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2011 Viper 90R Silver Series

Eton 2011 Viper 90R Silver Series Service Manual

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Page 1
Copyright ©2008-20ETON America, all rights reserved.
ETON America
20 VIPER SILVER SERIES
SERVICE MANUAL
Covers:
Viper 90R Silver
Page 2
VIPER 90R
SERVICE MANUAL
2009 by E-TON POWER TECH CO., LTD.
First edition, May 2009
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
E-TON POWER TECH CO., LTD.
is expressly prohibited.
Page 3
IMPORTANT
This manual was produced by the E-TON POWER TECH CO primarily for use by E-TON dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man­ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on E-TON machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use.
E-TON POWER TECH CO., Ltd. is continually striving to improve all its models. Modifications and sig­nificant changes in specifications or procedures will be forwarded to all authorized E-TON dealers and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
WARNING
NOTICE
რ
TIP
* Product and specifications are subject to change without notice.
A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
Page 4
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title : This title indicates a sub-section that is followed by step-by-step procedures accompa­nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.
1. An easy-to-see exploded diagram is provided for removal and disassembly jobs.
2. Numbers are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
. The meanings of the symbol marks are given on the next page.
4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements are given in addition to the exploded diagram and the job instruction chart.
BELT DRIVE
KICKSTARTER
6
7
8
9
1
2
3
Removing the kickstarter
Crankcase, cover
1
Kick pinion gear clip
2
Kick pinion gear
3
Washer
4
Circlip
5
Washer
6
Kick shaft assembly
7
Torsion spring
8
Spacer
9
Solid bush
Remove the parts in the order listed. Refer to “CRANKCASE COVER “.
Refer to “INSTALLING THE KICKSTARTER“.
1 1 1 1 1 1 1 1 1
For installation, reverse the removal pro­cedure.
4 - 32
ENG
2
3
c
5
New
4
RemarksOrder Job/Part Q’ty
1
2
1
b
a
d
2
1
BELT DRIVE
INSTALLING THE KICKSTARTER
1. Install: solid bush kickstarter shaft kickstarter spring
2. Hook: kickstarter spring
TIP
Hook the spring end on the kickstarter shaft
b
as shown, and hook the other end on the
projection .
3. Install: plain washer circlip
4. Install: kick pinion gear kick pinion gear clip
TIP
Install the clip at the position shown.
4 - 33
ENG
1
3
a
d
1
New
2
c
1
2
Page 5
GEN
INFO
CHK
ADJ
CARB
SPEC
ENG
CHAS
SYMBOLS
The following symbols are not relevant to every machine. Symbols to indicate the subject of each chapter.
General information Specifications Periodic checks and adjustments Engine Carburetor Chassis Electrical Troubleshooting
ELEC
E
B
–+
T
.
R
.
TRBL
SHTG
G
LS
Symbols to indicate the following.
Serviceable with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed Electrical data (, V, A)
Symbols to in the exploded diagrams indicate the types of lubricants and lubrication points.
M
M
Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lithium-soap-based grease Apply molybdenum disulfide grease
LT
Symbols to in the exploded diagrams indicate where to apply a locking agent and
New
when to install a new part .
Apply the locking agent (LOCTITE Replace
®
)
Page 6
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
ENGINE
1
2
3
4
CARBURETOR
CHASSIS
ELECTRICAL
TROUBLESHOOTING
5
6
–+
7
8
Page 7
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
ENGINE SERIAL NUMBER.......................................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS........................................................................... 1-2
GASKETS, OIL SEALS AND O-RINGS ....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS .................................................................................................. 1-3
CHECKING THE CONNECTIONS............................................................1-4
...........................................................................1-1
.........................................................................1-2
Page 8
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES.........................................................2-15
CHASSIS TIGHTENING TORQUES.......................................................2-16
HOW TO USE THE CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATION POINTS AND LUBRICANT TYPES
........................................................................2-1
............................................................................2-4
........................................................................2-11
.................................................................2-13
..............................................................................2-15
..................................................2-18
...............................2-18
....................................2-19
ENGINE...................................................................................................2-19
OIL FLOW DIAGRAMS
CABLE ROUTING
.................................................................................2-21
.........................................................................................2-22
Page 9
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION............................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
...................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART
HANDLEBAR, SEAT, FENDERS AND FUEL TANK.....................................3-3
HANDLEBAR...........................................................................................3-3
SEAT, FRONT PANEL AND FOOTREST BOARDS..............................3-4
FRONT FENDER.....................................................................................3-5
REAR FENDER, BATTERY AND C.D.I UNIT.........................................3-6
FUEL TANK AND FOOTREST BARS.....................................................3-7
ENGINE .........................................................................................................3-8
ADJUSTING THE VALVE CLEARANCE ................................................3-8
ADJUSTING THE ENGINE IDLING SPEED ...........................................3-10
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-11
ADJUSTING THE SPEED LIMITER........................................................3-12
CHECKING THE SPARK PLUG .............................................................3-13
CHECKING THE IGNITION TIMING.......................................................3-14
MEASURING THE COMPRESSION PRESSURE..................................3-15
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-18
CLEANING THE AIR FILTER ELEMENTS..............................................3-19
CLEANING THE SPARK ARRESTER ....................................................3-20
..........................3-1
CHASSIS .......................................................................................................3-22
CHECKING THE FRONT BRAKE SHOES..............................................3-22
ADJUSTING THE FRONT BRAKE..........................................................3-22
ADJUSTING THE PARKING BRAKE.......................................................3-23
CHECKING THE REAR BRAKE FLUID LEVEL......................................3-24
CHECKING THE REAR BRAKE PADS...................................................3-25
CHECKING THE BRAKE HOSE..............................................................3-25
BLEEDING THE HYDRAULIC BRAKE SYSTEM....................................3-25
CHANGING THE FINAL TRANSMISSION OIL.......................................3-27
ADJUSTING THE DRIVE CHAIN SLACK................................................3-27
CHECKING THE STEERING SYSTEM...................................................3-29
ADJUSTING THE TOE-IN.......................................................................3-30
CHECKING THE FRONT AND REAR SHOCK ABSORBERS ...............3-31
ADJUSTING THE SHOCK ABSORBERS...............................................3-32
CHECKING THE TIRES..........................................................................3-33
CHECKING THE WHEELS .....................................................................3-35
CHECKING AND LUBRICATING THE CABLES ....................................3-36
LUBRICATING THE LEVERS, STEERING SHAFT
AND STEERING KNUCKLES .................................................................3-36
ELECTRICAL SYSTEM.................................................................................3-37
CHECKING AND CHARGING THE BATTERY.......................................3-37
CHECKING THE FUSES.........................................................................3-44
Page 10
CHAPTER 4
ENGINE
ENGINE
CYLINDER HEAD
CAMSHAFT, ROCKER ARMS AND VALVES
...........................................................................................................4-1
EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS ................4-1
ENGINE MOUNTING BOLTS ...................................................................4-2
REMOVING THE ENGINE ........................................................................ 4-3
INSTALLING THE ENGINE....................................................................... 4-3
............................................................................................4-4
REMOVING THE CYLINDER HEAD......................................................... 4-6
CHECKING THE CAMSHAFT SPROCKET..............................................4-7
CHECKING THE CYL. HEAD COVER ASSY............................................4-7
CHECKING THE TIMING CHAIN GUIDES...............................................4-7
CHECKING THE TIMING CHAIN TENSIONER ASSEMBLY ...................4-7
CHECKING THE CYLINDER HEAD .........................................................4-8
INSTALLING THE CYLINDER HEAD .......................................................4-9
..............................................4-11
REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-12
REMOVING THE VALVES AND VALVE SPRINGS ................................4-12
CHECKING THE CAMSHAFT.................................................................. 4-13
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS .........4-13
CHECKING THE VALVES AND VALVE SPRINGS ................................. 4-15
INSTALLING THE VALVES AND VALVE SPRINGS ............................... 4-19
INSTALLING THE CAMSHAFT AND ROCKER ARMS ...........................4-20
CYLINDER AND PISTON
REMOVING THE PISTON .......................................................................4-22
CHECKING THE CYLINDER AND PISTON ............................................4-22
CHECKING THE PISTON RINGS............................................................ 4-24
CHECKING THE PISTON PIN ................................................................. 4-25
INSTALLING THE PISTON ...................................................................... 4-26
INSTALLING THE CYLINDER .................................................................4-27
C.D.I. MAGNETO
REMOVING THE C.D.I. MAGNETO ROTOR ..........................................4-29
CHECKING THE PICKUP COIL/STATOR ASSEMBLY........................... 4-29
INSTALLING THE C.D.I. MAGNETO ROTOR ......................................... 4-30
...........................................................................................4-28
..............................................................................4-21
Page 11
BELT DRIVE ................................................................................................4-31
CRANKCASE COVER.............................................................................4-31
KICKSTARTER........................................................................................4-32
INSTALLING THE KICKSTARTER.......................................................... 4-33
V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY.................................4-34
DISASSEMBLING THE SECONDARY SHEAVE....................................4-35
REMOVING THE PRIMARY SHEAVE.................................................... 4-36
REMOVING THE SECONDARY SHEAVE AND V-BELT........................ 4-36
DISASSEMBLING THE SECONDARY SHEAVE....................................4-37
CHECKING THE CLUTCH SHOE...........................................................4-37
CHECKING THE V-BELT........................................................................4-38
CHECKING THE DRIVE PULLEY...........................................................4-38
CHECKING THE PRIMARY ROLLER WEIGHTS...................................4-38
CHECKING THE PIECE SLIDER............................................................4-39
CHECKING THE DRIVEN PULLEY........................................................4-39
ASSEMBLING THE PRIMARY SHEAVE................................................4-40
ASSEMBLING THE SECONDARY SHEAVE..........................................4-41
INSTALLING THE BELT DRIVE..............................................................4-42
STARTER CLUTCH AND STARTER MOTOR ............................................4-44
CHECKING THE STARTER WHEEL GEAR...........................................4-45
OIL PUMP .....................................................................................................4-46
CHECKING THE OIL PUMP....................................................................4-47
INSTALLING THE OIL PUMP..................................................................4-48
CRANKCASE AND CRANKSHAFT ............................................................ 4-49
SEPARATING THE CRANKCASE..........................................................4-50
REMOVING THE CRANKSHAFT ASSEMBLY........................................4-51
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES...........4-51
CHECKING THE CRANKSHAFT AND CONNECTING ROD..................4-52
INSTALLING THE CRANKSHAFT..........................................................4-53
ASSEMBLING THE CRANKCASE..........................................................4-54
TRANSMISSION ..........................................................................................4-55
CHECKING THE TRANSMISSION.........................................................4-57
REMOVING THE GEAR SET..................................................................4-58
CHECKNG THE GEAR SET....................................................................4-59
INSTALLING THEGEAR SET..................................................................4-59
SHIFT MECHANISM................................................................................4-60
REMOVING GEAR BOX..........................................................................4-62
Page 12
CHAPTER 5
CARBURETOR
CARBURETOR
DISASSEMBLING THE CARBURETOR...................................................5-4
CHECKING THE CARBURETOR .............................................................5-4
ASSEMBLING THE CARBURETOR.........................................................5-6
INSTALLING THE CARBURETOR ...........................................................5-7
MEASURING AND ADJUSTING THE FUEL LEVEL ................................5-8
................................................................................................5-1
Page 13
CHAPTER 6
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS .................................................................................... 6-1
REAR WHEELS ......................................................................................6-2
CHECKING THE WHEELS .....................................................................6-3
CHECKING THE FRONT WHEEL HUBS ...............................................6-3
CHECKING THE REAR WHEEL HUBS.................................................. 6-4
INSTALLING THE WHEEL HUBS........................................................... 6-4
INSTALLING THE FRONT WHEELS...................................................... 6-5
INSTALLING THE REAR WHEELS........................................................ 6-5
FRONT BRAKES ..........................................................................................6-6
FRONT BRAKE S ....................................................................................6-6
REMOVING THE FRONT BRAKES .......................................................6-7
CHECKING THE FRONT BRAKE SHOE PLATES ................................6-7
CHECKING THE FRONT BRAKE SHOES.............................................. 6-7
CHECKING THE FRONT BRAKE DRUMS .............................................6-8
INSTALLING THE FRONT BRAKES ......................................................6-9
......................................................................6-1
REAR AXLE AND REAR AXLE HUB
REAR AXLE AND REAR AXLE HUB......................................................6-11
REMOVING THE REAR AXLE...............................................................6-13
CHECKING THE REAR AXLE...............................................................6-14
CHECKING THE DRIVEN SPROCKET..................................................6-14
CHECKING THE BRAKE DISC................................................................6-14
INSTALLING THE DRIVEN SPROCKET.................................................6-14
INSTALLING THE REAR AXLE...............................................................6-15
REAR BRAKE ...............................................................................................6-16
REAR BRAKE PADS...............................................................................6-16
REPLACING THE REAR BRAKE PADS.................................................6-17
REAR BRAKE MASTER CYLINDER......................................................6-19
CHECKING THE MASTER CYLINDER...................................................6-20
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................6-20
INSTALLING THE REAR BRAKE MASTER CYLINDER.........................6-21
REAR BRAKE CALIPER..........................................................................6-23
REMOVING THE PARKING BRAKE CABLE..........................................6-25
...........................................................6-11
CHECKING THE REAR BRAKE CALIPER.............................................6-25
INSTALLING THE REAR BRAKE CALIPER............................................6-26
Page 14
STEERING SYSTEM .....................................................................................6-28
HANDLEBAR...........................................................................................6-28
REMOVING THE HANDLEBAR GRIPS.................................................. 6-30
REMOVING THE REAR BRAKE SWITCH .............................................6-30
CHECKING THE HANDLEBAR ..............................................................6-30
INSTALLING THE HANDLEBAR ............................................................6-31
INSTALLING THE HANDLEBAR GRIPS ................................................6-31
INSTALLING THE REAR BRAKE MASTER CYLINDER........................ 6-32
INSTALLING THE FRONT BRAKE LEVER ASSEMBLY........................ 6-32
INSTALLING THE PARKING BRAKE LEVER.........................................6-33
STEERING STEM ...................................................................................6-34
REMOVING THE STEERING STEM ......................................................6-35
CHECKING THE STEERING STEM ....................................................... 6-35
INSTALLING THE LOWER HANDLEBAR HOLDER...............................6-36
INSTALLING THE STEERING STEM ..................................................... 6-36
INSTALLING THE LOCK WASHER........................................................6-36
TIE-RODS AND STEERING KNUCKLES ............................................... 6-37
REMOVING THE TIE-RODS................................................................... 6-38
REMOVING THE STEERING KNUCKLES..............................................6-38
CHECKING THE TIE-RODS ...................................................................6-38
CHECKING THE STEERING KNUCKLES.............................................. 6-38
INSTALLING THE TIE-RODS .................................................................6-39
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES.............6-40
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES..........................................................................................6-40
REMOVING THE FRONT ARMS.............................................................6-41
CHECKING THE FRONT ARMS.............................................................6-41
CHECKING THE FRONT SHOCK ABSORBERS...................................6-41
CHECKING THE BALL JOINTS..............................................................6-42
INSTALLING THE FRONT ARMS............................................................6-42
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN..................6-43
REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN.............6-43
REMOVING THE REAR SHOCK ABSORBER........................................6-45
CHECKING THE REAR SHOCK ABSORBER........................................6-45
REMOVING THE SWINGARM................................................................6-45
CHECKING THE SWINGARM.................................................................6-46
CHECKING THE DRIVE CHAIN..............................................................6-47
INSTALLING THE DRIVE SPROCKET................................................... 6-48
INSTALLING THE DRIVE CHAIN............................................................6-48
Page 15
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS
WIRING DIAGRAM .........................
CHECKING THE SWITCHS ............
CHECKING SWITCH CONTINUITY
IGNITION SYSTEM
CIRCUIT DIAGRAM ..................................................................................7-5
TROUBLESHOOTING ..............................................................................7-6
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM ................................................................................7-10
STARTING CIRCUIT OPERATION......................................................... 7-11
TROUBLESHOOTING ............................................................................7-12
STARTER MOTOR
CHECKING THE STARTER MOTOR .....................................................7-15
ASSEMBLING THE STARTER MOTOR.................................................7-16
.........................................................................................7-5
........................................................................................7-14
........................................................................7-1
................................................................7-2
................................................................7-3
.............................................................7-4
..................................................................7-10
CHARGING SYSTEM
CIRCUIT DIAGRAM ................................................................................7-17
TROUBLESHOOTING ............................................................................7-18
SIGNALING SYSTEM
CIRCUIT DIAGRAM ................................................................................7-19
TROUBLESHOOTING ............................................................................7-20
CHECKING THE SIGNALING SYSTEM .................................................7-21
....................................................................................7-17
....................................................................................7-19
Page 16
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM.......................................................................................... 8-1
ELECTRICAL SYSTEM.............................................................................8-1
COMPRESSION SYSTEM........................................................................8-2
POOR IDLE SPEED PERFORMANCE ........................................................... 8-2
POOR IDLE SPEED PERFORMANCE.....................................................8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE.................................. 8-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ...........................8-2
FAULTY CLUTCH ...........................................................................................8-3
ENGINE OPERATES BUT VEHICLE WILL NOT MOVE..........................8-3
CLUTCH SLIPPING.................................................................................. 8-3
POOR STARTING PERFORMANCE........................................................8-3
POOR SPEED PERFORMANCE..............................................................8-3
FAULTY GEAR SHIFTING .............................................................................. 8-3
OVERHEATING............................................................................................... 8-3
OVERHEATING ........................................................................................8-3
.......................................................8-1
FAULTY BRAKE .............................................................................................8-4
POOR BRAKING EFFECT........................................................................8-4
SHOCK ABSORBER MALFUNCTION ...........................................................8-4
MALFUNCTION.........................................................................................8-4
UNSTABLE HANDLING..................................................................................8-4
UNSTABLE HANDLING ............................................................................ 8-4
Page 17
MACHINE IDENTIFICATION
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped into the left side of the frame.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine.
GEN
INFO
1
1 - 1
Page 18
IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before removal and disassembly , remove all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equipment.
3. When disassembling always keep mated parts together. This includes gears, cylin­ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.
4. During disassembly, clean all of the parts and place them in trays in the order of dis­assembly. This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
GEN
INFO
REPLACEMENT PARTS
1. Use only genuine E-TON parts for all replacements.
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur­faces, oil seal lips and O-rings must be cleaned.
2. During reassembly properly oil all mating parts and bearings, and lubricate the oil seal lips with grease.
1 - 2
Page 19
IMPORTANT INFORMATION
რ
NOTICE
LOCK WASHERS/PLATES AND COTTER PINS
After removal, replace all lock washers/plates
and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu­facturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro­priate.
Oil seal
GEN
INFO
Do not spin the bearing with compressed air because this will damage the bearing surfaces.
Bearing
CIRCLIPS
Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip , make sure the sharp-edged corner is positioned opposite the thrust that the circlip receives.
Shaft
1 - 3
Page 20
IMPORTANT INFORMATION
TIP
TIP
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector Moisture Dry with an air blower. Rust/stains Connect and disconnect sev­eral times.
ĺ
ĺ
GEN
INFO
3. Check:
• all connections Loose connection
TIP
If the pin 1 on the terminal is flattened, bend it up.
4. Connect:
• lead
• coupler
• connector
Make sure all connections are tight.
5. Check:
• continuity (with the pocket tester)
ĺ
Connect properly.
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform steps (1) to (3).
• As a quick remedy, use a contact revitalizer available at most part stores.
1 - 4
Page 21
GENERAL SPECIFICATIONS
Item Standard
GENERAL SPECIFICATIONS
SPEC
SPEC
Model code Dimensions
Overall length 1,500 mm (59.1 in) Overall width 850 mm (33.5 in) Overall height 900 mm (35.4 in) Seat height 680 mm (26.8 in) Wheelbase 930 mm (36.6 in) Minimum ground clearance 120 mm (4.7 in) Minimum turning radius 3,000 mm (118.1in)
Basic weight
With oil and full fuel tank 113 kg (249.12 lb)
Engine
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder
Displacement 88 cm (5.37 cu.in)
Bore x stroke
Compression ratio 10.2 : 1
Standard compression pressure (at sea level) 1250 kPa
Virper 90
3
47.0 x 51.0 mm (1.85 x 2.01 in)
(12.5 kg/cm
Electric starter & kick starterStarting system
2
, 181.3 psi) at 1,000r/min
2
Lubrication system
Oil type or grade
Engine oil
10 30
0
SAE 5W-30
-20
-10 0
Final transmission oil SAE 80API “GL-4” Hypoid gear oil
Oil capacity
Engine oil
Periodic oil change 0.75 L (0.66 Imp qt, 0.80 US qt) Total amount 0.80 L (0.70 Imp qt, 0.85 US qt)
Final transmission oil
Total amount 0.30 L (0.27 Imp qt, 0.32 US qt)
Air filter
50
SAE 10W-40
10
90
70
SAE 20W-50
30 40 50 C
20
110
130 F
Wet sump
SAE5W-30 or SAE10W-40 or SAE20W-50
Wet type element
2 - 1
Page 22
SPEC
GENERAL SPECIFICATIONS
Item Standard
Fuel
Type Unleaded gasoline 92 octane
Fuel tank capacity plastic 4.5 L (0.99 lmp gal, 1.19 US gal)
3.6 L (0.79 lmp gal, 0.95 US gal) Fuel reserve amount plastic
lron
Carburetor
Type/quantity SVR 22-1D x 1 Manufacturer TK
Spark plug
Type/manufacturer NGK/CR7HSA Spark plug gap
Clutch type Dry, centrifugal automatic Transmission
Primary reduction system V-belt Primary reduction ratio 2.47-0.61:1 Secondary reduction system Spur Secondary reduction ratio 41/15 × 45/13 (9.46)
Third reduction system Chain drive
Third reduction ratio 28/13(2.154) Transmission type V-belt automatic
Chassis
Frame type Steel tube frame Caster angle 8°00’ Camber angle 1°00’ Kingpin angle 10.3°00’ Trail 28.6 mm (1.13 in) Tread (STD) front 702 mm (27.64 in)
Toe-in (with tires touching the ground) 10 mm (0.40 in)
Iron
1.0 L (0.22 Imp gal, 0.26 US gal)
0.5 L (0.11 lmp gal, 0.13 US gal)
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
rear 688 mm (27.10 in)
SPEC
Tire
Type Size
Manufacturer
Type front M939
Tire pressure (cold tire)
Maximum load* 70.0 kg (154.32 lb) Off-road riding front 23 ~ 28 kPa (0.23 ~ 0.28 kgf/cm, 3.3 ~ 4.1 psi)
*Load in total weight of rider and accessories
Tubeless
front AT18 rear AT18 front MAXXIS rear MAXXIS
rear M940
rear 23 ~ 28 kPa (0.23 ~ 0.28 kgf/cm, 3.3 ~ 4.1 psi)
2 - 2
x
7-8
x
9-8
2
2
Page 23
GENERAL SPECIFICATIONS
Item Standard
Brake
Front brake type Drum brake
operation Right hand operation
Rear brake type Single disc brake
operation Left hand operation
Suspension
Front suspension Single A-arm / Independent Rear suspension Swing arm
Shock absorber
Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/ oil damper
Wheel travel
Front wheel travel 50 mm (1.97 in) Rear wheel travel 100 mm (3.93 in)
Electrical
Ignition system AC-CDI Generator system AC magneto Battery type Lead-Acid Battery capacity 12 V 4.0 Ah
SPEC
SPEC
2 - 3
Page 24
SPEC
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Cylinder head
Warp limit 0.05 mm
Cylinder
Bore size 47.000 mm
Taper limit ---- 0.05 mm
Maximum out-of-round ---- 0.01 mm
Camshaft
Drive method Chain drive (Left) ---­Cam dimensions
7.00 ~ 7.40 cm (0.43 ~ 0.45 cu.in)
(1.8504 in)
3
(0.002 in)
47.10 mm (1.8543 in)
(0.002 in)
(0.0004 in)
A
B
Intake “A” 25.683 ~ 25.843 mm
(1.0111 ~ 1.0174 in)
“B” 20.985 ~ 21.015 mm
(0.8262 ~ 0.8274 in)
Exhaust “A” 25.525 ~ 25.685 mm
(1.0049 ~ 1.0112 in)
“B” 20.985 ~ 21.015 mm
(0.8262 ~ 0.8274 in)
Camshaft runout limit ---- 0.03 mm
25.583 mm (1.0072 in)
20.886 mm (0.8223 in)
25.425 mm (1.0010 in)
20.886 mm (0.8223 in)
(0.0012 in)
Timing chain
Timing chain type/No. of links KMC 92 RH 2005 / 86 ---­Timing chain adjustment method Automatic ----
2 - 4
Page 25
ENGINE SPECIFICATIONS
Item Standard Limit
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10.000 ~ 10.015 mm
(0.3937 ~ 0.3943 in)
Rocker arm shaft outside diameter 9.972 ~ 9.987 mm
(0.3926 ~ 0.3932 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.043 mm
(0.0005 ~ 0.0017 in)
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.07 ~ 0.10 mm
(0.003 ~ 0.004 in)
EX 0.07 ~ 0.10 mm
(0.003 ~ 0.004 in)
Valve dimensions
SPEC
SPEC
10.100 mm (0.3976 in)
9.910 mm (0.3902 in)
----
----
----
B
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter ----
“B” face width ----
“C” seat width
“D” margin thickness
Stem outside diameter
Guide inside diameter
IN 20.9 ~ 21.1 mm
(0.8228~ 0.8307 in)
EX 18.9 ~ 19.1 mm
(0.7441~ 0.7520 in)
IN 1.50 ~ 1.80 mm
(0.0591~ 0.0709 in)
EX 1.50 ~ 1.80 mm
(0.0591~ 0.0709 in)
IN 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
EX 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
IN 0.5 ~ 0.9 mm
(0.0197 ~ 0.0354 in)
EX 0.6 ~ 1.0 mm
(0.0236 ~ 0.0394 in)
IN 4.975 ~ 4.990 mm
(0.1959 ~ 0.1965 in)
EX 4.955 ~ 4.970 mm
(0.1951~ 0.1957 in)
IN 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)
EX 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)
C
D
----
----
1.6 mm (0.0630 in)
1.6 mm (0.0630 in)
----
----
4.900 mm (0.1930 in)
4.900 mm (0.1930 in)
5.030 mm (0.1980 in)
5.030 mm (0.1980 in)
2 - 5
Page 26
SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
SPEC
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
Stem runout limit ---- 0.02 mm
Valve seat width IN 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
EX 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
Valve spring
Inner spring
Free length IN 30.00 mm (1.18 in) 27.00 mm
EX 30.00 mm (1.18 in) 27.00 mm
Compressed pressure (installed) IN 39.14 ~ 47.77 N at 22.45 mm
(3.99 ~ 4.87 kg,
8.80 ~ 10.74 lb at 0.884 in)
EX 39.14 ~ 47.77 N at 22.45 mm
(3.99 ~ 4.87 kg,
8.80 ~ 10.74 lb at 0.884 in)
Tilt limit IN
EX
0.08 mm (0.0031 in)
0.10 mm (0.0039 in)
(0.0008 in)
1.6 mm (0.0630 in)
1.6 mm (0.0630 in)
(1.06 in)
(1.06 in)
°/1.1 mm
2.0 (2.0°/0.04 in)
°/1.1 mm
2.0 (2.0°/0.04 in)
----
----
Direction of winding (top view) IN Counterclockwise ----
Outer spring
Free length
EX Counterclockwise ----
IN 33.50 mm (1.32 in) 30.50 mm
(1.20 in)
EX 33.50 mm (1.32in) 30.50 mm
(1.20 in)
2 - 6
Page 27
ENGINE SPECIFICATIONS
SPEC
SPEC
LimitStandardItem
Compressed pressure
installed)
Tilt limit
Direction of winding
Piston
Piston to cylinder clearance 0.010 ~ 0.040 mm
Piston size “D”
IN
EX
IN
EX
IN(top view)
73.75 ~ 90.03 N at 25.45 mm (7.52 ~ 9.18 kg,
16.57 ~ 20.23 lb at 1.00 in)
73.75 ~ 90.03 N at 25.45 mm (7.52 ~ 9.18 kg,
16.57 ~ 20.23 lb at 1.00 in)
Counterclockwise
46.970 ~ 46.990 mm (1.8492 ~ 1.8500 in)
----
----
°/
1.2
2.0
(
2.0
2.0°/1.2 mm
(
2.0
0.10 mm (0.0039 in)(0.0004 ~ 0.0016 in)
mm
°/0.05 in)
°/0.05 in)
----Counterclockwise
----EX
D
Measuring point “H”
Piston off-set
Piston pin bore inside diameter 13.002 ~ 13.008 mm
Piston pin outside diameter 12.996 ~ 13.000 mm
H
5.0 mm (0.20 in)
----0.5 mm (0.02 in)
----Intake sidePiston off-set direction
13.040 mm
(0.5119 ~ 0.5121 in)
(0.5117 ~ 0.5118 in)
2 - 7
(0.5134 in)
12.960 mm (0.5102 in)
Page 28
Piston rings
Top ring
ENGINE SPECIFICATIONS
SPEC
SPEC
LimitStandardItem
Type Dimensions (B × T)
End gap (installed)
Side clearance (installed)
2nd ring
Type Dimensions (B × T)
End gap (installed)
Side clearance
Oil ring
Dimensions (B × T)
End gap (installed)
Crankshaft
B
T
B
T
B
T
F
Barrel
1.0 × 2.1 mm (0.0394 × 0.0827in)
0.10 ~ 0.25 mm (0.0039~0.0098in)
0.015 ~0.055 mm (0.0006~0.0022in)
1.0 × 2.0 mm
(0.0394 × 0.0787in)
0.25 ~ 0.40 mm (0.0098~0.0157in)
0.015 ~ 0.055 mm (0.0006~0.0022in)
2.0 × 1.9 mm
(0.0787 × 0.0748 in)
0.20 ~ 0.70 mm (0.0079~0.0276in)
----
----
0.45 mm (0.0177in)
0.09 mm (0.0035in)
----Taper
----
0.55mm (0.0217in)
0.09mm (0.0035in)
----
----
C1
A
Crank width 44.10 ~ 44.15mm
A
”
“
Big end side clearance “D” 0.10~0.30mm
Big end radial clearance “E” 0.007~0.015mm
Small end free play"F" 0.80~1.00mm
C2
E
E
D
----
(1.7362~1.7382in)
0.04 mm----Runout limit C1 (0.0016in)
0.04 mm----C2 (0.0016in)
0.50 mm
(0.0039~0.0118in)
(0.0003~0.0006in)
(0.0315~0.0394in)
2 - 8
(0.0197in)
----
1.50 mm (0.0591in)
Page 29
ENGINE SPECIFICATIONS
Clutch
Automatic centrifugalClutch type
4.0 mmClutch shoe thickness
(0.1575 in)
Clutch shoe spring free length Clutch housing inside diameter
Compression spring free length
Weight outside diameter
Clutch-in revolution Clutch-stall revolution
V-belt
V-belt width
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system Spur gear
Secondary reduction ratio
Max. main axle runout
Max. drive axle runout
Carburetors
Main jet
(A.J)
(P.J) Valve seat size Fuel level
(V.S)
(F.L)
30.5 mm
107.0 ~107.2 mm (4.21 ~4.22 in)
87.9 mm (3.46 in)
14.9 ~ 15.1 mm (0.587 ~0.594 in)
2110±140r/min 2350±150 r/min
18.0 mm (0.709 in)
V-belt automatic
2.47~0.61:1
41/15 × 45/13(9.462)
A26-00 #100
1.0
#4T12 1/1
2.090 H5.5
#32
1.6
5.0 ~ 6.0 mm (0.20 ~ 0.24 in)
Below the float chamber mating Surface
1,600 ~ 1,800 r/min
SPEC
SPEC
2. mm 0 (0.078 in)
107.5 mm (4.23in)
17.0 mm (0.669in)
0.08 mm (0.0031in)
0.08 mm (0.0031in)
LimitStandardItem
----
----
----
----I. D. mark
----(M.J)
----Air jet
----(J.N)Jet needle
----(N.J)Needle jet
----Pilot jet
----
----
----
----Engine idle speed
2 - 9
Page 30
Oil pump
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing clearance
Oil-pump-housing-to-inner-rotor-and-outer­rotor clearance
Lubrication chart
: Pressure feed : Splashed scavenge
ENGINE SPECIFICATIONS
0.04 ~ 0.12mm (0.0016 ~ 0.0047 in)
0.14 ~ 0.21 mm (0.0055 ~ 0.0083 in)
0.06 ~ 0.11 mm (0.0024 ~ 0.0043 in)
SPEC
SPEC
0.15 mm (0.006 in)
0.28 mm (0.0110 in)
0.20 mm (0.0079 in)
LimitStandardItem
----TrochoidOil pump type
Piston
Crankshaft pin
Piston pin
Oil pump
Oil strainer
Camshaft
Rocker arm
Timing chain area
Valve
2 - 10
Page 31
SPEC
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front suspension
Shock absorber travel 35 mm (1.38 in) ---­Optional spring No ----
Rear suspension
Shock absorber travel 40 mm (1.57 in) ---­Optional spring No ----
Front wheel
Type Panel wheel ---­Rim size 8x 5.5 AT ---­Rim material Steel ---­Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Rear wheel
Type Panel wheel ---­Rim size 8x 7 AT ---­Rim material Steel ---­Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Drive chain
Type/ manufacturer #520/ KMC
Link quantity 66
Drive chain slack 10 mm~25 mm (0.39 in~0.98 in)
Front drum brake
Type Brake drum inside diameter
Lining thickness
Shoe spring free length
Leading, trailing
85.0 mm (3.35 in)
3.0 mm (0.12 in)
46.3 mm (1.82 in)
----
86.0 mm (3.39 in)
1.5 mm (0.06 in)
----
2 - 11
Page 32
SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Rear disc brake
Type Disc outside diameter × thickness
Brake disk maximum deflection 0.15 mm
Pad thickness inner 3.7 mm (0.15 in)
Single
190.0 × 3.5 mm (7.48 × 0.11 in)
SPEC
(0.006 in)
----
----
----
Pad thickness outer 3.7 mm (0.15 in)
Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type
Brake lever
Brake lever free play (pivot) front 4.0 ~ 6.0 mm (0.16 ~ 0.24 in) ----
rear 0 ~ 1.5 mm (0 ~ 0.06 in) Throttle lever free play 1.0 ~ 3.0 mm (0.04 ~ 0.12 in) ----
Parking brake cable end length
12.7 mm (0.50 in)
30.23 mm (1.19 in) DOT 4
53.0 ~ 57.0 mm (2.09 ~ 2.24 in)
----
----
----
----
----
----
2 - 12
Page 33
SPEC
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Voltage Ignition system
Ignition timing (B.T.D.C.) 13.0 °±1°/1,700 r/min ---­Advanced timing (B.T.D.C.) 28.5 °±1°/4,000 r/min ---­Advancer type Electrical (digital) ----
C.D.I.
Magneto model/manufacturer C1120-A26-0000/SY ---­Pickup coil resistance/color
Source coil resistance/color
C.D.I. unit model/manufacturer C0410-A26-2000/EYE ----
Ignition coil
Model/manufacturer C0510-A26-3000/SHIHLIN ---­Minimum spark gap 6 mm (0.24 in) ---­Primary winding resistance Secondary winding resistance
Spark plug cap
Type Resin ---­Resistance 5 N ----
Charging system
Type A.C. magneto ---­Model/manufacturer C1120-A26-0000/SY ---­Nominal output 14 V 23.8 W at 6,000 r/min ---­Charging coil resistance/color
Rectifier/regulator
Regulator type Semi conductor-short circuit ---­No-load regulated voltage (DC) 14.0 ~ 15.0 V ----
Model/manufacturer C1600-B00-0000/SY
Capacity (DC) 10 A
Withstand voltage 500 V
12 V ----
120 ~ 180 at 20 °C (68 °F)/ White/Red—Black
480 ~ 640 at 20 °C (68 °F)/
Black/Red—Black
0.19 ~ 0.23 at 20 °C (68 °F)
2.79 ~ 3.41 k at 20 °C (68 °F)
0.547 ~ 0.716 at 20 °C (68 °F)/ White—Black
----
----
----
----
----
----
----
----
2 - 13
Page 34
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Electric starter system
Starter motor
0.35 kWOutput Armature coil resistance 0.014 ~ 0.019 at 20 °C (68 °
Brush overall length
Spring force
Starter relay
Coil winding resistance 4.23 ~ 5.12 at 20 °C (68 °F)
Circuit breakers
Type Amperage for individual circuit
Main fuse ----
1.0 ~ 3.0 N
(102~ 306gf, 3.60 ~ 10.80 oz)
Fuse
7.0 A × 1
SPEC
F)
----Constant meshType
----C1200-A26-9000/SYModel/manufacturer
----
----
3.5 mm7.0 mm (0.28 in) (0.14 in)
----
19.5 mm22.0 mm (0.87 in)Commutator diameter (0.77in)
----.6 mm ( 0.06 in)1Mica undercut
----C585A-LRA0-0000/SYModel/manufacturer
----150 AModel/manufacturer
----
----
2 - 14
Page 35
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
TIGHTENING TORQUES
SPEC
SPEC
Part to be tightened Part name
Cover head cylinder M6 4 12 1.2 8.7
Spark plug — Cylinder head (Pipe assy, inlet) Stud bolt
Cylinder head (Muffler pipe) Stud bolt M6 2 9 0.9 6.5 Valve adjuster nut hex Cylinder head(timing chain side) Timing chain tensioner(body) Timing chain tensioner(plug) Bolt Duct inlet and cover R side
Duct inlet and shroud assy A and B Shroud assy A and crank case, L Shroud assy A and B Shroud assy B and box tensioned lifter
Cylinder Stud bolt A
Stud bolt B Cover L side Face assy, movable drive
Outer clutch nut Nut Motor start comp
Fan comp cooling Flywheel comp Nut M12 1 55 5.5 40 Stator comp
Pulse Cover R side Gear oil pump driven
Sprocket drive
Cover mission Hole cap tap adjusting Bolt M30 Crankcase R and L Air cleaner holder Pivot cam chain set Air filter
Carburetor overflow drain screw Carburetor pipe assy, inlet
Exhaust pipe Muffler
Spark arrester
Bolt
Nut M 74151.511Holder cam shaft
Bolt Bolt
Bolt
Screw
Bolt Bolt
Screw
Bolt M6 1 12 1.2 8.7
Stud bolt Stud bolt
Bolt M6 8 12 1.2 8.7
Nut
Bolt M6 2 12 1.2 8.7
Bolt
Bolt M6 2 12 1.2 8.7 Bolt Bolt
Nut
Bolt
Bolt
Bolt
Screw
Nut Nut
Bolt
Screw
Thread
size
M10 1 11 M6 2 9 0.9 6.5
M5 2 9 0.9 6.5 Nut
M6 2 12 1.2 8.7 M6 2 12 1.2 8.7 M6 1 M6 2 12 1.2 8.7 M5 2 2 0.2 1.4
M6 1 12 1.2 8.7 M6 1 2 0.2 1.4 M3 2 1
M7 2 9 0.9 6.5 M7 2 9 0.9 6.5
M12 1 55 5.5 40 M10 1 40 4.0 30
M6 4 12 1.2 8.7
M5 2 5 0.5 3.6 M6 8 12 1.2 8.7
M6 1 12 1.2 8.7 M6 3 12 1.2 8.7 BoltPump assy oil
M6 2 10 1.0 7.2 Bolt M8 1 15 1.5 11 BoltGear oil drain bolt M6 7 12 1.2 8.7
M6 1 12 1.2 8.7 M6 3 12 1.2 8.7 Bolt
M6 1 10 1.0 7.2 Bolt M6 1 12 1.2 8.7
M6 1 1 0.1 0.7 M6 2 12 1.2 8.7 M6 2 13 1.3 9.4
M8 1 25 2.5 18
M5 1 5 0.5 3.6
Q’ty
1 8 0.8 5.8
Tightening torque
Nm m · kg ft · lb
1.1 8.0
0.6 4.3
6
0.1 0.7
Remarks
2 - 15
Page 36
CHASSIS TIGHTENING TORQUES
TIGHTENING TORQUES
SPEC
SPEC
Part to be tightened Thread size
Engine lower stay and engine Engine and frame Engine lower stay and frame Swingarm pivot shaft and frame Rear shock absorber and frame Rear shock absorber and swingarm Front shock absorber and frame Front shock absorber front arm Steering stem and frame Steering stem and tie-rod ball joint Tie-rod locknut Steering stem bushing and frame Steering knuckle and tie-rod ball joint Steering knuckle and front arm Steering knuckle and front brake drum Front wheel and front brake drum Front brake camshaft and camshaft lever Rear axle and rear axle nut Rear brake disc and disc bracket
Rear brake lever and handlebar holder
Parking brake adjusting bolt and locknut
Rear brake caliper and brake caliper bracket Rear axle and wheel hub Rear wheel and wheel hub Handlebar holder and steering stem Throttle lever and housing Fuel tank and frame Front fender and frame Rear fender and frame Rear carrier and frame Parking brake case and caliper
Front bumper and frame Footrest board and footrest bracket Footrest bracket and frame
Driven sprocket and sprocket bracket Parking brake lever and parking brake lever bracket
Tightening torque
Nm m · kg ft · lb
M10 M10 M10 M14 M10 M10 M10 M10 M14 M10 M10
M8 M10 M10 M12 M10
M6 M28 M10
M6
M8
M8 M14 M10
M6
M6
M6
M6
M6
M8
M8
M8
M6
M8 22 2.2 15.9
M10
M6
35 3.5 25.3 35 3.5 25.3 35 3.5 25.3 75 7.5 54.2 35 3.5 25.3 35 3.5 25.3 35 3.5 25.3 35 3.5 25.3 55 5.5 39.8 35 3.5 25.3 35 3.5 25.3 25 2.5 18.1 35 3.5 23.5 35 3.5 25.3 50 5.0 36.2 45 4.5 32.5 14 1.4 10.1
35 3.5 25.3
14 1.4 10.1
16 1.6 11.6
28 2.8 20.3
90 9.0 65.1
45 4.5 32.5 14 1.4 10.1 12 1.2 8.7 12 1.2 8.7 9 0.9 6.5 9 0.9 6.5 25 2.5 18.1 25 2.5 18.1 25 2.5 18.1 9 0.9 6.5
35 3.5 25.3 14 1.4 10.1
Remarks
See TIP.
2 - 16
Page 37
SPEC
TIGHTENING TORQUES
TIP
1. Before tightening the nuts, apply locking agent (LOCTITE®) to rear axle threads.
2. Tighten the inside nut to 60 Nm (6.0 m · kg, 43.4 ft · lb).
SPEC
.tun edisni eht gnidloh elihw )bl · tf 321 ,gk · m 0.71( mN 071 ot tun edistuo eht nethgiT.3
2 - 17
Page 38
HOW TO USE THE CONVERSION TABLE /
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
SPEC
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULTIPLIER IMPERIAL
** mm
2 mm
CONVERSION TABLE
Torque
Weight
Speed km/h 0.6214 mph
Distance
Volume/ Capacity
Misc.
x
0.03937 = ** in
x
0.03937 = 0.08 in
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m· kg m· kg cm · kg cm · kg
kg g
km m m cm mm
cc (cm cc (cm3) lt (liter) lt (liter)
kg/mm
2
kg/cm Centigrade (°C)
7.233
86.794
0.0723
0.8679
2.205
0.03527
0.6214
3.281
1.094
0.3937
0.03937
3
)
0.03527
0.06102
0.8799
0.2199
55.997
14.2234 9/5+32
ft · lb in · lb ft · lb in · lb
lb oz
mi ft yd in in
oz (Imp liq.) cu · in qt (Imp liq.) gal (Imp liq.)
lb/in psi (lb/in2) Fahrenheit (°F)
GENERAL TIGHTENING TORQUE SPECIFICATIONS
This chart specifies tightening torques for stan­dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe­cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats B: Outside thread diameter
General tightening
A
(nut)
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
B
(bolt)
torques
Nm m · kg ft · lb
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 18
Page 39
LUBRICATION POINTS AND LUBRICANT TYPES
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication Point Lubricant
SPEC
SPEC
Oil seal lips
O-ring (Except V-belt drive unit)
Cylinder head tightening nut mounting surface
Cylinder head stud bolt thread
Cylinder head gasket dowel pin
Crankshaft pin outside surface
Connecting rod
Piston outside and ring groove
Piston pin outside surface
Crankshaft journal
Camshaft profile journal
Valve stem (IN, EX)
Valve stem seal
Valve stem end (IN, EX)
LS
LS
E
E
E
E
E
E
E
E
M
M
M
M
Valve lifter
Oil pump assembly inside
Oil pipe union bolt thread and surface
Gasket (Oil pump assembly)
Idle gear 1 thrust surfaces
Idle gear 2
Drive shaft serration (Sprocket)
Drive shaft taper roller bearing
Transmission bearing
Secondary shaft bearing (right)
Primary sheave oil seal
E
E
E
LS
E
E
LS
LS
G
LS
LS
2 - 19
Page 40
LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Point Lubricant
SPEC
SPEC
Primary sheave inside, Collar, Solid bush,
Secondary fixed inner surface
Secondary sheave torque cam ditch
Gasket (Cylinder head cover)
Stopper guide (Cylinder head cover)
Crankcase mating surfaces
Oil pipe
C.D.I. magneto lead grommet
LS
BEL-RAY asembly lube
BEL-RAY asembly lube
Sealant
Sealant
Sealant
Sealant
Sealant
2 - 20
Page 41
OIL FLOW DIAGRAMS
Camshaft
1
Crankshaft
2
Oil pump
3
Oil filter
4
OIL FLOW DIAGRAMS
SPEC
SPEC
2 - 21
Page 42
CABLE ROUTING
1
Front brake cables
2
Rear brake hose
3
Throttle cable
4
Choke cable
5
Fuel tank breather hose
6
Air filter case check hose
7
Fuel hose
8
Fuel overflow
9
Throttle valve hose
10
Carburetor air vent hose
11
Oil catch hose
12
Crankcase breather hose
13
Parking brake cable
14
Fuel meter cable
CABLE ROUTING
15
16
17
18
0 A B
SPEC
SPEC
Shift switch lead
Buzzer cable
Shift motor line
Shift sensor line
Wire harness
Rear brake switch lead Handlebar switch lead
2 - 22
Page 43
SPEC
CABLE ROUTING
Shift motor
C
F-N-R shift switch
D
Pass the front brake cables, throttle cable and choke cable through the hose guide.
A
B
Fasten the choke cable, handlebar switch lead and rear brake switch lead with a plastic band.
Insert the fuel tank breather hose into the hole in the handlebar cover.
C
D
Fasten rear brake hose and throttle cable with a plastic band.
SPEC
2 - 23
Page 44
SPEC
CABLE ROUTING
Fasten rear brake hose with a plastic band.
E
Fasten the fuel overflow hose and carburetor air vent hose with a metal band. Be sure to not pinch the hose.
F
Brake fuel tube with a clip.
G
Route the parking brake cable under the cross pipe and left of the steering column as shown in the
H
illustration.
SPEC
2 - 24
Page 45
CABLE ROUTING
SPEC
SPEC
1
Fuel drain hose
2
Rear brake hose
3
Throttle cable
4
Parking brake cable
5
Front brake cables
6
Start relay cable
7
Air filter case check hose A
8
Oil catch hose
9
Crankcase breather hose
10
C.D.I cable
11
Shift sensor cable
12
Shift motor cable
13
Buzzer cable
Wire harness0 Positive starter motor lead Positive battery lead
B
C
Negative battery lead
D Negative starter motor lead
Starter motorE Generator leadF Main switch leadG
H
Ignition coil Rectifier/regulator
I J Starter relay
2 - 25
Page 46
SPEC
CABLE ROUTING
K Battery L Main fuse
M C.D.I. unit
N Buzzer
A
Pass these leads through rear fender.
B
Fasten the wire harness, main switch lead, heater control switch lead and with a plastic band.
C
Fasten the wire harness, negative battery lead and starter motor lead with a plastic band.
Fixed the negative battery lead and negative starter motor lead by a bolt.
D
SPEC
2 - 26
Page 47
CABLE ROUTING
SPEC
SPEC
1
Rear brake switch lead
2
Rear brake hose
3
Front brake cable (right)
4
Front brake cable (left)
5
Throttle cable
6
Fuel tank breather hose
7
Battery
8
Positive battery lead
9
Negative battery lead
10
Main fuse
11
Handlebar switch
12
Choke cable
13
Parking brake cable
14
Shift switch
A
1
2
15
Shift switch lead
16
C.D.I cable
17
C.D.I unit
18
Shift sensor cable
19
Shift motor cable
3
4
6
16
17
5
E
D
11
12
9
14
15
10
C
13
A
B
8
7
18
19
2 - 27
Page 48
SPEC
CABLE ROUTING
Fasten the handlebar switch lead , rear brake switch lead and choke cable with a plastic band.
A B
To starter relay.
C
To the frame.
D
Connect the negative battery lead to the battery so that the lead is routed to the side of the battery.
E
Connect the positive battery lead to the battery so that the lead contacts the battery case.
A
1
2
3
4
SPEC
6
16
17
5
E
D
11
12
9
14
15
10
C
A
13
B
8
7
18
19
2 - 28
Page 49
CABLE ROUTING
SPEC
SPEC
1
2
Rear brake hose
3
Choke cable
4
Rear brake switch lead
Fasten the handlebar switch lead , rear brake switch lead and choke cable
A
5
Handlebar switch lead Throttle cable
6
Front brake cable (left)
7
Front brake cable (right)
8
Parking brake cable
9
Shift switch lead
A Ignition coil
with a plastic band.
2 - 29
Page 50
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
CHK
ADJ
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as to new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
INITIAL EVERY
NO. ITEM
Fuel line
1
*
2 Spark plug
Valves
3
*
Carburetor
4
*
Crankcase breather
*
5
system
Exhaust system
6
*
7 Spark arrester Clean. ¥¥¥
CHECK OR MAINTENANCE
JOB
Check fuel hoses for cracks or other damage, and replace if necessary.
Check condition and clean, regap, or replace if necessary.
Check valve clearance and adjust if necessary. Check choke operation and correct if necessary.
Check engine idling speed and adjust if neces­sary.
Check breather hose for cracks or other damage, and replace if necessary.
Check for leakage and replace gasket(s) if neces­sary. Check for looseness and tighten all screw clamps and joints if necessary.
Whichev­er comes
¿rst
month 1 3 6 6 12
km
320
(mi)
(200)
hours 20 80 160 160 320
1300 (800)
¥¥¥¥¥
¥ ¥¥¥
2500
(1600)
¥¥¥¥
2500
(1600)
¥¥¥
¥¥¥
¥¥¥
5000
(3200)
3
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL EVERY
month 1 3 6 6 12
km
(mi)
hours 20 80 160 160 320
320
(200)
Every 20–40 hours (more often in wet or dusty areas)
1300
(800)
2500
(1600)
¥
¥¥¥
¥¥
NO. ITEM
1 $LU¿OWHUHOHPHQW
Clutch
2
*
3
Front brake
*
4
Rear brake
*
5
Brake hoses
*
6
Wheels
*
7
Tires
*
CHECK OR MAINTENANCE
JOB
Clean and replace if necessary.
Check operation.
Check operation and correct if necessary. Check brake lever free play and adjust if neces­sary.
Replace brake shoes. Whenever worn to the limit
Check operation and correct if necessary. Check fluid level and ATV for fluid leakage, and correct if necessary.
Replace brake pads. Whenever worn to the limit Check for cracks or other damage, and replace if
necessary. Replace. Every 4 years
Check runout and for damage, and replace if nec­essary.
Check tread depth and for damage, and replace if necessary. Check air pressure and balance, and correct if necessary.
Whichev­er comes
¿rst
2500
(1600)
¥¥¥¥
¥¥¥¥
¥¥
¥¥¥¥
¥¥¥¥
5000
(3200)
¥¥
3 - 1
Page 51
NO. ITEM
WARNING
8
Wheel hub bearings
*
9
Chassis fasteners
*
Shock absorber
10
*
assemblies Front knuckle piv-
11
*
ots
12
Steering shaft
*
13
Steering system
*
Engine oil
14
15
Engine oil strainer Clean.
16
Final transmission oil
Moving parts and
17
*
cables
Drive select lever
18
*
safety system cable
Throttle lever hous-
19
*
ing and cable
Front and rear brake
20
*
switches
21
Lights and switches
*
22
V-belt
23
Drive chain
24
Drive chain rollers
*
25
Parking brake
*
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
INITIAL EVERY
CHECK OR MAINTENANCE
Check for looseness or damage, and replace if necessary.
Make sure that all nuts, bolts, and screws are properly tightened.
Check operation and correct if necessary. Check for oil leakage and replace if necessary.
Lubricate with lithium-soap-based grease.
Lubricate with lithium-soap-based grease.
Check operation and repair or replace if damaged. Check toe-in and adjust if necessary.
Change. Check ATV for oil leakage, and correct if neces­sary.
Change. Check ATV for oil leakage, and correct if neces-
sary.
Lubricate.
Check operation and adjust or replace if neces­sary.
Check operation and correct if necessary. Check throttle cable free play and adjust if neces­sary. Lubricate throttle lever housing and cable.
Check operation and correct if necessary.
Check operation and correct if necessary. Adjust headlight beams.
Check operation
Check for wear, cracks or other damage, and replace
if necessary.
Check chain slack and adjust if necessary. Check rear wheel alignment and correct if neces-
sary.
Clean and lubricate.
Check for wear and replace if necessary.
Check operation and adjust if necessary.
JOB
Whichev­er comes
¿rst
month 1 3 6 6 12
km
(mi)
hours 20 80 160 160 320
320
(200)
1300
(800)
¥¥¥
¥¥
¥¥¥¥
¥¥¥
¥¥¥
¥¥¥
¥¥¥
CHK
ADJ
2500
(1600)
2500
(1600)
¥¥¥¥
¥¥¥
¥¥¥
¥¥¥
¥¥¥
¥¥¥¥
¥¥¥
¥¥¥
¥¥¥¥
¥¥¥
5000
(3200)
¥¥
¥¥
¥¥
¥¥¥¥¥
¥¥
¥¥
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
* Since these items require special tools, data and technical skills, have an E-TON dealer perform
the service.
Indicates a potential hazard that could result in serious injury or death.
3 - 2
Page 52
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
HANDLEBAR
1
2
T
.
14 Nm (1.4 m • kg, 10.1 ft • Ib)
R
.
CHK
ADJ
8
(x4)
3
T
.
28 Nm (2.8 m • kg, 20.3 ft • Ib)
R
.
Order Job/Part Q’ty Remarks
Removing the handlebar
1 Fuel tank breather hose 1 2 Handlebar cover 1
4
7
6
5
Remove the parts in the order listed.
TIP
When installing the handlebar cover, pass the fuel tank breather hose through the hole in the handlebar cover.
3 Front brake cable 2
4 Parking brake cable 1
5 Choke cable 1 6 Rear brake hose
7 Upper handlebar holder 8 Handlebar
Refer to “INSTALLING THE PARKING BRAKE LEVER”.
Refer to “INSTALLING THE REAR
1
BRAKE MASTER CYLINDER”.
1 1
For installation, reverse the removal pro­cedure.
3 - 3
Page 53
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
SEAT, FRONT PANEL AND FOOTREST BOARDS
4
2
CHK
ADJ
1
(x2)
Order Job/Part Q’ty Remarks
Removing the seat, front panel and footrest boards
1 Seat 1
Remove the parts in the order listed.
Refer to “HANDLEBAR”.Handlebar
TIP
Pull back the seat lock lever, than pull up on the rear of the seat.
(x4)
(x2)
3
2 Front panel 1
3 Footrest board (L) 1
4 Footrest board (R) 1
For installation, reverse the removal pro­cedure.
3 - 4
Page 54
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
FRONT FENDER
CHK
ADJ
T
9.0 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
1
3
T
9.0 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
4
2
T
9.0 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
Order Job/Part Q’ty Remarks
Removing the front fender
Remove the parts in the order listed.
Refer to “HANDLEBAR”.Handlebar
Seat and front panel Refer to “SEAT AND FRONT PANEL”.
1 Front body cover 1
2 Front fender (L) 1 3 Front fender (R) 1 4 Air cleaner joint clamp screw 1 Loosen.
For installation, reverse the removal pro­cedure.
3 - 5
Page 55
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
რ
NOTICE
REAR FENDER, BATTERY AND C.D.I UNIT
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
1
2
11
CHK
ADJ
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
9
10
3
7
6
8
Order Job/Part Q’ty Remarks
Removing the rear fender, battery and C.D.I unit
Seat and front panel Refer to “SEAT AND FRONT PANEL”.
Front fender Refer to “FRONT FENDER”. Wire harness and main fuse
11 21
Negative battery lead
3 1 Disconnect.
Positive battery lead
4
5
(x2)
Remove the parts in the order listed.
Refer to “HANDLEBAR”.Handlebar
Disconnect.
41
Battery
5
C.D.I cable
6
Shift sensor cable
7
Shift motor cable
8
C.D.I unit
9
Rear body cover
10
11
Rear fender (L) Rear fender (R)
First disconnect the negative lead, then disconnect the positive lead.
2 1 1
1 1 1 1
For installation, reverse the removal pro­cedure.
3 - 6
Page 56
HANDLEBAR, SEAT, FENDERS AND FUEL TANK
FUEL TANK AND FOOTREST BARS
2
4
3
(x4)
CHK
ADJ
1
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
4
(x4)
3
Order Job/Part Q’ty Remarks
Removing the fuel tank and footrest bars
Seat and front panel Refer to “SEAT AND FRONT PANEL”. Front fender Refer to “FRONT FENDER”.
1 Fuel hose 2 Disconnect.
2 Fuel tank 1
Remove the parts in the order listed.
TIP
Before disconnecting the fuel hose, turn the fuel cock to “OFF”.
For installation, reverse the removal pro­cedure.
3 Footrest bar 2
4 Footrest bear bar 2
3 - 7
Page 57
ADJUSTING THE VALVE CLEARANCE
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the valves.
TIP
•
Valve clearance adjustment should be made on a cold engine, at room tempera­ture.
•
When the valve clearance is to be mea­sured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
1. Remove:
• C.D.I. magneto cover
• Cylinder head cover Refer to “CYLINDER HEAD” in chapter 4.
CHK
ADJ
2. Measure:
• valve clearance Out of specification Adjust.
Valve clearance (cold) Intake valve
0.07 ~ 0.10 mm (0.003~ 0.004 in)
Exhaust valve
0.07 ~ 0.10 mm (0.003~ 0.004 in)
a. Turn the crankshaft clockwise with a wrench.
b. Align the “T” mark on the rotor with the
stationary pointer on the crankcase.
T
When the “T” mark is aligned with the sta­tionary pointer, the piston is at the Top Dead Center (TDC).
TIP
• When the piston is at the Top Dead Center (TDC) on the compression stroke, there should be clearance between the valve stem tips and their respective adjusting screws.
• Be sure to align the alignment mark on the camshaft sprocket with hole mark is forwa-
rd to up.
ĺ
3 - 8
Page 58
ADJUSTING THE VALVE CLEARANCE
c. Measure the valve clearance using a thick-
ness gauge . Out of specification Adjust
3. Adjust:
• valve clearance
a. Loosen the locknut . b. Insert a thickness gauge between the
adjuster end and the valve end.
c. Turn the adjuster clockwise or counter-
clockwise with the tappet adjusting tool until the proper clearance is obtained.
CHK
ADJ
d. Hold the adjuster to prevent it from moving
and then tighten the locknut.
Locknut
9 Nm (0.9 m · kg, 6.5 ft · lb)
T
.
R
.
e. Measure the valve clearance. f. If the clearance is incorrect, repeat the
above steps until the proper clearance is obtained.
4. Install:
• C.D.I. magneto cover
• Cylinder head cover
Refer to “CYLINDER HEAD” in chapter 4.
3 - 9
Page 59
ADJUSTING THE ENGINE IDLING SPEED
ADJUSTING THE ENGINE IDLING SPEED
1. Start the engine and let it warm up for sev­eral minutes.
2. Attach:
• engine tachometer (to the spark plug lead)
3. Measure:
• engine idling speed
Out of specification Adjust.
Engine idling speed
1,600 ~ 1,800 r/min
4. Adjust:
• engine idling speed
CHK
ADJ
ĺ
a. Turn the throttle stop screw in or out until
the specified idling speed is obtained.
Turning right
Turning left
5. Detach:
• engine tachometer
6. Adjust:
• throttle lever free play Refer to “ADJUSTING THE THROTTLE LEVER FREE PLAY”.
Throttle lever free play
1.0 ~ 3.0 mm (0.04 ~ 0.12 in)
Idling speed becomes higher.
Idling speed becomes lower.
3 - 10
Page 60
ADJUSTING THE THROTTLE LEVER FREE PLAY
WARNING
ADJUSTING THE THROTTLE LEVER FREE PLAY
TIP
Engine idling speed should be adjusted prop­erly before adjusting the throttle lever free play.
1. Measure:
a
• throttle lever free play Out of specification Adjust.
Throttle lever free play
1.0 ~ 3.0 mm (0.04 ~ 0.12 in)
2. Adjust:
• throttle lever free play
a. Pull back the adjuster cover . b. Loosen the locknut on the carburetor
side.
c. Turn the adjuster in or out until the cor-
rect free play is obtained.
CHK
ADJ
a
Turning in Free play is increased.
Turning out Free play is decreased.
d. Tighten the locknut . e. Push in the adjuster cover .
After adjusting the free play, turn the han­dlebar to the right and left to make sure that the engine idling speed does not increase.
3 - 11
Page 61
CHK
WARNING
ADJUSTING THE SPEED LIMITER
ADJUSTING THE SPEED LIMITER
The speed limiter keeps the carburetor throttle from becoming fully-opened even when the throttle lever is applied to the maximum posi­tion. Screwing in the adjuster stops the engine speed from increasing.
1. Measure:
a
• speed limiter length Out of specificationĺ Adjust.
Speed limiter length
Less than 11.0mm (0.43 in)
2. Adjust:
• speed limiter length
a. Loosen the locknut . b. Turn the adjuster in or out until the speci-
fied speed limiter length is obtained.
ADJ
a
Turning in
Turning out
c. Tighten the locknut.
• Particularly for a beginner rider, the speed limiter should be screwed in com­pletely. Screw it out little by little as their riding technique improves. Never remove the speed limiter for a beginning rider.
• For proper throttle lever operation do not turn out the adjuster more than 11.0 mm (0.43 in). Also, always adjust the throttle lever free play to 1.0 ~ 3.0 mm (0.04 ~
0.12 in).
Speed limiter length is decreased.
Speed limiter length is increased.
3 - 12
Page 62
CHECKING THE SPARK PLUG
CHECKING THE SPARK PLUG
1. Remove:
• spark plug
2. Check:
• spark plug type IncorrectĺChange.
Standard spark plug
CR7HSA/NGK
3. Check:
• electrode Wear/damageĺ Replace.
• insulator Abnormal colorĺ Replace. Normal color is a medium-to-light tan color.
4. Clean:
• spark plug (with a spark plug cleaner or wire brush)
CHK
ADJ
5. Measure:
• spark plug gap Use a wire gauge or thickness gauge. Out of specificationĺRegap.
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
6. Tighten:
• spark plug
a
T
11 Nm (1.1 m · kg, 8.0 ft · lb)
.
R
.
3 - 13
Page 63
CHECKING THE IGNITION TIMING
TIP
CHECKING THE IGNITION TIMING
Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing.
1. Remove:
• Shroud cap
2. Attach:
• engine tachometer
a
• timing light
(to spark plug lead)
a
CHK
ADJ
3. Check:
• ignition timing
a. Warm up the engine and keep it at the
specified speed.
F
T
b. Visually check the stationary pointer to
verify it is within the required firing range indicated on the rotor. Incorrect firing range Check the pickup coil.
4. Detach:
• timing light
• engine tachometer
5. Install:
• Shroud cap
TIP
The ignition timing is not adjustable.
Engine speed
1,600 ~ 1,800 r/min
ĺ
3 - 14
Page 64
MEASURING THE COMPRESSION PRESSURE
TIP
MEASURING THE COMPRESSION PRESSURE
Insufficient compression pressure will result in a loss of performance.
1. Measure:
• valve clearance Out of specificationĺ Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”.
2. Start the engine, warm it up for several min­utes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
NOTICE
რ
Before removing a spark plug, use com­pressed air to blow away any dirt accumu­lated in the spark plug well to prevent it from falling into the cylinder.
CHK
ADJ
5. Attach:
compression gauge
•
6. Measure:
• compression pressure Out of specification and (d).
Compression pressure (at sea level)
Minimum
1,050 kPa/1,000 r/min (10.5kg/cm , 152.3 psi)
Standard
1,250 kPa/1,000 r/min (12.5kg/cm , 181.3 psi)
Maximum
1,350 kPa/1,000 r/min (13.5kg/cm , 195.8 psi)
ĺ
Refer to steps (c)
2
2
2
3 - 15
Page 65
MEASURING THE COMPRESSION PRESSURE
WARNING
a. Set the main switch to “ON”. b. With the throttle wide open, crank the
engine until the reading on the compression gauge stabilizes.
To prevent sparking, ground the spark plug lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits ĺ Eliminate.
d. If the compression pressure is below the
minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table.
CHK
ADJ
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than without oil
Same as without oil
7. Install:
• spark plug
8. Connect:
• spark plug cap
Piston ring(s) wear or damage ĺ Repair.
Piston, valves, cylinder head gasket or piston possibly defective ĺ Repair.
T
11 Nm (1.1 m • kg, 8.0 ft • Ib)
.
R
.
3 - 16
Page 66
CHECKING THE ENGINE OIL LEVEL
TIP
TIP
რ
NOTICE
CHK
ADJ
a
b
CHECKING THE ENGINE OIL LEVEL
1. Place the machine on a level surface.
2. Check:
• engine oil level Oil level should be between the maximum
mark and minimum mark.
a
Oil level lowĺ Add oil to the proper level.
Do not screw the dipstick in when checking the oil level.
a. Warm up the engine for several minutes,
and stop it, then wait at least several min­utes for the oil to drain back into the crank­case.
WARNING
Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick.
b
b. Screw the dipstick completely out, and
wipe the dipstick clean, then just rest the dipstick in the hole.
c. Pull up the dipstick, and check the oil level
a
0
SAE 5W-30
-20
10 30
-10 0
50
SAE 20W-50
SAE 10W-40
10
90
70
30 40 50 °C
20
110
130 °F
whether or not it is between maximum and minimum level .
d. If the level is lower, add the oil up to the
proper level.
Recommended oil
Follow the chart on the left.
Recommended oil classification: API service SG type or higher, JASO standard MA.
b
• Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage.
• Do not allow foreign material to enter the crankcase.
3 - 17
Page 67
CHANGING THE ENGINE OIL
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
• dipstick
• engine oil drain bolt (along with the O-ring, spring and oil filter
screen)
4. Drain:
• engine oil (completely from the crankcase)
5. Check:
• engine oil drain bolt gasket Damage
ĺ Replace.
CHK
ADJ
6. Install:
• engine oil drain bolt (along with the O-ring, spring and oil filter
screen)
T
8 Nm (0.8 m • kg, 5.8 ft • Ib)
.
R
.
7. Fill:
• crankcase (with the specified amount of the recom­mended engine oil)
Quantity
Total amount
0.80 L (0.70 Imp qt, 0.85 US qt)
Periodic oil change
0.75 L (0.66 Imp qt, 0.80 US qt)
8. Install:
• dipstick
9. Start the engine, warm it up for several min­utes, and then turn it off.
10.Check:
• engine (for engine oil leaks)
11.Check:
• engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
12.Check:
• oil lubrication by oil check bolt
3 - 18
Page 68
CLEANING THE AIR FILTER ELEMENTS
CLEANING THE AIR FILTER ELEMENTS
TIP
There is a check hose at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter elements and air fil­ter case.
1. Remove:
• air filter case covers
CHK
ADJ
2. Loosen:
• bolt
3. Remove:
•
air filter element holders
• sponge materials
NOTICE
რ
The engine should never be run without the
•
air filter; excessive piston and/or cylinder wear may result. This model is equipped with two air filter
•
elements: one located on the left side and one located on the right side of the air box.
4. Check:
• sponge materials Damaged ĺ Replace.
5. Clean:
• sponge materials
a. Wash the sponge materials gently, but
thoroughly in solvent.
WARNING
Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause
explosion.or erif a
3 - 19
Page 69
CLEANING THE AIR FILTER ELEMENTS/
CLEANING THE SPARK ARRESTER
b. Squeeze the excess solvent out of the spo-
nge materials and let it dry.
NOTICE
რ
Do not twist or wring out the sponge materials. could damage the sponge materials.
c. Apply Yamaha foam air filter oil or other quality
foam air filter oil to the sponge materials.
d. Squeeze out the excess oil.
TIP
The sponge materials should be wet but not dripping.
6. Install:
• Sponge materials
• Air filter element holders
7. Tighten:
• bolt
8. Install:
• Air filter case covers
CHK
ADJ
TIP
Make sure its sealing surface matches the sealing surface of the case so there is no air leak.
CLEANING THE SPARK ARRESTER
1. Clean:
• spark arrester
WARNING
• Select a well-ventilated area free of com­bustible materials.
• Always let the exhaust system cool before performing this operation.
• Do not start the engine when removing
a. Remove the bolt and nut b. Remove the spark arrester by pulling it
out of the muffler.
l.relffum morf epipliat eht
3 - 20
Page 70
CLEANING THE SPARK ARRESTER
c. Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.
d. Insert the spark arrester into the muffler and
align the screw holes.
e. Insert the bolt, nut and tighten it.
Screw
5 Nm (0.5 m · kg, 3.6 ft · lb)
T
.
R
.
CHK
ADJ
3 - 21
Page 71
CHECKING THE FRONT BRAKE SHOES/
ADJUSTING THE FRONT BRAKE
CHK
ADJ
a
CHECKING THE FRONT BRAKE SHOES
1. Check:
•
Upper adjusting bolt Lower adjusting bolt•
aaa
As more than 12 mm (0.47 in)
the brake shoes as a set. Refer to “FRONT BRAKES” in chapter 6.
ADJUSTING THE FRONT BRAKE
TIP
Before adjusting the front brake, the front brake linings should be checked.
NOTICE
რ
Proper lever free play is essential to avoid excessive brake drag.
ĺ
Replace
CHASSIS
1. Measure:
• front brake lever free play Out of specification ĺ Adjust.
Front brake lever free play
4 ~ 6 mm (0.16 ~ 0.24 in)
2. Adjust:
• front brake lever free play
a. Loosen the locknuts . b. Turn the adjusters in or out until the
b
c
specified front brake lever free play is obtained.
TIP
Make sure that the difference between clear­ances and is less than 2 mm when the front brake lever is squeezed.
c. Tighten the locknuts.
b c
a
3 - 22
Page 72
ADJUSTING THE PARKING BRAKE
WARNING
ADJUSTING THE PARKING BRAKE
1. Check:
• parking brake cable end length Out of specification o Adjust.
Parking brake cable end length
53.0 ~ 57.0 mm (2.09 ~ 2.24 in)
2. Adjust:
• parking brake cable end length
a. Loosen the locknut and adjusting bolt
.
b. Loosen the locknut . c. Turn the adjusting nut in direction or
until the specified brake cable end
length is obtained. d. Tighten the locknut . e. Slowly turn the adjusting bolt clockwise until
resistance is felt. f. Turn it 1 /8 counterclockwise. g. Tighten the locknut .
CHK
ADJ
16 Nm (1.6 m•kg, 11 ft•lb)
After this adjustment is performed, lift the rear wheels off the ground by placing a block under the engine, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed perform the above steps again.
3 - 23
Page 73
CHECKING THE REAR BRAKE FLUID LEVEL
WARNING
CHECKING THE REAR BRAKE FLUID LEVEL
1. Place the machine on a level surface.
TIP
When checking the brake fluid level, make sure that the top of the brake master cylinder reser­voir or brake fluid reservoir is horizontal.
2. Check:
• brake fluid level
Below the minimum level mark ĺ Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT #4
CHK
ADJ
• Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid that is already in the system. Mixing brake flu­ids may result in a harmful chemical reac­tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
NOTICE
რ
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately
TIP
In order to ensure a correct reading of the brake fluid level, make sure that the top of the brake master cylinder reservoir or brake fluid reservoir is horizontal.
3 - 24
Page 74
CHECKING THE REAR BRAKE PADS/ CHECKING THE BRAKE
HOSE/ BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHECKING THE REAR BRAKE PADS
1. Check:
• brake pads Wear indicators almost touch the brake disc
a
ĺ Replace the brake pads as a set.
Refer to “REAR BRAKE” in chapter 6.
CHK
ADJ
Brake pad wear limit
1.0 mm (0.04 in)
2. Operate the rear brake lever.
CHECKING THE BRAKE HOSE
1. Remove:
• seat
• front fender
Refer to “SEAT, FENDERS AND FUEL TANK”.
2. Check:
• rear brake hose
Cracks/ wear/damage ĺ Replace.
3. Check:
• brake hose clamps
Loosen ĺ Tighten.
4. Hold the machine in an upright position and apply the rear brake.
5. Check:
• brake hose Apply the brake lever times. Fluid leakage ĺ Replace the hose or pipe. Refer to “REAR BRAKE” in chapter 6.
6. Install:
• front fender
• seat Refer to “SEAT, FENDERS AND FUEL TANK”.
a
BLEEDING THE HYDRAULIC BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system when­ever:
• the system is disassembled.
• a brake hose is loosened, disconnected or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
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Page 75
BLEEDING THE HYDRAULIC BRAKE SYSTEM
NOTE:
TIP
• Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
• When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre­caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure.
• If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.
1. Bleed:
• hydraulic brake system
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylin-
der reservoir or brake fluid reservoir).
c. Connect a clear plastic hose tightly to
the bleed screw .
CHK
ADJ
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever or brake pedal
several times.
f. Fully squeeze the brake lever or fully depress
the brake pedal and hold it in position.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the pressure and cause the brake lever to contact the grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake fluid in the plastic hose.
j. Tighten the bleed screw to specification.
T
5 Nm (0.5 m • kg, 3.6 ft • Ib)
.
R
.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid. Refer to “CHECKING THE REAR BRAKE FLUID LEVEL”.
WARNING
After bleeding the hydraulic brake system, check the brake operation.
3 - 26
Page 76
CHECKING THE FINAL TRANSMISSION OIL/
რ
NOTICE
ADJUSTING THE DRIVE CHAIN SLACK
CHANGING THE FINAL TRANSMISSION OIL
1. Place the machine on a level surface.
2. Place a receptacle under the final transmission
case.
3. Remove:
• dipstick
• final transmission oil drain plug
4. Drain:
• final transmission oil
5. Install:
• final transmission oil drain plug
T
15 Nm (1.5 m • kg, 10.8 ft • Ib)
.
R
.
TIP
Check the gasket(drain plug). If it is damaged, replace it with a new one.
6. Fill:
• final transmission case
CHK
ADJ
Total amount
0.30 L (0.27 Imp qt, 0.32 US qt)
Recommended oil
SAE80 API“GL-4” Hypoid gear oil
NOTICE
რ
Take care not to allow foreign material to enter the final gear case.
7. Install:
• dipstick
ADJUSTING THE DRIVE CHAIN SLACK
TIP
• Measure the drive chain slack halfway
between the drive axle and the rear axle.
• When checking and adjusting the drive chain
slack, there should be no weight on the vehi­cle and all tires must be touching the ground.
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the speci­fied limits.
3 - 27
Page 77
ADJUSTING THE DRIVE CHAIN SLACK
1. Measure:
• drive chain slack
Out of specification ĺ Adjust.
Drive chain slack
10 ~ 25 mm (0.39 ~ 0.98 in)
2. Adjust:
• drive chain slack
a
CHK
ADJ
3
2
1
a
b
TIP
The drive chain slack is adjusted by the rota­tion of the rear axle hub.
a. Loosen the rear axle pinch bolts . b. Loosen the locknut .
c. To tighten the drive chain, turn the drive chain
adjusting nut in direction . To loosen the drive chain, turn the drive chain adjusting nut
3
in direction .
NOTICE
რ
Excessive chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
d. Tighten the locknut. e. Tighten the rear wheel axle pinch bolts.
TIP
The chain should be cleaned and lubricated after every use of the vehicle.
3
2
b
T
55 Nm (5.5 m • kg, 39.8 ft • Ib)
.
R
.
1
a
3 - 28
Page 78
CHECKING THE STEERING SYSTEM
CHECKING THE STEERING SYSTEM
1. Place the machine on a level surface.
2. Check:
• steering shaft bushings and bearings
Move the handlebar up and down, and/or back and forth. Excessive play ĺ Replace the steering shaft bushings and or bearings. Refer to “STEERING SYSTEM” in chapter
6.
3. Check:
• tie-rod ends
Turn the handlebar to the left and/or right until it stops completely, then slightly move the handlebar slightly in the opposite direction. Tie-rod end(s) have vertical play Replace the tie-rod end(s). Refer to “STEERING SYSTEM” in chapter
6.
4. Raise the front end of the machine so that
there is no weight on the front wheels.
5. Check:
•
ball joints and/or wheel bearings Move the wheels laterally back and forth. Excessive free play ĺReplace the front arms (upper and lower) and/or wheel bearings.
CHK
ADJ
ĺ
3 - 29
Page 79
ADJUSTING THE TOE-IN
WARNING
ADJUSTING THE TOE-IN
1. Place the machine on a level surface.
2. Measure:
• toe-in
Out of specification ĺ Adjust.
Toe-in
10 mm (0.40 in)
TIP
Before measuring the toe-in, make sure that the tire pressure is correct.
a. Mark both front tire tread centers. b. Face the handlebar straight ahead. c. Measure the width between the marks. d. Rotate the front tires 180° until the marks
are exactly opposite one another. e. Measure the width between the marks. f. Calculate the toe-in using the formula given
below.
CHK
ADJ
Toe-in = –
g. If the toe-in is incorrect, adjust it.
Forward
3. Adjust:
• toe-in
• Be sure that both tie-rods are turned the
same amount. If not, the machine will drift right or left even though the handlebar is positioned straight. This may lead to mis­handling and an accident.
• After setting the toe-in to specification,
run the machine slowly for some distance with both hands lightly holding the han­dlebar and check that the handlebar responds correctly. If not, turn either the right or left tie-rod within the toe-in speci­fication.
3 - 30
Page 80
ADJUSTING THE TOE-IN/ CHECKING THE FRONT AND
TIP
REAR SHOCK ABSORBERS
CHK
ADJ
˄
˄
˅
2
2
a. Mark both tie-rods ends.
This reference point will be needed during
adjustment. b. Loosen the locknuts (tie-rod end) of both
tie-rods. c. The same number of turns should be given
to both the right and left tie-rods until the
specified toe-in is obtained. This is to keep
the length of the rods the same. d. Tighten the rod end locknuts of both tie-
rods.
Adjust the rod ends so that A and B are equal.
CHECKING THE FRONT AND REAR SHOCK ABSORBERS
1. Place the machine on a level surface.
2. Check:
• damper rod
Bends/damage ĺ Replace the front/rear
shock absorber assembly.
• oil leakage
Excessive oil leakage ĺ Replace the front/
rear shock absorber assembly.
• cylinder
Damage ĺ the front/rear shock absorber
assembly.
• spring
Fatigue ĺ the front/rear shock absorber
assembly.
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” and
“REAR SHOCK ABSORBER, SWINGARM
AND DRIVE CHAIN” in chapter 6.
3. Check:
• operation Pump the shock absorbers up and down for several times. Unsmooth operation ĺ Replace the front/ rear shock absorber assembly. Refer to “ADJUSTING THE SHOCK ABSORBERS”.
Front shock absorber Rear shock absorber
T
35 Nm (3.5 m • kg, 25.3 ft • Ib)
.
R
.
3 - 31
Page 81
ADJUSTING THE SHOCK ABSORBERS
ADJUSTING THE SHOCK ABSORBERS
WARNING
Always adjust the spring preload of both front shock absorbers to the same setting. Uneven adjustment can result in poor han­dling and loss of stability.
CHK
ADJ
A
1
2
3
4
5
B
1
2
3
4
5
1. Adjust:
• spring preload
a. Turn the adjusting ring in direction or
b
with the spanner wrench
Spring preload is
Direction
Direction
Standard position: Front-2, Rear-1 Minimum position: 1 Maximum position: 5
A
Front shock absorbers
B
Rear shock absorbers
a
increased (suspension is harder).
Spring preload is
b
decreased (suspension is softer).
.
a
3 - 32
Page 82
CHK
WARNING
CHECKING THE TIRES
CHECKING THE TIRES
This model is equipped with low pressure tires. It is important that they be inflated correctly and maintained at the proper pressures.
• TIRE CHARACTERISTICS
1) Tire characteristics influence the han­dling of ATVs. The tires listed below have been approved by E-TON POWER TECH Co., Ltd. for this model. If other tire com­binations are used, they can adversely affect your machine’s handling charac­teristics and are therefore not recom­mended.
Manufacturer Size Type
Front MAXXIS
ADJ
AT18
7-8
x
M939
Rear MAXXIS
• TIRE PRESSURE
1) Recommended tire pressure Front 25 kPa (0.25 kgf/cm Rear 25 kPa (0.25 kgf/cm
2) Tire pressure below the minimum speci­fication could cause the tire to dislodge from the rim under severe riding condi­tions. The following are minimums: Front 22 kPa (0.22 kgf/cm Rear 22 kPa (0.22 kgf/cm
3) Use no more than Front 250 kPa (2.5 kgf/cm Rear 250 kPa (2.5 kgf/cm when seating the tire beads. Higher pressures may cause the tire to burst. Inflate the tires slowly and carefully. Fast inflation could cause the tire to burst.
• MAXIMUM LOADING LIMIT Vehicle load limits: 70.0 kg (154 lb) *Total weight of the cargo, trailer hitch vertical load, rider, and accessories.
AT18 x
9-8
2
, 3.6 psi)
2
, 3.6 psi)
2
, 3.2 psi)
2
, 3.2 psi)
2
, 36 psi)
2
, 36 psi)
M940
3 - 33
Page 83
CHK
WARNING
CHECKING THE TIRES
1. Measure:
• tire pressure
Out of specification ĺ Adjust.
TIP
• The low-pressure tire gauge is included
as standard equipment.
• If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.
ADJ
Cold tire
pressure
Standard
Minimum
Maximum
Uneven or improper tire pressure may adversely affect the handling of this machine and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
Front Rear
25 kPa
(0.25 kgf/cm
3.6 psi)
23 kPa
(0.23 kgf/cm
3.3 psi)
28 kPa
(0.28 kgf/cm
4.1psi)
2
,
2
,
2
,
25 kPa
(0.25 kgf/cm2,
3.6 psi)
23 kPa
(0.23 kgf/cm2,
3.3 psi)
28 kPa
(0.2 8 kgf/cm2,
4.1psi)
3 - 34
Page 84
CHECKING THE TIRES/
WARNING
CHECKING THE WHEELS
2. Check:
• tire surfaces
Wear/damage ĺ Replace.
CHK
ADJ
Tire wear limit
Front and rear: 3 mm (0.12 in)
WARNING
It is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately.
CHECKING THE WHEELS
1. Check:
• wheel
Damage/bends ĺ Replace.
a
TIP
Always balance the wheel when a tire or wheel has been changed or replaced.
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire
to allow it to seat itself properly on the rim.
3 - 35
Page 85
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE
TIP
LEVERS, STEERING SHAFT AND STEERING KNUCKLES
CHECKING AND LUBRICATING THE CABLES
WARNING
WARNING
A damaged cable sheath may cause corro­sion and interfere with the cable move­ment. An unsafe condition may result so replace a damaged cable as soon as possi­ble.
1. Check:
• cable sheath Damage ĺ Replace.
2. Check:
• cable operation Unsmooth operation ĺ Lubricate or replace.
CHK
ADJ
Recommended lubricant
Lithium-soap-base grease
Hold the cable end up and apply several drops of lubricant to the cable.
LUBRICATING THE LEVERS, STEERING SHAFT AND STEERING KNUCKLES
Lubricate the pivoting point and metal-to-metal moving parts of the levers, steering shaft and steering knuckles.
Recommended lubricant
Lithium-soap-base grease
3 - 36
Page 86
CHECKING AND CHARGING THE BATTERY
WARNING
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures:
• Wear protective eye gear when handling or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
• DO NOT SMOKE when charging or han­dling batteries.
• KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol­lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
CHK
ADJ
NOTICE
რ
• This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.
• Charging time, charging amperage and charging voltage for an VRLA (Valve Re­gulated Lead Acid) battery are different from those of conventional batteries. The VRLA (Valve Regulated Lead Acid) battery
should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
3 - 37
Page 87
CHECKING AND CHARGING THE BATTERY
TIP
რ
NOTICE
TIP
Since VRLA (Valve Regulated Lead Acid) batteries are sealed, it is not possible to check
the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
1. Remove:
• seat
• battery band Refer to “SEAT, FENDERS AND FUEL TANK”.
2. Disconnect:
• battery leads (from the battery terminals)
First, disconnect the negative battery lead
, and then the positive battery lead .
CHK
ADJ
3. Remove:
• battery
4. Check:
• battery charge
a. Connect a pocket tester to the battery ter-
minals.
Positive tester probe ĺ
positive battery terminal
Negative tester probe ĺ
negative battery terminal
Relationship betweenthe open-circuit voltage and the charging time at 20 °C (68 °F)
Open-circuit voltage (V)
These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
Charging time (hours)
•The charge state of an VRLA (Valve Regulated Lead Acid) battery can be checked by measur­ing its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
• No charging is necessary when the open-cir­cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown
in the charts and the following example.
3 - 38
Page 88
CHECKING AND CHARGING THE BATTERY
WARNING
რ
NOTICE
Example
c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30%
CHK
ADJ
Charging
18 17 16 15
14 13 12 11
Open-circuit voltage (V)
10
Ambient temperature 20°C (68°F)
10030
14 13
12
11
10
Open-circuit voltage (V)
100 75 50 30 25 20 0
Charging condition of the battery (%)
04050602
Check the open-circuit voltage.
Time (minutes)
Ambient temperature 20°C (68°F)
5. Charge:
• battery (refer to the appropriate charging method illustration)
Do not quick charge a battery.
• Never remove the VRLA (Valve Regulated Lead Acid) battery sealing caps.
• Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat­tery overheating and battery plate dam­age.
• If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.
• When charging a battery, be sure to remove it from the machine. (If charging has to be done with the battery mounted on the machine, disconnect the negative battery lead from the battery terminal.)
• To reduce the chance of sparks, do not plug in the battery charger until the bat­tery charger leads are connected to the battery.
• Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
• Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
• If the battery becomes hot to the touch at any time during the charging process, dis­connect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!
3 - 39
Page 89
CHECKING AND CHARGING THE BATTERY
• As shown in the following illustration, the open-circuit voltage of an VRLA (Valve Regulated Lead Acid) battery stabilizes
about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
CHK
ADJ
3 - 40
Page 90
CHECKING AND CHARGING THE BATTERY
TIP
TIP
Charging method using a variable-current (voltage) charger
Charger
Ammeter
CHK
ADJ
YES
Adjust the voltage to obtain the standard charging amper­age.
Measure the open-circuit voltage prior to charging.
Connect a charger and ammeter to the battery and start charging.
Is the amperage higher than the standard charg­ing amperage written on the battery?
Adjust the charging voltage to 20 ~ 25 V.
Monitor the amperage for 3 ~ 5
YES
minutes. Is the standard charg­ing amperage exceeded?
Leave the battery unused for more than 30 minutes before measuring its open­circuit voltage.
Set the charging voltage to 16~ 17V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.)
NO
NO
If the amperage does not
Set the timer to the charging time determined by the open­circuit voltage. Refer to “CHECKING AND CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.
Leave the battery unused for more than 30 minutes before measur­ing its open-circuit voltage.
12.8 V ĺ Charging is complete.
12.0 ~ 12.7 V ĺ Recharging is required. Under 12.0 V ĺ Replace the battery.
exceed the standard charg­ing amperage after 5 min­utes, replace the battery.
3 - 41
Page 91
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
CHK
ADJ
YES
Charge the battery until the charging voltage reaches 15 V.
TIP
Set the charging time to a maxi­mum of 20 hours.
Measure the open-circuit voltage prior to charging.
Connect a charger and ammeter to the battery and start charging.
Is the amperage higher than the standard charg­ing amperage written on the battery?
This type of battery charger cannot charge an VRLA battery. A variable­voltage charger is recommended.
TIP
Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.
NO
Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.
12.8 V ĺ Charging is complete.
12.0 ~ 12.7 V ĺ Recharging is required. Under 12.0 V ĺ Replace the battery.
NOTICE
რ
Constant amperage chargers are not
suitable for charging VRLA batteries.
Charger
Ammeter
Voltmeter
3 - 42
Page 92
CHECKING AND CHARGING THE BATTERY
6. Install:
• battery
7. Connect:
• battery leads (to the battery terminals)
NOTICE
რ
First, connect the positive battery lead , and then the negative battery lead .
8. Check:
• battery terminals Dirt ? Clean with a wire brush. Loose connection ĺ Connect properly.
9. Lubricate:
• battery terminals
CHK
ADJ
Recommended lubricant
Dielectric grease
10.Install:
• battery band
• seat Refer to “SEAT, FENDERS AND FUEL TANK”.
3 - 43
Page 93
CHK
CHECKING THE FUSES
CHECKING THE FUSES
The following procedure applies to all of the fuses.
NOTICE
რ
To avoid a short circuit, always set the main switch to “OFF” when checking or replac­ing a fuse.
1.Remove:
• seat
Refer to “SEAT, FENDERS AND FUEL TANK”.
ADJ
2.Check:
• fuse
a. Connect the pocket tester to the fuse and
check the continuity.
TIP
Set the pocket tester selector to “x 1”.
b.If the pocket tester indicates “•”, replace the
fuse.
3.Replace:
• blown fuse
a.Set the main switch to “OFF”. b.Install a new fuse of the correct amperage. c.Set on the switches to verify if the electrical
circuit is operational.
d.If the fuse immediately blows again, check
the electrical circuit.
3 - 44
Page 94
CHECKING THE FUSES
WARNING
CHK
ADJ
Items
Main 7A
Reserve
Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat­ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
4. Install:
• seat Refer to “SEAT, FENDERS AND FUEL TANK”.
Amperage
rating
7A 1
Q’ty
1
3 - 45
Page 95
ENGINE
ENGINE
EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS
ENGINE
ENG
T
13 Nm (1.3 m • kg, 9.4 ft • lb)
.
R
.
3
4
5
1
T
25 Nm (2.5 m • kg, 18 ft •
.
R
.
2
4
Order Job/Part Q’ty Remarks
Removing the exhaust pipe/muffler, breather hose and leads
Rear fender Refer to “SEAT, FENDERS AND FUEL
1 Cover,chain case 1 1
2 Exhaust pipe/muffler 1 3 Exhaust pipe gasket 1 4 Spark plug lead 1 5 Generator lead 2
Remove the parts in the order listed.
TANK” in chapter 3.
For installation, reverse the removal pro­cedure.
4 - 1
Page 96
ENGINE MOUNTING BOLTS
რ
NOTICE
2
3
ENGINE
T
T
35 Nm (3.5 m • kg, 25.3 ft • Ib)
35 Nm (3.5 m • kg, 25.3 ft • Ib)
.
.
R
R
.
.
ENG
4
1
T
35 Nm (3.5 m • kg, 25.3 ft • Ib)
.
R
.
Order Job/Part Q’ty Remarks
Removing the engine mounting
Remove the parts in the order listed.
bolts
Carburetor Refer to “CARBURETOR” in chapter 5.
1 Drive chain 1
Refer to “REMOVING THE ENGINE”.
2 Lower engine mounting nut/bolt 1/1
3 Upper engine mounting nut/bolt 1/1
Refer to “INSTALLING THE ENGINE”.
4 Engine assembly 1
Install all of the bolts/nuts and then tighten them to full torque specifica­tions.
3
2
For installation, reverse the removal pro­cedure.
4 - 2
Page 97
ENGINE
REMOVING THE ENGINE
1. Remove:
• master link
• drive chain
INSTALLING THE ENGINE
1. Install:
1
• upper engine mounting bolt/nut
• lower engine mounting bolt/nut
TIP
Do not fully tighten the bolts and nuts.
ENG
2
2. Tighten:
• upper engine mounting nut
T
35 Nm (3.5 m • kg, 25.3 ft • Ib)
.
R
.
• lower engine mounting nut
T
35 Nm (3.5 m • kg, 25.3 ft • Ib)
.
R
.
3. Install:
• drive chain
• master link
TIP
The master link clip must be installed with the rounded end facing the direction of travel.
4 - 3
Page 98
CYLINDER HEAD
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
T
11 Nm (1.1 m • kg, 8.0 ft • Ib)
.
R
.
CYLINDER HEAD
T
6 Nm (0.6 m • kg, 4.3 ft • Ib)
.
R
.
ENG
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
.
R
.
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
T
15 Nm (1.5 m • kg, 10.8 ft • Ib)
.
R
.
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
Order Job/Part Q’ty Remarks
Removing the cylinder head
Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETOR” in chapter 5. Exhaust pipe/muffler Refer to “ENGINE”.
1 Spark plug lead 1
2 Spark plug 1
3 Lifter comp tensioned 1
4 Gasket, lifter tensioned 1
5 Carb. rubber cap
1
6 Pipe assy, inlet 1
7 Insulator carburetor 1
8 Gasket, carb. insulator 1
9 Gasket exhaust pipe 1
4 - 4
Page 99
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
T
11 Nm (1.1 m • kg, 8.0 ft • Ib)
.
R
.
CYLINDER HEAD
T
6 Nm (0.6 m • kg, 4.3 ft • Ib)
.
R
.
ENG
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
10 Nm (1.0 m • kg, 7.2 ft • Ib)
.
R
.
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
T
9 Nm (0.9 m • kg, 6.5 ft • Ib)
.
R
.
T
15 Nm (1.5 m • kg, 10.8 ft • Ib)
.
R
.
T
12 Nm (1.2 m • kg, 8.7 ft • Ib)
.
R
.
Order Job/Part Q’ty Remarks
10 Cover assy head cylinder 1
11 Holder cam shaft 1
12 Pin, dowel 4
Refer to “REMOVING THE CYLINDER HEAD” and “INSTALLING THE CYLIN­DER HEAD”.
13 Cam shaft comp. 1
14 Head comp cylinder 1
15 Gasket cylinder head 1
16 Guide cam chain 1
17 Guide tension cam chain 1
For installation, reverse the removal procedure.
4 - 5
Page 100
CYLINDER HEAD
TIP
TIP
REMOVING THE CYLINDER HEAD
1. Align:
• “T” mark on the rotor (with the stationary pointer on the crank­case)
a. Turn the crankshaft clockwise with a wrench.
b. Align the “T” mark on the rotor with the
stationary pointer on the crankcase. When the “T” mark is aligned with the sta­tionary pointer, the piston is at Top Dead Center (TDC).
TDC on compression stroke check:
• Both rocker arms must have a valve clear­ance when the camshaft sprocket alignment mark is aligned with the cylinder head alignment mark camshaft sprocket away from the cylinder he-
ad.
• If not, give the crankshaft one counterclock­wise turn to meet the above condition.
, and the round hole in
ENG
2.Remove:
bolt, flg. (small head)
•
•
cover assy head cylinder
•
nut flange
•
pipe assy, inlet
•
nut flange
•
washer
•
holder cam shaft
• Working in a crisscross pattern, loosen each nut 1/4 of a turn.
bolt, flg. (small head)
•
lifter comp tensioned
•
4 - 6
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