FORWARD CONTENTS HOW TO USE THIS MANUAL Mechanism Illustrations Mio 50 / 100 SERVICE MANUAL
Homepage Contents Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Mio 50 / 100 scooters. 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 scooter, Mio 50 / 100, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Homepage Contents How To Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG Mio 50 / 100 scooters. 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 information and special tools manual.
Homepage Contents Page Content Index 1-1 ~ 1-18 General Information 1 2-1 ~ 2-18 Service Maintenance Information 2 3-1 ~ 3-8 Lubrication System 3 4-1 ~ 4-12 Fuel System 4 5-1 ~ 5-8 Engine Removal 5 6-1 ~ 6-18 Cylinder Head/Valve 6 7-1 ~ 7-8 Cylinder/Piston 7 8-1 ~ 8-14 “V” Type Belt Driving System / Kick-Starter 8 9-1 ~ 9-8 Final Driving Mechanism 9 10-1 ~ 10-8 Alternator 10 11-1 ~ 11-8 Crankshaft / Crankcase 11 12-1 ~ 12-16 Body Cover 12 13-1 ~ 13-14 Brake 13 14-1 ~
Home page Contents Mechanism Illustrations HU05U / HU10U / HU10W Oil gauge Fuel tank Front winker Fuel tank cap Battery / Fuse / C.D.I.
Homepage Contents 1.
To this chapter contents 1. General Information 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.
To this chapter contents 1. General Information Service Precautions y Always use with SANYANG genuine parts and recommended oils. Using non-designed parts for SANYANG ATV may damage the ATV. y 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. y When servicing this ATV, use only metric tools.
To this chapter contents 1. General Information y 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.
To this chapter contents 1. General Information y Lubricate the rotation face with specified lubricant on the lubrication points before assembling. y After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly. y And the two posts of battery have to be greased after connected the cables. y Check if positions and operation for installed parts is in correct and properly. y Make sure service safety each other when conducting by two persons.
To this chapter contents 1. General Information y When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation. y Do not pull the wires as removing a connector or wires. Hold the connector body. y Insert the terminal completely. Check if the terminal is covered by the boot. Do not let boot open facing up. y Secure wires and wire harnesses to the frame with respective wire bands at the designated locations.
To this chapter contents 1. General Information y Do not let the wire harness contact with rotating, moving or vibrating components as routing the harness. y 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. y Keep wire harnesses far away from the hot parts. y Secure the rubber boot firmly as applying it on wire harness.
To this chapter contents 1. General Information y Do not let the wire harness been twisted as installation. y With sand paper to clean rust on connector pins/terminals if found. And then conduct connection operation later. Clean rust y 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.
To this chapter contents 1. General Information Specifications Dimension MAKER Overall Length 1710 mm Overall Width 700 mm Overall Height 1005 mm Wheel Base 1170 mm Curb Weight Weight SANYANG Front 31 kg Rear 49 kg Total 80 kg Passengers/Weight MODEL Suspension System Tire Specifications Front TELESCOPE Rear UNlT SWING Front 3.0-10 Rear 90/90-10 42J 50J Front DRUM (ø 110 mm) Rear DRUM (ø 95 mm) Brake System Two / 110 kg Max.
To this chapter contents 1. General Information Specifications Dimension MAKER SANYANG Overall Length 1710 mm Overall Width 700 mm Overall Height 1020 mm Wheel Base 1220 mm Front Weight Curb Weight MODEL Suspension System Tire Specifications HU10U/W Front TELESCOPE Rear UNlT SWING Front 90/90-10 50J Rear 90/90-10 50J 32.5 kg DRUM (ø 110 mm) Front Rear 55 kg Total 87.5 kg Passengers/Weight DISK (ø 160 mm) Brake System Two / 110 kg Rear DRUM (ø 110 mm) Max.
To this chapter contents 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 5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut Tighten Torque 0.45~0.6kgf-m 0.8~1.2kgf-m 1.8~2.5kgf-m 3.0~4.0kgf-m 5.0~6.0kgf-m Type 5 mm screw 6 mm screw、SH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut Tighten Torque 0.35~0.5kgf-m 0.
To this chapter contents 1. General Information Frame Torque Values Item Mounting bolt for steering handlebar Mounting nut for steering rod Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks 1 10 4.0~5.0 1 25.4 1.0~2.0 Cone seat for steering rod 1 25.4 0.2~0.3 Front wheel shaft nut 1 12 5.0~7.0 Rear wheel shaft nut 1 16 11.0~13.0 Wheel hub/rim mounting nuts 8 8 2.8~3.
To this chapter contents 1. General Information Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Loosen carburetor drain bolt to check if there is gasoline inside the carburetor Fuel supplied tom carburetor sufficient No fuel is supplied to carburetor Remove spark plug, install it into spark plug cap, and perform a spark test against engine ground. Check if sparks Weak sparks, no spark at all Perform cylinder compression pressure test.
To this chapter contents 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 Engine speed can be increased. Engine speed can not be increased. Check ignition timing (Using ignition lamp) Ignition timing correct Incorrect ignition timing 1. Air cleaner clogged 1. Poor fuel supply 2. Lines in fuel tank evaporation system clogged 3. Exhaust pipe clogged 4.
To this chapter contents 1. General Information 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 CDI or AC alternator) Adjust the air screw of carburetor Good Poor 1. Rich mixture (loosen the screw) 2. Lean mixture (tighten the screw) Air sucked through carburetor gasket No air sucked Air sucked 1. Poor heat insulation gasket 2.
To this chapter contents 1. General Information E. Clutch, Driving And Driving Pulley FAULT CONDITIONS Engine can be started but motorcycle can not be moved. Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running) Poor initial driving (Poor climbing performance) 1-16 PROBABLE CAUSES 1. 2. 3. 4. 5. 6.
To this chapter contents 1.
To this chapter contents 1.
Home page Contents 2. Maintenance Information Precautions in Operation...................... 2-1 Cylinder Compression Pressure..... 2-9 Periodical Maintenance Schedule........ 2-2 Driving System ................................. 2-9 Lubrication System ............................... 2-3 Steering System ............................... 2-10 Fuel System ........................................... 2-4 Suspension System ......................... 2-10 Air Cleaner ........................................
To this chapter contents 2.
To this chapter contents 2. Maintenance Information Lubrication System Engine Oil Capacity Caution y The vehicle must be parked on a level ground when checking oil capacity. y Run the engine for 2-3 minutes then stop, wait about 2-3 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. Oil change Shut off the engine and remove dipstick.
To this chapter contents 2. Maintenance Information Gear Oil Inspection Oil refilling bolt 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.
To this chapter contents 2. Maintenance Information Air Cleaner Element Remove the air cleaner cover (7 screws) Remove element. Check the element if dirt or damaged. Replace it with new one if dirt or damaged. 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.
To this chapter contents 2. Maintenance Information Primary adjustment is conducted from cable button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Adjustment nut Crankcase Blow-By Ventilation Pull out the plug from draining hose to clean deposits Caution z When always riding in rainy area or full throttle position, maintenance travel must be shorted.
To this chapter contents 2. Maintenance Information Valve clearance inspection and adjustment Check & adjust valve clearance with feeler gauge after open the valve adjustment hole cap. Valve clearance: HU10U/W 0.12±0.02mm (IN/EX) HU05U IN: 0.05±0.02mm EX: 0.10±0.02mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution z 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.
To this chapter contents 2. Maintenance Information Ignition System “F” Mark Ignition Timing Caution z z 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 not. Remove right side cover. Remove ignition timing hole cap located on the cooling fan cap. Or remove the cooling fan cover. Connect tachometer and ignition lamp.
To this chapter contents 2. Maintenance Information 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 y Rotate the engine until the reading in the gauge no more increasing. y Usually, the highest pressure reading will be obtained in 4~7 seconds.
To this chapter contents 2. Maintenance Information Steering System Caution z 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 Caution z z Do not ride the motorcycle with poor shock absorber.
To this chapter contents 2. Maintenance Information Front Disk Brake System 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. Also check brake system for leaking if low brake level found. Caution z z z In order to maintain brake fluid in the reservoir in horizontal position, do not remove the cap until handle bar stop.
To this chapter contents 2. Maintenance Information ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid Master cylinder cap Caution z Upper limit Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance. Brake fluid Brake lining wear limit 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.
To this chapter contents 2. Maintenance Information Drum Brake System Front Brake Free Play: (Drum brake) Measure free play of rear brake level at the end of the lever. Free play: 10~20mm Adjust the free play by turning the front brake adjustment nut if necessary. 10∼20mm “△”mark Decreasing free play Increasing free play Adjustment nut Rear Brake Free Play: (Drum Brake Type) Measure the free [lay of the front brake lever at the end of the lever.
To this chapter contents 2. Maintenance Information BRAKE LAMP SWITCH Rear brake light switch The brake light switch lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. Wheel / Tire Check if the tire pressure of front & rear wheel is within standard. Caution z Tire pressure check should be done as cold tire.
To this chapter contents 2. Maintenance Information Battery Battery Removal Open the seat cushion and then the battery cap. (2 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 z z If there is rust on the posts very serious, spray some hot water on the posts.
To this chapter contents 2. Maintenance Information Special Service Tools Catalogue (ø28mm) Name Puller/presser for crankcase bushing Parts no. SYM-1120310 Name Valve spring compressor Parts no. SYM-1471100 (ø20mm) Name Parts no. SYM-1120320 Name Oil seal tapping installer Parts no. SYM-9121600 Valve clearance adjustment wrench Bearing installer Parts no. SYM-9110400 2-16 Name Name Valve spring compressor Parts no. SYM-9120200 Bearing installer Parts no.
To this chapter contents 2. Maintenance Information Name Bearing remover (inner type) Parts no. SYM-6204002 Name Clutch mounting nut wrench Parts no. SYM-9020200 Name Cylinder head/oil filter cap wrench Parts no. SYM-ALL23461 Name Bearing remover (outer type) Parts no. SYM-6204001 Name Universal fixer Parts no. SYM-2210100 Name Name clutch spring compressor Parts no. SYM-2301000 Name Alternator flywheel remover Parts no. SYM-3110A01 Valve rocker arm puller Parts no.
To this chapter contents 2.
Home page Contents 3.
To this chapter contents 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: HU10U/W 750c.c. HU05U 800c.c. Replacement: HU10U/W 650c.c. HU05U 700c.c. Oil viscosity: SAE 10W-30 or equivalent (Recommended King-Mate serial oils) Oil viscosity Gear Oil Disassembly: HU10U/W 110c.c. HU05U 100c.c. Replacement: HU10U/W 100c.c. HU05U 90c.c.
To this chapter contents 3. Lubrication System Engine OIL Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick 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 z 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.
To this chapter contents 3. Lubrication System 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. Special Service Tools: Strainer cap wrench SYM-ALL12361 Torque value：1.3~1.
To this chapter contents 3. Lubrication System Oil Pump Universal fixer 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) Special Service Tools: One way clutch socket SYM-9020100 Universal fixer SYM-2210100 One way clutch socket Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 screws). 2 screws Remove the oil pump.
To this chapter contents 3. Lubrication System 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 Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor.
To this chapter contents 3. Lubrication System Install driving gear and clamp. Caution z Make sure if the oil pump can be rotated smoothly. Oil Pump Installation Install the oil pump (2 screws). 2 screws Install oil pump drive gear. Install the one-way clutch and starting gear (1nut) Install the engine right cover. Install the alternator (refer to chapter 10).
To this chapter contents 3. Lubrication System 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. Refill plug of gear oil 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.
Home page Contents 4. Fuel System Mechanism Illustration ......................4-1 Idle Speed Adjustment ...................... 4-8 Operational Precautions....................4-2 Fuel Tank ............................................ 4-9 Trouble Diagnosis ..............................4-3 Air Cleaner.......................................... 4-11 Carburetor...........................................
To this chapter contents 4. Fuel System Operational Precautions 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. Caution z z z z Do not bend or twist throttle valve cable. Damaged cable will make unstable drive ability.
To this chapter contents 4.
To this chapter contents 4. Fuel System Carburetor Air cleaner clamp Carburetor Removal Remove the luggage box and seat. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Remove air cut-off valve hose Disconnect automatic by-starter connectors. Release the clamp strip of air cleaner. Release the clamp strip of carburetor isolator. Take the carburetor out.
To this chapter contents 4. Fuel System Air Cut-off Valve 2 screws Removal Removal the throttle cable seat (screws x 2) Remove the screws (screw x 2) of the air cut-off valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack. Installation Install the valve as reverse order of removal. Caution z Do not damage the vacuum diaphragm or in opposite installation direction.
To this chapter contents 4. Fuel System AUTOMATIC BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the automatic by-starter. Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the automatic by-starter with a new one if resistance value exceeds standard. Remove the carburetor, allow it to cool off for 30 minutes. Connect a pressure tester form air pump. Connect fuel rich circuit.
To this chapter contents 4. Fuel System FLOAT CHAMBER Disassembly Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. Checking Drain screw Check float needle valve and valve seat for drop difference damage, wear out, dirty or clogged. Caution z In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one.
To this chapter contents 4. Fuel System Air-fuel mixture Assembly Install main jet, fuel needle jet holder, nozzle, idle jet and air-fuel mixture adjustment screw. Caution z Set the adjustment screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking Fuel Level Caution z z Check again to ensure float valve, float for proper installation.
To this chapter contents 4. Fuel System Fuel Tank Fuel unit coupler Fuel meter gauge removal Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove fuel unit coupler. Remove the rear bracket (4 bolts & 3 screws) Each side 2 bolts 3 screws Turn fuel unit setting plate to the left, and then remove fuel unit.
To this chapter contents 4. Fuel System Fuel tank removal Each side 2 bolts Remove the left and right side covers. Open seat. Remove the luggage box. Remove rear carrier. Remove the left and right body covers. Remove the pedal (please refer to chapter 12 for these components above.) Remove fuel unit coupler. Remove the rear bracket (4 bolts & 3 screws) 3 screws Remove the fuel tank mounting bolts (4 bolts). Remove the all lines from the fuel tank.
To this chapter contents 4. Fuel System Air Cleaner Removal the element of the air cleaner Remove the air cleaner cover (7 screws). 7 screws Remove air cleaner element. Installation Install the air cleaner in the reverse order of removal.
To this chapter contents 4. Fuel System Removal of Air Cleaner Open the seat. Remove the luggage box (chapter 12). Remove the left side cover (chapter 12). Loose the air cleaner adapting-pipe clamp. Remove the EEC, PCV, AI system hoses. Remove the mounting bolts of the air cleaner body. (2 bolts) 2 bolts Remove the air cleaner assembly. Installation Install the air cleaner in the reverse order of removal.
Home page Contents 5. Removal & Installation of Engine Mechanism Illustrations ····················· 5-1 Removal of Engine Bush····················· 5-6 Operational Precautions····················· 5-2 Engine Hanger······································ 5-7 Engine Removal ·································· 5-3 Installation of Engine··························· 5-8 Mechanism Illustrations 3.5~4.5kgf-m 5 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.
To this chapter contents 5. Removal & Installation of Engine Operational Precautions General Information y Engine must be supported by a bracket or adjustable tool in height. y The following parts can be serviced with the engine installed on the frame. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3. Final reduction gear mechanism Specification Specification Item MIO 50 MIO 100 Replacement 700 c.c. 650 c.c. Disassemble 800 c.c. 750 c.c. Replacement 90 c.c. 100 c.c.
To this chapter contents 5. Removal & Installation of Engine Engine Removal Open the seat. Remove the luggage box (Bolt× 4, Nut×1). Remove battery cover. Remove the battery negative (-) cable. Remove the battery positive (+) cable. Remove right and left side covers (1 screw on each side.). Each side 1 screw Remove the power connector of auto by-starter. Remove the generator power wire and pulse generator connector. Remove the starter motor wire.
To this chapter contents 5. Removal & Installation of Engine Remove the fuel line, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and then the air cleaner guide. Remove the exhaust muffler (2 Bolts, 2 Nuts). 2 Nuts 2 Bolts Remove the air cleaner connection bolts (2 bolts). 2 Bolts Remove the rear brake cable nut and cable.
To this chapter contents 5. Removal & Installation of Engine Remove the rear cushion lower bolt (1 bolt). Remove the engine hanger nuts and bolts (engine side), and then remove the engine. 1 bolt 螺栓×1 With a bracket to support the engine to prevent from it damage by falling down as removing the engine. Remove the rear wheel with air tools after the engine removed.
To this chapter contents 5. Removal & Installation of Engine Removal of Engine Bush If engine hanger frame and the cushion rubber of rear cushion bush damaged. Then, with the bush remover / presser, ø28mm & ø20mm, to press the bush out, and replace it with new one. Engine hanger bush: ø 28mm Rear cushion bush: ø 20mm Pressing out Place the detent section of the bush remover toward the bush, and drive both the pressing ring and bolt in to press the bush out.
To this chapter contents 5. Removal & Installation of Engine Engine Hanger Removal Remove the right side bolt of engine hanger. (1 bolt on each side) 1 bolt on each side Remove the engine hanger. Check if the engine hanger bush and cushion rubber for damage. If so, replace with new ones. Installation Tighten the bolts and nuts of engine hanger. Engine hanger nut: Torque Value: 4.5~5.
To this chapter contents 5. Removal & Installation of Engine Installation of Engine Install the engine according to the reversing order of removal. Caution z z z Note both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose. Route all cables and wires in accordance with the routine layout. Engine hanger nut: Torque Value: 4.5~5.5kgf-m Rear cushion bolt: Torque Value: upper：3.5~4.5kgf-m under：2.4~3.0kgf-m Rear wheel axle nut: Torque Value: 11.0~13.
Home page Contents 6.
To this chapter contents 6. Cylinder Head / Valve Operational Precautions General Information y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. y Cylinder head service cannot be carried out when engine is in frame. Specification Unit: mm Model HU10U/W Item Valve clearance (intake/exhaust valve as cold engine) Compression pressure HU05U Standard Limit Standard Limit 0.12 ± 0.02 ─ 0.05/ 0.10 ± 0.
To this chapter contents 6. Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure Low compression pressure 1. Valve y Improper valve adjustment y Burnt or bended valve y Improper valve timing y Valve spring damaged y Valve carbon y Poor sealing on valve seat y Improper spark plug installation 2.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Removal 5 Screws Remove the right cooling shroud from the engine outer cover. (5 screws) Remove the left cooling shroud (1 bolt). Remove the crankcase blow-by system hose from the cylinder head. 1 bolt Blow-by system hose Remove the cam chain tensioner (2 bolts). Tensioner Remove the cylinder head side cover.
To this chapter contents 6. Cylinder Head / Valve Turn the flywheel in counter clockwise motion with T type wrench until the “Timing” mark on camshaft aligned with the mark on the cylinder head. Remove camshaft sprocket mounting bolt and remove the sprocket. Remove the left side cylinder head and cylinder connection bolts (2 bolts) 1 bolt 2 bolts Timing mark Remove the cylinder head mounting nuts (4 nuts). 4 nuts Remove the cylinder head.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Disassembly (HU05U) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wrench: SYM-ALL12361 Remove the camshaft stopper of the rocker arm shaft (1 bolt). With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker arm. Special Service Tool: Valve rocker arm shaft puller: SYM-1445100-A1A Take out the rocker arm and shaft.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Disassembly (HU10U/W) Remove the valve cover from the cylinder head. Special Service Tool: Cylinder head wrench: SYM-ALL12361 Remove the camshaft stopper of the rocker arm shaft (1 bolt). 固定擋板 With valve rocker arm puller to drive into the rocker arm shaft, and then remove the rocker arm shaft and the rocker arm. Special Service Tool: Valve rocker arm shaft puller: SYM-1445100-A1A Take out the rocker arm and shaft.
To this chapter contents 6. Cylinder Head / Valve Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit: (Refer to page 2) Inspect the camshaft bearing for looseness or wear out. If any damaged, replace whole set of camshaft and bearing. Measure the cam rocker arm I.D. Service Limit: (Refer to page 2) Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
To this chapter contents 6. Cylinder Head / Valve Valve Disassembly Remove the valves Special Service Tool: Valve remover/installer SYM-1471110/20 Caution z Place a rag under the bottom of the combustion chamber as disassembling to prevent from valve stem deformation. Remove the valve spring retainer, valve springs and valves. Valve stem Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Inspection Cylinder Head Check if spark plug and valve holes are crack. Measure cylinder head wrap age with a straightedge and flat feeler gauge. Service limit: 0.05mm Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: 31.5mm The narrow pitch of the spring shall face to the combustion chamber. Valve stem Check if valve stems are bend, crack or burn.
To this chapter contents 6. Cylinder Head / Valve Caution z If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too. Caution z It has to correct valve seat when replacing valve guide.
To this chapter contents 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 z z Do not let emery enter into between valve stem and valve guide. Clean up the emery after corrected, and apply with red paint onto contact faces of valve and valve seat. Remove the valve and check its contact face.
To this chapter contents 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. 1.0mm Caution z Make sure that all roughness and uneven faces had been grinded. Grind valve seat again if necessary. 45° Coat the valve seat surface with red paint.
To this chapter contents 6. Cylinder Head / Valve After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded. Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Install valve springs and retainers.
To this chapter contents 6. Cylinder Head / Valve Assembly the cylinder head. Caution z The tangent of rocker shaft of intake valve should match with the bolt hole of camshaft mounting seat. Lock pins Cylinder Head Installation Install the lock pins and new cylinder head gasket onto the cylinder. Install the camshaft chain plate. Chain plate Gasket Tighten the cylinder head nuts (4 nuts) At first, tighten the 4 nut on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.
To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment Auto-chain tensioner Install the auto-chain tensioner. Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
To this chapter contents 6. Cylinder Head / Valve Install the cooling shroud of the engine body outer cover. (5 bolts) 5 Screws Install the engine onto the frame.
To this chapter contents 6.
Home page Contents 7. Cylinder / Piston Mechanism Illustrations ····················· 7-1 Piston Removal ····································7-5 Operational Precautions····················· 7-2 Piston Ring Installation ·······················7-7 Trouble Diagnosis ······························· 7-2 Piston Installation ································7-8 Cylinder Removal ································ 7-3 Cylinder Installation·····························7-8 Mechanism Illustrations 0.8~1.
To this chapter contents 7. Cylinder / Piston Operational Precautions General Information y Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit: mm Model HU10U/W Item HU05U Standard Limit Standard Limit 49.995~50.015 50.500 37.015~36.995 37.500 Bend / wrap age － 0.050 － 0.050 Cylindrical roundness － 0.050 － 0.050 Cylindrical roundness － 0.050 － 0.050 top ring 0.015~0.050 0.090 0.015~0.050 0.090 2nd ring 0.015~0.050 0.
To this chapter contents 7. Cylinder / Piston Cylinder Removal Remove cylinder head. (Refer to chapter 6) Remove cam chain plate. Cam chain plate Remove cylinder. Remove cylinder gasket and lock pins. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution z To soap the residues into solvent so that the residues can be removed more easily.
To this chapter contents 7. Cylinder / Piston Inspection Check if the inner diameter of cylinder is worn out or damaged. In the 3 positions (top, center and bottom) of cylinder, measure the X and Y direction values respective in the cylinder. Service limit: (Refer to page 2) Calculate both the real roundness (the difference between X and Y motion values) and the cylindrical roundness (the difference in the top, center or bottom positions of X or Y motion values.) Then, determinate by the max.
To this chapter contents 7. Cylinder / Piston Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring. Remove piston rings. Caution z Pay attention to remove piston rings because they are fragile. Disassemble the piston rings. Check if the piston rings are damaged or its grooves are worn.
To this chapter contents 7. Cylinder / Piston Measure the outer diameter of piston pin. Service Limit: (Refer to page 2) Measure the inner diameter of connecting rod small end. Service Limit: (Refer to page 2) Measure the inner diameter of piston pin hole. Service Limit: (Refer to page 2) Calculate clearance between piston pin and its hole. Service Limit: (Refer to page 2) Measure piston outer diameter. Caution z The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin.
To this chapter contents 7. Cylinder / Piston Piston Ring Installation Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown below. Caution z z z Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side. Make sure that all piston rings can be rotated freely after installed.
To this chapter contents 7. Cylinder / Piston Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution z z Do not let the opening of piston pin snap ring align with the opening piston ring. Place a piece of cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation.
Home page Contents 8. V-Belt Drive System / Kick Starter Mechanism Illustrations ····················8-1 Kick Starter········································· 8-3 Operational Precautions····················8-2 Drive Belt ············································ 8-5 Trouble Diagnosis ······························8-2 Movable Drive Face ··························· 8-7 Left Crankcase Cover ························8-3 Clutch / Driven Pulley ························ 8-10 Mechanism Illustrations 5.
To this chapter contents 8. V-Belt Drive System / Kick Starter Operational Precautions General Information y Movable drive face, clutch, and driven pulley can be serviced on the motorcycle. y Drive belt and driven pulley surface must be free of grease. Specification Unit: mm HU10U/W Item HU05U Standard value Limit Standard value Limit Drive belt width 17.800~18.200 17.200 17.800~18.200 17.200 ID of movable drive face 23.989~24.052 24.060 23.964~23.985 24.015 OD of drive face boss 23.
To this chapter contents 8. V-Belt Drive System / Kick Starter Left Crankcase Cover Left crankcase cover removal Remove body cover Remove air cleaner (2 bolts) 2 bolts Remove left crankcase cover (8 bolts). Installation of the left crankcase cover Install the left crankcase cover (8 bolts) Tighten the air cleaner (2 bolts) 8 bolts Kick Starter 1 bolt Disassembly Remove left crankcase cover. Remove kick starter arm (1 bolt). Remove snap ring and thrust washer from left crankcase cover.
To this chapter contents 8. V-Belt Drive System / Kick Starter Remove the inner plate inside of left crankcase cover. (6 screws) 6 screws Install kick starter arm, rotate the lever slightly and then remove driven gear and washer. Remove the kick starter arm, kick starter spindle, spindle bush and return spring as well as socket. Return spring Kick starter spindle Inspection Check if kick starter spindle, kick spindle bush, kick driven gear for wear or damage. Replace it with new one if necessary.
To this chapter contents 8. V-Belt Drive System / Kick Starter Drive Belt Removal Remove left crankcase cover Hold drive face with universal fixture, and remove nut and drive face. Special Service Tool: Universal fixture SYM-2210100 Universal fixture Hold the clutch outer with the universal fixture, and the remove the nut and the clutch outer. Caution z Nut Using special service tools for tightening or loosening the nut. Fixed rear wheel or rear brake only will damage reduction gear system.
To this chapter contents 8. V-Belt Drive System / Kick Starter Installation Pull out the sliding driven face and then insert the drive belt into the driven pulley. Caution z Sliding driven face Pull out sliding driven face and then insert the drive belt into the driven pulley so that the drive belt set can be installed onto pulley more easily. Install the clutch set with drive belt onto the drive shaft. The other end of belt install onto the movable drive face. Install the clutch outer.
To this chapter contents 8. V-Belt Drive System / Kick Starter Movable Drive Face Removal Remove left crankcase cover. Hold drive face with universal fixture, and then remove drive face nut. Remove drive face. Special Service Tool: Universal fixture SYM-2210100 Universal fixture Take out the drive belt from the drive face. Remove movable drive face set and drive face boss from crankshaft. Drive face boss Movable drive face Crankshaft Remove ramp plate.
To this chapter contents 8. V-Belt Drive System / Kick Starter Inspection The operation of movable drive face is means of the weight roller to pressing on it with centrifuge force. And then the speed is changed by the ramp plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected. Check if rollers are wear out or damage. Replace it if necessary. Measure each rollers’ outer diameter. Replace it if exceed the service limit. Service limit: 15.
To this chapter contents 8. V-Belt Drive System / Kick Starter Apply with some grease to inside of drive face boss hole, and install drive face boss. Drive face surface Caution z The drive face surface has to be free of grease. Clean it with cleaning solvent. Install movable drive face assembly onto crankshaft.
To this chapter contents 8. V-Belt Drive System / Kick Starter Clutch / Driven Pulley Special nut wrench Disassembly Remove drive belt and clutch / driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution z Do not press the compressor too much. Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special nut wrench.
To this chapter contents 8. V-Belt Drive System / Kick Starter Clutch lining Measure each clutch lining thickness. if exceeds service limit. Replace it Clutch lining Service limit: 2.0mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit Service limit: HU01U/W 156.0mm HU05U 87.9mm Free length Driven pulley Check following items: y If both surfaces are damage or wear. y If guide pin groove is damage or wear.
To this chapter contents 8. V-Belt Drive System / Kick Starter Clutch Block Replacement Remove snap and washer, and the remove clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Drive plate Spring Snap ring Clutch block Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins. Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.
To this chapter contents 8. V-Belt Drive System / Kick Starter Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Caution z z Oil seal If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly. If the pulley equipped with ball bearing, it has to remove snap ring and then the bearing.
To this chapter contents 8. V-Belt Drive System / Kick Starter Installation of Clutch / Driven Pulley Assembly Oil seal Install new oil seal and O-ring onto sliding driven face. Apply with specified grease to lubricate the inside of sliding driven face. Specified grease O-ring Install sliding driven face onto driven face. Install guide pin and guide pin roller. Sliding driven face Oil seal Guide pin Guide pin roller O-ring Install oil seal collar.
Home page Contents 9.
To this chapter contents 9. Final Drive Mechanism Operational Precautions Specification Application gear oil: GEAR OIL SAE 85W-140 Recommended oil: KING MATE serial gear oils Oil quantity: HU10U/W 110 c.c. (100 c.c. when replacing) HU05U 100 c.c. (90 c.c. when replacing) Torque value Gear box cover Gear oil drain plug Gear oil filling bolt 2.0~2.4kgf-m 1.0~1.4kgf-m 0.8~1.
To this chapter contents 9. Final Drive Mechanism Disassembly of Final Drive Mechanism HU05U HU05U Remove the rear wheel (refer to chapter 15). Remove the clutch. Drain gear oil out from gear box. Remove gear box cover and then remove the cover and the drive shaft. (7 screws) 7 screws Dowel pin Remove counter shaft and gear. Remove final driven gear and shaft. Remove drive shaft. Remove gasket and dowel pins.
To this chapter contents 9. Final Drive Mechanism Inspection of Final Drive Mechanism Check if the countershaft and the gear are worn out or damage. Check if the final driven shaft and gear are wear out or damage. Check bearings on gear box and cover. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box & cover tightly.
To this chapter contents 9. Final Drive Mechanism Bearing Replacement Caution z Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove drive shaft bearing from left crankcase using following tools; Special Service Tool: Inner type bearing puller SYM-6204002 Install new drive shaft bearing into left crankcase.
To this chapter contents 9. Final Drive Mechanism Install a new drive shaft bearing onto gear box cover. Then, install the drive shaft. Special Service Tool: Bearing (6204) installer SYM-9110400 Install the drive shaft. Special Service Tool: Drive shaft puller SYM-1130010 Puller set SYM-1130000-L Install new oil seal with the special service tool.
To this chapter contents 9. Final Drive Mechanism Re-assembly of Final Driven Mechanism Dowel pin HU05U Apply with grease onto the oil seal lip of final driven shaft. Install final driven shaft and final driven gear, countershaft, and countershaft gear. Final driven shaft / Gear Counter shaft / gear Drive shaft Install the dowel pins (2 pins) and new gasket. Install the gear box cover and 7 bolts (tighten the bolts). Torque value: 2.0~2.
To this chapter contents 9. Final Drive Mechanism Install the driven pulley / clutch outer / belt / movable drive face / drive face. Install the left crankshaft cover and kick starter. Install the rear wheel. Add gear oil.
Home page Contents 10. Alternator / Starting Clutch Mechanism Illustrations ····················· 10-1 Starting Clutch ····································· 10-5 Operational Precautions····················· 10-2 Right Crankcase Cover Installation···· 10-7 Alternator Removal ····························· 10-3 Alternator Coil Set Installation············ 10-8 Right Crankcase Cover Removal ······· 10-4 Flywheel Installation···························· 10-8 Mechanism Illustrations 5.0~6.0kgf-m 9.
To this chapter contents 10. Alternator / Starting Clutch Operational Precautions General information y Refer to chapter 5: Engine removal and installation y Refer to chapter 1 : The troubleshooting and inspection of alternator y Refer to chapter 16: The service procedures and precaution items of starter motor Specification Unit: mm Item Service Limit ID of starting driven gear 32.060 OD of clutch cover 27.
To this chapter contents 10. Alternator / Starting Clutch Alternator Removal 2 Nuts Drain out the engine oil. Remove the right side cover. Remove the exhaust pipe (2 bolts, 2 nuts). 2 Bolts Remove the fan shroud (2 screws, 2 bolts). 2 Bolts 2 Bolts Remove the cooling fan (4 bolts). Cooling fan Hold the flywheel with the universal fixture. Remove the 10mm nut on the flywheel.
To this chapter contents 10. Alternator / Starting Clutch Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller SYM-3110000 Caution z Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller. Flywheel puller Remove the connectors of the alternator and pulse generator. Connectors Remove the 6 bolts for the pulse generator, the alternator coil and cable guide. Then, remove the alternator assembly.
To this chapter contents 10. Alternator / Starting Clutch Starting Clutch Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen mounting nut and gasket. Special service tools: Nut puller of starter gear SYM-9020100 Universal fixture SYM-2210100 Mounting nut Caution z The mounting nut is left-turn thread. Mounting nut socket Remove the starting driven gear. Remove starting clutch, starting idle-gear, and shaft.
To this chapter contents 10. Alternator / Starting Clutch Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Check the starting idle gear and shaft for wear or damage. Measure the ID of the starting idle gear. Service Limit: ID: 10.05 mm or less Measure the OD of the starting idle gear. Service Limit: OD: 9.94 mm or less Disassembly Remove the hex blots (3 bolts) inside the starting clutch.
To this chapter contents 10. Alternator / Starting Clutch Installation Install the components in the reverse procedures of removal. Plug Spring Caution z Add adhesive onto the thread of hex socket bolt. Roller Torque value: 1.0~1.4kgf-m Clutch body Clutch cover Starting clutch Installation Install idle gear shaft and idle gear. Install starting clutch and the starting clutch. Hold the starting driven gear with the universal fixture. Tighten the 22mm anti-loosen mounting nut and gasket.
To this chapter contents 10. Alternator / Starting Clutch Alternator Coil Set Installation Install the coil set onto right crankcase cover. (2 bolts) Install pulse generator (2 bolts) Tighten the cable guide (2 bolts) Torque: 1.5~2.0kgf-m Tie the wire harness hose onto the indent of crankcase Caution z Make sure that the wire harness is placed under the pulse generator. Install both the AC generator and the pulse generator connectors. Flywheel Installation Make sure that there is no magnetic powder.
Home page Contents 11. Crankcase / Crankshaft Mechanism Illustrations ····················11-1 Disassembly of Crankcase·················· 11-3 Operational Precautions····················11-2 Crankshaft Inspection ························· 11-5 Trouble Diagnosis ······························11-2 Assembly of Crankcase······················· 11-6 Mechanism Illustrations 1.5~2.0kgf-m 1.0~1.4kgf-m 11 0.7~1.0kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m 3.5~4.
To this chapter contents 11. Crankcase / Crankshaft Operational Precautions General information y This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. y Complete following operations before disassembling crankcase.
To this chapter contents 11. Crankcase / Crankshaft Disassembly of Crankcase 螺栓×2 Remove the cam chain tensioner (hex socket bolt) from the left side of crankcase. Remove the connection bolts (2 bolts) of the right-side crankcase. Remove the right-side crankcase. Slightly shake the crankshaft and then remove it and the chain. Remove the gasket and the 2 dowel pins. Scrape gasket residues off the crankcase contact surface. Caution z z Do not damage contact surface of the crankcase.
To this chapter contents 11. Crankcase / Crankshaft Remove the oil seal of left-side crankcase.
To this chapter contents 11. Crankcase / Crankshaft Crankshaft Inspection Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm. Measure the radical clearance of the big end at the vertical directions. Service limit: Replace when it is more than 0.05 mm. Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge. Service limit: Replace when it is more than 0.10 mm.
To this chapter contents 11. Crankcase / Crankshaft Assembly of Crankcase Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution z Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and then install two and new crankcase gasket. Dowel pins Install the right crankcase and tighten the crankcase bolts (2 bolts). Torque value: 1.5~2.0kgf-m 2 bolts Install the cam chain tensioner.
To this chapter contents 11. Crankcase / Crankshaft Apply with some grease onto the oil seal lip and then install it onto the left crankcase.
To this chapter contents 11.
Home page Contents 12.
To this chapter contents 12. Body Cover Maintenance Information Body covers disassemble sequence: Handle front cover Front cover Handle rear cover Front under spoiler Front fender Front inner cover Luggage box & seat Rear mudguard Right/left side cover Center cover Under cover Battery cover Rear carrier Floor panel Right/left body cover Rear fender z z z z z Be careful not to damage various covers in disassembly or re-assembly operation.
To this chapter contents 12. Body Cover Front Cover Removal Remove the mounting screws (2 screws) of front cover from the front inner cover side. 2 Screws Remove the front mounting screw (1 screw) of the front cover. Push the front cover upward and then pull it forward so that the lower mounting groove of front cover can be separated from the front under spoiler. 1 screw Disconnect the headlight and position light wire coupler. Light coupler Remove the front cover.
To this chapter contents 12. Body Cover Handle Cover Removal Loosen the handle front cover mounting screws (2 screws) of the handle from the handle rear cover. Push the two side screws, then hooks of handle two sides so that the handle covers can be separated. Push 2 Screws Remove two side screws. Remove handle front cover.
To this chapter contents 12. Body Cover Remove the speedometer cable. Disconnect the instrument panel and switch wiring couplers. Couplers Remove the handle rear cover rear side screw (1 screw). 1 screw Remove meter mounting bolts (2 bolts). Remove handle rear cover and meter. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Front Fender Remove speedometer cable (1 screw). Remove front brake cable (drum brake type). Remove front brake caliper (disk brake type). Speedometer cable Front brake cable Remove the front wheel. (1 nut) 1 nut Remove the inner-up bolts (2 bolts) from the front fender. Remove front fender. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Front under Spoiler 10 screws Remove front cover. Remove the 10 screws on left & right both sides of rear-end from the inner cover. Remove the front-upper screws, bolts. (2 screws & 2 bolts) 2 screws 2 bolts Disconnect the winker light couplers. Couplers Remove the front under spoiler. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Front Inner Cover 1 screw Removal Remove the front cover and the front under spoiler. Remove the main switch cap. (1 screw) Remove the rear mounting screw (1 screw) of the inner cover. 1 screw Remove winker relay and meter control unit. Winker relay Meter control unit Pry out all wire clamps and then take out the front inner cover. Installation Install the front inner cover according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Luggage Box 4 Bolts Remove the mounting bolts (4 bolts) from the luggage box. Disconnect the engine start control switch coupler. Start control switch coupler Remove luggage box. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Rear Carrier Remove the rear carrier mounting bolts and nuts (2 bolts & 2 nuts) 2 nuts 2 bolts Remove rear carrier. Installation Install according to the reverse procedure of removal. Battery Cover Remove batter cover screws (2 screws). 2 screws Remove batter cover. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Side Cover Removal Remove the 2 screws on both left & right sides covers. 1 screw on each side Remove right and left side covers. Installation Install according to the reverse procedure of removal. Rear Center Cover 2 nuts Remove the rear carrier mounting bolts and nuts (2 bolts & 2 nuts) Remove rear center cover mounting screw (1 screw). 2 bolts 1 screw Remove rear center cover. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Center Cover Removal Remove center cover upper screw. (1 screw) 1 screw Remove center cover right and left screws. (2 screws) 1 screw on each side Remove center cover. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Body Cover Removal Remove the right and left side covers (2 screws). Remove the luggage box (4 bolts). Remove the rear carrier (2 bolts & 2 nuts). Remove the body cover two side screws. (1 screw on each side) 1 screw on each side Remove the body cover rear side screws. (1 screw on each side) 1 screw on each side Remove seat lock cable. Seat lock cable Remove body cover. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Floor Panel 4 plugs Removal Remove the center cover, side covers, luggage box and body cover as well as body cover. Remove the 4 floor panel plugs. There are 4 floor panel mounting bolts. Remove battery cover, and then remove battery. Caution z z z At first, remove the negative “-“ cable Then, remove the positive “+” cable Remove the battery Remove the floor panel mounting bolts (4 bolts). 4 bolts Remove floor panel.
To this chapter contents 12. Body Cover Rear Fender 2 bolts Remove the rear fender rear bolts (2 bolts). Remove the 2 bolts on the two sides. (1 bolts on each side). 1 bolt on each side Remove rear fender. Installation Install according to the reverse procedure of removal.
To this chapter contents 12. Body Cover Rear Mudguard Remove the rear mudguard right side bolt (1 bolt). Loosen air cleaner mounting bolts, and then remove the rear mudguard left side bolts (2 bolts). 3 bolts Remove the rear mudguard. Installation Install according to the reverse procedure of removal.
Home page Contents 13.
To this chapter contents 13. Brake Mechanism Diagram-Front Drum Brake System 0.8~1.2kgf-m 2.8~3.2kgf-m 5.0~7.
To this chapter contents 13. Brake Mechanism Diagram-Rear Drum Brake System 0.8~1.2kgf-m 2.8~3.2kgf-m 0.8~1.2kgf-m 11.0~13.
To this chapter contents 13. Brake Operational Precautions General information Caution ● Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. y The brake caliper can be removed without removing the hydraulic system. y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic system.
To this chapter contents 13. Brake Trouble Diagnosis Disc Brake Soft brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disc 7. Low brake fluid 8. Blocked brake pipe 9. Warp/bent brake disc 10. Bent brake lever Hard operation of brake lever 1. Blocked brake system 2. Poor brake caliper 3. Blocked brake pipe 4. Seized/worn master cylinder piston 5. Bent brake lever Uneven brake 1.
To this chapter contents 13. Brake Hydraulic Brake System Inspection Inspection of Hydraulic Brake System Inspection Hose connection Visual inspect for brake fluid leaking or damage. Check if brake hose connections loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components. Operate the brake system and check the brake lining.
To this chapter contents 13. Brake Remove the master cylinder cap and diaphragm. Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. Clean dirty brake disc. Caution ● ● ● Master cylinder cap Diaphragm The dirty brake lining or disc will reduce the brake performance. The mixed non-compatible brake fluid will reduce brake performance. Foreign materials will block the system causing brake performance to be reduced or totally lost.
To this chapter contents 13. Brake Brake Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses. Hose bolt 2 Bolts Caution ● Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper. Make sure the brake lining condition. Replace the lining if the brake lining wear limitation groove close to the brake disc.
To this chapter contents 13. Brake Brake Disc Brake disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel. Check the disc for deformation and bend. Allowable limit: 0.30 mm Caution ● ● Do not let grease touch to the brake disc that will cause brake performance.
To this chapter contents 13. Brake Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit. Service limit: 11.055 mm Master cylinder Dial Measure the outer diameter of the piston. Replace the piston if its measured value exceeds allowable limit. Service limit: 10.
To this chapter contents 13. Brake Installation Mounting seat Place the master cylinder onto handlebar, and install the split ring and bolts. The “UP” mark on the split ring should face upward. Align the split ring on the master cylinder seat with the alignment point on the handlebar. Tighten the upper bolt of the seat to specified torque value, and then tighten lower bolt to the same specified torque value. Split ring “UP” mark Install the brake lever, and connect leads to brake light switch.
To this chapter contents 13. Brake Drum Brake System Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust. Caution ● Inhaling asbestos dust may cause respiration system disorder even cancer. Never use an air hose or a dry brush as to clean the brake parts. ● Grease on brake lining will reduce braking efficiency. Front brake drum Inspection Remove the brake drum from wheel rim.
To this chapter contents 13. Brake Removal Front Brake cam Caution ● Brake linings must be replaced as a set. Remove brake shoes from the brake panel by pulling out the brake linings. Installation Apply a thin coat of grease to the brake cam and the anchor pin. Hook the brake spring onto the brake cam. Pull out the brake linings and install them onto the brake panel. Wipe off the excessive grease from the brake cam and the anchor pin after installation.
To this chapter contents 13. Brake Installation Front brake panel Apply a thin cost of grease onto the brake cam shaft. Install the brake cam. Apply a thin cost of grease onto the oil seal lip and then install the oil seal onto the brake cam shaft. Finally, install it on the brake panel. Align the end-part of the brake return spring with the hole of brake panel. Align both the inner gear of wear indicator and the mark on the brake arm with the indent gear of brake cam, and then install it.
Home page Contents 14. Steering / Front Wheel / Front Cushion Mechanism Diagram ··························14-1 Front Wheel ········································ 14-5 Operational Precautions····················14-2 Front Cushion ···································· 14-10 Trouble diagnosis ······························14-2 Front Fork / Steering Column ··········· 14-10 Steering Handle ··································14-3 Mechanism Diagram 1.0~2.0kgf-m 4.0~5.0kgf-m 0.2~0.3kgf-m 14 2.4~3.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Operational Precautions General information y Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. y Be careful not to allow oil or grease get on brake drum, disk or linings.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Steering Handle Handle switch screw Brake lever screw Removal Remove handle front & rear covers, meter and the front cover (refer to chapter 12). Drum Brake Type Remove the rear brake lever bolt & nut, and then remove the front brake cable. Brake lever nut Remove left handle screw and cable clamp. Remove the left handle switch.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Disc Brake Type Split ring Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring. 2 bolts Caution z Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder. Handle switch screw Remove handle switch screw and then remove the throttle grip, throttle cable, and handle switch cover & seat.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Front Wheel Removal Disc Brake Support body bottom and lift front wheel free of ground with a stand. Remove the screw, and disconnect speedometer cable from the gear box. Screw Remove the wheel axle nut and pull out the axle. Then, remove the front wheel. Wheel axle nut Caution z Do not operate the front brake lever to avoid to pressing out the brake lining when removing the master cylinder.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: above 0.2 mm. Wheel axle Wheel Rim Place the wheel onto a rotated bracket. Turn the wheel with hand and measure its wobble value with a dial gauge. Service limit: Radial : above 0.2 mm Axial : above 0.2 mm Disassembly (Disc brake type) Remove 3 socket-hex head bolts and the brake disc. Remove the left axle ring and dust seal.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Disassembly (Drum Brake Type) Remove the right dust seal. Dust seal DRUM BRAKE Bearing Bearing Bearing spacer Remove the bearing with the inner type bearing remover. Take out the bearing spacer and then remove the other bearing. Tool: Inner type bearing remover SYM-6204002 Bearing Inspection Turn the inner race of bearing with fingers. The bearing should be turn smoothly.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Installation Disc Brake Apply with some grease inside of the dust seal. Install the dust seal and the front wheel side collar. Apply with some grease on both sides of the speedometer gear oil seal, and then install the seal.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Place the front wheel between the front cushions. Stopper Drum Brake Align the brake panel slot with the stopper of the cushion. Disc Brake Align the flange part on the speedometer gear with the slot of cushion stopper. Disc brake Drum brake Disc Brake Install the front wheel axle from right cushion side. Install the wheel axle nut, and tighten it to specified torque value. Torque value: 5.0~7.
To this chapter contents 14. Steering / Front Wheel / Front Cushion Front Cushion Removal Remove the front fender, front lower spoiler, front cover, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left cushion. (1 bolt) As for disc brake, remove the cable guide on the right cushion. (1 bolt) Cable guide Brake fluid hose clipper Drum brake Disc brake Remove the top connection bolt of the right cushion.
To this chapter contents 14. Steering / Front Wheel / Front Cushion With a plastic hammer tap the steering column slightly, and then remove the top ball bearing seat. Remove the lower-end cone bearing seat on the frame with a punch. Caution z Do not damage the frame and the steering column. Installation Install a new top-cone bearing seat onto the top of steering column. And then, push the lower-cone bearing seat from bottom until to locking position.
To this chapter contents 14.
Home page Contents 15. Rear Wheel / Rear Cushion Mechanism Diagram ··························· 15-1 Exhaust Muffler ···································· 15-3 Operational Precautions····················· 15-2 Rear Wheel ··········································· 15-3 Trouble Diagnosis ······························· 15-2 Rear Cushion········································ 15-4 Mechanism Diagram 2.4~3.0kgf-m 0.8~1.2kgf-m 3.5~4.5kgf-m 15 11.0~13.0kgf-m 1.0~1.4kgf-m 3.0~3.
To this chapter contents 15. Rear Wheel / Rear Cushion Operational Precautions General information As for the wheel removal, service, and installation procedures, please refers to the service manual of high speed tire. Specification Unit: mm Items Wheel wobbling Standard (mm) Limit (mm) Radial - 2.0 Axial - 2.0 4.0 2.
To this chapter contents 15. Rear Wheel / Rear Cushion Exhaust Muffler 2 Nuts Removal Remove the front-end nut of the exhaust muffler. (2 nuts) Remove the bolts. (2 bolts) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal. Caution ● Replace the exhaust muffler gasket if it is broken or deformed. Before tightening the exhaust bolts, it has to tighten the exhaust nuts firstly. Torque value: Exhaust muffler connection bolt 3.0~3.
To this chapter contents 15. Rear Wheel / Rear Cushion Rear Cushion 2 Bolts Removal Remove the left & right side covers. (2 screws) Remove the luggage box. (4 bolts) Remove the rear carrier. (2 bolts, 2 nuts) Remove the body cover (4 screws) Remove the air cleaner bolts (2 bolts) Remove the lower nut of the rear cushion (1 bolt) Remove the upper nut of the rear cushion (1 bolt) Remove the rear cushion. Installation Install the rear cushion according to the reverse procedure of removal.
Home page Contents 16.
To this chapter contents 16. Electrical Equipment Operational Precautions Charging System y y y y y y y y y y y y y 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.) MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water. Battery must be taken out from scooter when charging the battery. But do not open the battery caps.
To this chapter contents 16. Electrical Equipment Specification Charging System Specification Items Battery HU10U/W HU05U Capacity/type 12V4Ah / YTX5L-BS or GTX5L-BS Charging rate STD: 0.4A/5~10hrs, emergency charging: 4A/0.5hrs Voltage (20℃) Full charged 13.0~13.2V Under charged 12.3V Capacity Alternator 14V / 3A Lighting coil resistance (20℃) Between yellow-white: 0.1~0.8Ω 0.531Ω±20% Charging coil resistance (20℃) Between white-green: 0.2~1.0Ω 0.
To this chapter contents 16. Electrical Equipment Trouble Diagnosis Charging System Ignition System No power supply y Dead battery y Disconnect battery cable y Fuse burned out y Faulty main switch No spark produced by spark plug y The spark plug is out of work y The cable is poorly connected, open or short-circuited - Between alternator and C.D.I. - Between CDI and ignition coil. - Between CDI and main switch y Poor main switch y Poor C.D.I.
To this chapter contents 16. Electrical Equipment Charging System Wire Diagram Fuse (7A) G W R Y Voltage regulator / Rectifier Battery Alternator W-White Y-Yellow G-Green R-Red B-Black P-Pink P 30W 5.9Ω Automatic by-starter 5W 12Ω (HU05U) 5W 10.2Ω (HU10U/W) G/B Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
To this chapter contents 16. Electrical Equipment BATTERY Removal Remove the battery cover (2 screws) Caution z z Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, and then send to hospital. When clothes are spread by electrolyte, it will contact with skin. So, it must flush with great quantity water to take off the clothes.
To this chapter contents 16. Electrical Equipment Voltage Check With a digital voltage meter or multi-meter to measure battery voltage. Voltage: Fully charged: 13.0 ~ 13.2V (at 20℃) Undercharged: Below 12.3 V (at 20℃) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal. Connect the Charger negative (-) to the battery negative (-) terminal. Standard Max. Charging current 0.4A 4.0A Charging time 5~10H 1H Caution ● ● ● ● Strictly keep flames away from a charging battery.
To this chapter contents 16. Electrical Equipment Charging Voltage/Current Inspection Digital voltmeter Ammeter Fuse connector Connect a tachometer. Turn on the headlamp to high beam and start the engine. Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage/current. Specified Charging Current: (Headlamp OFF) 0.6A or more / 2500rpm 1.2 A or more / 6000 rpm (Headlamp ON) 0.4A or more/2500rpm 1.0 A or more / 6000 rpm Control Charging Voltage: HU10U/W 13.
To this chapter contents 16. Electrical Equipment Voltage Regulator Inspection Remove the front fender. (4 screws) Disconnect the 4P coupler on the diode, and check the continuity between main wire terminals according to following method. Main wire circuit inspection Item (wire color) Check voltage between battery terminal (red) and ground. Check continuity between ground (green) and frame. Check illumination wire (yellow) to ground.
To this chapter contents 16. Electrical Equipment Alternator charging coil Caution ● The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 4P coupler of the alternator. Measure the resistance between the white wire on the alternator and frame ground with a multi-meter. Standard value: 0.2-1.0Ω Replace the alternator charging coil if the measured value exceeds standard.
To this chapter contents 16. Electrical Equipment Ignition System Ignition System Circuit ENG. Start control switch Main switch B L/Y R G B/R Spark plug C.D.I Unit Alternator Exciter coil IGN.
To this chapter contents 16. Electrical Equipment CDI. Unit CDI. Unit Removal Remove the battery cover. Remove the CDI. Inspection Disconnect the coupler from the CDI unit. Make the following inspection at each terminal of the harness side coupler. CDI.
To this chapter contents 16. Electrical Equipment Ignition coil Removal Remove the luggage box, body cover and floor panel. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix screws for the ignition coil, and remove the coil. Install the coil in reverse order of removal. Caution ● Install primary coil with black/yellow lead connected to black coupler and green lead connected to green coupler.
To this chapter contents 16. Electrical Equipment Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7~12kΩ (20°C) Remove the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: HU10U/W 3~5KΩ±10% (20°C) HU05U 4.0KΩ±15% (20°C) Secondary coil is good if resistance within standard. Secondary coil is broken if resistance is infinite.
To this chapter contents 16. Electrical Equipment Start System Start Circuit R R/W Fuse Main switch Rear brake switch Start motor Start switch B Y/R G/Y B Battery G Starter relay Front brake switch Start relay inspection Turn main switch ON. Operate the brake lever. Press start button. If there a click sound, the start circuit is normal. W-White Y-Yellow G-Green R-Red B-Black Start relay Remove the luggage box assembly. Disconnect the battery negative (-) terminal.
To this chapter contents 16. Electrical Equipment Start Motor Removal Remove the right side cover. (1 screw) Remove the air cleaner mounting bolts. (2 bolts) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the start motor power wire. Remove the start motor mounting bolts and motor. (2 bolts) Starting Motor Installation Install the motor in reverse order of removal. Meter Removal Remove the handle front cover.
To this chapter contents 16. Electrical Equipment Remove handle rear cover and meter set (2 bolts & 1 screw). Remove meter mounting screws (3 screws), and then remove meter. Starting Motor Installation Install the meter in reverse order of removal.
To this chapter contents 16. Electrical Equipment Light / Bulb Headlight Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight wire coupler. Remove the rubber boot. Press down the bulb spring locker and then remove the locker with turning it left motion. Remove the bulb. Replace the bulb with new one if necessary. (12V 30W/30W) Caution z z Do not touch the bulb surface with fingers because the bulb will create hot-spot so that let it be burnt.
To this chapter contents 16. Electrical Equipment Position light Bulb Replacement Remove the front cover (3 screws) Disconnect the headlight and position light wire coupler. Pull out the bulb and replace it with new one. (12V/10W) Front Turn Winker Light Bulb Replacement Remove the front cover. (3 screws) Turn left and pull out the bulb seat. Pull out the bulb and replace it with new one. (12V/10W) Installation Install the bulb in reverse order of removal.
To this chapter contents 16. Electrical Equipment Bulbs Replacement of Tail Light / Brake Light Remove the rear light lens screws. (2 screws) Remove the rear light lens. Push and turn left the bulb, and then remove the bulb. Replace the bulbs of the tail light, brake light (12V 5W/18W). Installation Install the bulb in reverse order of removal.
To this chapter contents 16. Electrical Equipment Bulbs Replacement of Rear Winker Light Remove the rear winker light lens screws. (1 screw) Pull out the bulb and replace it with new one. (12V/10W) Bulbs Replacement of Speedometer Remove the handle front cover. (3 screws) Pull out the bulb and replace it with new one.
To this chapter contents 16. Electrical Equipment Switch / Horn Main Switch Check Remove front cover. (3 screws) Disconnect main switch leads coupler. Check coupler terminals as following pins for continuity. Pin BAT1 BAT2 IG E Location LOCK OFF ON ● ● Wire color Red Black ● ● ● ● Black/ White Green Main switch coupler Replacement Remove main switch cover. (1 screw) Remove the main switch coupler and bolts (2 bolts) Remove the main switch. Install a new main switch and tighten the bolts.
To this chapter contents 16.
To this chapter contents 16. Electrical Equipment Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever. If the switch damaged, replace it with new one. Brake light switch Horn Remove the front fender. Connect the light blue wire on the horn to the battery positive (+) terminal, and the green wire to the battery negative (-) terminal. Then, the horn should sound. Replace it if necessary.
To this chapter contents 16. Electrical Equipment Fuel Unit Fuel Unit Remove Fuel Tank Removal (Please refer to chapter 4 for more detailed.) Disconnect the fuel unit sender coupler. Remove the fuel level sender. Caution ● Do not damage or bend the float arm as removing. The resistance values are listed below when the float arm in F and E positions. Float arm position Resistance value E(empty) 97.5~107.5 Ω F(full) 4~10 Ω Connect the fuel unit sender to the main harness. Turn the main switch ON.
To this chapter contents 16.
Home page Contents 17. Emission Control System Names of Mechanisms in the Emission Control System···································· 17-1 Function of Mechanisms in the Emission Control System···································· 17-1 Catalytic Converting System (CATA) · 17-4 Positive Crankcase Ventilation System (P.C.V.
To this chapter contents 17. Emission Control System Fuel Evaporative Emission Control System (E.E.C.) 1. Construction: y Reduce HC to pollute air. y To absorber fuel vapor and saving fuel consumption Fuel tank cap (closed type) Fuel vapor separator Fuel tank Vacuum hose Fuel hose Automatic control fuel cup Vapor hose Vapor purge control solenoid Blow-by hose Air cleaner Active carbon canister Flesh air inlet Engine Flesh air Fuel Fuel vapor Vacuum 2.
To this chapter contents 17. Emission Control System Evaporative Emission Control System (EEC) 1. Visual check: 1) Check the outside of canister for damage. 2) Check all hoses for breakage. 2. Leak test: 1) Disconnect the Vapor purge control solenoid hose, and connect a T-type hose connector to a pressure gauge and a pressure source as shown below: Fuel tank Pressure gauge Pressure source Active carbon canister Plugged 2) Plug canister vent. 3) Apply 100mmAq into pressure source inlet then plug it.
To this chapter contents 17. Emission Control System Catalytic Converting System (CATA) 1. Construction: Catalytic converter Engine Exhaust muffler 2. Description: 1) The function of the catalytic converter is to transfer unburned CO, HC, and NOx harmless CO2, H2O, N2 gases. 2) Pt, Pd, Rh…etc. precious metals are used into the catalytic converter so use only unleaded gasoline to prevent from cause the catalytic converter to fail.
To this chapter contents 17. Emission Control System Positive Crankcase Ventilation System (P.C.V.) 1. Construction Flesh air Fuel vapor separator Blow-by pipe Exhaust pipe Carburetor Air filter Crankcase Cylinder head Flesh air Mixture gas Blow-by Engine oil Piston 2. Principle of operation: y Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor separator by engine vacuum.
To this chapter contents 17. Emission Control System Inspection Items Secondary air injection system 1. Visual inspect the reed valve, air injection cut valve, and secondary air filter as well as hoses for damage. 2. Leaking check. 3. Warm-up running check. Fuel Evaporation Control System 1. Visual inspect the carbon canister and hoses for damage. 2. Leaking check. 3. Function test of the purge control solenoid. Catalytic converter 1. Check if exhaust gas content is within standard. 2.
To this chapter contents 17. Emission Control System Countermeasure for Emission Pollutants Not Within Standard as In Idle Speed (4-Stroke Engine) Conduct periodical inspection (check one time for 1500 km/6 months) Test exhaust contents at idling (note 1) Adjustment carburetor (note 2) Clean the carburetor (SJ, MJ, SAJ, MAJ) Replace the carburetor Keep the CO value in 1.5~4.5% (note 3) by adjusting the carburetor. Clean the carbon deposit in cylinder and combustion chamber.
To this chapter contents 17.
Home page Contents 18.
Home page Contents 18.
