve spring damage
Valve carbon deposit.
2. Cylinder head
Cylinder head gasket leaking or damage
Tilt or crack cylinder
3. Piston
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
Chain wear out or looseness
Auto-tensioner wear out or damage
Camshaft sprocket
Rocker arm or rocker arm shaft wear out
6-3
To this chapter contents
6. Cylinder Head / Valve
Cylinder Head Removal
Remove engine. (Refer to chapter 5)
Remove 2 bolts of thermostat and then remove
the thermostat.
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Tensioner bolts
Thermostat bolts
Remove Air Injection system (AI) pipe mounting
bolts.
Remove spark plug.
Remove cylinder head cover (4 bolts).
6-4
4 bolts
4 bolts
To this chapter contents
6. Cylinder Head / Valve
Remove the side cover mounting blots of cylinder
head, and then take out the side cover.
3 bolts
Remove left crankcase cover, and turn the
Turn the drive face, and align the timing mark on
the sprocket with that of cylinder head, piston is at
TDC position.
Remove cam sprocket bolts and then remove the
sprocket by prying chain out.
Timing mark
2 bolts
Bolt ×2
Remove the 2 cylinder head mounting bolts from
cylinder head right side, and then remove 4 nuts
and washers from cylinder head upper side.
Remove the cylinder head.
4 nuts
Remove cylinder head gasket and 2 dowel pins.
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
2 dowel pins
Caution
Do not damage the matching surfaces of
cylinder and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Cam chain guide
6-5
To this chapter contents
6. Cylinder Head / Valve
Cylinder Head Disassembly
Cam shaft setting plate
1 bolt
Remove cam shaft setting plate (1 bolt).
Remove rocker arm shafts and rocker arms.
Special Service Tool:
Rocker arm and cam shaft puller SYM-1445100
Rocker arm shaft and
cam shaft puller
Cam shafts
Remove cam shafts.
Special Service Tool:
Rocker arm and cam shaft puller SYM-1445100
Rocker arm
shaft and cam
shaft puller
Use a valve cotter remove & assembly tool to
press the valve spring, and then remove valves.
Caution
In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.
Special Service Tool:
Valve cotter remove & assembly tool
SYM-1471110-SY125
6-6
Valve cotter remove
and assembly tool
To this chapter contents
6. Cylinder Head / Valve
Remove valve cotters, spring retainers, springs
and valves.
Inlet valve
Exhaust valve
Inner spring
Spring retainer
Outer spring
Cotter
Remove valve stem seals.
Valve stem seals
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.
6-7
To this chapter contents
6. Cylinder Head / Valve
Cylinder Head Inspection
Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm
EX: Replacement when less than 34.725mm
Inspect the camshaft bearing for looseness or
wear out. If any damage, replace whole set of
camshaft and bearing.
Rocker Arm
Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?
Service Limit: Replace when it is less than
12.080 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
11.936 mm.
Calculate the clearance between the rocker arm
shaft and the rocker arm.
Service Limit: Replace when it is less than 0.10
mm.
6-8
To this chapter contents
6. Cylinder Head / Valve
Valve spring free length
Measure the free length of intake and exhaust
valve springs.
Service limit:
Inner spring 35.20 mm
Outer spring 36.90 mm
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.
Tool: 5.0 mm 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
5.0 mm 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.
6-9
To this chapter contents
6. Cylinder Head / Valve
Valve Stem Replacement
Heat up cylinder head to 100~150 ℃ with heated
plate or toaster.
Valve guide driver
5.0mm
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.
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Caution
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℃.
Valve guide driver
5.0 mm
Adjust the valve guide driver and let valve guide
height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 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.
Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-10
Valve guide reamer 5.0 mm
To this chapter contents
6. Cylinder Head / Valve
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 engine oil 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.
Valve seat width
Valve seat inspection
If the valve seat is too width, narrow or rough,
corrects it.
Valve seat width
Service limit: 1.6mm
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve
seat chamfer cutter.
Refer to operation manual of the valve seat
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any rough
or uneven surface from valve seat.
Caution
Roughness
45°
After valve guide had been replaced, it has to
be ground with 45° valve seal chamfer cutter to
correct its seat face.
Use 32° cutter to cut a quarter upper parts out.
Old valve seat width
32°
6-11
To this chapter contents
6. Cylinder Head / Valve
Use 60° cutter to cut a quarter lower parts 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 ground.
Grind valve seat again if necessary.
45°
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
32°
The contact surfaces of valve and valve seat
are very important to the valve sealing capacity.
If the contact surface too high, grind the valve seat
with 32° cutter.
Then, grind the valve seat to specified width.
Contact surface too low
Old valve seat width
If the contact surface too low, grind the valve seat
with 60° cutter.
Then, grind the valve seat to specified width.
60°
6-12
To this chapter contents
6. Cylinder Head / Valve
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and valve
after ground.
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 spring retainer
Valve cotter
Valve stem seal
Inlet valve
Caution
The closed coils of valve spring should face
down to combustion chamber.
Valve spring
Exhaust valve
Put the valve cotters onto valve spring retainer.
Use a valve cotter remove & assembly tool to
press the valve springs, and then install valves.
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 cotter remove & assembly tool
SYM-1471110-SY125
Valve cotter remove
and assembly tool
Tap the valve stems gently with a plastic hammer
to make sure valve retainer and valve cotter is
settled.
Caution
Place and hold cylinder head on to working
table so that can prevent from valve damaged.
6-13
To this chapter contents
6. Cylinder Head / Valve
Install camshaft into cylinder head.
Install valve rocker arm, rocker arm shaft and cam
shaft setting plate.
2 bolts
Cam shaft setting plate
Cylinder Head Installation
Gasket
Clean up all residues and foreign materials onto
the matching surfaces of both cylinder and
cylinder head.
Install chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.
Caution
Do not damage the matching surfaces of
cylinder and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Install 4 washers and tighten 4 nuts on the cylinder
head upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head right side.
Torque value:
Nut
3.6~4.0kgf-m
Bolt 1.0~1.4kgf-m
Chain guide
Dowel pins
Bolt ×2
4 nuts
Timing mark
Install cam chain on to sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.
Caution
Make sure timing marks are matched.
2 bolts
6-14
To this chapter contents
6. Cylinder Head / Valve
Install cylinder head side cover (3 bolts).
3 bolts
Tensioner bolts
Install thermostat (2 bolts).
Loosen auto tensioner adjustment bolt and
remove bolt and spring.
Install tensioner and install spring and adjustment
bolt.
Thermostat bolts
Install cylinder cover (4 bolts).
Install Air Injection system (AI) pipe. (4 bolts)
Install inlet pipe onto cylinder head.
Install and tighten spark plug.
Torque value: 1.0~2.0kgf-m
4 bolts
4 bolts
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can
not be exceeded standard value in order to
avoid causing cylinder head deformation,
engine noise and leaking so that motorcycle’s
performance be effected.
Install the engine onto frame (refer chapter 5).
6-15
To this chapter contents
6. Cylinder Head / Valve
Valve Clearance Adjustment
4 bolts
Loosen Air Injection system (AI) pipe upper side
bolt (2 bolts).
Remove cylinder head cover.
Remove the cylinder head side cover.
Remove left crankcase cover, and turn the drive
face, and align the timing mark on the cam
sprocket with that of cylinder head, piston is at
TDC position.
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 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Install the cylinder head side cover.
Start the engine and make sure that engine oil
flows onto the cylinder head.
Stop the engine after confirmed, and then install
the cylinder head cover and AI pipe.
Caution
If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.
6-16
3 bolts
Timing mark
2 bolts
Home page
Contents
7. Cylinder / Piston
Mechanism Diagram ···························· 7-1
Piston Ring Installation ······················· 7-6
Precautions in Operation ···················· 7-2
Piston Installation ································ 7-7
Troubleshooting··································· 7-2
Cylinder Installation····························· 7-7
Cylinder / Piston Removal··················· 7-3
Mechanism Diagram
0.8~1.2kgf-m
1.0~1.4kgf-m
1.2~1.6kgf-m
1.0~1.4kgf-m
7-1
7
To 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.
Unit:
:mm
Specification
LM25W5
Item
Standard
Limit
Standard
Limit
70.995~71.015
71.100
72.995~73.015
73.100
Out of round
-
0.050
-
0.050
Taper
-
0.050
-
0.050
Warpage
-
0.050
-
0.050
Top
0.015~0.050
0.090
0.015~0.050
0.090
2nd
0.015~0.050
0.090
0.015~0.050
0.090
Too
0.150~0.300
0.500
0.150~0.300
0.500
nd
0.300~0.450
0.650
0.300~0.450
0.650
0.200~0.700
-
0.200~0.700
-
70.430~70.480
70.380
72.430~72.480
72.380
0.010~0.040
0.100
0.010~0.040
0.100
17.002~17.008
17.020
17.002~17.008
17.020
16.994~17.000
16.960
16.994~17.000
16.960
0.002~0.014
0.020
0.002~0.014
0.020
17.016~17.034
17.064
17.016~17.034
17.064
I.D.
Cylinder
Clearance
between
piston ring and
ring groove
Piston/
Piston
ring
LM30W
Piston ring end
gap
2
Oil
(side rail)
Piston O.D. (2nd)
Clearance between piston
and cylinder
ID of piston pin boss
Piston pin O.D.
Clearance between piston and piston pin
Connecting rod small end I.D.
Troubleshooting
Low or Unstable Compression Pressure
Smoking in Exhaust Pipe
Cylinder or piston ring worn out
Piston or piston ring worn out
Piston ring installation improperly
Cylinder or piston damage
Knock or Noise
Engine Overheat
Cylinder or piston ring worn out
Carbon deposits on cylinder head top-side
Piston pin hole and piston pin wear out
Carbon deposits on cylinder head top side
Cooling pipe clogged or not enough in coolant
flow
7-2
To this chapter contents
7. Cylinder / Piston
Cylinder / Piston Removal
Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.
Coolant hose
Cover the holes of crankcase and cam chain with
a piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.
Remove cylinder gasket and dowel pin.
Clean up all residues or foreign materials from the
two matching surfaces of cylinder and crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective in
the cylinder.
Service limit:
LM25W5: 71.100 mm
LM30W: 73.100 mm
Top
Center
Bottom
7-3
To this chapter contents
7. Cylinder / Piston
Measure the cylinder upper surface for warpage.
Service limit: 0.05 mm
Measure the clearance between piston rings and
ring grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
Remove piston rings
Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.
Place piston rings respective into cylinder below
20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Measure the piston ring end gap.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
7-4
To this chapter contents
7. Cylinder / Piston
Measure the outer diameter of piston pin.
Service Limit: 16.96 mm
Measure the inner diameter of connecting rod
small end.
Service Limit: 17.064 mm
Measure the inner diameter of piston pin hole.
Service Limit: 17.02 mm
Calculate clearance between piston pin and its
hole.
Service Limit: 0.02 mm
Measure the piston outer diameter.
Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit:
:
LM25W5: 70.380 mm
LM30W: 72.380 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
7-5
To this chapter contents
7. Cylinder / Piston
Piston Ring Installation
Clean up piston top, ring groove, and piston surface.
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
2nd ring
Oil ring
Top groove
2nd groove
Oil groove
7-6
To 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 inlet valve.
Install new piston pin clip.
Clip end gap
Caution
Do not let the opening of piston pin clip align
with the piston cutout.
Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.
Cutout
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
Soap the residues into solvent so that the
residues can be removed more easily.
Install dowel pins and new cylinder gasket.
Dowel pins
7-7
To this chapter contents
7. Cylinder / Piston
Coat some 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 piston and piston rings will be
damaged.
Install coolant hose onto cylinder.
Install cylinder head (refer to Chapter 6).
7-8
Home page
Contents
8. V-Belt Drive System
Mechanism Diagram···························· 8-1
Drive Belt·············································· 8-5
Precautions in Operation ···················· 8-2
Drive Face ············································ 8-7
Troubleshooting ·································· 8-2
Clutch Outer / Driven Pulley ··············· 8-10
Left Crankcase Cover·························· 8-3
Mechanism Diagram
8.5~10.5kgf-m
6.0~7.0kgf-m
0.7~1.1kgf-m
0.7~1.1kgf-m
8-1
8
To this chapter contents
8. V-Belt Drive System
Precautions in Operation
General Information
Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
Drive belt and drive pulley must be free of grease.
Specification
Item
Drive belt width
Standard value
Limit
24.000 mm
22.500 mm
OD of movable drive face boss
29.946~29.980 mm
29.926 mm
ID of movable drive face
30.000~30.040 mm
30.060 mm
OD of weight roller
19.500~20.000 mm
19.000 mm
144.850~145.150 mm
145.450 mm
6.000 mm
3.000 mm
102.400 mm
97.400 mm
OD of driven pulley boss
40.950~40.990 mm
40.930 mm
ID of driven face
41.000~41.050 mm
41.070 mm
Weight of weight roller
17.700~18.300
17.200
ID of clutch outer
Thickness of clutch weight
Free length of driven pulley spring
g
Torque value
Special Service Tools
Drive face nut: 8.5~10.5kgf-m
Clutch outer nut: 5.0~6.0kgf-m
Drive plate nut: 5.0~6.0kgf-m
Clutch spring compressor: SYM-2301000
Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
Troubleshooting
Engine can be started but motorcycle can
not be moved
Insufficient horsepower or poor high
speed performance
1. Worn drive Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
1. Worn drive belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
8-2
g
To this chapter contents
8. V-Belt Drive System
Left Crankcase Cover
Left crankcase cover removal
Loosen 4 bolts from left side crank out cover &
remove it.
Remove left crankcase cover. (8 bolts)
Remove 2 dowel pin and gasket.
8 bolts
Left crankcase cover install
Install left crankcase cover in the reverse
procedures of removal.
Bearing setting plate
Drive shaft holder bearing
8-3
To this chapter contents
8. V-Belt Drive System
Left crankcase cover inspection
Remove 2 bolts to remove left crankcase cover
bearing setting plate.
Check bearing on left crankcase cover.
Rotate 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 cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Bearing replacement
Remove bearing with special service tools
Special tools:
Inner bearing puller
SYM-6204022
Install bearing with special service tools.
Special tools:
Right crank case bearing 6201 assembles tool
SYM-9614000-HMA 6201
8-4
2 bolts
To this chapter contents
8. V-Belt Drive System
Drive Belt
Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.
Special Tool:
:Universal holder
Hold clutch outer with universal holder, and
remove nut, bearing stay collar and clutch outer.
Universal holder
Bearing stay collar
Caution
Using special service tools for tightening or
loosening the nut.
Fixed rear wheel or rear brake will damage
reduction gear system.
Push the drive belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive belt.
Remove the drive belt from the groove of driven
pulley.
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
Service Limit: 22.5 mm
Replace the belt if exceeds the service limit.
Belt tooth
Width
Caution
Using the genuine parts for replacement.
The surfaces of drive belt or pulley must be
free of grease.
Clean up all grease or dirt before installation.
8-5
To this chapter contents
8. V-Belt Drive System
Installation
Caution
Pull out driven face to avoid it closing.
Cannot oppress friction plate comp in order to
avoid creates the distortion or the damage.
Driven face
Install drive belt onto driven pulley.
Install the driven pulley that has installed the belt
onto drive shaft.
On the drive belt another end to the movable drive
face.
Universal holder
Bearing stay collar
Install the clutch outer and bearing stay collar.
Hold the clutch outer whit universal holder, and
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Universal holder
Install the drive face, washer and drive face nut.
Hold drive face with universal holder, and then
tighten nut to specified torque value.
Torque value: 8.5~10.5kgf-m
8-6
To this chapter contents
8. V-Belt Drive System
Drive Face
Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Movable drive face
Remove movable drive face comp and drive face
boss from crankshaft.
Crankshaft
Remove ramp plate.
Ramp plate
Remove weight rollers from movable drive face.
Movable drive face
Drive face boss
Weight roller
8-7
To this chapter contents
8. V-Belt Drive System
Inspection
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 19.0 mm
Weight: 17.2g
Weight roller
Check if drive face boss is worn or damaged and
replace it if necessary.
Movable drive face
Measure the outer diameter of movable drive face
boss, and replace it if it exceed service limit.
Service limit: 29.962 mm
Drive face boss
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 30.060 mm
Reassembly/installation
Install weight rollers.
Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Closure surface
Install ramp plate.
Ramp plate
Guide collar
8-8
To this chapter contents
8. V-Belt Drive System
With 4~5g grease spreads wipes drives in the
movable drive face axis hole.
Install drive face boss.
Caution
The movable drive face surface has to be free
of grease. Clean it with cleaning solvent.
Drive face boss
Install movable drive face comp. onto crankshaft.
Drive face boss
Movable drive face
Crank shaft
Driven pulley installation
Press down
Press drive belt into pulley groove, and then pull
the belt onto drive shaft.
Drive belt
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces
have to be free of grease. Clean it with
cleaning solvent.
Hold drives face with universal holder.
Tighten nut to specified torque.
Torque value: 8.5~10.5kgf-m
Install left crankcase cover.
8-9
To this chapter contents
8. V-Belt Drive System
Clutch Outer / Driven Pulley
Clutch nut wrench
Disassembly
Remove drive belt, clutch outer and driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench 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 service
tool.
Release the clutch spring compressor and remove
friction plate, clutch weight and spring from driven
pulley.
Clutch spring compressor
Remove seal collar from driven pulley.
Collar
Remove guide pin, guide pin roller, and movable
driven face, and then remove O-ring & oil seal
seat from movable driven face.
Movable driven face
Guide pin
Seal
Guide pin
O-ring
Guide pin roller
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 145.450 mm
Inner
diameter
8-10
Clutch outer
To this chapter contents
8. V-Belt Drive System
Clutch weight
Measure each clutch weight thickness.
it if exceeds service limit.
Service limit: 3.0 mm
Replace
Clutch weight
Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 97.400 mm
Free length
Driven pulley
Check following items:
If both surfaces are damaged or worn.
If guide pin groove is damaged or worn.
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 40.93 mm
Inner diameter 41.07 mm
Driven face
Movable driven face
Guide pin groove
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Needle bearing
Outer ball bearing
8-11
To this chapter contents
8. V-Belt Drive System
Clutch weight Replacement
Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.
Spring
Driving plate
Caution
Some of models are equipped with one
mounting plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight
Check if shock absorption rubber is damage or
deformation. Replace it if necessary.
Apply with grease onto setting pins.
Install new clutch weight onto setting pin and then
push to the specified location.
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.
Shock absorption rubber
Setting pin
Shock absorption rubber
Caution
Grease or lubricant will damage the clutch
weight and affect the block’s connection
capacity.
Clutch weight
Install the spring into groove with pliers.
Spring
8-12
To this chapter contents
8. V-Belt Drive System
Install snap ring and mounting plate onto setting
pin.
Snap ring
Replacement of Driven Pulley Bearing
Remove inner bearing.
Caution
Outer bearing
Clipper
If the inner bearing equipped with oil seal on
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 oil.
Snap ring
Outer bearing
Install new inner bearing.
Bearing end
Caution
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.
Install snap ring into the groove of drive face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
Inner bearing
8-13
To this chapter contents
8. V-Belt Drive System
Installation of Clutch Outer/Driven Pulley
Assembly
Oil seal
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.
Specified grease
O-ring
Install the movable driven face onto driven face.
Install the guide pin and guide pin roller.
Movable driven face
Guide pin
Oil seal
Guide pin
O-ring
Guide pin roller
Install the collar.
Collar
Install friction plate, spring and clutch weight 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 clutch
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m
Install clutch outer/driven pulley and drive belt onto
drive shaft.
Clutch nut wrench
Clutch spring compressor
8-14
Homepage
Contents
9. Final Drive Mechanism
Mechanism Diagram ............................ 9-1
Final Drive Mechanism Inspection .....9-3
Precautions in Operation .................... 9-2
Bearing Replacement ..........................9-4
Troubleshooting................................... 9-2
Final Drive Mechanism Reassembly ..9-6
Final Drive Mechanism Disassembly . 9-3
Mechanism Diagram
Radial ball bearing 6206 UU
Oil seal 45*65*10
Radial ball bearing 6204
Final shaft
Counter gear
Final gear
Counter shaft
Radial ball bearing 6204
Needle bearing NK18/20R
Oil seal 25*40*7
Radial ball bearing 6205
Drive shaft
Radial ball bearing CSB305C
2.4~3.0 kgf-m
Needle bearing HKS 25*33*18
9-1
9
To this chapter contents
9. Final Drive Mechanism
Precautions in Operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 110 c.c. (100 c.c. when replacing)
Torque value
Gear box cover
1.0~1.4 kg-m
Tools
Special tools
Bearing (6203/6004UZ) driver
Bearing (6204) driver
Bearing (6301) driver
Oil seal (27*42*7) driver
Oil seal (20*32*6) driver
Inner bearing puller
Outer bearing puller
Troubleshooting
Engine can be started but motorcycle
can not be moved.
Damaged driving gear
Burnt out driving gear
Noise
Worn or burnt gear
Worn gear
Gear oil leaks
Excessive gear oil.
Worn or damage oil seal
9-2
To this chapter contents
9. Final Drive Mechanism
Final Drive Mechanism
Disassembly
Remove driven pulley.
Drain gear oil out from gear box.
Remove gear box cover bolts and then remove
the cover.
Remove gasket and dowel pin.
7 bolts
Remove drive shaft.
Remove final driving gear and shaft.
Remove countershaft and gear.
Final Drive Mechanism Inspection
Check if the countershaft is wear or damage.
Check if the final shaft and gear are burn, wear
or damage.
9-3
To this chapter contents
9. Final Drive Mechanism
Check bearings on gear box.
Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Check gear box cover bearing as the same way
above, and replace it if necessary.
Caution
If remove the drive shaft from the cover
upper side, then its bearing has to be
replaced.
Check drive 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 bearing puller
Install new driving shaft bearing into left
crankcase.
Tool:
Bearing (6301) driver
Press the bearing into cover with hydraulic
presser.
9-4
To this chapter contents
9. Final Drive Mechanism
Remove oil seal, and then remove final shaft
bearing from left crankcase.
Install new final shaft bearing.
Press the bearing in with hydraulic presser.
Tool:
Bearing (6203/6004UZ) driver
Oil seal (27*42*7) driver
Press out the driving shaft from gear box cover.
Using bearing protector as operation.
Remove oil seal from gear box cover and discard
the seal.
Use bearing puller to remove the final shaft
bearing from the cover.
Bearing puller
If the driving shaft is pulled out with its bearing,
then remove the bearing with bearing puller and
bearing protector.
Tool:
Bearing (6204)driver or
Multi-functional bearing puller
Bearing protector
Install a new driving shaft bearing onto gear box
cover.
Tool:
Bearing (6204) driver
Press the bearing in with hydraulic presser.
9-5
To this chapter contents
9. Final Drive Mechanism
Install a new final shaft bearing onto gear box
cover.
Tool:
Bearing (6203/6004UZ) driver
Press the bearing in with hydraulic presser.
Install the driving shaft onto gear box cover and
then place it to proper position.
Apply with grease onto new oil seal lip, and then
install the oil seal.
Tool:
Oil seal (20*32*6) driver
Final Drive Mechanism Reassembly
Apply with grease onto the oil seal lip of final
driving shaft.
Install countershaft, final shaft and final driving
gear.
Final shaft
Countershaft
Final driving gear
9-6
To this chapter contents
9. Final Drive Mechanism
Install dowel pin and new gasket.
dowel
pin
Gasket
Install gear box cover and bolts, and tighten.
Torque value: 1.0~1.4 kgf-m
Install driven pulley/clutch outer/belt.
Install movable drive face, drive face and left
crankcase.
Install rear wheel.
Add gear oil.
7 bolts
9-7
To this chapter contents
9. Final Drive Mechanism
NOTE:
9-8
Homepage
Contents
10. AC Generator / Starting Clutch
Mechanism Diagram ..................... 10-1
Flywheel Removal..........................10-3
Precautions in Operation ............. 10-2
Flywheel Installation......................10-7
Right Crankcase Cover Removal. 10-3
A.C.G. Set Installation ...................10-7
A.C.G. Set Removal....................... 10-3
Right Crankcase Installation.........10-7
Mechanism Diagram
0.7~1.1 kgf-m
0.7~1.1 kgf-m
8.5~10.5 kgf-m
2.8~3.2 kgf-m
10-1
10
To this chapter contents
10. AC Generator / Starting Clutch
Precautions in Operation
‧ Refer to chapter 5: Engine removal and installation
‧ Refer to chapter 16: The troubleshooting and inspection of alternator
‧ Refer to chapter 16: The service procedures and precaution items of starter motor
Specification
Item
Standard value (mm)
Limit (mm)
ID of starting clutch gear
20.026~20.045
20.100
OD of starting clutch gear
42.175~42.200
42.100
Torque value
Flywheel nut
5.0~6.0 kgf-m
Starting clutch hexagon bolt
1.0~1.4 kgf-m with adhesive
8 mm bolts
0.8~1.2 kgf-m
12 mm bolts
1.0~1.4 kgf-m
Tools
Special tools
A.C.G. flywheel puller
Universal holder
10-2
To this chapter contents
10. AC Generator / Starting Clutch
Right Crankcase Cover Removal
12 bolts
Remove 12 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.
A.C.G. Set Removal
2 screws
Remove 2 screws from pulse generator and
then remove it.
Remove 3 bolts from right crankcase cover and
A.C.G. set.
3 bolts
Flywheel Removal
Remove the flywheel nut.
Install the shaft protector to the crankshaft.
Shaft protector
Pull out flywheel with A.C.G. flywheel puller.
Tool:
A.C.G. Flywheel puller
10-3
To this chapter contents
10. AC Generator / Starting Clutch
Flywheel Installation
Insert the pin onto crankshaft.
Align the key 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 kg-m
Tool:
Flywheel holder
A.C.G. Set Installation
Install the A.C.G. set onto right crankcase cover
(3 bolts).
Install pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
2 screws
Caution
Make sure that the wire harness is placed
under pulse generator.
3 bolts
Right Crankcase Cover Installation
Install dowel pin and new gasket.
Install right crankcase cover onto the crankcase.
Note that align the water pump shaft indent with
the oil pump shaft.
Install right crankcase cover (12 bolts).
Connect water hose to the right crankcase
cover.
Install the water pump cover onto crankcase
cover.
.
10-4
Homepage
Contents
11. Crankshaft / Crankcase
Mechanism Diagram ...................... 11-1
Crankshaft bearing replacement .. 11-5
Precautions in Operation .............. 11-2
Crankshaft bearing installation .... 11-5
Troubleshooting............................. 11-2
Crankcase Assembly ...................... 11-6
11
Crankcase Disassembly ................ 11-3
Mechanism Diagram
0.7~1.1 kgf-m
6.0~7.0 kgf-m
2.0~2.4 kgf-m
1.0~2.0 kgf-m
1.0~1.4 kgf-m
Radial ball bearing CSB304
Radial ball bearing 6301
1.0~1.4 kgf-m
1.1~1.5 kgf-m
3.5~4.5 kgf-m
1.0~1.4 kgf-m
Oil seal 35*55*7.5
0.7~1.1 kgf-m
1.0~1.4 kgf-m
11-1
To this chapter contents
11. Crankshaft / Crankcase
Precautions in Operation
• This Section concerns disassembly of the crankcase for repair purpose.
• Remove following components before disassembling crankcase.
─Engine
Section 5
-Cylinder head
Section 6
-Cylinder and piston
Section 7
-Drive pulley and driven pulley
Section 8
-AC generator/Start driven gear
Section 10
-Starting motor
Section 16
•
In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the
timing chain, it is preferably to replace crankshaft as a unit.
Service data
Crankshaft
Item
Connecting rod side clearance of the big end
Vertical clearance of the big end of the connecting
rod
Run-out
Torque value
Bolts for crankcase
Bolts for cam chain adjuster
Tools
Special tools
R/L. crank disassemble/ install tool
L. crank shaft bearing driver
Crank shaft bearing fixing socket
Crank shaft puller
Outer bearing puller
Inner bearing puller
Troubleshooting
Engine noise
• Loose crankshaft bearing
• Loose crankshaft pin bearing
• Worn out piston pin and pin hole
11-2
0.8~1.2kgf-m
1.2~1.6kgf-m
Standard
0.100~0.400
Unit: mm
Limit
0.600
0~0.008
0.050
-
0.100
To this chapter contents
11. Crankshaft / Crankcase
Tensioner
Crankcase Disassembly
Remove the cam chain.
Loosen the bolt and remove the tensioner.
Remove the water pump shaft locknut.
Water pump shaft locknut
Cam chain
Remove the oil separator (bolt x 2).
boltsX2
Remove the oil pump drive sprocket, driven
sprocket and drive chain.
Oil pump drive sprocket
Oil pump driven sprocket
Remove the right crankcase bolts (bolt x 3).
Bolt x 3
11-3
To this chapter contents
11. Crankshaft / Crankcase
Remove the left crankcase bolts (bolt x 11).
Remove the right crankcase from the left
crankcase.
Remove the crankshaft and balancer shaft from
the left crankcase.
Check the main bearing on the crankcase for any
wear.
Replace the main bearing with special tool if
necessary.
11-4
Bolt x 11
To this chapter contents
11. Crankshaft / Crankcase
Crankshaft bearing replacement
Align the main bearing remover with the main
bearing.
Fix the remover with the universal holder and
press out the main bearing.
Crankshaft bearing installation
Use the crankshaft main bearing holder to fasten
the upper and lower main bearing.
Align the oil path on the main bearing and the
crankcase.
Press the main bearing into the crankcase.
Special tool: main bearing installer / remover
SYM-9100310-L4A
11-5
To this chapter contents
11. Crankshaft / Crankcase
Crankcase assembly
Install the crankshaft and balancer shaft to the left
crankcase.
The marks on the crankshaft and balancer shaft
must be aligned.
Assemble the right crankcase to the left
crankcase.
Tighten the bolts on the right crankcase.
Install the oil pump drive sprocket, driven sprocket
and drive chain.
11-6
Marks on the crankshaft and
balancer shaft
To this chapter contents
11. Crankshaft / Crankcase
Install the oil separator (bolt x2).
Tighten the bolts on the left crankcase ( bolt x 11).
Bolt x 11
Tighten the water pump shaft locknut.
Install the cam chain and tensioner.
11-7
To this chapter contents
11. Crankshaft / Crankcase
NOTE:
11-8
Home page
Contents
12. Cooling System
Mechanism Diagram...................... 12-1
Radiator ..........................................12-5
Precautions in Operation .............. 12-2
Steps to fill coolant after engine service
.........................................................12-7
Troubleshooting ............................ 12-3
12
System Test ................................... 12-4
Mechanism Diagram
Reserve tank
Reserve tank inlet pipe
Radiator filler cap
Thermo switch (fan)
Radiator
Cooling fan
Thermo unit
(temp meter)
Thermostat
Water pump
Engine coolant outlet pipe
Engine coolant inlet pipe
12-1
To this chapter contents
12. Cooling System
Precautions in Operation
Warning:
˙While the engine is running, never attempt to open the radiator filler cap, the pressurized hot
coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to
perform unless the engine is completely cooled down.
Refill the radiator with distilled water or specified additives.
Add coolant to the reservoir.
The cooling system can be serviced on the motorcycle.
Avoiding spilling the coolant on the painted surface.
Test the cooling system for any leakage after the repair.
Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and
the water thermometer.
Technical Specification
Specification
Item
0.9±0.15 Kg/cm²
Pressure to open filler cap
850c.c.
420c.c.
Capacity of coolant: Engine + radiator
Reservoir upper
Thermostat
Boiling point
Begins to activate at : 82~92ºC
Stroke : 0.05~3.0mm/80ºC
Not-pressured : 107.7ºC
Pressurized: 125.6ºC
Torque Value
For water pump rotor
Tools Requirement
Special tools
Water pump bearing driver (6901)
Water pump oil seal driver (Inner)
Water pump mechanical seal driver
Inner bearing puller
12-2
1.0~1.4kgf-m
To this chapter contents
12. Cooling System
Troubleshooting
The engine temperature is too high
The water thermometer and the temperature sensor do not work properly.
The thermostat is stuck to close.
Insufficient coolant.
The water hose and jacket are clogged.
Fan motor malfunction.
The malfunction of the radiator filler cap.
The engine temperature is too low
The malfunction of the water thermometer and the temperature sensor.
The thermostat is stuck to open.
Coolant is leaking
The water pump mechanical seal does not function properly.
The O ring is deteriorated.
The water hose is broken or aged.
12-3
To this chapter contents
12. Cooling System
System Test
Warning
Never attempt to carry out service work on
the cooling system unless the engine is
completely cooled down, otherwise, you
may get scalded.
Remove the reserve tank cap cover, and then
remove tank cap.
Reserve tank cap
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Drain bolt
By-pass pipe
Refilling system with coolant and bleeding the air
bubbles.
Run the engine, and remove by-pass pipe.
Check by-pass hole for any bubble come out.
If there is no bubble emitted but only coolant
flow out, then joint on backflow pipe, and turn
off the engine.
Remove radiator filler cap.
Starts the engine, check if there is any bubbles
come out from the radiator, and the coolant is
stable.
Stop the engine, and add coolant to proper
level if necessary.
Tighten the radiator filler cap.
Caution
In order to avoid the radiator rusting,
please do not use the uncertified
coolant.
Coolant recommended: SYM Bramax radiator
agent.
Concentration: 50%
12-4
To this chapter contents
12. Cooling System
Check reserve tank
Open the inner box lid.
Check the liquid level in the tank.
Add coolant to proper level if necessary.
Caution
Add too much coolant in the reserve
tank might cause overflow when the
temperature increased.
Viewing window
Radiator
Check
Check for any leakage from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure
water jet to clean it.
Care shall be taken when straightening the sink
fan.
Remove
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Drain bolt
Remove the front cover and under spoiler (refer
chapter 13).
Loosen the radiator mounting bolts (4 bolts).
Each side 2 bolts
12-5
To this chapter contents
12. Cooling System
Thermo switch coupler
Disconnect the couplers for the thermo switch
and fan motor.
Remove engine coolant inlet pipe, reserve tank
inlet pipe and radiator inlet pipe.
Engine coolant.
Remove reserve tank coolant inlet pipe.
Remove the radiator and the cooling fun.
Coolant inlet pipe
Cooling fun
Loosen the cooling fun mounting bolts (3 bolts).
Remove thermo switch.
3 bolts
Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.
Caution
12-6
Liquid packing must be applied to the
thermo switch before installation in
order to avoid damaging the radiator.
Thermo switch
To this chapter contents
12. Cooling System
Technical Data
Valve begins to open 71 ~ 80℃
Valve stroke
3.5 ~ 4.5 mm at 80℃
Installation
Install in reverse order of removal.
Caution
Always use a new oil ring and apply a coat of
grease on it before installation.
Refill the specified coolant as necessary.
Remove
Steps to fill coolant after engine
service
1:
Open the radiator cap.
2:
Remove the hose from engine, and drain out the
coolant.
3:
Pump in high pressure air from the water hole in
order to vent out the water from the pipe.
12-7
To this chapter contents
12. Cooling System
4:
Remove the engine circulation pipe, and pump
in high pressure air to the pipe.
Pump in high pressure
air
5:
Based on the above steps, coolant could be
drained out.
Steps to fill coolant:
1:
Remove the tube connecting to
thermostat(19320) cover.
12-8
Open this tube
To this chapter contents
12. Cooling System
2:
Close the fuel tube (95001-08550) loop.
Close this tube
3:
Fill up the coolant from filler neck (19039)
without interruption.
12-9
To this chapter contents
12. Cooling System
4:
Check the air exhausted through the thermostat
tube head until coolant come out.
Thermostat tube head
Thermostat cover joint end
5:
Check the air exhausted through the thermostat
cover joint until coolant come out.
Reconnect thermostat tube
6:
Reconnect thermostat tube(19320) to thermostat
cover joint(19315)
7:
Loosen flange bolt ( 8X12) on the water pump
cover(19221) for exhausting air until coolant
come out.
Tighten the flange bolt when finish.
Air evacuating bolt
12-10
To this chapter contents
12. Cooling System
8:
Open the radiator cap, and turn on the engine.
Overflow is normal. Continue adding water to
radiator until equilibrant if the amount of water
diminished.
9:
Maintain the liquid level in reserve tank between
upper and lower limit.
12-11
To this chapter contents
12. Cooling System
NOTE:
12-12
Home page
Contents
13. Body Cover
l
Mechanism Diagram···························13-1
Side Cover ·········································· 13-11
Maintenance ········································13-4
Rear Carrier ········································ 13-12
Handle Cover·······································13-5
Luggage Box ······································ 13-13
Front Cover ·········································13-6
Rear Body Cover ································ 13-14
Meter Panel··········································13-8
Floor Panel ········································· 13-15
Inner Box ·············································13-9
Front Fender······································· 13-15
Mechanism Diagram
Wind screen cover
Wind screen
Wind screen garnish
Meter visor
Meter panel
FR. upper cover
Front under spoiler
Radiator cover
Front fender
FR. inner box
13-1
13
13. Body Cover
Mechanism Diagram
Upper handle cover
Double seat
Left lower handle cover
Right lower handle cover
Rear back seat
Right side cover
Right floor panel
Right body cover
Inner box lid stiffener
RH. RR. grip
Inner box lid
LH. RR. grip
13-2
13. Body Cover
Mechanism Diagram
Maintenance cover
Left floor panel
Left side cover
RR. luggage box
FR. luggage box
Left body cover
Rear cover
Under cover
Rear fender
13-3
13. Body Cover
Maintenance
Body covers disassemble sequence:
R/L. lower handle covers
Double seat
Upper handle cover
Wind screen
Rear back seat
Front fender
Front upper cover
R/L. grip
Under cover
Meter visor
R/L. body cover
R/L. side cover
Meter panel
Air box
Front under spoiler
Luggage box
Inner box
Rear fender
Maintenance cover
R/L. floor panel
Be careful not to damage various covers in assembly or disassembly operation.
Never injure hooks molded on the body covers.
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.
13-4
To this chapter contents
13. Body Cover
Handle Cover
Remove
Loosen the 2 screws from handle upper cover
front end.
2 screws
Loosen the 2 screws from handle upper cover rear
end.
Remove right and left handle side cover.
2 screws
Installation
Install in reverse order of removal procedures.
13-5
To this chapter contents
13. Body Cover
Front Cover
Remove
Loosen 4 screws from the wind screen garnish
and remove the wind screen garnish.
Each side 2 screws
Loosen 6 screws from the wind screen and
remove the wind screen.
6 screws
Loosen 4 screws from the meter visor and remove
the meter visor.
4 screws
Loosen 4 screws (2 screws on each side) from the
inner box.
Each side 2 screws
13-6
To this chapter contents
13. Body Cover
Loosen 2 bolts from the front cover under side.
4 bolts
Loosen 2 screws and 2 bolts from the front cover
upper side.
Each side 1 screw
Disconnect the headlight, foggy light and winker
light couplers.
Remove the front cover.
Each side 1 bolt
Headlight coupler
Installation
Install in reverse order of removal procedures.
Winker & foggy light coupler
13-7
To this chapter contents
13. Body Cover
Meter Panel
Remove
Remove wind screen garnish, wind screen, meter
visor and front cover.
Remove reserve tank cap.
Loosen 4screws from right & left side of the meter
panel.
Each side 1 screws
Loosen 2 screws from in side of meter panel.
Meter coupler
Loosen the meter cord coupler.
Remove the meter panel.
Installation
Install in reverse order of removal procedures.
13-8
To this chapter contents
13. Body Cover
Inner Box
Reserve tank
Remove
Remove wind screen garnish, wind screen, meter
visor, front cover, meter panel, R/L side cover and
front under spoiler.
Loosen 1 screw from reserve tank stay.
1 screw
1 screw
Loosen 1 screw from fuse box and remove it.
Loosen 1 screw from main switch cap and remove
the cap.
Loosen DC power output mounting nut, and
remove DC power output.
Loosen 1 screw from battery cover and remove it.
1 screw
Remove the battery negative (-) cable.
Remove the battery positive (+) cable.
Remove the battery.
Positive
13-9
To this chapter contents
13. Body Cover
Loosen 2 bolts from inner box under side.
Each side 2 bolts
Loosen 2 bolts from inside of the inner box.
Disconnect the hazard light and foggy light switch
couplers.
Remove inner box.
Installation
Install in reverse order of removal procedures.
1 bolts
13-10
To this chapter contents
13. Body Cover
Side Cover
Remove
Loosen 2 screws from the side cover side end.
1 screw
Loosen 2 screws from the side cover upper end.
2 screws
Remove the side cover.
Installation
Install in reverse order of removal procedures.
13-11
To this chapter contents
13. Body Cover
Rear Carrier
Remove
Loosen 4 bolts from the rear carrier and remove it.
Installation
Install in reverse order of removal procedures.
13-12
To this chapter contents
13. Body Cover
Luggage Box
3 screws
Remove
Open the seat.
Loosen 3 screws from the luggage box rear cover.
Disconnect the luggage box light and switch
coupler.
Remove the luggage box rear cover.
Loosen 2 bolts from luggage box front side
2 bolts
Loosen 4bolts from luggage box rear side.
4 bolts
Remove the luggage box.
3 bolts
Installation
Install in reverse order of removal procedures.
13-13
To this chapter contents
13. Body Cover
Rear Body Cover
Remove
Loosen right and left side screws from rear end of
floor panel.
Remove the cover
Loosen right, left side and middle screws from rear
side of the body cover.
3 screws
Disconnect the tail light coupler.
2 screws
Remove the body cover.
Installation
Install in reverse order of removal procedures.
Tail light coupler
13-14
To this chapter contents
13. Body Cover
Floor Panel
Each side 1 screw
Remove
Remove wind screen garnish, wind screen, meter
visor, front cover, R/L side cover, front under
spoiler, inner box, luggage box and body cover.
Loosen 4 bolts and 2 screws from floor panel.
Each side 2 bolts
Remove floor panel.
Installation
Install in reverse order of removal procedures.
Each side 2 bolts
Front Fender
Remove
Loosen 4 screws from front cushion.
Each side 2 screws
Remove the front fender.
Installation
Install in reverse order of removal procedures.
13-15
To this chapter contents
13. Body Cover
NOTE:
13-16
Home page
Contents
14. Brake System
Mechanism Diagram···························· 14-1
Brake Fluid Replacement / Air-bleed·· 14-6
Precautions in Operation ···················· 14-2
Front Brake Caliper······························ 14-7
Troubleshooting ·································· 14-3
Rear Brake Caliper······························· 14-8
Disk Brake System Inspection············ 14-4
Brake Disk ············································ 14-9
Adding Brake Fluid ······························ 14-5
Master Cylinder ···································· 14-9
Mechanism Diagram
14
Front brake Master cylinder
3.0~4.0 kgf-m
Rear brake Master cylinder
0.8~1.0 kgf-m
3.0~4.0 kgf-m
Delay valve
3.5~4.5 kgf-m
Right front brake caliper
3.5~4.5 kgf-m
Left front brake caliper
Rear brake caliper
2.4~3.0 kgf-m
14-1
To this chapter contents
14. Brake System
Precautions in Operation
Caution
Inhaling asbestos may cause disorders of respiration system or lung cancer; therefore, never use
compressed air 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.
Air should be bled from the hydraulic system when remove it or the brake system is slack.
While refilling brake fluid, avoid mixing any other substances.
Do not spill brake fluid on the painted surfaces, because plastic or rubber parts might be damaged.
Check the operation of the brake system before riding.
Specifications
unit: mm
Item
Standard
Limit
The thickness of the front brake disk
4.000
2.500
The thickness of the rear brake disk
5.000
3.500
Front and rear brake disk eccentricity
< 0.100
0.300
Front brake master cylinder inner diameter
11.000~11.043
11.055
Front brake master cylinder piston outer diameter
10.957~10.984
10.945
Rear brake master cylinder inner diameter
14.000~14.043
14.055
Rear brake master cylinder piston outer diameter
13.957~13.984
13.945
Diameter of front disk
240.000
Diameter of rear disk
220.000
─
Thickness of the front brake lining
5.000
2.000
Thickness of the rear brake lining
.1
6.000
2.000
Torque values:
Brake hose bolts
3.0~4.0kgf-m
Bolt for front brake caliper
2.9~3.5kgf-m
Brake lever nut
0.8~1.0kgf-m
Air-bleed valve
0.8~1.0kgf-m
14-2
To this chapter contents
14. Brake System
Troubleshooting
Slack 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/disk
7. Low brake fluid
8. Blocked brake hose
9. Deformed/ bent brake disk
10. Bent brake lever
Malfunction of the brake lever
1.
2.
3.
4.
5.
Blocked brake system
Poor brake caliper
Blocked brake pipe
Seized/ worn master cylinder piston
Bent brake lever
Uneven brake
1.
2.
3.
4.
Dirty brake lining/ disk
Poor wheel alignment
Clogged brake hose
Deformed or bent brake disk
Tight brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or bent brake disk
Brake abnormal noise
1.
2.
3.
4.
Dirty lining
Deformed brake disk
Poor brake caliper installation
Imbalance of brake disk or wheel
14-3
To this chapter contents
14. Brake System
Disk Brake System Inspection
Inspection
Examine for leaking or damage visually.
Inspect brake tube seam with spanner to check if
it becomes loose.
Checking if there is any interferes, contacts
between protected pipeline and other parts by
turning the handle bar right or left, pressing the
cushion up and down.
Remove the front brake pad cap.
Check the brake wear from the brake caliper.
The brake pad must be replaced with new lining
when it reaches the wear limit.
Brake linings wear limit grooves
Park the motorcycle on an even ground, and
check if fluid level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 3).
Caution
Inclined or just stopped vehicles could not be
measured oil level accurately. For accuracy,
vehicles should stay in still position for 3-to
minutes.
In order to prevent chemical change, please do
not use counterfeiting or other uncertified brake
fluid.
Please use the same brand of brake fluid
consistently for brake efficiency.
14-4
Brake caliper
Brake disk
To this chapter contents
14. Brake System
Adding Brake Fluid
Front brake master cylinder
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintain the brake system, it is supposed
to cover the surface of rubber parts by rags.
Caution
Please do not refill the brake fluid over upper
limit. Overflow may result in damages on painted
surface such as rubber or plastic parts.
Rear brake master cylinder
Remove the master cylinder cap and diaphragm.
Fill high quality brake fluid with same brand into
master cylinder.
Clean the dirty brake disk.
Caution
Dirty brake lining or disk will reduce the brake
performance.
Mix incompatible brake fluid will reduce brake
performance.
Other substance will block the brake fluid
system, and lead to reduce the brake
performance or lose brake ability completely.
Master cylinder cap
Diaphragm
Upper level
Brake
Fluid
14-5
To this chapter contents
14. Brake System
Brake Fluid Replacement / Air-bleed
Connect drain hose to air-bleed valve.
Open the drain valve on the calipers and delay
valve, hold and release the brake lever until the
old brake fluid is entirely drained out.
Close the drain valve and add specified brake fluid
into the brake master cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
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 turn, and at the
same time hold the brake lever until there is no air
bubble in the drain hose and also feeling
resistance on the brake lever.
Air-bleed valve
Delay valve
Air-bleed valve
Close the drain valve when finish 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 loose, please bleed the system as
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turn, and then close the valve.
Caution
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 enters 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.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap
Air-bleed valve
Bubble
Air-bleed valve
Caution
Divulges the air to have to pump by the minute
first divulges, then to caliper.
May use fluid the replacement machine, the
replacement fluid, the time is quicker, the air
bubble also Compared with cannot remain
Transparent hose
14-6
To this chapter contents
14. Brake System
Front Brake Caliper
Brake hose bolts
Removal
Place a container under the brake caliper, and
loosen the brake hose bolts and finally remove the
brake hoses.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper mounting bolts and the
caliper.
Installation
Caliper mounting bolts
Install the brake caliper and tighten the mounting
bolts.
Torque: 2.9~3.5kgf-m
Caution
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of brake
disk.
Pin clips
Use two seal washers and hose bolts to lock the
hoses and brake caliper in place.
Torque: 3.0~4.0kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
Brake pad replacement
Remove brake caliper.
Remove brake pad caps.
Remove the brake pad guidance shafts cotter
pins.
Brake pad pins
Remove the brake pad guidance shafts and
locking spring, and then remove brake pads.
Locking spring
Install the new brake pads onto brake caliper.
Install the brake pad guidance shafts and locking
springs.
Install the brake pad guidance shafts cotter pins.
Install the brake caliper and tighten the mounting
bolts.
14-7
To this chapter contents
14. Brake System
Rear Brake Caliper
Caliper mounting bolts
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper mounting bolts and the
caliper.
Installation
Install the brake caliper and tighten the mounting
bolts.
Brake hose bolts
Torque: 2.9~3.5kgf-m
Caution
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of brake
disk.
Use two seal washers and hose bolts to lock the
hoses and brake caliper in place.
Torque: 3.0~4.0kgf-m
Refill the brake fluid to the reservoir and bleed the
air if necessary.
Brake pad replacement
Remove the brake caliper upper parts (2 socket
bolts).
Take out the brake pads.
Install the new brake pads onto brake caliper
bracket.
Install the brake caliper upper parts and tighten
the socket bolts.
14-8
Socket bolt
To this chapter contents
14. Brake System
Brake Disk
Brake disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit:
Front brake disk 2.5 mm
Rear brake disk 3.5 mm
Micrometer
Remove the brake disk from wheel.
Check the disk for deformation and bend.
Allowable limit: 0.30 mm
Caution
The dirty brake lining or disk will reduce
the brake performance.
Brake lining includes the asbestos
ingredient, cannot use the air-gun to clean
it. The operator should wear a mask and
glove, and use vacuum cleaner clean it.
Master Cylinder
Brake hose
Master Cylinder Removal
Caution
Do not let other substance enter into the
cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and circlip should be replaced as a
set.
Brake switch
Remove the handlebar covers.
Remove the leads of brake light switch.
Drain out the brake fluid.
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder bolts and the master
cylinder.
2 bolts
14-9
To this chapter contents
14. Brake System
Remove the rubber pad.
Remove the circlip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Cir clip
Rubber
boot
Piston
Piston
cup
Spring
Master cylinder
Master Cylinder 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:
Front brake: 11.055 mm
Rear brake: 14.055 mm
Measure the outer diameter of the piston.
Replace the piston if the measured value exceeds
allowable limit.
Master cylinder
Allowable limit:
Front brake: 10.945 mm
Rear brake: 13.945 mm
Master cylinder piston
Master Cylinder Assembly
Caution
It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
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 faced inside of
master cylinder while installing the master cup.
Install the cir clip.
Piston
Caution
Never install cup lip in the opposite direction.
Make sure the cir clip is seated securely in
the groove.
Install the rubber pad into groove properly.
14-10
Cir clip
Rubber
boot
Piston
cup
Spring
Master cylinder
To this chapter contents
14. Brake System
Master Cylinder Install
Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
Install the brake lever, and connect leads to brake
light switch.
2 bolts
Connect brake hoses with 2 new washers.
Tighten the brake hose bolt to the specified torque
value.
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
to avoid twisting them together.
Washers
Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Brake light
switch
Brake hose
Kink of brake leads, hose or pipe may reduce
brake performance.
Add specified brake fluid and bleed the system.
14-11
To this chapter contents
14. Brake System
NOTE:
14-12
Home page
Contents
Mechanism Diagram···························· 15-1
Front Wheel ·········································· 15-5
Precautions in Operation ···················· 15-2
Front Cushion ······································ 15-8
Troubleshooting ·································· 15-2
Steering Stem······································· 15-9
Steering Handle ··································· 15-3
Mechanism Diagram
2.9~3.5kgf-m
6.0~8.0kgf-m
2.4~3.0kgf-m
6.0~8.0kgf-m
2.4~3.0kgf-m
2.4~3.0kgf-m
5.0~7.0kgf-m
15-1
15
To this chapter contents
Precautions in Operation
General
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of
the tire.
Torque Values
Nut for the front wheel axle
5.0 ~ 7.0kgf-m
Nut for the steering handle
4.0 ~ 5.0kgf-m
Lock nut for the steering handle stem
1.0 ~ 2.0kgf-m
Top crown for the steering handle stem
0.2 ~ 0.3kgf-m
Locating screw for the speedometer cable
0.15 ~0.3kgf-m
Front cushion upper lock bolt
2.4 ~ 3.0kgf-m
Front brake disk
4.0~4.5kgf-m
Special Tools
Steering handle top thread wrench
SYM-5320000、SYM-5321100
Inner bearing puller
SYM-6204020
Steering nut wrench
SYM-6204010
Driver 32*35mm
Driver 42*47mm
Troubleshooting
Hard to steer
The front wheel rim run-out
The steering handle stem nut is too tight.
The rim is bent.
The ball and the top crown of the steering
The wheel axle nut is not tightened enough.
handle stem are damaged.
Insufficient tire pressure.
Side-worn or poor tire.
The bearing clearance of the wheel axle is too
large.
The steering handlebar is tilted
Uneven arrangement of the front cushion.
Soft front cushion
The front fork is bent.
The front cushion spring is worn out.
The front wheel axle is bent
The oil seal of the front cushion is leaking.
Noise in front cushion
Front cushion rod is bent.
The joint of the front cushion gets loose.
15-2
To this chapter contents
Master cylinder
Steering Handle
Remove
Remove the right and left handle side cover,
handle upper cover and front cover. (Refer to
chapter 13)
Loosen the lock bolts for the master cylinder of the
front brake.
2 bolts
Holder
Fixing nut
Loosen the deceleration throttle cable fixing nut.
Loosen 1 screw from the acceleration throttle
fixing plate.
1 screw
Loosen 2 screws from the throttle holder.
2 screws
Remove throttle holder, handle switch, cables and
grip.
Throttle cables
15-3
To this chapter contents
Loosen 2 bolts from the master cylinder of the rear
brake.
Remove holder and master cylinder.
Master cylinder
Holder
2 bolts
Loosen left handle switch connecter.
Loosen 2 screws from left side handle switch
holder.
Remove the right handle switch.
Switch connecter
2 screws
Loosen handle mounting nut.
Remove handle mounting bolt, and then remove
the handle.
Installation
Install handle and align with bolt hole.
Install bolt and nut and then tighten it.
Torque value: 4.0~5.0kgf-m
Handle mounting nut
Apply grease to throttle cable and the sliding
surface of handle.
Align the lock pin with the hole on the handle.
After the installation completes, carry on the
following inspection and adjustment:
Throttle grip operation.
All electric appliances, the meter function
15-4
To this chapter contents
Front Wheel
2 screws
Loosen 2 bolts from the front brake caliper and
remove it
Caution
Care shall be taken not to push the brake
lever to avoid the brake pad being squeezed
out. In case that the brake pad is accidentally
squeezed out, use a screwdriver to force it
back to the place.
Axle nut
Loosen screw & remove speedometer cable.
Turn loose the axle nut.
Speedometer cable
Pull out the front wheel axle.
Remove the front wheel and both side collar.
15-5
To this chapter contents
Inspection
Wheel axle
Place the wheel axle on a V block, measure its
displacement.
Service limit: 0.2 mm
Bearing
Use finger to move the inner ring of each bearing,
it shall move smoothly and quietly. Check the
outer ring is securely attached on the wheel hub.
If the motion of the inner ring of the bearing is not
smooth, or noisy and loose when being moved,
replace with a new one.
Free play
Free play
Caution
The bearing shall be replaced in pair.
Wheel
Place the wheel on to a rotation seat to check its
rim wobbling.
Turn the wheel with hand and measure its rim
wobbling value with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Disassembly
Remove brake disk (5 bolts).
Remove dust seal, bearing and dist collar from left
side.
Remove dust seal and bearing from right side.
Special tools:
Inner bearing puller
SYM-6204020
Inner
bearing puller
15-6
To this chapter contents
Assembly
Fill out the block of bearing by grease.
Drive the left bearing, dust seal and install the dist
collar.
Install the right side bearing.
Dust seal
Dist collar
Bearing
6201U
Caution
Carefully install the bearing in correct and
evenly.
Bearing outer face should be faced up as
bearing installation.
Dust seal
Bearing 6201U
Install the brake disk and then tighten the bolts.
Torque value: 4.0~4.5kgf-m
15-7
To this chapter contents
Front Cushion
Remove
3 bolts at both
side
Remove front cover, front under spoiler and front
fender.
Remove three bolts at both sides.
Remove front wheel.
Remove front brake caliper.
Remove speedometer cable.
15-8
To this chapter contents
Steering Stem
Remove
Stem mounting nut
Steering stem top thread
wrench
Remove handle, front wheel and front cushion.
Remove the steering stem mounting nut.
Top cone race
Top cone race
Remove top cone race and steering stem.
Caution
Place the steel ball onto a parts container to
prevent from missing.
Special tools:
Steering stem top thread wrench SYM-5320010
Handle stand nut wrench SYM-5321100
Handle stand nut
Slightly tap the top and bottom ball bearing seats
with a plastic hammer to remove the seats.
Remove bottom cone race body with a punch.
Caution
Do not damage the steering stem.
Installation
Install a new bottom cone race onto the steering
stem.
Push the cone race until to mounted position.
Caution
Do not tilt the ball bearing seats as
installation.
Apply with grease onto the ball bearing seats, and
install steel balls onto the seats. (Top: 26 balls,
bottom: 29 balls)
Steering stem mounting nut
Top cone race
Top ball
bearing seat
Bottom ball
bearing seat
Steel balls
Bottom cone race
15-9
To this chapter contents
Lubricate the top cone race seat with grease.
Screw the cone race into top ball bearing seat till
touching, and then screw out the cane race
1/4~3/8 turn.
Torque value: 0.25kgf-m
Steering lock nut
Return 1/2 turn
Caution
Check the steering stem that should be
rotated freely, and no clearance in vertical
direction.
Locking to
1/4~3/8 turn
Top cone-race
Install the steering stem mounting nut and tighten
the nut by means of holding the top cone race
body.
Torque value: 1.0~2.0kgf-m
Install in reverse order of removal procedures.
15-10
To this chapter contents
NOTE:
Steering stem adjustment: When the steering stem is too tight.
Steps: please refer to figure 1
1.
Stay front wheel on the ground, and make sure that the component ①,②,③,④ are connected all
together appropriately.
2.
Lock the component 53220-HMA-00(STRG. HEAD TOP THREAD COMP.) with the torque of
350 ± 50 Kgf-cm.
3.
Turn the steering stem right to left for 5-6 times in order to make the bearing fit in.
4.
Keep the front wheel on the ground, loosen the component 53220-HMA-00 over 1/4 turn, and make
the lock torque to zero.
5.
Start second lock procedure. To begin with the component 53220-HMA-00. Make sure that the lock
torque is between 100~130 Kgf-cm.
Turn the steering stem, and adjust it to appropriate position.
6.
Lock the component 50306-M9Q-00 with the torque of 300~350 Kgf-cm. Please be aware that
component 53220-HMA-00 is not allowed to rotate along with the component 50306-M9Q-00 during
this lock procedure.
7.
Lock torque for the component 90304-L4A-00 is between 650~700 Kgf-cm.
Fig.1 Steering system components.
15-11
Home page
Contents
16. Rear Wheel / Rear Fork / Rear Cushion
Mechanism Diagram···························16-1
Rear Wheel ········································· 16-3
Operational Precautions ····················16-2
Rear Fork ············································ 16-5
Troubleshooting ·································16-2
Rear Cushion······································ 16-6
Muffler··················································16-3
Mechanism Diagram
3.5~4.5kgf-m
2.8~3.2kgf-m
3.5~4.5kgf-m
11.0~13.0kgf-m
1.0~1.4kgf-m
2.9~3.5kgf-m
16-1
16
To this chapter contents
16. Rear Wheel / Rear Fork / Rear Cushion
Operational Precautions
General
Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation
of the tires.
Service data
Unit: mm
Item
Run-out of rear rim
Standard
Allowable Limit
Radial
-
2.0
Axial
-
2.0
Torque Value
Rear wheel axle nut
Rear cushion upper bolt
Rear cushion under bolt
Rear fork mounting bolt
Exhaust muffler mounting nut
Exhaust muffler mounting bolt
Brake clipper mounting bolts
Brake disc mounting bolt
11.0~13.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
4.0~5.0kgf-m
1.0~1.2kgf-m
3.2~3.8kgf-m
2.9~3.5kgf-m
4.0~5.0kgf-m
Troubleshooting
Run-out of rear wheel
Poor Performance of Brake
Deformed or bent wheel hub.
Improper tires.
Loose wheel shaft.
Soft Cushion
The spring is too weak.
Noisy Brake
Worn brake lining.
Offset brake disc.
Improper assembly of brake caliper.
Brake disc or wheel imbalance.
16-2
Improperly adjusted brake.
Contaminated brake disc.
Worn brake lining.
Air inside brake fluid pipe.
Grease on brake disc.
The brake fluid piping is clogged.
The brake fluid pipe is deformed or bent.
The brake fluid pipe is deformed or bent.
Insufficient amount of brake fluid in the reservoir
To this chapter contents
16. Rear Wheel / Rear Fork / Rear Cushion
Muffler
Removal
Loosen the 2 nuts from exhaust muffler front side.
2 nuts
Loosen the 3 mounting bolts by exhaust muffler
right side.
Remove exhaust muffler.
Installation
Install in reverse order of removal procedures.
Caution
Replace the front side muffler pipe gasket if
worn or deformed.
Torque Value:
Muffler mounting bolt 3.2 ~ 3.8kgf-m
Muffler mounting nut 1.0 ~ 1.2kgf-m
3 bolts
Rear Wheel
Hose clamp
Removal
Remove the exhaust muffler.
Remove the rear brake caliper (2 bolts) and brake
hose clamp (1 bolt).
Caution
Care shall be taken not to push the brake
lever to avoid the brake pad being squeezed
out. In case that the brake pad is accidentally
squeezed out, use a screwdriver to force it
back to the place.
2 bolts
2 bolts
Remove the lower bolt of the right side rear
cushion.
Remove 2 bolts of the rear fork.
1 bolt
16-3
To this chapter contents
16. Rear Wheel / Rear Fork / Rear Cushion
Remove rear wheel axle nut.
1 nut
Remove rear fork and both side collars.
Remove the rear wheel.
Inspection rear wheel rim
Place the wheel rim on a rotational support.
Rotate it by hand and measure the run-out with a
dial indicator.
Run-out limit: 2.0 mm
Installation
Install in reverse order of removal procedures.
Torque Value:
Rear wheel axle nut
11.0~13.0kgf-m
Rear cushion under bolt
2.4~3.0kgf-m
Rear fork mounting bolt
4.0~5.0kgf-m
Brake clipper mounting bolts 2.9~3.5kgf-m
16-4
To this chapter contents
16. Rear Wheel / Rear Fork / Rear Cushion
Rear Fork
Free play
Inspection rear fork bearing
Rotate the inner ring of the bearing with a finger.
The bearing should move smoothly and quietly.
Check the fit of the bearing and rim.
Replace the bearing if its motion is not smooth or
noisy.
Replacement of rear fork bearing
Free play
Cir clip
Remove the bearing lock cir clip.
Uses the bearing driver; drive out the bearing.
Special tool: Bearing driver
Install new rear fork bearing and bearing puller
(6303) onto rear fork.
Install assembly directs puller bearing puller.
Special Service Tools:
Rear fork bearing 6303 bearing puller
SYM-6303000-HMA H9A 6303
Assembly directs puller
SYM-2341110
Assembly
directs puller
Use screw driver hold bearing puller lower part,
and turn the bearing puller upper part to install the
rear fork bearing.
16-5
To this chapter contents
16. Rear Wheel / Rear Fork / Rear Cushion
Install the bearing lock cir clip.
Cir clip
Outside collar
Bearing
(6303UU)
Inside collar
Rear Cushion
Left
Upper bolt
Removal
Remove the luggage box, rear carrier and body
covers.
Loosen the mounting bolts of the air cleaner (2
bolts).
Remove the exhaust muffler (3 bolts, 2 nuts).
Remove the under bolts by left and right rear
cushions.
Remove the upper bolts by left and right rear
cushions, and then remove the cushion.
Installation
Install in reverse order of removal procedures.
Under bolt
Right
Upper bolt
Caution
The rear cushion must be replaced as a unit.
Never disassemble the rear cushion as that
would damage the structure.
Torque Value
Rear cushion upper bolt: 3.5~4.5kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Under bolt
16-6
Home page
Contents
17. Electrical System
Mechanism Diagram ··························17-1
Starting System ································· 17-11
Precautions in Operation···················17-2
Meter ··················································· 17-13
Specification ·······································17-2
Light / Bulb········································· 17-15
Troubleshooting ·································17-3
Switch / Horn······································ 17-17
Battery ·················································17-4
Fuel Unit ············································· 17-19
Fuse ·····················································17-5
Cooling Fan Thermo Switch ············· 17-20
Charging System ································17-6
Thermo Unit ······································· 17-21
Ignition System···································17-9
Water Temperature Meter ················· 17-21
Mechanism Diagram
Speed sensor
Horn
Headlight lo-beam relay
Rollover sensor
Winker & Hazard
control unit
Headlight hi-beam relay
Thermo switch
(Cooling fan)
Power relay
Key relay
Engine stop relay
Battery
Fuse box
Main switch
Start relay
Passing / Beam / Winker /
Horn / Seat open switch
AISV
Side stand switch
Start / Headlight /
Engine stop switch
Fuel pump / fuel unit
O2 Sensor
Spark plug
Ignition coil
Fuel injector
MAP Sensor
Thermo unit
TW Sensor
ISC
TPS
CPS
TA Sensor
A.C. Generator
Seat open linear motor
ECU
Reg. Rec.
17-1
17
To this chapter contents
17. Electrical System
Precautions in Operation
When removing the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
The model of the spark plug and the tightening torque.
The ignition timing.
Adjustment of headlight.
Removal and installation of AC generator.
The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled water.
To recharge the battery, remove the battery from rack without removing ventilation caps.
Unless in emergency, never rapid-charge the battery.
The voltage must be checked with the voltmeter while charging the battery.
As ECU assembly does not require an ignition timing check. In case ignition timing is incorrect, check
ECU and AC generator. Verify with an ignition timing light after replacement if necessary.
Specification
Charging system
Description
Specification
Capacity
12V10Ah
Charging rate
1.2A / 5~10hr (standard) 5A / 1hr (rapid charging)
Battery
Leak current
Below 10mA
Charging current
1.2A / 1500 rpm
Control voltage in charging
14.5+0.5 V / 2,000 rpm
Ignition system
Description
Model
Specification
NGK CR8E (Recommended)
Spark plug
Gap
Primary winding
Ignition coil and
resistance
0.6~0.7 mm
2.8Ω±15%
Without cap:9 KΩ± 20%
Secondary winding
With cap:14.1 KΩ± 20%
Crankshaft position sensor resistance (20℃)
80~160 Ω
At idle speed
BTDC 10° / 1650 rpm
Full advanced
BTDC 30°
Ignition timing advance
17-2
To this chapter contents
17. Electrical System
Troubleshooting
No voltage
Battery over discharged
The cable disconnected
The fuse is blown
Improper operation of the main switch
Low voltage
The battery is not fully charged
Poor connection.
Poor charging system
Poor voltage regulator
No spark produced by spark plug
The spark plug is out of work
The cable is poorly connected, open or
short-circuited
Poor connection between ECU and ignition coil
Poor connection between ECU and main switch
Poor main switch
Poor ECU.
A.C.G. is out of work
Starter motor does not work
The fuse is blown
The battery is not fully charged
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
Intermittent power supply
The connector of the charging system becomes
loose
Poor connection of the battery cable
Poor connection or short-circuit of the
discharging system
Poor connection or short-circuit of the power
generation system
Charging system does not operate properly
Burnt fuse
Poor contact, open or short circuit
Poor regulator rectifier
Poor ACG
Engine does not crank smoothly
Primary winding circuit
- Poor ignition coil
- Poor connection of cable and connectors
- Poor main switch
Secondary winding circuit
- Poor ignition coil
- Poor spark plug
- Poor ignition coil cable
- Current leakage in the spark plug
Incorrect ignition timing
- Poor ACG
- Improper installation of CPS
- Poor ECU
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 runs in reverse direction
Poor battery
17-3
To this chapter contents
17. Electrical System
Battery
Removal
Loosen 1 screw and remove the battery cover.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery.
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 12.8V ↑ at 20℃
℃
Undercharged: Below 12.0 V at 20℃
℃
Warning
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by battery
cables.
Charging
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard
Maximum
Charging current
1.2A
5A
Charging time
10 hr
1 hr
Warning
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by battery
cables.
Caution
Never rapid charge the battery unless in
emergency.
Verify the battery is recharged with current and
duration prescribed above.
Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable terminal
with grease.
17-4
To this chapter contents
17. Electrical System
Fuse
Fuse circuit diagram
17-5
To this chapter contents
17. Electrical System
Charging System
R
B
G
Y
Regulator rectifier Inspection
+
-
Y1
Y1
(KΩ)
Y2
Y3
R
B
Y/L
G
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
∞
5~30
∞
1~10
Y2
∞
Y3
∞
∞
R
∞
5~30
∞
5~30
∞
5~30
∞
2~20
∞
2~20
∞
2~20
B
Y/L
G
Inspection on regulator rectifier wire
Remove the luggage box, rear carrier and body
covers.
Disconnect two 3 pin couplers of the regulator
rectifier.
Inspect the rectifier coupler to the wire harness
passes the condition.
Item
Check Points
∞
∞
∞
∞
1~10
R─ B
Battery voltage
(ON)
R─ G
Battery voltage
Charging coil
Y─ Y
0.2~0.4 Ω
If the readings measured are not normal, check
parts in the circuit.
∞
5~30
If the parts are normal, then trouble is in the wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
Couplers
Standard Value
Main switch
connection
Battery
connection
17-6
Red
Black
Green
Yellow
Regulator rectifier
To this chapter contents
17. Electrical System
Inspection on AC. Generator coil
Remove the luggage box, rear carrier and body
covers.
Disconnect 3 pin couplers of the generator coil.
Connect an ohmmeter to the each terminal end.
Check the continuity of the each terminal end, and
engine ground with short circuit.
If there is no continuity or short circuit, replace the
AC. Generator.
V
Ω
Y1
70~80
0.2~0.4
Y2
70~80
0.2~0.4
Y3
70~80
0.2~0.4
And you can check voltage when engine is
running.
Y1
Ω
Y2
Ω
Ω
Y3
Ω
Y1
V
Y2
V
V
Y3
Current Leakage Inspection
Turn the main switch OFF, and remove the
negative cable terminal (-) from the battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal.
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.
Allowable current leakage: Less than 10mA
Battery negative terminal
Caution
In the current leakage test, set the current
range at the largest 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.
If the leaked current exceeds the specified value, it
may indicate a short circuit.
17-7
To this chapter contents
17. Electrical System
Inspection on Charging Voltage
Voltmeter
Ammeter
Connect a tachometer.
Turn on the headlight to high beam and start the
engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 V/1650 rpm
Caution
Fuse connector
Caution
Before conducting the inspection, be sure that
the battery is fully charged. If undercharged,
the current changes dramatically.
Use a fully charged battery having a voltage
larger than 13.0 V to prevent the current
fluctuation.
While starting the engine, the starter motor
draws large amount of current from the battery.
After the engine is warmed up, replace the original
battery with a fully charged one.
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.
Caution
Do not use any short-circuit cable.
It is possible to measure the current by
connecting an ammeter between the battery
positive terminal and the cable positive
terminal; however, while the starter motor is
activated, the surge current draws from the
battery may damage the ammeter. Use the kick
starter to start the engine to prevent this
happen.
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.
17-8
When it comes to replacement, make sure
that the current and voltage of the new battery
are the same as the old one.
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
occurs.
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 systems; correct it if any by following
steps indicated in the checking list.
(1) The standard charging voltage and current
can only reach when the revolution of the
engine exceeds the specified rpm.
- Light bulbs used exceed their rate and
consume too much power.
- The replaced battery is aged and does not
have enough capacity.
(2) The charging voltage is normal, while the
current is not.
- The replaced battery is aged and does not
have enough capacity.
- Battery used does 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.
17. Electrical System
ECU. coupler (ECU. side)
01 pin(R/Y): Drive components Power.
03 pin(L/O): Crankshaft position sensor positive
09 pin(G): Crankshaft position sensor negative
18 pin(Y/G):Ignition coil
17-9
To this chapter contents
17. Electrical System
Inspection on ignition coil
Remove the right floor garnish.
Disengage the connector of the ignition coil.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 2.8Ω±15% (20ºC)
Replacement of ignition coil
Remove the cap from the spark plug.
Spark plug cap
Loosen 2 bolts and replace the ignition coil if
necessary.
Inspection of crank position sensor
Remove luggage box (bolt×6).
Disconnect the coupler of the crank position
sensor and measure the resistance between the
terminals of green/white and blue/yellow.
Standard resistance: 80~160Ω
Caution
It is not necessary to remove the coil from the
engine during this process.
Please refer to the section 11 for disassembly of
coil.
17-10
Ignition coil
Coupler
To this chapter contents
17. Electrical System
Starting System
R
B
G
Y
Red
Black
Green
Yellow
W
L
SB
O
White
Blue
Sky blue
Orange
Inspection of starter relay
Open the main switch.
Press the brake.
Push the starter switch.
If a sound of “Looh Looh” is heard, it indicates the
relay is working properly.
Open the inner box lid, and remove battery cover.
Disconnect the negative cable terminal of the
battery.
Remove the luggage box.
Disconnect the cable positive terminal from the
start relay.
17-11
To this chapter contents
17. Electrical System
Disconnect the positive cable of the starter motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal end.
Connect the yellow/red cable to the battery
positive terminal and the green/yellow cable to the
battery negative terminal.
Check the continuity of the large terminal end.
If there is no continuity, replace the relay.
Removal of Starter motor
Turns off the main switch
Remove the luggage box.
Disconnect the coupler of the start relay.
Disconnect the cable negative terminal of the
battery.
Disconnect the starter motor power cable.
Loosen 2 bolts & remove starter motor.
Installation of starter motor
Install in reverse order of removal procedures.
17-12
2 bolts
To this chapter contents
17. Electrical System
Meter
Meter circuit diagram
Meter
(Ignition)
Fuse 10A
R
O
Turn right indicator
Main switch
Fuse 20A
SB
Turn left indicator
B
R
L
Charge
indicator
REG. REC.
Y/L
L/W
Eng. temperature
indicator
Thermo sensor
Battery
High beam indicator
Side stand warning
light
W/B
Parking right indicator
G/L
Y/G
Fuel indicator
Fuel unit
Fuel injection indicator
Y/W
BR
Speed sensor
GR/W
O/B
G/P
Meter illumination
R/G
Transistor ignition
Speedometer
Sense 5 bolts of the disk
G
Meter coupler
BATT+
1
11
20
Green
GND.
EFI
Blue /
White
Side
stand
G
R
B
G
Y
P
BR
Red
Black
Green
Yellow
Pink
Brown
W
L
SB
O
GR
White
Blue
Sky blue
Orange
Gray
Wire harness coupler
10
Wire harness coupler
Yellow
Red
Black
/ Green
Tachometer
1
10
11
20
Green
Green /
Pink
Green
Red /
Green
Yellow
/ White
Gray /
White
Orange
/ black
IGN+
BATT-
SP-
BATT-
RPM
Fuel+
SP+
SP
Blue
Yellow
/ Blue
Brown
Sky
Blue
Orange
White /
Black
Green /
Blue
Hi-beam
Charge
ILLUMI.
Turn-R
Turn-L
Foggy
TEMP.
17-13
To this chapter contents
17. Electrical System
Removal of meter
Remove wind screen garnish, wind screen, meter
visor, front cover, meter visor.
(Refer chapter 14)
Disconnect the coupler of the speedometer, and
take off the meter panel and meter.
Meter coupler
Loosen 4 screws from meter panel.
Remove the speedometer.
Installation of meter
Install in reverse order of removal procedures
17-14
4 screws
To this chapter contents
17. Electrical System
Light / Bulb
Headlight and foggy light circuit diagram
(Headlight)
Fuse 15A
R
B
G
R/W
Position & meter
illumination light
Light switch
Red
Black
Green
Lo-beam relay
BR
Beam switch
W
L
BR
White
Blue
Brown
Lo-beam light
W
G
W
L/W
Hi-beam relay
Main switch
Hi-beam light
L
L
B
G
Fuse 20A
Passing switch
Hi-beam indicator
B
( fan)
Fuse 20A
Foggy right indicator
R
Foggy switch
R/L
W/B
G
Key relay
R
G
Foggy right
G
R/L
B/L
Thermo switch
G
Fan
Battery
Winker light circuit diagram
(Ignition)
Fuse 15A
R
B
G
R
Red
Black
Green
O
SB
GR
Orange
Sky blue
Gray
R. winker indicator
Main switch
O
Fuse 20A
O
B
SB
R
G
Winker
switch
GR
Hazard
switch
Battery
FR. R. winker light
B
RR. R. winker light
Winker &
Hazard control
unit
SB
FR. L. winker light
RR. L. winker light
L. winker indicator
17-15
To this chapter contents
17. Electrical System
Headlight bulb replacement
Pull out the rubber socket, and press the 2 springs,
then remove light bulb.
Specification:
Lo-beam bulb
Hi-beam bulb
12V 55W (H11)
12V 55W (H11)
Caution
It would be much easier to replace the light
bulb if dismounting the front cover.
Never touch the bulb with bare fingers, which
may create a heat point and lead to premature
bulb failure.
Clean the fingerprint left on the bulb with
alcohol.
Installation
Install the bulb of the headlight in reverse order of
removal.
Front winker bulb replacement
Hold the winker bulb socket.
Rotate the winker bulb and remove it.
Replace with new bulb if necessary.
Specification:
Winker light bulb
12V 21W
Installation
Install the bulb of the headlight in reverse order of
removal.
17-16
2 springs
To this chapter contents
17. Electrical System
Switch / Horn
Main switch
Inspection
Remove the front cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below
Pin
BAT
BAT1
BAT2
Position
LOCK
Main switch coupler
OFF
ON
Wire Color
Red
Black
Blake
Replacement of main switch
Remove main switch cap.
Disconnect the coupler of the main switch and
loosen the mounting bolts (3 bolts).
Remove the main switch.
Install the new main switch and tighten the
mounting bolts.
Install the main switch coupler and cap.
Right handle switch
Remove the handle cover and front cover.
Disconnect the coupler of right handle switch.
Check the continuity between two points as
indicated in the table below
Headlight switch
Pin
TL
Position
CI
HL
CI
Black
Blue
/White
blot
Headlight switch
Engine stop switch
●
Wire Color
Brown Black
Engine start and stop switch
Pin
ST
E
Position
Start switch
Right handle switch coupler
ST
E
FREE
Wire Color
Black
Black Yellow Sky blue/
/Green / Red Orange
17-17
To this chapter contents
17. Electrical System
High and low beam switch
Left handle switch
Remove the handle cover and front cover.
Disconnect the coupler of left handle switch.
Check the continuity between two points as
indicated in the table below
High and low beam switch
Pin
LO
Position
Wire color
White
HL
Blue /
White
HI
Horn switch
Blue
Left handle switch coupler
Winker switch
Pin
Position
R
WR
L
Sky blue
Gray
Orange
FROM R
N PUSH OFF
FROM L
Wire color
Brake Switch
While grasp the brake lever firmly, the terminals of
white/green and green/yellow of the brake should
have continuity.
Replace the switch if damaged.
Horn
Remove the front cover and front under spoiler.
Apply 12 V power source to two terminals of the
horn, the horn should work.
Replace the horn if necessary.
Horn
17-18
Brake switch
Winker switch
To this chapter contents
17. Electrical System
Fuel Unit
Fuel Pump and unit
Open the seat.
Remove the luggage box.
Remove the rear carrier.
Remove right & left side cover.
Remove the body cover
Remove the floor panel.
Disconnect the coupler of the fuel unit.
Loosen 4 bolts from fuel unit and remove it.
Caution
Great care shall be taken not to damage or
bend the float arm of the gauge.
Fuel unit coupler
When the float arm shifts to the F position or the E
position, the resistance measured shall be as
follows:
Position
Resistance
E (Empty)
90~100 Ω
F (Full)
4~8 Ω
Connect the wiring to the fuel unit and the
ohmmeter as shown.
Connect the fuel unit coupler to the wire harness.
Turn on the main switch.
Move the float arm to verify the proper position of
the fuel gauge needle indicates.
Arm Position
Needle Position
Up (Full)
F (Full)
Down (Empty)
E (Empty)
Full
Caution
While conducting the test, turn on the direction
indicator lamp to make sure that the battery is
in serviceable condition.
Empty
17-19
To this chapter contents
17. Electrical System
Cooling Fan Thermo Switch
The thermo switch mounted on the radiator
controls the operation of the cooling fan motor.
In case that the fan motor fails working, disconnect
the green and black/blue leads, and connect jump
wires to the terminals, then turn on the main
switch. The fan motor should operate afterwards.
If the fan motor still fails running, measure the
battery voltage between the green and black / blue
leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit.
If the fan motor runs, check the thermo switch in
the manner as described below:
Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and closing
temperatures. To confirm the switch is
close-circuited at room temperature. Increase the
coolant temperature gradually, and the switch
should have a continuity at 95-101℃.
Caution
Keep the coolant at a constant temperature at
least for three minutes. Suddenly increase the
coolant temperature will give rise to wrong
readings of thermometer and the tester to
indicate wrong readings.
Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.
17-20
Thermo switch
Thermo switch
Thermometer
To this chapter contents
17. Electrical System
Thermo Unit
Thermo unit
Remove the thermo unit.
Hang the thermo unit in an oil heater, heat the oil and
measure the resistance at each temperature.
Temperature
50°C
80°C
100°C
120°C
Standard (Ω
Ω ) 134~149 47.5~57.0 26~29 14.8~17.2
Caution
Wear gloves and goggles when performing this
test.
Caution
Engine oil should be used as a heating medium
and the test temperature must be higher than
100℃.
Contacting the container wall by the
thermometer and the thermo unit may result in
wrong readings.
Water Temperature Meter
Disconnect the thermo sensor coupler and connect it
to engine ground.
Turn on the main switch.
The needle of the water temperature meter should
move to other end, H position.
Caution
Do not ground the sensor more than 5
seconds, or the meter will be damaged.
Thermo unit
17-21
To this chapter contents
17. Electrical System
NOTE:
17-22
Homepage
Contents
18. Wiring Diagram
18
18-1
Homepage
18. Wiring Diagram
NOTE:
18-2
Contents
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