Eton VECTOR ST-300 Service Manual

VECTOR 300

Service Manual

1

Contents

1. INFORMATION

1-1 Safety

1-2 Notes
1-3 Engine Specifications
1-4 Serial Number
1-5 Torque Values
1-6 Special Tools

2. MAINTENANCE

2-1 Maintenance Data

2-2 Maintenance Schedule
2-3 Fuel Tube
2-4 Throttle Operation
2-5 Throttle Cable Adjustment
2-6 Air Cleaner
2-7 Spark Plug
2-8 Idle Speed
2-9 Drive Chain
2-10 Brake System
2-11 Wheels And Tires
2-12 Steering Shaft Holder Bushing
2-13 Toe-In

3. ENGINE REMOVE AND INSTALLATION

3-1 General Information

3-2 Engine Removal
3-3 Engine Installation

4. LUBRICATION SYSTEM

4-1 Mechanism Diagram

4-2 Precautions In Operation
4-3 Troubleshooting
4-4 Engine Oil
4-5 Engine Oil Strainer Clean
4-6 Oil Pump
4-7 Gear Oil

5. FUEL SYSTEM

5-1 Mechanism Diagram

5-2 Precautions In Operation
5-3 Trouble Diagnosis
5-4 Carburetor Remove / Install
5-5 Air Cut-Off Valve
5-6 Throttle Valve
5-7 Float Chamber
5-8 Adjustment Of Idle Speed
5-9 Fuel Tank
5-10 Air Cleaner

6. CYLINDER HEAD/VALVE

6-1 Mechanism Diagram

6-2 Precautions In Operation
6-3 Troubleshooting
6-4 Cylinder Head Removal
6-5 Cylinder Head Inspection
6-6 Valve Stem Replacement
6-7 Valve Seat Inspection And Service
6-8 Cylinder Head Reassembly
6-9 Cylinder Head Installation
6-10 Valve Clearance Adjustment

7. CYLINDER/PISTON

7-1 Mechanism Diagram

7-2 Precautions In Operation
7-3 Trouble Diagnosis
7-4 Cylinder And Piston Removal
7-5 Piston Ring Installation
7-6 Piston Installation
7-7 Cylinder Installation

8. V-BELT DRIVING SYSTEM

8-1 Mechanism Diagram

8-2 Maintenance Description
8-3 Trouble Diagnosis
8-4 Left Crankcase Cover
8-5 Drive Belt
8-6 Drive Face
8-7 Clutch Outer/Driven Pulley

9. FINAL DRIVING MECHANISM

9-1 Mechanism Diagram - Transmission Cover

9-2 Precautions In Operation
9-3 Trouble Diagnosis
9-4 Disassembly Of Transmission
9-5 Inspection Of Mission Mechanism
9-6 Bearing Replacement
9-7 Re-assembly Of Final Driving Mechanism

10. ALTERNATOR/STARTING CLUTCH

10-1 Mechanism Diagram

10-2 Precautions In Operation
10-3 Right Crankcase Cover Removal
10-4 A.C.G. Set Removal
10-5 Right Cover Bearing
10-6 Flywheel Removal
10-7 Starting Clutch
10-8 Flywheel Installation
10-9 A.C.G. Set Installation
10-10 Right Crankcase Cover Installation

11. CRANKCASE / CRANK

11-1 Mechanism Diagram

11-2 General Information
11-3 Trouble Diagnosis
11-4 Disassembly Of Crankcase
11-5 Crankshaft Inspection
11-6 Assembly Of Crankcase

12. COOLING SYSTEM

12-1 Mechanism Diagram

12-2 General Information
12-3 Trouble Diagnosis
12-4 Trouble Diagnosis For Cooling System
12-5 System Test
12-6 Radiator
12-7 Water Pump
12-8 Thermostat

13. STEERING AND SUSPENSION

13-1 Parts Drawing

13-2 Troubleshooting
13-3 Handlebar
13-4 Throttle Housing
13-5 Steering System

14. FRONT WHEEL AND BRAKE SYSTEM

14-1 Parts Drawing

14-2 Troubleshooting
14-3 Front Wheels
14-4 Hydraulic Brake
14-5 Suspension Adjustment

15. REAR WHEEL AND BRAKE SYSTEM

15-1 Parts Drawing

15-2 Troubleshooting
15-3 Remove Rear Wheel And Rear Brake
15-4 Swingarm & Rear Axle Holder
15-5 Suspension Adjustment

16. FENDERS AND EXHAUST PIPE

16-1 Fenders Drawing

16-2 Rear Fenders Removal
16-3 Front Fender Removal
16-4 Exhaust Pipe Removal

17. ELECTRICAL SYSTEM

17-1 Troubleshooting

17-2 Ignition Coil
17-3 Ignition Timing
17-4 Battery Information
17-5 Electric Starter
17-6 Light Bulbs Replacement
17-7 Instrument Pane
17-8 Wiring Diagram

18.TROUBLESHOOTING

18-1 Engine Can Not Work

18-2 Poor Performance At Low And Idle Speeds
18-3 Poor Performance At High Speed
18-4 Loss Power
18-5 Poor Handling

1. INFORMATION

1-1 Safety
1-2 Notes
1-3 EngineSpecifications

1-4 Serial Number
1-5 Torque Values
1-6 Special Tools







1-1 Safety

GASOLINE

Gasoline is extremely flammable and is explosive under certain conditio n.
Do not smoke or allow sparks or flames in your work area.

● CARBON MONOXIDE

Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and lead to death.

● BATTERY ELECTROLYTE

The battery electrolyte contains sulfuric acid. Protect your eyes, skin and
clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte
gets in your eyes.

● HOT PARTS

Engine and exhaust pipe become very hot and remain hot for one hour after the
engine is run. Wear insulated gloves before handling these parts.

● USED ENGINE/GEAR OIL

Used engine oil and gear oil may cause skin disease if repeatedly contact with
the skin for long periods.
Keep out of reach of children.

1-2 Notes

All information, illustrations, directions and specifications included in this publication are base on the latest
product information available at the time of approval for printing.
JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and
without incurring any obligation whatever.

No part of this publication may be reproduced without written permission.

6

1-3 EngineSpecifications

Type

Displacement 287.2c.c.
Bore and Stroke 75 mm x 65 mm
Compression 10.0:1
Maximum Hp 20ps / 6500
Maximum Torque (Nm/rpm) 24.6 Nm / 5000

Carburetor

Ignition DC-CDI
Starting Electric
Lubrication Auto oil injection
Transmission Automatic (C.V.T. V-belt + Reverse)

CHASSIS

Overall Length
Overall Width
Overall Height
Wheel base
Ground Clearance
Dry Weight
Fuel Tank Capacity

SUSPENSION

Front
Rear

BRAKES

Front
Rear

TIRES

Front
Rear

PRESSURE【 psi ( kgf/cm2)】

Front
Rear

COLORING

Specifications subject to change without notice.

4 Stroke，Sin gle Cylinder, Water cooled

1815mm
1062mm
1130mm
1193mm

150mm

Double A-Arm & Adjustable
Swing Arm & Adjustable Shock

Front Hydraulic Disc*2
Rear Hydraulic Disc*1

21x7-10
22x10-10

12(0.8)
12(0.8)

225Kg

12L

7

1-4 Serial Number

The frame serial number is stamped on the front of the frame.
The engine serial number is stamped on the left side of the crankcase.

Frame serial number

8

1-5 Torque Values

STANDARD

● 5 mm bolt and nut

5 N.m (3.5 lbf.ft)

● 6 mm bolt and nut

● 8 mm bolt and nut

●10 mm bolt and nut

●12 mm bolt and nut

ENGINE

● Cylinder head nut

● Spark plug

● Cylinder head bolt

● Alternator bolt

FRAME

● Handlebar upper holder bolt

● Throttle housing cover screw

● Steering shaft nut

● S te ering shaft holder bolt

10 N.m (7.2 lbf.ft)

22 N.m (16 lbf.ft)
35 N.m (25 lbf.ft)
55 N.m (40 lbf.ft)

38 N.m (27.4 lbf.ft)

12 N.m (8.9 lbf.

15 N.m (10.1 lbf.ft)

8 N.m (5.9 lbf.ft)

24 N.m (17.7 lbf.ft)

4 N.m (2.9 lbf.ft)

50 N.m (36.9 lbf.ft)

33 N.m (24 lbf.ft)

ft)

● Wheel rim bolt

● Tie rod lock nut

● King pin nut

● Handlebar lo wer holder nut

● Front wheel bolt

● Front axle castle nut

● Front brake arm nut

● Rear brake arm nut

● Rear axl e castle nut

● Rear wheel bolt

● Exhaust muffler mounting bolt

● Engine hanger bolt

● Rear axle holder bolt

Nuts, Bolts Tightness

● Swing arm pivot nut

● Rear shock absorber mounting nut

18 N.m (13.3 lbf.ft)
35 N.m (25.8 lbf.ft)

40 N.m (29 lbf.ft)
40 N.m (29.5 lbf.ft)
24 N.m (17.7 lbf.ft)

40-60 N.m (30-45 lbf.ft)

4 N.m (3.0 lbf.ft)
7 N.m (5.2 lbf.ft)

40-60 N.m (30-45 lbf.ft)

24 N.m (17.7 lbf.ft)
30 N.m (22.1 lbf.ft)

30 N.m ( 22 lbf.ft)

90 N.m (65 lbf.ft)

90 N.m (65 lbf.ft)

45 N.m (33 lbf.ft)

Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all
bolts and nuts on the frame are tightened securely.

Check all fixing pins, snap rings, hose clamp, and wire holders for security.

1-6 Special Tools

For Frame

1. Adjustable Hook Spencer
(E1105-LRA0-FT1)
Purpose: Adjusting of suspension

2. Ball Joint Puller(E0205-LRA0-FT1)

Purpose: Taking out the ball joint from front knuckle as repairing.

10

For Engine

1. TACKING ACG FLY WHEEL TOOL

(C1110-RB1-FT1)

2. COUNTER SHIFT IMPLEMENT (I1003-RB1-FT1)

3. ADJUST TAPPET IMPLEMENT

(A4721-HMA-FT1)

4. SLEEVE OF FABRICATING TRANSMISSION

SHAFT & OIL SEAL (I1202-RB1-FT1)

11

5. SLEEVE OF FABRICATING L CRANK & OIL

SEAL (I1201-HMA-FT1)

6. TAKING 6205 BRG. TOOL (I6150-6205-FT1)

7. 6205 BRG. KNOCK TOOL (I6150-6205-FT2)

8. L CRANK CASE COVER 6006 BRG. FABRICATING TOOL

(I6150-6006-FT1)

12

9. FABRICATING R CRANK CASE COVER 6201

BRG. TOOL (I6140-6201-FT1)

10. TAKING BRG. RB1 TOOL (I6150-RB1-FT1)

11. PNEUMATIC TAKING BRG. 6205 TOOL (I6150-6205-FT3)

12. TAKING TAPPET PIN TOOL (A4451-HMA-FT1)

13

13. ASSEMBLING DRIVE SHAFT TOOL
(B3411-RB1-FT1)

14. TAKING TRANSMISSION SHAFT BRG. 6305
TOOL (I6100-6305-FT1)

15. KNOCKING BRG.(6901) WATER PUMP IMPLEMENT
(I1001-KJ9-FT1)

14

16. KNOCKING WATER PUMP OIL SEAL IMPLEMENT (INSIDE)
(I1205-KF0-FT1 )

17. KNOCKING WATER PUMP OIL SEAL(IRON) IMPLEMENT
(A9217-H9A-FT1)

18. TAKING & LOCKING SPECIAL NUT 36MM SLEEVE
(I0202-HMA-FT1)

19. TAKING & FABRICATING IN. VALVE TOOL
(A4711-HMA-FT1)

15

20. TAKING BRG. 62040 LARGE-SIZE TOOL
(I6100-6204-FT3 )

21. ALL-PURPOSE FIXER (B2101-HMA-FT1)

22. KNOCKING BRG.(6204) IMPLEMENT
(I6100-6204-FT2)

16

2. MAINTENANCE

2-1 Maintenance Data 2-8 Idle Speed

2-2 Maintenance Schedule 2-9 Drive Chain
2-3 Fuel Tube 2-10 Brake System
2-4 Throttle Operation 2-11 Wheels And Tires
2-5 Throttle Cable Adjustment 2-12 Steering Shaft Holder Bushing
2-6 Air Cleaner 2-13 Toe-In
2-7 Spark Plug

2-1 Maintenance Data

SPECIFICATION

SPARK PLUG

SPARK PLUG GAP 0.8 mm
RECOMMENDED SPARK PLUGS NGK CR8E

THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1700±100 rpm

BRAKE LEVER FREE PLAY 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
TOE-IN 5±10 mm

TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL 1.4 Liter (1.2Liter for change)
GEAR LUBRICATION OIL 750cc (650cc for change)

17

2-2 Maintenance Schedule

The internal maintenance in the following table is based on average riding, normal conditions.
Riding in unusually dusty areas, require more frequent servicing.

300KM Every Every Every Every Notes
1 Month 3 Months 6 Months 1 Year 2 Years
Fuel Lines I I R
Throttle Operation I I
Air Filter I C R
Fuel Filter R
Spark Plug I I R
Drive Chain I, L Lubricate for every 1 month
Brake Shoes I
Brake System I I
Brake Fluid I R
Nuts, Bolts & Fasteners I
WHEEL/TIRES I I
Wheels I I
Steering System I I
Suspension System I I
C.V.T Drive belt I R
Transmission Oil R Replace for every 3,000km or 6 Months
Engine Oil R Replace for every 3,000km or 6 Months
Battery I I,C I,C
Oil Filter (Screen) C C
Valve Clearance I I
Coolant I I R
Cooling Fan I I
Carburetor (Idle Speed) I I
Choke I

Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary

C: Clean L: Lubricate R: Replace

2-3 Fuel Tube

Inspect the fuel lines for deterioration, damaging or
leakage and replace if necessary.

18

2-4 Throttle Operation

Inspect for smooth throttle lever full opening and automatic
full closing in all steering positions.
Inspect if there is no deterioration, damage or kink in the
throttle cable, replace it if necessary.

Check the throttle lever, free play is 5-10 mm at the tip of the
throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to prevent
premature wear.

2-5 Throttle Cable Adjustment

Slide the rubber cap of the adjuster off the throttle
Housing, loosen the lock nut and adjust the free play
of the throttle lever by turning the adjuster on the throttle housing.
Inspect the free play of the throttle lever.

Throttle

2-6 Air Cleaner

Please remove the four hooks, and then disassemble
two screws inside the air cleaner case.
Pull out the air filter element from the air cleaner case.
Washing the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the every component into air cleaner in the reverse order of
removal.

Note: for more detail please check chapter 5-10

2-7 Spark Plug

This spark plug is located at the front of the engine.
Disconnect the spark plug cap and unscrew the spark plug.
Check the condition of spark plug electrodes wear.

19

Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
The spark plug gap shall keep in 0.8mm
With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading.
Tighten the spark plug with 1.0~1.2kgf-m

2-8 Idle Speed

Connect an engine speed meter.
Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. “Turn in” (clockwise) will
get higher speed. “Turn out” (counter clockwise) will get lower speed.

IDLE SPEED: 1700±100 rpm

2-9 Drive Chain

Stopping the ATV and shift the transmission into neutral(N) .
Measure the drive chain slack midway between the
sprockets.

Chain slack =15~25mm (5/8~1 inch)

Adjust the chain slack.
Loosen the lock nuts and turn drive chain adjusting nuts
until get the correct slack.
Tighten the axle holder bolts.

Torque = 90N.m (65 lbf.ft)

When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator.
Please use special chain oil to lubricate the drive chain.
Clean the drive chain with kerosene and wipe it dry.
Inspect the drive chain for any possible wearing or damaging.
Replace the chain, if it is worn excessively or damaged.

Inspect the sprocket teeth, if it is excessive wearing or damaging,
please replace it.

20

2-10 Brake System

Inspect the front brake lever and cable for excessive play or other
damage.
Replace or repair if necessary.
Measure the brake lever free play at the end of the brake lever trip.

Front Brake lever free play is 15-25 mm.

Turn the parking brake to the left side is “parking off”, while
turn to right side is “parking on”. As you found out the
parking brake which has been decreased its brake ability, you
might screw the adjustable nut to modify the clearance of
brake shoe to the correct position. Also, another method of
adjustment of parking brake, please refer to next page.

Inspect the rear brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the rear brake lever free play at the
end of the lever trip.

Rear Brake lever free play is 15-25 mm.

21

Brake lever

Adjustable nut

Parking Brake

Parking Off

Adjustable nut

Parking On

Adjustment

Brake level

NOTE:

y The second method to adjust brake level is under the driver

seat and rear brake component.

y In order to avoid a pre-load occurred between brake disk and

lining. After all adjusting of brake system are completed,
please check the small clearance between brake disk and
lining.

Loosen the adjustable nut near the rear brake caliper. Screw the
adjustable bolt by hand with C.W. turn to the end, then back to a
quarter turn. Tighten the nut to complete the parking brake
adjustment.

Also, as you fount out the brake ability which is a bit insufficient,
you can screw the adjustable nut of parking Brake

.

Rear Brake

Adjustable nut

Parking Brake Adjustable nut

22

2-11 Wheels And Tires

Inspect the tire surfaces for cuts, nails or other sharp objects.
Check the each tire surface at cold tire condition.

*The standard of tire pressure is 12(0.8) psi ( kgf/cm2)

2-12 Steering Shaft Holder Bushing

Remove the front fender first.
Remove the steering shaft holder and check the steering shaft bushing
for wears or damage.
If the bushing is worn or damaged, please change a new one.
Grease the steering shaft bushing and install the parts
in the reverse order of removal.

Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)

2-13 Toe-In

Keep the vehicle on level ground and the front wheels facing straight
ahead.
Mark the centers of the tires to indicate the axle center height.
Measure the distance between the marks.

Carefully to move the vehicle back, let the wheels turn 180 degree,
so the marks on the tires are aligned with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear measurements.

Toe-in: 5±10mm

23

If the toe-in is out of standard, adjust it by changing
the length of the tie-rods equally by turning the tie-rod
while holding the ball joint.
Tighten the lock nuts.

Torque: 35-43 N.m

Lock Nuts

24

3. ENGINE REMOVE AND INSTALLATION

3-1 General Information 3-3 Engine Installation
3-2 Engine Removal

3.1 General Information

ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR
ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY

3-2 Engine Removal

Before removing engine, you need to remove all of components such as seat, front and back fender,
fuel tube, exhaust pipe, carburetor cable and drive chain…etc. You can then see three hanger bolts which have
screwed on engine.

Loosen these three hanger bolts. You have succeeded to remove this engine.

There are some pictures to describe main step of removing engine.

Disconnect the wire connectors. There are three connectors for
carburetor auto-choke, starter motor and generator respectively.

Remove the drive chain cover.
Remove the drive chain retaining clip and master link,
and remove the drive chain.

Hanger bolt

25

3-3 Engine Installation

The Engine installation is essentially in the reverse order of removal.
The torque of engine hanger bolt is 30 N.m
Route the wires and cable in reverse order properly.

26

4. LUBRICATION SYSTEM

4-1 Mechanism Diagram
4-2 Precautions In Operation
4-3 Troubleshooting

4-5 Engine Oil Strainer Clean
4-6 Oil Pump
4-7 Gear Oil

4-4 Engine Oil

4-1 Mechanism Diagram

Press-In Lubrication

Oil Route

Con-Rod

Valve Rocker Arm

Cam Shaft

Spray Lubrication

Oil Route

Spray Lubrication

Press-In Lubrication

Rotate Direction

Oil Pump

Oil Strainer

27

4-2 Precautions In Operation

General Information:

z This chapter contains maintenance operation

for the engine oil pump and gear oil
replacement.

Specifications

Engine oil quantity Disassembly: 1400 c.c.

Change: 1200c.c.

Oil viscosity SAE 10W-30 (Recommended

King serial oils)

Gear oil Disassembly: 750c.c.

Change: 650c.c.

Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)

Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20

Oil pump

Torque value

Torque value oil strainer cap 1.5~3.0kgf-m
Engine oil drain bolt 1.9~2.5kgf-m
Gear oil drain bolt 1.0~1.5kgf-m

Gear oil join bolt 1.0~1.5kgf-m
Oil pump connection bolt 0.8~1.2kgf-m

Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12

單位:mm

4-3 Troubleshooting

Low engine oil level

y Oil leaking
y Valve guide or seat worn out
y Piston ring worn out

Low oil pressure

y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage

Dirty oil

y No oil change in periodical
y Cylinder head gasket damage
y Piston ring worn out

28

4-4 Engine Oil

Turn off engine, and park the ATV in flat surface
with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out
recommended oil to upper level.

Oil Change

Caution

Drain oil as engine warmed up so that makes sure
oil can be drained smoothly and completely.

Place an oil pan under the ATV, and remove oil
drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.

Drain bolt

Torque value：1.9~2.5kgf-m

4-5 Engine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer .
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.

Torque value：1.5~3.0kgf-m

Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.

Engine oil capacity: 1200c.c. when replacing

Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.

Oil strainer cap

O-ring

29

Oil strainer

4-6 Oil Pump

Oil Pump Removal

Remove generator and starting gear. (Refer to
chapter 10) 。

Remove cir clip and take out oil pump driving
chain and sprocket.

Make sure that pump shaft can be rotated freely.
Remove 2 screws on the oil pump, and then
remove oil pump.

Oil Pump Disassembly

Remove the screws on oil pump cover and
remove the cover.
Remove oil pump shaft roller and shaft.

Clip

2 screws

1 screw

Roller

30

Oil Pump Inspection

Check the clearance between oil pump body and
outer rotor.

Limit: 0.25 mm

Check clearance between inner and outer rotors.
Limit: 0.20 mm

Check clearance between rotor side face and
pump body
Limit: 0.12 mm

Oil Pump Re-assembly

Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of
inner rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins
properly.

Pins

31

Tighten the oil pump screw.

Oil Pump Installation

Install the oil pump, and then tighten screws.

Torque value：0.8~1.2kgf-m

Make sure that oil pump shaft can be rotated
freely.

Install oil pump drive chain and sprocket, and
then install cir clip onto oil pump shaft.

Install starting gear and generator.
(Refer to chapter 10)

1 screw

Roller

2 screws

Clip

32

4-7 Gear Oil

Gear Oil Change

Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.

Torque value: 1.0~1.5kgf-m

Make sure that the drain bolt washer can be re-used.
Add oil to specified quantity from the join hole.

Gear Oil Quantity: 650c.c. when replacing

Make sure that the join bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.

Gear oil join bolt

Gear oil drain bolt

5. FUEL SYSTEM

5-1 Mechanism Diagram

5-6 Throttle Valve
5-2 Precautions in Operation
5-3 Trouble Diagnosis
5-4 Carburetor Remove / Install
5-5 Air Cut-Off Valve

5-1 Mechanism Diagram

5-7 Float Chamber

5-8 Adjustment Of Idle Speed

5-9 Fuel Tank

5-10 Air Cleaner

Fuel tank cap

Fuel unit

Fuel tank

Inlet pipe

Auto fuel cock

Carburetor

Fuel strainer

5-2 Precautions In Operation

General Information

Warning

Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.

Cautions

y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as

re-assembly

y There is a drain screw in the float chamber for draining residual gasoline.
y Do not disassemble air cut valve arbitrarily.

Tool
Special service tools

| Vacuum/air pressure pump
| Fuel level gauge

Specification of CARBURETOR

ITEM UA25A

Carburetor diameter Ø22mm
I.D. number PTG 050
Fuel level 14.8mm
Main injector # 110
Idle injector # 35
Idle speed 1700 ± 100rpm
Throttle lever clearance 1~3 mm
Air screw 2 turns

5-3 Trouble Diagnosis

Poor engine start

y No fuel in fuel tank
y Clogged fuel tube
y Too much fuel in cylinder
y No spark from spark plug(malfunction of

ignition system )

y Clogged air cleaner
y Malfunction of carburetor chock
y Malfunction of throttle operation

Stall after started

y Malfunction of carburetor chock
y Incorrect ignition timing
y Malfunction of carburetor
y Dirty engine oil
y Air existing in intake system
y Incorrect idle speed

Rough idle

y Malfunction of ignition system
y Incorrect idle speed
y Malfunction of carburetor
y Dirty fuel

Intermittently misfire as acceleration

y Malfunction of ignition system

Late ignition timing

y Malfunction of ignition system
y Malfunction of carburetor

Power insufficiency and fuel consuming

y Fuel system clogged
y Malfunction of ignition system

Mixture too lean

y Clogged fuel injector
y Vacuum piston stick and closed
y Malfunction of float valve
y Fuel level too low in float chamber
y Clogged fuel tank cap vent
y Clogged fuel filter
y Obstructed fuel pipe
y Clogged air vent hose
y Air existing in intake system

Mixture too rich

y Clogged air injector
y Malfunction of float valve
y Fuel level too high in float chamber
y Malfunction of carburetor chock
y Dirty air cleaner

5-4 Carburetor Remove / Install

Removal

Drain out fuel in the float chamber.

Loosen the choke cable fixed iron sheet screw from
plate.
Remove the choke cable.

Disconnect the fuel hose.
Release the clamp strip of air cleaner.

Remove the carburetor upper parts from the
carburetor.
Release the 2 nuts of carburetor insulator, and then
remove the carburetor.

Installation

Install in reverse order of removal procedures.

Drain bolt

Vacuum pipe

1 screw

Choke cable

Fuel pipe

Clamp

2 nuts

5-5 Air Cut-Off Valve

A

Disassembly

Remove 2 screws.

Remove air cut-off valve cover, spring and valve.

Inspection

Check the valve is in normal.
If the valve is in normal, it will restrict air-flow.
If air-flow is no restricting, replace carburetor
assembly.
Check the vacuum pipe o-ring is in normal.

Assembly

Install in reverse order of removal procedures.

2 screws

O-ring

ir cut-off valve

Spring

Cover

5-6 Throttle Valve

p

Disassembly

Remove carburetor upper parts, and then remove
throttle valve and throttle cable.

Disconnect the throttle cable from the throttle valve
and remove the valve spring.
Remove the fuel needle clamp and fuel needle.

Assembly

Place the fuel needle onto the throttle valve and clip it
with needle clamp.
Install the sealed cap, carburetor upper part, and
throttle valve spring.
Connect the throttle valve cable to the throttle valve.
Install the throttle valve into the carburetor body.

Throttle valve

Throttle

Spring

Needle clam

Fuel needle clip
Fuel needle

Caution

Align the groove inside the throttle valve with the
throttle stopper screw of the carburetor body.

Tighten the carburetor upper part.
Adjust the free play of throttle valve cable.

5-7 Float Chamber

Disassembly

Remove 3 mounting screws and remove float
chamber cover.

Remove the fuel level plate, float pin, float and float
valve.

Inspection

Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve seat
face for wear, dirt.

Fuel level plate

3 Screws

Float valve

Pin

Pin

Caution

In case of worn out or dirt, the float valve and
valve seat will not tightly close causing fuel level
to increase and as a result, fuel flooding. A worn
out or dirty float valve must be replaced with a
new a new one.

Float valve

Remove main jet, needle jet holder, needle jet, slow
jet and air adjustment screw.

Caution

Take care not to damage jets and adjust screw.

y Before removing adjustment screw, turn it all

the way down and note the number of turns.

y Does not turn adjust screw forcefully to avoid

damaging valve seat face.

Clean jets with cleaning fluid. Then use compressed
air to blow the dirt off.
Blow carburetor body passages with compressed air.

Assembly

Install main jet, needle jet holder, needle jet, slow jet
and air adjustment screw.

Needle jet holder

Needle jet

Main jet

Slow jet

Air adjustment screw

Caution

Set the air adjustment screw in according to
number of turns noted before it was removed.

Install the float valve, float, and float pin.

Checking fuel level

Caution

y Check again to ensure float valve, float for

proper installation.

y To ensure correct measurement, position the

float meter in such a way so that float chamber
face is vertical to the main jet.

Fuel level: 14.8mm

Installation of carburetor

Install carburetor in the reverse order of removal.
Following adjustments must be made after
installation.

․Throttle cable adjustment.
․Idle adjustment

Float gauge

Throttle adjustment screw

Lock nut

5-8 Adjustment Of Idle Speed

Caution

y Inspection & adjustment for idle speed have to

be performed after all parts in engine that
needed adjustment have been adjusted.

y Idle speed check and adjustment have to be

done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)

Park the ATV warm up engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1700 ± 100 rpm

Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.

1. Connect the tachometer onto engine.

2. Adjust the throttle valve stopper screw and let
engine runs in 1600±100 rpm.

3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that
emission value in idle speed is within standard.

4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.

5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.

Emission standard CO: below 0,8~1.5%

HC: below 900ppm

Ignition cable

Stopper screw

Air adjustment screw

5-9 Fuel Tank

V

Fuel unit removal

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).

4 bolts

Caution

․Do not bend the float arm of fuel unit
․Do not fill out too much fuel to fuel tank.

Fuel unit inspection (Refer to electrical equipment

chapter 17).

Fuel unit installation

Install the gauge in the reverse order of removal.

Caution

Do not forget to install the gasket of fuel unit or
damage it.

Fuel tank removal

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).

Remove the fuel tube.
Remove the vacuum tube.

Remove fuel tank front and rear side 4 bolts, and then
remove fuel tank.

Installation

Install the tank in the reverse order of removal.

Coupler

acuum tube

FRONT

REAR

Fuel tube

4 bolts

5-10 Air Cleaner

Removal

Loosen the clamp strip of air cleaner and carburetor,
and then remove the vapor hose.

Loosen the clamp strip of air cleaner, and then
remove the air cleaner vapor hose.
Remove the air cleaner (4 bolts).

Installation

Install the tank in the reverse order of removal.

Cleaning air cleaner element

Remove the air cleaner cover (4 catch hooks).

Remove element mounting screw.
Loosen the clamp strip of air cleaner element, and
then remove the air cleaner element.
Clean the element with non-flammable or high-flash
point solvent and then squeeze it for dry.

Caution

Clamp

Clamp

4 bolts

4 hooks

Never use gasoline or acid organized solvent to
clean the element.

Soap the element into cleaning engine oil and then
squeeze it out. Install the element onto the element
seat and then install the air cleaner cover.

Clamp

1 screw

6. CYLINDER HEAD/VALVE

6-1 Mechanism Diagram
6-2 Precautions In Operation
6-3 Troubleshooting
6-4 Cylinder Head Removal
6-5 Cylinder Head Inspection

6-1 Mechanism Diagram

1.0~1.4kgf-m

6-6 Valve Stem Replacement
6-7 Valve Seat Inspection And Service
6-8 Cylinder Head Reassembly
6-9 Cylinder Head Installation
6-10 Valve Clearance Adjustment

1.0~1.4kgf-m

1.0~1.4kgf-m

1.0~1.4kgf-m

0.7~1.1kgf-m

1.0~1.4kgf-m

3.6~4.0kgf-m

2.4~3.0kgf-m

1.0~1.2kgf-m

1.0~1.2kgf-m

6-2 Precautions In Operation

General Information

y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as

rocker arm.

y Cylinder head service can be carried out when engine is in frame.

Specification of CYLINDER HEAD

Item Standard Limit

Compression pressure 12±2 kg/cm2 ---

Camshaft Height of cam lobe

ID of valve rocker arm 11.982~12.000 12.080

Rocker arm

OD of valve rocker arm shaft 11.966~11.984 11.936

OD of valve stem

ID of valve guide 5.000~5.012 5.030
Clearance between

valve stem and guide

Valve

Free length of valve
spring

Valve seat width 3.400 4.000

Valve clearance

Tilt angle of cylinder head --- 0.050

Torque Value

Cylinder head cover bolt 1.0~1.4kgf-m
Exhaust pipe stud bolt 2.4~3.0kgf-m
Cylinder head bolt 1.0~1.4kgf-m
Cylinder head Nut 3.6~4.0kgf-m
Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cylinder side cover bolt 1.0~1.4kgf-m
Cam sprocket bolt 1.0~1.4kgf-m
Tappet adjustment screw nut 0.7~1.1kgf-m
Spark plug 1.0~1.2kgf-m

Tools
Special service tools

Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor

Intake 5.90 5.85
Exhaust 5.70 5.65

Intake 4.975~4.990 4.900
Exhaust 4.950~4.975 4.900

Intake 0.010~0.037
Exhaust 0.025~0.062
Intake 38.700 35.200
Exhaust 40.400 36.900

Intake 0.10±0.02mm ­Exhaust 0.15±0.02mm -

0.080

0.100

6-3 Troubleshooting

Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by
performing cylinder compression test and judging the abnormal noise generated.

Low compression pressure

1. Valve

y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage

y Valve carbon deposit.

2. Cylinder head

y Cylinder head gasket leaking or damage
y Tilt or crack cylinder

3. Piston

y Piston ring worn out.

High compression pressure

y Too much carbon deposit on combustion chamber or piston head

Noise

y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Chain wear out or looseness
y Auto-tensioner wear out or damage
y Camshaft sprocket
y Rocker arm or rocker arm shaft wear out

6-4 Cylinder Head Removal

g

Remove engine. (Refer to chapter 5)
Remove the inlet pipe (2 nuts).

Remove 1 bolt of thermostat and then remove the
thermostat.
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).

Remove Air Injection system (AI) pipe mounting
bolts.
Remove spark plug.

Remove the side cover mounting blots of cylinder
head, and then take out the side cover.

2 nuts

Tensioner bolts

4 bolts

3 bolts

Thermostat bolts

Spark plu

Remove left crankcase cover, and turn the

p

Turn the drive face, and align the timing mark on
the sprocket with that of cylinder head, piston is at
TDC position.
Remove cam sprocket bolts and then remove the
sprocket by prying chain out.

Remove cam shaft setting plate (1 bolt).

Remove rocker arm shafts and rocker arms.

Special Service Tool:
Rocker arm and cam shaft puller

Remove cam shafts.

Special Service Tool:
Rocker arm and cam shaft puller

2 bolts

Timing mark

Cam shaft setting plate

Rocker arm shafts

Rocker arm shaft and

cam shaft

uller

Cam shafts

Rocker arm

shaft and cam

Remove the 2 cylinder head mounting bolts from
cylinder head right side, and then remove 4 nuts and
washers from cylinder head upper side.
Remove the cylinder head.

Remove cylinder head gasket and 2 dowel pins.
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.

2 bolts

4 Nuts

Gasket

Caution

y Do not damage the matching surfaces of

cylinder and cylinder head.

y Avoid residues of gasket or foreign materials

falling into crankcase as cleaning.

Use a valve cotter remove & assembly tool to press
the valve spring, and then remove valves.

Caution

y In order to avoid loosing spring elasticity, do

not press the spring too much. Thus, press
length is based on the valve cotter in which can
be removed.

Chain guide

Valve cotter remove

Inlet valve

Dowel pins

Inner spring

Spring retainer

Special Service Tool:
Valve cotter remove & assembly tool

Exhaust valve

Outer spring

Cotter

V

Remove valve stem seals.

Clean carbon deposits in combustion chamber.
Clean residues and foreign materials on cylinder
head matching surface.

Caution

alve stem seals

Do not damage the matching surface of cylinder
head.

6-5 Cylinder Head Inspection

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge and
thickness gauge.

Service limit: 0.5 mm

Camshaft

Inspect cam lobe height for damaged.

Service Limit:

IN: Replacement when less than 34.45mm
EX: Replacement when less than 34.30mm

Inspect the camshaft bearing for looseness or wear
out. If any damage, replace whole set of camshaft
and bearing.

Rocker Arm

Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?

Service Limit: Replace when it is less than 12.10
mm.

Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm shaft
and cam rocker arm.

Service Limit: Replace when it is less than 11.91
mm.

Calculate the clearance between the rocker arm shaft
and the rocker arm.

Service Limit: Replace when it is less than 0.10
mm.

Valve spring free length

Measure the free length of intake and exhaust valve
springs.

Service limit:
Inner spring 35.00 mm
Outer spring 39.00 mm

Valve stem

Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.

Service Limit: IN: 4.90 mm

EX: 4.90 mm

Valve guide

Caution

Before measuring the valve guide, clean carbon
deposits with reamer.

Tool: 5.0 mm valve guide reamer

Measure and record each valve guide inner
diameters.

Service limit: 5.03 mm

The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.

Service Limit: IN→0.08 mm

EX→0.10 mm

5.0 mm valve guide reamer

Caution

If clearance between valve stem and valve guide
exceeded service limit, check whether the new
clearance that only replaces new valve guide is
within service limit or not. If so, replace valve
guide.

Correct it with reamer after replacement.
If clearance still exceeds service limit after replaced valve guide, replace valve stem too.

Caution

It has to correct valve seat when replacing valve
guide.

6-6 Valve Stem Replacement

5.0

V

Heat up cylinder head to 100~150 ℃ with heated
plate or toaster.

Caution

y Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed
as heating it.

y Wear on a pair of glove to protect your hands

when operating.

Hold the cylinder head, and then press out old valve
guide from combustion chamber side.

Tool: Valve guide driver: 5.0 mm

Caution

Valve guide driver

mm

Valve guide driver

5.0 mm

y Check if new valve guide is deformation after

pressed it in.

y When pressing in the new valve guide, cylinder

head still have to be kept in 100~150℃.

Adjust the valve guide driver and let valve guide height is in 13 mm.
Press in new valve guide from rocker arm side.

Tool: Valve guide driver: 5.0 mm

Wait for the cylinder head cooling down to room

alve guide reamer 5.0 mm

temperature, and then correct the new valve guide
with reamer.

Caution

y Using cutting oil when correcting valve guide

with a reamer.

y Turn the reamer in same direction when it be

inserted or rotated.

Correct valve seat, and clean up all metal residues from cylinder head.

Tool: Valve guide reamer: 5.0 mm

6-7 Valve Seat Inspection And Service

g

Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other manual
grinding tool.

Caution

y Do not let emery enter into between valve stem and

valve guide.

y Clean up the emery after corrected, and apply with

engine oil onto contact faces of valve and valve seat.

Remove the valve and check its contact face.

Caution

Valve seat width

Replace the valve with new one if valve seal is
roughness, wear out, or incomplete contacted with
valve seat.

Valve seat inspection

If the valve seat is too width, narrow or rough, corrects it.

Valve seat width

Service limit: 1.6mm

Check the contact condition of valve seat.

Valve seat grinding

The worn valve seat has to be ground with valve seat
chamfer cutter.
Refer to operation manual of the valve seat chamfer
cutter.
Use 45° valve seat chamfer cutter to cut any rough or
uneven surface from valve seat.

Rou

hness

45°

Old valve seat width

Caution

After valve guide had been replaced, it has to be
ground with 45° valve seal chamfer cutter to
correct its seat face.

Use 32° cutter to cut a quarter upper parts out.

32°

Use 60° cutter to cut a quarter lower parts out.

g

Remove the cutter and check new valve seat.

Use 45° cutter to grind the valve seat to specified width.

Caution

Old valve seat width

60°

Make sure that all roughness and uneven faces
had been ground.

Grind valve seat again if necessary.

Coat the valve seat surface with red paint.
Install the valve through valve guide until the valve
contacting with valve seat, slightly press down the valve
but do not rotate it so that a seal track will be created on
contact surface.

Caution

Contact surface too hi

1.0mm

45°

h

Old valve seat width

32°

The contact surfaces of valve and valve seat are
very important to the valve sealing capacity.

If the contact surface too high, grind the valve seat with
32° cutter.
Then, grind the valve seat to specified width.

If the contact surface too low, grind the valve seat with
60° cutter.
Then, grind the valve seat to specified width.

Contact surface too low

Old valve seat width

60°

After the valve seat ground, coat valve seat surface

V

with emery and then slightly press the ground
surface.
Clean up all emery coated onto cylinder and valve
after ground.

6-8 Cylinder Head Reassembly

Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.

Caution

The closed coils of valve spring should face down
to combustion chamber.

Use a valve cotter remove & assembly tool to press
the valve spring, and then remove valves.

Caution

In order to avoid damaging the valve stem and the
cylinder head, in the combustion chamber place a
rag between the valve spring remover/installer as
compressing the valve spring directly.

Special Service Tool:
Valve cotter remove & assembly tool

Tap the valve stems gently with a plastic hammer to
make sure valve retainer and valve cotter is settled.

Valve spring retainer

alve cotter

Valve spring

Exhaust valve

Valve cotter remove

Valve stem seal

Inlet valve

Caution

Place and hold cylinder head on to working table
so that can prevent from valve damaged.

6-9 Cylinder Head Installation

Clean up all residues and foreign materials onto the
matching surfaces of both cylinder and cylinder
head.
Install chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.

Caution

Do not damage the matching surfaces of cylinder
and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.

Install 4 washers and tighten 4 nuts on the cylinder
head upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head right side.

Torque value:
Nut 3.6~4.0kgf-m
Bolt 1.0~1.4kgf-m

Install camshaft into cylinder head, and install
rocker arm, rocker arm shaft.

Install rocker arm pin mounting plate.

Chain guide

Dowel pins

2 bolts

Cam shaft setting plate

Gasket

4 Nuts

Install cam chain on to sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.

Caution

Make sure timing marks are matched.

Install cylinder head side cover (3 bolts).
Install thermostat (2 bolts).

Loosen auto tensioner adjustment bolt and remove
bolt and spring.
Install tensioner and install spring and adjustment
bolt.

Install cylinder cover (4 bolts).

2 bolts

3 bolts

Thermostat bolts

Tensioner adjustment bolt

Timing mark

4 bolts

Install Air Injection system (AI) pipe. (4 bolts)

g

Install inlet pipe onto cylinder
Install and tighten spark plug

Torque value: 1.0~2.0kgf-m

Caution

This model is equipped with more precision 4-valve
mechanism so its tighten torque can not be exceeded
standard value in order to avoid causing cylinder head
deformation, engine noise and leaking so that

motorcycle’s performance be effected.

Install the engine onto frame (refer chapter 5).

4 bolts

Spark plu

6-10 Valve Clearance Adjustment

Loosen Air Injection system (AI) pipe upper side bolt

Caution

Checks and adjustment must be performed when
the engine temperature is below 35℃.

Remove front fender, fuel tank cover and fuel tank.
Remove cylinder head cover.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position
in compression stroke.

Caution

Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.

Valve clearance inspection and adjustment.
Check & adjust valve clearance with feeler gauge.

Standard Value: IN 0.10 ± 0.02 mm

Loosen fixing nut and turn the adjustment nut for
adjustment.

EX 0.15 ± 0.02 mm

Timing mark

2 bolts

Caution

Re-check the valve clearance after tightened the
fixing nut.

7. CYLINDER/PISTON

Contents

7-1 Mechanism Diagram
7-2 Precautions I
7-3 Trouble Diagnosis
7-4 Cylinder And Piston Removal

n Operation

7-1 Mechanism Diagram

7-5 Piston Ring Installation
7-6 Piston Installation
7-7 Cylinder Installation

1.0~1.4kgf-m

0.8~1.2kgf-m

To this chapter contents

7-2 Precautions In Operation

General Information

y Both cylinder and piston service cannot be carried out when engine mounted on frame.

UA25A

Specification Unit：mm

Item Standard Limit

Cylinder

Piston/
Piston ring

OD of piston pin 16.994~17.000 16.960
Clearance between piston and piston pin 0.002~0.014 0.020
ID of connecting rod small-end 17.016~17.034 17.064

ID 74.995~75.015 75.100
Bend - 0.050

Clearance between piston
rings

Ring-end gap

OD of piston (2nd) 74.430~75.480 75.380
Clearance between piston and cylinder 0.010~0.040 0.100
ID of piston pin boss 17.002~17.008 17.020

Top ring 0.015~0.050 0.090

nd

ring 0.015~0.050 0.090

2
Top ring 0.150~0.300 0.500
2nd ring 0.300~0.450 0.650
Oil ring side rail 0.200~0.700 -

7-3 Trouble Diagnosis

Low or Unstable Compression Pressure

y Cylinder or piston ring worn out

Knock or Noise

y Cylinder or piston ring worn out
y Carbon deposits on cylinder head top-side
y Piston pin hole and piston pin wear out

Smoking in Exhaust Pipe

y Piston or piston ring worn out
y Piston ring installation improperly
y Cylinder or piston damage

Engine Overheat

y Carbon deposits on cylinder head top side
y Cooling pipe clogged or not enough in coolant

flow

7-4 Cylinder And Piston Removal

Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.

Cover the holes of crankcase and cam chain with
a piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.

Remove cylinder gasket and dowel pin.
Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.

Dowel pins

Caution

y Soap the residues into solvent so that the

residues can be removed more easily.

Inspection

Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective
in the cylinder.

Service limit: 75.100 mm

Top
Center

Bottom

Check cylinder if warp.

Service limit: 0.05 mm

Measure clearance between piston rings and
grooves.

Service Limit: Top ring: 0.09 mm

nd

2

ring: 0.09 mm

Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.

Caution

Pay attention to remove piston rings because
they are fragile.

Place piston rings respective into cylinder below
20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.

Service Limit: Top ring: 0.50 mm

nd

ring: 0.65 mm

2

Measure the outer diameter of piston pin.

Service Limit: 16.96 mm

Measure the inner diameter of connecting rod
small end.

Service Limit: 17.064 mm

Measure the inner diameter of piston pin hole.
Service Limit: 17.02 mm
Calculate clearance between piston pin and its
hole.

Service Limit: 0.02 mm

Measure piston outer diameter.

Caution

The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.

Service limit：75.380 mm

Compare measured value with service limit to
calculate the clearance between piston and
cylinder.

To this chapter contents

7-5 Piston Ring Installation

Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.

Caution

y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.

Top ring

nd

2

ring

Oil ring

Top groove

nd

2

groove

Oil groove

To this chapter contents

Clean up all residues and foreign materials on
the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.

Caution

Soap the residues into solvent so that the
residues can be removed more easily.

7-6 Piston Installation

Install piston and piston pin, and place the IN
marks on the piston top side forward to inlet
valve.

Install new piston pin clip.

Caution

y Do not let the opening of piston pin clip align

with the piston cutout.

y Place a piece of cloth between piston and

crankcase in order to prevent snap ring from
falling into crankcase as operation.

IN mark

Clip end gap

7-7 Cylinder Installation

Install dowel pins and new gasket.

Cutout

Dowel pins

Coat some engine oil to inside of cylinder, piston
and piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.

Caution

Do not push piston into cylinder forcefully
because piston and piston rings will be
damaged.。

Install coolant hose onto cylinder.
Install cylinder head (refer to Chapter 6).

Coolant hose

8. V-BELT DRIVING SYSTEM

8-1 Mechanism Diagram
8-2 Maintenance Description
8-3 Trouble Diagnosis
8-4 Left Crankcase Cover

8-1 Mechanism Diagram

8-5 Drive Belt
8-6 Drive Face
8-7 Clutch Outer/Driven Pulley

8.5~10.5kgf-m

5.0~6.0kgf-m

5.0~6.0kgf-m

8-2 Maintenance Description

Precautions in Operation
General Information

y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
y Drive belt and drive pulley must be free of grease.

Specification

Item Standard value Limit
Driving belt width 24.000 mm 22.500 mm
OD of movable drive face boss 29.946~29.980 mm 29.926 mm
ID of movable drive face 30.000~30.040 mm 30.060 mm
OD of weight roller 19.500~20.000 mm 19.000 mm
ID of clutch outer 144.850~145.150 mm 145.450 mm
Thickness of clutch weight 6.000 mm 3.000 mm
Free length of driven pulley spring 102.400 mm 97.400 mm
OD of driven pulley boss 40.950~40.990 mm 40.930 mm
ID of driven face 41.000~41.050 mm 41.070 mm
Weight of weight roller 17.700~18.300 g 17.200 g

Torque value

y Drive face nut: 8.5~10.5kgf-m
y Clutch outer nut: 5.0~6.0kgf-m
y Drive plate nut: 5.0~6.0kgf-m

Special Service Tools

Clutch spring compressor: SYM-2301000
Inner bearing puller:
Clutch nut wrench 39 x 41 mm:
Universal holder:
Bearing driver:

SYM-6204002

SYM-9020200

SYM-2210100

SYM-9100100

8-3 Trouble Diagnosis

Engine can be started but motorcycle can
not be moved

1. Worn drive Belt

2. Worn drive face

3. Worn or damaged clutch weight

4. Broken driven pulley

Shudder or misfire when driving

1. Broken clutch weight

2. Worn clutch weight

Insufficient horsepower or poor high
speed performance

1. Worn drive belt

2. Insufficient spring force of driven pulley

3. Worn roller

4. Driven pulley operation un-smoothly

8-4 Left Crankcase Cover

Left crankcase cover removal

Release the 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover. (10 bolts)
Remove 2 dowel pin and gasket.

Left crankcase cover install

Install left crankcase cover in the reverse
procedures of removal.

Clamp strips

10 bolts

Starter drive pulley

Dowel pins

L crank case cover gasket

Left cover plate

Left cover plate gasket

Starter drive pulley

Dowel pins

L bearing setting plate

Ratchet cover

Volute spring

Starter grip

L crank case cover

Left crankcase cover inspection

Remove 2 bolts to remove left crankcase cover
bearing setting plate.

Check bearing on left crankcase cover.
Rotate bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on cover tightly.
If bearing rotation is uneven, noising, or loose

2 bolts

9 bolts

bearing mounted, then replace it.

Remove the bearing 6006 with inner bearing
puller.

Tools number:SYM-6204025
Tools name: INNER BEARING PULLER.

Bearing 6006 install with special tool.

Tools number:SYM-1134600-HMA RB1 6006.
Tools name: L CRANK CASE COVER
BEARING INSTALL TOOL.

Disassembly

Remove 5 screws from l cover plate and remove l
cover plate.

Remove 1 bolt from ratchet cover

Remove 2 starter ratchets and 2 ratchet springs

5 screws

1 bolt

Remove starter drive pulley and volute spring

Caution

y If remove the volute spring from the l crank

cover then its has to be replaced.

Loosen the starter rope from the starter grip.

Installation

Install in reverse order of removal procedures

Caution

First before installing the drive pulley must
establish 2 1/2 of the pressures transferred to
pressure springs.

8-5 Drive Belt

Removal

Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.

Special Tool：
Tool number : SYM-2210100
Tool name: universal holder

Hold clutch outer with universal holder, and
remove nut, bearing stay collar and clutch outer.

Caution

y Using special service tools for tightening or

Universal holder

Universal holder

Bearing stay collar

loosening the nut.

y Fixed rear wheel or rear brake will damage

reduction gear system.

Push the drive belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive belt.
Remove the drive belt from the groove of driven
pulley.

Inspection

Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.

Service Limit: 22.5 mm

Replace the belt if exceeds the service limit.

Caution

y Using the genuine parts for replacement.
y The surfaces of drive belt or pulley must be

free of grease.

y Clean up all grease or dirt before installation.

Belt tooth

Width

Installation

Caution

z Pull out driven face to avoid it closing.

z Cannot oppress friction plate comp in order

to avoid creates the distortion or the
damage.

Install drive belt onto driven pulley.

Install the driven pulley that has installed the belt
onto drive shaft.
On the drive belt another end to the movable drive
face.

Install the clutch outer and bearing stay collar.

Driven face

Universal holder

Bearing stay collar

Hold the clutch outer whit universal holder, and
then tighten nut to specified torque value.

Torque value: 5.0~6.0kgf-m

Install the drive face, washer and drive face nut.
Hold drive face with universal holder, and then
tighten nut to specified torque value.

Torque value: 8.5~10.5kgf-m

Universal holder

8-6 Drive Face

Removal

Remove left crankcase cover.
Hold drive face with universal holder, and then

remove drive face nut.
Remove drive face and drive belt.

Remove movable drive face comp and drive face
boss from crankshaft.

Remove ramp plate.

Crankshaft

Ramp plate

Universal holder

Movable drive face

Drive face boss

Remove weight rollers from movable drive face.

Movable drive face

Weight roller

Inspection

The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.

Service limit: 19.0 mm
Weight: 17.2g

Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive face
boss, and replace it if it exceed service limit.

Service limit: 29.962 mm

Weight roller

Movable drive face

Drive face boss

Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.

Service limit: 30.060 mm

Reassembly/installation
Install weight rollers.

Caution

The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.

Install ramp plate.

Weight roller

Ramp plate

Closure surface

8-10

Guide collar

With 4~5g grease spreads wipes drives in the
movable drive face axis hole.
Install drive face boss.

Caution

The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.

Install movable drive face comp. onto crankshaft.

Driven pulley installation

Press drive belt into pulley groove, and then pull
the belt onto drive shaft.

Install drive face, washer and nut.

Movable drive face

Crank shaft

Press down

Drive belt

Drive face boss

Drive face boss

Caution

Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.

Hold drives face with universal holder.
Tighten nut to specified torque.

Torque value: 8.5~10.5kgf-m

Install left crankcase cover.

8-7 Clutch Outer/Driven Pulley

Disassembly

Remove drive belt, clutch outer and driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.

Caution

Do not press the compressor too much.

Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
friction plate, clutch weight and spring from driven
pulley.

Remove seal collar from driven pulley.

Remove guide pin, guide pin roller, and movable
driven face, and then remove O-ring & oil seal
seat from movable driven face.

Clutch nut wrench

Movable driven face

Clutch spring compressor

Seal

Guide pin

Collar

Inspection
Clutch outer

Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.

Service limit: 145.450 mm

O-ring

Inner
diameter

Guide pin

Guide pin roller

Clutch outer

Clutch lining

Measure each clutch weight thickness. Replace
it if exceeds service limit.

Service limit: 3.0 mm

Clutch lining

Clutch weight

Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.

Service limit: 97.4 mm

Driven pulley

Check following items:

y If both surfaces are damaged or worn.
y If guide pin groove is damaged or worn.

Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.

Service limit: Outer diameter 40.93 mm
Inner diameter 41.07 mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.

Free length

Driven face

Movable driven face

Guide pin groove

Needle bearing

Outer ball bearing

To this chapter contents

Clutch weight Replacement

Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.

Caution

Some of models are equipped with one mounting
plate instead of 3 snap rings.

Check if spring is damage or insufficient elasticity.

Check if shock absorption rubber is damage or
deformation. Replace it if necessary.
Apply with grease onto setting pins.

Spring

Clutch weight

Shock absorption rubber

Driving plate

Snap ring

Setting pin

Install new clutch weight onto setting pin and then
push to the specified location.
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.

Caution

Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity.

Install the spring into groove with pliers.

Shock absorption rubber

Clutch weight

Spring

Install snap ring and mounting plate onto setting
pin.

Replacement of Driven Pulley Bearing

Remove inner bearing.

Caution

y If the inner bearing equipped with oil seal on

side in the driven pulley, then remove the oil
seal firstly.

y If the pulley equipped with ball bearing, it has to

remove snap ring and then the bearing.

Remove snap ring and then push bearing forward
to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified oil.

Snap ring

Outer bearing

Clipper

Inner needle
bearing

Snap ring

Snap ring

Install new inner bearing.

Caution

y Its sealing end should be forwarded to outside

as bearing installation.

y Install needle bearing with hydraulic presser.

Install ball bearing by means of hydraulic
presser.

Install snap ring into the groove of drive face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).

Outer bearing

Bearing end

Inner bearing

Installation of Clutch OUTER/Driven Pulley
Assembly

Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.

Install the movable driven face onto driven face.
Install the guide pin and guide pin roller.

Install the collar.

Install friction plate, spring and clutch weight into
clutch spring compressor, and press down the
assembly by turning manual lever until mounting
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.

Torque value: 5.0~6.0kgf-m

Install clutch outer/driven pulley and drive belt onto
drive shaft.

Oil seal

O-ring

Specified grease

Movable driven face

O-ring Guide pin

Oil seal

Guide pin

Guide pin roller

Collar

Clutch nut wrench

Clutch spring compressor

9. FINAL DRIVING MECHANISM

9-1 Mechanism Diagram - Transmission

Cover
9-2 Precautions In operation
9-3 Trouble Diagnosis
9-4 Disassembly Of Transmission

9-5 Inspection Of Mission Mechanism
9-6 Bearing Replacement
9-7 Re-assembly Of Final Driving

Mechanism

9-1 Mechanism Diagram - Transmission Cover

9-2 Precautions In operation

Specification

Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 750c.c. (650c.c. when replacing)

Torque value

Gear box cover 2.6~3.0kgf-m

Gear oil drain bolt 0.8~1.2kgf-m
Gear oil fill bolt 3.5~4.5kgf-m

Tools

Special tools

Bearing driver (6204): SYM-9110400
Bearing driver (6205LLU): SYM-9100400-HMA
Bearing driver (6305): SYM-9100400-RB1
Needle bearing driver (HK2016): SYM-9100300-RB1
Drive shaft and oil seal driver: SYM-9120200-HMA
Drive shaft puller: SYM-2341100
Inner bearing puller: SYM-6204002

9-3 Trouble Diagnosis

Engine can be started but motorcycle can
not be moved.

y Damaged drive gear
y Burnt out drive gear
y Damaged gear shift system

Noise

y Worn or burnt gear
y Worn gear

Gear oil leaks

y Excessive gear oil.
y Worn or damage oil seal

9-4 Disassembly Of Transmission

Remove gear change lever (1 bolt).

Loosen speedometer cable mounting nut, and then
remove the cable.
Remove 3 bolts and remove drive chain protector.
Turn the socket bolt clockwise, and then remove
speedometer gear box.

Caution

The socket bolt is provided with left turn
thread.

Remove 2 bolts, and then remove the drive
sprocket fixing plate, drive chain and drive
sprocket.

Remove gear fill bolt.
Place an oil pan under the ATV, and remove gear
oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.

Torque value:
Gear oil fill bolt 3.5~4.5kgf-m
Gear oil drain bolt 0.8~1.2kgf-m

Speedometer cable

Socket bolt

2 bolts

Drain bolt

1 bolt

3 bolts

Fill bolt

Remove gear box cover bolts (9 bolts) and then
remove the cover.

Remove shift drum catch ball, spring and bolt.

Remove shift spindle, shift fork shaft, shift fork
and shift drum.

Remove final shaft, counter shaft and reverse shaft.

Shift drum fixed catch bolt

Shift fork shaft and fork

Reverse shaft

9 bolts

Shift drum

Shift spindle

Drive shaft

Final shaft

Counter shaft

Remove drive shaft bearing setting plate (1 bolt).

Remove the drive shaft.

Special tool:

Shaft protector

Remove gasket and dowel pin.

Caution

Bearing setting plate

y If non- essential do not remove the drive shaft

from the case upper side.

y If remove the drive shaft from the gear box,

then its bearing and oil seal has to be
replaced.

Oil seal

Bearing

9-5 Inspection Of Mission Mechanism

Check if the shift spindle is wear or damage.

Check if the shift drum is wear or damage.

Check if the shift fork and shaft is wear or damage.

Check if the counter shaft is wear or damage.

Check if the reverse shaft is wear or damage.

Check if the final shaft and gear are burn, wear or
damage.

Check bearings on gear box and gear box cover.
Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it if
necessary.

Caution

y If remove the drive shaft from the crankcase

upper side, then its bearing has to be replaced.

Gear box

Reverse shaft

Final shaft bearing

Gear box cover

Drive shaft bearing

Counter shaft needle bearing

Final shaft bearing

Counter shaft bearingReverse shaft bearing

9-6 Bearing Replacement

Caution

y Never install used bearings. Once bearing

removed, it has to be replaced with new one.

Crankcase side

Remove drive shaft bearing setting plate, and then
remove drive shaft bearing from left crankcase
using following tools.
Remove reverse shaft bearing and counter shaft
bearing from left crankcase using following tools.
Remove drive shaft oil seal.

Special tool:
Inner bearing puller

Install new final shaft, counter shaft and reverse
shaft bearings into left crankcase.

Special tool:
Bearing driver (6204)
Needle bearing driver (HK2016)

Install new drive shaft bearings and baring driver
into left crankcase.

Install the universal bearing puller and bearing
driver.
Turn the universal bearing puller to install drive
shaft bearing.

Special tool:
Bearing driver (6305)
Universal bearing puller

Inner bearing puller

Clutch nut wrench

Drive shaft and

seal install bush

Bearing driver

Drive shaft and

seal install bush

Drive shaft puller

Install drive shaft.

Special tool:
Drive shaft puller
Drive shaft and oil seal install bush
Clutch nut wrench

Apply with grease onto new drive shaft oil seal lip,
and then install the oil seal.

Special tool:
Drive shaft and oil seal install bush

Install drive shaft bearing setting plate (1 bolt).

Gear box side

Use inner bearing puller to remove the final shaft
needle bearing, gear shift shaft bearing and counter
shaft bearing from the cover inner side.

Special tool:

Inner bearing puller

Remove cir clip of final shat out side bearing.
.

Clutch nut wrench

Drive shaft and

seal install bush

Cir clip

Drive shaft and

seal install bush

Drive shaft puller

Inner bearing puller

Special tool:

Inner bearing puller

Remove oil seal from gear box cover and discard
the seal

Install new bearing and bearing driver into gear
box cover outer side.

Install the universal bearing puller and bearing
driver.

Turn the universal bearing puller to install drive
shaft bearing.

Special tool:
Bearing driver (6205)
Universal bearing puller

Install new oil seal and bearing driver into gear
box cover inner side.

Install the universal bearing puller and bearing
driver.
Turn the universal bearing puller to install drive
shaft oil seal.

Special tool:
Bearing driver (6205)
Universal bearing puller

Inner bearing puller

Universal

bearing puller

Bearing driver

Bearing driver

Universal

bearing puller

Universal

bearing puller

9-7 Re-assembly Of Final Driving
Mechanism

Apply with grease onto the oil seal lip of final
driving shaft.

Install counter shaft, reverse shaft and final shaft
onto gear box.

Install shift drum, shift fork and fork shaft onto
gear box.

Install shift drum fixed catch ball, spring and bolt
onto gear box.

Reverse shaft

Final shaft

Shift fork shaft and fork

Oil seal

Drive shaft

Counter shaft

Shift drum

Shift spindle

Shift drum fixed catch bolt

Align the position mark on the shift spindle
sprocket with that of shift drum, and then install
shift spindle.

Install dowel pins and new gasket.

Install gear box cover and bolts, and tighten.

Torque value: 1.0~1.4kgf-m

Install the shift spindle bracket, drive chain
protector, speedometer gear box and gear change
lever.
Add gear oil.

Gear oil quantity: 750c.c.

Position mark

Dowel pins

9 bolts

10. ALTERNATOR/STARTING CLUTCH

10-1 Mechanism Diagram
10-2 Precautions In Operation
10-3 Right Crankcase Cover Removal
10-4 A.C.G. Set Removal
10-5 Right Cover Bearing

10-1 Mechanism Diagram

10-6 Flywheel Removal
10-7 Starting Clutch
10-8 Flywheel Installation
10-9 A.C.G. Set Installation
10-10 Right Crankcase Cover Installation

0.8~1.2kgf-m

5.0~6.0kgf-m

1.0~1.4kgf-m

10-2 Precautions In Operation

General information

y Refer to chapter 17: The troubleshooting and inspection of alternator
y Refer to chapter 17: The service procedures and precaution items of starter motor

Specification

Item Standard value (mm) Limit (mm)
ID of starting clutch gear 25.026~25.045 25.100
OD of starting clutch gear 42.175~42.200 42.100

Torque value

Flywheel nut 5.0~6.0kgf-m
Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive
8 mm bolts 0.8~1.2kgf-m
12 mm bolts 1.0~1.4kgf-m

Tools
Special tools

A.C.G. flywheel puller: SYM-3110A00
Universal holder: SYM-2210100

10-3 Right Crankcase Cover Removal

p

Remove left footrest.
Drain out the engine oil and coolant, and then
remove coolant hoses.
Remove water pump cover (4 bolts).
Remove 11 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.

10-4 A.C.G. Set Removal

Remove 2 mounted screws from pulse generator
and then remove it.
Remove 3 screws from right crankcase cover and
then remove generator coil set.

10-5 Right Cover Bearing

Inspection

Rotate the bearing with finger to check if the
bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.

Remove the cir clip, and then remove bearing.

Special tool:
Inner bearing puller

3 screws

11 bolts

Water pump cover bolts

2 screws

Cir cli