TGB BLADE 600 Service Manual
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TGB BLADE 600 Service Manual

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SERVICE MANUAL
TAIWAN GOLDEN BEE CO.,LTD.

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  • Page 1 SERVICE MANUAL TAIWAN GOLDEN BEE CO.,LTD.
  • Page 2 FORWARD This service manual contains the technical data of each component inspection and repairs for the ATV. 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 ATV are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.

  • Page 3: General Information

    HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    CONTENT Content Page Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-6 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-18 ENGINE REMOVAL 6-1 ~ 6-16 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-12 “V”...
  • Page 5 SERIAL NUMBER Frame Number Engine Number...
  • Page 6 1. GENERAL INFORMATION Symbols and Marks......1-1 Torque Values ........1-10 Troubles Diagnosis.......….. 1-12 General Safety ........1-2 Service Precautions ......1-3 Lubrication Points......1-17 Specifications ........1-9 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.
  • Page 7 1. GENERAL INFORMATION General Safety Battery Carbon monoxide If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, ‧ Battery emits explosive gases; flame is if you have to run your engine in a closed area, strictly prohibited.
  • Page 8 1. GENERAL INFORMATION Service Precaution ● Al w ays use with TGB genuine parts and ● Never bend or twist a control cable to prevent recommended oils. Using non-designed parts for unsmooth control and premature worn out. TGB ATV may damage the ATV.
  • Page 9 1. GENERAL INFORMATION ● The length of bolts and screws for ● Remove residues of the old gasket or sealant assemblies, cover plates or boxes is different before re-installation grind with a grindstone if from one another, be sure they are correctly the contact surface has any damage.
  • Page 10 1. GENERAL INFORMATION ● Lubricate the rotation face with specified ● After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. ● And the two posts of battery have to be greased after connected the cables.
  • Page 11 ● Insert the terminal completely. ● Do not pull the wires as removing a connector or wires. Hold the connector body. Check if the terminal is covered by the boot. Do not let boot open facing up. ● Make sure if the connector pins are bent, extruded or loosen.
  • Page 12 1. GENERAL INFORMATION ● Do not let the wire harness contact with ● Protect wires or wire harnesses with electrical rotating, moving or vibrating components as tape or tube if they contact a sharp edge or routing the harness. corner. Thoroughly clean the surface where tape is to be applied.
  • Page 13 1. GENERAL INFORMATION ● Do not let the wire harness been twisted as ● With sand paper to clean rust on connector installation. pins/terminals if found and then conduct connection operation later. Clean rust ● Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in...

  • Page 14: Lubrication System

    1. GENERAL INFORMATION Specifications 500 cc Overall Length 2120 2365 [mm] Overall Width 1240 1230 [mm] Overall Height 1502 1460 [mm] Wheel Base 1290 1450 [mm] Front [kg] Mass of vehicle in running Rear [kg] order (without driver) Total [kg] Type 4-Stroke Engine Installation and arrangement...
  • Page 15 1. GENERAL INFORMATION Capacity [ml] Spark Plug NGK DCR8E Battery 12/18 V/AH 55×2 Front Lamps (HI/LO) 55×2 5×1 Lamps Rear Lamps 21×1 Brake Lamps 10×4 Turn Lamps 1-10...
  • Page 16 1. GENERAL INFORMATION 600cc Overall Length 2120 1950 2365 [mm] Overall Width 1240 1240 1230 [mm] Overall Height 1502 1412 1460 [mm] Wheel Base 1290 1290 1450 [mm] Front [kg] Mass of vehicle in running Rear [kg] order (without driver) Total [kg] Type...
  • Page 17 1. GENERAL INFORMATION Capacity Front Spec. SAE 85W-90 Differential Gear Capacity [ml] lubrication Spec. SAE 85W-90 Rear Gear Capacity [ml] Spark Plug NGK DCR8E Battery 12/18 V/AH 55×2 Front Lamps (HI/LO) 55×2 5×1 Lamps Rear Lamps 21×1 Brake Lamps 10×4 Turn Lamps 1-12...
  • Page 18 1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Tighten Type Tighten 5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m...
  • Page 19 1. GENERAL INFORMATION Frame Torque Values Thread Dia. Torque Values Item Q’ty Remarks (mm) (kgf-m) Handlebar upper holder bolt 2.40 Steering shaft nut 5.00 5.00 Steering tie-rod nut Knuckle nut 5.00 Steering shaft holder bolt 3.40 Tie rod lock nut 3.60 Handlebar under holder nut 4.00...
  • Page 20 1. GENERAL INFORMATION 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 ● No fuel in fuel tank the carburetor ● Check if the pipes, fuel tank to carburetor and intake vacuum, are clogged.
  • Page 21 1. GENERAL INFORMATION 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 ● Air cleaner clogged ● Poor fuel supply Engine speed can be Engine speed can not be ●...
  • Page 22 1. GENERAL INFORMATION Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) ● Incorrect ignition timing (malfunction Normal Abnormal of Ignition Coil or AC alternator) Adjust the airscrew of carburetor ● Rich mixture (loosen the screw) Good Poor ●...
  • Page 23 1. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS ● Drive belt worn out or deformation ● Ramp plate of movable drive face damaged Engine can be started but motorcycle ● Driving pulley spring broken cannot be moved. ●...
  • Page 24 1. GENERAL INFORMATION Check and adjustment Fault condition Probable causes Raise wheels off ground and spin by hand ● Brake dragging ● Drive chain too tight Abnormal Spin freely ● Damaged wheel bearing ● Wheel bearing needs lubrication Check tire pressure ●...
  • Page 25 1. GENERAL INFORMATION Oil and Lubrication Points Brake Fluid Grease 1-20...
  • Page 26 1. GENERAL INFORMATION Gear Oil 1-21...
  • Page 27 2. MAINTENANCE INFORMATION Precautions in Operation · · · · · · · · · · · · · · · · · · · · · · 2-1 Brake System (Disk Brake) · · · · · · · · · · · · · · · · · 2-8 Periodical Maintenance Schedule ·...
  • Page 28 R ~ Replacement T ~ Tighten Have your ATV checked, adjusted, and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the ATV at the optimum condition. The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
  • Page 29 2. MAINTENANCE INFORMATION Fuel Lines Remove the seat . Loosen 2 screws and 2 bolts. Remove the tank cover. 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.

  • Page 30: Valve Clearance

    2. MAINTENANCE INFORMATION Valve Clearance Caution Checks and adjustment must be performed when the engine temperature is below 35℃. Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. Turn camshaft bolt in C.W. direction and let the “T”...
  • Page 31 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Caution ● Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. ● Idle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Park the ATV with onto neutral and warm up...
  • Page 32 2. MAINTENANCE INFORMATION Ignition System Caution ● C.D.I ignition system is set by manufacturer so it cannot be adjusted. ● Ignition timing check procedure is for checking whether CDI function is in normal or not. Connect tachometer and ignition light. Start engine.
  • Page 33 2. MAINTENANCE INFORMATION Drive Belt Loosen the 2 clamp strips of clutch cover, and then remove the clutch cover vapor hose. Remove 14 bolts of the clutch 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 Width limit: 26.8 mm or above...
  • Page 34 2. MAINTENANCE INFORMATION Brake System (Disk Brake) Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
  • Page 35 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 ● To check front brake lining must be remove front wheel first.
  • Page 36 2. MAINTENANCE INFORMATION Headlight Beam Distance Turn on main switch. Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high. Caution ●To adjust the headlight beam follows related regulations. ● Improper headlight beam adjustment will make in coming driver dazzled or insufficient lighting.
  • Page 37 2. MAINTENANCE INFORMATION Steering Handle 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 check the handle top bearing.
  • Page 38 2. MAINTENANCE INFORMATION Special Tools List PARTS NO. : 440649 PARTS NO. : 440650 PARTS NAME : EXTENSION PULLER / REMOVER PARTS NAME : BUSHING(924739) REMOVER PARTS NO. : 440651 PARTS NO. : 440652 PARTS NAME : BEARING(924384) REMOVER φ15 PARTS NAME : BEARING(924384) REMOVER φ20 PARTS NO.
  • Page 39 2. MAINTENANCE INFORMATION PARTS NO. : 440657 PARTS NO. : 440658 PARTS NAME : CRANK SHAFT HOLDER PARTS NAME : STARTER (924136) HOLDER PARTS NO. : 440659 PARTS NO. : 440660 PARTS NAME : FLYWHEEL REMOVER PARTS NAME : CHAIN WHEEL(925094) &...
  • Page 40 2. MAINTENANCE INFORMATION PARTS NO. : 440665 PARTS NO. : 440666 PARTS NAME : IDLER GEAR (924187) PARTS NAME : CLUTCH AND CVT PULLER HOLDER PARTS NO. : 440667 PARTS NO. : 440668 PARTS NAME : UNIVERSAL JOINT PARTS NAME : CYLINDER HEAD VALVE HEAD (924646) AND SPRING INSTALLER/REMOVER INSTALLER...
  • Page 41 2. MAINTENANCE INFORMATION PARTS NO. : 552301 PARTS NO. : 552302 PARTS NAME : OIL SEAL INSTALLER PARTS NAME : FINAL DRIVE NUT (N33701) INSTALLER/REMOVER 2-15...
  • Page 42 2. MAINTENANCE INFORMATION Note : 2-16...
  • Page 43 3.LUBRICATION SYSTEM Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-1 Engine Oil · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-3 Precautions in Operation ·...
  • Page 44 3.LUBRICATION SYSTEM Precautions in Operation General Information This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Overhaul: Blade Model: with oil radiator: 3850 c.c. without radiator: 3500 c.c. Target Model: with oil radiator: 3800 c.c. without radiator: 3500 c.c.
  • Page 45 3.LUBRICATION SYSTEM Engine Oil  Turn off engine, and park the ATV in flat surface  Turning the dipstick counter clockwise and release.  Wipe dipstick clean.  Reinstall dipstick into crankcase. Turn dipstick clockwise to the end and remove dipstick again to check oil level on dipstick.
  • Page 46 3.LUBRICATION SYSTEM Oil Pump Oil Pump Removal One way clutch Remove the one way clutch. Remove the clutch shoe. Remove the snap ring. Remove the washer. Remove the oil pump driver gear. Caution The clutch shoe nut has left-hand threads. Remove the snap ring.
  • Page 47 3.LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body.
  • Page 48 3.LUBRICATION SYSTEM Tighten the oil pump screw. Oil Pump Installation Install the oil pump, and then tighten 3 screws. Torque value：1.0kgf-m Make sure that oil pump shaft can be rotated freely. Install the washer. Install the pin. Install the oil driven gear. Install the washer.

  • Page 49: Fuel System

    4-1. FUEL INJECTION SYSTEM EFI system components inspection……..13 Fuel Injection System Components………..1 Fuel line inspection……………………..…26 Precautions in servicing……………………..2 Fuel flow inspection……………………….27 General………………………………………..2 Fuel pump………………………………..…28 Fuel system………………………..…………2 Fuel pump relay……………………………29 Connector/coupler……………….…….…….3 Sensor circuit malfunction Fuse……………………………….…….…….3 troubleshooting…………………..…………31 ECU/various sensors…………………..……3 Fault diagnosis………………………..……54 Electrical circuit inspection procedure. ……4 Integrated fault diagnosis program.
  • Page 50 4-1. FUEL INJECTION SYSTEM PRECAUTIONS IN SERVICING When handling the Fuel Injection component parts or servicing the Fuel Injection system, observe the following points for the safety of the system. GENERAL Be sure to relieve the fuel pressure while the engine is OFF. Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
  • Page 51 4-1. FUEL INJECTION SYSTEM CONNECTOR/COUPLER • When connecting a connector, be sure to push it in until a click is felt. • With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.
  • Page 52 4-1. FUEL INJECTION SYSTEM • Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to the ECU or sensors may result. • Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result. ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.
  • Page 53 4-1. FUEL INJECTION SYSTEM CONTINUITY CHECK • Measure resistance across coupler B (between A and C in the figure). • If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. • Disconnect the coupler B and measure resistance between couplers A and B.
  • Page 54 4-1. FUEL INJECTION SYSTEM SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
  • Page 55 4-1. FUEL INJECTION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number Starter valve vacuum difference Idle speed 1500+/- 100 rpm Throttle grip free play 2~4 mm Ω Intake air temperature sensor resistance Engine coolant temperature sensor Ω resistance Ω Fuel injector resistance Ignition pulse generator peak voltage Manifold absolute pressure at idle 420 +/- 30 mm Hg...
  • Page 56 4-1. FUEL INJECTION SYSTEM PARTS LOCATION 1 ECU 8 Fuel Pump (Reservoir) 2 Roll Over Sensor 9 Fuel Filter x 2 3 Injector 10 Ignition Coil 4 Speed Sensor 11 Throttle Position Sensor 5 Engine Coolant Temperature 12 Idle Speed Controller 6 Crank Position Sensor 13 Temperature Manifold Air Pressure 7 Pressure Regulator...
  • Page 57 4-1. FUEL INJECTION SYSTEM WIRING DIAGRAM 4-1-9...
  • Page 58 4-1. FUEL INJECTION SYSTEM ECU TERMINAL HARNESS ECU PLUG Wire Wire Circuit Note Circuit Note Code Color Code Color VSENS Sensor voltage Br/W Blank Gr/R SGND2 Signal ground Blank W/Br Throttle position sensor Br/L Key SW voltage Blank CAN_H Diagnosis Tool Blank Gear B Engine Check...
  • Page 59 4-1. FUEL INJECTION SYSTEM SYSTEM TROUBLSHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model:...
  • Page 60 4-1. FUEL INJECTION SYSTEM ATV ENVIROMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition □Fair □Cloudy □Rain □Snow □Always □Other __________ Weather □Hot □Warm □Cool □Cold( ℃) □Always Temperature □Always □Sometimes ( day, month) □Only once times/ Frequency □Under certain condition □Urban □Suburb □Highway □Mountainous (□Uphill □Down hill) □Tar macadam □Gravel □Other __________ Road ATV condition...
  • Page 61 4-1. FUEL INJECTION SYSTEM EFI SYSTEM COMPONENTS INSPECTION T-MAP SENSOR • Turn the ignition OFF. • Disconnect the T-MAP sensor 4P connector. • Check for loose or poor contact on the MAP sensor connector. • Connect the T-MAP sensor connector. •...
  • Page 62 4-1. FUEL INJECTION SYSTEM ECT SENSOR INSPECTION • Turn the ignition switch OFF. • Disconnect ECT sensor 2P connector. • Check for loose or poor contact on the ECT sensor connector. • Connect the ECT sensor connector. • Turn the ignition switch ON. •...
  • Page 63 4-1. FUEL INJECTION SYSTEM REMOVAL / INSTALLATION • Disconnect the ECT sensor 2P connector from the sensor • Remove the ECT sensor. • Install the new ECT sensor. TORQUE: 120 kgf/cm • Connect the ECT sensor 2P connector. Standard: RESISTANCE TEMPERATURE(℃) TOL.
  • Page 64 4-1. FUEL INJECTION SYSTEM TP SENSOR INSPECTION • Turn the ignition switch OFF. • Disconnect the TP sensor 3P connector. • Check for loose or poor contact on the TP sensor connector. • Connect the TP sensor connector. • Start the engine and check the MIL light. •...
  • Page 65 4-1. FUEL INJECTION SYSTEM VEHICLE SPEED SENSOR • Turn the ignition switch OFF. • Disconnect the vehicle speed sensor 3P connector. • Check for loose or poor contact on the vehicle speed sensor connector. • Connect the vehicle speed sensor 3P connector. •...
  • Page 66 4-1. FUEL INJECTION SYSTEM INJECTOR • Turn the ignition switch OFF. • Disconnect the injector 2P connector. • Check for loose or poor contact on the injector 2P connector. • Connect the injector 2P connector. • Turn the ignition switch ON. •...
  • Page 67 4-1. FUEL INJECTION SYSTEM INSPECTION • Start the engine and let it idle. • Confirm the injector operating sounds with a sounding rod or stethoscope. • If the injector does not operate, replace the injector. REMOVAL • Disconnect the injector 2P connector. •...
  • Page 68 4-1. FUEL INJECTION SYSTEM CRANK POSITION SENSOR • Turn the ignition switch OFF. • Disconnect the crank position sensor 2P connector. • Check for loose or poor contact on the crank position sensor 2P connector. • Connect the crank position sensor 2P connector. •...
  • Page 69 4-1. FUEL INJECTION SYSTEM IGNITION COIL • Turn the ignition switch OFF. • Disconnect the ignition coil 2P connector. • Check for loose or poor contact on the ignition coil 2P connector. • Connect the ignition coil 2P connector. • Turn the starter motor more than 10 seconds and then check that the MIL light.
  • Page 70 4-1. FUEL INJECTION SYSTEM THROTTLE BODY REMOVAL NOTE: • Before disconnecting the fuel hose, release the fuel pressure by loosening the clamp. • Always replace the clamp when the fuel hose is removed or loosened. DISASSEMBLY • Disconnect the TP sensor, T-MAP sensor and ISC sensor connector from the throttle •...
  • Page 71 4-1. FUEL INJECTION SYSTEM PRESSURE REGULATOR REMOVAL / INSTALLATION NOTE: • Remove the pressure regulator mounting bolts and cover then remove the pressure regulator. • Disconnect injector fuel hose (2) to release fuel pressure. • Disconnect fuel supply hose (1). •...
  • Page 72 4-1. FUEL INJECTION SYSTEM ROLL OVER SENSOR INSPECTION • Remove the seat set. • Turn the ignition switch ON and measure the voltage between the following terminals of the Roll Over sensor connector with the connector connected. Angle STANDARD 0∘ 1.0~1.4 V 65∘...
  • Page 73 4-1. FUEL INJECTION SYSTEM REMOVAL / INSTALLATION • Remove the seat set. • Disconnect the ECU 48P connectors. POWER INPUT LINE • Turn the ignition switch ON. • Measure the voltage between the ECU and ground. • There should be battery voltage. •...
  • Page 74 4-1. FUEL INJECTION SYSTEM FUEL LINE INSPECTION FUEL PRESSURE INSPECTION NOTE: • Before disconnecting fuel hose, release the fuel pressure by loosening the pressure regulator fuel hose clamp on the injector hose. • Always replace the clamp when the hose is removed or loosened.
  • Page 75 4-1. FUEL INJECTION SYSTEM • Disconnect the pressure regulator output hose and plug the hose. • Slowly catch the remaining fuel using an approved gasoline container. • Install the 3-way connector and attach the fuel pressure gauge as shown. • Connect the battery negative cable. •...
  • Page 76 4-1. FUEL INJECTION SYSTEM FUEL FLOW INSPECTION • Disconnect the fuel pump relay. • Jump the Black/Purple and Red/Orange wire terminals of the wire harness side using a jumper wire. • When the fuel return hose is disconnected, gasoline will spill out from the hose. Use an approved gasoline container to drain the gasoline.
  • Page 77 4-1. FUEL INJECTION SYSTEM REMOVAL NOTE: • Before disconnecting the fuel hose, release the fuel pressure. • Always replace the clamp when the fuel hose is removed or loosened. • Remove the fuel tank • Remove the fuel pump mounting nuts. •...
  • Page 78 4-1. FUEL INJECTION SYSTEM FUEL TANK/RESERVOIR (FUEL PUMP ASSEMBLY) ROMOVAL • Loosen the fuel tank mounting bolt/nut. • Release the fuel pressure. Gray • Disconnect the fuel tank air vent hose and supply hose. Air Vent hose • Remove the clamp then disconnect the fuel hose. •...
  • Page 79 4-1. FUEL INJECTION SYSTEM SENSOR CIRCUIT TROUBLESHOOTING CPS SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Metal particles or foreign material being The signal does not reach ECU for 3 sec. or more, after receiving the starter signal. stuck on the CPS sensor and rotor tip •...
  • Page 80 4-1. FUEL INJECTION SYSTEM Are the resistance and continuity OK? YES Go to next step 2 NO Replace CPS sensor with new one 7) After repairing the trouble, clear the DTC using Diagnosis Tool. Step 2 1) Crank the engine a few seconds with the starter motor, and measure the CPS sensor peak voltage at the coupler.
  • Page 81 4-1. FUEL INJECTION SYSTEM TMAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Clogged vacuum passage between throttle T-MAP sensor voltage low or high (0.1 V Sensor voltage < 4.8 V) body and T-MAP sensor • Air being drawn from vacuum passage NOTE: Note that atmospheric pressure varies between throttle body and T-MAP sensor...
  • Page 82 4-1. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to next step 2 • Loose or poor contacts on the ECU coupler terminal 1 or 27 • Open or short circuit in the Yellow/Black wire or Gray/Red wire 8) After repairing the trouble, clear the DTC using Diagnosis tool.
  • Page 83 4-1. FUEL INJECTION SYSTEM TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • TP sensor maladjusted Output voltage is not within the following • TP sensor circuit open or short range. • TP sensor malfunction Difference between actual throttle opening •...
  • Page 84 4-1. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to next step 2 • Loose or poor contacts on the ECU coupler (terminal 1 or 27) • Open or short circuit in the Yellow/Black wire or Gray/Red wire Step 1 (When sensor voltage is higher than specified) 1) Loosen and lift up the fuel tank.
  • Page 85 4-1. FUEL INJECTION SYSTEM 4) Disconnect the TP sensor coupler. 5) Check the continuity between W/Br wire and ground. 6) Also, check the continuity between W/Br wire and Gr/R wire C. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 86 4-1. FUEL INJECTION SYSTEM Are the continuity and resistance OK? YES Go to step 3 • Reset the TP sensor position correctly. • Replace the new TP sensor (throttle body). 7) After repairing the trouble, clear the DTC using Diagnosis tool. Step 3 1) Connect the TP sensor coupler.
  • Page 87 4-1. FUEL INJECTION SYSTEM ECT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • ECT sensor circuit open or short Output voltage is not within the following • ECT sensor malfunction range. • ECU malfunction 0.1 Sensor voltage < 4.6 V Sensor voltage is higher than specified •...
  • Page 88 4-1. FUEL INJECTION SYSTEM Is the voltage OK? YES Go to step 2 • Loose or poor contacts on the ECU coupler (terminal 42 or 27) • Open or short circuit in the Y/R wire or Gr/R wire Step 1 (When sensor voltage is higher than specified) 1) Turn the ignition switch OFF.
  • Page 89 4-1. FUEL INJECTION SYSTEM 6) Connect the ECT sensor coupler. 7) Turn the ignition switch ON. 8) Measure the voltage between Y/R wire and ground. Output voltage: 0.1 – 4.6 V (+ Y/R – - Ground) Are the continuity and voltage OK? Go to step 2 Y/R wire shorted to ground.
  • Page 90 4-1. FUEL INJECTION SYSTEM IGNITION SYSTEM MALFUNCTION TROUBLESHOOTING No spark or poor spark NOTE: Check that the transmission is in neutral and check that the fuse is not blown and the battery is fully charged before diagnosing. Step 1 1) Check the ignition system couplers for poor connections.
  • Page 91 4-1. FUEL INJECTION SYSTEM Step 3 1) Measure the ignition coil primary peak voltage. NOTE: This inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Is the peak voltage OK? Go to step 4 Go to step 5 Step 4 1) Check the plug caps for poor contacts.
  • Page 92 4-1. FUEL INJECTION SYSTEM FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Injector circuit open or short CPS signals produced but fuel injector • Injector malfunction signal is interrupted continuous by 4 times • ECU malfunction or more. Step 1 1) Turn the ignition switch OFF.
  • Page 93 4-1. FUEL INJECTION SYSTEM NOTE: Injector voltage can be detected only 3 seconds after ignition switch is turned ON. Is the voltage OK? • L/G wire open or shorted to ground, or poor 47 connection (cylinder side) • If wire and connection are OK, intermittent trouble or faulty ECU.
  • Page 94 4-1. FUEL INJECTION SYSTEM FP RELAY CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • Fuel pump relay circuit open or short No voltage is applied to fuel pump although • Fuel pump relay malfunction fuel pump relay is turned ON, or voltage is •...
  • Page 95 4-1. FUEL INJECTION SYSTEM ROLL OVEWR SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • TO sensor circuit open or short The sensor voltage should be the following • TO sensor malfunction for 2 sec. and more, after ignition switch is •...
  • Page 96 4-1. FUEL INJECTION SYSTEM (When sensor voltage is higher than specified) 1) Remove the seat set. 2) Turn the ignition switch OFF. 3) Check the Roll over sensor coupler for loose or poor contacts. If OK, then check the Roll over sensor lead wire continuity.
  • Page 97 4-1. FUEL INJECTION SYSTEM Go to step 2 Y/B or Pu/B wire open or Pu/B wire shorted to ground 10) After repairing the trouble, clear the DTC using Diagnosis tool. Step 2 1) Connect the Roll over sensor coupler. 2) Insert the needle pointed probes to the lead wire coupler.
  • Page 98 4-1. FUEL INJECTION SYSTEM IDLE SPEED CONTROLLER CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE • ISC malfunction The operation voltage does not reach the • ISC circuit open or short ISC. • ISC motor malfunction ECU does not receive communication signal from the ISC.
  • Page 99 4-1. FUEL INJECTION SYSTEM ISC continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the ISC resistance (between Br/B, G/B, Y/B and B/Y wires). ISC resistance: Approx. 6.5 Ω Is the resistance OK? •Br/B, G/B, Y/B and B/Y wire open or shorted to ground, or poor 28, 39, 40 and 41 connection •...
  • Page 100 4-1. FUEL INJECTION SYSTEM Fault Diagnosis EFI Circuit inspection 4-1-52...
  • Page 101 4-1. FUEL INJECTION SYSTEM Can not Start the engine or difficult to start inspection 4-1-53...
  • Page 102 4-1. FUEL INJECTION SYSTEM Idle flameout diagnosis 4-1-54...
  • Page 103 4-1. FUEL INJECTION SYSTEM Integrated Fault Diagnosis Program 4-1-55...
  • Page 104 4-1. FUEL INJECTION SYSTEM Fault Diagnosis Note When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or can not start engine, MIL light at the dashboard will be lighting, to inform drivers to carry out maintenance. Overhaul, the diagnosis tool can be used for troubleshooting.
  • Page 105 4-1. FUEL INJECTION SYSTEM Fault Code And The Sensors Of The Table No. Fault codes Fault Description XXXXX Un define B2225 Tilt switch diagnosis (SCP) B2226 Tilt switch diagnosis (SCG_OL) P0000 No DTC P0031 Sensor heater diagnosis #0 (SCG/OL) P0032 Sensor heater diagnosis #0 (SCP) P0051 Sensor heater diagnosis #1 (SCG/OL)
  • Page 106 4-1. FUEL INJECTION SYSTEM P0265 Injection valve diagnosis #1 (SCP) P0351 Ignition diagnosis #0 (SCP) P0352 Ignition diagnosis #1 (SCP) P0370 Loss of synchronization diagnosis P0371 Crankshaft sensor diagnosis P0373 Crankshaft sensor diagnosis P0462 FUEL sensor diagnosis (SCG) P0463 FUEL sensor diagnosis (SCP_OL) P0484 Cooling fan diagnosis (SCP) P0485...
  • Page 107 Method of Use: 1. Connected to the diagnostic connector for diagnosis tool. NACS→TGB interface→Transfer Cable→TGB 3 pin/6 pin Diagnosis Cable→Vehicle. 2. When the IG of the motorcycle is on, the system starts to run, entering into boot screen. 3. Key ON and the diagnosis display screen appeared the words connection.
  • Page 108 4-1. FUEL INJECTION SYSTEM 5. Press “ENTER” button again for more detailed vehicle information. Press ▲▼ button to view all information. Diagnosis Use Note Press ”ENTER” button to the function menu. Options main functional areas: 1. Vehicle Info 2. Diagnostic Trouble Code 3.
  • Page 109 4-1. FUEL INJECTION SYSTEM 2. Diagnostic Trouble Code Move the cursor to “Diagnostic Trouble Code” and press ENTER to see the content. 2-1. Current Current” is for the Diagnostic Trouble Code occurred at the time 2-2. History “History” is for Diagnostic Trouble Code occurred in the past. Move the cursor to ”Current”...
  • Page 110 4-1. FUEL INJECTION SYSTEM Move the cursor to “History” and press “ENTER” to continue After entering the page, press ▲▼ to view all the Diagnostic Trouble Code occurred in the past. After viewing the Diagnostic Trouble Code, press ESC to return to the previous page. ※...
  • Page 111 4-1. FUEL INJECTION SYSTEM Freeze Data (01/03) Number of data Engine speed Throttle valve volt Intake pressure MAP Freeze Data (02/03) Engine temp Lambda Control volt Battery volt Atmospheric pressure Intake air temp 2-4. Erase DTC Move the cursor to “Erase DTC” item and press ENTER to EARSE ALL DIAGNOSTIC TROUBLE CODE DIRECTLY! When you see the following picture on the screen, the Diagnostic Trouble Code erasure is completed.
  • Page 112 4-1. FUEL INJECTION SYSTEM 3. Live Data Back to the main menu, move the cursor to “Live Data” and press ENTER to view the content. Press ▲▼ button to view all Live Data 4. Actuator Move the cursor to “Activator” and press ENTER to see the content (To perform this function, IG must be ON and engine stop running.) 4-1-64...
  • Page 113 4-1. FUEL INJECTION SYSTEM This is the page after entering the “Activator” function Take one activation function for example: move the cursor to “Ignition coil” item and press ENTER to continue. When pressing “Actuating “▲ button, the test is activated and the “Value” column shows Open.
  • Page 114 4-1. FUEL INJECTION SYSTEM There are two items under “Special Function”: “Reset TPS” and “Reset Adaptive”. Move the cursor to “Reset TPS” and press ENTER. Then you will see the following picture, which means the RESET is completed. Press ESC button to return to the previous page. 4-1-66...
  • Page 115 4-1. FUEL INJECTION SYSTEM Troubleshooting Table Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation. 2. Spare parts, according to the "EFI System components description" implementation. 4-1-67...
  • Page 116 4-1. FUEL INJECTION SYSTEM Comprehensive Maintenance List Maintenanc Testing Procedures Test items Determine benchmarks Fault reasons e Project  Use meter direct  Battery  Battery voltage = 10 V  Battery electricity  Battery connector measurement battery above voltage loose Power and ...

  • Page 117: Engine Removal

    5. ENGINE REMOVAL Precautions in Operation ..... 5-1 Engine Installation ........ 5-9 Removal of Engine ......5-2 Engine Disassembly......5-12 Precautions in Operation General Information ● The engine has to be supported with special service tools that can be lifted or adjustable. ●...
  • Page 118 5. ENGINE REMOVAL Engine Removal Before taking the engine out of the frame. Clean and wash the engine using A steam cleaner. Engine removal is explained in the following. Steps. Reinstall the engine by reversing the removal procedure. ‧Before removal the engine. Drain engine oil ‧Remove the seat.
  • Page 119 5. ENGINE REMOVAL Remove the gearshift lever. Remove the fuel hose and vacuum hose. Fuel pipe Vacuum pipe Remove the air cleaner. Remove the cover of throttle body.
  • Page 120 5. ENGINE REMOVAL Remove the speedometer cable. Remove the gearshift mud. Remove the connector of lead wire. Remove the signal generator lead wire connector and generator lead wire connector. Remove the spark plug cap.
  • Page 121 5. ENGINE REMOVAL Remove the right footrest. Remove the brake pedal. Remove the muffler. Remove the exhaust pipe.
  • Page 122 5. ENGINE REMOVAL Remove the front and rear tube Remove the front shaft bolts and springs. Remove the selflock nut and take out the bolt. Note: Install the selflock nut with specified torque (540~590 kgf-cm). Remove the nut onto the bush and take down engine bolster.(each side)
  • Page 123 5. ENGINE REMOVAL Remove the nut under the bush and take out the bush from first hole.(each side) Front hole Longer Remove the selflock nut and take out the bolt. Note: Install the selflock nut with specified torque (540~590 kgf-cm). Take down the bush (each side).
  • Page 124 5. ENGINE REMOVAL Remove the nut and selflock nut. Take out the engine bolster, bolt and washers. Note: Install the selflock nut with specified torque (540~590 kgf-cm). Remove the nut. Take out the bush. Longer Remove the bolt and take out the engine bolster.

  • Page 125: Engine Installation

    5. ENGINE REMOVAL Engine installation Remove the engine in the reverse order of engine removal. Caution The engine mounting nuts are self-locking once the nut was been removed it is no longer of any use. Be sure to use new nuts. For every time engine Torque value：5.4~5.9 kgf-m installation and tighten them according the torque standard.
  • Page 126 5. ENGINE REMOVAL Rear Differential Assy. Torque value: Front and rear propeller shaft flange coupling bolt: 45N-m(4.5kgf-m, 32.5lb-ft) Install the gasket. Check if the gasket has been damage. Please replace with the new one. Apply sealant to the muffler mounting bolt Install muffler.
  • Page 127 5. ENGINE REMOVAL Exhaust pipe nut: Connector bolt: Muffler mounting bolt: 25N-m (2.5kgf-m, 16.5lb-ft) Apply sealant to the muffler mounting bolt to the muffler fixed bolts and tighten them. Apply sealant to the muffler mounting bolt to the muffler fixed bolts and tighten them. (N/A) Install 2 muffler’s bolt comp.

  • Page 128: Engine Disassembly

    5. ENGINE REMOVAL Engine Disassembly Remove starter motor wire. Remove oil pressure switch’s wire. Remove the hose. Remove the spark plug cap. Remove the wire. Spark Plug Cap Remove the thermostat. Remove the spring bolt and remove the cam chain tensioner adjuster assy. 5-12...
  • Page 129 5. ENGINE REMOVAL Remove the engine oil pipe nuts. Remove the outlet water hose. 5-13...

  • Page 130: Cylinder Head/Valve

    6. CYLINDER HEAD/VALVE Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1 Valve Stem Replacement· · · · · · · · · · · · · · · · · · · 6-10 Precautions in Operation ·...
  • Page 131 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 can be carried out when engine is in frame. Specification 500 cc 600 cc...

  • Page 132: Troubleshooting

    6. CYLINDER HEAD/VALVE Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve ● Improper valve adjustment ●...
  • Page 133 6. CYLINDER HEAD/VALVE Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 bolts) Bolts Remove 1 bolt of thermostat and then remove Thermostat bolts the thermostat. Tensioner bolts Remove hole bolt and spring for the cam chain tensioner.
  • Page 134 6. CYLINDER HEAD/VALVE Remove cylinder head cover, and hole bolts(4 bolts) Remove fix stand for spindle .cam (6 bolts) Remove cam sprocket bolts and then remove the sprocket by prying chain out. Remove cam chain tensioner and hole bolt. Remove cam shafts. Remove Rocker arm and cam shaft puller...
  • Page 135 6. CYLINDER HEAD/VALVE Remove the 4 cylinder head mounting bolts from cylinder head right side, and then remove 4 bolts and washers from cylinder head upper side. Remove the cylinder head. Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.

  • Page 136: Cylinder Head Inspection

    6. CYLINDER HEAD/VALVE Remove valve stem seals. Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
  • Page 137 6. CYLINDER HEAD/VALVE Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.080 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
  • Page 138 6. CYLINDER HEAD/VALVE Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
  • Page 139 6. CYLINDER HEAD/VALVE Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated plate or toaster. Caution ● Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. ● Wear on a pair of glove to protect your hands when operating.
  • Page 140 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution ● Do not let emery enter into between valve stem and valve guide.
  • Page 141 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old Valve seat width 60° Use 45° cutter to grind the valve seat to specified width. Old Valve seat width Caution Make sure that all roughness and uneven faces had been ground.

  • Page 142: Cylinder Head Reassembly

    6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide.
  • Page 143 6. CYLINDER HEAD/VALVE Cylinder Head Installation Cylinder head Installation For installation, reverse the removal procedure. NOTE: Never invert front and rear cylinder heads. ▪ Ensure dowel pins and key are in place. NOTICE: Timing chain guide (fixed) has to be fixed between cylinder and cylinder head.
  • Page 144 6. CYLINDER HEAD/VALVE Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution Make sure timing marks are matched. Install the lock washer so that it is covering the locating pin.

  • Page 145: Valve Clearance Adjustment

    6. CYLINDER HEAD/VALVE Install and tighten spark plug Torque value: 1.0~2.0kgf-m ten the sprocket mounting bolts. Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.

  • Page 146: Cylinder/Piston

    7. CYLINDER/PISTON Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-1 Piston Ring Installation · · · · · · · · · · · · · · · · · · · 7-6 Precautions in Operation ·...
  • Page 147 7. CYLINDER/PISTON Precautions in Operation General Information Specification 500 cc 600 cc Item Standard Limit Standard Limit 92.022~92.052 92.100 95.022~95.052 95.100 Cylinder Bend 0.050 0.050 Clearance Top ring 0.04~0.075 0.011 0.04~0.075 0.011 between piston ring 0.02~0.055 0.090 0.02~0.055 0.090 rings Top ring 0.150~0.300 0.500...
  • Page 148 7. CYLINDER/PISTON Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
  • Page 149 7. CYLINDER/PISTON Check cylinder if warp. Service Limit: 0.09 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. Place piston rings respective into cylinder below 20 mm of cylinder top.
  • Page 150 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 19.960 mm Measure the inner diameter of connecting rod small end. Service Limit: 20.065 mm Measure the inner diameter of piston pin hole. Service Limit: 20.020 mm Calculate clearance between piston pin and its hole.

  • Page 151: Piston Ring Installation

    7. CYLINDER/PISTON Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution ● Do not damage piston and piston rings as installation.

  • Page 152: Piston Installation

    7. CYLINDER/PISTON Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily. Piston Installation Install piston and piston pin, and place the marks on the piston topside forward to exhaust...
  • Page 153 7. CYLINDER/PISTON Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder.
  • Page 154 8. V-BELT DRIVING SYSTEM Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-1 Drive Belt · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-5 Maintenance Description ·...
  • Page 155 13.800 g Special Service Tools Torque value Clutch spring compressor: ● Drive face nut: 10~12kgf-m Inner bearing puller: TGB- ● Clutch outer nut: 10~12.0kgf-m Clutch nut wrench 27 x 15 mm: TGB- ● Drive plate nut: 10~12kgf-m Universal holder: TGB-...
  • Page 156 8. V-BELT DRIVING SYSTEM Clutch Cover Clutch cover removal Release the 2 clamp strips of clutch cover ducts, and then remove the ducts. Remove clutch cover. (14 bolts) Remove 2-dowel pin and gasket. Clutch cover install Install left clutch cover in the reverse procedures of removal.
  • Page 157 8. V-BELT DRIVING SYSTEM Drive Belt Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool ： Clutch And CVT Holder (440666) Hold clutch outer with universal holder, and remove nut, and clutch outer. Caution ●...
  • Page 158 8. V-BELT DRIVING SYSTEM Installation Caution ●Pull out driven face to avoid it closing. ●Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. ●Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.
  • Page 159 8. V-BELT DRIVING SYSTEM Drive Face Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face Movable drive face boss from crankshaft.
  • Page 160 8. V-BELT DRIVING SYSTEM Inspection The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary.
  • Page 161 8. V-BELT DRIVING SYSTEM With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution ●The movable drive face surface has to be free of grease. ●Clean it with cleaning solvent. Driven pulley installation (By 2 screw) Press drive belt into pulley groove, and then pull the belt onto drive shaft.
  • Page 162 8. V-BELT DRIVING SYSTEM Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution ●Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special...
  • Page 163 8. V-BELT DRIVING SYSTEM Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 225 mm Free Length Driven pulley Check following items: If both surfaces are damaged or worn. Driven Face If guide pin groove is damaged or worn.
  • Page 164 8. V-BELT DRIVING SYSTEM Installation of Clutch OUTER/Driven Pulley Oil Seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Special Grease O-ring Install the movable driven face onto driven face. Install the guide pin and guide pin roller.
  • Page 165 8. V-BELT DRIVING SYSTEM Notes : 8-12...
  • Page 166 9-1. FRONT DIFFERENTIAL FRONT DRIVE (FRONT DIFFERENTIAL) 9-1-1...

  • Page 167: Drive System

    9-1. FRONT DIFFERENTIAL DRIVE SYSTEM FRONT DRIVE GENERAL During assemble/installation, use torque values and service products as in the exploded views. Clean threads before applying thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.

  • Page 168: Front Differential

    9-1. FRONT DIFFERENTIAL DRIVE SHAFT REMOVAL ▪ Lift and support vehicle. ▪ Remove the wheel hub. ▪ Remove the knuckle. ▪ Apply special tool # 440649 strongly pull drive shaft out of differential. ▪ Discard the stop ring at the end of the shaft. INSPECTION ▪...
  • Page 169 9-1. FRONT DIFFERENTIAL INSTALLATION ▪ For installation, reverse the removal procedure. ▪ Install new circlip. ▪ Pack bearing area with grease. NOTE: Do not use or add other grease. ▪ Install new drive shaft clamps. FRONT DIFFERENTIAL REMOVAL Caution Be sure the differential set temperature below 35℃...
  • Page 170 9-1. FRONT DIFFERENTIAL ▪ Lift up the differential and slide forward to detach from the propeller shaft. ▪ Remove the front differential by pulling it from the RH side. NOTICE: Be careful not to knock or to bend vent hose fitting while removing front differential.
  • Page 171 9-1. FRONT DIFFERENTIAL ▪ Check the oil seal, replace if necessary. ▪ Remove the anti-slip gear set (A) and shim (B), check the bearing, replace if necessary. ▪ Remove the “C” clip. ▪ Remove the oil seal and discard, replace new one when reassemble.
  • Page 172 9-1. FRONT DIFFERENTIAL ▪ Using special tool pull out the bearing. Check the bearing replace if necessary. ▪ Using plier remove the “C” clip. ▪ Using rubber hammer lightly knock out the pivot gear. ▪ Remove the “C” clip (as shown) and pull out the shift shaft.
  • Page 173 9-1. FRONT DIFFERENTIAL ASSEMBLY ▪ Apply the Loctite #510 on the contact surface of half case. NOTE: Before apply Loctite, clean the old glue. ▪ Cross tighten the bolts as shown. Torque : 120~150kgf-cm) ▪ Apply the Loctite #510 on the contact surface of LOCK cover.
  • Page 174 9-1. FRONT DIFFERENTIAL Torque : A : gear oil levelcheck bolt 70~90kgf-cm) B : Gear oil filling bolt 300~350kgf-cm CABLE ADJUSTING LOCK MODE CABLE ADJUSTMENT. ▪ Loose jam nut to adjust the cable length. ▪ Adjust the suitable length by the rotate the nuts as shown.
  • Page 175 9-1. FRONT DIFFERENTIAL INSTALLATION ▪ For installation, reverse the removal procedure. ▪ Fill the gear oil and tighten the bolt. Caution Oil standard:SAE#90 hypoid gear oil Oil capacity: 350c.c. Bolt Torque : 33N-m DIFFERENTIAL MOTOR ▪ Disconnected the wiring connector. ▪...
  • Page 176 9-2.REAR DIFFERENTIAL REAR DRIVE (REAR DIFFERENTIAL) A:4.2~4.4 kgf-m B:3.0~3.5 kgf-m C:0.7~0.9 kgf-m D:2.0~2.2 kgf-m E、F:1.2~1.5 kgf-m G: 11~12kgf-m 9-2-1...
  • Page 177 9-2. REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL Caution Be sure the differential set temperature below 35℃ ▪ Drain the differential oil. ▪ Remove both drive shafts. ▪ Detach vent hose from rear differential. ▪ Remove the lock mode cables. ▪ Remove the four bolts and bracket as shown. ▪...
  • Page 178 9-2.REAR DIFFERENTIAL INSTALLATION Reverse the removal procedure install the rear differential. ▪ Apply grease into the propeller shaft end. ▪ Install the rear differential and insert the differential shaft into the connecting shaft, put the boot on the position as shown. ▪...
  • Page 179 9-2. REAR DIFFERENTIAL ▪ Tighten the upper and bottom front end bolt as shown. Torque : 4.5~5.5kgf-m. ▪ Install and fixed the vent hose as shown. NOTE: keep the vent hose away from the exhaust. ▪ Install the cable, apply special tool #560023 to adjust the length.
  • Page 180 9-2.REAR DIFFERENTIAL REAR DIFFERENTIAL DISASSEMBLY ▪ Remove the differential housing eight bolts. ▪ Apply rubber hammer lightly knock the case (red area as shown) to separate the half case. ▪ Check “O” ring, replace if necessary. ▪ Remove the anti-slip limited gear assy. and the shims.
  • Page 181 9-2. REAR DIFFERENTIAL ▪ Check the two bearing, replace if necessary. NOTE: beware the foreign object falling into the slip limited gear assy. ▪ Check the bearing on the left half case, replace if necessary. ▪ Check oil seal, replace if necessary. NOTE: Apply grease on rear area as shown before install oil seal.
  • Page 182 9-2.REAR DIFFERENTIAL REAR DIFFERENTIAL ASSEMBLE ▪ Install shim into the case as shown. ▪ Install anti slip limited gear assy. into the case and apply rubber hammer lightly knock to the position as shown. ▪ Install two dowel pin on the left half case. ▪...
  • Page 183 9-2. REAR DIFFERENTIAL LOCK MODE ASSY. DISASSEMBLE ▪ Remove five bolts. ▪ Apply rubber hammer light knock to separate the case. ▪ Check the oil seal, replace if necessary. NOTE: shift shaft seal recommend replace after assemble. ▪ Check bearing, replace if necessary. ▪...
  • Page 184 9-2.REAR DIFFERENTIAL LOCK MODE ASSY. ASSEMBLE ▪ Install the two dowel pin as shown. ▪ Install the lock sleeve and shift rod. ▪ Clean the old glue and apply Loctite #510 on the contact surface as shown. ▪ Assemble the case. 9-2-1...
  • Page 185 9-2. REAR DIFFERENTIAL ▪ Apply Loctite #263 on the three bolts and cross tighten as shown. NOTE: S70810 is shortest bolt. Torque : 1.2~1.5kgf-m。 NOTE: Check and test the shift rod function ▪ Install shift rod oil seal. ▪ Install bracket and tighten the two bolts. ▪...
  • Page 186 9-2.REAR DIFFERENTIAL PIVOT GEAR DISASSEMBLE ▪ Remove four bolts and lightly knock out the housing. ▪ Check the oil seal and O ring, replace if necessary. ▪ Using special tool #560010 to remove the ring snap. ▪ Apply rubber hammer from the inside of case lightly knock out the gear to remove the shaft from the case.
  • Page 187 9-2. REAR DIFFERENTIAL PIVOT GEAR ASSEMBLE ▪ Reverse the disassemble procedure install the shaft and bearing into case. ▪ Apply Loctite #263 on the ring snap, and Apply special tool #560010 to install. Torque : 11~12kgf-m ▪ Apply Loctite #263 on the four bolts, and install the housing and tighten.
  • Page 188 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-1 Flywheel Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-4 Precautions in Operation·...
  • Page 189 10. ALTERNATOR/STARTING CLUTCH Precautions in Operation General information ● Refer to chapter 17: The troubleshooting and inspection of alternator ● Refer to chapter 17: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear OD of starting clutch gear 52.548~52.445...

  • Page 190: Left Crankcase Cover Removal

    10. ALTERNATOR/STARTING CLUTCH Left Crankcase Cover Removal 15 bolts Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump (2 bolts). Remove 15 bolts from the left crankcase cover. Water pump bolts Remove the left crankcase cover.
  • Page 191 10. ALTERNATOR/STARTING CLUTCH Check the oil seal for wear or damage. Oil seal Replace it if necessary. Install a new one bearing (16005) by bearing driver. Bearing Flywheel Removal Remove left crankcase cover. Flywheel nut Remove starter reduction gear and shaft. Pull out flywheel with A.C.G.
  • Page 192 10. ALTERNATOR/STARTING CLUTCH Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. Service Limit: ID: 29 mm OD: 52.54mm Check the starting reduction gear and shaft for wear or damage.
  • Page 193 10. ALTERNATOR/STARTING CLUTCH One way clutch removal Remove starting driven gear. Starting driven gear Remove 6 socket bolts, and then remove one way clutch. 6 socket bolts One way clutch Starting driven gear One way clutch Installation Install the components in the reverse procedures 6 socket bolts of removal.
  • Page 194 10. ALTERNATOR/STARTING CLUTCH Install starting driven gear. Starting driven gear Flywheel Installation Align the key on crankshaft with the flywheel Groove groove, and then install the flywheel. Hold the flywheel by drive face with universal holder, and tighten flywheel nut. Caution Flywheel nut not to be reused should be replaced when disassembled...

  • Page 195: Left Crankcase Cover Installation

    10. ALTERNATOR/STARTING CLUTCH A.C.G. Set Installation Put the new gasket on. Install the A.C.G. coil set onto left crankcase cover (3 screws). Torque value:1.7kgf-m Bend up the gasket tongue positively to lock screws. Install pulse generator (3 screws). Tie the wire harness securely onto the indent of crankcase.
  • Page 196 10. ALTERNATOR/STARTING CLUTCH Install left crankcase cover (15 screws). 15 bolts Install the dowel pin, new gasket and water pump cover onto left crankcase cover. Water pump bolts Install the water pipe. Install the recoil starter assy.(4 bolts). 10-9...
  • Page 197 10. ALTERNATOR/STARTING CLUTCH Note: 10-10...

  • Page 198: Crankshaft/Crankcase

    11. CRANKSHAFT / CRANKCASE L CASE R CASE 11-1...
  • Page 199 11. CRANKSHAFT / CRANKCASE Oil SEAL Remove the oil seal with the special tool. Oil seal remover 440656 Install the oil seal with the special tool. Bearing installer set 440655 Caution Change the new oil seal to prevent oil leakage. NOTE: Be sure the stamped mark on the oil seal faces outside.
  • Page 200 11. CRANKSHAFT / CRANKCASE BEARING REASEMBLY Install the bearing. NOTE: Be sure The sealed cover of the bearing must face outside. Install the chuck,Bearing. NOTE: When installing the Bearing chuck,apply a small quantity of Loctite 262 (Thread locker) to the screws.
  • Page 201 11. CRANKSHAFT / CRANKCASE DRIVE BELT COVER Remove the snap ring with the snap ring pliers. NOTE: If any damage the bearing, replace the new one. Remove the bearing. REASSEMBLY Install the bearing. Install the snap ring with snap ring pliers. 11-4...
  • Page 202 11. CRANKSHAFT / CRANKCASE L CRANK CASE COVER Remove the oil pressure valve When installing the oil valve, tighten it to the specified Torque. Oil pressure value:25N．M(2.5kgf-m,17lb-ft) Using an shaped tool to check the oil pressure valve Operation. If the piston does not operate, replace the new one.
  • Page 203 11. CRANKSHAFT / CRANKCASE Remove the oil seal. REASSEMBLY Install the bearing. Apply Grease to the bearing,O-ring and Oil seal lip. Install the oil seal. NOTE: When installing the oil seals, be sure the stamped mark on the oil seal faces outside. Apply a small quantity of Loctite 262 (Thread locker) to the screws and install the bearing...
  • Page 204 11. CRANKSHAFT / CRANKCASE CRANKSHAFT Mounting the crankshaft in the crankcase. NOTE: Use the front fork oil seal installer as an attachment. Front fork oil seal installer 440655 Apply a small quantity of Loctite 262 (Thread locker) to the thread and install and the gearshift cam stopper.
  • Page 205 11. CRANKSHAFT / CRANKCASE Apply Loctite 510 (Flange sealant) to the mating surface of the left crankcase. L CASE R CASE 11-8...

  • Page 206: Oil Pump

    11. CRANKSHAFT / CRANKCASE Assemble the crankcase within few minutes. NOTE: After crankcase screws have been tightened, check if crankshaft rotate smoothly. Fit the clamp to the bolt. Check the each shaft rotates smoothly after the crankcase bolts have been tightend. OIL PUMP Install the oil pump.

  • Page 207: Clutch Shoe

    11. CRANKSHAFT / CRANKCASE OIL PUMP DRIVE GEAR Install the pin. Install the oil pump drive gear and washer. Apply lock tail to the oil pump drive gear bolt. NOTE: Flange side of the gear is positioned inside. Tighten the oil pump drive gear bolt to the specified torque.
  • Page 208 11. CRANKSHAFT / CRANKCASE Install the one way clutch outside. Caution “OUTSIDE” The one way clutch outside facing must on the shaft outside. NEUTRAL SWITCH Install the springs and switch contacts. Install the neutral switch. CLUTCH CASE Install the dowel pins and put the new gasket. Tighten the clutch case bolts.
  • Page 209 11. CRANKSHAFT / CRANKCASE AIR DEFECTOR&FIXED DRIVE FACE Install the air defector. Install the fixed drive face. MOVABLE DRIVE/DRIVEN FACE AND DRIVE BELT Install the drive belt,between the movable driven face and fixed driven face by tapping with a plastic mallet. Caution The drive belt contact surface of the driven face should be thoroughly cleaned.
  • Page 210 11. CRANKSHAFT / CRANKCASE Tighten the movable drive face nut to the specified torque with the special tool. Movable drive face nut: 115 N．M( 11.5 kgf- m,85 lb-ft) Clutch And CVT Holder (440666) NOTE: Turn the fixed drive face until the belt is seated in and both the drive and driven faces check the belt without slip.
  • Page 211 11. CRANKSHAFT / CRANKCASE WATER PUMP GEAR Install the pin. Install the water pump chain to the two water pump gears as show. Install the water pump gears with special tool. Install the washer. Chain Wheel & Washer Installer (440660) Install the water pump gears and tighe the nut NOTE: Make sure the crankshaft can turning smoothly.
  • Page 212 11. CRANKSHAFT / CRANKCASE GENERATOR Install the key. Install the one way clutch and generator rotor sets. Caution Be sure the one way clutch on the crankshaft is fitted into the generator rotor properly. Tighten the generator rotor nut to the specified torque with the special tool.

  • Page 213: Left Crankcase Cover

    11. CRANKSHAFT / CRANKCASE GEARSHIFT Install the cam driven gear. Reassemble the gearshift shaft. Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear. STARTER DRIVEN GEAR/IDLE GEAR Install the starter idle gear and driver gear. LEFT CRANKCASE COVER Install the dowel pins and put the new gasket.
  • Page 214 11. CRANKSHAFT / CRANKCASE Tighten the left crankcase cover bolt. NOTE: Fit the clamp to the bolt. SPEEDOMETER GEARBOX Fit a new gasket and install the speedometer gearbox. WATER PUMP Check the water pump shaft position with water pump gear shaft. Apply engine oil on the O-ring of water pump.
  • Page 215 11. CRANKSHAFT / CRANKCASE STARTER CUP Apply engine oil to the O-ring and lip of the oil seal. Install the starter cup. Tighten the starter cup nut by using a suitable bar. Starter cup nut: 35 N．M( 3.5 kgf- m, 25 lb-ft) Cup, Starter Holder (440658) Install 4 studs, and then put 2 gaskets and 2 O-rings.
  • Page 216 11. CRANKSHAFT / CRANKCASE GEARSHIFT for Parking Install the Gear Stopper 925735. Torque: 2.7 kgf-m Assemble the Secondary dial pole 925742. Install the Secondary dial pole by aligning the punched mark with the center of the cam driven gear. 11-19...
  • Page 217 11. CRANKSHAFT / CRANKCASE NOTE： 11-20...

  • Page 218: Cooling System

    12. COOLING SYSTEM General Information General Warning While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.
  • Page 219 12. COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any cooled down, open cap to Water leaking problem leakage? check the capacity of coolant in radiator.
  • Page 220 12. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure cooling fan switch and inspect cooling fan was to confirm voltage be Replace cooling operating after the changed (12→0V)? fan switch temperature gauge over 3 checks? E-2. Connect cooling fan F.

  • Page 221: System Test

    ● Stop the engine. Add coolant to proper level if necessary. ● Screw and tighten up the radiator filler cap. Coolant recommended: TGB Bramax radiator Drain Bolt agent. Concentration: 50% By pass pipe...
  • Page 222 12. COOLING SYSTEM Check reserve tank ● Remove the front center cover, and then remove reserve tank filler cap. ● Check the liquid level in the front fender Upper right side. Add coolant to proper level if too low. ● Reinstall the reserve tank filler cap. Lower Caution The reserve tank liquid level coca too is not...
  • Page 223 12. COOLING SYSTEM Loosen the radiator 4 bolts. Remove coolant upper side pipes. Remove coolant outlet pipe. Disconnect the couplers for the cooling fan switch and fan motor, and then remove radiator and cooling fan. Disassembly Loosen the 4 bolts from the fan duct, and then remove the fan duct.

  • Page 224: Water Pump

    12. COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection ● Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. ● Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 225 12. COOLING SYSTEM Thermostat Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.
  • Page 226 12. COOLING SYSTEM Oil Radiator Check Remove the protector, and check for any leakage from weld seam. Blow oil radiator clean using compressed air. If the oil radiator is blocked by dirt, use low pressure water jet to clean it. Remove two oil pipes.
  • Page 227 12. COOLING SYSTEM Note : 12-10...

  • Page 228: Body Cover

    13. BODY COVER BLADE MODEL Mechanism Diagram 13-1...
  • Page 229 13. BODY COVER Maintenance Body covers dissemble sequence Fuel tank cover Right and left foot board Right and left foot board Right and left front internal fender Right and left front shock mount, front bumper Front air inlet plate Right and left head lamp support, body cover Rear body cover Front protector Rear protector...
  • Page 230 13. BODY COVER Remove seat Remove 2 bolts from battery fixed. Remove cable and battery fixed. Remove 1 screw and take off shift lever Remove fuel cap. Remove 4 screws，and then remove fuel tank cover. Installation Install in reverse order of removal procedures. 13-3...
  • Page 231 13. BODY COVER Remove screws from right or left foot board (each side 4 screws). Remove screws from right or left foot board (each side 9 screws). Remove M6 bolts from right or left foot board remove right or left foot board (each side 3 bolts).
  • Page 232 13. BODY COVER Remove screws from front bumper (each side 3 screws). Remove head lamp couplers，and then remove front bumper. Remove bolts from right and left headlamp support (each side 2 bolts). Remove bolts from front air inlet plate (each side 2 bolts) ，and then remove front air inlet plate Remove bolts from front body cover (each side...
  • Page 233 13. BODY COVER Remove lock cap. Remove power source couplers，and then remove front body cover. Remove bolts (each side 1 bolts). Remove 2 couplers Installation Install in reverse order of removal procedures. 13-6...
  • Page 234 13. BODY COVER Remove 1 couplers and 1 nut from starting motor relay，and then remove starting motor relay. Remove 1 bolts from rear body covert. Remove 1 nut from rear reflector assembly (each side 1 bolts). Remove number-plate lamp couplers 、rear lamp assembly couplers (L/R) and turn signal lamp couplers (L/R).
  • Page 235 13. BODY COVER Remove screws from rear body covert (each side 2 screws) ，and then remove rear body covert. Remove 2 bolts from front protector. Remove 2 bolts from front protector，and then remove front protector. Remove bolts from bear protector (each side 1 bolts).
  • Page 236 13. BODY COVER Remove bolts from bear protector (each side 1 bolts)，and then remove bear protector. Remove 7 screws from upper bracket assembly. Remove speedometer assembly couplers，and then remove upper bracket assembly. Installation Install in reverse order of removal procedures. 13-9...
  • Page 237 13. BODY COVER TARGET MODEL 13-10...
  • Page 238 13. BODY COVER Body covers dissemble sequence Seat, battery fixed Fuel cup Feont body cover, front cover ornamental Right / left side cover Right / left foot board Tail carrier, Tail carrier ornamental Rear body cover Bumper, number-plate bracket, first housing Front / rear protector Handle bar front cover Upper bracket assembly...
  • Page 239 13. BODY COVER Remove seat. Remove 3 bolts from battery fixed. Remove battery fixeds. Remove 2 wire from battery. Remove battery. Remove 2 bolts from battery fixed.Then,remove cable. Remove 1 couplers from starting motor relay , and then remove starting motor relay. Remove bolts (each side 1 bolts) and 2 couplers Remove fuse box.
  • Page 240 13. BODY COVER Remove 6 bolts from battery fixed. Remove battery fixed. Remove 1 screw and take off shift lever. Remove fuel cap. Remove bolts (each side) from front body cover. Installation Install in reverse order of removal procedures 13-13...
  • Page 241 13. BODY COVER Remove screws (each side) from the part of front body cover,and then remove front body cover. Remove front cover ornamental. Remove 8 screws from right or left side cover. (each side 4 screws) Remove right or left side cover. Installation Install in reverse order of removal procedures.
  • Page 242 13. BODY COVER Remove bolts and screws from right or left foot board.(each side 5 bolts) Remove right or left foot board. Remove screw from tail carrier. Then,remove tail carrier ornamental. Remove 3 bolts from tail carrier,then remove tail carrier. Remove the bolts from rear body cover.
  • Page 243 14. BRAKE SYSTEM BRAKE FRONT BRAKE 14-1...
  • Page 244 14. BRAKE SYSTEM AND BODY COVER REAR BRAKE 14-2...
  • Page 245 14. BRAKE SYSTEM BRAKE SPECIFICATIONS FRONT BRAKES Item Standard Service Limit Bake Pad Thickness 1.5 mm Brake Disc Thickness 4.75 mm 4.24 mm Brake Disc Run out 0.25 mm Caliper Piston Diameter 14” tire 25.3 mm 25.25 mm Caliper Bore Diameter 14” tire 25.4 mm 25.45 mm Caliper Piston Diameter 12”...
  • Page 246 14. BRAKE SYSTEM AND BODY COVER BRAKE SYSTEM SERVICE NOTES Disc brake systems are lightweight, low maintenance and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.
  • Page 247 14. BRAKE SYSTEM BRAKE LIGHT SWITCH Brake Light Switch Location There are two brake light switches, which located on the brake liquid distributor, one at front and other at LH rear. Brake Light Switch Continuity Test 1. Disconnect brake light switch connector. 2.
  • Page 248 14. BRAKE SYSTEM AND BODY COVER MASTER CYLINDER Master Cylinder Removal (Hand Brake) 1. Drain brake system. 2. Remove master cylinder. 3. Unscrew brake hose from master cylinder. Master Cylinder Removal (Pedal Brake) 4. Disconnect master cylinder rod from brake pedal.
  • Page 249 14. BRAKE SYSTEM CALIPER Caliper Removal 1. Safety lift and support the vehicle. 2. Remove wheels. 3. If caliper is removed from vehicle for replacement: 3.1 Drain brake system. 3.2Unscrew brake hose from caliper. 4. Remove fasteners retaining brake hose to knuckle.
  • Page 250 14. BRAKE SYSTEM AND BODY COVER BRAKE PADS Brake Pads Replacement 1. Remove caliper from knuckle. 2. Remove brake pad pins from caliper. 3. Remove brake pads. 4. Clean pistons end using brake cleaner. 5. Push caliper pistons inward. NOTE: To avoid damaging pistons, use an old pad to push it into the caliper using a C-clamp.
  • Page 251 15-1-1. STEERING SYSTEM AND SUSPENSION STEERING SYSTEM EPS MODEL 15-1-1...
  • Page 252 15-1-1. STEERING AND SUSPENSION NON EPS MODEL 15-1-2...
  • Page 253 15-1-1. STEERING SYSTEM AND SUSPENSION STEERING SYSTEM GENERAL During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to. Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.) must be replaced.
  • Page 254 15-1-1. STEERING AND SUSPENSION PROCEDURES HANDLEBAR COVER Handlebar Cover Removal 1. Loosen six screws on the dashboard cover. 2. Remove the two screws on the both rear mirror bracket. 3. Remove the top cover screws and pull out the cover from the handlebar. Handlebar Cover Inspection Check covers for cracks or other damages.
  • Page 255 15-1-1. STEERING SYSTEM AND SUSPENSION Handlebar Removal 1. Remove handlebar cover. NOTE: Remove handlebar grips, throttle lever, brake lever and switch only if the handlebar is defective and requires replacement. 2. Remove four bolts from the dashboard bracket. 3. Remove the dashboard. 4.
  • Page 256 15-1-1. STEERING AND SUSPENSION Steering Shaft Removal (without EPS) 1. Remove handlebar cover. 2. Remove dashboard support. 3. Loosen handlebar mounting bolts and remove handlebar. 4. Remove the body top cover. 5. Remove steering shaft bracket and bolts. 6. Remove the inner fender. 7.Remove the cotter pin and castle nut at the arm plate.
  • Page 257 15-1-1. STEERING SYSTEM AND SUSPENSION Steering Tie-Rod Assembly (w/EPS) Steering Tie-Rod Assembly (w/o EPS) 15-1-1...
  • Page 258 15-1-1. STEERING AND SUSPENSION WHEEL AND TIRE TIRES GENERAL WARNING WARNING Do not rotate tires. The front and rear tires have a different size. Respect direction of Torque wrench tightening specifications rotation when applicable. must strictly be adhered to. Castle Nut TIRE PRESSURE Torque: 1600-1800 kgf-cm Wheel Nut...
  • Page 259 15-1-1. STEERING SYSTEM AND SUSPENSION FRONT SUSPENSION 15-1-1...
  • Page 260 15-1-1. STEERING AND SUSPENSION FRONT SUSPENSION GENERAL ▪ The procedure explained below is the same for the RH and LH sides unless otherwise noted. ▪ During assembly/installation, use the torque values and service products as in the exploded view. ▪ Clean threads before applying a thread locker. WARNING Torque wrench tightening specifications must strictly be adhered to.
  • Page 261 15-1-1. STEERING SYSTEM AND SUSPENSION - Seizing or binding condition except at extreme end of either stroke. - Oil leakage. - A gurgling noise, after completing one full compression and extension stroke. ▪ Replace if any faults are present. Shock Absorber Installation For installation, reverse the removal procedure.
  • Page 262 15-1-1. STEERING AND SUSPENSION UPPER A ARM Upper A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove fasteners retaining brake hose to vehicle. 4. Remove and discard cotter pin retaining ball joint.
  • Page 263 15-1-1. STEERING SYSTEM AND SUSPENSION REAR SUSPENSION 15-1-1...
  • Page 264 15-1-1. STEERING AND SUSPENSION REAR SUSPENSION GENERAL The procedure explained below is the same for the RH and LH sides unless otherwise noted. During assembly/installation, use the torque values and service products as in the exploded view. Clean threads before applying a thread locker.
  • Page 265 15-1-1. STEERING SYSTEM AND SUSPENSION - Seizing or binding condition except at extreme end of either stroke. - Oil leakage. - A gurgling noise, after completing one full compression and extension stroke. ▪ Replace if any faults are present. Shock Absorber Installation For installation, reverse the removal procedure.
  • Page 266 15-1-1. STEERING AND SUSPENSION UPPER A ARM Upper A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove bolts and nuts securing A arm to frame. 4. Remove bolts and nut securing upper knuckle.
  • Page 267 15-1-1. STEERING SYSTEM AND SUSPENSION LOWER A ARM Lower A Arm Removal 1. Safety lifts and supports the vehicle off the ground. 2. Remove wheel. 3. Remove bolts and nuts securing A arm to frame. 4. Remove bolts and nut securing lower knuckle.
  • Page 268 15-2. ELECTRIC POWER STEERING EPS (Electric Power Steering) 15-2-1...
  • Page 269 15-2. ELECTRIC POWER STEERING (EPS) Electric Power Steering When electrical system is under high load GENERAL (battery not at full charge, operating the vehicle During assembly/installation, use the torque for prolonged periods of time at slow speed and values and service products as in the exploded low RPM which, requires higher power steering view.
  • Page 270 15-2. ELECTRIC POWER STEERING The internal protection system decreases the Steering Torque Sensor assistance level available to protect its The steering column is connected to the shaft electronic board. The normal assistance level on the EPS unit. A small area of the EPS shaft will return when riding conditions are back to is magnetized.
  • Page 271 15-2. ELECTRIC POWER STEERING How to View EPS Mode Selection 1. To view the active EPS assist mode, press MODE button from the dashboard and move to EPS select page, the EPS page will blinking then press the RESET button to engage the EPS assist.
  • Page 272 15-2. ELECTRIC POWER STEERING SYSTEM DESCRIPTION (COMPONENTS) EPS Unit ▪ The EPS unit is a self-contained unit that includes the steering gear, the EPS module, the EPS motor and the torque sensor. ▪ The EPS module provides DC power to the motor.
  • Page 273 15-2. ELECTRIC POWER STEERING TROUBLESHOOTING LOW POWER STEERING ASSIST NO POWER STEERING 1. Low battery voltage. 1. EPS malfunction. - Check battery terminals. Clean, repair, - If the CHECK ENGINE light is on and a EPS replace or tighten as required. FAULT message is visible in the dashboard, - Test battery voltage.
  • Page 274 15-2. ELECTRIC POWER STEERING EPS unit Power Fuse Test A 40 A EPS fuse located at the right side under the passenger seat in the EPS fuse box provides power for the EPS motor. 1. To remove fuse box cover, simultaneously squeeze tabs inwards on each end of fuse box cover as you pull upward on the cover.
  • Page 275 15-2. ELECTRIC POWER STEERING EPS unit Input Voltage Test (Power Side) ① ③ 1. Disconnect the EPS power connector. 2. Test for 12 VDC EPS motor power at pin as per following table. ② EPS power connector pin 1 + Battery GND The voltage should be battery voltage ▪...
  • Page 276 15-2. ELECTRIC POWER STEERING EPS Unit Ground Circuit Test 1. Disconnect the EPS ground connector (GDN) 2. Test for continuity between PINS to battery ground. EPS GND connector pin A + Battery GND EPS GND connector pin B+ Battery GND The voltage should be Continuity (close to 0 Ω...
  • Page 277 15-2. ELECTRIC POWER STEERING PS System Load Test If the charging system cannot sustain normal voltage when the EPS is operating, EPS may be greatly reduced or nonexistent. Carry out the following steps. 1. Connect the red lead of voltmeter set to VDC to the EPS fuse box battery terminal.
  • Page 278 15-2. ELECTRIC POWER STEERING EPS Unit Current Test 1. Connect vehicle to the latest BUS software. 2. Click on the Rear Data button. 3. Choose the Monitoring page tab. 4. At the bottom of the Monitoring page, choose the EPS tab. 5.
  • Page 279 15-2. ELECTRIC POWER STEERING EPS Unit Removal Remove the following items: • Both internal fender. • The front bumper. • Disconnect the wiring of headlamp and power source. • The front cover. • The inlet tube. ▪ Loose the handle steering lock nut. ▪...
  • Page 280 15-2. ELECTRIC POWER STEERING Loose the clamp of anti-dust rubber. Lift up and dismounting the EPS unit. Take out the EPS unit from the left side of vehicle. NOTE: Be careful do not damage the cable of torque sensor. Remove the four bolts ① and the bracket ②. ②...
  • Page 281 15-2. ELECTRIC POWER STEERING Steering lower Bearing Seat Refer to the picture for install new bearing and seal into the bearing seat then assemble the bearing seat assembly. ① Steering Pad. ② Bearing Seat ③ Oil Seal ④ Bearing x 2 ⑤...
  • Page 282 15-2. ELECTRIC POWER STEERING Fuse Removal Simultaneously squeeze tabs inwards on each end of fuse box cover as you pull downward on the cover. Replace the damage fuse. Installation Install the control in the reverse order of removal. 15-2-15...
  • Page 283 16. ELECTRICAL SYSTEM /Mechanism Diagram · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17-1 Meters · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 17-12 Maintenance Data ·...
  • Page 284 16. ELECTRICAL SYSTEM Maintenance Data Operational precaution ● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) ● The model of the spark plug and the tightening torque. ●...
  • Page 285 16. ELECTRICAL SYSTEM Trouble Diagnosis Charging system does not No voltage operate properly ● Battery discharged ● Burnt fuse ● The cable disconnected ● Poor contact, open or short circuit ● The fuse is blown ● Poor regulator ● Improper operation of the main switch ●...
  • Page 286 16. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery. Voltage Check Use the digital voltmeter to check the voltage of the battery.

  • Page 287: Charging System

    16. ELECTRICAL SYSTEM Charging System Charging circuit Main Switch Blue Black Yellow Fuse 20 A Black/Red Yellow Yellow Battery AC Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
  • Page 288 16. ELECTRICAL SYSTEM Inspection on Charging Voltage Connect a tachometer. Turn on the headlight to high beam and start the engine. Accelerate the engine to the specified revolution per minute and measure the charging voltage. Specified Charging Current: 1.2 A / 6000 rpm Control Charging Voltage: 14.5 + 0.5 V / 2000 rpm Caution...
  • Page 289 16. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch Battery voltage Bl –...
  • Page 290 16. ELECTRICAL SYSTEM Ignition System Black Ignition circuit diagram Green White Yellow C.D.I unit Blue BR/B B1/Y Ignition LG/R Main Fuse Coil Spark Battery Plug Main Switch Pulse Generator C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result...
  • Page 291 16. ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Ω Standard resistance: 2.9 ± 10% Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding.

  • Page 292: Starting System

    16. ELECTRICAL SYSTEM Starting System Starting circuit diagram Black Blue C.D.I Main Switch Green BR/B Fuse 20A White Yellow Main Fuse 30 A Brown Brake Switch Battery Change Switch Starter Relay Starter Motor B1/W Brake light Starter Switch Inspection on starter relay Open the main switch.
  • Page 293 16. ELECTRICAL SYSTEM Removal of Starter motor Remove the seat. Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove starter motor cable. Loosen the lock bolts and remove the starter motor. Installation of Starter motor Install in reverse order of removal procedures. 16-11...
  • Page 294 16. ELECTRICAL SYSTEM Meters Removal Loosen 7 screws of the meter stay. Remove the front center cover, and then remove meter couplers and main switch coupler. Remove speedometer cable. Main Switch coupler Remove speedometer cable, and then remove meter set, main switch and handle cover. Speedometer Cable Remove 4 nuts and meter wire, and then remove speedometer and fuel meter.
  • Page 295 16. ELECTRICAL SYSTEM Light / Bulb Replacing Bulb for Headlight Remove waterproof cover for the headlight. Remove 2 coupler. Remove bulb setting hook. T ake out the bulb connector and the bulb. Replace with new bulb if necessary. (Main beam H3 12V 55W) (Dipped 12V 55W) Caution ●...
  • Page 296 16. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Pull out the front winker light bulb seat. Replace with new front winker light bulb. (12V 21W) Replacing Bulb of Position Light Pull out the position light bulb seat. Replace with new position light bulb. (12V 5W) 16-14...
  • Page 297 16. ELECTRICAL SYSTEM Replacing Bulb of Taillight Turn the taillight and rear winker light bulb connectors by CCW. Replace with new taillight bulb. (12V 5W/21W) Rear Winker Light Replace with new rear winker light bulb. (12V 21W) Replacing Bulb of License Light Turn the license light bulb connectors by CCW.
  • Page 298 16. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front center cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position Wire Color Red/White Brown/Blue Replacement of main switch Disconnect the coupler of the main switch. Push out the main switch.
  • Page 299 16. ELECTRICAL SYSTEM Headlight Switch BAT3 Position Red/ Red/ Blue/ Wire Color Green Yellow Brown Winker switch Position PUSH OFF Wire Color Brown Brown/White Green Horn switch BAT3 Position FREE Wire Color Brown/White Pink Hazard switch Position Wire Color Brown/White Black 16-17...
  • Page 300 16. ELECTRICAL SYSTEM Lock switch Position LOCK Wire Color Black Pu/W Remove three bolts from the frame. Remove the transfer shift cables of right and left side from the front differential assy. Note： Check if the servomotor„s condition is poor, please replace with the new one.
  • Page 301 16. ELECTRICAL SYSTEM Front Brake Switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Rear Brake Switch While grasp the brake lever firmly, the terminals of white/black and Brown/White of the brake should have continuity.
  • Page 302 16. ELECTRICAL SYSTEM Fuel Unit Remove the seat. Remove the fuel tank cap. Remove the fuel tank cover and front fender (refer chapter 13). Disconnect the coupler of the fuel unit. Remove the fuel unit (4 bolts). Caution ● Great care shall be taken not to damage or bend the float arm of the gauge.
  • Page 303 16. ELECTRICAL SYSTEM Cooling Fan Switch The cooling fan switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
  • Page 304 16. ELECTRICAL SYSTEM Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2 Caution ●Wear gloves and goggles when performing this test.

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