Sym ATTILA RS-21 EFi 150 Service Manual

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HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG ATTILA RS-21 EFi 150 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the motorcycle are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

This manual that contains all data, illustration, indication and specifications is based on current production information. SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this manual can be duplicated by any means without written permission of SANYANG.

Service Department

SANYANG Industry Co., LTD.

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How to Use This Manual

This service manual describes basic information of different system parts and system inspection & service for SANYANG ATTILA RS-21 EFi 150 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance and special service tools

information. The third to the eleventh chapters cover engine, fuel injection and driving

systems. The twelfth to fifteenth chapters are contained the parts set of assembly

body. The sixteenth chapter is electrical equipment. The seventh chapter is exhaust emission control system. The eighteenth chapter is for wiring diagram

Please see index of content for quick having the special parts and system information.

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Page

Content Index

1-1 ~ 1-16 2-1 ~ 2-16 3-1 ~ 3-8 4-1 ~ 4-38 5-1 ~ 5-10 6-1 ~ 6-16 7-1 ~ 7-8

General Information / Trouble Diagnosis Service Maintenance Information Lubrication System Fuel System Engine Removal Cylinder Head / Valve Cylinder / Piston

Contents

1 2 3 4 5 6

8-1 ~ 8-14 9-1 ~ 9-6 10-1 ~ 10-10 11-1 ~ 11-6 12-1 ~ 12-14 13-1 ~ 13-10 14-1 ~ 14-8 15-1 ~ 15-6 16-1 ~ 16-18

“V” Type Belt Driving System / Foot-Starter Final Driving Mechanism Alternator / Starting Clutch

Crankcase/Crankshaft Body Cover

Brake System Steering/Front Wheel/Suspension Rear Wheel/Suspension Electrical Equipment

10 11 12 13 14 15 16

17-1 ~ 17-8

Exhaust Emission Control System

18-1 ~ 18-2

Electrical Diagram

Model illustration

Battery / fuse

Winker relay

Horn

Home page

Contents

Engine temperature sensor

Spark plug

Crankshaft position sensor

IG. Coil / Start relay / Fuel pump relay

Fuel tank / Fuel pump

Engine control unit (ECU)

Front winker light

Headlight

Rear brake leve

Front brake lever

Engine number

Engine oil drain plug

High & Low beam / Passing / Turn signal / Horn switch

Intake temperature & MAP sensor (T-MAP)

Throttle position sensor (TPS) / Air by-pass valve / Fuel injector /

Seat lock

Tail light / Rear winker light

Air cleaner

Gear oil Inspection plug

Gear oil drain plug

Light / Starter switch

Ignition switch

Oil level Oil strainer

Exhaust muffler

Home page Contents

Symbols And Marks.................. 1-1

General safety........................... 1-2

1. General Information/Trouble Diagnosis

Torque Values (Frame) ........... 1-11

Standard Torque Values for

Reference................................. 1-11

Service Precautions.................. 1-3

Troubles Diagnosis................. 1-12

Specifications............................ 1-9

Parts To Be Greased............... 1-16

Torque Values (Engine).......... 1-10

Symbols And Marks

Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

Warning

Caution

Engine oil

Means that serious injury or even death may result if procedures are not followed.

Means that equipment damages may result if procedures are not followed.

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended. (KING MATE G-3)

Gear oil

Locking sealant

Oil seal Apply with lubricant.

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid “DOT3” or “WELLRUN” brake fluid.

Special tools Special service tools.

correct

wrong

Indication

King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended. (SAE 85W-140)

Apply sealant, medium strength sealant should be used unless otherwise specified.

Meaning correct installation.

Meaning wrong installation.

Indication of components.

directions

Indicates position and operation directions.

Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt

cross through the component (invisibility).

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This chapter Contents

1. General Information/Trouble Diagnosis

General safety

Carbon monoxide

If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.

Caution

Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.

Gasoline

Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode under some conditions, keep it away from children.

Used engine oil

Caution

Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verdict. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.

Battery

Caution

• Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when charging the battery.

• Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water, then go to hospital to see an ophthalmologist.

• If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor oil or vegetable oil, and then go to see a doctor.

• Keep electrolyte beyond reach of children.

Brake shoe

Do not use an compressed air or a dry brush to clean components of the brake system, use a vacuum cleaner or the equivalent to avoid asbestos dust flying.

Caution

Inhaling asbestos dust may cause disorders and cancer of the breathing system.

Brake fluid

Caution

Hot components

Caution

Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.

1-2

Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep brake fluid beyond reach of children.

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1. General Information/Trouble Diagnosis

Service Precautions

• Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG motorcycle may damage the motorcycle.

• Special tools are designed for remove and install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.

• When servicing this motorcycle, use only metric tools. Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.

• Clean the outside of the parts or the cover before removing it from the motorcycle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause a damage.

• Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.

• Never bend or twist a control cable to prevent stiff control and premature worn out.

• Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.

• When loosening a component which has different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.

• Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.

• Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).

• Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.

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This chapter Contents

1. General Information/Trouble Diagnosis

• The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.

• Tighten assemblies with different dimension fasteners as follows: Tighten all the fasteners with fingers, then tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.

• When oil seal is installed, fill the groove with grease, install the oil seal with the name of the manufacturer facing outside, check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.

Manufacturer's name

• Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage.

• The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.

Groove

Clamp

Connector

• Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.

• The tool should be pressed against two (inner and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.

Boots

1-4

Both of these examples can result in bearing

damage.

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• Lubricate the rotation face with specified lubricant on the lubrication points before assembling.

• Check if positions and operation for installed parts is in correct and properly.

• Make sure service safety each other when conducting by two persons.

• Note that do not let parts fall down.

1. General Information/Trouble Diagnosis

• Before battery removal operation, it has to remove the battery negative (-) cable firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.

• After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.

• Make sure that the battery post caps are located in properly after the battery posts had been serviced.

• If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse.

capacity

verification

1-5

This chapter Contents

1. General Information/Trouble Diagnosis

• When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation.

• Do not pull the wires as removing a connector or wires. Hold the connector body.

• Make sure if the connector pins are bent, extruded or loosen.

• Insert the connector completely.

If there are two lockers on two connector sides, make sure the lockers are locked in properly. Check if any wire loose.

• Check if the connector is covered by the twin

connector boot completely and secured properly.

• Before terminal connection, check if the boot is crack or the terminal is loose.

• Insert the terminal completely. Check if the terminal is covered by the boot. Do not let boot open facing up.

• Secure wires and wire harnesses to the frame with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

• Wire band and wire harness have to be clamped secured properly.

• Do not squeeze wires against the weld or its clamp.

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1. General Information/Trouble Diagnosis

• Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness.

• Keep wire harnesses far away from the hot parts.

NEVER TOUCH

• Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of bolts and screws.

• Route harnesses so that they neither pull too tight nor have excessive slack.

NEVER TOO TIGHT

• Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied.

• Secure the rubber boot firmly as applying it on wire harness.

• Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the damaged parts or replace them.

• Never clamp or squeeze the wire harness as installing other components.

Never clamp or

squeeze the wire

harness

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This chapter Contents

1. General Information/Trouble Diagnosis

• Do not let the wire harness been twisted as installation.

• Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

• Before operating a test instrument, operator

should read the operation manual of the instrument. And then, conduct test in accordance with the instruction.

Do you know how to set the instrument to its measurement position and the insert locations of its two probes?

• With sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later.

Clean rust

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Specifications

Maker SANYANG MODEL HE15W

Overall Length 1933 mm Front TELESCOPE

Overall Width 700 mm

Overall Height 1160 mm Front 100 / 90-12 (T/L)

DIMENSION

Wheel Base 1335 mm

Curb

Weight

Passengers/

WEIGHT

Total

Weight

Front 48 kg

Rear 75 kg

Total 123 kg

Weight

Front 78 kg

Rear 155 kg

Total 233 kg

Type 4-STROKE ENGINE Clutch Centrifugal, dry type

1. General Information/Trouble Diagnosis

Suspension

System

Tire

Specifications

Brake System

Two /110 kg Max. Speed 100 km/hr Above

PERFOR

MANCE

Reduction

Rear UNlT SWING

Rear 130 / 70 –12 (T/L)

Front DISK (ø 273 mm)

Rear DISK (ø 200 mm)

Climb Ability 28° Below

Primary

Reduction

Secondary

Reduction

BELT

GEAR

Installation and

arrangement

Fuel Used Unleaded Speedometer 0 ~ 140 km/hr

Cycle/Cooling

Bore 57.4 mm Muffler Expansion & Pulse Type

Stroke 57.8 mm

Cylinder

Number/Arran

gement

ENGINE

Displacement 149.5 cc

Compression

Ratio

Max. HP 12.4 ps / 8500 rpm

Max. Torque 1.15 kg-m / 6500 rpm E.E.C. YES

Ignition C.D.I. P.C.V. YES

Starting System Power & Foot

Vertical, below center,

incline 80°

4-stroke/forced air

cooled

Exhaust Pipe Position

Single Cylinder Lubrication System Separated-lubrication

9.6 : 1 CO Below 4 % Exhaust

Catalytic reaction

control system

Transmission C.V.T.

Horn 70~90 dB/A

Right side, and

and Direction

Solid

Particulate

Concentration

HC Below 2000 ppm

Backward

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This chapter Contents

1. General Information/Trouble Diagnosis

Torque Values (Engine)

Item Q’ty

Cylinder head bolts 4 6 1.0~1.4 Cylinder head nuts 4 8 2.0~2.4

Cylinder/cylinder head two-ends bolts

Cylinder head left bolts 4 6 1.0~1.4 Valve adjustment fixing nuts 4 5 0.7~1.1 Apply oil to thread Cylinder head left cover bolts 2 6 1.0~1.4 Spark plug 1 10 1.0~1.2

Carburetor heat protector connecting nuts

Engine oil draining plug 1 12 3.5~4.5 Engine oil strainer cap 1 30 1.0~2.0 Gear oil draining plug 1 8 0.8~1.2

Thread Dia.

(mm)

4 8 0.7~1.1 Tighten to crankcase

2 6 0.7~1.1

Torque

Value(Kg-m)

Remarks

Gear oil filling bolt 1 10 1.0~1.4 Oil pump screws 3 3 0.1~0.3 Engine left side cover bolts 8 6 1.0~1.5 Rubber washer attached Camshaft chain tensioner bolt 1 6 0.35~0.5 Hex socket bolt Camshaft chain adjuster bolts 1 6 0.8~1.2 Clutch driving plate nut 1 28 5.0~6.0 Clutch outer bracket nut 1 12 5.0~6.0 Driving disk nut 1 12 5.0~6.0 Flywheel nut 1 12 5.0~6.0 One-way clutch tighten bolts 3 6 1.0~1.4 Apply locking sealant One-way clutch nut 1 22 9.0~10.0 Apply oil to thread

Crankcase bolts/right crank cover bolt

Gear box cap bolts 7 8 2.0~2.4

12 8 1.5~2.0

Exhaust pipe bolts 2 8 3.0~3.6 Exhaust pipe connection nut 2 7 0.5~1.0

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1. General Information/Trouble Diagnosis

Torque Values (Frame)

Item Q’ty

Mounting bolt for steering handlebar

Mounting nut for steering rod Cone seat for steering rod Front wheel shaft nut Rear wheel shaft nut Wheel hub/rim mounting nuts

Speedometer cable locking screw Front shock absorber mounting bolts Rear shock absorber upper connection bolt Rear shock absorber upper connection bolt

Brake lever bolts Front brake hose bolts Front brake air-bleeding valve Front brake disc mounting bolts

Front brake clipper mounting bolts Drum brake arm bolts (front/rear) Engine suspension bracket bolts

Engine connection bolt Main standard nut Foot-starting lever bolt Air cleaner bolts

The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table.

1 10 4.0~5.0 1 25.4 1.0~2.0

1 25.4 0.2~0.3 1 12 5.0~7.0 1 16 11.0~13.0 1 5 0.15~0.3

4 8 2.4~3.0

1 10 3.5~4.5

1 8 2.4~3.0

4 6 1.0~1.4 2 4 0.1~0.2

2 6 1.0~1.4 2 10 3.0~4.0 1 6 0.7~1.1

4 8 4.0~4.5

2 8 2.9~3.5

2 10 4.5~5.5 1 12 5.0~7.0

1 10 3.5~4.5 1 6 1.6~1.8 2 6 1.0~1.4

Thread Dia.

(mm)

Torque

Value(Kg-m)

Remarks

On frame side On engine side

Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque

5mm bolt、nut 6mm bolt、nut

8mm bolt、nut 10mm bolt、nut 12mm bolt、nut

0.45~0.60 kgf-m

0.80~1.20 kgf-m

1.80~2.50 kgf-m

3.00~4.00 kgf-m

5.00~6.00 kgf-m

3mm screw 4mm screw 5mm screw

6mm screw、SH nut

6mm bolt、nut 8mm bolt、nut

10mm bolt、nut

0.05~0.08 kgf-m

0.10~0.15 kgf-m

0.35~0.50 kgf-m

0.70~1.10 kgf-m

1.00~1.40 kgf-m

2.40~3.00 kgf-m

3.50~4.50 kgf-m

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This chapter Contents

1. General Information/Trouble Diagnosis

Troubles Diagnosis

A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to check if there is gasoline inside the carburetor

Fuel supplied to fuel injector sufficient

Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground.

Check if spark.

Perform cylinder compression pressure test.

砂孔

cylinder compression pressure normal

Re-start by following the starting procedures.

No fuel is supplied to fuel injector

Weak spark, no spark at all.

Low compression pressure or no pressure.

1. No fuel in fuel tank

2. Check if the pipes, fuel tank to fuel injector and intake vacuum, are clogged.

3. Malfunction of fuel pump relay or poor wire connection

4. Lines in fuel tank evaporation system clogged

5. Malfunction of fuel pump

6. Fuel filter clogged

1. Malfunction of spark plug

2. Spark plug foul

3. Malfunction of ECU

4. Malfunction of AC generator

5. Ignition coil is in open or short circuit

6. Ignition coil leads open or short circuit

7. Malfunction of main switch

1. Piston ring seized

2. Malfunction of cylinder valves

3. Worn cylinder and piston ring

4. Cylinder gasket leak

5. Leak in compression parts

No ignition

Remove the spark plug again and check it.

Dry spark plug Wet spark plug

1-12

1. Malfunction of throttle valve operation

There are some signs of ignition, nut engine can not be started.

2. Air sucked into intake manifold

3. Incorrect ignition timing

1. Dirt or clogged fuel injecto

2. Malfunction of throttle valve operation

3. Throttle valve opening too wide

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1. General Information/Trouble Diagnosis

B. Engine run sluggish (Speed does not pick up, lack of power)

Check and adjustment Fault condition Probable causes

Try gradual acceleration and check engine speed

Engine speed can be increased.

Check ignition timing (Using ignition lamp)

1. Air cleaner clogged

Engine speed can not be increased.

2. Poor fuel supply

3. Lines in fuel tank evaporation system clogged

4. Exhaust pipe clogged

5. Fuel injector clogged

Ignition timing correct

Check cylinder compression pressure (using compression pressure gauge)

Compression pressure correct

Check if fuel injector is clogged

Incorrect ignition timing

No compression

ressure

1. Malfunction of ECU

2. Malfunction of AC alternator

1. Cylinder & piston ring worn out

2. Cylinder gasket leaked

3. Sand hole in compression parts

4. Valve deterioration

5. Seized piston ring

No clogged

Remove spark plug

No foul or discoloration

Check if engine over heat

Continually drive in acceleration or high speed

Clogged

Fouled and discoloration

Normal Engine overheat

No knock

Knock

1. Replace fuel injecto

1. Remove dirt

2. Incorrect spark plug heat range

1. Piston and cylinder worn out

2. Injector clogged

3. Poor fuel quality

4. Too much carbon deposited in combustion chamber

5. Ignition timing too advanced

1. Too much carbon deposited in combustion chamber

2. Malfunction of fuel injector

3. Poor fuel quality

4. Ignition timing too advanced

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This chapter Contents

1. General Information/Trouble Diagnosis

C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing (using ignition lamp)

Normal Abnormal

1. Incorrect ignition timing (malfunction of ECU or AC alternator)

Check If air sucked through throttle valve gasket

No air sucked Air sucked

Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground

Good spark Poor spark

D. Engine runs sluggish (High speed)

Check and adjustment Fault condition Probable causes

1. Heat insulation gasket to damage

2. Throttle valve lock loose

3. Intake gasket to damage

4. By-pass hose crack

1. Spark plug fouled

2. Malfunction of ECU

3. Malfunction of AC generator

4. Malfunction of ignition coil

5. Open or short circuit in spark plug leads

6. Malfunction of main switch

Check ignition timing

Check for fuel supplying system in fuel pump

Check if fuel injector is clogged

No clogged

1-14

Normal Abnormal

Good Poor

Clogged

1. Malfunction of ECU

2. Malfunction of AC alternator

1. Insufficient fuel in fuel tank

2. Fuel line clogged

3. Restricted fuel tank EEC line

1. Replace fuel injector

E. Clutch, driving and driving pulley

FAULT CONDITIONS PROBABLE CAUSES

1. General Information/Trouble Diagnosis

Engine can be started but motorcycle can not be moved.

1. Drive belt worn out or deformation

2. Ramp plate of movable drive face damaged

3. Driving pulley spring broken

4. Clutch weights broken

5. Drive slide-shaft gear groove broken

6. Transmission gear damaged

Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)

1. Clutch weights spring broken

2. Clutch outer stuck with clutch weights

3. Connection parts in clutch and shaft worn out or burned

Poor initial driving ( Poor climbing performance)

1. Drive belt worn out or deformation

2. Weight roller worn out

3. Movable drive face shaft worn out

4. Driven pulley spring deformation

5. Driven pulley shaft worn out

6. Greased in drive belt and driven face.

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This chapter Contents

1. General Information/Trouble Diagnosis

Parts To Be Greased

Steering shaft bearing

Acceleration cable/ Front & rear brake lever pivot

Seat lock

Speedometer gear/ front wheel bearing

Side stand pivot

Main stand pivot

Rear wheel bearing

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Contents

2. Maintenance Information

Precautions In Operation .......... 2-1

Periodical Maintenance

Schedule..................................... 2-2

Lubrication System.................... 2-3

Gear Oil....................................... 2-4

Fuel System................................2-4

Air Cleaner..................................2-5

Throttle Valve Operation ........... 2-5

Crankcase Ventilation ............... 2-6

Valve Clearance Adjustment.....2-6

Valve Clearance Inspection

And Adjustment ......................... 2-7

Idle Speed / Exhaust Gas

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

Spark Plug ..................................2-8

Cylinder Compression

Pressure......................................2-9

Driving System...........................2-9

Steering System.......................2-10

Suspension System.................2-10

Disk Brake System (Front/Rear

Disk Brake) ...............................2-11

Wheel / Tire...............................2-13

Battery.......................................2-14

Headlamp Adjustment.............2-14

Nuts, Bolts Tighteness............2-14

Special Service Tools

Catalogue..................................2-15

Ignition System.......................... 2-8

Precautions In Operation

Specification

Fuel Tank Capacity 6100 c.c.

Engine Oil Transmission Gear oil

Clearance of throttle valve 2~6 mm Spark plug NGK CR8E Gap: 0.8 mm “F” Mark in idling speed BTDC 13º / 1600 rpm Full timing advanced BTDC 34º / 8000 rpm Idling speed 1600±100 rpm Cylinder compression pressure 12 ± 2 kgf/cm² Valve clearance: IN/EX 0.12 ± 0.02 mm

Tire dimension

Tire pressure (cold)

Battery 12V8Ah (MF battery) type: YTX9A-BS (8Hr)

Capacity 1000 c.c.

Change 800 c.c.

Capacity 110 c.c.

Change 100 c.c.

Front 100/90-12 59J (T/L)

Rear 130/70-12 59J (T/L)

Single Front: 1.75 kg/cm² rear : 2.25 kg/cm²

Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²

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2. Maintenance Information

Periodical Maintenance Schedule

Maintenance

Code

☆Air cleaner

☆2nd air jet cleaner

☆Fuel filter

☆Oil filter

☆Engine oil change

6 Tire pressure

7 Battery inspection

8 Brake & free play check

9 Steering handle check

10 Cushion operation check

11 Every screw tightening check

12 Gear oil check for leaking

15 Frame lubrication

16 Exhaust pipe

23 Lights/electrical equipment/mutli-meters

24 Main/side stands & springs

25 Fuel lines

27 Cam chain

33 Throttle body

34 Input signals from EFI ECU

35 Sensors of EMS fuel injector

Note: I - Inspection, A-Adjustment R- Replacement C- Cleaning L- Lubrication (The 33rd, 34th, and 35th items are

The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first. Remarks:

☆Spark plug check or change ☆Gear oil change

☆Ignition timing ☆Emission check in Idling ☆Throttle operation ☆Engine bolt tightening ☆CVT driving device(belt﹞ ☆CVT driving device(roller)

☆Valve clearance ☆Crankcase vapor control System ☆Crankcase blow-by over-flow pipe I ☆2nd air jet system ☆vapor control system

for the fuel injection system)

1. These marks ”☆” in the schedule are emission control items. According to EPA regulations, these items must be

perform normally periodical maintenance following the user manual instructions.

2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment.

3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the motorcycle has accumulated a higher mileage.

4. Preventive maintenance

a. Ignition system - Perform maintenance and check when continuous abnormal ignition, misfire, after-burn,

overheating occur.

b. Carbon deposit removal - Remove carbon deposits in cylinder head, piston heads, exhaust system when

power is obvious lower. Than ever

c. Replace worn out pistons, cylinder head.

item

Initial

300KM

I C C R I C C R

I I R C C C R

I I

I I R R

L I I I I

A I

I I I I

I R

C I I I I I I I I I A I C

I I C

A I A C

I I I

1 Month

every1000KM

3 month

every3000KM

Replacement for every 1000km

Replacement for every 5000km

Replacement for every 2000km

6 month

every6000KM

1 year

every12000KM

2-2

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Lubrication System

Engine Oil Capacity

Caution

• The vehicle must be parked on a level

ground when checking oil capacity.

• Run the engine for 3-5 minutes then stop,

wait about 3-5 more minutes allowing engine oil to settle before checking the oil level.

Remove dipstick to check the oil level. If oil level is below the lower limit mark, add oil to the specified upper limit mark.

Engine Oil change

Shut off the engine and remove dipstick. Remove the oil drain plug on the bottom-left of crankcase to drain oil. After draining out oil, clean oil plug and its gasket and reinstall. Replace the gasket if it is damaged.

Torque value: 3.5~4.5 kgf-m

2. Maintenance Information

Caution

Warm up the engine. This will make the oil flow out easily.

Add oil to the specified capacity. Oil Viscosity: SAE 10W-30, or equivalent recommended using King-Mate serial oil.

Engine oil capacity: Disassembly: 1050cc

Change: 800cc

When checking for oil leak, run the engine at idle speed for a few minutes, then check oil capacity with dipstick.

Cleaning the oil strainer

Drain oil from engine, remove the strainer cover, spring and strainer. If there is an accumulation on the screen, wash it off with suitable solvent (recommended using compressed air to cleaning the foreign). Check O-ring for damage, replace if necessary. Reinstall strainer, spring, O-ring and strainer cover.

Torque value: 1.3~1.7 kgf-m

Oil drain plug

2-3

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2. Maintenance Information

Gear Oil

Inspection

Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole. Check gear oil if enough.

Replacement

At first, remove the gear oil refilling bolt, and then remove the draining plug. Install the draining plug after drained oil out.

Torque value: 0.8~1.2 kgf-m

Caution

Inspect if washer is in good condition. Replace it with new one if it was deformed or damaged.

Fill out specified gear oil from the engine oil filling opening. Install the oil filling bolt.

Torque value: 1.0~1.4 kgf-m Quantity: 100 c.c. Recommended: King-Mate HYPOID GEAR OIL (#140)

Gear oil refilling bolt

Gear oil draining plug

Fuel pipes

Fuel System

Fuel Lines

Remove luggage box, rear carrier, body covers. Check all lines, and replace it when they are deterioration, damage or leaking.

Warning

Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

Fuel filter

Remove luggage box, rear carrier, body covers. Remove fuel pump and fuel unit assembly. Check if the fuel filter is clogged, broken. If so, clean or replace the fuel filter with new one.

Caution

The arrow on the fuel pump and fuel sender mean the assembly direction of fuel tank, check if it is in corrective installation.

Fuel filter

2-4

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Air Cleaner

Air element

Remove the air cleaner cover (6 screws). Remove the lock plate from the element of air cleaner. Check the element if dirt or damaged. If it dirt, clean it with solvent and then soap it into cleaning engine oil after cleaned. Finally, squeeze it. Replace it with new one if dirt or damaged.

Caution

• Make sure that the air cleaner cover had

been installed properly after installation because improperly installation will cause foreign sucking into cylinder.

• Do not wet the air cleaner as washing the

motorcycle. Or it may effect engine performance.

2. Maintenance Information

6 screws

Throttle Valve Operation

Have a wide open of throttle valve as handle bar in any position and release it to let back original (full closed) position. Check handle bar if its operation is smooth. Check throttle valve cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth. Measure handle bar free play in its flange part.

Free play：2~6 mm

Adjustment can be done in either ends. Secondary adjustment is conducted from top side. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment nut.

2~6 mm

Rubber boot

Adjustment nut

Fixing nut

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2. Maintenance Information

Primary adjustment is conducted from button side of cable on the throttle body. Loosen fixing nut, and adjust by turning the adjustment nut for its free-play. Tighten the fixing nut, and check acceleration operation condition after adjusted.

Crankcase Ventilation

Pull out the plug from draining hose to clean deposits.

Fixing nut

Adjustment nut

Caution

When always riding in rainy area or full throttle position, maintenance travel must be shorted. The deposits can be seen in the transparent section of draining hose.

Valve Clearance Adjustment

Caution

Checks and adjustment must be performed

when engine is cold (below 35℃).

Remove luggage box. Remove center cover. Remove cylinder head left cap. Remove the ignition timing check hole cap on the cooling fan cover. With T type wrench, turn crankshaft in clockwise motion so that mark (T) on the generator flywheel aligns with the mark on the crankshaft, and camshaft is at TDC position also as same as level of cylinder head top-end. A single hole on camshaft sprocket is forward to up. (Piston is at TDC position in the compression stroke.)

Crankcase blow-by plug

TDC mark

Caution

The model that equipped with starting compression pressure reduction system can not be rotated in counter-clockwise to prevent from operating compression pressure reduction function so that valve clearance can not be measured.

2-6

Ignition timing mark

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Valve Clearance Inspection And Adjustment

Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX): 0.12 ± 0.02 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Caution

It has to make sure that valve rock-arm is be adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.

Idle Speed / Exhaust Gas

2. Maintenance Information

Adjustment

Connect the DATASCAN connector with the body harness connector. Turn on main switch and start the motor. Then the DATASCAN will open to initial window automatically. Adjust the Data Scan to data monitor menu.

Caution

• Inspection & adjustment for idle speed

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

• Idle speed check and adjustment have to

be done after engine is being warn up to

working temperature 115~130℃. (around

10 minutes)

• This inspection & adjustment have to be

done with DATASCAN. Never adjust the adjustment screw on the throttle body arbitrarily to prevent from effect fuel injection precision.

If idle speed and CO have to be adjusted, then turn the DATASCAN to idle speed & CO adjustment function window. Press ”ENTER” key to enter adjustment function. The cursor “▲, ▼” is for a digit and the “◄, ►” is for denary scale.

Emission standard:

Engine RPM

HC CO 1.5 ± 0.5%

Please refer to chapter 4, fuel system, for the detailed usage of DATASCAN.

1600 ± 100rpm

900 ppm↓

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2. Maintenance Information

Ignition System

Ignition Timing

Caution

C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is in normal or

Remove right side cover. Remove ignition timing hole cap located on the cooling fan cap. Connect tachometer and ignition lamp. Start engine and set engine idle speed in 1600 rpm, and if the mark aligns with the “F”, then it means that ignition timing is correct. Increase engine speed to 8000 rpm to check ignition timing advance. If the detent aligns with advance mark “װ”, then it means ignition timing advance is in functional. If not, check CDI set, pulse flywheel, and pulse generator. Replace these components if malfunction of these parts are found.

F mark

Ignition lamp

Spark Plug

Appointed spark plug：CR8E (NGK)

Remove trunk. Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap.

Spark plug gap: 0.8 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed.

Torque value: 1.0~1.2 kgf-m

Connect spark plug cap.

Spark plug

Side electrode

Central electrode

2-8

0.8mm

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Cylinder Compression Pressure

Warn up engine and then turn off the engine. Remove the trunk and the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the foot-starting lever.

Caution

Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.

Compression pressure: 12 ± 2 Kg/cm²

Check following items if the pressure is too low:

• Incorrect valve clearance

2. Maintenance Information

Spark plug

• Valve leaking

• Cylinder head leaking, piston, piston ring and

cylinder worn out

If the pressure is too high, it means carbon deposits in combustion chamber or piston head.

Driving System

Drive Belt

Remove left side cover. Remove mounting bolt located under air cleaner. Remove 9 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.

Width limit: 18.5mm or more

Clutch Pad

Start the motorcycle and gradually increase throttle valve openness to check clutch pad operation. If the motorcycle moves with shaking, then check its clutch pad for wearing. Replace it if necessary.

Cylinder pressure gauge

Gear teeth

Width

Clutch pad

Clutch

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2. Maintenance Information

Steering System

Caution

Check all wires and cables if they are interfered with the rotation of steering handle bar.

Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then adjust the handle top bearing.

Suspension System

Warning

• Do not ride the motorcycle with poor shock

absorber.

• Looseness, wear or damage shock

absorber will make poor stability and drive ability.

Front shock absorber

Hold front brake lever and press down the front shock absorber for several times to check its operation. Hold front brake lever and push forward the front shock absorber for several times to check its locking status. Check if it is scratched or leaking. Replace damaged and non-repairable components. Tighten all nuts and bolts.

Rear Shock absorber

Press down the rear shock absorber for several times to check its operation. Check if it is scratched or leaking. Replace damaged and non-repairable components. Park the motorcycle with main standard. Start engine and let the rear wheel rotate after increased engine rpm. Check engine for any parts loose or shaking. Also check the engine suspension bushing for wear out. Replace the bushing if worn out. Tighten all nuts and bolts.

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2. Maintenance Information

Disk Brake System (Front/Rear Disk Brake)

Brake System Metal Hoses

Make sure the brake metal hoses for corrosion or leaking oil, and also check brake system for leaking.

Brake Fluid

Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found.

Caution

In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop. Do not operate the brake lever after the cap had been removed. Otherwise, the brake fluid will spread out if operated the lever. Do not mix non-compatible brake fluid together.

Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid. Place the diaphragm in. Operate the brake lever so that brake fluid contents inside the brake system hoses.

Air Bleed Operation

Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.

Brake metals hose

Master cylinder cap

Lower limit

Screws

Master cylinder cap

Diaphragm plate

Diaphragm

Upper limit

Caution

Before closing the air bleed valve, do not release the brake lever.

Added Brake Fluid

Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.

Caution

Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

Bubbles

Draining valve

Transparent draining hose

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2. Maintenance Information

Brake Lining Wear

The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc.

Caution

It is not necessary to remove brake hose when replacing the brake lining.

Remove the brake clipper bolt, and take out the clipper.

Brake lining wear limit

Brake clipper

Brake disc

Caution

Do not operate the brake lever after the clipper removed to avoid clipping the brake lining.

Pry out the brake lining with a flat driver if lining be clipped.

Remove brake lining bolt. Take out the lining.

Caution

In order to maintain brake power balance, the brake lining must be replaced with one set.

Brake Lamp Switch

The brake lamp switch is to lit up brake lamp as brake applied. Make sure that electrical starter can be operated only under brake applying.

Brake clipper bolt

Brake lining

Bolt

Master cylinder

2-12

Brake lamp switch

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Wheel / Tire

Check if both front & rear tires’ pressure is in correct.

Caution

Tire pressure check should be done as cold tire.

Appointed tire pressure

Tire size Front tire Rear tire

2. Maintenance Information

Tire pressure as cold tire (Kg/cm²)

Appointed Tire Front wheel: 100/90-12 59J (T/L) Rear wheel: 130/70-12 59J (T/L)

Check if tire surface is ticked with nails, stones or other materials. Check if tire surface or wall for crack or damaged, and replace it if necessary. The tire tread depth can be checked by visual inspection or depth gauge.

•Replace the tire if tire tread dent or unusual

wearing out.

•The tire should be replaced if the wear limit mark “△” is in visible.

Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:

Load for single Load for two persons

Front tire: 1.5 mm Rear tire: 2.0 mm

1.75 2.25

1.75 2.5

Caution

The wear limit marks “∆” are located around the tire wall even for inspection.

Wear limit indicator

“△” mark

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2. Maintenance Information

Battery

Battery Removal

Remove right cover. (3 screws)

Battery cables removal:

1. At first, remove the negative “-” cable.

2. Then, remove the positive “+” cable.

3. Remove the battery.

If there is some rust on battery posts, clean it with steel brush. Install the battery in the reverse procedures of removal.

Caution

• If there is rust on the posts very serious,

spray some hot water on the posts. Then, clean it with steel brush so that can remove rust for more easily.

• Apply some grease on the posts after

rust removed to prevent from rust again.

Headlamp Adjustment

Headlamp adjustment

Remove the front fender. Turn the headlamp adjustment screw to adjust headlamp beam height. (C.W. is for increasing beam height, and C.C.W. is for decreasing beam height) Reinstall the front fender.

Caution

• To adjust the headlamp beam follows

related regulations. Do not adjust it arbitrarily if not necessary.

• Improper headlamp beam adjustment will

make in coming driver dazzled or insufficient lighting.

Headlamp adjustment screw

Nuts, Bolts Tighteness

Perform periodical maintenance in accord with the Periodical Maintenance Schedule. Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose (pipe) clamps, and wire holders for security.

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2. Maintenance Information

Special Service Tools Catalogue

(ψ30mm)

Name

Parts no. SYM-3110A01 Parts no. SYM-1120310 Parts no. SYM-1120320

Alternator fly wheel remover

Name

Puller/presser for crankcase bushing

Name

(ψ22mm)

Puller/presser for crankcase bushing

Name

Parts no. SYM-1120300-H9A Parts no. SYM-1471100 Parts no. SYM-1471110/20

Presser for crankcase bushing

Name

Valve spring compressor

Name

Valve spring compressor

Name

Parts no. SYM-9001200 Parts no. SYM-2210100 Parts no. SYM-2301000

Valve clearance adjustment wrench

Name Universal fixer Name

Clutch spring compressor

Name Valve clearance adjuster Name

Parts no. SYM-9001210 Parts no. SYM-6204002 Parts no. SYM-6204001

Bearing remover (inner type)

Name

Bearing remover (outer type)

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2. Maintenance Information

(6301)

Name Bearing installer Name Bearing installer Name

Parts no. SYM-9610000 Parts no. SYM-9110400 Parts no. SYM-9620000

(6204)

(6203/6004UZ)

Bearing installer ψ

17mm

(27*42*7)

Name Oil seal installer Name Oil seal installer Name Oil seal installer

Parts no. SYM-9125500 Parts no. SYM-9121600 Parts no. SYM-9120200

(25*40*8)

(20*32*6)

Name

Parts no. SYM-9020200 Parts no.

Clutch mounting bolt wrench

Name

2-16

Valve cap / Oil filter cap wrench SYM-1236100

Name

Parts no.

Fuel pressure gauge

SYM-HT07010

Home page

Contents

3. Lubrication System

Mechanism Illustration .............. 3-1

Operational Precautions:...........3-2

Trouble Diagnosis......................3-2

Engine Oil ................................... 3-3

Cleaning Engine Oil Strainer.....3-3

Oil Pump Removal ..................... 3-4

Mechanism Illustration

Rock Arm

Scoop lubrication

Connecting rod

Forcedly lubrication

Crankshaft

Oil strainer

Oil Pump Disassembly.............. 3-4

Oil Pump Inspection.................. 3-5

Oil Pump Re-assembly.............. 3-5

Oil Pump Installation................. 3-6

Gear Oil.......................................3-7

Forcedly lubrication

Cam Shaft

Inner passage

Oil pump

3-1

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3. Lubrication System

Operational Precautions:

General Information

z This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.

Specifications

Engine oil quantity Disassembly 1000 c.c.

Replacement 800 c.c

Oil viscosity SAE 10W-30 or equivalent

(Recommended King-Mate serial oils)

Gear Oil Disassembly 110 c.c.

Replacement 100 c.c.

Oil viscosity of gear oil SAE 85W-140

(Recommended King-Mate gear oil series SYM HYPOID GEAR OIL)

Oil viscosity

unit: mm

Items Standard (mm) Limit (mm)

Inner rotor clearance - 0.12

Oil pump

Clearance between outer rotor and body - 0.12 Clearance between rotor side and body 0.05~0.10 0.20

Torque value

Engine oil drain plug 3.5~4.5 kgf-m Engine oil filter cover 1.3~1.7 kgf-m Gear oil drain plug 0.8~1.2 kgf-m Gear oil filling bolt 1.0~1.4 kgf-m Oil pump connection screw 0.1~0.3 kgf-m

Trouble Diagnosis

Low engine oil level

• Oil leaking

• Valve guide or seat worn out

• Piston ring worn out

Low Oil Pressure

• Low engine oil level

• Clogged in oil strainer, circuits or pipes

• Oil pump damage

Dirty oil

• No oil change in periodical

• Cylinder head gasket damage

• Piston ring worn out

3-2

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Engine Oil

Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

Oil Replacement

Caution

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

Place an oil pan under the motorcycle, and remove oil strainer cap.

Make sure if the aluminum washer of the draining bolt is damaged. If so, replace it with new one.

Install the drain bolt and tighten it.

Torque value: 3.5~4.5 kgf-m

3. Lubrication System

Oil stick

Drain plug

Cleaning Engine Oil Strainer

Remove the oil strainer cap. Remove oil strainer and spring. Clean oil strainer. (Recommended using compressed air to clean dirty foreign.) Check if the strainer and O-ring of the oil strainer are broken. Replace with new one if found. Install the oil strainer and spring. Install the oil strainer cap and tighten it.

Torque value: 1.3~1.7 kgf-m

Fill out oil to the oil filler. (Oil viscosity SAE 10W-30) (Recommended King-Mate serial oils)

Engine oil quantity: Replacement 800 c.c.

After oil replaced, insert ignition key into the re-set bottom under instrument panel so that the oil indicator is changed from red to green and set oil replacement mileage to zero. Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again if within standard level after 3-5 minutes. Check if engine oil leaks.

Oil filter cover

3-3

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3. Lubrication System

Oil Pump Removal

Remove the alternator (refer to chapter 10). Remove the engine right cover. Remove the one-way clutch and starting gear (1 nut). Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 screws), and then the oil pump driving gear clamp and the gear. Remove oil pump body screws (3 screws).

Oil Pump Disassembly

Remove the screws on oil pump cover and disassemble the pump as illustration shown.

Right crankcase cover

Oil pump driving gear

Oil pump body

Engine right cover

Oil pump shaft

Starting gear

Starting clutch

起動離合器組

3-4

Outer rotor

Inner rotor

Oil pump cover

Oil pump outer cover

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Oil Pump Inspection

Check the clearance between oil pump body and outer rotor.

Limit：below 0.12mm

Check clearance between inner and outer rotors.

Limit: below 0.12mm

Check clearance between rotor side face and pump body.

Limit: below 2.0 mm

3. Lubrication System

Oil Pump Re-assembly

Install inner and outer rotors into the pump body. Align the indent on driving shaft with that of inner rotor. Install the driving shaft. Install the oil pump cover and fixing pin properly and then tighten screw. (1 screw)

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3. Lubrication System

Install driving gear and clamp.

Caution

Install the oil pump cover and fixing pin properly.

Oil Pump Installation

Install the oil pump (3 screws).

Caution

The elliptical hole on the driving gear is not match with the screw hole. Thus, the elliptical hole has to align with the screw hoe before tightening it.

Install oil pump outer cover (2 bolts).

Install the starting gear and the alternator. (Refer to chapter 10)

3 screws

2 screws

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Gear Oil

Oil Level Inspection

Park the motorcycle on flat surface with main stand. Turn off engine and remove both engine oil filling bolt and oil draining plug.

Remove gear oil filling hole bolt and place a measurement cup under the draining plug. Remove the oil draining plug and the pour gear oil into the measurement cup. Measure the gear oil quantity if within standard value. Add specified gear oil if the oil level too low. (Standard quantity: 110cc. / replacement: 100 cc.)

Gear Oil Replacement Remove the gear oil filling hole bolt and its draining plug and then drain oil completely.

Install the draining plug and tighten it (Make sure if the plug washer is damaged. If so, replace it with new one.)

Torque Value: 0.8~1.2 kgf-m

Add new gear oil (100 c.c.) from the gear oil filling hole and then install the gear oil filling hole bolt after added oil. And then, tighten the bolt.

Torque Value: 1.0~1.4 kgf-m ※Recommended to apply with SYM HYPOID

GEAR OIL (SAE 85W-140)

Start engine and run it for 2~3 minutes. Turn of f engine and check if oil leaking.

3. Lubrication System

Filling bolt

Draining plug

3-7

3. Lubrication System

NOTES:

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3-8

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Contents

4. FUEL INJECTION SYSTEM

Mechanism Illustration ...............4-1

EFI System Components............4-2

Introduction Of Fuel Control

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

Electronical Fuel Injection Components & Operation Principle

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

Precautions In Operation ...........4-4

Trouble Diagnosis .......................4-5

Components Description Of Efi. 4-9

Fuel Lines ..................................4-11

Ignition System .........................4-12

Crank Position Sensor..............4-13

Air By-pass Valve......................4-15

Fuel Injector...............................4-15

Fuel Pump..................................4-15

Fuel Tank ...................................4-16

Air Cleaner .................................4-19

Trouble Diagnosis & Solutions Of

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

Error Code Message and Solution

Operation ...................................4-21

EFi Data scan Operation Manual

....................................................4-23

EFi Component Malfunction

Check& Replacement

Procedure (PI Engine)............ 4-36

Temperature Sensor .................4-14

Mechanism Illustration

Battery

Engine temperature sensor

Ignition coil

Fuel injector

Throttle position sensor (TPS)

Data Scan

(Diagnosisor)

ECU

Hazardous lamp

Fuel pump & pressure regulator

Fuel tank

Air by-pass valve

Crankshaft position sensor

Vacuum hose

Intake temperature & MAP sensor (T-MAP)

4-1

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4. FUEL INJECTION SYSTEM

EFI System Components

Throttle position

sensor

Engine temperature

sensor

Battery voltage

Main switch ON

Fuel pump

Transistor ignition

coil

5V 12V

Intake temperature

/MAP sensor

Crankshaft

position sensor

4-2

ECU

Fuel injector

Idle air by-pass

valve

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4. FUEL INJECTION SYSTEM

Introduction Of Fuel Control System

The engine of this model was based on a 150 c.c. four-stroke & 4-valve SOHC electronic controlled single cylinder, air-cooler, engine. It adopts a charcoal canister to absorb the fuel vapor generated through evaporation in the fuel system & crankcase. Then, introducing evapor into combustion chamber.

Electronic Fuel Injection Device:

This device consists of both the fuel supply system ---fuel tank, electrical fuel pump, fuel filter, and fuel pump regulator as well and the fuel control system---fuel injector and ECU. Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel pressure is kept within 2.5bar by means of the fuel regulator. Then, the injection signal from ECU is to let fuel inject to cylinder in every crankshaft rotation. In addition, the residual fuel is back to fuel tank by the fuel regulator. The fuel pump is stalled into the fuel tank so that can reduce noise and simplify the fuel pipe routing. The electronic controlled ignition & injection system can control fuel consumption & emission efficiently so that reaches to the purpose of environmental purification.

Fuel delivery way in most of motorcycle’s engines is by carburetor. The absorption capacity of engine is to create vacuum inside of the carburetor so that fuel is suck into combustion chamber with air. Therefore, under such operation, air & fuel mixture ratio is decided by flowing air and fuel absorbed quantity. Thus, the 3 factors, air detective quantity, fuel quantity decision and fuel absorbed quantity, are conducted inside of the carburetor.

However, as for the fuel injection system, it detects air absorbed quantity and temperature. Thus, the fuel supply quantity is decided by the default preset in the system computer. Then, fuel is injected out by the fuel injector. Comparing with carburetor engine, the 3 factors are independent, and can increase their precision easily so that fuel supply can be much more accurate.

The engine is equipped with a fuel injection of computerized control and its main characters are as following:

1. The necessary fuel injection quantity is decided by correspondence with engine rotation. And, the

2. The decision of fuel injection quantity and injection timing are controlled by a 8-bite highly

3. The pressure regulator is always to keep the variances of intake manifold and fuel pressures in a

4. The engine can measure the manifold pressure to enrich fuel injection based on high position

5. The idle speed control system is to provide manifold with the 2

engine also is applied with a good reaction and high accurate throttle valve. (So, fuel injection quantity and timing are decided by engine RPM and the throttle valve opening.)

accurate micro-computer. constant value (2.5bar). So, with the change of intake manifold pressure, the fuel injection quantity

can be kept in proper level. level so that enhance driving capacity. stability and starting capacity.

air to increase idle speed’s

Electronical Fuel Injection Components & Operation Principle Introduction

The electronic fuel injection components is consists of both the fuel supply system ---fuel tank, electrical fuel pump, fuel filter, and fuel pump regulator as well and the fuel control system---fuel injector and ECU.

Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel pressure is kept within 2.5bar by means of the fuel regulator. Then, the injection signal from ECU is to let fuel inject to cylinder in every crankshaft rotation (i.e. the fuel supply system is to inject fuel to cylinder one time. In addition, the residual fuel is back to fuel tank by the fuel regulator through the fuel return pipe. In order to reduce noise and simplify the fuel pipe routing the fuel pump usually is designed to install into the fuel tank.

Generally speaking, the electronic controlled ignition & fuel injection system can control fuel consumption & emission efficiently so that reaches to the purpose of environmental purification.

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4. FUEL INJECTION SYSTEM

Precautions In Operation

General Information

Warning

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

Cautions

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

as re-assembly.

Specification

Item Idle speed 1600±100 rpm Throttle handle free play 2~6 mm

Torque value

Engine temperature sensor: 0.74~0.88 kgf-m

Tool

Special service tools

Vacuum/air pressure pump Injection system diagnosisor (Data Scan)

4-4

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4. FUEL INJECTION SYSTEM

Trouble Diagnosis

EFI Electrical Circuit Inspection

Does the warning lamp goes on for 2 seconds and then off?

Battery voltage over 12.5V?

The voltage difference between battery and ECU is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the ECU connector.

3. Turn on the ignition switch.

4. With a multi-meter to measure the voltage between the 17

5. Make sure the voltage difference between battery and ECU is less than 0.2V.

pin(+) and the 1st pin (-).

The voltage difference between battery and active components is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the connectors of the fuel injector, by-pass valve, and ignition coil.

3. Measure the voltage between battery negative side and the each connector (1).

4. Make sure the voltage difference between

battery and those active components is less than 0.2V.

The voltage difference between 5V-sensors is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the connectors of throttle valve position sensor and intake manifold temperature/pressure sensors.

3. Turn on the ignition switch.

4. Measure the voltage between the pins(1)(4) of throttle valve position, and the pins of intake manifold temperature/pressure sensors (1) (3) is within 5V±0.2V.

The voltage difference between battery and fuel pump is less than 0.2V.

1. Turn off the ignition switch.

2. Disconnect the fuel pump connector.

3. With the probes of multi-meter to touch the positive & negative sides of the fuel pump.

4. Turn on the ignition switch.

5. Record the voltage difference of the fuel pump within 3 seconds.

6. Make sure the voltage difference between battery and fuel pump is less than 0.2V.

Turn on the ignition switch.

END

1. Burnt Bulb?

2. Blown fuse?

3. Battery voltage too low?

4. Poor wire contact on ECU circuit?

5. Poor contact on the master switch?

6. Malfunction of ECU?

1. abnormal charging circuit?

2. Battery cannot be charged?

3. Short wire circuit?

1. abnormal wire connection?

1. abnormal wire connection ?

1. abnormal wire connection?

2. Malfunction of ECU?

1. abnormal wire connection?

2. Malfunction of relay?

3. Malfunction of ECU?

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4. FUEL INJECTION SYSTEM

Engine cannot be started or difficult to start.

Does the warning lamp goes on for 2 seconds and then off?

Cannot be started or difficult to start

1. Check electrical circuit according to

procedure.

Is the warning lamp out of order?

Is the fuel system abnormal?

Is the electrical circuit abnormal?

1. Connect the Data Scan and check EMS trouble content.

2. Trouble shooting according to the troubleshooting procedure.

1. Low fuel in fuel tank.

2. The fuel pressure of the injector is lower than 2.5bar.

3. Fuel leaking in pipe?

4. abnormal regulator?

5. Fuel pump pile leaking?

6. abnormal fuel pump?

7. abnormal fuel injector?

1. No spark on the spark plug?

2. wet spark plug?

3. Loosen spark plug cap?

4. short in RPM sensor?

5. Loosen high voltage cable?

6. No connection for the by-pass valve?

7. abnormal ECU?

8. Clean the throttle valve body and ECU does not be set-up?

Is the engine abnormal?

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END

1. No valve clearance?

2. Incorrect ignition timing?

3. Stuck valve?

4. worn out cylinder and piston ring?

5. improperly adjustment of the air

adjustment screw onto the throttle valve body?

Diagnosis Of Idle Speed Misfire

Idle speed misfire

1. Connect the Data Scan and check trouble content

2. Troubleshooting according to the troubleshooting procedure.

Is fuel enough?

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4. FUEL INJECTION SYSTEM

Does the throttle valve cable stuck so could not be set-up?

Is the CO value in idle speed out of set up range? (0.5%~3.0%)

Connect the Data Scan and enter into CO adjustment at idle menu. Positive value is for enrichment, and negative value is for lean.

Are the battery wires loose?

Is the vacuum hose leaking?

Does the carbon deposited onto the throttle valve body?

Replace with new one for confirmation

Does the by-pass valve operate or out of order?

If the idle speed misfire problem still can not be solved after check above related EFI components item by item, then check if the other traditional components on the engine is in abnormal.

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4. FUEL INJECTION SYSTEM

Abnormal CO Correct Value

Idle speed misfire.

Connect the Data Scan and check trouble content if there is an abnormal CO correct value in idle speed.

Is fuel enough?

Is the voltage enough?

re the battery wires loose?

Does the throttle valve cable stuck so could not be set-up?

Connect the Data Scan and enter into the data analysis menu.

Start the engine and warm it up to 115℃~125℃. Make sure whether the engine RPM, the openness (75

º~90º) of the by-pass

valve, and the fuel injection time are in normal.

Switch the Data Scan to CO adjustment at idle menu. Positive value is for enrichment, and negative value is for lean.

Is the vacuum hose leaking?

Is the CO value in idle speed out of set up range? (0.5%~3.0%)

Keep the engine running for 3~5 minutes and then turn off the engine after confirmed engine operation in normal. Conduct Error code erasing operation.

If the abnormal co correct value problem still cannot be solved after check above related EFI components item by item, then check if the other traditional components on the engine is in abnormal.

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Components Description Of EFi

ECU (Electronic Control Unit):

• Powered by DC 8~16V, and has 22 terminals connector on the unit.

• The hardware component consists of an 8-bite computer that be its

control center. It contains the functional circuit interface of engine condition sensing and the driving actuator for the by-pas valve, fuel injector, and fuel pump, as well as transistor ignition coil.

• Its major software is a monitor strategy operation program that includes with controlling strategy, MAP and self-diagnosis programs.

Fuel Injector:

• Powered by DC 8~16V, and has 2 terminals connector on the injector.

• Its major component is the solenoid valve of high resistance driven by voltage.

• The two terminals are connected to power source and ground respective. It is controlled by ECU to decide the injection timing, and the injector pulse width. Working with 4-valve engine, the unique 2-hole designed injector can provide each intake valve with suitable fuel quantity to reduce HC emission.

Fuel Pump:

• Powered by DC 8~16V, and has 2 terminals connector on the pump.

• The two terminals are connected to power source and ground

respective. The ECU is to control and manage the operation of fuel pump through electrical power.

• Its major component is a driving fan pump that equipped with a low electrical consuming DC motor. Powered by 12V voltage and keep fuel pressure inside the fuel pump in 2.5 bar which can offer 14 liter fuel per hour.

• The fuel pump is located inside of the fuel tank, and installed a filter in front of its inlet so that can prevent from foreign materials sucking into the fuel pump to damage it and the fuel injector.

By-pass Valve for Idle Speed:

• Powered by DC 8~16V, and has 2 terminals connector on the pump.

• The two terminals are connected to power source and ground

respective. The ECU is to control and manage the operation of by-pass valve through electrical power.

• Its major component is the solenoid valve of high resistance driven by voltage.

• By means of signals from all sensors, ECU outputs a signal to control the opening angle of the valve so that can adjust air flowing to the intake manifold through the by-pass valve, and then correct the idle speed to have engine in normal operation.

Transistor Ignition Coil:

• Powered by DC 8~16V, and has 2 terminals connector on the coil.

• The two terminals are connected to power source and ground

respective. Its major component is the highly transferred rate transformer.

• Its ignition timing is controlled by computer program. From the signals of ignition timing, crank position sensor, throttle valve position sensor, and engine temperature sensor as well as intake temperature sensor, and correspondence with engine speed, then the ECU decides the ignition timing properly by means of controlling of primary current in ON & OFF operation to create the secondary voltage of 25000~30000V. And then, the voltage trigged the spark plug ignition. Such kind of ignition system not only can enhance engine performance to max. but also increase fuel consumption efficiency and improve emission quality.

4. FUEL INJECTION SYSTEM

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4. FUEL INJECTION SYSTEM

Intake temperature and pressure sensor:

• Powered by 5V DC from ECU. It has 4 terminals on the sensor. One terminal is for power, and 2 terminals are for signal output. And, the rest one is for ground.

• The major component of the intake pressure sensor is a variable transistor IC. Its reference voltage is DC 5V, and output voltage range is DC 0~5V.

• It is a sensor of combination by both sensing pressure and temperature, and can measure the absolute pressure and temperature in intake process. It also conduct fuel injection quantity correction based on environmental temperature and position level.

Engine temperature sensor:

• Powered by 5V DC from ECU, and has 2 terminals connector on the sensor. One terminal is for voltage output and the other one for ground.

• Its major component is the thermistor of negative temperature coefficient-NTC. (temperature up, resistance down)

• It locates onto the cylinder head. Correspondence with engine coolant temperature change, it transferred to voltage signal and sent to ECU to calculate current temperature. Then, the ECU will correct fuel injection time and ignition timing according to engine warm up condition.

Throttle Valve Position sensor:

• Powered by 5V DC from ECU, and has 3-terminal connector on the sensor. One terminal is for power, and one for voltage output, and then the last one is for ground.

• Its major component is a highly precious variable resistor. The input voltage range: 5V DC.

• It is located on the side of throttle body. By means of the throttle

valve rotation to cause voltage change in linear, it provides ECU with current throttle valve openness information. And also, the ECU conducts the most properly fuel injection and ignition timing according to the signal.

24-1 tooth

24 -1齒24 -1齒

Throttle Body:

• The throttle body is the air flow adjustment mechanism of the fuel injection. (Its function is likely the carburetor.)

• The throttle valve shaft is to turn the throttle valve position sensor in synchronously so the ECU that can detect the throttle valve openness in time.

• The guide onto the throttle body is connected to the idle speed air

by-pass valve. By means of the ECU to control the idle speed air by-pass valve, air-flow is adjusted by the valve so that stabilizes idle speed.

Crank position/rpm sensor:

• It does not need power supply, and has 2-signal terminals connector on the sensor.

• Its major component is the magnetic pickup coil, and its output voltage range is ±0.8~100V.

• The air gap between the sensor and flywheel must have .07~1.1mm.

• The magnetic sensor is sent an inductive voltage that is created by

cutting the magnetic field with the rotation gear (24-1 tooth) onto the flywheel to the ECU. Then, the ECU calculates current engine speed and crank position based on the voltage so that controls fuel injection quantity and ignition timing in properly.

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4. FUEL INJECTION SYSTEM

Fuel Lines

System Description:

1. All sensors’ signals sent to the ECU firstly after the electrical fuel pump inside the fuel tank key-on. Then, ECU controls the fuel pump relay so let the pump operate. If the engine did not start for 2~3 seconds, then the fuel pump will be turned off to save power. The pressure regulator is to maintain the fuel pressure in 2.5bar, and the fuel injector inject properly fuel quantity according to running conditions and environmental corrective coefficient. When key-off or engine stopped, the fuel pump stops operating.

2. The fuel filter is to filter foreign materials so it has to be replaced regularly.

3. Do not let the starting motor keep running when the engine can not be started in smoothly to cause battery voltage insufficient (under 8V) and the pump will not be operated. The corrective method is to start the engine by connecting a new battery or with foot-lever.

Fuel injector

Fuel filter

Fuel tank

Fuel pump & pressure regulator

Vacuum hose

ECU

Battery

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4. FUEL INJECTION SYSTEM

Ignition System

1. Principle of operation:

2. Specification

Throttle valve openness

Intake temperature/pressure

Engine temperature

rpm/TDC

TDC/ crank position sensor

ACG/flywheel gear ring (24-1 tooth)

The engine is equipped with a computerized ignition control system that collects signals from TDC/crankshaft position sensor, throttle position sensor, temperature sensor, and intake temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite micro-computer in the system is to control ignition timing properly. The secondary coil creates 25000~30000V high voltage to ignite the spark plug by means of the transistor to open/close operation of the primary current inside of the computerized system. Such operation not only have max engine performance output but also increases fuel consumption ratio.

1) Ignition timing: BTDC 13°/1600RPM

2) Spark plug: NGK CR8E Gap: 0.7~0.8mm

3) ACG Pulse generator coil: 120＋10% Ω (G/W-Y)

4) Ignition coil: Primary circuit: 0.63 ± 0.03 Ω (20℃)

5) Battery: Type: YTX9A-BS.8Ah Capacity: 12V 8Ah

Diode

ECU

Ignition coil

Spark plug

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4. FUEL INJECTION SYSTEM

Crank Position Sensor

The magnetic field type sensor is to induct a voltage signal to calculate engine speed with ACG gear ring (24-1 tooth).

There is one tooth in every 15 degree on the gear ring. But, one of teeth is flatted to be TDC base.

Description:

The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have a stable and normal running engine.

1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance

2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow

3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with

ECU signal

Secondary voltage

sensor’s signal

engine idle speed to prevent from unstable engine running and misfired within initial starting.

according to engine temperature (engine oil temperature) so that have a fast idle speed.

acceleration operation to provide intake manifold with proper air-flow quantity. Such operation will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake manifold increasing, and then to reduce HC emission.

Closed

TDC TDC

Ignition

Flywheel gear ring

Time

No teeth

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4. FUEL INJECTION SYSTEM

Temperature Sensor

Engine oil temperature sensor: According to the semiconductor’s variable character, the sensor

Intake temperature and pressure sensor: a sensor that is combined both pressure and NTC can

Engine temperature sensor

Intake temperature and pressure sensor

ECU

detects the change of engine oil and metal wall and then transferred into a voltage signal sending to the ECU. Then, the ECU corrects fuel injection and ignition timing.

NTC-Negative Temperature

Coefficient Resistor

detect the absolute pressure and temperature in the intake manifold, and then provides the ECU with signal for adjustment fuel injection quantity based on environmental temperature and location level.

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4. FUEL INJECTION SYSTEM

Air By-pass Valve

Description: The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have a stable and normal running engine.

1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance engine idle speed to prevent from unstable engine running and misfired within initial starting.

2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow according to engine temperature (engine oil temperature) so that have a fast idle speed.

3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with acceleration operation to provide intake manifold with proper air-flow quantity. Such operation will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake manifold increasing, and then to reduce HC emission.

Air by-pass valve

Fuel injector

ECU

TPS

air temperature engine oil temperature

engine speed manifold pressure throttle openness

Fuel Injector

The 2-hole fuel injector provides two intake valves with one fuel injection so that can reduce HC emission. A short mounted nut can lock the fuel injector easily and receive fuel from the fuel pump. The mounting bracket can limit the fuel injector rotation in left or right motion. The fuel injection quantity is controlled by the ECU signal. The fuel pressure regulator can keep pressure difference in between fuel pressure and manifold vacuum around 2.5bar by means of diaphragm and spring. Therefore, with such operation, the fuel injector can control its fuel injection quantity by injection width (time) under different engine loads.

Fuel Pump

The electrical fuel pump is powered by battery and controlled by the ECU for on or off. The pump can output 14 l/h fuel quantity in 2.5 bar.

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4. FUEL INJECTION SYSTEM

Fuel Tank

Removal of fuel pump/pressure control valve/fuel sender

Open the seat cushion. Remove the luggage assembly. (bolt x 4, screw x

1) Remove the rear carrier. ( bolt x 4) Remove both the left and right body covers. (screw x 4) Remove the rear lamp. (screw x 4)

Disconnect the connectors of fuel pump relay, diode, and fuel sender. Remove the fuel cut valve. (screw x 4)

Removal of fuel pump/fuel sender

Slightly knock the fuel pump mounting plate to let the plate out of locker.

Remove the mounting plate and the fuel pump body.

Fuel cut valve

Diode

Relay

Caution

The fuel pump mounting plate is easily deformed as removing the plate. Thus, in order to prevent from fuel leaking, check it in detailed and replace it with new one if necessary.

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Remove the rubber oil seal.

Installation of the fuel pump and the fuel sender

Install them in reverse procedure of removal.

Caution

The oil seal of fuel pump can not be omitted, deformed or damaged.

Caution

4. FUEL INJECTION SYSTEM

The ▲ mark must be aligned

• Do not bent the fuel sender floating arm.

• Do not fill out too much fuel in the tank.

• The ▲ mark must be aligned as installing

the fuel pump mounting plate.

The fuel sender check. (refer to chapter 16-Electrical Equipment)

Removal of fuel tank

Open the seat cushion. Remove the luggage assembly. (bolt x 4, screw x

Remove the body cover. (screw x 4) Remove the rear lamp assembly. (screw x 4) Disconnect the connectors of fuel pump relay, regulator, and fuel sender. Remove the fuel pump. Remove the fuel cut valve.

Remove the fuel inlet. (bolt x 2)

Bolt x 4

Bolt x 2

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4. FUEL INJECTION SYSTEM

Remove the fuel tank mounting bracket. (bolt x 4)

Remove the fuel tank. Loosen the fuel inlet clamper and then remove the fuel inlet and the connection hose. Remove all hoses from the pressure regulator.

Installation

Install the fuel tank in reverse procedure of removal.

Fuel return hose

Bolt x 4

Pressure regulator

Fuel inlet hose

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Fuel outlet hose

To fuel injector

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Air Cleaner

Remove the air cleaner cover. (screw x 6)

Remove the air cleaner assembly.

Installation:

Install the air cleaner in reverse procedure of removal.

4. FUEL INJECTION SYSTEM

Screw x 6

Application of fuel injection system diagnosisor

Open the front luggage cover. Connect the ECU connector and then turn on the main switch. Operate the diagnosisor according to its operation instruction.

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4. FUEL INJECTION SYSTEM

Trouble Diagnosis & Solutions Of EFi

Judgment of Flash Code

When the engine might have problem and also no tester to detect, the problem can be detected by reading the flash times of CHK lamp on the odometer. And then, the motorcycle is warned what kind of problem had occurred by means of the solution priority lamp of the tester operation message table, or the FLASH CODE. There are descriptions for the two ways below:

To show “the solution priority”

Turn the KEY ON directly, and the CHK lamp goes up for 2 seconds. Then, the CHK lamp will lit up by 3 types for showing the priority of problem solution so that reminds the rider to have the motorcycle conduct troubleshooting.

The 1 The 2 The 3

Priority: the CHK lamp lit up by every 0.3 second.

Priority: the CHK lamp lit up continuously.

Priority: the CHK lamp is not lit up.

Priority Lit up types

0.3 sec

ON OFF

To show “FLASH CODE”:

Before turning the KEY ON, wide open the throttle valve. Then, turn the KEY ON, the CHK lamp lit up for 2 seconds and off. But, the CHK lamp will lit up again after off 3 seconds. In the means time, close the throttle valve. Finally, it is to determine what problem occurred based on the flash time of CHK lamp.

Before show up, CHK lamp will lit up for 4 seconds firstly. Then, according to the lamp flash times (every 0.5 second), the problem will be determined by comparing with the operation message table. If there has the 2

problem in the system, the CHK lamp will have flash operation again after its lit

up for 4 seconds.

lit up

= lit off

Throttle valve 100% on

The 1st problem shown up

The 2

problem shown up

2 3 4 0.5 0.5 4 4 0.5 0.5 0.5 0.5 0.5 0.5 4

4 seconds for problem flash

4 seconds for problem

Lamp test

Turn on the main switch

3 seconds for delay

Close the throttle valve

4 seconds for problem flash

starting

flash ending

starting

flash ending

4 seconds for problem

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4. FUEL INJECTION SYSTEM

Error Code Message and Solution Operation

DTC

Code

P0217 1 1

P0335 2 2

P1120 2 3

P1121 2 4

P1122 2 5

P0560 1 6

P0110 2 7

P0410 2 8

Solution

Priority

Flash

code

Message Solution Operation

1. Stopping the motorcycle immediately, and solve it with priority

Engine temperature overheat

Crank position sensor

Poor contact of the throttle valve sensor

Application malfunction of the throttle position sensor

Rotation speed malfunction of the throttle position sensor

Abnormal battery voltage warning

Abnormal intake temperature sensor

Abnormal air by-pass valve

2. Check if the lubricant system for abnormal?

3. Is the ignition or fuel supply system in normal?

4. Has the engine shown burnt?

5. Make sure if the engine temperature senor is in normal.

6. Make sure if the connector is in normal.

1. Check if the connection of the crank position sensor is open-circuit.

2. Check if the air gap between the sensor and gear tooth is within specification.

3. Check if the crank rotation is run-out.

4. Check if the sensor is in normal according to the new component replacement procedure.

1. Connect the disgnosisor and reset the throttle valve position. Make sure if the idle speed position is within specified range.

2. Make sure if the wire circuit of the throttle valve position sensor is loosen or short.

3. Check if the openness of idle speed by-pass valve is within specification. (40~100%)

4. Adjust the idle speed CO value to specified range. (0.5%~2.0%)

5. If this problem symptom still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

1. Make sure if the wire circuit of the throttle valve position sensor is loosen or short.

2. If this problem symptom still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

1. Make sure if the wire circuit of the throttle valve position sensor is loosen or short.

2. If this problem symptom still existing, check if the throttle position sensor (TPS) is in normal according to the new component replacement procedure.

1. Make sure if the battery voltage is too low or high (below 10V or exceed 16V)

2. Make sure if the ACG generator charging system circuit is short or abnormal.

3. Make sure if the 15 positive post is short.

4. Make sure if the battery is in normal. Replace it with new if the battery is out or order.

1. Make sure if the sensor’s resistor is in normal (20℃ 2353~2544Ω).

2. Make sure if the sensor’s wire is in open-circuit (the 22th terminal on ECU).

3. Make sure if the sensor is normal according to the new component replacement procedure.

1. Make sure if the sensor’s resistor is open or short circuit.

2. Make sure if the sensor’s wire is in open-circuit (the 13th terminal on ECU)

3. Make sure if the by-pass valve is normal according to the new component replacement procedure.

terminal on the ECU to battery

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4. FUEL INJECTION SYSTEM

DTC

Code

P0505 2 9

P0251 2 10

P0350 2 11

P0230 2 12

P0219 2 13

P1560 2 14

P0700 2 15

P0115 2 16

P1561 2 17

P0650 3 18

P1410 2 19

P0105 2 20

Solution

Priority

Flash

code

Message Solution Operation

Application range abnormal of the air by-pass valve

Abnormal fuel injector

Abnormal ignition circuit

Abnormal fuel pump relay

Engine over-speeding

Abnormal 5V driving voltage

High RPM warning for starting engine

Abnormal engine temperature sensor

Abnormal engine temperature gauge

Abnormal warning lamp

Adjustment of CO

Abnormal MAP sensor

1. Check if the openness of idle speed by-pass valve is within specification. (40~100%)

2. Make sure if the idle speed valve openness is in normal. (stuck or poor adjustment of air screw)

3. Make sure if the intake manifold is leaking.

1. Make sure if the fuel injector resistor is within specification. (14.5 Ω, 20℃)

2. Make sure if the connector or wire is in open-circuit. (the 3

terminal of ECU)

3. Make sure if the fuel injector power supplied is in normal. (12~15V)

1. Make sure if the ignition coil resistor is within specification. (0.63 Ω, 23℃)

2. Make sure if the connector or wire is in open-circuit. (the 12th terminal of ECU)

3. Make sure if the ignition coil power supplied is in normal. (12~15V)

4. Make sure if the ignition coil is normal according to the new component replacement procedure.

1. Make sure if the connector or wire is in open-circuit.

2. Replace with new relay to make sure if this abnormal is disappeared.

1. Engine speed exceed safety limit. Decreasing the speed and then the DTC code disappeared.

2. Check if the CVT belt is broken.

1. Make sure if the 18

2. Make sure if the sensor’s power voltage is 5V. (The

& 18th terminals)

terminal of ECU is 5V.

3. Replace the ECU and confirm again.

1. If the engine speed is exceed 300rpm as starting, in order to prevent run-away, the ECU will decrease engine speed or stop the engine.

2. Rider should avoid to starting engine with WOT suddenly.

3. Check if acceleration cable is stuck. Re-set the idle speed adjustment position.

1. Make sure if the sensor’s resistor is within specification. (25℃, 10319~11981Ω)

2. Make sure if the sensor’s wire is in open-circuit. (the 9th terminal of ECU)

3. Make sure if the sensor is normal according to the new component replacement procedure.

1. Check if the warning lamp is burnt.

2. Check if the warning lamp circuit is open. (the 4th terminal of ECU)

1. Make sure if the sensor’s voltage is within specification. (101kpa, 3.925V)

2. Check if the sensor circuit is open. (the 8

terminal

of ECU)

3. Make sure if the sensor is normal according to the new component replacement procedure.

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4. FUEL INJECTION SYSTEM

EFi Data scan Operation Manual

A. DTC Codes Retrieved by Data Scan

Description:

When a problem comes out, with the Data Scan to diagnosis the problem and solve it.

Method:

1. Stop the engine and do not turn on the ignition switch.

2. Open the front grove cover, and connect the connector on the motorcycle with the Data Scan’s connector.

3. The menu will show connection and software & hardware versions.

4. Press “Enter” to enter main menu.

5. Move the ▼ ▲ key to “ read DTC” and then press “Enter” key.

6. The menu will show 3 functions, 1) Current problem searching 2) Just occurred problem searching, and 3) past problem searching, for selection.

7. When selecting the 1) & 2) functions, then it will search the DTC code of current & just occurred problems.

8. Compare with the DTC code table, and conduct the troubleshooting procedure.

B. EFI Data Scan Introduction

Connector

LCD monitor

Spare keys

Next page and value adjustment key

Exit function key

Software card slot

Main body

Data transmission indicator

Enter function key

Connection cable

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4. FUEL INJECTION SYSTEM

C. Data Scan Function Menu

1. P1120: Throttle position sensor connection problem

2. P0560: Abnormal battery voltage

3. P0700: Starting speed exceeds CVT matching speed

The DTC codes can be erased only under turn on the ignition switch and engine stopped.

With the narrow mark to adjust value. 5＋1 －103 4＋10 6－1

Adjustment range does not exceed ±75.

Engine speed

1. Problem searching.

2. Just occurred problem searching,

3. past problem list

Monitor menu (1/8) Engine speed 3700rpm Intake temperature 35℃ Engine

1. Re-set throttle position. (the command must be done after adjusting the idle speed screw or replacing the throttle body.)

2. Carbon deposited time re-set. (the command must be done after cleaning the throttle body or replaced new one ECU.)

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4. FUEL INJECTION SYSTEM

D. Operation Steps & Menu Function Description

1. Connect the Data Scan’s connector onto the specified signal connector of the EFI system on the motorcycle.

2. Turn the ignition switch on and then the LCD monitor goes on and show “SANGYANG Motor Co.” as fig 1.

3. Press the “ENTER” key to continue, the monitor goes show “CONNECTING” as fig 2.

Fig 1 Fig 2

When press “ENTER” key, it shown 2 pages (1/2~2/2) of motorcycle data. To select function menu with the ◄ ► cursor.

Fig 3 Fig 4

4. In the (2/2) menu, press “ENTER” and then enter into the main menu. (as fig 5) Then with the ▲▼ cursor to select main menu, and then press “ENTER” to conduct 1~7 function. Each functions’ menu is described as below:

Fig 5

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4. FUEL INJECTION SYSTEM

When selecting the “1. retrieving DTC code” (LCD background changed into black), and press “ENTER”, then there have 3 sub-functions can be selected.

Fig 6

With the ▲▼ cursor to select “1. active DTC codes” (LCD background changed into black), press “ENTER” , and then enter into problem searching menu & verify if problem occurred right now. The menu will show problem symptom when problem have been detected. Then, conduct repairing procedure for the problem. However, if there is no DTC codes been shown on the menu , it means the EFI system is in normal. Press “EXIT” key to back to the main menu.

Fig 7 Fig 8

With the ▲▼ cursor to select “2. occurred DTC codes” (LCD background changed into black), press “ENTER” , and then enter into problem record menu. (as fig 9)

Fig 9

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4. FUEL INJECTION SYSTEM

To verify if there has problem occurred in past. When the menu record shows the past problem record, it will show the problem symptom (as fig 10). Then, suggestion to erase the DTC codes. (please refer to DTC codes Erase on page 28). However, if there is no problem shown on the menu, it means that there is no problem record in past. Press “EXIT” key to back to the main menu.

Fig 10 Fig 11

With the ▲▼ cursor to select “3. history DTC codes” (LCD background changed into black), press “ENTER” , and then enter into problem record menu. (as fig 12)

Fig 12

When the menu record shows the history problem record, it will show the problem symptom (as fig

13). Then, suggestion to erase the DTC codes. (Please refer to DTC codes Erase on page 37). However, if there is no history problem record shown on the menu, it means that there is no problem record in history. Press “EXIT” key to back to the main menu.

Fig 13 Fig 14

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4. FUEL INJECTION SYSTEM

Remarks:

a. Current DTC codes: It means that the problem onto EFI system is occurring. When the

problem is solved, the recorded will disappear.

b. Past DTC codes: It means that the problem onto the EFI system just occurred. The DTC

codes are recorded. Even the Current problem erased, the DTC codes still be recorded into the past DTC codes until turning off the ignition switch so that the past DTC codes can be erased.

c. History DTC codes: It means that the problem onto the EFI system had been occurred. So,

the DTC codes were recorded. Unless with command to erase the problem history record, the problem record will be kept continuously.

5. With the ▲▼ cursor to select “2. DTC Code Erase” (LCD background changed into black), (as fig

15), press “ENTER” key to erase the DTC codes (as fig 15-1, 16, 17). This function can be conducted only when the ignition switch is turned on and the engine stopped. Press “EXIT” key to back to the main menu.

are solved and its DTC codes also have been

Fig 15 Fig 15-1

Fig 16 Fig 17

6. With the ▲▼ cursor to select “3. Data analysis” (LCD background changed into black), (as fig

18), press “ENTER” key to enter into EFI data analysis. There are 8 instantly dynamic data values shown on the menu. (1/7~7/7) (as fig 19, 20, 21, 22, 23, 24, 25, 26) Select desired menu with ◄ ► cursor.

◎ As the fig 19 (1/8) shown, the menu provides with 3 set dynamic values of engine rpm, intake

temperature & sensor’s voltage, and engine temperature & sensor’s voltage.

Fig 18 Fig 19

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◎ As the fig 20 (2/8) shown, the menu provides with 3-set dynamic values of engine rpm,

atmosphere pressure & sensor’s voltage, and throttle valve opening & sensor’s voltage.

◎ As the fig 21 (3/8) shown, the menu provides with 3-set dynamic values of engine rpm, CO

voltage meter, battery voltage, and sensor’s voltage.

Fig 20 Fig 21

Description:

CO voltage meter: it is designed onto the ECU. This model does not has this function. Battery voltage: it means that the ECU receives voltages from the terminals of power supply, fuel injector, transistor ignition coil, and fuel pump. Sensor voltage supply: it means that DC 5V supplied by the ECU and detected voltage.

(standard voltage value: 5V±0.5%)

◎ As the fig 22 (4/8) shown, the menu provides with 4-set dynamic values of engine rpm,

injection timing, ignition timing, and ignition charging timing.

Description:

Injection timing: It means that the fuel injector opening times controlled by the ECU. i.e. the fuel injection quantity. ignition angle: It means that the ignition angle (timing) for the engine controlled by the ECU. ignition charging timing: It means that the charging timing (ignition energy) set by the ignition transistor.

Fig 22

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4. FUEL INJECTION SYSTEM

◎ As the fig 23 (5/8) shown, the menu provides with 4-set dynamic values of engine rpm, initial

position voltage of throttle valve idle speed, idle speed target value, and idle speed CO corrective value.

Description: initial position voltage of throttle valve idle speed: It means that the ECU memorizes the idle speed voltage from the first time of throttle position sensor. This value can be a reference for the throttle position sensor damaged. idle speed target value: It means that the idle speed target value set by the ECU based on current engine temperature and intake temperature. idle speed CO corrective value: Based on CO value of the engine emission, it corrects the air-flow of idle speed air by-pass valve.

Fig 23

◎ As the fig 24 (6/8) shown, the menu provides with 4-set dynamic values of engine rpm,

accumulated running time, PWM output of temperature gauge, and idle speed valve opening.

Description:

accumulated running time: It means that the ECU’s inner timer starts to count the ECU operation time at every time to turn on the ignition switch, even the engine does not start, and until turn off the ignition switch. PWM output of temperature gauge: this model does not has this function. idle speed valve opening.: It means that the opening of air by-pass valve at current idle speed.

Fig 24

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4. FUEL INJECTION SYSTEM

◎ As the fig 25 (7/8) shown, the menu provides with 2-set dynamic values of fuel pump

condition and manual TPI initialization.

Description:

Fuel pump condition: It means the ON & OFF condition of current fuel pump. manual TPI initialization: It means the action status of the manual TPI initialization.

Fig 25

◎ As the fig 26 (8/8) shown, the menu provides with 2-set dynamic values of CO deposit time

and CO deposit time reset value.

Description:

CO deposit time: It means that the ECU inner timer starts to count the engine throttle body

CO deposit time reset value: It means that the engine inner timer starts to reset the engine

7. When you do not want to check the data analysis above, press “EXIT” key to back to the “4. Idle speed CO adjustment” (LCD background changed into black) ( as fig 26) on the main menu.

Press “ENTER” key to enter into idle speed CO adjustment. (as fig 27) With the ▲▼ and ◄ ►

cursors to adjust the idle speed CO value.

Micro adjustment: Press ▲ for one time then +1, but press ▼ for one time then –1. Macro adjustment: Press ► for one time then +10, but press ◄ for one time then –10. After adjustment, press “EXIT” key to back to main menu.

Fig 26 Fig 27

used time.

throttle body used time. When you replaced the new one ECU.

Fig 26

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4. FUEL INJECTION SYSTEM

8. With the ▲▼ cursor to select “5 operation test” function, press “ENTER” key to enter into “5. re-set/Zero setting command” main function menu. (as fig 28)

Fig 28

With the ▲▼ cursor to select “1. Reset TPI adaption” or “2. Re-set CO deposited time” function. (as fig 29, 30, 31, 32, 33, 34) (Note: Do not enter this menu if not necessary.)

Description:

1. Reset TPI adaption: After replaced the throttle body with new one or idle speed

2. Reset CO deposit time: After clean carbon deposition on the throttle body or replaced it,

Press ENTER key to left this set up function menu.

Fig 29

Fig 30 Fig 31

adjustment screw had been removed, this command has to be conducted.

and replaced the ECU with new one, but without clean or replaced the throttle body, this command has to be conducted.

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4. FUEL INJECTION SYSTEM

Press ENTER key to left this set up function menu.

Fig 32

Fig 33 Fig 34

9. With the ▲▼ cursor to select “6. Waveform” analysis (as fig 35), press ENTER to enter into the waveform analysis menu. (as fig 36). 1. engine speed, 2. ignition timing (BTDC), 3. TPS, and 4. Atmosphere pressure sensor.

Fig 35

Fig 36

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With the ▲▼ cursor to select “1. engine speed (as fig 37), press ENTER to enter into the “engine speed” menu to check current waveform. There are 3 instantly dynamic data values shown on the menu. (as fig 38, 39, 40). Select desired menu with ◄ ► cursor.

Fig 37 Fig 38

Fig 39 Fig 40

With the ▲▼ cursor to select “2. ignition timing (BTDC) (as fig 41), press ENTER to enter into the “ignition timing” menu to check current waveform. (as fig 42). Press EXIT key to left the “ignition timing” waveform menu.

Fig 41 Fig 42

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With the ▲▼ cursor to select “3. throttle position sensor (TPS) (as fig 43), press ENTER to enter into the “3. TPS” menu to check current waveform. (as fig 42). Press EXIT key to left the “TPS” waveform menu.

Fig 43 Fig 44

With the ▲▼ cursor to select “4. Atmosphere Pressure Sensor (as fig 45), press ENTER to enter into the “Atmosphere Pressure Sensor” menu to check current waveform. (as fig 46). Press EXIT key to left the “Atmosphere Pressure Sensor” waveform menu.

Fig 45 Fig 46

10. With the ▲▼ cursor to select “7. Identification” analysis (as fig 47), press ENTER to enter into the Identification analysis menu. (as fig 48, 49).

Fig 47

Fig 48 Fig 49

11. Here are all operation menus for the EFI Data Scan.

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4. FUEL INJECTION SYSTEM

EFi Component Malfunction Check& Replacement Procedure (PI Engine)

PI (Port Injection) → Intake manifold injection engine

Item

Parts No.

Parts Name

1 390-002

Ignition coil

Service

schedule At least 20000km life-expecta ncy Check it every 3000km

Inspection Method Adjustment & replacement procedure

1. With the Data Scan to check if the ignition coil is malfunction.

2. Erase the DTC code s and replace with new one & confirm again. If the DTC codes disappear, then the ignition coil is abnormal. Replace it with new one.

3. If the DTC codes still exist, replace the ECU for confirm. If the DTC codes disappear, then the ECU is abnormal. Replace it with new one.

4. Before the ignition coil is verified in abnormal, check the coil resistance and connector wire for short-circuit.

1. If the ignition coil has to be changed, erase the DTC codes with the Data Scan.

2. Turn off ignition switch, and replace the coil with new one.

3. Turn on ignition switch and make sure the DTC codes disappear.

2 379-010

By-pass valve

3 358-016

fuel pump & regulator

At least 20000km life-expecta ncy Check it every 3000km

At least 20000km life-expecta ncy Check it every 6000km

1. Check if the by-pass valve DTC code shown with the Data Scan.

2. Erase the DTC codes and replace with new one & confirm again. If the DTC codes disappear, then the by-pass valve is abnormal. Replace it with new one.

3. If the DTC codes still exist, check if the wire connector and by-pass valve resistance are in normal.

4. If the DTC codes still exist, replace the ECU for confirm. If the DTC codes disappear, then the ECU is abnormal. Replace it with new one.

1. Connect a pressure gauge between the regulator and fuel injector.

2. Make sure fuel pressure is within

2.5bar. The pressure is reached within 3 seconds after turn on ignition switch.

3. If the fuel pressure is out of specification, check if the fuel pipe is leaking. Is the fuel pump voltage over 12V?

4. Replace the regulator and confirm again.

1. If the by-pass valve has to be changed, erase the DTC codes with the Data Scan.

2. Turn off the ignition switch, and then replace the valve with new one.

3. Turn on ignition switch and make sure the DTC codes disappear.

4. Check idle speed CO and adjust it if necessary.

1. The oil seal has to be replaced if it

has to replace the regulator.

2. Oil seal has to be installed onto the

outer cover, and then assemble it

4 366-005

Engine temperature sensor

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At least 20000km life-expecta ncy Check it every 3000km

1. Has the DTC code shown with the Data Scan.

2. Engine temperature has to be reached to room temperature after engine stopped for a while.

3. Erase the DTC codes and replace with new one & confirm again. If the DTC codes disappear, then the sensor is abnormal. Replace it with new one.

4. If the DTC codes still exist, check if wire connector and sensor’s resistance are normal.

1. If the sensor has to be changed, erase the DTC codes with the Data Scan

2. Turn off ignition switch, and remove connector.

3. Remove the sensor with tools.

4. New component tighten torque is

0.74~0.88kg-m.

5. Connect the connector, and the Data Scan. Then, turn on ignition switch.

6. Make sure if the DTC codes are disappeared.

7. The value of stopped engine temperature should near to room temperature.

Item

5 366-008

6 308-008

Parts No.

Parts Name

Intake temperature /pressure sensor

Throttle body

Service

schedule At least 20000km life-expectancy Check every 3000km

At least 20000km life-expectancy Check every 3000km

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4. FUEL INJECTION SYSTEM

Inspection Method

1. Conne ct the Data Scan a s inspection. The engine intake temperature and pressure should close to environmental temperature & atmosphere pressure. (conduct this task after stopped the engine for a while)

2. If the DTC codes of intake temperature or pressure shown on the Data Scan, replace the pressure sensor firstly with new one. Make sure if the DTC codes are disappear. If not, check the connector wire for short-circuit. Replace the connector if necessary.

3. If the DTC codes still exist, replace the ECU.

4. If the DTC codes are disappear, install the original pressure sensor and check it again. If the DTC codes are disappear, then, replace the ECU with new one.

1. Please refer to idle speed adjustment section for the idle speed CO adjustment.

2. Connect the Data Scan and check if the throttle position DTC code appears.

3. If the code appears, replace the throttle body to make sure the code can be erased.

4. If the code di sappears, replace the throttle body.

5. If the code still exists, replace the ECU with new one. Then, if the code can be erased, the ECU has to be replaced.

Adjustment & replacement

procedure Replacement procedure for T-MAP (intake temperature/pressure sensor)

1. Turn off the ignition switch.

2. Disconnect the connector of

intake temperature/pressure sensor. Replace the sensor with new one.

3. Connect the connector with Data

Scan.

4. Turn on the ignition switch, and

check if the intake temperature/ pressure close to environmental temperature and atmosphere pressure with the Data Scan.

5. Erase the DTC codes, and make

sure the problem is solved.

The throttle body replacement procedure:

1. Install a new throttle body

2. Make sure there is no leaking.

3. Connect the Data Scan and

record carbon accumulated time.

4. Re-set the time with the Data

Scan.

5. Re-set the throttle position data

with the Data Scan.

6. Throttle valve WOT set up. Turn

off ignition switch, and WOT the throttle valve and hold it. Turn on the ignition switch and hold for 2 seconds. Release the throttle valve.

7. Please refer to the idle speed

adjustment section for the idle speed CO if necessary.

7 337-004

Fuel injector

At least 20000km life-expectancy Check every 3000km

1. Chec k if the fuel injector DTC code appears.

2. If the code appears, replace a new fuel injector for confirmation. If the code can be erased, then, replace the fuel injector.

3. If the code sti ll can not be clear, check if connector wire is in short-circuit.

4. If the code still exists, replace the ECU with new one. Then, if the code can be erased, the ECU has to be replaced.

Confirmation or replacement procedure for the fuel injector:

1. Erase the DTC code with the Daya Scan.

2. Turn off ignition switch and disconnect the fuel injector connector.

3. Connect the connector to a new fuel injector.

4. Connect the Data Scasn, and turn on the ignition switch.

5. Make sure the DTC code had been clear.

6. Please refer to idle speed adjustment section for idle speed CO value confirmation.

(Firstly, make sure if the fuel injector DTC code had been clear, and then install a new fuel injector.)

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4. FUEL INJECTION SYSTEM

Item

Parts No.

Parts Name

8 325-002

ECU

Service

schedule At least 20000km life-expectancy Check every 3000km

Inspection Method

1. Connect the Data Scan.

2. Record the ECU service time.

Adjustment & replacement

procedure

ECU replacement procedure:

1. Connect the Data Scan onto the original ECU.

2. Record the ECU service time.

3. Turn off the ignition switch.

4. Replace the ECU with new one.

5. Re-set the ECU service time.

6. Clean the carbon deposition around the throttle body.

7. Please refer to idle speed adjustment section for idle speed CO value confirmation.

9 Idle speed

CO Adjustment

Check for new motorcycle and every 3000km.

1. Warm up the motorcycle by running it in 50km/hr for 5 minutes.

2. Connect the Data Scan.

3. Record the idle speed CO value, rpm, and carbon deposition accumulated time.

1. Warm up the motorcycle by running it in 50km/hr for 5 minutes.

2. Connect the Data Scan.

3. Record the idle speed CO value, rpm, and carbon deposition accumulated time.

4. With the Data Scan to adjust the idle speed CO value to be

0.5%~2.0%.

5. Record the idle speed CO value, rpm and CO variant value.

6. (The engine temperature has to be in 115℃~140℃, and intake temperature to be in 25℃~40℃ as adjusting.)

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Contents

5. REMOVAL OF ENGINE

Operational Precautions ........... 5-1

Engine Removal......................... 5-2

Engine Suspension Frame ........ 5-8

Installation Of Engine ................5-9

Removal Of Engine

Suspension Bushing .............. 5-7

Operational Precautions

General Information

z Engine must be supported by a bracket or adjustable tool in height. z The following parts can be serviced with the engine installed on the frame.

1. Throttle valve

2. Driving disk, driving belt, clutch, and transporting disk

3. Final reduction gear mechanism

Specification

Item Specification

Replacement 800 c.c.

Engine Oil Capacity

Disassemble 1000 c.c.

Replacement 100 c.c.

Gear Oil Capacity

Disassemble 110 c.c.

Torque Values

Engine suspension bolt (Frame side) 4.5~5.5 kgf-m Engine suspension nut (engine side) 4.5~5.5 kgf-m Bolt of rear shock absorber upper connection 3.5~4.5 kgf-m Bolt of rear shock absorber lower connection 2.4~3.0 kgf-m Bolt of rear brake clipper 2.9~3.5 kgf-m Nut of rear wheel axle 11.0~13.0 kgf-m Nut of exhaust connection 0.5~1.0 kgf-m Bolt of exhaust fixed 3.0~3.6 kgf-m Bolt of rear bracket 3.0~3.6 kgf-m

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5. REMOVAL OF ENGINE

Engine Removal

Remove the battery cap (Nut ×3). Remove the battery negative (-) cable. Remove the battery positive (+) cable.

Open seat cushion. Remove the trunk assembly. (bolt x 4, screw x 1) Remove rear bracket and fuel tank cap. (hex-socket bolt x 4) Remove both left & right body covers and central upper cover set. (screw x 4) Remove both left & right side covers. (screw x4) Remove both left & right pedals of rear seat. (screw x 8) Remove central cover. (screw x2)

Remove the connector of rear lamp power wire. Remove the generator power wire and speed sensor connector.

Remove the starter motor cable on the relay.

Starter motor cable

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Remove the spark plug. Remove the engine temperature sensor connector.

Caution

Open the latch located under the temperature sensor before disconnect it so that the connector can be pull out and not be damaged.

Remove the by-pass pipe and disconnect circuit connector.

Remove the throttle body lines and throttle body cables. Disconnect the connector of throttle position sensor. Loosen the clamp of the air cleaner duct, and then remove the duct.

Remove the fuel injector line and circuit connectors.

5. REMOVAL OF ENGINE

Spark plug cap Temperature sensor

By-pass valve connector

Throttle position sensor connecto

Fuel injector connector

Fuel supply line

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5. REMOVAL OF ENGINE

Remove the throttle body and the fuel injector. (nut x 2)

Loose the strap screw of the air duct on the engine left side, and then remove the air duct. Remove the air cleaner bolts. (bolt x 2)

Remove the front-end nuts of exhaust pipe. (Nut ×2)

Remove the rear-end bolts of exhaust pipe. (Bolt ×3) Remove the exhaust pipe.

Nut x2

Bolt x 2

The strap screw of the air duct

Nut x2

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Remove the rear brake pipe seat. (bolt x 2) Remove the rear brake assembly. (bolt x 2)

Remove the front-end nut of rear bracket. (bolt x

2) Remove the rear wheel axle nut. (nut x 1)

Remove the rear bracket.

5. REMOVAL OF ENGINE

Bolt x 2

Nut x 1

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5. REMOVAL OF ENGINE

Engine suspension removal

Remove the rear shock absorber lower bolt. (bolt x 1)

Remove the side hole cap of cooling fan.

Remove the engine suspension nuts, and then remove the bolt from the side hole.

Bolt x 1

Side hole cap

Caution

With a bracket to support the engine to prevent from it damage by falling down as removing the engine.

Check if the engine suspension, rear shock absorber bushing, and cushion rubber for damage. Replace them with new ones if so.

Nut x 1

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Removal Of Engine Suspension Bushing

If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / pressor, Ø 28mm & Ø 20mm, to press the bushing out, and replace it with new one.

Engine suspension bushing: Ø 28mm Rear shock absorber bushing: Ø 20mm

Pressing out

Place the detent section of the bushing remover toward the bushing, and drive both the pressing ring and bolt in to press the bushing out.

Pressing In

Place the flat section of the remover toward the bushing, and then drive the bushing, pressing ring, and bolt in to install the bushing.

5. REMOVAL OF ENGINE

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5. REMOVAL OF ENGINE

Engine Suspension Frame

Removal

Remove the right side bolt of engine suspension frame.

Remove the left side bolt of engine suspension frame.

Check if the engine suspension frame bushing and cushion rubber for damage. If so, replace with new ones.

Installation

Tighten the bolts and nuts of engine suspension frame.

Engine suspension frame nut: Torque Value: 4.5~5.5 kgf-m

Engine suspension bolt (right side)

Engine suspension bolt (left side)

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Installation Of Engine

Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones. Install the engine according to the reversing order of removal.

Caution

z Note both feet and hands safety for

squeezing as engine installation.

z Do not bent or squeeze each wires or

hose.

z Route all cables and wires in accordance

with the routine layout.

Engine suspension nut: Torque Value: 4.5~5.5 kgf-m

Rear shock absorber bolt: Torque Value: Top: 3.5~4.5 kgf-m

Down: 2.4~3.0 kgf-m

Rear wheel axle nut: Torque Value: 11.0~13.0 kgf-m

5. REMOVAL OF ENGINE

Nut x 1

Nut x1

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5. REMOVAL OF ENGINE

NOTES:

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Contents

6. Cylinder Head/Valve

Mechanism Illustration...............6-1

Precautions In Operation...........6-2

Troubleshooting.........................6-3

Cylinder Head Removal .............6-4

Cylinder Head Disassembly ......6-6

Cylinder Head Inspection ..........6-7

Mechanism Illustration

0.7~1.1 kgf-m

Valve Stem Replacement.......... 6-9

Valve Seat Inspection And Service

.................................................. 6-10

Cylinder Head Reassembly .... 6-12

Cylinder Head Installation ...... 6-14

Valve Clearance

Adjustment............................ 6-16

1.0~1.4 kgf-m

1.0~1.2kgf-m

0.8~1.2kgf-m

2.0~2.4kgf-m

1.0~1.4kgf-m

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6. Cylinder Head/Valve

Precautions In Operation

General Information

• This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm.

• Cylinder head service cannot be carried out when engine is in frame.

Specification Unit: mm

Item Standard Limit

Compression pressure 12 ± 2 kg/cm² -

Intake 25.688 25.290

Camshaft Height of cam lobe

Exhaust 25.519 25.120

Rocker

arm

OD of valve stem

Valve

Torque Value

Cylinder head bolt 1.0~1.4kgf-m Cylinder head bolt (LH) 1.0~1.4kgf-m Cylinder head Nut 1.8~2.2kgf-m (apply with oil on bolt thread & seat) Sealing bolt of timing chain auto-tensioner 0.8~1.2kgf-m Bolt of timing chain auto-tensioner 1.0~1.4kgf-m Timing gear cover bolts 0.7~1.1kgf-m (apply with oil on bolt thread & seat) Spark plug 1.0~1.4kgf-m

Clearance between

valve stem and guide

Connection Flatness of cylinder head

ID of valve rocker arm 12.000~12.015 12.100

OD of valve rocker arm shaft 11.966~11.984 11.910

Intake 4.975~4.990 4.900

Exhaust 4.950~4.975 4.900

Guide seat 5.000~5.012 5.030

Intake 0.010~0.037 0.080

Exhaust 0.025~0.062 0.100

Free length of valve spring 35.000 31.500

Valve seat width 1.000 1.600

- 0.050

TOOLS

Special service tools

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

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6. Cylinder Head/Valve

Troubleshooting

Engine performance will be effected by troubles on engine top-end. The troubles usually can be determinated or by performing cylinder compression test and judging the abnormal noise generated.

Rough Idle

• Low compression pressure

Low compression pressure

1. Valve

z Improper valve adjustment z Burnt or bended valve z Improper valve timing z Valve spring damaged z Valve carbon z Poor sealing on valve seat z Improper spark plug installation

2. Cylinder head

z Cylinder head gasket leaking or damage z Tilt or crack cylinder surface

3. Piston

z Piston ring worn out

High compression pressure

• Too much carbon deposit on combustion chamber or piston head

Noise

• Improper valve clearance adjustment

• Burnt valve or damaged valve spring

• Camshaft wear out or damage

• Cam chain wear out or looseness

• Auto-tensioner wear out or damage of cam chain

• Camshaft sprocket wear out

• Rocker arm or rocker arm shaft wear out

White smoke

• Valve guide or valve stem wear out

• Valve stem seal wear out

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6. Cylinder Head/Valve

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Cylinder Head Removal

Remove:

Remove the cooling fan cover. (screw x 2, bolt x

Remove the right cover of engine. (screw x 4)

Remove the left cover of engine. (screw x 4)

Remove the left cap bolt of cylinder head (bolt x2), and then remove the left cap of cylinder head. Remove the spark plug.

Screw x 2

Bolt x 2

Screw x 2

Down

Screw x 2

Bolt x 1

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Turn the flywheel in counter clockwise motion with T type wrench until the “T” mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position.

Loosen the screw cap of camshaft chain tensioner and remove O-ring. With a flat screwdriver to tighten the screw of camshaft chain tensioner in a clockwise motion for release tensioner.

Remove the cam sprocket. (bolt x2)

Remove the left bolt (bolt x2) of cylinder head firstly, and then remove the 4 nuts & washers from the cylinder head top-end. Pry out the chain and take out the sprocket. Then, remove the cylinder head.

6. Cylinder Head/Valve

BTDC

Bolt x 2

Bolt x 2Nut x 4

Caution

• Loosen the nuts diagonally by 2-3

sequences.

• Do not let the chain fall into the crankcase

after removed the s

rocket.

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6. Cylinder Head/Valve

Cylinder Head Disassembly

Remove the adjustment hole cap for the EX & IN valve clearance. (bolt x 6)

Firstly, remove the camshaft stopper, and then drive a 6mm bolt into camshaft. Finally, remove the camshaft and rocker arm.

Use a valve compressor to press the valve spring. After removed valve split locks, release the compressor and then take out spring retainer, valve spring and valves.

Adjustment hole cap

Stopper

Camshaft

Valve split lock

Caution

In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve split locks in which can be removed.

Special Service Tool: Valve spring compressor Or with the valve spring remover/installer to

compress the valve spring directly. Then, remove the valve and valve spring.

Caution

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

Special Service Tool: Valve spring remover/ installer.

6-6

This chapter Contents

Remove valve, valve stem and valve spring.

Cylinder Head Inspection

Camshaft

Inspect cam lobe height for damaged.

Service Limit:

IN: Replacement when less than 25.29mm EX: Replacement when less than 25.12mm

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

Rocker Arm

Measure the cam rocker arm I.D.

Service Limit: Replace when it is less than

12.10 mm.

Rocker Arm Shaft

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

Service Limit: Replace when it is less than

11.91 mm.

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

Service Limit: Replace when it is less than

0.10 mm.

6. Cylinder Head/Valve

6-7

Sym ATTILA RS-21 EFi 150 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual