Service Manual SANYANG ATTILA RS-21 EFi 150
Service Manual SANYANG ATTILA RS-21 EFi 150
Service Manual SANYANG ATTILA RS-21 EFi 150
SERVICE MANUAL
Home page Contents
Forward
If the style and construction of the motorcycle are different from that of the
photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
This manual that contains all data, illustration, indication and specifications
is based on current production information. SANYANG reserves the right to
make changes at any time without notice and without incurring any obligation
whatever. No part of this manual can be duplicated by any means without
written permission of SANYANG.
Service Department
SANYANG Industry Co., LTD.
Home page Contents
How to Use This Manual
Please see index of content for quick having the special parts and system
information.
Home page
Contents
Intake temperature
& MAP sensor
(T-MAP)
Engine control unit Throttle position sensor (TPS) /
(ECU) Air by-pass valve /
Fuel injector /
Seat lock
Front winker light
Tail light /
Rear winker light
Headlight
Air cleaner
Gear oil
Inspection plug
Oil level
Oil strainer
Exhaust
muffler
Home page Contents
1. General Information/Trouble Diagnosis
Brake fluid Use recommended brake fluid “DOT3” or “WELLRUN” brake fluid.
Indicates where the bolt installation direction, --- means that bolt
cross through the component (invisibility).
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1. General Information/Trouble Diagnosis
General safety
Carbon monoxide Battery
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, if • Battery emits explosive gases; flame is
you have to run your engine in a closed area, be strictly prohibited. Keep the place well
sure to use an extractor. ventilated when charging the battery.
Caution • Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be
Exhaust contains toxic gas which may cause careful do not be spray on your eyes or
one to lose consciousness and even result in skin. If you get battery acid on your skin,
death. flush it off immediately with water. If you
get battery acid in your eyes, flush it off
Gasoline immediately with water, then go to hospital
to see an ophthalmologist.
Gasoline is a low ignition point and explosive
• If you swallow it by mistake, drink a lot of
material. Work in a well-ventilated place, no
water or milk, and take some laxative such
flame or spark should be allowed in the work
as castor oil or vegetable oil, and then go
place or where gasoline is being stored.
to see a doctor.
Caution • Keep electrolyte beyond reach of children.
Gasoline is highly flammable, and may
explode under some conditions, keep it away Brake shoe
from children. Do not use an compressed air or a dry brush to
clean components of the brake system, use a
Used engine oil
vacuum cleaner or the equivalent to avoid
asbestos dust flying.
Caution
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer Inhaling asbestos dust may cause disorders
although it might not be verdict. and cancer of the breathing system.
We recommend that you wash your hands
with soap and water right after contacting.
Brake fluid
Keep the used oil beyond reach of children.
Caution
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1. General Information/Trouble Diagnosis
Service Precautions
• Always use with SANYANG genuine parts and • Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts stiff control and premature worn out.
for SANYANG motorcycle may damage the
motorcycle.
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1. General Information/Trouble Diagnosis
• The length of bolts and screws for assemblies, • Remove residues of the old gasket or sealant
cover plates or boxes is different from one before reinstallation, grind with a grindstone if
another, be sure they are correctly installed. In the contact surface has any damage.
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.
Groove
Boots
• The tool should be pressed against two (inner
• When oil seal is installed, fill the groove with and outer) bearing races when removing a ball
grease, install the oil seal with the name of the bearing. Damage may result if the tool is
manufacturer facing outside, check the shaft pressed against only one race (either inner
on which the oil seal is to be installed for race or outer race). In this case, the bearing
smoothness and for burrs that may damage should be replaced. To avoid damaging the
the oil seal. bearing, use equal force on both races.
Manufacturer's name
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1. General Information/Trouble Diagnosis
• Lubricate the rotation face with specified • Before battery removal operation, it has to
lubricant on the lubrication points before remove the battery negative (-) cable firstly.
assembling. Notre tools like open-end wrench do not
contact with body to prevent from circuit short
and create spark.
capacity
verification
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1. General Information/Trouble Diagnosis
• Before terminal connection, check if the boot is
• When separating a connector, it locker has to crack or the terminal is loose.
be unlocked firstly. Then, conduct the service
operation.
• Insert the connector completely. • Wire band and wire harness have to be
If there are two lockers on two connector sides, clamped secured properly.
make sure the lockers are locked in properly.
Check if any wire loose.
• Check if the connector is covered by the twin • Do not squeeze wires against the weld or its
connector boot completely and secured clamp.
properly.
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1. General Information/Trouble Diagnosis
• 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.
NEVER TOUCH
NEVER TOO
TIGHT
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1. General Information/Trouble Diagnosis
• 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
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1. General Information/Trouble Diagnosis
Specifications
Maker SANYANG MODEL HE15W
Overall Length 1933 mm Front TELESCOPE
DIMENSION
Suspension
Overall Width 700 mm System Rear UNlT SWING
Overall Height 1160 mm Tire Front 100 / 90-12 (T/L)
Wheel Base 1335 mm Specifications Rear 130 / 70 –12 (T/L)
Front 48 kg
Curb Front DISK (ø 273 mm)
Rear 75 kg Brake System
Weight
Total 123 kg Rear DISK (ø 200 mm)
Passengers/
WEIGHT
Number/Arran
Single Cylinder Lubrication System Separated-lubrication
gement
Solid
Concentration
Displacement 149.5 cc -
Particulate
Exhaust
Compression
9.6 : 1 CO Below 4 %
Ratio
Max. HP 12.4 ps / 8500 rpm HC Below 2000 ppm
Max. Torque 1.15 kg-m / 6500 rpm E.E.C. YES
Ignition C.D.I. P.C.V. YES
Catalytic reaction
Starting System Power & Foot NO
control system
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1. General Information/Trouble Diagnosis
Torque Values (Engine)
Thread Dia. Torque
Item Q’ty Remarks
(mm) Value(Kg-m)
Cylinder head bolts 4 6 1.0~1.4
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1. General Information/Trouble Diagnosis
Torque Values (Frame)
Thread Dia. Torque
Item Q’ty Remarks
(mm) Value(Kg-m)
Mounting bolt for steering
1 10 4.0~5.0
handlebar
Mounting nut for steering rod 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 1 5 0.15~0.3
Speedometer cable locking
4 8 2.4~3.0
screw
Front shock absorber mounting
1 10 3.5~4.5
bolts
Rear shock absorber upper
1 8 2.4~3.0
connection bolt
Rear shock absorber upper
4 6 1.0~1.4
connection bolt
Brake lever bolts 2 4 0.1~0.2
Front brake hose bolts 2 6 1.0~1.4
Front brake air-bleeding valve 2 10 3.0~4.0
Front brake disc mounting bolts 1 6 0.7~1.1
Front brake clipper mounting
4 8 4.0~4.5
bolts
Drum brake arm bolts
2 8 2.9~3.5
(front/rear)
Engine suspension bracket
2 10 4.5~5.5 On frame side
bolts
Engine connection bolt 1 12 5.0~7.0 On engine side
Main standard nut 1 10 3.5~4.5
Foot-starting lever bolt 1 6 1.6~1.8
Air cleaner bolts 2 6 1.0~1.4
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
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1. General Information/Trouble Diagnosis
Troubles Diagnosis
A. Engine hard to start or can not be started
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1. General Information/Trouble Diagnosis
B. Engine run sluggish (Speed does not pick up, lack of power)
Check cylinder
compression pressure
(using compression
pressure gauge)
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
Compression pressure No compression
correct 3. Sand hole in compression parts
pressure
4. Valve deterioration
Check if fuel injector is 5. Seized piston ring
clogged
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1. General Information/Trouble Diagnosis
C. Engine runs sluggish (especially in low speed and idling)
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1. General Information/Trouble Diagnosis
E. Clutch, driving and driving pulley
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1. General Information/Trouble Diagnosis
Parts To Be Greased
Speedometer gear/ Side stand pivot Main stand pivot Rear wheel bearing
front wheel bearing
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2. Maintenance Information
Precautions In Operation
Specification
Fuel Tank Capacity 6100 c.c.
Capacity
1000 c.c.
Engine Oil
Change800 c.c.
Capacity
110 c.c.
Transmission Gear oil
Change100 c.c.
Clearance of throttle valve 2~6 mm
Spark plug NGK CR8E Gap: 0.8 mm
“F” Mark in idling speed BTDC 13º / 1600 rpm
Full timing advanced BTDC 34º / 8000 rpm
Idling speed 1600±100 rpm
Cylinder compression pressure 12 ± 2 kgf/cm²
Valve clearance: IN/EX 0.12 ± 0.02 mm
Front 100/90-12 59J (T/L)
Tire dimension
Rear 130/70-12 59J (T/L)
Single Front: 1.75 kg/cm² rear : 2.25 kg/cm²
Tire pressure (cold)
Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²
Battery 12V8Ah (MF battery) type: YTX9A-BS (8Hr)
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2. Maintenance Information
Periodical Maintenance Schedule
Maintenance Initial 1 Month 3 month 6 month 1 year
Code item 300KM every1000KM every3000KM every6000KM every12000KM
1 ☆Air cleaner I C C R
2 ☆2nd air jet cleaner I C C R
3 ☆Fuel filter I I R
4 ☆Oil filter C C C
5 ☆Engine oil change R Replacement for every 1000km
6 Tire pressure I I
7 Battery inspection I I
8 Brake & free play check I I
9 Steering handle check I I
10 Cushion operation check I I
11 Every screw tightening check I I
12 Gear oil check for leaking I I
13 ☆Spark plug check or change I I R
14 ☆Gear oil change R Replacement for every 5000km
15 Frame lubrication L
16 Exhaust pipe I I
17 ☆Ignition timing I I
18 ☆Emission check in Idling A I
19 ☆Throttle operation I I
20 ☆Engine bolt tightening I I
21 ☆CVT driving device(belt﹞ I R
22 ☆CVT driving device(roller) C
23 Lights/electrical equipment/mutli-meters I I
24 Main/side stands & springs I I
25 Fuel lines I I
27 Cam chain I I
28 ☆Valve clearance I A
29 ☆Crankcase vapor control System I C
30 ☆Crankcase blow-by over-flow pipe I Replacement for every 2000km
31 ☆2nd air jet system I I C
32 ☆vapor control system I
33 Throttle body A I A C
34 Input signals from EFI ECU I
35 Sensors of EMS fuel injector I I
Note: I - Inspection, A-Adjustment R- Replacement C- Cleaning L- Lubrication (The 33rd, 34th, and 35th items are
for the fuel injection system)
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes
first.
Remarks:
1. These marks ”☆” in the schedule are emission control items. According to EPA regulations, these items must be
perform normally periodical maintenance following the user manual instructions.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after
the motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system - Perform maintenance and check when continuous abnormal ignition, misfire, after-burn,
overheating occur.
b. Carbon deposit removal - Remove carbon deposits in cylinder head, piston heads, exhaust system when
power is obvious lower. Than ever
c. Replace worn out pistons, cylinder head.
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2. Maintenance Information
Lubrication System
Engine Oil Capacity
Caution
• The vehicle must be parked on a level
ground when checking oil capacity.
• Run the engine for 3-5 minutes then stop,
wait about 3-5 more minutes allowing
engine oil to settle before checking the oil
level.
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2. Maintenance Information
Gear Oil
Inspection
Check gear oil if leaking.
Park the motorcycle with main stand on flat level
place.
Turn off engine and remove the gear oil draining
plug.
Place a measurement cup under the draining
hole.
Check gear oil if enough.
Gear oil
Replacement refilling bolt
At first, remove the gear oil refilling bolt, and then
remove the draining plug.
Install the draining plug after drained oil out.
Torque value: 0.8~1.2 kgf-m
Caution
Inspect if washer is in good condition.
Replace it with new one if it was deformed or
damaged.
Fill out specified gear oil from the engine oil filling
opening.
Install the oil filling bolt. Gear oil draining plug
Torque value: 1.0~1.4 kgf-m
Quantity: 100 c.c.
Fuel pipes
Recommended: King-Mate HYPOID GEAR OIL
(#140)
Fuel System
Fuel Lines
Remove luggage box, rear carrier, body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind
of fire is strictly prohibited as dealing it.
Fuel filter
Fuel filter
Remove luggage box, rear carrier, body covers.
Remove fuel pump and fuel unit assembly.
Check if the fuel filter is clogged, broken. If so,
clean or replace the fuel filter with new one.
Caution
The arrow on the fuel pump and fuel sender
mean the assembly direction of fuel tank,
check if it is in corrective installation.
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2. Maintenance Information
Air Cleaner
Air element 6 screws
Remove the air cleaner cover (6 screws).
Remove the lock plate from the element of air
cleaner.
Check the element if dirt or damaged.
If it dirt, clean it with solvent and then soap it into
cleaning engine oil after cleaned. Finally,
squeeze it.
Replace it with new one if dirt or damaged.
Caution
Rubber boot
Fixing nut
Adjustment nut
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2. Maintenance Information
Primary adjustment is conducted from button
side of cable on the throttle body.
Loosen fixing nut, and adjust by turning the
adjustment nut for its free-play.
Tighten the fixing nut, and check acceleration
operation condition after adjusted.
Crankcase Ventilation
Pull out the plug from draining hose to clean
deposits.
Caution
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2. Maintenance Information
Valve Clearance Inspection And
Adjustment
Check & adjust valve clearance with feeler
gauge.
Valve clearance (IN/EX): 0.12 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
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2. Maintenance Information
Ignition System
F mark
Ignition Timing
Caution
C.D.I ignition system is set by manufacturer
so it can not be adjusted.
Ignition timing check procedure is for Ignition
lamp
checking whether CDI function is in normal or
Remove right side cover.
Remove ignition timing hole cap located on the
cooling fan cap.
Connect tachometer and ignition lamp.
Start engine and set engine idle speed in 1600
rpm, and if the mark aligns with the “F”, then it
means that ignition timing is correct.
Increase engine speed to 8000 rpm to check
ignition timing advance. If the detent aligns with
advance mark “”װ, then it means ignition timing
advance is in functional.
If not, check CDI set, pulse flywheel, and pulse
generator. Replace these components if
malfunction of these parts are found.
Spark Plug
Appointed spark plug:CR8E (NGK)
Remove trunk.
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
Spark plug
by screwing it. Tighten the plug by turning 1/2
turn more with plug socket after installed.
Torque value: 1.0~1.2 kgf-m
Connect spark plug cap. Side electrode
Central electrode
0.8mm
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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
Rotate the engine until the reading in the
gauge no more increasing.
Usually, the highest pressure reading will be Spark plug
obtained in 4~7 seconds.
• Valve leaking
• Cylinder head leaking, piston, piston ring and Cylinder
pressure
cylinder worn out
gauge
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
Clutch pad
Clutch Pad
Start the motorcycle and gradually increase
throttle valve openness to check clutch pad
operation.
If the motorcycle moves with shaking, then check Clutch
its clutch pad for wearing. Replace it if
necessary.
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2. Maintenance Information
Steering System
Caution
Check all wires and cables if they are
interfered with the rotation of steering handle
bar.
Suspension System
Warning
• Do not ride the motorcycle with poor shock
absorber.
• Looseness, wear or damage shock
absorber will make poor stability and drive
ability.
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2. Maintenance Information
Disk Brake System (Front/Rear Disk
Brake) Brake metals hose
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 Master
system for leaking if low brake level found. cylinder
cap
Caution
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2. Maintenance Information
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Brake lining
Replace the brake lining if the wear limit mark wear limit
closed to the edge of brake disc.
Caution
Bolt
Brake lamp
switch
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2. Maintenance Information
Wheel / Tire
Check if both front & rear tires’ pressure is in
correct.
Caution
Tire pressure check should be done as cold
tire.
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2. Maintenance Information
Battery
Battery Removal
Remove right cover. (3 screws)
Headlamp Adjustment
Headlamp adjustment
Remove the front fender.
Turn the headlamp adjustment screw to adjust
headlamp beam height. (C.W. is for increasing
beam height, and C.C.W. is for decreasing beam
height)
Reinstall the front fender.
Caution
Headlamp adjustment screw
• To adjust the headlamp beam follows
related regulations. Do not adjust it
arbitrarily if not necessary.
• Improper headlamp beam adjustment will
make in coming driver dazzled or
insufficient lighting.
(ψ30mm) (ψ22mm)
Alternator fly wheel Puller/presser for Puller/presser for
Name Name Name
remover crankcase bushing crankcase bushing
Parts no. SYM-3110A01 Parts no. SYM-1120310 Parts no. SYM-1120320
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2. Maintenance Information
Name Oil seal installer Name Oil seal installer Name Oil seal installer
Parts no. SYM-9125500 Parts no. SYM-9121600 Parts no. SYM-9120200
Clutch mounting bolt Valve cap / Oil filter cap Fuel pressure gauge
Name Name Name
wrench wrench
Parts no. SYM-9020200 Parts no. SYM-1236100 Parts no. SYM-HT07010
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3. Lubrication System
Mechanism Illustration
Rock Arm
Forcedly lubrication
Cam Shaft
Scoop lubrication
Inner passage
Connecting rod
Forcedly lubrication
Crankshaft
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3. Lubrication System
Operational Precautions:
General Information
z This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil.
Specifications
Oil viscosity
Engine oil quantity Disassembly 1000 c.c.
Replacement 800 c.c
Oil viscosity SAE 10W-30 or equivalent
(Recommended King-Mate
serial oils)
Gear Oil Disassembly 110 c.c.
Replacement 100 c.c.
Oil viscosity of gear oil SAE 85W-140
(Recommended King-Mate
gear oil series SYM
HYPOID GEAR OIL)
unit: mm
Items Standard (mm) Limit (mm)
Torque value
Engine oil drain plug 3.5~4.5 kgf-m
Engine oil filter cover 1.3~1.7 kgf-m
Gear oil drain plug 0.8~1.2 kgf-m
Gear oil filling bolt 1.0~1.4 kgf-m
Oil pump connection screw 0.1~0.3 kgf-m
Trouble Diagnosis
Low engine oil level Dirty oil
• Oil leaking • No oil change in periodical
• Valve guide or seat worn out • Cylinder head gasket damage
• Piston ring worn out • Piston ring worn out
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3. Lubrication System
Engine Oil
Turn off engine, and park the motorcycle in flat
surface with main stand. Check oil level with oil
dipstick after 3-5 minutes.
Do not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Replacement
Oil stick
Caution
Drain oil as engine warmed up so that make Drain plug
sure oil can be drained smoothly and
completely.
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3. Lubrication System
Oil Pump Removal
Remove the alternator (refer to chapter 10).
Remove the engine right cover.
Remove the one-way clutch and starting gear
(1 nut).
Make sure that the pump axle can be rotated
freely.
Remove the oil pump cover (2 screws), and then
the oil pump driving gear clamp and the gear.
Remove oil pump body screws (3 screws).
Starting gear
Starting
起動離合器組clutch
Right crankcase
cover
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3. Lubrication System
Oil Pump Inspection
Check the clearance between oil pump body and
outer rotor.
Limit:below 0.12mm
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3. Lubrication System
Install driving gear and clamp.
Caution
Caution
3 screws
2 screws
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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.
Filling bolt
Draining plug
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3. Lubrication System
NOTES:
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4. FUEL INJECTION SYSTEM
Mechanism Illustration
Data Scan
(Diagnosisor)
ECU
Hazardous lamp
Battery
Fuel pump & pressure regulator
Throttle position
Engine temperature sensor sensor (TPS)
Fuel
Ignition coil tank
Fuel
injector
Vacuum hose
Battery voltage
Main switch ON
Throttle position
sensor Fuel pump
ECU
Intake temperature
/MAP sensor Fuel injector
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4. FUEL INJECTION SYSTEM
Introduction Of Fuel Control System
The engine of this model was based on a 150 c.c. four-stroke & 4-valve SOHC electronic controlled
single cylinder, air-cooler, engine. It adopts a charcoal canister to absorb the fuel vapor generated
through evaporation in the fuel system & crankcase. Then, introducing evapor into combustion
chamber.
Fuel delivery way in most of motorcycle’s engines is by carburetor. The absorption capacity of engine
is to create vacuum inside of the carburetor so that fuel is suck into combustion chamber with air.
Therefore, under such operation, air & fuel mixture ratio is decided by flowing air and fuel absorbed
quantity. Thus, the 3 factors, air detective quantity, fuel quantity decision and fuel absorbed quantity,
are conducted inside of the carburetor.
However, as for the fuel injection system, it detects air absorbed quantity and temperature. Thus, the
fuel supply quantity is decided by the default preset in the system computer. Then, fuel is injected out
by the fuel injector. Comparing with carburetor engine, the 3 factors are independent, and can
increase their precision easily so that fuel supply can be much more accurate.
The engine is equipped with a fuel injection of computerized control and its main characters are as
following:
1. The necessary fuel injection quantity is decided by correspondence with engine rotation. And, the
engine also is applied with a good reaction and high accurate throttle valve. (So, fuel injection
quantity and timing are decided by engine RPM and the throttle valve opening.)
2. The decision of fuel injection quantity and injection timing are controlled by a 8-bite highly
accurate micro-computer.
3. The pressure regulator is always to keep the variances of intake manifold and fuel pressures in a
constant value (2.5bar). So, with the change of intake manifold pressure, the fuel injection quantity
can be kept in proper level.
4. The engine can measure the manifold pressure to enrich fuel injection based on high position
level so that enhance driving capacity.
5. The idle speed control system is to provide manifold with the 2nd air to increase idle speed’s
stability and starting capacity.
Fuel is delivered to the fuel injector onto the intake manifold through fuel tank to fuel pump. Fuel
pressure is kept within 2.5bar by means of the fuel regulator. Then, the injection signal from ECU is
to let fuel inject to cylinder in every crankshaft rotation (i.e. the fuel supply system is to inject fuel to
cylinder one time. In addition, the residual fuel is back to fuel tank by the fuel regulator through the
fuel return pipe. In order to reduce noise and simplify the fuel pipe routing the fuel pump usually is
designed to install into the fuel tank.
Generally speaking, the electronic controlled ignition & fuel injection system can control fuel
consumption & emission efficiently so that reaches to the purpose of environmental purification.
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4. FUEL INJECTION SYSTEM
Precautions In Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place
and strictly prohibit flame when working with gasoline.
Cautions
˙ Do not bend or twist throttle valve cable. Damaged cable will make unstable drive ability.
˙ When disassembling fuel system parts, pay attention to O-ring position, replace with new one
as re-assembly.
Specification
Item
Idle speed 1600±100 rpm
Throttle handle free play 2~6 mm
Torque value
Engine temperature sensor: 0.74~0.88 kgf-m
Tool
Special service tools
Vacuum/air pressure pump
Injection system diagnosisor (Data Scan)
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4. FUEL INJECTION SYSTEM
Trouble Diagnosis
Turn on the ignition switch.
EFI Electrical Circuit Inspection
1. Burnt Bulb?
2. Blown fuse?
3. Battery voltage too low?
NG 4. Poor wire contact on ECU
Does the warning lamp goes on for 2 seconds
circuit?
and then off?
5. Poor contact on the master
switch?
OK 6. Malfunction of ECU?
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4. FUEL INJECTION SYSTEM
Cannot be started or
difficult to start
1. No valve clearance?
2. Incorrect ignition timing?
NG 3. Stuck valve?
Is the engine abnormal? 4. worn out cylinder and piston ring?
5. improperly adjustment of the air
OK adjustment screw onto the throttle
valve body?
END
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4. FUEL INJECTION SYSTEM
Replace with
new one for
confirmation
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Components Description Of EFi
ECU (Electronic Control Unit):
• Powered by DC 8~16V, and has 22 terminals connector on the unit.
• The hardware component consists of an 8-bite computer that be its
control center. It contains the functional circuit interface of engine
condition sensing and the driving actuator for the by-pas valve, fuel
injector, and fuel pump, as well as transistor ignition coil.
• Its major software is a monitor strategy operation program that
includes with controlling strategy, MAP and self-diagnosis programs.
Fuel Injector:
• Powered by DC 8~16V, and has 2 terminals connector on the
injector.
• Its major component is the solenoid valve of high resistance driven by
voltage.
• The two terminals are connected to power source and ground
respective. It is controlled by ECU to decide the injection timing, and
the injector pulse width. Working with 4-valve engine, the unique
2-hole designed injector can provide each intake valve with suitable
fuel quantity to reduce HC emission.
Fuel Pump:
• Powered by DC 8~16V, and has 2 terminals connector on the pump.
• The two terminals are connected to power source and ground
respective. The ECU is to control and manage the operation of fuel
pump through electrical power.
• Its major component is a driving fan pump that equipped with a low
electrical consuming DC motor. Powered by 12V voltage and keep
fuel pressure inside the fuel pump in 2.5 bar which can offer 14 liter
fuel per hour.
• The fuel pump is located inside of the fuel tank, and installed a filter in
front of its inlet so that can prevent from foreign materials sucking into
the fuel pump to damage it and the fuel injector.
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Intake temperature and pressure sensor:
• Powered by 5V DC from ECU. It has 4 terminals on the sensor.
One terminal is for power, and 2 terminals are for signal output.
And, the rest one is for ground.
• The major component of the intake pressure sensor is a variable
transistor IC. Its reference voltage is DC 5V, and output voltage
range is DC 0~5V.
• It is a sensor of combination by both sensing pressure and
temperature, and can measure the absolute pressure and
temperature in intake process. It also conduct fuel injection quantity
correction based on environmental temperature and position level.
Throttle Body:
• The throttle body is the air flow adjustment mechanism of the fuel
injection. (Its function is likely the carburetor.)
• The throttle valve shaft is to turn the throttle valve position sensor in
synchronously so the ECU that can detect the throttle valve
openness in time.
• The guide onto the throttle body is connected to the idle speed air
by-pass valve. By means of the ECU to control the idle speed air
by-pass valve, air-flow is adjusted by the valve so that stabilizes idle
speed.
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Fuel Lines
Fuel filter
Fuel tank
Fuel injector
Fuel pump & pressure regulator
Vacuum hose
ECU
Battery
System Description:
1. All sensors’ signals sent to the ECU firstly after the electrical fuel pump inside the fuel tank key-on.
Then, ECU controls the fuel pump relay so let the pump operate. If the engine did not start for
2~3 seconds, then the fuel pump will be turned off to save power. The pressure regulator is to
maintain the fuel pressure in 2.5bar, and the fuel injector inject properly fuel quantity according to
running conditions and environmental corrective coefficient. When key-off or engine stopped, the
fuel pump stops operating.
2. The fuel filter is to filter foreign materials so it has to be replaced regularly.
3. Do not let the starting motor keep running when the engine can not be started in smoothly to
cause battery voltage insufficient (under 8V) and the pump will not be operated. The corrective
method is to start the engine by connecting a new battery or with foot-lever.
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Ignition System
Spark plug
Intake temperature/pressure ECU
Engine temperature
rpm/TDC
Ignition coil
TDC/ crank
position sensor
1. Principle of operation:
The engine is equipped with a computerized ignition control system that collects signals from
TDC/crankshaft position sensor, throttle position sensor, temperature sensor, and intake
temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite
micro-computer in the system is to control ignition timing properly. The secondary coil creates
25000~30000V high voltage to ignite the spark plug by means of the transistor to open/close
operation of the primary current inside of the computerized system. Such operation not only have
max engine performance output but also increases fuel consumption ratio.
2. Specification
1) Ignition timing: BTDC 13°/1600RPM
3) ACG
Pulse generator coil: 120+10% Ω (G/W-Y)
4) Ignition coil:
Primary circuit: 0.63 ± 0.03 Ω (20℃)
5) Battery:
Type: YTX9A-BS.8Ah
Capacity: 12V 8Ah
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Crank Position Sensor
The magnetic field type sensor is to induct a
voltage signal to calculate engine speed with
ACG gear ring (24-1 tooth).
Flywheel
gear ring
ECU signal
Closed
Secondary Ignition
TDC TDC
voltage
Description:
The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that
can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have
a stable and normal running engine.
1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance
engine idle speed to prevent from unstable engine running and misfired within initial starting.
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow
according to engine temperature (engine oil temperature) so that have a fast idle speed.
3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with
acceleration operation to provide intake manifold with proper air-flow quantity. Such operation
will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake
manifold increasing, and then to reduce HC emission.
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Temperature Sensor
Engine temperature sensor
Intake temperature and
pressure sensor
ECU
Engine oil temperature sensor: According to the semiconductor’s variable character, the sensor
detects the change of engine oil and metal wall and then transferred
into a voltage signal sending to the ECU. Then, the ECU corrects fuel
injection and ignition timing.
NTC-Negative Temperature
Coefficient Resistor
Intake temperature and pressure sensor: a sensor that is combined both pressure and NTC can
detect the absolute pressure and temperature in the intake
manifold, and then provides the ECU with signal for
adjustment fuel injection quantity based on environmental
temperature and location level.
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Air By-pass Valve
Fuel injector
TPS
air temperature
engine oil temperature
ECU engine speed
manifold pressure
throttle openness
Description: Air by-pass valve
The ECU that received all sensors’ signals to control the throttle valve openness with PWM so that
can adjust air-flow into the by-pass valve of the intake manifold. And then adjust idle speed and have
a stable and normal running engine.
1. When engine starting---the by-pass valve open for a while to increase air-flow and then enhance
engine idle speed to prevent from unstable engine running and misfired within initial starting.
2. Warm-up---when engine oil is in low temperature condition, the by-pass valve adjusts air-flow
according to engine temperature (engine oil temperature) so that have a fast idle speed.
3. Speed Decreasing---with the ECU controlling, the by-pass valve also corresponds with
acceleration operation to provide intake manifold with proper air-flow quantity. Such operation
will let engine rpm reduce slowly to prevent from engine misfired, negative pressure in intake
manifold increasing, and then to reduce HC emission.
Fuel Injector
The 2-hole fuel injector provides two intake valves with one fuel injection so that can reduce HC
emission. A short mounted nut can lock the fuel injector easily and receive fuel from the fuel pump.
The mounting bracket can limit the fuel injector rotation in left or right motion. The fuel injection
quantity is controlled by the ECU signal. The fuel pressure regulator can keep pressure difference in
between fuel pressure and manifold vacuum around 2.5bar by means of diaphragm and spring.
Therefore, with such operation, the fuel injector can control its fuel injection quantity by injection width
(time) under different engine loads.
Fuel Pump
The electrical fuel pump is powered by battery and controlled by the ECU for on or off. The pump can
output 14 l/h fuel quantity in 2.5 bar.
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Fuel Tank
Removal of fuel pump/pressure control
valve/fuel sender
Open the seat cushion.
Remove the luggage assembly. (bolt x 4, screw x
1)
Remove the rear carrier. ( bolt x 4)
Remove both the left and right body covers.
(screw x 4)
Remove the rear lamp. (screw x 4)
Fuel cut valve
Diode Relay
Caution
The fuel pump mounting plate is easily
deformed as removing the plate. Thus, in
order to prevent from fuel leaking, check it in
detailed and replace it with new one if
necessary.
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Caution
The oil seal of fuel pump can not be omitted, The ▲ mark must be aligned
deformed or damaged.
Caution
Bolt x 2
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4. FUEL INJECTION SYSTEM
Bolt x 4
Installation
Install the fuel tank in reverse procedure of
removal.
Pressure regulator
To fuel injector
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4. FUEL INJECTION SYSTEM
Air Cleaner
Remove the air cleaner cover. (screw x 6)
Screw x 6
Installation:
Install the air cleaner in reverse procedure of
removal.
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Trouble Diagnosis & Solutions Of EFi
Judgment of Flash Code
When the engine might have problem and also no tester to detect, the problem can be detected by
reading the flash times of CHK lamp on the odometer. And then, the motorcycle is warned what kind
of problem had occurred by means of the solution priority lamp of the tester operation message table,
or the FLASH CODE.
There are descriptions for the two ways below:
To show “the solution priority”
Turn the KEY ON directly, and the CHK lamp goes up for 2 seconds. Then, the CHK lamp will lit up by
3 types for showing the priority of problem solution so that reminds the rider to have the motorcycle
conduct troubleshooting.
The 1st Priority: the CHK lamp lit up by every 0.3 second.
The 2nd Priority: the CHK lamp lit up continuously.
The 3rd Priority: the CHK lamp is not lit up.
0.3 sec
ON
1
OFF 0.3 sec
ON
2
OFF
ON
3
OFF
To show “FLASH CODE”:
Before turning the KEY ON, wide open the throttle valve. Then, turn the KEY ON, the CHK lamp lit up
for 2 seconds and off. But, the CHK lamp will lit up again after off 3 seconds. In the means time,
close the throttle valve. Finally, it is to determine what problem occurred based on the flash time of
CHK lamp.
Before show up, CHK lamp will lit up for 4 seconds firstly. Then, according to the lamp flash times
(every 0.5 second), the problem will be determined by comparing with the operation message table.
If there has the 2nd problem in the system, the CHK lamp will have flash operation again after its lit
up for 4 seconds.
st nd
The 1 problem shown up The 2 problem shown up
flash ending
4 seconds for problem
Lamp test
starting
4 seconds for problem flash
Turn on the main switch
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Error Code Message and Solution Operation
DTC Solution Flash
Message Solution Operation
Code Priority code
1. Stopping the motorcycle immediately, and solve it
with priority
2. Check if the lubricant system for abnormal?
Engine
3. Is the ignition or fuel supply system in normal?
P0217 1 1 temperature
4. Has the engine shown burnt?
overheat
5. Make sure if the engine temperature senor is in
normal.
6. Make sure if the connector is in normal.
1. Check if the connection of the crank position sensor
is open-circuit.
2. Check if the air gap between the sensor and gear
Crank position
P0335 2 2 tooth is within specification.
sensor
3. Check if the crank rotation is run-out.
4. Check if the sensor is in normal according to the
new component replacement procedure.
1. Connect the disgnosisor and reset the throttle valve
position. Make sure if the idle speed position is
within specified range.
2. Make sure if the wire circuit of the throttle valve
position sensor is loosen or short.
Poor contact of
3. Check if the openness of idle speed by-pass valve
P1120 2 3 the throttle
is within specification. (40~100%)
valve sensor
4. Adjust the idle speed CO value to specified range.
(0.5%~2.0%)
5. If this problem symptom still existing, check if the
throttle position sensor (TPS) is in normal according
to the new component replacement procedure.
1. Make sure if the wire circuit of the throttle valve
Application
position sensor is loosen or short.
malfunction of
P1121 2 4 2. If this problem symptom still existing, check if the
the throttle
throttle position sensor (TPS) is in normal according
position sensor
to the new component replacement procedure.
1. Make sure if the wire circuit of the throttle valve
Rotation speed
position sensor is loosen or short.
malfunction of
P1122 2 5 2. If this problem symptom still existing, check if the
the throttle
throttle position sensor (TPS) is in normal according
position sensor
to the new component replacement procedure.
1. Make sure if the battery voltage is too low or high
(below 10V or exceed 16V)
2. Make sure if the ACG generator charging system
Abnormal
circuit is short or abnormal.
P0560 1 6 battery voltage
3. Make sure if the 15th terminal on the ECU to battery
warning
positive post is short.
4. Make sure if the battery is in normal. Replace it with
new if the battery is out or order.
1. Make sure if the sensor’s resistor is in normal (20℃
Abnormal 2353~2544Ω).
intake 2. Make sure if the sensor’s wire is in open-circuit (the
P0110 2 7
temperature 22th terminal on ECU).
sensor 3. Make sure if the sensor is normal according to the
new component replacement procedure.
1. Make sure if the sensor’s resistor is open or short
circuit.
Abnormal air 2. Make sure if the sensor’s wire is in open-circuit (the
P0410 2 8
by-pass valve 13th terminal on ECU)
3. Make sure if the by-pass valve is normal according
to the new component replacement procedure.
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EFi Data scan Operation Manual
A. DTC Codes Retrieved by Data Scan
Description:
When a problem comes out, with the Data Scan to diagnosis the problem and solve it.
Method:
1. Stop the engine and do not turn on the ignition switch.
2. Open the front grove cover, and connect the connector on the motorcycle with the Data Scan’s
connector.
3. The menu will show connection and software & hardware versions.
4. Press “Enter” to enter main menu.
5. Move the ▼ ▲ key to “ read DTC” and then press “Enter” key.
6. The menu will show 3 functions, 1) Current problem searching 2) Just occurred problem searching,
and 3) past problem searching, for selection.
7. When selecting the 1) & 2) functions, then it will search the DTC code of current & just occurred
problems.
8. Compare with the DTC code table, and conduct the troubleshooting procedure.
Connector
Main body
LCD monitor
Data transmission
indicator Connection
cable
Spare keys
Next page
and value
adjustment
key
Enter function
Exit function key
key
Software card
slot
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C. Data Scan Function Menu
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D. Operation Steps & Menu Function Description
1. Connect the Data Scan’s connector onto the specified signal connector of the EFI system on the
motorcycle.
2. Turn the ignition switch on and then the LCD monitor goes on and show “SANGYANG Motor Co.”
as fig 1.
3. Press the “ENTER” key to continue, the monitor goes show “CONNECTING” as fig 2.
Fig 1 Fig 2
When press “ENTER” key, it shown 2 pages (1/2~2/2) of motorcycle data. To select function menu
with the ◄ ► cursor.
Fig 3 Fig 4
4. In the (2/2) menu, press “ENTER” and then enter into the main menu. (as fig 5)
Then with the ▲▼ cursor to select main menu, and then press “ENTER” to conduct 1~7 function.
Each functions’ menu is described as below:
Fig 5
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When selecting the “1. retrieving DTC code” (LCD background changed into black), and press
“ENTER”, then there have 3 sub-functions can be selected.
Fig 6
With the ▲▼ cursor to select “1. active DTC codes” (LCD background changed into black), press
“ENTER” , and then enter into problem searching menu & verify if problem occurred right now.
The menu will show problem symptom when problem have been detected. Then, conduct
repairing procedure for the problem. However, if there is no DTC codes been shown on the
menu , it means the EFI system is in normal. Press “EXIT” key to back to the main menu.
Fig 7 Fig 8
With the ▲▼ cursor to select “2. occurred DTC codes” (LCD background changed into black),
press “ENTER” , and then enter into problem record menu. (as fig 9)
Fig 9
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To verify if there has problem occurred in past. When the menu record shows the past problem
record, it will show the problem symptom (as fig 10). Then, suggestion to erase the DTC codes.
(please refer to DTC codes Erase on page 28). However, if there is no problem shown on the
menu, it means that there is no problem record in past. Press “EXIT” key to back to the main
menu.
Fig 10 Fig 11
With the ▲▼ cursor to select “3. history DTC codes” (LCD background changed into black), press
“ENTER” , and then enter into problem record menu. (as fig 12)
Fig 12
When the menu record shows the history problem record, it will show the problem symptom (as fig
13). Then, suggestion to erase the DTC codes. (Please refer to DTC codes Erase on page 37).
However, if there is no history problem record shown on the menu, it means that there is no
problem record in history. Press “EXIT” key to back to the main menu.
Fig 13 Fig 14
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Remarks:
a. Current DTC codes: It means that the problem onto EFI system is occurring. When the
problem is solved, the recorded will disappear.
b. Past DTC codes: It means that the problem onto the EFI system just occurred. The DTC
codes are recorded. Even the Current problem are solved and its DTC codes also have been
erased, the DTC codes still be recorded into the past DTC codes until turning off the ignition
switch so that the past DTC codes can be erased.
c. History DTC codes: It means that the problem onto the EFI system had been occurred. So,
the DTC codes were recorded. Unless with command to erase the problem history record, the
problem record will be kept continuously.
5. With the ▲▼ cursor to select “2. DTC Code Erase” (LCD background changed into black), (as fig
15), press “ENTER” key to erase the DTC codes (as fig 15-1, 16, 17). This function can be
conducted only when the ignition switch is turned on and the engine stopped. Press “EXIT” key to
back to the main menu.
Fig 16 Fig 17
6. With the ▲▼ cursor to select “3. Data analysis” (LCD background changed into black), (as fig
18), press “ENTER” key to enter into EFI data analysis. There are 8 instantly dynamic data
values shown on the menu. (1/7~7/7) (as fig 19, 20, 21, 22, 23, 24, 25, 26) Select desired
menu with ◄ ► cursor.
◎ As the fig 19 (1/8) shown, the menu provides with 3 set dynamic values of engine rpm, intake
temperature & sensor’s voltage, and engine temperature & sensor’s voltage.
Fig 18 Fig 19
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◎ As the fig 20 (2/8) shown, the menu provides with 3-set dynamic values of engine rpm,
atmosphere pressure & sensor’s voltage, and throttle valve opening & sensor’s voltage.
◎ As the fig 21 (3/8) shown, the menu provides with 3-set dynamic values of engine rpm, CO
voltage meter, battery voltage, and sensor’s voltage.
Fig 20 Fig 21
Description:
CO voltage meter: it is designed onto the ECU. This model does not has this function.
Battery voltage: it means that the ECU receives voltages from the terminals of power
supply, fuel injector, transistor ignition coil, and fuel pump.
Sensor voltage supply: it means that DC 5V supplied by the ECU and detected voltage.
(standard voltage value: 5V±0.5%)
◎ As the fig 22 (4/8) shown, the menu provides with 4-set dynamic values of engine rpm,
injection timing, ignition timing, and ignition charging timing.
Description:
Injection timing: It means that the fuel injector opening times controlled by the ECU. i.e. the
fuel injection quantity.
ignition angle: It means that the ignition angle (timing) for the engine controlled by the ECU.
ignition charging timing: It means that the charging timing (ignition energy) set by the
ignition transistor.
Fig 22
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◎ As the fig 23 (5/8) shown, the menu provides with 4-set dynamic values of engine rpm, initial
position voltage of throttle valve idle speed, idle speed target value, and idle speed CO
corrective value.
Description:
initial position voltage of throttle valve idle speed: It means that the ECU memorizes the idle
speed voltage from the first time of throttle position sensor. This value can be a reference
for the throttle position sensor damaged.
idle speed target value: It means that the idle speed target value set by the ECU based on
current engine temperature and intake temperature.
idle speed CO corrective value: Based on CO value of the engine emission, it corrects the
air-flow of idle speed air by-pass valve.
Fig 23
◎ As the fig 24 (6/8) shown, the menu provides with 4-set dynamic values of engine rpm,
accumulated running time, PWM output of temperature gauge, and idle speed valve opening.
Description:
accumulated running time: It means that the ECU’s inner timer starts to count the ECU
operation time at every time to turn on the ignition switch, even the engine does not start,
and until turn off the ignition switch.
PWM output of temperature gauge: this model does not has this function.
idle speed valve opening.: It means that the opening of air by-pass valve at current idle
speed.
Fig 24
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◎ As the fig 25 (7/8) shown, the menu provides with 2-set dynamic values of fuel pump
condition and manual TPI initialization.
Description:
Fuel pump condition: It means the ON & OFF condition of current fuel pump.
manual TPI initialization: It means the action status of the manual TPI initialization.
Fig 25
◎ As the fig 26 (8/8) shown, the menu provides with 2-set dynamic values of CO deposit time
and CO deposit time reset value.
Description:
CO deposit time: It means that the ECU inner timer starts to count the engine throttle body
used time.
CO deposit time reset value: It means that the engine inner timer starts to reset the engine
throttle body used time. When you replaced the new one ECU.
Fig 26
7. When you do not want to check the data analysis above, press “EXIT” key to back to the “4. Idle
speed CO adjustment” (LCD background changed into black) ( as fig 26) on the main menu.
Press “ENTER” key to enter into idle speed CO adjustment. (as fig 27) With the ▲▼ and ◄ ►
cursors to adjust the idle speed CO value.
Micro adjustment: Press ▲ for one time then +1, but press ▼ for one time then –1.
Macro adjustment: Press ► for one time then +10, but press ◄ for one time then –10.
After adjustment, press “EXIT” key to back to main menu.
Fig 26 Fig 27
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8. With the ▲▼ cursor to select “5 operation test” function, press “ENTER” key to enter into “5.
re-set/Zero setting command” main function menu. (as fig 28)
Fig 28
With the ▲▼ cursor to select “1. Reset TPI adaption” or “2. Re-set CO deposited time” function.
(as fig 29, 30, 31, 32, 33, 34) (Note: Do not enter this menu if not necessary.)
Description:
1. Reset TPI adaption: After replaced the throttle body with new one or idle speed
adjustment screw had been removed, this command has to be
conducted.
2. Reset CO deposit time: After clean carbon deposition on the throttle body or replaced it,
and replaced the ECU with new one, but without clean or
replaced the throttle body, this command has to be conducted.
Press ENTER key to left this set up function menu.
Fig 29
Fig 30 Fig 31
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Fig 32
Fig 33 Fig 34
9. With the ▲▼ cursor to select “6. Waveform” analysis (as fig 35), press ENTER to enter into the
waveform analysis menu. (as fig 36). 1. engine speed, 2. ignition timing (BTDC), 3. TPS, and 4.
Atmosphere pressure sensor.
Fig 35
Fig 36
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With the ▲▼ cursor to select “1. engine speed (as fig 37), press ENTER to enter into the “engine
speed” menu to check current waveform. There are 3 instantly dynamic data values shown on the
menu. (as fig 38, 39, 40). Select desired menu with ◄ ► cursor.
Fig 37 Fig 38
Fig 39 Fig 40
With the ▲▼ cursor to select “2. ignition timing (BTDC) (as fig 41), press ENTER to enter into the
“ignition timing” menu to check current waveform. (as fig 42). Press EXIT key to left the “ignition
timing” waveform menu.
Fig 41 Fig 42
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With the ▲▼ cursor to select “3. throttle position sensor (TPS) (as fig 43), press ENTER to enter
into the “3. TPS” menu to check current waveform. (as fig 42). Press EXIT key to left the “TPS”
waveform menu.
Fig 43 Fig 44
With the ▲▼ cursor to select “4. Atmosphere Pressure Sensor (as fig 45), press ENTER to enter
into the “Atmosphere Pressure Sensor” menu to check current waveform. (as fig 46). Press EXIT
key to left the “Atmosphere Pressure Sensor” waveform menu.
Fig 45 Fig 46
10. With the ▲▼ cursor to select “7. Identification” analysis (as fig 47), press ENTER to enter into the
Identification analysis menu. (as fig 48, 49).
Fig 47
Fig 48 Fig 49
11. Here are all operation menus for the EFI Data Scan.
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EFi Component Malfunction Check& Replacement Procedure (PI Engine)
PI (Port Injection) → Intake manifold injection engine
Parts No. Service
Item Inspection Method Adjustment & replacement procedure
Parts Name schedule
1 390-002 At least 1. With the Data Scan to check if the 1. If the ignition coil has to be
Ignition coil 20000km ignition coil is malfunction. changed, erase the DTC codes with
life-expecta 2. Erase the DTC codes and replace the Data Scan.
ncy with new one & confirm again. If the 2. Turn off ignition switch, and replace
Check it DTC codes disappear, then the the coil with new one.
every ignition coil is abnormal. Replace it 3. Turn on ignition switch and make
3000km with new one. sure the DTC codes disappear.
3. If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new one.
4. Before the ignition coil is verified in
abnormal, check the coil resistance
and connector wire for short-circuit.
2 379-010 At least 1. Check if the by-pass valve DTC 1. If the by-pass valve has to be
By-pass 20000km code shown with the Data Scan. changed, erase the DTC codes with
valve life-expecta 2. Erase the DTC codes and replace the Data Scan.
ncy with new one & confirm again. If the 2. Turn off the ignition switch, and
Check it DTC codes disappear, then the then replace the valve with new
every by-pass valve is abnormal. one.
3000km Replace it with new one. 3. Turn on ignition switch and make
3. If the DTC codes still exist, check if sure the DTC codes disappear.
the wire connector and by-pass 4. Check idle speed CO and adjust it if
valve resistance are in normal. necessary.
4. If the DTC codes still exist, replace
the ECU for confirm. If the DTC
codes disappear, then the ECU is
abnormal. Replace it with new
one.
3 358-016 At least 1. Connect a pressure gauge between 1. The oil seal has to be replaced if it
fuel pump & 20000km the regulator and fuel injector. has to replace the regulator.
regulator life-expecta 2. Make sure fuel pressure is within 2. Oil seal has to be installed onto the
ncy 2.5bar. The pressure is reached outer cover, and then assemble it
Check it within 3 seconds after turn on
every ignition switch.
6000km 3. If the fuel pressure is out of
specification, check if the fuel pipe is
leaking. Is the fuel pump voltage
over 12V?
4. Replace the regulator and confirm
again.
4 366-005 At least 1. Has the DTC code shown with the 1. If the sensor has to be changed,
Engine 20000km Data Scan. erase the DTC codes with the Data
temperature life-expecta 2. Engine temperature has to be Scan
sensor ncy reached to room temperature after 2. Turn off ignition switch, and
Check it engine stopped for a while. remove connector.
every 3. Erase the DTC codes and replace 3. Remove the sensor with tools.
3000km with new one & confirm again. If the 4. New component tighten torque is
DTC codes disappear, then the 0.74~0.88kg-m.
sensor is abnormal. Replace it 5. Connect the connector, and the
with new one. Data Scan. Then, turn on ignition
4. If the DTC codes still exist, check if switch.
wire connector and sensor’s 6. Make sure if the DTC codes are
resistance are normal. disappeared.
7. The value of stopped engine
temperature should near to room
temperature.
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4. FUEL INJECTION SYSTEM
Parts No. Service Adjustment & replacement
Item Inspection Method
Parts Name schedule procedure
5 366-008 At least 1. Connect the Data Scan as Replacement procedure for T-MAP
Intake 20000km inspection. The engine intake (intake temperature/pressure
temperature life-expectancy temperature and pressure should sensor)
/pressure Check every close to environmental 1. Turn off the ignition switch.
sensor 3000km temperature & atmosphere 2. Disconnect the connector of
pressure. (conduct this task after intake temperature/pressure
stopped the engine for a while) sensor. Replace the sensor with
2. If the DTC codes of intake new one.
temperature or pressure shown on 3. Connect the connector with Data
the Data Scan, replace the Scan.
pressure sensor firstly with new 4. Turn on the ignition switch, and
one. Make sure if the DTC codes check if the intake temperature/
are disappear. If not, check the pressure close to environmental
connector wire for short-circuit. temperature and atmosphere
Replace the connector if pressure with the Data Scan.
necessary. 5. Erase the DTC codes, and make
3. If the DTC codes still exist, replace sure the problem is solved.
the ECU.
4. If the DTC codes are disappear,
install the original pressure sensor
and check it again. If the DTC
codes are disappear, then, replace
the ECU with new one.
6 308-008 At least 1. Please refer to idle speed The throttle body replacement
Throttle 20000km adjustment section for the idle procedure:
body life-expectancy speed CO adjustment. 1. Install a new throttle body
Check every 2. Connect the Data Scan and check 2. Make sure there is no leaking.
3000km if the throttle position DTC code 3. Connect the Data Scan and
appears. record carbon accumulated time.
3. If the code appears, replace the 4. Re-set the time with the Data
throttle body to make sure the Scan.
code can be erased. 5. Re-set the throttle position data
4. If the code disappears, replace the with the Data Scan.
throttle body. 6. Throttle valve WOT set up. Turn
5. If the code still exists, replace the off ignition switch, and WOT the
ECU with new one. Then, if the throttle valve and hold it. Turn on
code can be erased, the ECU has the ignition switch and hold for 2
to be replaced. seconds. Release the throttle
valve.
7. Please refer to the idle speed
adjustment section for the idle
speed CO if necessary.
7 337-004 At least 1. Check if the fuel injector DTC code Confirmation or replacement
Fuel injector 20000km appears. procedure for the fuel injector:
life-expectancy 2. If the code appears, replace a new 1. Erase the DTC code with the
Check every fuel injector for confirmation. If the Daya Scan.
3000km code can be erased, then, replace 2. Turn off ignition switch and
the fuel injector. disconnect the fuel injector
3. If the code still can not be clear, connector.
check if connector wire is in 3. Connect the connector to a new
short-circuit. fuel injector.
4. If the code still exists, replace the 4. Connect the Data Scasn, and turn
ECU with new one. Then, if the on the ignition switch.
code can be erased, the ECU has 5. Make sure the DTC code had
to be replaced. been clear.
6. Please refer to idle speed
adjustment section for idle speed
CO value confirmation.
(Firstly, make sure if the fuel injector
DTC code had been clear, and then
install a new fuel injector.)
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4. FUEL INJECTION SYSTEM
Parts No. Service Adjustment & replacement
Item Inspection Method
Parts Name schedule procedure
8 325-002 At least 1. Connect the Data Scan. ECU replacement procedure:
ECU 20000km 2. Record the ECU service time. 1. Connect the Data Scan onto the
life-expectancy original ECU.
Check every 2. Record the ECU service time.
3000km 3. Turn off the ignition switch.
4. Replace the ECU with new one.
5. Re-set the ECU service time.
6. Clean the carbon deposition
around the throttle body.
7. Please refer to idle speed
adjustment section for idle speed
CO value confirmation.
9 Idle speed Check for new 1. Warm up the motorcycle by 1. Warm up the motorcycle by
CO motorcycle and running it in 50km/hr for 5 minutes. running it in 50km/hr for 5
Adjustment every 3000km. 2. Connect the Data Scan. minutes.
3. Record the idle speed CO value, 2. Connect the Data Scan.
rpm, and carbon deposition 3. Record the idle speed CO value,
accumulated time. rpm, and carbon deposition
accumulated time.
4. With the Data Scan to adjust the
idle speed CO value to be
0.5%~2.0%.
5. Record the idle speed CO value,
rpm and CO variant value.
6. (The engine temperature has to
be in 115℃~140℃, and intake
temperature to be in 25℃~40℃
as adjusting.)
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5. REMOVAL OF ENGINE
Operational Precautions
General Information
z Engine must be supported by a bracket or adjustable tool in height.
z The following parts can be serviced with the engine installed on the frame. 5
1. Throttle valve
2. Driving disk, driving belt, clutch, and transporting disk
3. Final reduction gear mechanism
Specification
Item Specification
Torque Values
Engine suspension bolt (Frame side) 4.5~5.5 kgf-m
Engine suspension nut (engine side) 4.5~5.5 kgf-m
Bolt of rear shock absorber upper connection 3.5~4.5 kgf-m
Bolt of rear shock absorber lower connection 2.4~3.0 kgf-m
Bolt of rear brake clipper 2.9~3.5 kgf-m
Nut of rear wheel axle 11.0~13.0 kgf-m
Nut of exhaust connection 0.5~1.0 kgf-m
Bolt of exhaust fixed 3.0~3.6 kgf-m
Bolt of rear bracket 3.0~3.6 kgf-m
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5. REMOVAL OF ENGINE
Engine Removal
Remove the battery cap (Nut ×3).
Remove the battery negative (-) cable.
Remove the battery positive (+) cable.
Remove the starter motor cable on the relay. Starter motor cable
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5. REMOVAL OF ENGINE
Remove the by-pass pipe and disconnect circuit By-pass valve connector
connector.
Throttle position
sensor connector
Remove the throttle body lines and throttle body Fuel injector connector
cables.
Disconnect the connector of throttle position
sensor.
Loosen the clamp of the air cleaner duct, and
then remove the duct.
Remove the fuel injector line and circuit Fuel supply line
connectors.
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5. REMOVAL OF ENGINE
Bolt x 3
5-4
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5. REMOVAL OF ENGINE
Bolt x 2
Nut x 1
5-5
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5. REMOVAL OF ENGINE
Engine suspension removal
Remove the rear shock absorber lower bolt.
(bolt x 1)
Bolt x 1
Remove the side hole cap of cooling fan. Side hole cap
Nut x 1
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5. REMOVAL OF ENGINE
Removal Of Engine Suspension
Bushing
If engine suspension frame and the cushion
rubber of rear shock absorber bushing damaged.
Then, with the bushing remover / pressor,
Ø 28mm & Ø 20mm, to press the bushing out,
and replace it with new one.
Pressing out
Place the detent section of the bushing remover
toward the bushing, and drive both the pressing
ring and bolt in to press the bushing out.
Pressing In
Place the flat section of the remover toward the
bushing, and then drive the bushing, pressing
ring, and bolt in to install the bushing.
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5. REMOVAL OF ENGINE
Engine Suspension Frame
Removal
Remove the right side bolt of engine suspension
frame.
Engine suspension
bolt (right side)
Engine suspension
bolt (left side)
Installation
Tighten the bolts and nuts of engine suspension
frame.
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5. REMOVAL OF ENGINE
Installation Of Engine
Check if the bushings of engine suspension
frame and shock absorber for damaged. If so,
replace with new ones.
Install the engine according to the reversing
order of removal.
Caution
z Note both feet and hands safety for
squeezing as engine installation.
z Do not bent or squeeze each wires or Nut x 1
hose.
z Route all cables and wires in accordance
with the routine layout.
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5. REMOVAL OF ENGINE
NOTES:
5-10
Home page Contents
6. Cylinder Head/Valve
Mechanism Illustration
6
1.0~1.4 kgf-m
0.7~1.1 kgf-m
1.0~1.2kgf-m
0.8~1.2kgf-m
2.0~2.4kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
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6. Cylinder Head/Valve
Precautions In Operation
General Information
• This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well
as rocker arm.
• Cylinder head service cannot be carried out when engine is in frame.
Specification Unit: mm
Item Standard Limit
Torque Value
Cylinder head bolt 1.0~1.4kgf-m
Cylinder head bolt (LH) 1.0~1.4kgf-m
Cylinder head Nut 1.8~2.2kgf-m (apply with oil on bolt thread & seat)
Sealing bolt of timing chain auto-tensioner 0.8~1.2kgf-m
Bolt of timing chain auto-tensioner 1.0~1.4kgf-m
Timing gear cover bolts 0.7~1.1kgf-m (apply with oil on bolt thread & seat)
Spark plug 1.0~1.4kgf-m
TOOLS
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
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6. Cylinder Head/Valve
Troubleshooting
Engine performance will be effected by troubles on engine top-end. The troubles usually can be
determinated or by performing cylinder compression test and judging the abnormal noise generated.
Rough Idle
• Low compression pressure
2. Cylinder head
z Cylinder head gasket leaking or damage
z Tilt or crack cylinder surface
3. Piston
z Piston ring worn out
Noise
• Improper valve clearance adjustment
• Burnt valve or damaged valve spring
• Camshaft wear out or damage
• Cam chain wear out or looseness
• Auto-tensioner wear out or damage of cam chain
• Camshaft sprocket wear out
• Rocker arm or rocker arm shaft wear out
White smoke
• Valve guide or valve stem wear out
• Valve stem seal wear out
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6. Cylinder Head/Valve
Cylinder Head Removal Bolt x 2
Remove:
Remove the cooling fan cover. (screw x 2, bolt x
2)
Screw x 2
Screw x 2 Screw x 2
Bolt x 1
Bolt x 2
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6. Cylinder Head/Valve
BTDC
Bolt x 2
Remove the left bolt (bolt x2) of cylinder head Nut x 4 Bolt x 2
firstly, and then remove the 4 nuts & washers
from the cylinder head top-end.
Pry out the chain and take out the sprocket.
Then, remove the cylinder head.
Caution
• Loosen the nuts diagonally by 2-3
sequences.
• Do not let the chain fall into the crankcase
after removed the sprocket.
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6. Cylinder Head/Valve
Cylinder Head Disassembly
Remove the adjustment hole cap for the EX & IN
valve clearance. (bolt x 6)
Adjustment
hole cap
Camshaft
Caution
In order to avoid loosing spring elasticity, do
not press the spring too much. Thus, press
length is based on the valve split locks in
which can be removed.
Caution
In order to avoid damaging the valve stem
and the cylinder head, in the combustion
chamber place a rag between the valve
spring remover/installer as compressing the
valve spring directly.
Rocker Arm
Measure the cam rocker arm I.D.
Service Limit: Replace when it is less than
12.10 mm.
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6. Cylinder Head/Valve
Caution
• Do not damage the matching surfaces of
cylinder and cylinder head.
• Avoid residues of gasket or foreign
materials falling into crankcase as
cleaning.
Chain plate
Cylinder head gasket
Caution
Do not damage the matching surface of
cylinder head.
Cylinder Head
Check if spark plug and valve holes are crack.
Measure cylinder head wrapage with a
straightedge and flat feeler gauge.
Service limit: 0.5 mm
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6. Cylinder Head/Valve
Valve Stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN→4.90 mm
EX→4.90 mm
Valve Guide
Caution
Before measuring the valve guide, clean
carbon deposits with reamer.
5.0mm valve guide
Special Service Tool: 5.0mm valve guide reamer reamer
Measure and record each valve guide inner
diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.08 mm
EX→0.10 mm
Caution
If clearance between valve stem and valve
guide exceeded service limit, check whether
the new clearance that only replaces new
valve guide is within service limit or not. If
so, replace valve guide.
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.
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6. Cylinder Head/Valve
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
13 mm Valve guide driver
Tool: Valve guide driver: 5 mm
5.0mm
(0.15in)
Caution
• Check if new valve guide is deformation
after pressed it in.
• When pressing in the new valve guide,
cylinder head still have to be kept in
100~150℃.
Adjust the valve guide driver and let valve guide
height is in 13mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve
guide with reamer.
Caution Valve guide reamer
5.0mm
• Using cutting oil when correcting valve
guide with a reamer.
• Turn the reamer in same direction when it
be inserted or rotated.
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6. Cylinder Head/Valve
Valve Seat Inspection
If the valve seat is too width, narrow or rough,
correct it. Roughness
Valve seat width
Service limit: 1.6 mm
Check the contact condition of valve seat.
Valve Seat Grinding
The worn valve seat has to be grinded with valve
seat chamfer cutter. 45°
Use 45° valve seat chamfer cutter to cut any
rough or uneven surface from valve seat.
Caution
32°
60°
45°
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6. Cylinder Head/Valve
Coat the valve seat surface with red paint.
Install the valve through valve guide until the Contact surface
valve contacting with valve seat, slightly press too high
down the valve but do not rotate it so that a seal
track will be created on contact surface. Old valve seat
width
Caution
The contact surfaces of valve and valve seat 32°
are very important to the valve sealing
capacity.
If the contact surface too low, grind the valve seat Contact surface
Old valve seat
too low
with 60° cutter. width
Then, grind the valve seat to specified width.
60°
Caution
Valve
The closed coils of valve spring should face
down to combustion chamber.
Valve spring
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6. Cylinder Head/Valve
Use valve spring compressor to press valve
spring.
Install valve split locks and release the valve
compressor.
Caution
In order to avoid loosing spring elasticity, do
not press the spring too much. Thus, press
length is based on the valve split locks in
which can be removed.
Caution
In order to avoid damaging the valve stem
and the cylinder head, in the combustion
chamber place a rag between the valve
spring remover/installer as compressing the
valve spring directly.
Caution
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6. Cylinder Head/Valve
Install the camshaft onto the cylinder head and EX rocker arm shaft Lock plate
then the rocker arm and the rocker arm shaft.
Lock the lock plate after rotate the rocker arm
shaft to properly position.
Caution
There is different shapes on the top-end of
rocker arm shaft. The machined surface on
the rocker arm shaft has to face toward
exhaust side, and then the larger surface
has to align with the bolt hole of cylinder
h d IN rocker arm shaft
Lock pins
Cylinder Head Installation
Install the lock pins and new cylinder head
gasket onto the cylinder head.
Install the camshaft chain plate.
Chain plate
Cylinder head gasket
Caution
This model is equipped with precious 4
valves mechanism so tighten torque can not
be over the limited value and tightening the
bolts diagonally by 2-3 sequences. It can
prevent from cylinder head deformation and
then cause noise or leaking problems so that
effect motorcycle’s performance.
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6. Cylinder Head/Valve
Bolt x 2
Bolt x 1
Screw x 2 Screw x 2
6-15
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6. Cylinder Head/Valve
Screw x 2
Caution
• The cylinder components will be serious
wear out if lubricant did not flow onto the Intake valve
cylinder head. So it has to be adjustment hole cap
confirmed.
• It has to be in idle speed when conduct
this procedure. Never increase engine
speed in high RPM.
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7. Cylinder/Piston
Mechanism Illustration
7
0.8~1.2 kgf-m
7-1
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7. Cylinder/Piston
Precautions In Operation
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification Unit: mm
Item Standard Limit
ID 57.400~57.410 57.500
Bend/wrapage - 0.050
Cylinder
Cylindrical roundness - 0.050
Trouble Diagnosis
Low Or Unstable Compression Pressure Smoking in Exhaust Pipe
• Cylinder or piston ring worn out • Piston or piston ring worn out
• Piston ring installation improperly
• Cylinder or piston damage
High Compression Pressure
• Carbon deposit onto the piston & combustion
Engine Overheat
chamber
• Carbon deposits on cylinder head top side
Knock or Noise
• Cylinder or piston ring worn out
• Carbon deposits on cylinder head top-side
• Piston pin hole and piston pin wear out
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7. Cylinder/Piston
Cylinder Removal
Remove cylinder head. (refer to chapter 6)
Remove 2 bolts and then take out the cam chain
auto-tensioner.
Bolt x 2
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7. Cylinder/Piston
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
To soap the residues into solvent so that the
residues can be removed more easily.
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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.
Caution
Pay attention to remove piston rings because
they are fragile.
Caution
Push the piston rings into cylinder with
piston top-end in parallel motion.
Service Limit:
Top ring: replace if over 0.5 mm Piston rings
2nd ring: replace if over 0.65 mm
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7. Cylinder/Piston
Measure the outer diameter of piston pin.
Service Limit: 14.96 mm
7-6
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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.
Caution
• 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.
Top ring
2nd ring
120°
Side
ring
Spacer Oil ring
Side
ring
Over 20 mm
Top groove
2nd groove
Oil groove
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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
• 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.
Cylinder Installation
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
To soap the residues into solvent so that the
residues can be removed more easily.
Bolt x 2
7-8
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8. V-Belt Driving System/Foot Starter
Mechanism Illustration
5.0~6.0 kgf-m
5.0~6.0 kgf-m
5.0~6.0 kgf-m
1.0~1.5 kgf-m
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8. V-Belt Driving System/Foot Starter
Maintenance Description
PRECAUTIONS IN OPERATION
• Driving pulley, clutch, and driven pulley can be serviced on the motorcycle.
• Driving belt and driving pulley surface must be free of grease.
Specification Unit: mm
Item Standard value Limit
Driving belt width 19.500 18.500
ID of sliding pulley bushing 27.000~27.021 27.060
OD of sliding pulley hub 26.970~26.990 26.940
OD of weight roller 19.950~20.100 19.500
ID of clutch jacket 130.000~130.200 130.500
Thickness of clutch lining 4.000~4.100 2.000
Free length of driving pulley spring 128.400 123.400
OD of driving pulley 33.965~33.985 33.940
ID of sliding pulley 34.000~34.025 34.060
ID: Inner Diameter
OD: Outer diameter
Trouble Diagnosis
Engine can be started but motorcycle can Insufficient horsepower or poor high speed
not be moved performance
1. Worn driving Belt 1. Worn driving belt
2. Worn tilt plate 2. Insufficient spring capacity of driven pulley
3. Worn or damaged clutch lining 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly
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8. V-Belt Driving System/Foot Starter
Left Crankcase Cover
Removal of Crankcase Cover
Remove body cover.
Remove foot starter lever. ( bolt x 1)
Remove the outer cover of engine left-side cover.
(screw x 3)
Loosen vent strap on the front-left side of cover,
and then remove the vent.
Remove air cleaner. (bolt x 2)
Remove the engine left-side cover. ( bolt x 8)
Foot Starter
Disassembly
Remove snap ring and thrust washer from
engine left-side cover.
Install foot starter lever, rotate the lever slightly
and then remove driving gear and washer.
Remove the lever, foot starter, starter shaft, and
return spring as well as socket.
Inspection
Check if starter shaft, driving gear, socket and
bearing hole for wear or damage. Replace it with
new one if necessary. Starter shaft Return spring Driving gear
Check the return spring and friction spring for
spring force or damaged. Replace it with one if
poor parts found.
Reassembly
Install socket, return spring and starter shaft as
diagram shown.
Install thrust washer and snap ring onto starter
shaft.
Install foot starter lever temporary.
Rotate the lever and then align driving gear with
width-tooth on the starter shaft.
Install the friction of driving gear onto convex part
of the cover.
Installation of the left crankcase cover
Install the left crankcase cover. (8 screws)
Install front vent tube of left cover and tighten the
strap. Return
Starter
Install foot starter lever. (1 bolt) spring
shaft
Tighten the air cleaner. (2 bolts)
Install the body cover.
Friction
spring
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8. V-Belt Driving System/Foot Starter
Driving Belt
Removal
Remove left crankcase cover.
Hold driving pulley with universal fixture, and
remove nut and clutch jacket.
Universal
fixer
Universal
fixer
Inspection
Check the driving belt for crack or wear.
Replace it if necessary. Tooth
Measure the width of driving belt as diagram Width
shown. Replace the belt if exceeds the service
limit.
Service Limit: 18.5 mm
Caution
• Using the genuine parts for replacement.
• The surfaces of driving belt or pulley must
be free of grease.
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8. V-Belt Driving System/Foot Starter
Installation
Pull out the driving pulley and then insert the
driving belt into the driving pulley.
Sliding
Caution driven
Pull out driving pulley and then insert the pulley
driving belt into the driving pulley so that the
driving belt set can be installed onto sliding
pulley more easily.
Nut
Universal fixer
Caution
When install the driving belt, if there is a
arrow mark, then the arrow mark must point
to rotation motion. If not, the letters on the
belt must be forwarded to assembly
direction
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8. V-Belt Driving System/Foot Starter
Sliding Pulley
REMOVAL
Remove left crankcase cover.
Hold driving pulley with universal fixture, and
then remove driving pulley nut.
Remove driving pulley.
Universal
fixture
Driving
Crankshaft
pulley hub
Sliding
pulley
Weight roller
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8. V-Belt Driving System/Foot Starter
Inspection
The operation of sliding pulley is means of the
weight roller to pressing on it with centrifuge Weight roller
force. And then the speed is changed by the title
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 roller’s outer diameter. Replace it
if exceed the service limit.
Service limit: 19.50 mm
Closed end
Install the title plate guide boot (3 pieces) onto Guide boot
the title plate.
Install the title plate.
Tilt plate
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8. V-Belt Driving System/Foot Starter
Apply with grease 4~5 g to inside of driving shaft
hole, and install driving pulley hub.
Caution
The pulley surface has to be free of grease.
Clean it with cleaning solvent.
Pulley surface
Pulley hub
Crankshaft
Caution
Make sure that two sides of pulley surfaces
have to be free of grease. Clean it with
cleaning solvent.
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8. V-Belt Driving System/Foot Starter
Clutch/Driven Pulley Special nut wrench
DISASSEMBLY
Remove driving 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
Do not press the compressor too much.
Oil seal
Guide pin
O-ring Guide pin roller
INSPECTION
Clutch jacket
Measure the inner diameter of clutch jacket
friction face. Replace the clutch jacket if exceed
service limit.
Service limit: 130.5 mm
Inner
diameter
Clutch jacket
8-9
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8. V-Belt Driving System/Foot Starter
Clutch lining
Measure each clutch lining thickness. Replace Clutch lining
it if exceeds service limit.
Service limit: 2.0 mm
Clutch
Driven pulley
Check following items:
• If both surfaces are damage or wear. Free length
• If guide pin groove is damage or wear.
• Replace damaged or worn components.
• Measure the outer diameter of driven surface
and the inner diameter of driven pulley.
Replace it if exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm Driven pulley
Needle bearing
Outer ball
bearing
8-10
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8. V-Belt Driving System/Foot Starter
Clutch Block Replacement Spring
Remove snap and washer, and the remove Driving
clutch block and spring from driving plate. plate
Check if spring is damage or insufficient
elasticity.
Snap ring
Clutch block
Setting pin
Apply with grease onto setting pins. But, the Shock absorption
clutch block should not be greased. If so, replace rubber
it.
Install new clutch block onto setting pin and then
push to specified location.
Caution
• Grease or lubricant will damage the clutch
block and effect the block’s connection
capacity.
Clutch block
8-11
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8. V-Belt Driving System/Foot Starter
Install snap ring and mounting plate onto setting
pin.
Snap ring
Align oil seal lip with bearing, and then install the Inner bearing
new oil seal. (if necessary)
8-12
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8. V-Belt Driving System/Foot Starter
INSTALLATION OF CLUTCH/DRIVEN PULLEY Oil seal
ASSEMBLY
Install new oil seal and O-ring onto sliding pulley.
Apply with specified grease to lubricate the inside
of sliding pulley.
Specified
O-ring grease
Guide pin
O-ring Guide pin roller
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8. V-Belt Driving System/Foot Starter
NOTES:
8-14
Home page Contents
9. Final Driving Mechanism
Mechanism Illustration
Final driving
Countershaft shaft
0.8~1.2 kgf-m
Countershaft
gear
Driving gear
2.0~2.4 kgf-m
1.0~1.4 kgf-m
9-1
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9. Final Driving Mechanism
Operational precautions
Specification Torque value
Application gear oil: 4-stroke lubricant Gear box cover 2.0~2.4 kgf-m
Recommended oil: KING MATE serial gear oils Gear oil drain plug 1.0~1.4 kgf-m
Oil quantity: 110 c.c. (100 c.c. when replacing) Gear oil filling bolt 0.8~1.2 kgf-m
Tools
Special service tools
Inner type bearing puller
Outer type bearing puller
Gear box oil seal installer
Gear box bearing installer
Trouble Diagnosis
Engine can be started but motorcycle can Gear oil leaks
not be moved • Excessive gear oil
• Damaged driving gear • Worn or damage oil seal
• Burnt out driving gear
• Broken driving belt
Noise
• Worn or burnt gear
• Worn gear
9-2
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9. Final Driving Mechanism
Disassembly of Final Driving
Mechanism
Remove the rear wheel. (refer to chapter 15)
Remove the clutch.
Drain gear oil out from gear box.
Remove gear box cover bolts (7 bolts) and then
remove the cover and the final driving shaft.
Remove gasket and setting pin.
7 bolts
Countershaft
Driving shaft
9-3
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9. Final Driving Mechanism
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.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Caution
• Do not remove the driving shaft from the
cover top side.
• If remove the driving shaft from the gear
box, then its bearing has to be replaced.
Bearing Replacement
Caution
• Never install used bearings. Once bearing
removed, it has to be replaced with new
one.
9-4
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9. Final Driving Mechanism
Press out the driving shaft from the gear box.
Remove oil seal from the gear box.
Remove the driving shaft bearing from the gear
box cover with the inner type bearing puller.
Caution
• Using the bearing protector as pressing
out the driving shaft from the gear box
cover.
Specified tool:
Inner type bearing puller.
If the driving shaft is pulled out with its bearing, Shaft protector
then remove the bearing with bearing puller and
bearing protector.
Special tool:
Multi-functional bearing puller
Bearing protector
Universal bearing
puller (inner type)
9-5
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9. Final Driving Mechanism
Re-Assembly Of Final Driving
Mechanism Final Final driving Counter
driving shaft gear shaft
Install final driving shaft and final driving gear, shaft
countershaft, and countershaft gear.
Setting pins
7 bolts
9-6
Home page Contents
10. Alternator/Starting Clutch
Mechanism Illustration
5.0~6.0 kgf-m
9.0~10.0 kgf-m
1.0~1.4 kgf-m
10
0.1~0.3 kgf-m
1.5~2.0 kgf-m
1.3~1.7 kgf-m
10-1
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10. Alternator/Starting Clutch
Precautions in Operation
General information
z Refer to chapter 5: Engine removal and installation
z Refer to chapter 1: The troubleshooting and inspection of alternator
z Refer to chapter 16: The service procedures and precaution items of starter motor
Specification Unit: mm
Item Service Limit
Torque value:
Flywheel nut 5.0~6.0 kgf-m
Starting clutch mounting bolt 9.0~10.0 kgf-m with oil on the thread
10-2
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10. Alternator/Starting Clutch
Alternator Removal
Crankshaft Flywheel
position sensor Fan
Fan shroud
Cooling fan
10-3
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10. Alternator/Starting Clutch
Remove the flywheel with the flywheel puller.
Special service tools:
Flywheel puller
shaft protector
Caution
Install a shaft protector on the right end of
crankshaft to avoid damaging the crankshaft
before installing the flywheel puller.
Flywheel puller
Crankshaft
position sensor
Alternator Coil Set Removal
Remove the connectors of the alternator and
crankshaft position sensor.
Alternator connector
Cable guide
Crankshaft
Remove the 6 bolts for the crankshaft position position
sensor, the alternator coil and cable guide. sensor
Then, remove the alternator assembly.
Caution
Do not damage the alternator coil.
Coil
8 bolts
10-4
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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 Mounting nut
gasket.
Special service tools:
Anti-loosen mounting nut socket
Universal fixture
Caution
The mounting nut is left-turn thread. Mounting nut socket
10-5
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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
Disassembly
Remove the hex blots (3 bolts) inside the starting Plug Spring
clutch.
Separate the clutch body and the clutch cover.
Remove the rollers, plugs, and springs on the
one way clutch.
Roller
Check each rollers and plugs for wear or
damage.
Install rollers, plugs and springs.
Clutch body
Clutch cover
10-6
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10. Alternator/Starting Clutch
Installation
Install the components in the reverse procedures
of removal. Plug Spring
Caution
Add adhensive onto the thread of hex socket
bolt. Roller
Torque value: 1.0~1.4 kgf-m
Clutch body
Clutch cover
10-7
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10. Alternator/Starting Clutch
Right Crankcase Cover Installation 8 bolts
Install setting pin and new gasket on the
crankcase.
Replace the right crankshaft oil seal of the
crankcase and apply some oil onto the oil seal
lip.
Install right crankcase cover onto the right
crankcase. (8 bolts)
Torque value: 1.5~2.0 kgf-m
Cable guide
Mounted Coil Set Installation Crankshaft
Install the coil set onto right crankcase cover. (2 position
sensor
screws)
Install crankshaft position sensor. (2 screws)
Tighten the cable guide. (2 screws)
Torque: 1.5~2.0 kgf-m
Tie the wire harness hose onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed
under the crankshaft position sensor. Coil
Crankshaft position
Connect the connectors of alternator and
sensor connector
crankshaft position sensor.
Alternator connector
10-8
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10. Alternator/Starting Clutch
Install the cooling fan. (4 bolts)
Cooling fan
10-9
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10. Alternator/Starting Clutch
NOTES:
10-10
Home page Contents
11. Crankcase/Crankshaft
Mechanism Illustration
1.5~2.0 kgf-m
1.0~1.4 kgf-m
11
0.7~1.0 kgf-m
0.8~1.2 kgf-m
0.8~1.2 kgf-m
3.5~4.5 kgf-m
11-1
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11. Crankcase/Crankshaft
Operational precautions
General Information
• This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft
can be serviced.
• Complete following operations before disassembling crankcase.
Engine Chapter 5
Cylinder head Chapter 6
Cylinder/ piston Chapter 7
V-belt Drive pulley Chapter 8
Alternator/Foot Starting Clutch Chapter 10
Start motor Chapter 16
• If the crankshaft bearing or timing sprocket need be replaced, then the crankshaft set have to
replaced.
Specification Unit: mm
Item Standard Limit
Left, right clearance of the big end of the connecting rod 0.100~0.300 0.550
Right angle clearance of the big end of the connecting rod 0.000~0.008 0.050
Run-out ─ 0.100
Torque value
Bolts for crankcase : 1.5~2.0 kgf-m
Bolts for cylinder/cylinder head : 0.7~1.0 kgf-m
Engine oil draining plug : 3.5~4.5 kgf-m
Bolts for cam chain tensioner : 0.8~1.2 kgf-m
Trouble diagnosis
Engine noise
• Loose crankshaft bearing
• Loose crankshaft pin bearing
• Wear piston pin or piston pin hole
11-2
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11. Crankcase/Crankshaft
Disassembly Of Crankcase
Hex-socket bolt x 1
Remove the cam chain tensioner (hex socket
bolt x 1) from the left crankcase side.
11-3
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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
60 mm 90 mm
Bearing Inspection
Rotate the bearing with fingers and make sure
the bearing can be rotated smoothly and quietly. Clearance
Check if the inner ring is connected onto the
crankshaft tightly. Clearance
Replace crankshaft as a set when noise or
looseness is detected.
曲軸軸承
11-4
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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
Do not damage the cam chain as installing
the crankshaft.
11-5
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11. Crankcase/Crankshaft
Apply with some grease onto the oil seal lip and
then install it onto the left crankcase.
11-6
Home page Contents
12. Body Cover
Mechanism Illustration
Seat
Luggage box
Battery
cover Left foot plate
Inner rear Rear
fender fender
Front cover
Left side cover
Floor panel
Front under
spoiler Under Cover
12-1
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12. Body Cover
Maintenance Information
Body covers disassemble sequence:
Handlebar Rear
Front cover Center cover
Cover
Handlebar Left/right
side cover Front fender Luggage box & seat
Left/right
Inner rear fender
side-covers
Floor Panel
Under Cover
12-2
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12. Body Cover
Front Cover
Removal
Remove the 4 mounting screws from the top-end
of front luggage box.
Screw x 4
Screw x 1
Installation
Install according to the reverse procedure of
removal.
12-3
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12. Body Cover
Handlebar Cover Screw x 5
Removal
Remove the handlebar rear cover (screw x 5).
Disconnect the wire connectors of left & right
switches.
Remove the handlebar rear cover.
Caution
• Open the hooks on the two end-section
of the handlebar cover as removing the
cover. The, remove the handlebar cover.
Do not pull it forcedly to avoid to breaking
the hooks.
Installation
Install according to the reverse procedure of
removal.
12-4
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12. Body Cover
Front Fender
Removal
Remove the front guard screws. (left & right x 2)
Installation
Install according to the reverse procedure of
removal.
12-5
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12. Body Cover
Front Under Spoiler
Removal
Remove the front fender, front brake system, and
odometer cable, as well as the front wheel.
Bolt x 2
Installation
Install according to the reverse procedure of
removal.
Frame hook
12-6
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12. Body Cover
Inner Box
Removal
Remove the front under spoiler firstly.
Bolt x 2
Nut x 1
ECU connector
Bend out all wire strap.
Disconnect the wire connector of ECU, and the
diagnosis connector.
Remove the screw (screw x 4) from the top-end
of front under spoiler.
Diagnosis connector
Installation
Install according to the reverse procedure of
removal.
12-7
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12. Body Cover
Center Cover
Removal
Remove the 1 upper screw inside of the luggage
box.
Installation
Install according to the reverse procedure of
removal.
Bolt x 2
Bolt x 2
Luggage Box
Removal
Open the seat.
Remove the 1 upper screw inside of the front
luggage box.
Remove the 2 mounting nuts and 2 bolts of the
luggage box.
Nut x 1
Installation
Install according to the reverse procedure of
removal.
12-8
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12. Body Cover
Rear Carrier Bolt x 4
Removal
Remove the hex-socket bolts (bolt x 4) of the rear
carrier.
Caution
Installation
Install according to the reverse procedure of
removal.
12-9
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12. Body Cover
Body Cover
Removal
Remove the rear carrier, luggage box and seat
firstly.
Remove the body cover mounting screw. (2
screws on each side)
Installation
Install according to the reverse procedure of
removal.
12-10
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12. Body Cover
Left & Right Side-Foot Plates Bolt x 1
Removal
Remove the foot connection screws & bolt. ( 3
screws & 1 bolt on left & right each side)
Screw x 3
Installation
Install according to the reverse procedure of
removal.
Screw x 1
Installation
Install according to the reverse procedure of
removal.
12-11
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12. Body Cover
Floor Panel Bolt x2
Removal
• Remove the center cover, luggage box, body
side covers, and body cover firstly.
• Remove the front mounting bolts (bolt x 2) of
the floor panel.
Remove the battery cover. (screw x 3)
Screw x 3
Installation
Install according to the reverse procedure of
removal.
12-12
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12. Body Cover
Rear Fender
Removal Bolt x 2
Remove the upper bolts (bolt x 2) from the rear
fender.
Installation
Install according to the reverse procedure of
removal.
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12. Body Cover
NOTES:
12-14
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13. Brake
3.5 kgf-m
13
0.55 kgf-m
1.8 kgf-m
4.5 kgf-m
13-1
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13. Brake
Rear Disc Brake System
3.5 kgf-m
0.55 kgf-m
4.5 kgf-m
13-2
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13. Brake
Precautions in Operation
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.
• The brake caliper can be removed without removing the hydraulic system.
• After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
• While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
• Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
• Check the operation of the brake system before you go.
Specifications Unit: mm
Item Standard Limit
Torque values
Brake hose bolt 3.50 kgf-m
13-3
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13. Brake
Trouble Diognosis
Soft brake lever Uneven brake
1. Air inside the hydraulic system Dirty brake lining/disc
2. Hydraulic system leaking Poor wheel alignment
3. Worn master piston Clogged brake hose
4. Worn brake pad Deformed or warped brake disc
5. Poor brake caliper Restricted brake hose and fittings
6. Worn brake lining/disc
7. Low brake fluid Tight brake
8. Blocked brake pipe Dirty brake lining/disc
9. Warp/bent brake disc Poor wheel alignment
10. Bent brake lever Deformed or warped brake disc
13-4
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13. Brake
Hydraulic Brake System Inspection
Hose connection
Inspection
Visual inspect for brake fluid leaking or damage.
Check if brake hose connection 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.
13-5
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13. Brake
13-6
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13. Brake
Brake Caliper
Removal Bolts x 2
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hoses.
CAUTION
• Do not spill brake fluid on painted surfaces.
• The exhaust pipe has to be removed
before remove the rear brake caliper.
13-7
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13. Brake
Brake Disc
Inspection
Visually check the brake disc for wear or break.
Measure the thickness of the disc at several Brake
places. Replace the disc if it has exceeded the disc
service limit.
Allowable limit: 2.0 mm
Micrometer
CAUTION
The whole set of master cylinder, piston,
spring, diaphragm and clip should be
replaced after removal.
Remove the front and rear handlebar guards.
Remove the leads of brake lamp switch.
Drain out the brake fluid. Brake
Remove the brake lever from the brake master hose
cylinder.
Remove the brake hose.
Remove the master cylinder seat and the master Clip
cylinder. Rubber
Remove the rubber pad. washer
Piston
Remove the clip.
Remove the piston and the spring. Spring
Clean the master cylinder with recommended
brake fluid.
Master
cylinder
13-8
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13. Brake
Inspection
Master
Check the master cylinder for damage or scratch. cylinder
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.
Allowable limit: 11.055 mm
Dial
gauge
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit: 10.945 mm Piston
Micrometer
Assembly
CAUTION
Rubber Sub-rubber
• It is necessary to replace the whole set boot washer
comprising piston, spring, piston cup, and
clip. clip
• Make sure there is no dust on all Piston
components before assembling.
Main rubber
Apply clean brake fluid to the piston cup, and washer
then install the cup onto the piston. Spring
Install the larger end of the spring onto the
master cylinder.
The master cup’s cavity should be face inside of Master
master cylinder when installing the master cup. cylinder
Install the clip.
CAUTION
• Never install cup lip in the opposite
direction.
• Make sure the clip is seated securely in the
groove.
13-9
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13. Brake
INSTALLATION
Master cylinder
Place the master cylinder onto handlebar, and Mounting
install the split ring and bolts. The “UP” mark on seat
the split ring should face upward.
Align the split ring on the master cylinder seat Punch
with the alignment point on the handlebar. point
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
13-10
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14. Steering/Front Wheel/Front Shock Absorber
Mechanism Illustration
4.0~5.0 kgf-m
1.0~2.0 kgf-m
0.2~0.3 kgf-m
2.4~3.0 kgf-m 14
3.1~3.5 kgf-m
5.0~7.0 kgf-m
14-1
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14. Steering/Front Wheel/Front Shock Absorber
Precautions in Operation
General Information
• 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.
• Be careful not to allow oil or grease get on brake drum or linings.
Torque values
Front wheel axle 5.0~7.0 kgf-m
Tools
Special service tools
Steering column wrench
Bearing remover
Inner type bearing remover
Attachment, 32×35 mm
Attachment, 42×47 mm
Steering column nut wrench
Steering column top cone ring nut wrench
Trouble diagnosis
Front wheel wobbling
Hard steering stem • Bent wheel rim
• Over tightening of steering stem lock nut
• Loose wheel axle nut
• Damaged steering stem steel ball and
• Poor wheel or wearing
steering stem bearing seat • Too much clearance on wheel bearing
• Insufficient tire pressure
14-2
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14. Steering/Front Wheel/Front Shock Absorber
Steering Handlebar Master cylinder
REMOVAL
Remove handlebar front & rear cover and the
front cover (refer to chapter 12).
Disc Brake
Remove the 2 bolts of the brake master cylinder,
and then take out the master cylinder and the
split ring.
Caution
Mounting
Do not operate the front brake lever to avoid Bolts
seat
to pressing out the brake lining when
removing the master cylinder.
Screw
Bolts x 2
Installation
Install the handlebar according to the reverse
procedure of removal.
Apply with some grease onto the handlebar
moving parts when installing the throttle
handlebar housing, throttle handlebar, and Nut
throttle cable.
14-3
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14. Steering/Front Wheel/Front Shock Absorber
Front Wheel
Removal Speedometer
Support body bottom and lift front wheel free of cable
ground.
Remove the screw, and disconnect speedometer
cable from the gear box.
Remove the wheel axle nut and pull out the axle.
Then, remove the front wheel.
Caution
Do not operate the front brake lever to avoid
to pressing out the brake lining when
removing the master cylinder.
Wheel axle
nut
Inspection
Wheel axle
Set the axle in V-blocks and measure the run-out.
Service limit: 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 : 2.0 mm
Axial : 2.0 mm
14-4
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14. Steering/Front Wheel/Front Shock Absorber
Disassembly
Remove the left axle ring and dust seal. Bearing
Remove the dust seal on the right side of
speedometer gear.
Remove the bearing with the inner type bearing
remover.
Take out the bearing spacer and then remove the Wheel side
other bearing. collar
Speedometer
Tool: Bearing
gear dust
Inner type bearing remover. seal
Dust seal
Bearing bushing
Bearing Inspection
Turn the inner race of bearing with fingers. The Clearance
bearing should be turn smoothly. Also check if Clearance
the outer collar is tightly connected to the wheel
hub.
If the bearing do not turn smoothly, or if they are
too loose in the races, or damaged, then, remove
and replace the bearings with new ones.
Caution
The bearing must be replaced in pair.
Installation
Install the bearing according to the reverse
procedure of removal.
Apply some grease into the bearing seat of the
wheel hub.
Install the left bearing onto the seat.
Install the bearing spacer and then install the
right bearing onto the seat.
14-5
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14. Steering/Front Wheel/Front Shock Absorber
Caution
Do not install used bearing and replace the
bearing once it has been removed.
Do not the bearing in tile motion when
installing.
Tool:
C-type compressor or bearing compressor.
Brake panel
slot
14-6
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14. Steering/Front Wheel/Front Shock Absorber
Front shock absorber
Removal
Remove the front fender, front under spoiler, front
cover, and front wheel as well as front brake
components.
Remove the brake fluid hose clipper or cable
guide on the left shock absorber. (bolt x 1)
As for disc brake, remove the cable guide on the
right shock absorber. (bolt x 1)
Brake
fluid hose
clipper
Shock absorbers
Installation
Install the shock absorbers according to the
reverse procedure of removal.
Align the shock absorber top-edge with the
top-end level of the front fork when installing the
front shock absorber onto the front fork. Then,
tighten the nut.
Torque value: 2.4~3.0 kgf-m
14-7
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14. Steering/Front Wheel/Front Shock Absorber
With a plastic hammer to tap the steering ball
race slightly, and then remove the top ball
bearing race.
Remove the lower-end cone bearing race on the
frame with a punch.
Caution
Do not damage the frame and the steering
race.
Top
cone-race
14-8
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Mechanism Illustration
3.5~4.5 kgf-m
2.4~3.0 kgf-m
0.55 kgf-m
3.5 kgf-m
15
4.5 kgf-m
15-1
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Precautions in Operation
General Information
As for the wheel removal, service, and installation procedures, please refer to the service manual of
high speed tire.
Specification Unit: mm
Items Standard Limit
Radial - 2.0
Wheel wobbling
Axial - 2.0
Torque values
Rear axle nut 10.0~12.0 kgf-m
Trouble Diagnosis
Rear wheel wobbling Braking Noise Poor brake performance
• bend wheel rim • worn brake lining • Poor brake adjustment
• poor tire • brake drum deformation • contaminated brake lining
• loosen wheel shaft • improperly brake panel • worn brake lining
installation • Air inside of the brake
Shock absorber too soft • unparalleled brake drum or hose/pipe
• insufficient shock absorber wheel unparallel. • greased brake disc
spring force • Clogged brake pipe
• Bent brake pipe
• Insufficient brake fluid
15-2
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Exhaust Muffler Nuts x 2
Removal
Remove the front-end nut of the exhaust muffler.
(nut x 2)
Remove the bolts. (bolts x 3)
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.
Torque value:
Exhaust muffler connection bolt: 3.2~3.8 kgf-m
Exhaust muffler connection nut: 1.0~1.2 kgf-m
Bolts x 3
Rear Wheel
INSPECTION
Measure wheel rim wobbling.
Service limit:
Radial: 2.0 mm
Axial: 2.0 mm
• If the wheel rim wobbling out of the
specification, except resulted from the wheel
rim deformation, it might be loosen or worn
final driving shaft bearing or bend, deformed
driving shaft.
Removal
Remove the rear brake pipe mounting seat.
(bolt x 2)
Remove the rear brake assembly. (bolt x 2)
Bolt x 2
15-3
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Remove the front bolt from the rear carrier.
Bolt x 2
(bolt x 2)
Remove the rear wheel axle nut. (nut x 1)
Nut x 1
Caution
Never hold the brake lever as caliper was
removed so that prevent from pushing out
the brake pad.
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Replacement of Rear Wheel Bearing Bearing
Remove the outer bearing from the fork.
With inner type bearing puller to remove bearing.
Remove inner oil seal.
Caution
Oil seal
Do not use the used oil seal.
Installation
Install rear wheel. Brake pipe clipper
Install bearing bushing onto the fork.
Install the fork onto the rear wheel axle.
Install the bearing bushing and washer onto the
fork.
Tighten the rear wheel axle nut.
Install the brake caliper, and then tighten caliper
bolt & pipe mounting bracket.
Install the exhaust pipe, and then tighten its bolt
and but.
Install body covers according to the reverse
procedure of removal.
Torque value:
Rear axle nut 10.0~12.0 kgf-m
Rear brake caliper bolt 2.9~3.5 kgf-m
Exhaust pipe connection bolt 3.2~3.8 kgf-m
Exhaust pipe connection nut 1.0~1.2 kgf-m
Caution
Pay attention to on the installation direction
of the rear carrier axle ring. The small end
of inner & outer axle rings have to forward to
arm bearing.
Bolt x 3
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15. Rear Wheel/Rear Fork/ Rear Shock Absorber
Rear Shock Absorber
Removal
Remove the luggage box. (bolt x4, screw x1)
Remove the body cover. (screw x 4)
Remove the air cleaner. (bolt x2)
Installation
Install the rear shock absorber according to the
reverse procedure of removal.
Caution
The rear shock absorber has to be replaced
with one set and can not be replaced by
unauthorized persons. Otherwise, it might
damage the rubber bushing and
construction.
Torque values
Rear shock absorber lower mount bolt:
2.4~3.0 kgf-m
Rear shock absorber upper mount bolt:
3.5~4.5 kgf-m
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16. Electrical Equipment
Precautions In Operation
• When remove the battery, the disconnection sequence of cable terminals shall be strictly
observed.
• Spark plug heat range/model and tighten torque.
• Ignition plug.
• Headlamp adjustment.
• Removal and installation of alternator.
• 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.
• Do not quick charge the battery unless in emergency.
• A voltmeter must be used when checking battery charging condition.
• Starting motor can be removed directly from engine.
Specification
Charging System
Items Specification
Capacity 12V8Ah
Battery
Charging rate STD: 0.16A/5hrs, emergency charging: 16A/0.5hrs
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16. Electrical Equipment
Trouble diagnosis
No power supply Intermittent power supply
• Dead battery • Loose charging system connection
• Disconnect battery cable • Loose battery cables
• Fuse burned out • Loose connection or short-circuit in discharging
• Faulty ignition switch system
• Loose connection or short-circuit in lighting
system
Low voltage Charging system failure
• Weak battery • burn Fuse
• Loose battery connection • Loose, broken or shorted wire or wire
• Charging system failure connection
• Voltage-current regulator failure • Faulty voltage regulator
• Faulty alternator
Starter motor does not work Weak starter motor
• The fuse is blown • Poor charging system
• The battery is not fully charge • The battery is not fully charged
• Poor main switch • Poor connection in the windings
• Poor starter switch • The motor gear is jammed by foreign material
• The front and rear brake switches do not Starter motor is working, but engine does not
operate correctly crank
• Starter relay is out of work • Poor starter motor pinion
• The ignition coil is poorly connected, open or • The starter motor run in reverse direction
Battery
Removal
Remove the rubber carpet.
Remove the battery cap. (screw x 3)
Remove the battery mounting bracket. (bolt x 2)
Firstly, remove the negative(-) post, and remove
the positive (+) post.
Remove the battery.
Voltage Inspection
Measure the voltage with a digital voltage meter.
Voltage Value:
Fully charged: 13.0~13.2V at 20℃
undercharged: less 12.3V at 20℃
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16. Electrical Equipment
Charging system
Charging wire circuit
Main switch
Green Black
Red
Fuse Pink
Yellow
20A
Battery
Alternator
Regulator
Charging
Connect the battery charger’s positive (+)
terminal to battery’s positive (+) post.
Connect the battery charger’s positive (-)
terminal to battery’s positive (-) post.
Standard Max
Warning
• Strictly keep flames away from a charging
battery.
• The charging ON/OFF is controlled by the
charger’s switch. Do not control the
charging by battery jump wires.
Caution
• Quick charge a battery should be used only
in an emergency.
• Make sure the current and charging time of
above description.
• The battery will be damaged by too much
current or too rush charging.
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16. Electrical Equipment
Current Leakage Test
Current Leakage Inspection
Turn the main switch to OFF position, and
remove the negative cable terminal (-) from the
Battery (-) terminal
battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal (as
shown on left diagram).
Caution
Ground
• In the current leakage test, set the current wire
range at larger scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.
• Do not turn the main switch to ON position
during test.
Caution
• Before conducting the inspection, be sure
that the battery is fully charged. Use a fully Digital meter
charged battery having a voltage larger than
13.0 V. If undercharged, the current changes Ammeter
dramatically.
• While starting the engine, the starter motor
draws large amount of current from the
battery. Thus, do not start the engine with
battery.
Caution
When the probe is reversibly connected, use
a voltmeter having an indication that the
current flows from the positive or the negative
direction and the measurement should be at
zero, ammeter at one direction only.
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16. Electrical Equipment
Caution
Main switch
• Do not use short-circuit cable.
• It is possible to measure the current by
connecting an ammeter between the
battery positive terminal and the cable
position terminal, however, while the starter
motor is activated, the surge current of the
motor draws from the battery may damage
the ammeter. Use the foot lever to start the
engine.
• The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing through.
It may damage the ammeter.
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16. Electrical Equipment
REGULATOR INSPECTION
Remove the rear carrier. (refer to chapter 12,
section 8)
Remove the body cover. (refer to chapter 12,
section 8)
Disconnect the 3P connector of the regulator.
Measurement
Item Standard Value
point
Main switch Battery voltage
R~B
connection wire (ON)
Battery
R~G Battery voltage
connection wire
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16. Electrical Equipment
Ignition System
Ignition System Circuit
Ignition
Spark plug coil
Main switch
Battery
Black Red
Make the following inspection at each terminal of the harness side connector.
ITEM Measure at: result
Green / white-
Crank position sensor 120±10% Ω
blue / yellow
Primary Black / white-red 0.63Ω
Ignition Coil
Black / white-
Secondary 2.9MΩ
high voltage cable
Ignition coil
Remove the luggage box.
Remove the ignition coil connector and the spark
plug cap.
Measure the resistor between the terminals of
ignition coil primary circuit.
Standard value: 0.63Ω
Remove the spark plug cap from the spark plug
wire, and measure the resistor between the spark
plug wire and primary circuit terminal (black/
white).
Standard value: without cap 2.95 MΩ
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16. Electrical Equipment
Replacement
Remove the mounting bolt of ignition coil if
necessary, and replace the ignition coil.
Ignition coil
Spark plug
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16. Electrical Equipment
Starting System
Starting Circuit
Engine switch
Main fuse 20A Battery
Red
Positive (+)
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16. Electrical Equipment
STARTING MOTOR REMOVAL
Remove the luggage. (chapter 12, section 6)
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16. Electrical Equipment
Meter
Removal
Remove the front cover. (chapter 12, section 4)
速度錶導線
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16. Electrical Equipment
Remove the front cover of handlebar. (chapter 12,
Screw x 4
section 3)
Screw x 4
Remove the instrument panel assembly.
(screw x 4)
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16. Electrical Equipment
Lamp/Bulb
Headlamp Bulb Replacement
Remove the front fender. (chapter 12, section 4)
Disconnect the headlamp wire connector, and
then remove the rubber boot.
Press down the bulb spring locker and then
remove the locker with turning it in CCW motion.
Replace the bulb with new one if necessary.
Caution
• Do not touch the bulb surface with fingers
because the bulb will create hot-spot so
that let it be burnt. It has to be package
with cloth or wear glove as installing.
• Wipe the bulb with cloth to prevent from
damaged if the bulb be touched by hands.
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16. Electrical Equipment
Rear Turning Signal Lamp Replacement
Pry out the lamp cover from the preset slot onto
the lower parts of cover.
Check if the bulb is burnt or damage, and replace
it if necessary.
Connect power to check if the bulb has been
installed properly after installation.
Preset slot
Screw x 2
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16. Electrical Equipment
Main switch/Horn
Main Switch
Inspection
Remove front fender. (chapter 12, section 4)
Disconnect main switch leads connector.
Check connector terminals for continuity.
BAT1 BAT2
LOCK
OFF
ON ● ●
Replacement
Remove the handlebar bolt. (bolt x 1)
Bolt x 1
Bolts x 3
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16. Electrical Equipment
Handlebar switch
Remove the rear handlebar cover. (chapter 12,
section 3)
Disconnect the connector of the handlebar
switch.
Check the continuity of follow pins listed below
columns.
Starting switch
ST E
Starting
FREE motor switch
● ●
Headlamp switch
CI TL HL
● ●
● ● ●
Wire Brown/
Black brown
color white
Headlamp switch
High/Low beam switch
Hi/Lo beam switch
LO HL HI PASS
● ●
● ●
PASSING ● ● ● ●
Brown/
Wire color White Blue Black
white
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● ●
FROM R ● ●
N PUSH OFF
FROM L ● ●
Horn switch
● ●
Light
Wire color Gray Orange
blue
Horn
Remove the front fender.
Connect 12V power to the 2 pins on the horn.
Then, the horn should sound.
Replace it if necessary.
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16. Electrical Equipment
Fuel Pump
Removal
Open the seat cushion.
Remove the luggage box assembly. (Chapter 12,
section 6)
Remove the rear carrier. (Chapter 12, section 8)
Remove the left & right side body covers.
(Chapter 12, section 8)
Caution
Do not damage or bend the float arm as
removing.
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17. Emission Control System
Note 1: Clean or replace the air cleaner element more often when the motorcycle is operated on
dusty roads or in the Heavily- polluted environment.
Note 2: Maintenance should be performed more often if the motorcycle is frequently operated in high
speed and after the motorcycle has accumulated a higher mileage.
3. Perform the periodical maintenance in accordance with the periodical maintenance schedule.
(refer to the periodical maintenance schedule)
4. Per the emission control system, strictly limited to be adjusted or replaced arbitrarily (such as
spark plug usage, idle speed adjustment, ignition timing, as carburetor adjustment).
5. Cautions:
• Since the malfunction of ignition, charging, and fuel systems are effected the catalytic converter
very much, please have your motorcycle to SYM authorized dealers or service centers to
conduct adjustment or service.
Thus, it has to replace parts with SYM genuine parts and conduct by SYM authorized dealers or 17
service centers if the motorcycle needs to replace one of the emission control system parts.
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17. Emission Control System
Names Of Mechanisms In The Emission Control System
Four-Stroke engine model:
1. Catalyst converter (C.A.T.A.→Catalyst Converter)
2. Evaporative Emission Control System (E.E.C. → Evaporative Emission Control System)
3. Positive Crankcase Ventilation System (P.C.V. → Positive Crankcase Ventilation System)
Engine refinements:
Four Valves designed combustion chamber, together with optimum compression ratio, ignition timing,
intake and exhaust timing, have all contributed to maximize the intake/exhaust efficiency and
combustion efficiency.
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17. Emission Control System
Fuel Evaporative Emission Control System (E.E.C.)
1. Construction:
• Reduce HC to pollute air.
• To absorber fuel vapor and saving fuel consumption.
Fuel hose
Fuel vapor separator
Fuel cap (closed type)
Fuel tank
Vacuum hose
Injector
Vapor hose
Blow-by
Vapor purge return hose
control solenoid
Air filter
2. Principle of operation:
1. Vapor generated in fuel tank and fuel system through evaporation is contained in the confined
system to prevent it from escaping into the atmosphere, at the same time, the vapor will be
introduced into a charcoal canister where the hydrocarbon in the vapor will be absorbed by
active carbon.
2. When engine is running, the negative pressure of intake opens the purge line, breaks HC off
from active carbon and then sucks it into engine together with air from bottom of the canister.
3. The canister can be used repeatedly without reducing its performance because of the
system's purge function.
3. Trouble Diagnosis:
Fuel can not flow to carburetor
1. No fuel in the fuel tank
2. loosen vacuum hose of the fuel pump
3. plugged hose in the system
4. Cautions:
1. Do not exceed the reed valve of the fuel filler when filling out fuel.
2. Do not have rush acceleration or running in high speed when applying the spare fuel.
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17. Emission Control System
Service Methods for the E.E.C. system
1. Visual check:
1) Check the outside of canister for damage.
2) Check all hoses for breakage.
2. Leak test:
1) Disconnect the P.C.V. 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 100 mmAq into pressure source inlet then plug it. The pressure at the gauge should not
drop to below 10 mmAq within 10 seconds.
Pressure
gauge
To engine vacuum
Pressure
To air filter
source
P.C.V.
2) Apply 100 mmAq into pressure source inlet as engine stopped then plug it. The pressure at
the gauge should not drop to below 10 mmAq within 10 seconds.
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17. Emission Control System
Crankcase blow-by system
1. Construction:
Draining
hose
Injector
Air cleaner
Crankcase
Fresh air
Mixture
Blow-by
Engine oil
Piston
2. Principle of operation:
• Install a separated chamber on cylinder head, and suck the blow-by gas to the fuel vapor
separator by engine vacuum.
• Drill a hole in the air cleaner and install a vapor separator, so that blow-by from crankcase will
flow through a cylinder check valve and then separated by the separator.
• The separated vapor will be sucked into combustion chamber by engine negative pressure to
be burned again instead of discharging into atmosphere. Drain liquidized fuel in the drain pipe
periodically.
3. Service Methods
Visual check
• Remove drain plug to drain the fuel when fuel level on the drain pipe reaches 80 % full.
• Check connecting hose for damage and looseness.
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17. Emission Control System
Ignition System
1. CONSTRUCTION:
Spark plug
ECU
Engine temperature
RPM/TDC
Ignition coil
TDC/crankshaft
position sensor
2. Principle of operation:
The engine is equipped with a computerized ignition control system that collects signals from
TDC/crankshaft position sensor, throttle position sensor, temperature sensor, and intake
temperature as well as pressure sensor. Then, correspondence with engine RPM, this 8-bite chip
of ECU in the system is to control ignition timing properly. The secondary coil creates
25000~30000V high voltage to ignite the spark plug by means of the transistor to open/close
operation of the primary current inside of the computerized system.
3. SPECIFICATION
1) Ignition timing: BTDC 13°/1600RPM
2) Spark plug: NGK CR8E
Gap: 0.7~0.8mm
3) A.C.G.
Pulse coil resistor: 120+10% Ω (G/W-Y)
4) Ignition coil
Primary circuit: 0.63 ± 0.03 Ω (20℃)
5) Battery
Type: TYX9A-BS.8Ah
Capacity: 12V 8Ah
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17. Emission Control System
Inspection Items
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 valve.
Catalyst Converter:
1. Check if exhaust emission is within standard.
2. Remove the exhaust pipe and shake it slightly to check if noise.
Ignition system:
• Spark plug check and replacement.
• High voltage coil check and replacement.
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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)
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18. Wiring Diagram
18
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18. Wiring Diagram
NOTES:
18-2