E-TON Yukon II, ATV3U 150, Challenger 150 Service Manual

E-TON POWER

ATV3U 150

YUKON II (U.S.)

CHALLENGER 150 (EUR)

SERVICE MANUAL

2009 by E-TON POWER TECH CO., LTD.

Any reproduction or unauthorized use

Yukon II & Challenger 150

SERVICE MANUAL

First edition, October 2009

All rights reserved.

without the written permission of

E-TON POWER TECH CO., LTD.

is expressly prohibited.

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.

HOW TO USE THIS MANUAL

New

New

1

2

1

2

New

1

1

1

TIP

1

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.

CARBURETOR

9

8

11

Order Job/Part Q’ty Remarks

Carb chamber

10
11

Float pin 1

12

Pilot jet

13
14

Main jet 1
Needle jet holder 1

15

Needle jet 1

16
17

Needle valve assy 1

6

16

13

15

17

14

12

10

(x4)

1

1Float
1

1

3

7

For assembly, reverse the disassembly
procedure.

CARB

(x4)

CARBURETOR

DISASSEMBLING THE CARBURETOR

Before disassembling the carburetor, make sure
to note the number of times the air adjusting
screw is turned out from the seated position to

2

4

5

its set position.

CHECKING THE CARBURETOR

1. Check:

• carburetor body

• float chamber

Cracks/damage → Replace.

• fuel passages

Obstruction → Clean.

• float chamber body

Dirt → Clean.

• float chamber rubber gasket

*****************************************************

a. Wash the carburetor in a petroleum-based

solvent. Do not use any caustic carburetor
cleaning solution.

b. Blow out all of the passages and jets with

compressed air.

*****************************************************

2. Check:

• float

Damage → Replace.

3. Check:

• needle valve

Damage/obstruction/wear → Replace.

5 - 45 - 3

CARB

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 (Ω, 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

New

Symbols to in the exploded diagrams
indicate where to apply a locking agent and
when to install a new part .

®

Apply the locking agent (LOCTITE
Replace

)

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

ENGINE

1

2

3

4

CARBURETOR

CHASSIS

ELECTRICAL

TROUBLESHOOTING

5

6

–+

7

8

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

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

.................................................2-17

..............................2-17

....................................2-18

ENGINE...................................................................................................2-18

OIL FLOW DIAGRAMS

CABLE ROUTING

.................................................................................2-20

.........................................................................................2-21

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION ...........................................................................................3-1

PERIODIC MAINTENANCE CHART FOR THE

...................................................................3-1EMISSION CONTROL SYSTEM

GENERAL MAINTENANCE AND LUBRICATION CHART

RACKS, SEAT, FENDERS AND FUEL TANK ............................................ 3-3

RACKS, SEAT AND FRONT PANEL
FRONT FENDER
REAR FENDER, FOOTREST BOARDS BETTERY AND C.D.I UNIT

FUEL TANK AND FOOTREST BARS.....................................................3-6

ENGINE .........................................................................................................3-7

ADJUSTING THE VALVE CLEARANCE ................................................3-7

ADJUSTING THE ENGINE IDLING SPEED ...........................................3-8

ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-9

ADJUSTING THE SPEED LIMITER........................................................3-10

CHECKING THE SPARK PLUG .............................................................3-11

CHECKING THE IGNITION TIMING.......................................................3-12

MEASURING THE COMPRESSION PRESSURE..................................3-13

CHECKING THE ENGINE OIL LEVEL....................................................3-14

CHANGING THE ENGINE OIL ...............................................................3-16

CLEANING THE AIR FILTER ELEMENTS..............................................3-17

CLEANING THE SPARK ARRESTER .................................................... 3-18

....................................................................................3-4

.....................................................3-3

..........................3-1

.....3-5

CHASSIS .......................................................................................................3-19

CHECKING THE FRONT BRAKE SHOES..............................................3-19

ADJUSTING THE FRONT BRAKE..........................................................3-19

CHECKING THE REAR BRAKE FLUID LEVEL......................................3-20

CHECKING THE REAR BRAKE PADS...................................................3-21

CHECKING THE BRAKE HOSE..............................................................3-21

BLEEDING THE HYDRAULIC BRAKE SYSTEM....................................3-21

CHANGING THE FINAL TRANSMISSION OIL.......................................3-23

ADJUSTING THE DRIVE CHAIN SLACK................................................3-23

CHECKING THE STEERING SYSTEM...................................................3-24

ADJUSTING THE TOE-IN.......................................................................3-25

CHECKING THE FRONT AND REAR SHOCK ABSORBERS ...............3-27

ADJUSTING THE SHOCK ABSORBERS...............................................3-28

CHECKING THE TIRES..........................................................................3-28

CHECKING THE WHEELS ..................................................................... 3-30

CHECKING AND LUBRICATING THE CABLES ....................................3-31

LUBRICATING THE LEVERS, STEERING SHAFT

AND STEERING KNUCKLES .................................................................3-31

ELECTRICAL SYSTEM.................................................................................3-32

CHECKING AND CHARGING THE BATTERY.......................................3-32

CHECKING THE FUSES.........................................................................3-38

CHAPTER 4

ENGINE

ENGINE

CYLINDER HEAD

CAMSHAFT, ROCKER ARMS AND VALVES

..........................................................................................................4-1

EXHAUST PIPE/MUFFLER, CABLES 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 ..................................................... 4-8

..............................................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 ..............................4-18

INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................4-19

CYLINDER AND PISTON

REMOVING THE PISTON .......................................................................4-21

CHECKING THE CYLINDER AND PISTON ........................................... 4-21

CHECKING THE PISTON RINGS............................................................4-23

CHECKING THE PISTON PIN................................................................4-24

INSTALLING THE PISTON.....................................................................4-24

INSTALLING THE CYLINDER ................................................................ 4-25

C.D.I. MAGNETO

REMOVING THE C.D.I. MAGNETO ROTOR .........................................4-27

CHECKING THE PICKUP COIL/STATOR ASSEMBLY.......................... 4-27

INSTALLING THE C.D.I. MAGNETO ROTOR........................................4-27

BELT DRIVE...................................................................................................4-28

CRANKCASE COVER..............................................................................4-28

KICKSTARTER........................................................................................4-29

INSTALLING THE KICKSTARTER..........................................................4-30

V-BELT, CLUTCH, DRIVE AND DRIVEN PULLEY.................................4-31

............................................................................................4-26

..............................................................................4-20

DISASSEMBLING THE SECONDARY SHEAVE....................................4-32

REMOVING THE PRIMARY SHEAVE.................................................... 4-33

REMOVING THE SECONDARY SHEAVE AND V-BELT........................4-33

DISASSEMBLING THE SECONDARY SHEAVE....................................4-34

CHECKING THE CLUTCH SHOE...........................................................4-34

CHECKING THE V-BELT........................................................................4-34

CHECKING THE DRIVE PULLEY...........................................................4-35

CHECKING THE PRIMARY ROLLER WEIGHTS...................................4-35

CHECKING THE PIECE SLIDER............................................................4-35

CHECKING THE DRIVEN PULLEY........................................................4-35

ASSEMBLING THE PRIMARY SHEAVE................................................ 4-36

ASSEMBLING THE SECONDARY SHEAVE..........................................4-37

INSTALLING THE BELT DRIVE..............................................................4-38

STARTER CLUTCH AND STARTER MOTOR ............................................4-39

CHECKING THE STARTER WHEEL GEAR...........................................4-40

OIL PUMP .....................................................................................................4-41

REMOVING THE OIL PUMP....................................................................4-42

CHECKING THE OIL PUMP....................................................................4-43

INSTALLING THE OIL PUMP..................................................................4-44

CRANKCASE AND CRANKSHAFT ............................................................4-45

SEPARATING THE CRANKCASE..........................................................4-46

REMOVING THE CRANKSHAFT ASSEMBLY........................................4-46

CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES...........4-46

CHECKING THE CRANKSHAFT AND CONNECTING ROD..................4-47

INSTALLING THE CRANKSHAFT.......................................................... 4-48

ASSEMBLING THE CRANKCASE..........................................................4-48

TRANSMISSION ..........................................................................................4-49

TRANSMISSION.....................................................................................4-49

SHIFT SHAFT..........................................................................................4-50

CHECKING THE SHIFT FORK...............................................................4-51

CHECKING THE DRUM COMP GEAR SHIFT.......................................4-51

CHECKING THE TRANSMISSION.........................................................4-51

REMOVING THE GEAR SET..................................................................4-52

CHECKING THE GEAR SET..................................................................4-53

INSTALLING THE GEAR SET................................................................4-54

CHAPTER 5

CARBURETOR

CARBURETOR

DISASSEMBLING THE CARBURETOR...................................................5-4

CHECKING THE CARBURETOR .............................................................5-4

ASSEMBLING THE CARBURETOR.........................................................5-6

INSTALLING THE CARBURETOR ...........................................................5-6

MEASURING AND ADJUSTING THE FUEL LEVEL ................................5-7

................................................................................................5-1

CHAPTER 6

CHASSIS

FRONT AND REAR WHEELS

FRONT WHEELS ....................................................................................

REAR WHEELS ......................................................................................

CHECKING THE WHEELS .....................................................................

CHECKING THE FRONT WHEEL HUBS ...............................................

CHECKING THE REAR WHEEL HUBS..................................................

INSTALLING THE WHEEL HUBS...........................................................

INSTALLING THE FRONT WHEELS......................................................

INSTALLING THE REAR WHEELS........................................................

FRONT BRAKES ..........................................................................................

FRONT BRAKE S ....................................................................................

REMOVING THE FRONT BRAKES .......................................................

CHECKING THE FRONT BRAKE SHOE PLATES ................................

CHECKING THE FRONT BRAKE SHOES...............................................

CHECKING THE FRONT BRAKE DRUMS .............................................

INSTALLING THE FRONT BRAKES ......................................................

......................................................................

6-1
6-1
6-2
6-3
6-3
6-4
6-4
6-5
6-5

6-6
6-6
6-7
6-7
6-7
6-8
6-8

REAR AXLE AND REAR AXLE HUB

REAR AXLE AND REAR AXLE HUB......................................................

REMOVING THE REAR AXLE...............................................................

CHECKING THE REAR AXLE...............................................................

CHECKING THE DRIVEN SPROCKET..................................................

CHECKING THE BRAKE DISC................................................................

INSTALLING THE DRIVEN SPROCKET.................................................

INSTALLING THE REAR AXLE...............................................................

REAR BRAKE ...............................................................................................

REAR BRAKE CALIPER.........................................................................

CHECKING THE REAR BRAKE CALIPER.............................................

INSTALLING THE REAR BRAKE CALIPER...........................................

REPLACING THE REAR BRAKE PADS.................................................

REAR BRAKE MASTER CYLINDER......................................................

CHECKING THE MASTER CYLINDER...................................................

ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................

INSTALLING THE REAR BRAKE MASTER CYLINDER.........................

...........................................................

6-10
6-10
6-12
6-12
6-12

6-13
6-13
6-13

6-14
6-14
6-15
6-15
6-17
6-19
6-20
6-20
6-20

STEERING SYSTEM ..................................................................................... 6-23

HANDLEBAR...........................................................................................6-23

REMOVING THE HANDLEBAR GRIPS..................................................6-25

REMOVING THE REAR BRAKE SWITCH .............................................6-25

CHECKING THE HANDLEBAR ..............................................................6-25

INSTALLING THE HANDLEBAR ............................................................6-26

INSTALLING THE HANDLEBAR GRIPS ................................................ 6-26

INSTALLING THE REAR BRAKE MASTER CYLINDER........................ 6-27

INSTALLING THE FRONT BRAKE LEVER ASSEMBLY........................6-27

STEERING STEM ................................................................................... 6-28

REMOVING THE STEERING STEM ......................................................6-29

CHECKING THE STEERING STEM .......................................................6-29

INSTALLING THE LOWER HANDLEBAR HOLDER...............................6-29

INSTALLING THE STEERING STEM.....................................................6-30

INSTALLING THE LOCK WASHER........................................................6-30

TIE-RODS AND STEERING KNUCKLES ...............................................6-31

REMOVING THE TIE-RODS...................................................................6-32

REMOVING THE STEERING KNUCKLES..............................................6-32

CHECKING THE TIE-RODS ................................................................... 6-32

CHECKING THE STEERING KNUCKLES..............................................6-32

INSTALLING THE TIE-RODS ................................................................. 6-33

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES............. 6-34

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES..........................................................................................6-34

REMOVING THE FRONT ARMS............................................................. 6-35

CHECKING THE FRONT ARMS.............................................................6-35

CHECKING THE FRONT SHOCK ABSORBERS...................................6-35

CHECKING THE BALL JOINTS..............................................................6-36

INSTALLING THE FRONT ARMS............................................................6-36

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN..................6-37

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN............. 6-37

REMOVING THE REAR SHOCK ABSORBER........................................6-39

CHECKING THE REAR SHOCK ABSORBER........................................6-39

REMOVING THE SWINGARM................................................................6-39

CHECKING THE SWINGARM.................................................................6-40

CHECKING THE DRIVE CHAIN..............................................................6-40

INSTALLING THE DRIVE SPROCKET...................................................6-41

INSTALLING THE DRIVE CHAIN............................................................6-41

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS

WIRING DIAGRAM .........................

CHECKING SWITCH CONTINUITY

CHECKING THE SWITCHES

CHECKING THE BULBS AND BULB SOCKETS

TYPES OF BULBS.....................................................................................7-5

CHECKING THE CONDITION OF THE BULBS........................................7-6

CHECKING THE CONDITION OF THE BULBS SOCKETS......................7-6

IGNITION SYSTEM

CIRCUIT DIAGRAM .................................................................................. 7-7

TROUBLESHOOTING ..............................................................................7-8

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM .................................................................................. 7-11

STARTING CIRCUIT OUT-OFF SYSTEM OPERATION...........................7-12

TROUBLESHOOTING ..............................................................................7-13

.........................................................................................7-7

........................................................................7-1

................................................................7-2

.............................................................7-3

........................................................................7-4

..........................................7-5

....................................................................7-11

STARTER MOTOR

REMOVING THE STARTER MOTOR.......................................................7-16

CHECKING THE STARTER MOTOR ....................................................... 7-16

ASSEMBLING THE STARTER MOTOR...................................................7-17

CHARGING SYSTEM

CIRCUIT DIAGRAM .................................................................................. 7-18

TROUBLESHOOTING ..............................................................................7-19

LIGHTING SYSTEM

CIRCUIT DIAGRAM ..................................................................................7-21

TROUBLESHOOTING ..............................................................................7-22

CHECKING THE LIGHTING SYSTEM......................................................7-23

SIGNALING SYSTEM

CIRCUIT DIAGRAM ..................................................................................7-25

TROUBLESHOOTING ..............................................................................7-26

CHECKING THE SIGNALING SYSTEM....................................................7-27

AUTO CHOKE SYSTEM

CIRCUIT DIAGRAM .................................................................................. 7-32

TROUBLESHOOTING ..............................................................................7-33

..........................................................................................7-15

......................................................................................7-18

........................................................................................7-21

.....................................................................................7-25

................................................................................7-32

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

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

MACHINE IDENTIFICATION

GEN

INFO

1

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped
into the front side of the frame.

ENGINE SERIAL NUMBER

The engine serial number is stamped on the
engine.

1

1

1

1

1 - 1

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

IMPORTANT INFORMATION

რ

NOTICE

1

1

1

1

2

1

2

1

1

1

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

3

4

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.

4

Shaft

3

1 - 3

IMPORTANT INFORMATION

TIP

TIP

TIP

1

1

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.

3. Check:

• all connections
Loose connection → Connect properly.

GEN

INFO

If the pin 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)

• 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

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

GENERAL SPECIFICATIONS

SPEC

Model code

YUKON II (U.S.) CHALLENGER 150 (EUR)

Dimensions

Overall length 1730 mm (68.1 in)
Overall width 980 mm (38.6 in)
Overall height 1070 mm (42.1 in)
Seat height 760 mm (29.9 in)
Wheelbase 1115 mm (43.9 in)
Minimum ground clearance 160 mm (6.3 in)
Minimum turning radius 2540 mm (100.0 in)

Basic weight

With oil and full fuel tank 179.4 kg (395.51 lb)

Engine

Engine type Liquid cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 149.5 cm (9.12 cu.in)
Bore x stroke

57.4 x 57.8 mm (2.26 x 2.28 in)

3

Compression ratio 9.7 : 1
Standard compression pressure (at sea level) 1250 kPa

(12.5 kg/cm

2

, 181.3 psi) at 1,000r/min

Electric starter & kick starterStarting system

2

Lubrication system

Wet sump

Oil type or grade

Engine oil

10 30

0

-20

-10 0

SAE 10W-40

SAE 10W-30

SAE 5W-30

50

SAE 15W-40

10

90

70

SAE 20W-50

30 40 50 C

20

110

130 F

SAE5W-30 or SAE 10W-30 or SAE10W-40 or
SAE15W-40 or SAE 20W-40 or SAE 20W-50

Final transmission oil SAE 80W-90 gear oil

Oil capacity

Engine oil

Periodic oil change 0.90 L (0.79 Imp qt, 0.95 US qt)
Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)

Transmission oil

Periodic oil change 0.70 L (0.62 Imp qt, 0.74 US qt)
Total amount 0.75 L (0.66 Imp qt, 0.79 US qt)

Air filter

Wet element

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Fuel

Type Unleaded gasoline only
Fuel tank capacity plastic 6.5 L (1.43 lmp gal, 1.71 US gal)

Fuel reserve amount plastic

Carburetor

Type/quantity CVEK-019 x 1/USAǴCVEK-008 x 1/EUR
Manufacturer KEI HIN

Spark plug

Type/manufacturer NGK/C7HSA
Spark plug gap

Clutch type Dry, centrifugal automatic
Transmission

Primary reduction system V-belt
Primary reduction ratio 2.50-1.0 :1
Secondary reduction system Spur gear
Secondary reduction ratio 36/14×40/15 (6.857)

Transmission type V-belt automatic

1.0 L (0.22 Imp gal, 0.26 US gal)

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

SPEC

Chassis

Frame type Steel tube frame
Toe-in (with tires touching the ground)

Tire

Type
Size

Manufacturer

Type front C9207

Tire pressure (cold tire)

Maximum load* 105 kg (231.49 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

front AT21
rear AT22
front MAXXIS
rear MAXXIS

rear C9209

rear 23 ~ 28 kPa (0.23 ~ 0.28 kgf/cm, 3.3 ~ 4.1 psi)

10 ~ 15 mm (0.39 ~ 0.59 in)

Tubeless

x

7-10

x

10-10

2
2

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Brake

Front brake type

operation Right hand operation

Rear brake type

operation Left hand operation

Suspension

Front suspension Leading arm
Rear suspension Swing arm

Shock absorber

Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper

Electrical

Ignition system DC-CDI
Generator system AC magneto
Battery type Lead-Acid
Battery capacity 12 V / 8.0 Ah

Headlight type Bulb
Bulb voltage wattage /wattage × quantity

Headlight 12 V 20 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Indicator lights

Neutral
Forward
Reverse

Drum brake

Single disc brake

12V, 50mA, 0.6W × 1
12V, 50mA, 0.6W × 1
12V, 50mA, 0.6W × 1

SPEC

2 - 3

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Warp limit 0.05 mm

Cylinder

Bore size 57.400 ~ 57.410 mm

Taper limit ----

Maximum out-of-round ---- 0.10 mm

Camshaft

Drive method Chain drive (Left) ---­Cam dimensions

13.7 ~14.1 cm

(2.2598 ~ 2.2602 in)

3

(0.002 in)

57.50 mm
(2.2638 in)

0.10 mm
(0.0039 in)

(0.0039 in)

A

B

Intake “A” 29.745 ~ 29.845 mm

(1.1711 ~ 1.1750 in)

“B” 25.185 ~ 25.215 mm

(0.9915 ~ 0.9927 in)

Exhaust “A” 29.510 ~ 29.610 mm

(1.1618 ~ 1.1657 in)

“B” 25.185 ~ 25.215 mm

(0.9915 ~ 0.9927 in)

Camshaft runout limit ---- 0.03 mm

Timing chain

Timing chain type/No. of links KMC 92 RH 2005 / 94 ---­Timing chain adjustment method Automatic ----

29.645 mm
(1.1671 in)

25.076 mm
(0.9872 in)

29.410 mm
(1.1578 in)

25.076 mm
(0.9872 in)

(0.0012 in)

2 - 4

ENGINE SPECIFICATIONS

Item Standard Limit

Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000 ~ 10.018 mm

(0.3937 ~ 0.3944 in)

Rocker arm shaft outside diameter

Rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.046 mm

Valve, valve seat, valve guide

Valve clearance (cold) IN 0.07 mm

EX 0.07 mm

Valve dimensions

9.972 ~ 9.987 mm
(0.3926 ~ 0.3932 in)

(0.0005 ~ 0.0018 in)

(0.003 in)

(0.003 in)

SPEC

10.100 mm
(0.3976 in)

9.910 mm
(0.3902 in)

0.190 mm
(0.0075 in)

----

----

B

A

Head Diameter Face Width Seat Width Margin Thickness

“A” head diameter ----

IN 27.4 ~ 27.6 mm

C

(1.0787 ~ 1.0866 in)

EX 23.4 ~ 23.6 mm

(0.9213 ~ 0.9291 in)

“B” face width ----

IN 1.00 ~ 1.40 mm

(0.0394 ~ 0.0551 in)

EX 1.00 ~ 1.40 mm

(0.0394 ~ 0.0551 in)

“C” seat width

IN 0.70 ~ 1.00 mm

(0.0276 ~ 0.0394 in)

EX 0.70 ~ 1.00 mm

(0.0276 ~ 0.0394 in)

“D” margin thickness

IN 0.55 ~ 0.85 mm

(0.0217 ~ 0.0335 in)

EX 0.95 ~ 1.25 mm

(0.0374 ~ 0.0492 in)

Stem outside diameter

Guide inside diameter

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)

4.900 mm
(0.1930 in)

4.900 mm
(0.1930 in)

5.030 mm
(0.1980 in)

5.030 mm
(0.1980 in)

D

----

----

----

----

----

----

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.030 ~ 0.057 mm

(0.0012 ~ 0.0022 in)

Stem runout limit ---- 0.02 mm

Valve seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

Valve spring

Inner spring

Free length IN 32.3 mm (1.27 in) 29.3 mm

EX 32.3 mm (1.27 in) 29.3 mm

Compressed pressure
(installed) IN 33.55 ~ 41.00 N at 26.00 mm

(3.42 ~ 4.18 kg,

7.54 ~ 9.21 lb at 1.0236 in)

EX 33.55 ~ 41.00 N at 26.00 mm

(3.99 ~ 4.87 kg,

7.54 ~ 9.21 lb at 1.0236 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)

(1.15 in)

(1.15 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 35.00 mm (1.38 in) 32.00 mm

(1.26 in)

EX 35.00 mm (1.38in) 32.00 mm

(1.26 in)

2 - 6

ENGINE SPECIFICATIONS

SPEC

LimitStandardItem

Compressed pressure

installed)

Tilt limit

Direction of winding

Piston

Piston to cylinder clearance 0.005 ~ 0.035 mm

Piston size “D”

IN

EX

IN

EX

IN(top view)

82.10 ~ 100.40 N at 29.00 mm
(8.37 ~ 10.23 kg,

18.45 ~ 22.56 lb at 1.1417 in)

82.10 ~ 100.40 N at 29.00 mm
(8.37 ~ 10.23 kg,

18.45 ~ 22.56 lb at 1.1417 in)

Clockwise

57.375 ~ 57.395 mm
(2.2589 ~ 2.2596 in)

----

----

°/

1.2

2.0

(

2.0

2.0°/1.2 mm

(

2.0

0.10 mm
(0.0039 in)(0.0002 ~ 0.0013 in)

mm

°/0.05 in)

°/0.05 in)

----Clockwise

----EX

D

Measuring point “H”

Piston off-set

Piston pin bore inside diameter 15.002 ~ 15.008 mm

Piston pin outside diameter 14.994 ~ 15.000 mm

H

5.0 mm (0.20 in)

----0.5 mm (0.02 in)

----Intake sidePiston off-set direction

15.040 mm

(0.5906 ~ 0.5909 in)

(0.5903 ~ 0.5906 in)

(0.5921 in)

14.960 mm
(0.5890 in)

2 - 7

Piston rings

Top ring

ENGINE SPECIFICATIONS

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

Barrel

1.00 × 2.30 mm

----

----

(0.0394 × 0.0906 in)

0.15 ~ 0.30 mm
(0.0059 ~ 0.0118 in)

0.015 ~ 0.055 mm
(0.0006 ~ 0.0022 in)

B

T

0.45 mm
(0.0177in)

0.09 mm
(0.0035in)

----Taper

1.00 × 2.40 mm

----

(0.0394 × 0.0945in)

0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)

0.015 ~ 0.055 mm
(0.0006 ~ 0.0021 in)

B

T

2.00 × 2.20 mm

0.60mm
(0.0236 in)

0.09mm
(0.0035 in)

----

(0.0787 × 0.0866 in)

0.20 ~ 0.80 mm
(0.0079 ~ 0.0315 in)

0.40mm
(0.0157 in)

C1

A

Crank width 45.00 ~ 45.05 mm

A

”

“

Big end side clearance “D” 0.10 ~ 0.30mm

Big end radial clearance “E” 0.004 ~ 0.014 mm

C2

E

E

D

----

(1.7717 ~ 1.7736 in)

0.04 mm----Runout limit C1
(0.0016 in)

0.04 mm----C2
(0.0016 in)

0.50 mm

(0.0039 ~ 0.0118 in)

(0.0197 in)

----

(0.0001 ~ 0.0006 in)

2 - 8

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

I. D. mark

Main jet

(A.J)

(P.J)
Valve seat size
Fuel level

(V.S)

(F.L)

32.0 mm (1.2598 in)

124.9 ~ 125.1 mm
(4.9173 ~ 4.9252 in)

168.9 mm (6.6496 in)

17.9 ~ 18.1 mm
(0.7047 ~ 0.7126 in)

1360 ~ 1540 r/min
1760 ~ 2040 r/min

20.0 mm (0.7874 in)

V-belt automatic

2.50 - 1.00 :1

36/13 × 40/15 (7.38)

CVEK-019 (USA/CAN)
CVEK-008 (EUR)

#108 (USA/CAN)

#104 (EUR)

#90
N9RA (USA/CAN)

4HGCG (EUR)

2.1 H5.5
#35

2.0

18.8 mm (0.7402 in)

Below the float chamber mating
Surface

1,600 ~ 1,800 r/min

SPEC

LimitStandardItem

----

0 mm.2

(0.0787 in)

----

125.5 mm
(4.9409 in)

164.0 mm
(6.4567 in)

19.0 mm

(0.7480 in)

0.08 mm

(0.0031in)

0.08 mm

(0.0031in)

----

----

----(M.J)

----

----Air jet

----(J.N)Jet needle

----

----(N.J)Needle jet

----Pilot jet

----

----

----

----Engine idle speed

2 - 9

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

0.00 ~ 0.15mm
(0.0000 ~ 0.0059 in)

0.15 ~ 0.21 mm
(0.0059 ~ 0.0083 in)

0.05 ~ 0.10 mm
(0.0020 ~ 0.0039 in)

SPEC

LimitStandardItem

----TrochoidOil pump type

0.15 mm
(0.0059 in)

0.25 mm
(0.0098 in)

0.17 mm
(0.0067 in)

Piston

Crankshaft
pin

Piston pin

Oil pump

Oil strainer

Camshaft

Rocker arm

Timing
chain area

Valve

2 - 10

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Front suspension

Shock absorber travel 50 mm (1.97 in) ----

Fork spring free length 175 mm (6.89 in)
Spring rate 3.0±0.30 kgf/mm

Rear suspension

Shock absorber travel 85 mm (3.35 in) ----

Spring free length 235 mm (9.25 in)
Spring rate 3.0±0.30 kgf/mm

Front wheel

Type Panel wheel ---­Rim size 10 x 5.5 AT ---­Rim material Steel ---­Rim runout limit radial 2.0 mm

Rear wheel

Type Panel wheel ---­Rim size ---­Rim material Steel ---­Rim runout limit radial 2.0 mm

Drive chain

(K )

1

(K )

2

(K )

1

(K )

2

4.0±0.40 kgf/mm

3.6±0.38 kgf/mm

---­(0.08 in)

lateral 2.0 mm

---­(0.08 in)

10 x 8 AT

---­(0.08 in)

lateral 2.0 mm

---­(0.08 in)

Type/ manufacturer #520/ KMC
Link quantity 78

Front drum brake

Type
Brake drum inside diameter

Lining thickness

Shoe spring free length

Leading, trailing

110.5 mm (4.35 in)

4.0 mm (0.16 in)

60.0 mm (2.36 in)

2 - 11

----

111.5 mm
(4.39 in)

1.5 mm
(0.06 in)

----

CHASSIS SPECIFICATIONS

Item Standard Limit

Rear disc brake

Type
Disc outside diameter × thickness

Brake disk maximum deflection 0.25 mm

Pad thickness inner 6.2 mm (0.24 in)
Pad thickness outer 6.2 mm (0.24 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type

Brake lever

Brake lever free play (pivot)

Throttle lever free play 1 ~ 3 mm (0.04 ~ 0.12 in)

front
rear ----

Dual cylinder

190.0 mm × 3.5 mm

(7.48 in × 0.14 in)

12.7 mm (0.50 in)

25.4 mm (1.00 in)

DOT 4

4 ~ 7 mm (0.16 ~ 0.28 in)
0 ~ 3 mm (0.00 ~ 0.12 in)

SPEC

3.00 mm
(0.120 in)

(0.009 in)

2.00 mm

2.00 mm

----

----

----

----

----

----

2 - 12

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Voltage
Ignition system

Ignition timing (B.T.D.C.) 13.0 ° /1,700 r/min ---­Advanced timing (B.T.D.C.) 29.0 ° /4,000 r/min ---­Advancer type Electrical (digital) ----

C.D.I.

Magneto model/manufacturer C1120-V30-9000/SHINGYIH ---­Pickup coil resistance/color

Source coil resistance/color

C.D.I. unit model/manufacturer C0410-V30-9001/ E-YANG ----

Ignition coil

Model/manufacturer C051A- FIA0 -0010/ SHIHLIN ---­Minimum spark gap 6.0 mm (0.24 in) ---­Primary winding resistance
Secondary winding resistance

Spark plug cap

Type Resin ---­Resistance 3.75 ~ 6.25 k Ω ----

Charging system

Type AC magneto
Model/manufacturer ---­Nominal output 14 V 105 W at 5,000 r/min ----

Rectifier/regulator

Regulator type Semi conductor-short circuit ---­No-load regulated voltage (DC) 14.0 ~ 15.0 V ----

Model/manufacturer C1600-B00-9000/SHINGYIH

12 V ----

120 ~ 180 Ω at 20 °C (68 °F)/
Blue—Yellow/Green

0.72 ~ 0.97 Ω at 20 °C (68 °F)/
White/Red—White

0.19 ~ 0.25 at 20 °C (68 °F)

6.8 ~ 9.2 k at 20 °C (68 °F)Ω

C1120-V30-9000/SHINGYIH

Ω

----

----

----

----

----

----

2 - 13

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Electric starter system

Starter motor

0.50 kWOutput

Armature coil resistance 0.005 ~ 0.007 at 20 °C (68 °

Brush overall length

Spring force

Starter relay

Coil winding resistance 2.98 ~ 4.03 at 20 °C (68 °F)

Circuit breakers

Type
Amperage for individual circuit

Main fuse ----

6.67 ~ 9.03 N

(680 ~ 920 gf, 23.99 ~ 32.45 oz)

Fuse

10.0 A × 1

Ω

Ω

SPEC

F)

----Constant meshType

----C1200-V30-0000/SHINGYIHModel/manufacturer

----

----

5.5 mm11.5 mm (0.45 in)
(0.22 in)

----

19.4 mm22.0 mm (0.87 in)Commutator diameter
(0.76 in)

----.7 mm ( 0.07 in)1Mica undercut

----C5850-A04-0000/SHINGYIHModel/manufacturer

----150 AModel/manufacturer

----

----

2 - 14

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Exhaust pipe Nut

Cover head cylinder M6Bolt 4 12 1.2

Spark plug — M10 1 11 1.1
Cylinder head (Pipe assy, inlet) M6Stud bolt 2 9 0.9
Cylinder head (Muffler pipe) M6Stud bolt 2 9 0.9

Pipe assy inlet M6Nut 2 12 1.2
Lifter comp tensioner M6Bolt 2 12 1.2
Lifter comp tensioner M6Screw

BoltCylinder M6 1 12 1.2

Bolt M6Fan comp cooling
C.D.I. magneto rotor Nut M12 1 55 5.5
Stator comp
Stator comp
Arm comp kick starter
Cover, crank case left
Plate crank case (L)

Outer clutch Nut M12 1 55 5.5
Plate comp drive Nut M28 1 55 5.5
Motor start comp
Gear comp starting clutch

Crankcase R and L
Crankcase L
Crankcase L
Crankcase R

Sprocket drive

Fixed support rod shift

Engine oil filler cap Dipstick

Bolt

Bolt

Bolt

Bolt

Bolt

Bolt

Bolt

Bolt M12 1 25 2.5Final transmission oil filler cap

Bolt

Screw M5Reverse switch

Bolt

Bolt 2 12 1.2M6Fixed support catch

Bolt

Screw

Bolt

Thread

size

M6 2 13 1.3
M8Muffler Bolt 1 25 2.5

M8Holder cam shaft Nut 4 20 2.0

M6BoltCylinder head(timing chain side) 2 12 1.2

M6
M5
M6
M6
M6

M12Face assy, movable drive Nut 1 55 5.5

M6

M22

M6BoltSeparator oil 2 12 1.2
M6NutOil pump driven sprocket 1 12 1.2
M6BoltOil pump body 2 12 1.2
M6Bolt
M6Bolt
M6Stud bolt
M6Stud bolt

M12Bolt 1 25 2.5Final transmission oil drain plug

M6

M20 1 25 2.5
M35Bolt 2 8 0.8Engine oil drain plug

M5Spark arrester
M5Cooler comp

Q’ty

Tightening torque
Nm m · kg ft · lb

1 6 0.6

4 12 1.2

2121.2
2 5 0.5
1 12 1.2
8 12 1.2
2 12 1.2

2 12 1.2
1 95 9.5

2 12 1.2
1 12 1.2
2 12 1.2
2 12 1.2

2 10 1.0
2 8 0.5
1 12 1.2M6

1 12 1.2M6Spring transmission plate

1 5 0.5
4 25 2.5

Remarks

9.4

18.0

8.7

14.5

8.0

6.5

6.5

8.7

8.7

8.7

4.3

8.7

8.7

40.0

8.7

3.6

8.7

8.7

8.7

40.0

40.0

40.0

8.7

68.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

18.1

18.1

7.2

5.8

8.7

8.7

8.7

18.1

5.8

3.6

18.1

2 - 15

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

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 nut

Rear brake disc and disc bracket
Rear brake lever and handlebar holder
Rear brake caliper and brake caliper bracket
Brake hose and union bolt

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
Front bumper and frame
Footrest board and footrest bracket
Footrest bracket and frame

Driven sprocket and sprocket bracket M10
Exhaust muffler mounting bolt
King pin nut

M10
M10
M10
M14
M10
M10
M10
M10
M10
M10
M10

M8
M10
M10
M14
M10

M6
M28
M10

M6

M8

M8 28 2.8 20.3
M14
M10

M6

M6

M6

M6

M6

M8

M8

M6

M8 22 2.2 15.9

M8 25 2.5 18.1

M10 35 3.5 25.3

Tightening torque

Nm m · kg ft · lb

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
80 8.0 57.9
40 4.0 28.9
14 1.4 10.1

170 17.0 123.0

35 3.5 25.3
14 1.4 10.1
28 2.8 20.3

80 8.0 57.9

40 4.0 28.9
14 1.4 10.1
4 0.4 2.9
14 1.4 10.1
9 0.9 6.5
9 0.9 6.5
25 2.5 18.1
25 2.5 18.1
9 0.9 6.5

35 3.5 25.3

Remarks

LT

2 - 16

HOW TO USE THE CONVERSION TABLE /

GENERAL TIGHTENING TORQUE SPECIFICATIONS

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

3

cc (cm

3

cc (cm
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

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 - 17

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication Point Lubricant

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 - 18

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication Point Lubricant

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 assembly lube

BEL-RAY assembly lube

Sealant

Sealant

Sealant

Sealant

Sealant

2 - 19

OIL FLOW DIAGRAMS

1

Camshaft

2

Crankshaft

3

Oil pump

4

Oil filter

1

OIL FLOW DIAGRAMS

SPEC

2

3

4

2 - 20

CABLE ROUTING

1

Choke cable (USA/CAN)

2

Rear brake hose

3

Front brake cable (left)

4

Front brake cable (right)

5

Throttle cable

6

Fuel tank breather hose

7

Vacuum tube

8

Fuel filter hose

9

Rubber tube
Bear tube

10

Oil catch hose

11

Crankcase breather hose

12
13

Oil cooler hoses

0 Wire harness

CABLE ROUTING

1

Handlebar switch lead

2 Rear brake switch lead
3 Fuel sender lead
4 Starter relay lead
5 Negative battery lead
6 Generator lead
7 Head light lead

SPEC

5

4

2

1

3

2

C

A

1

7

8

0

D

B

6

E

3

4

F

A

A

13

A

A

12

11

10

9

2 - 21

8

C

7

10

6

5

9

9

G

2

CABLE ROUTING

8 Rectifier/regulator lead 9 Tail light lead 10 Buzzer lead

A

Fasten the rear brake switch lead and handlebar switch lead with a plastic band.

B

Insert the fuel tank breather hose into the hole in the handlebar cover.

C

Fasten the wire harness with a plastic band and a clamper pulser cord.

D

Fasten the wire harness and Generator lead with a plastic band.

E

Fasten the wire harness and Starter relay lead with a clamper pulser cord.

F

Fasten the wire harness and CVT exhaust tube with a plastic band.

G

Pass the rear brake hose through the hose guide.

SPEC

5

4

2

1

3

2

C

A

1

7

8

0

D

B

6

E

3

4

F

A

A

13

A

A

12

11

10

9

2 - 22

8

C

7

10

6

5

9

9

G

2

CABLE ROUTING

SPEC

1

Throttle cable

2

Choke cable (USA/CAN)

0

Wire harness

1

Main switch lead

2
3
4
5

14

lead

Meter

Light controller

PTC controller

Horn

16

15

Head light lead

6

Ignition coil

7

Negative starter motor lead

8

Generator lead

9

10

Positive battery lead

11

Reverse switch lead

12

Neutral switch lead

13

Starter relay lead

17

14

Battery
Negative battery lead

15
16

Main fuse (on wire harness)

17

C.D.I. unit

0

10

A

11

12

13

10

1211

1

0

B

2

3

6

4

5

9

8

1

2

7

2 - 23

CABLE ROUTING

A

Pass these leads through rear fender.

B

Fasten the power supply lead on the wire harness with a plastic band.

SPEC

14

15

16

10

17

11

1

0

B

0

12

2

10

A

11

12

13

3

6

4

5

9

8

1

2

7

2 - 24

CABLE ROUTING

SPEC

1

Choke cable (USA/CAN)

2

Rear brake hose

3

Fuel tank breather hose

4

Throttle cable

5

Front brake cable (right)

6

Front brake cable (left)

A

2

8

9

7

0

Wire harness

C.D.I. unit

1
2

Negative battery lead

3

Main fuse (on

4

Battery

5

Positive battery lead

6

Reverse switch lead

wire harness)

Neutral switch lead

Rear brake switch lead

8
9

Handlebar switch lead

1

6

5

4

3

0

1

2

B

3

7

6

5

4

C

E

D

2 - 25

CABLE ROUTING

Fasten the handlebar switch lead, rear brake switch lead with a plastic band.

A

To the frame.

B

To starter relay.

C

Connect the positive battery lead to the battery so that the lead contacts the battery case.

D

Connect the negative battery lead to the battery so that the lead is routed to the side of the battery.

E

1

A

SPEC

2

8

6

5

4

9

3

0

1

2

B

3

7

6

5

4

C

E

D

2 - 26

CABLE ROUTING

SPEC

1

Throttle cable

2

Rear brake hose

3

Choke cable (USA/CAN)

4

Oil catch hose

5

Crankcase breather hose

6

Oil cooler hoses

A

Fasten the handlebar switch lead and rear brake switch lead with a plastic band.

B

Fasten the Haed light leads with plastic bands.

7

Front brake cable (left)

8

Front brake cable (right)

0 Wire harness
1 Head light lead
2 Head light lead (right)
3 Horn

A

7

1

5

(left)

1

2

8

A

ɐ

6

4 Light controller
5 Main switch
6 Meter
7 Rear brake switch
8 Handlebar swit

7

8

3

2

7

8

8

7

3

4

3

A

4

0

5

2

1

6

B

2 - 27

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

month 1 3 6 6 12

km

(mi)

hours 20 80 160 160 320

320

(200)

1300
(800)

√√√√√

√√√√

2500

(1600)

√√√√

2500

(1600)

√√√

√√√

√√√

5000

(3200)

NO. ITEM

Fuel line

1

*

2 Spark plug

Valves

3

*

Carburetor

4

*

Crankcase breather

*

5

system

Exhaust system

6

*

7 Spark arrester

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.

Clean. √ √ √

Whichev­er comes

first

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)

√

√√√

√√

Every 4 years

Every 600 hours of operation

NO. ITEM

1 Air filter element

Clutch

2

*

3

Front brake

*

4

Rear brake

*

5

Brake hoses

*

6

Wheels

*

7

Tires

*

8

Fuel filter

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.

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.

Replace.

Whichev­er comes

first

2500

(1600)

2500

(1600)

√√√√

√√√√

√√

√√√√

√√√√

5000

(3200)

√

3 - 1

NO. ITEM

9

Wheel hub bearings

*

10

11

12

13

14

15

16

17

18

19

20

21

24

Chassis fasteners

*

Shock absorber

*

assemblies
Front knuckle piv-

*

ots
Steering shaft

*

Steering system

*

Engine oil

Engine oil strainer

Final transmission oil

Moving parts and

*

cables

Throttle lever hous-

*

ing and cable

Front and rear brake

*

switches

Lights and switches

*

V-belt22

Drive chain23

Drive chain rollers

*

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.

Replace.

Check ATV for oil leakage, and correct if neces­sary.

Clean.

Change.
Check ATV for oil leakage, and correct if neces-

sary.

Lubricate.

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.

JOB

Whichev­er comes

first

month 1 3 6 6 12

km

(mi)

hours 20 80 160 160 320

320

(200)

1300
(800)

√√√

Every 1,000 km

√√

√√√√

√√√

√√√

√√√

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.

WARNING

Indicates a potential hazard that could result in serious injury or death.

3 - 2

RACKS, SEAT, FENDERS AND FUEL TANK

CHK

ADJ

RACKS,

SEAT, FENDERS AND FUEL TANK

RACKS, SEAT AND FRONT PANEL

4

1

7

6

5

3

2

T

.

25 Nm (2.5 m • kg, 18.1 ft • Ib)

R

T

.

25 Nm (2.5 m • kg, 18.1 ft • Ib)

R

.

.

Order Job/Part Q’ty Remarks

Removing the

racks, seat and front

Remove the parts in the order listed.

panel

1 Front rack
2 Rear rack
3Seat

1
1
1

TIP

Pull back the seat lock lever, than pull up
on the rear of the seat.

4 Front panel
5 Fuel tank breather hose 1

1

TIP

When installing the handlebar cover,
pass the fuel tank breather hose through

the hole in the handlebar cover.

6 Front plate of handlebar cover 1
7 Handlebar cover 1

Disconnect the meter lead and the main
switch lead.

For installation, reverse the removal pro­cedure.

3 - 3

FRONT FENDER

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

RACKS, SEAT, FENDERS AND FUEL TANK

1

3

CHK

ADJ

2

Order Job/Part Q’ty Remarks

Removing the front fender

Remove the parts in the order listed.

Racks, seat and front panel Refer to “RACKS, SEAT AND FRONT

PANEL”.

1 Fuel tank top panel 1
2 CVT inlet tube 1 Remove.
3 Front fender 1

For installation, reverse the removal pro­cedure.

3 - 4

RACKS, SEAT, FENDERS AND FUEL TANK

REAR FENDER, FOOTREST BOARDS BETTERY AND C.D.I UNIT

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

5

CHK

ADJ

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

3

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

1

2

4

6

6

Order Job/Part Q’ty Remarks

Removing the rear fender, footrest
boards bettery and c.D.I unit

Racks, seat and front panel Refer to “RACKS, SEAT AND FRONT

Front fender Refer to “FRONT FENDER”.

1 Battery band 1
2 Negative battery lead 1 Disconnect.

3 Positive battery lead 1 Disconnect.
4 Battery 1.

5 Rear fender 1
6 Footrest board 2

Remove the parts in the order listed.

PANEL”.

NOTICE

First disconnect the negative lead, then
disconnect the positive lead.

For installation, reverse the removal pro­cedure.

3 - 5

RACKS, SEAT, FENDERS AND FUEL TANK

FUEL TANK AND FOOTREST BARS

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

CHK

ADJ

(USA)

3

RES

OFF

ON

2

4

1

FUEL

3

2

4

T

25 Nm (2.5 m • kg, 18.1 ft Ib)

.

R

.

Order Job/Part Q’ty Remarks

Removing the fuel tank and footrest

Remove the parts in the order listed.

bars

Racks, seat and front panel

Refer to “RACKS, SEAT AND FRONT
PANEL”.

Front fender Refer to “FRONT FENDER”.

1 Vacuum tube comp 1

Except for USA.
2 Fuel filter assy 1
3 Fuel tank 1

(Fuel tank with the fuel cock) (USA) (1)

TIP

Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.

4 Footrest bar 2

For installation, reverse the removal pro-

cedure.

•

3 - 6

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 temperatrue.

ture.

•

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 mm (0.003 in)

Exhaust valve

0.07 mm (0.003 in)

a. Turn the crankshaft clockwise with a wrench.

2

T

1

2

1

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 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 forwa­rd to up.

→

1

2

1

2

3 - 7

ADJUSTING THE VALVE CLEARANCE/

ADJUSTING THE ENGINE IDLING SPEED

CHK

ADJ

1

c. Measure the valve clearance using a thick-

ness gauge .

1

Out of specification → Adjust.

2

3

3. Adjust:

• valve clearance

a. Loosen the locknut .

1

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

1

2

3

4

until the proper clearance is obtained.

d. Hold the adjuster to prevent it from moving

4

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.

ADJUSTING THE ENGINE IDLING SPEED

1. Start the engine and let it warm up for sev­eral minutes.

2. Attach:

• engine tachometer

1

(to the spark plug lead)

1

3. Measure:

• engine idling speed

Out of specification → Adjust.

Engine idling speed

1,600 ~ 1,800 r/min

3 - 8

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

CHK

ADJ

1

4. Adjust:

• engine idling speed

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 (0.0 4 ~ 0.12 in)

Idling speed becomes
higher.

Idling speed becomes
lower.

1

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 (0.0 4 ~ 0.12 in)

a

3 - 9

ADJUSTING THE THROTTLE LEVER FREE PLAY/

ADJUSTING THE SPEED LIMITER

CHK

ADJ

2

1

3

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.

Turning in Free play is increased.

Turning out Free play is decreased.

d. Tighten the locknut .
e. Push in the adjuster cover .

WARNING

After adjusting the free play, turn the han­dlebar to the right and left to make sure
that the engine idling speed does not

increase.

TIP

Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant
to prevent premature wear.

2

3

2

1

1

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 specification→ Adjust.

Speed limiter length

Less than 11.0mm (0.43 in)

1

3 - 10

ADJUSTING THE SPEED LIMITER/

CHECKING THE SPARK PLUG

2. Adjust:

• speed limiter length

CHK

ADJ

a. Loosen the locknut .
b. Turn the adjuster in or out until the speci-

1

2

fied speed limiter length is obtained.

Turning in

Turning out

c. Tighten the locknut.

WARNING

• 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).

1

2

Speed limiter length is
decreased.

Speed limiter length is
increased.

CHECKING THE SPARK PLUG

1. Remove:

• spark plug

2. Check:

• spark plug type
Incorrect → Change.

Standard spark plug

C7HSA/NGK

3. Check:

• electrode
Wear/damage → Replace.

• insulator
Abnormal color → Replace.
Normal color is a medium-to-light tan color.

1

2

TIP

Before installing a spork plug, clean the gasket
surface and plug surface.

1

2

3 - 11

CHECKING THE SPARK PLUG/

CHECKING THE IGNITION TIMING

CHK

ADJ

4. Clean:

• spark plug
(with a spark plug cleaner or wire brush)

5. Measure:

•sparkpluggap

a

Use a wire gauge or thickness gauge.

a

Out of specification → Regap.

Spark plug gap

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

6. Tighten:

• spark plug

T

11 Nm (1.1 m · kg, 8.0 ft · lb)

.

R

.

CHECKING THE IGNITION TIMING

TIP

Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.

1

1. Remove:

• Shroud cap

1

2. Attach:

• engine tachometer

a

(to spark plug lead)

• timing light

a

3. Check:

• ignition timing

a. Warm up the engine and keep it at the

specified speed.

Engine speed

1,600 ~ 1,800 r/min

F

T

1

b. Visually check the stationary pointer to

verify it is within the required firing range

2

indicated on the rotor.

1

2

Incorrect firing range → Check the pickup
coil.

3 - 12

CHECKING THE IGNITION TIMING/

MEASURING THE COMPRESSION PRESSURE

4. Detach:

• timing light

• engine tachometer

5. Install:

• Shroud cap

TIP

The ignition timing is not adjustable.

MEASURING THE COMPRESSION
PRESSURE

TIP

Insufficient compression pressure will result in
a loss of performance.

1. Measure:

• valve clearance
Out of specification → 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

CHK

ADJ

NOTICE

რ

Before removing as park plug,use compressed
air to blow away any dirt accumulated in the
spark plug well to prevent it from falling into the
cylinder.

5. Attach:

• compression gauge

1

6. Measure:

• compression pressure
Out of specification → Refer to steps(c) and
(d).

Compression pressure (at sea level)

Minimum

Standard 1,250 kPa/1,000 r/min

Maximum 1,350 kPa/1,000 r/min

1

1,050 kPa/1,000 r/min
(10.5kg/cm , 152.3 psi)

(12.5kg/cm , 181.3 psi)

(13.5kg/cm , 195.8 psi)

2

2

2

3 - 13

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

a. Set the main switch to “ON”.
b. With the throttle wide open, crank the

engine until the reading on the compression
gauge stabilizes.

WARNING

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 → 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

Pistonring(s) wear or
damage → Repair.

Piston, valves, cylinder

Same as without oil

head gasket or piston
possibly defective →
Repair.

7. Install:

• spark plug

T

11 Nm (1.1 m • kg, 8.0 ft • Ib)

.

R

.

8. Connect:

• spark plug cap

CHECKING THE ENGINE OIL LEVEL

1

a

b

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 b

Oil level low → Add oil to the proper level.

TIP

Do not screw the dipstick in when checking

1

the oil level.

3 - 14

CHECKING THE ENGINE 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.

CHK

ADJ

0

-20

10 30

SAE 5W-30

-10 0

50

SAE 15W-40

SAE 10W-40

SAE 10W-30

10

70

SAE 20W-50

20

90

30 40 50 °C

110

130 °F

b. Screw the dipstick completely out, and

1

wipe the dipstick clean, then just rest the
dipstick in the hole.

c. Pull up the dipstick, and check the oil level

whether or not it is between maximum
and minimum level .

b

a

d. If the level is lower, add the oil up to the

proper level.

Recommended oil

Follow the chart on the left.

TIP

Recommended oil classification:
API service SG type or higher, JASO standard
MA.

NOTICE

რ

• 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 - 15

CHK

CHANGING THE ENGINE OIL

CHANGING THE ENGINE OIL

1

2

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

1

• 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 → Replace.

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

.

ADJ

2

1

7. Fill:

• crankcase

1

(with the specified amount of the recom­mended engine oil)

Quantity

Total amount

1.00 L (0.88 Imp qt, 1.06 US qt)

Periodic oil change

0.90 L (0.79 Imp qt, 0.95 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 - 16

CHK

CLEANING THE AIR FILTER ELEMENTS

CLEANING THE AIR FILTER ELEMENTS

1. Loosen:

2

5

• bolts / screws

2. Remove:

• air filter case cover

• seals

• air filter element

1

4

2

5

ADJ

3

3

1

4

NOTICE

რ

The engine should never be run without the

•

air filter; excessive piston and/or cylinder
wear may result.

3. Check:

• air filter element
Dusty → Clean the air filter element with

compressed air.
Damaged → Replace.

4. Install:

• seals

• air filter element

NOTICE

რ

Place the air filter element in the original
position, and then install the screw.

5. Tighten:

• bolts / screws

6. Install:

• Air filter case covers

TIP

Make sure its sealing surface matches the
sealing surface of the case so there is no air
leak.

3 - 17

CHK

CLEANING THE SPARK ARRESTER

CLEANING THE SPARK ARRESTER

1

3

2

(Only U.S.)

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
the tailpipe from muffler.l

ADJ

c

b

a

a. Remove the bolt and nut .

Remove the screw . (Only U.S.)

b. Remove the spark arrester by pulling it out of

the muffler.
Remove the back cover of muffler and the
spark arrester . (Only U.S.)

c. Tap the tailpipe lightly with a soft-face hammer 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 and the back cover of

muffler into the muffler, then align the screw holes.

e. Insert the screw and tighten it.

1 2

a

3

b

c

Screw

5 Nm (0.5 m · kg, 3.6 ft · lb)

T

.

R

.

3 - 18

CHECKING THE FRONT BRAKE SHOES/

ADJUSTING THE FRONT BRAKE

CHASSIS

CHECKING THE FRONT BRAKE SHOES

1. Operate the brake:

2. Check:

• wear indicator

Wear indicators reaches the wear limit line

1

2

→ Replace the brake shoes as a set.

Refer to “FRONT BRAKES” in chapter 6.

3. Adjust:

Adjust the front and rear brake lever free play
after replace the brake shoes.

ADJUSTING THE FRONT BRAKE

TIP

Before adjusting the front brake, the front
brake linings should be checked.

1

CHK

ADJ

2

NOTICE

რ

Proper lever free play is essential to avoid

a

1

2

b

excessive brake drag.

1. Measure:

• front brake lever free play
Out of specification

Front brake lever free play

4 ~ 7 mm (0.16 ~ 0.28 in)

2. Adjust:

• front brake lever free play

a. Loosen the locknuts .
b. Turn the adjusters in or out until the

specified front brake lever free play is obtained.

TIP

Make sure that the difference between clear­ances and is less than 4 mm when the
front brake lever is squeezed.

b

c

→

a

Adjust.

1

2

c

c. Tighten the locknuts.

3 - 19

CHECKING THE REAR BRAKE FLUID LEVEL

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

1

Below the minimum level mark → Add
the recommended brake fluid to the proper
level.

Recommended brake fluid

DOT #4

CHK

ADJ

1

WARNING

• 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 - 20

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

a

→ Replace the brake pads as a set.

Refer to “REAR BRAKE” in chapter 6.

CHK

ADJ

Brake pad wear limit

2.0 mm (0.08 in)

2. Operate the rear brake lever.

CHECKING THE BRAKE HOSE

1. Remove:

• seat

1

• front fender

Refer to “SEAT, FENDERS AND FUEL
TANK”.

2. Check:

• rear brake hose

Cracks/wear/damage → Replace.

3. Check:

• brake hose clamps

Loosen → 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 → Replace the hose or pipe.
Refer to “REAR BRAKE” in chapter 6.

6. Install:

• front fender

• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

1

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.

3 - 21

CHK

BLEEDING THE HYDRAULIC BRAKE SYSTEM

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.

1

2

b. Install the diaphragm (brake master cylin-

der reservoir or brake fluid reservoir).

c. Connect a clear plastic hose tightly to

the bleed screw .

2

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.

ADJ

1

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 - 22

CHECKING THE FINAL TRANSMISSION OIL/

1

2

1

2

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:

• final transmission oil filler cap

• final transmission oil drain plug

4. Drain:

• final transmission oil

5. Install:

• final transmission oil drain plug

T

25 Nm (2.5 m • kg, 18.1 ft • Ib)

.

R

.

• final transmission oil filler cap

T

25 Nm (2.5 m • kg, 18.1 ft • Ib)

.

R

.

TIP

Check the gasket (drain plug). If it is damaged,

replace it with a new one.

CHK

ADJ

6. Fill:

• final transmission case

Total amount

0.75 L (0.66 Imp qt, 0.79 US qt)

Recommended oil

SAE80W-90 gear oil

NOTICE

რ

Take care not to allow foreign material to
enter the final gear case.

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.

NOTICE

რ

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 - 23

ADJUSTING THE DRIVE CHAIN SLACK/

CHECKING THE STEERING SYSTEM

1. Measure:

• drive chain slack
Out of specification → Adjust.

a

CHK

ADJ

a

Drive chain slack

15 ~ 25 mm (0.59 ~ 0.98 in)

2. Adjust:

• drive chain slack

3

2

a

b

1

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 .

2

1

c. To tighten the drive chain, turn the drive chain
adjusting nut in direction . To loosen the

3

a

drive chain, turn the drive chain adjusting nut

3

in direction .

NOTICE

რ

b

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.

T

55 Nm (5.5 m • kg, 39.8 ft • Ib)

.

R

.

TIP

The chain should be cleaned and lubricated
after every use of the vehicle.

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 → Replace the steering shaft
bushings and or bearings.
Refer to “STEERING SYSTEM” in chapter 6.

3 - 24

CHECKING THE STEERING SYSTEM/

ADJUSTING THE TOE-IN

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.

1

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 → Replace the front arms
(upper and lower) and/or wheel bearings.

1

CHK

ADJ

ADJUSTING THE TOE-IN

1. Place the machine on a level surface.

2. Measure:

• toe-in
Out of specification → Adjust.

Toe-in

10 ~ 15 mm (0.39 ~ 0.59 in)

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.

Toe-i n = –

g. If the toe-in is incorrect, adjust it.

Forward

3 - 25

CHK

ADJUSTING THE TOE-IN

3. Adjust:

• toe-in

WARNING

• 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.

a. Mark both tie-rods ends.

This reference point will be needed during
adjustment.

2

1

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.

T

35 Nm (3.5 m • kg, 25.3 ft • Ib)

.

R

.

ADJ

1

2

A

ɇ

ɇ

B

ɇ

ɇ

TIP

Adjust the rod ends so that A and B are equal.

3- 26

CHECKING THE FRONT ANDREAR SHOCK ABSORBERS

CHECKING THE FRONT AND REAR SHOCK
ABSORBERS

1. Place the machine on a level surface.

2. Check:

• damper rod
Bends/damage → Replace the front/rear shock
absorber assembly.

• oil leakage

1

1

Excessive oil leakage → Replace the front/

rear shock absorber assembly.

• cylinder
Damage → the front/rear shock absorber
assembly.

• spring
Fatigue → 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 → Replace the front/
rear shock absorber assembly.
Refer to “ADJUSTING THE SHOCK ABSOR­BERS”.

Front shock absorber
Rear shock absorber

1

CHK

ADJ

3 - 27

ADJUSTING THE SHOCK ABSORBERS/

CHECKING THE TIRES

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.

1. Adjust:

• spring preload

CHK

ADJ

a. Turn the adjusting ring in direction or

1

1

a

b

2

2

5

4

3

b

with the spanner wrench

Spring preload is increased

Direction

Direction

a

b

(suspension is harder).

Spring preload is decrease

(suspension is softer).

1

2

.

a

Standard position: Front-1, Rear-1
Minimum position: 1

a

1

b

1

2

5

4

3

Maximum position: 5

Front shock absorbers
Rear shock absorbers

2

CHECKING THE TIRES

WARNING

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.

3 - 28

Manufacturer Size Type

Front MAXXIS

Rear MAXXIS

AT21

7-10

AT22 x

10-10

x

C9207

C9209

CHK

CHECKING THE TIRES

• 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 23 kPa (0.23 kgf/cm
Rear 23 kPa (0.23 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: 75.0 kg (165.35 lb)
* Total weight of the cargo, trailer hitch

vertical load, rider, and accessories.

ADJ

2

, 3.6 psi)

2

, 3.6 psi)

2

, 3.3 psi)

2

, 3.3 psi)

2

, 36 psi)

2

, 36 psi)

1. Measure:

• tire pressure

1

Out of specification → Adjust.

TIP

• The low-pressure tire gauge is included

1

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.

Cold tire

pressure

Standard

Minimum

Front Rear

25 kPa

(0.25 kgf/cm

2

,

3.6 psi)

23 kPa

2

(0.23 kgf/cm

,

3.3 psi)

25 kPa

(0.25 kgf/cm2,

3.6 psi)

23 kPa

(0.23 kgf/cm2,

3.3 psi)

3 - 29

Maximum

28 kPa

(0.28 kgf/cm

4.1psi)

28 kPa

2

,

(0.2 8 kgf/cm

4.1psi)

2

,

CHECKING THE TIRES/

CHECKING THE WHEELS

WARNING

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.

2. Check:

• tire surfaces
Wear/damage → Replace.

CHK

ADJ

a

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

1

Damage/bends → Replace.

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.

Tire wear limit

Front and rear: 3 mm (0.12 in)

WARNING

1

WARNING

a

3 - 30

CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE

LEVERS, STEERING SHAFT AND STEERING KNUCKLES

CHECKING AND LUBRICATING THE
CABLES

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 → Replace.

2. Check:

• cable operation
Unsmooth operation → Lubricate or replace.

Recommended lubricant

Lithium-soap-base grease

CHK

ADJ

TIP

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 - 31

CHECKING AND CHARGING THE BATTERY

ELECTRICAL SYSTEM

CHECKING AND CHARGING THE BATTERY

WARNING

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 - 32

CHECKING AND CHARGING THE BATTERY

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)

CHK

ADJ

1

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)

2

TIP

First, disconnect the negative battery lead

1

, and then the positive battery lead .

2

3. Remove:

• battery

4. Check:

• battery charge

a. Connect a pocket tester to the battery ter-

minals.

Positive tester probe →

positive battery terminal

Negative tester probe →

negative battery terminal

TIP

•The charge state of an VRLA (Valve Regulated
LeadAcid)battery canbecheckedby 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 - 33

Charging

18
17
16
15

14
13
12
11

Open-circuit voltage (V)

10

CHK

CHECKING AND CHARGING THE BATTERY

Example

c. Open-circuit voltage = 12.0 V
d. Charging time

Using 0.9A-charging current about 5 hours.
(Normal charging)

Or using 4A-charging current about 1 hour.
(Quick charging)

e. Charge of the battery = 20 ~ 30%

5. Charge:

•battery
(refer to the appropriate charging method
illustration)

WARNING

Quick charging should be limited to an emer­gency; Normal charging is preferred.

Ambient temperature
20°C (68°F)

NOTICE

რ

• 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

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)

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.)

•Toreducethechanceofsparks,donot
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!

ADJ

3 - 34

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 - 35

CHECKING AND CHARGING THE BATTERY

Charging method using a variable-current (voltage) charger

Charger

Ammeter

Measure the open-circuit
voltage prior to charging.

CHK

ADJ

TIP

Leave the battery unused for more than
30 minutes before measuring its open­circuit voltage.

YES

Adjust the voltage to obtain
the standard charging amper­age.

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?

TIP

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.

exceed the standard charg­ing amperage after 5 min­utes, replace the battery.

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 → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.

3 - 36

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 → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.

NOTICE

რ

Constant amperage chargers are not suitable
for charging VRLA batteries.

Charger

Ammeter

Voltmeter

3 - 37

CHECKING AND CHARGING THE BATTERY/

CHECKING THE FUSES

6. Install:

• battery

7. Connect:

• battery leads
(to the battery terminals)

CHK

ADJ

2

1

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 → Connect properly.

9. Lubricate:

• battery terminals

Recommended lubricant

Dielectric grease

10.Install:

• battery band

• seat
Refer to “SEAT, FENDERS AND FUEL TANK”.

CHECKING THE FUSES

1

2

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”.

2.Check:

• fuse

1

a. Connect the pocket tester to the fuse and

TIP

Set the pocket tester selector to “Ω x 1”.

1

check the continuity.

3 - 38

CHK

CHECKING THE FUSES

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.

ADJ

Items

Main 10.0 A

Reserve

WARNING

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

10.0 A 1

Q’ty

1

3 - 39

ENGINE

ENGINE

EXHAUST PIPE/MUFFLER, CABLES AND LEADS

4

5

10

10

ENGINE

ENG

3

8

6

7

2

9

4

1

25 Nm (2.5 m • kg, 18.1 ft • Ib)

T

13 Nm (1.3 m • kg, 9.4 ft • Ib)

.

R

.

Order Job/Part Q’ty Remarks

Removing the exhaust pipe/muffler,
cables and leads

Racks, seat, fenders and fuel tank Refer to “RACKS, SEAT, FENDERS AND

1 Exhaust pipe/muffler 1
2 Exhaust pipe gasket 1
3 Throttle cable 1
4

Choke cable 1

Generator lead 1

5
6 Spark plug lead 1

7 Reverse switch lead 1
8 Neutral switch lead 1
9 Negative starter motor lead 1

10 Negative battery lead 1

Remove the parts in the order listed.

FUEL TANK” in chapter 3.

Refer to “CARBURETOR” in chapter 5.

For installation, reverse the removal pro­cedure.

4 - 1

ENGINE MOUNTING BOLTS

T

35 Nm (3.5 m • kg, 25.3 ft • Ib)

.

R

.

5

ENGINE

T

15 Nm (1.5 m • kg, 10.8 ft • Ib)

.

ENG

2

5

3

4

(4)

6

5

Order Job/Part Q’ty Remarks

Removing the engine mounting bolts

Remove the parts in the order listed.

Exhaust pipe/muffler Refer to “EXHAUST PIPE/MUFFLER,

CABLE AND LEADS” .

1 Drive chain 1

Refer to “REMOVING THE ENGINE”.

12 Inlet tube, c.v.t comp

3 Catch tank

1

14 Cooler comp oil assy
5 Flange bolt / nut
6 Engine assembly

3/3

1

Refer to “INSTALLING THE ENGINE”.

NOTICE

Install all of the bolts/nuts and then
tighten them to full torque specifica­tions.

5

1

For installation, reverse the removal pro­cedure.

4 - 2

ENGINE

ENG

2

REMOVING THE ENGINE

1. Remove:

• master link

• drive chain

1
2

INSTALLING THE ENGINE

1. Install:

• flange bolts/ nuts

TIP

1

Do not fully tighten the bolts and nuts.

2. Tighten:

1

• flange bolts/ nuts

1

T

35 Nm (3.5 m • kg, 25.3 ft • Ib)

.

R

.

3. Install:

• drive chain

• master link

TIP

1
2

The master link clip must be installed with the
rounded end facing the direction of travel.

2

4 - 3

CYLINDER HEAD

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

T

6 Nm (0.6 m • kg, 4.3 ft • Ib)

.

R

.

CYLINDER HEAD

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

5

ENG

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

T

11 Nm (1.1 m • kg, 8.0 ft • Ib)

.

R

.

(x4)

9

1

(x4)

LS

M

10

(x4)

13

E

2

11

12

T

20 Nm (2.0 m • kg, 14.5 ft • Ib)

.

R

.

8

17

LS

3

4

6

7

New

15

14

New

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

16

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 tensioner 1
4 Gasket, lifter tensioner 1
5 Pipe assy inlet

1

6 Gasket, carb insulator 1
7 Insulator carb 1

Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLIN-

8 Gasket exhaust pipe 1

DER HEAD”.

9 Cover assy head cylinder 1

4 - 4

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

T

6 Nm (0.6 m • kg, 4.3 ft • Ib)

.

R

.

CYLINDER HEAD

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

5

ENG

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

T

11 Nm (1.1 m • kg, 8.0 ft • Ib)

.

R

.

(x4)

9

1

(x4)

LS

M

10

(x4)

13

E

2

11

12

T

20 Nm (2.0 m • kg, 14.5 ft • Ib)

.

R

.

8

17

LS

3

4

6

7

New

15

14

New

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

16

T

12 Nm (1.2 m • kg, 8.7 ft • Ib)

.

R

.

Order Job/Part Q’ty Remarks

10 1
11 2

Holder, cam shaft
Knock pin

Refer to “REMOVING THE CYLINDER
HEAD” and “INSTALLING THE CYLIN-

12 1
13 1
14 1
15 2

16 1
17 1

Cam shaft comp
Head comp cylinder
Gasket cylinder head
Knock pin

Guide cam chain
Guide tension cam chain

DER HEAD”.

For installation, reverse the removal
procedure.

4 - 5

CYLINDER HEAD

REMOVING THE CYLINDER HEAD

1. Align:

• “T” mark on the rotor
(with the stationary pointer on the crank­case)

2

a. Turn the crankshaft clockwise with a wrench.

1

5

3

4

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).

TIP

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)

•

3

4

7

6

1

5

2

8

9

•

cover assy head cylinder

•

nut flange

•

pipe assy inlet

•

nut flange

•

washer

•

holder, cam shaft

TIP

• Working in a crisscross pattern, loosen each
nut 1/4 of a turn.

bolt, flg. (small head)•

lifter comp tensioner

•

3

4

5

6

1

2

7

8
9

4 - 6

1

2

1

2

1
2

1

2

1

1

2

1

2

CYLINDER HEAD

TIP

3. Remove:

cam shaft comp

•
head comp cylinder

•

ENG

Fasten a safety wire to the timing chain to
prevent it from falling into crankcase.

CHECKING THE CAMSHAFT SPROCKET

3

4

1. Check:

• camshaft sprocket
More than 1/4 tooth wear → Replace the
cam shaft comp and timing chain as a set.

1/4 of a tooth
correct

3

roller

4

sprocket

CHECKING THE CYL. HEAD COVER ASSY

1. Check:

• cover assy head cylinder

• gasket cover head cylinder
Cracks/damage → Replace.

CHECKING THE TIMING CHAIN GUIDES

1. Check:

• guide tension cam chain

• guide cam chain
Wear/damage → Replace.

CHECKING THE TIMING CHAIN
TENSIONER ASSEMBLY

1. Check:

• lifter comp tensioned
Wear/damage → Replace.

4 - 7

CYLINDER HEAD

CHECKING THE CYLINDER HEAD

1. Eliminate:

• combustion chamber carbon deposits
(with a rounded scraper)

TIP

Do not use a sharp instrument to avoid damag­ing or scratching:

• spark plug bore threads

• valve seats

2. Check:

• cylinder head
Damage/scratches → Replace.

3. Measure:

• cylinder head warpage
Out of specification → Resurface the cylin­der head.

ENG

Maximum cylinder head warpage

0.05 mm (0.002 in)

a. Place a straightedge and a thickness gauge

across the cylinder head.

b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-

der head as follows.

d. Place a 400 ~ 600 grit wet sandpaper on

the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.

TIP

To ensure an even surface, rotate the cylinder
head several times.

INSTALLING THE CYLINDER HEAD

1

2

3

4

5

1. Install:

head comp cylinder

•

cam shaft comp

•

holder, cam shaft

•

washer

•

nut

•

4

5

1

2

3

TIP

Tighten the nuts in two stages and a crisscross
pattern.

4 - 8

CYLINDER HEAD

2. Install:

• cam shaft comp

ENG

1

3

2

a. Rotate the camshaft to align the round h-

ole in camshaft sprocket away from t-

1

he cylinder head.
b.Turn the crankshaft clockwise with a wrench.
c. Align the “T” mark on the rotor with the

stationary pointer on the crankcase.

When the “T” mark is aligned with the sta-

tionary pointer, the piston is at the Top Dead

Center (TDC).

NOTICE

რ

Do not turn the crankshaft during the cam-

comp installation.

shaft

d. Place the timing chain onto the camshaft

sprocket.
e. Install the camshaft cap onto the camshaft

comp and

finger tighten the nut with wa-

2

3

sher.

TIP

When the camshaft sprocket alignment ma-

4

rk is aligned with the cylinder head alig-

1

4

nment mark , be sure to align the round

1

hole in camshaft sprocket away from the

5

cylinder head.

5

f. Force the camshaft clockwise and counter-

clockwise to remove timing chain slack.
g. Insert a screwdriver into the timing chain

tensioner hole and push the timing chain

guide inward.
h. While pushing the timing chain guide and

the camshaft sprocket alignment mark

is aligned with the cylinder head alignment

mark ,be sure to align the round hole

in camshaft sprocket away from the cylinder

head.

5

4

1

4 - 9

CYLINDER HEAD

i. If the marks are aligned, temporarily tighten

the camshaft sprocket bolt. If the marks are

not aligned, change the meshing position of

the camshaft sprocket and timing chain.

3. Install:

bolt, flg. (small head)

1

2

3

4

•
lifter comp tensioner

•

WARNING

Always use a new gasket.

4. Adjust:

• timing chain tensioner

5. Check:

• camshaft sprocket alignment mark

• rotor “T” mark
Out of alignment → Adjust.

6. Install:

bolt, flg. (small head)

•

cover assy head cylinder

•

•

nut flange

•

pipe assy inlet

3

4

ENG

1
2

1

2

1

2

4 - 10

CAMSHAFT, ROCKER ARMS AND VALVES

CAMSHAFT, ROCKER ARMS AND VALVES

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

8

7

4

5

M

E

2

9

M

10

E

11

1

ENG

13

12

M

14

E

12

11

10

9

3

8

7

E

4

5

T

9 Nm (0.9 m • kg, 6.5 ft • Ib)

.

R

.

M

6

Order Job/Part Q’ty Remarks

Removing the camshaft, rocker

Remove the parts in the order listed.

arms and valves

Cylinder head Refer to “CYLINDER HEAD”.

1 Cam shaft comp 1

Refer to “REMOVING THE ROCKER

2 Shaft in rocker arm
3 Shaft ex rocker arm
4 Arm valve rocker
5 Screw tappet adjusting
6 Plate comp stopper
7 Cotter valve
8 Retainer valve spring

9 Spring valve outer
10 Spring valve inner
11 Seat valve spring outer
12 Seal valve stem 2

1

ARMS AND CAMSHAFT” and

1

“INSTALLING THE CAMSHAFT AND

2

ROCKER ARMS”.

2
1
4

2
2

Refer to “REMOVING THE VALVES

2

AND VALVE SPRINGS” and “INSTALL­ING THE VALVES AND VALVE

2

SPRINGS”.

13 Valve exhaust 1
14 Valve inlet 1

For installation, reverse the removal pro­cedure.

4 - 11

1

2

1

2

1

1

1

2

1

2

CAMSHAFT, ROCKER ARMS AND VALVES

TIP

REMOVING THE ROCKER ARMS AND
CAMSHAFT

1. Loosen:

• locknuts

• screw, valve adjusting

2. Remove:

• shaft in rocker arm

• shaft ex rocker arm

• intake rocker arm

• exhaust rocker arm

Remove the rocker arm shafts with the slide
hammer bolt and weight .

ENG

3. Remove:

• camshaft comp

REMOVING THE VALVES AND VALVE
SPRINGS

1. Check:

• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat and valve seat width.
Refer to “CHECKING THE VALVES AND
VALVE SPRINGS”.

a. Pour a clean solvent into the intake and

exhaust ports.

b. Check that the valve seals properly.

There should be no leakage at the valve
seat .

4 - 12

CAMSHAFT, ROCKER ARMS AND VALVES

2. Remove:

• valve cotters

TIP

2

1

Attach a valve spring compressor and attach­ment between the valve spring retainer and
the cylinder head to remove the valve cotters.

2

ENG

1

a

b

CHECKING THE CAMSHAFT

1. Check:

• cam lobes
Pitting/scratches/blue discoloration → Replace.

2. Measure:

• cam lobe dimensions and
Out of specification → Replace.

Camshaft lobe limit

Intake

a

29.745 ~ 29.845 mm
(1.1711 ~ 1.1750 in)

b

25.185 ~ 25.215 mm
(0.9915 ~ 0.9927 in)

Exhaust

a

29.510 ~ 29.610 mm
(1.1618 ~ 1.1657 in)

b

25.185 ~ 25.215 mm
(0.9915 ~ 0.9927 in)

a b

CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS

The following procedure applies to all of the
rocker arms and rocker arm shafts.

1. Check:

• rocker arm
Damage/wear → Replace.

2. Check:

• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrica­tion system.

3. Check:

• camshaft lobe
Excessive wear → Replace the camshaft.

4 - 13

CAMSHAFT, ROCKER ARMS AND VALVES

4. Measure:

• rocker arm inside diameter
Out of specification → Replace.

Rocker arm inside diameter

10.000 ~ 10.018 mm
(0.3937 ~ 0.3944 in)

1

ENG

a

a

5. Measure:

• rocker arm shaft outside diameter
Out of specification → Replace.

Rocker arm shaft outside diameter

9.972 ~ 9.987 mm
(0.3926 ~ 0.3932 in)

6. Calculate:

• rocker-arm-to-rocker-arm-shaft clearance

TIP

Calculate the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.

Out of specification → Replace the defective
part(s).

Rocker-arm-to-rocker-arm-shaft
clearance

0.013 ~ 0.046 mm
(0.0005 ~ 0.0018 in)

a

4 - 14