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Summary of Contents for Sym MAXSYM 400i
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Page 1: Service Manual
MAXSYM 400i SERVICE MANUAL FOREWORD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATION 20120303…
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Page 2
Foreword This service manual contains the technical data of each component inspection and repair for the Sanyang MAXSYM 400i scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. -
Page 3: General Information
How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang MAXSYM 400i scooter. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
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Page 4
Homepage Contents Contents Page Content Index 1-1 ~ 1-16 General Information 2-1 ~ 2-16 Maintenance Information 3-1 ~ 3-6 Lubrication System 4-1 ~ 4-58 Fuel Injection System 5-1 ~ 5-4 Engine Removal 6-1 ~ 6-16 Cylinder Head / Valve 7-1 ~ 7-8 Cylinder / Piston 8-1 ~ 8-14 V-Belt Drive System… -
Page 5
Home page Contents Mechanism Illustration Start / engine stop switch Front winker Luggage box Fuel tank / fuel pump Dimmer / winker / horn seat open / pass switch Main switch Coolant filler cap Taillight / rear winker Headlight Air cleaner Reserve tank Main stand Side stand… -
Page 6: Table Of Contents
Homepage Contents 1. General Information Symbols and Marks····························1-1 Torque Values ···································· 1-10 General Safety ····································1-2 Troubleshooting································· 1-12 Before Servicing·································1-3 Lubrication Points ····························· 1-16 Specifications ·····································1-9 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed. If supplemental information is needed for these symbols and marks, explanations will be added in the text instead of using the symbols or marks.
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Page 7: General Safety
To this chapter contents 1. General Information General Safety Carbon Monoxide Battery Before you start the engine, make sure the place Caution is well ventilated. Never start the engine in an unventilated place. If you have to start the engine ‧…
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Page 8: Before Servicing
To this chapter contents 1. General Information Before Servicing Always use SANYANG genuine parts and Never bend or twist control cables to avoid recommended oil. Using improper parts may unsmooth control and premature worn out. cause damage to or destruction of the vehicle.
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Page 9
To this chapter contents 1. General Information 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. -
Page 10
To this chapter contents 1. General Information Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables. -
Page 11
To this chapter contents 1. General Information When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated… -
Page 12
To this chapter contents 1. General Information Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness. -
Page 13
To this chapter contents 1. General Information Do not let the wire harness been twisted as With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering… -
Page 14: Specifications
To this chapter contents 1. General Information Specifications MAKER SANYANG MODEL LX40A1-6 / F Overall Length Front 2270 mm TELESCOPIC FORK Suspension System Overall Width Rear 825 mm UNlT SWING Overall Height Front 1410 mm 120 / 70-15 56S Tire…
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Page 15: Torque Values
To this chapter contents 1. General Information Torque Values The torque values listed in below are for more important tightening torque values. Please see standard values for those not listed in the table. Standard Torque Values for Reference Type Tighten Torque Type Tighten Torque 5 mm bolt、nut…
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Page 16
To this chapter contents 1. General Information Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle 4.0~5.0 post Lock nut for steering stem 1.0~2.0 Steering top cone race 2.0~3.0 Front wheel axle nut 5.0~7.0 Rear wheel axle nut 11.0~13.0… -
Page 17: Troubleshooting
To this chapter contents 1. General Information Troubleshooting A. Engine cannot be started or difficult to be started Check and adjustment Fault condition Probable causes Press the fuel injector feed pipe and confirm whether there is fuel in the feed pipe 1.
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Page 18
To this chapter contents 1. General Information B. Engine runs sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Accelerate gradually and check engine RPM 1. Clogged air cleaner Engine RPM cannot be 2. -
Page 19
To this chapter contents 1. General Information C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) 1. Incorrect ignition timing Normal Abnormal (malfunction of ECU or AC Check for any air sucked in through the throttle body insulator gasket 1. -
Page 20
To this chapter contents 1. General Information E. CLUTCH AND DRIVING PULLEY FAULT CONDITION PROBABLE CAUSES 1. Worn out or damaged drive belt 2. Damaged movable drive face 3. Damaged driven face spring Engine can be started but the 4. Broken clutch weight vehicle cannot run 5. -
Page 21: Lubrication Points
To this chapter contents 1. General Information Lubrication Points Acceleration cable/ Front & rear brake lever pivot Seat locker Steering stem bearing Front wheel bearing Side stand pivot Main stand pivot Rear wheel bearing 1-16…
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Page 22: Maintenance Information
Home page Contents 2. Maintenance Information Precautions in Operation ···················· 2-1 Cylinder Compression Pressure ········ 2-8 Periodical Maintenance Schedule ······ 2-2 Drive Belt ·············································· 2-8 Engine Oil············································· 2-3 Steering Handle Top Bearing·············· 2-9 Engine Oil Strainer Clean···················· 2-3 Cushion ················································ 2-9 Gear Oil·················································…
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Page 23: Periodical Maintenance Schedule
To this chapter contents 2. Maintenance Information Periodical Maintenance Schedule 1 month 3 months 6 months 1 year item every every every every 1,000KM 5,000KM 10,000KM 15,000KM ☆Air cleaner element ☆Fuel filter ☆Oil filter (paper) First replacement Second replacement at 20,000km at 1000 km Further replacement every 20,000km ☆Oil filter screen…
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Page 24: Engine Oil
To this chapter contents 2. Maintenance Information Engine Oil Turn off engine, and park the vehicle in a flat surface with main stand. Check oil level with oil dipstick Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
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Page 25: Gear Oil
To this chapter contents 2. Maintenance Information Gear Oil Oil inspection bolt Oil level inspection Park the vehicle on a flat surface with main stand. Turn off the engine. Gear Oil Change Remove oil inspection bolt. Remove drain plug and drain oil out. Install the drain plug after draining.
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Page 26: Air Cleaner
To this chapter contents 2. Maintenance Information Primary adjustment is conducted from bottom side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration Adjustment nut operation condition. Air Cleaner Air Cleaner Element Remove 6 screws from the air cleaner cover.
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Page 27: P.c.v. System
To this chapter contents 2. Maintenance Information P.C.V. system Remove the plug from lower of the breather chamber hose. Release the dry internal deposit. Every 5,000 kilometers release oil Caution In releases the breather chamber hose in the transparent section is worthy of looking at as any deposit In the multi-rain or the accelerator in the situation rides, must reduce the maintenance…
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Page 28: Spark Plug
To this chapter contents 2. Maintenance Information Spark Plug Recommended spark plug: CR8E Remove luggage box Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Spark plug gap: 0.6~0.7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary.
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Page 29: Cylinder Compression Pressure
To this chapter contents 2. Maintenance Information Cylinder Compression Pressure Warm up engine. Turn off the engine. Remove luggage box and central cover Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.
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Page 30: Steering Handle Top Bearing
To this chapter contents 2. Maintenance Information Steering Handle Top Bearing Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.
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Page 31: Disk Brake System
To this chapter contents 2. Maintenance Information Disk Brake System Brake System Hose Make sure the brake hoses for corrosion or leaking oil. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
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Page 32
To this chapter contents 2. Maintenance Information Brake Lining Wear Lining The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limitation mark closed to the edge of brake disc. Caution It is not necessary to remove brake hose when replacing the brake lining. -
Page 33: Brake Light Switch / Start Switch
To this chapter contents 2. Maintenance Information Brake Light Switch / Start Switch Stop switch The brake light switch is to light up brake lamp as brake applied. Make sure that starter motor can be operated only under brake applying. Wheel / Tire Caution Tire pressure check should be done as cold…
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Page 34: Battery
To this chapter contents 2. Maintenance Information Battery Open the inner box lid. Loosen screw & remove the battery cover Battery cable remove： ： ： ： Disconnect the cable negative terminal (-), then the cable positive terminal (+) Remove the battery from the motorcycle.。 If there is some rust on battery posts, clean it with steel brush Install the battery in the reverse procedures of…
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Page 35: Special Tools List
To this chapter contents 2. Maintenance Information Special Tools List Valve rocker arm shaft L/Cover Radial Ball Brg 6006 Valve cotter remove & NAME NAME NAME disassemble tool Drive assembly tool SYM-1445100-01 SYM-9615010-REA 6006 SYM-1471110/20 Clutch spring compressor Tappet adjusting wrench Oil seal driver 45*65*10 NAME NAME…
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Page 36
To this chapter contents 2. Maintenance Information Driven pulley bearing installer Drive shaft bearing installer Counter shaft bearing driver NAME NAME NAME SYM-9100600-L4A DPB SYM-9100420-A6305 SYM-9610000-L4A N1820 Clutch nut wrench Universal holder NAME NAME NAME AC.G. FLYWHEEL PULLER SYM-9020200 SYM-2210100 SYM-3110000-HMA NAME Final shaft bearing installer… -
Page 37
To this chapter contents 2. Maintenance Information Crankshaft bearing install / Crankshaft bearing install tool Fuel pressure gauge NAME NAME NAME remove tool SYM-9100310-L4A SYM-9100310-L4A SYM-HT07010 NAME Vacuum pressure gauge NAME Cylinder pressure gauge NAME Vehicle circuit test tool kit SYM-HT07011 SYM-HT07008 SYM-HE170008… -
Page 38: Lubrication System
Contents Homepage 3. Lubrication System Precautions in Operations … 3-1 Oil Pump Inspection…… 3-4 Troubleshooting……3-1 Oil Pump Reassembly….3-4 Engine Oil ……..3-2 Oil Pump Installation….. 3-5 Oil Pump Removal ……3-3 Gear Oil ………. 3-6 Oil Pump Disassembly ….3-3 Precautions in Operation ‧…
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Page 39
To this chapter contents 3. Lubrication System Engine Oil Turn off engine, and park the vehicle in a flat surface with main stand. Check oil level with oil dipstick Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. -
Page 40: Oil Pump Removal
To this chapter contents 3. Lubrication System Oil Pump Removal Remove generator and starting gear. Remove the oil separator (bolt x 2). Oil separator Remove snap ring and take out oil pump driving chain and sprocket. Torque value: 0.8~1.2 Kg-m Make sure that pump shaft can be rotated freely.
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Page 41: Oil Pump Inspection
To this chapter contents 3. Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Reassembly…
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Page 42: Oil Pump Installation
To this chapter contents 3. Lubrication System Install the oil pump cover and fixing pin properly SCREW× × × × 1 Tighten screw Make sure that oil pump shaft can be rotated freely. Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value: 0.8~1.2 Kg-m Make sure that oil pump shaft can be rotated freely.
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Page 43
To this chapter contents 3. Lubrication System Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off the engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measurement device. -
Page 44: Fuel Injection System
Home page Contents 4. Fuel Injection System EFi System Components····················· 4-1 Integrated Troubleshooting Procedure ······························································· 4-36 EFi System Vehicle Configuration ····· 4-2 Air Cleaner ············································ 4-39 EFi System Operation ························· 4-3 EFi System Diagnosis Methods ·········· 4-40 EFi System Introduction······················ 4-4 Check Light Flault Codes Differentiation Fuel System··········································…
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Page 45: Efi System Vehicle Configuration
To this chapter contents 4. Fuel Injection System EFi System Vehicle Configuration Right Injector MAP Sensor TW Sensor Sensor Left EFi Check light Rollover sensor Diagnostic coupler TA Sensor AISV Fuel pump Test switch…
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Page 46: Efi System Operation
To this chapter contents 4. Fuel Injection System EFi System Operation Crankshaft Position Sensor Manifold Absolute Pressure Sensor INJECTOR Throttle Position Sensor IGN COIL (ECU) Engine Coolant Temperature Sensor Engine Control Unit FUEL PUMP Sensor LAMBDA CHECK LIGHT Roll Over Sensor Air Injection AISV Solenoid Valve…
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Page 47: Efi System Introduction
To this chapter contents 4. Fuel Injection System EFi System Introduction Based on 4-stroke SOHC engine, displacement 400 c.c. electronically controlled fuel injection, fuel vapor absorbed by activated carbon canister. The engine burns off the blow-by fuel-gas in the crankcase through the fuel-air separating device.
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Page 48: Fuel System
To this chapter contents 4. Fuel Injection System Fuel System Fuel pump Injector Fuel pump relay Power relay Battery System Description After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the fuel pump operate.
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Page 49: Ignition System
To this chapter contents 4. Fuel Injection System Ignition System Intake air temperature Manifold absolute pressure Engine coolant temperature Throttle position Ignition coil Oxygen content ACG/ Flywheel Gear (23+1 Long teeth) Crankshaft position Power relay sensor Battery REG. REC. Principle The computer programmed ignition system receives the signals from the Crankshaft position sensor, Throttle position sensor, O Sensor, MAP sensor, Intake air temperature sensor, Engine coolant…
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Page 50: Sensors / Drivers
To this chapter contents 4. Fuel Injection System Sensors / Drivers Crankshaft Position Sensor (CPS) Crankshaft position sensor Flywheel Description The magnetic field type sensor generates a voltage signal to calculate engine speed with ACG gear ring (18-1 tooth). There is one tooth every 20 degree on the gear ring. But, one of the teeth is blank for the TDC calculating base.
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Page 51
To this chapter contents 4. Fuel Injection System Manifold Absolute Pressure (MAP) / Engine Water Temperature (TW) / Intake Air Temperature (TA) Sensors MAP Sensor TA Sensor TW Sensor Engine water temperature / Intake air temperature sensor: Use the variable resistor of negative temperature coefficient (thermistor) to sense the outside temperature. The electrical resistance value goes down when the temperature rises. -
Page 52
To this chapter contents 4. Fuel Injection System Sensor Power relay Sensor Battery Sensor Ceramics tube Electrode Emissions Atmosphere Rich ← 14.7 → Lean Function Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts the air-fuel ratio by changing the fuel injection time. -
Page 53
To this chapter contents 4. Fuel Injection System Throttle Position Sensor (TPS) Battery U 5V TPS output voltage Throttle valve opening angle Basic Principle TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value change, determining the throttle position. -
Page 54
To this chapter contents 4. Fuel Injection System Idle Speed Control Valve (ISC stepper motor) Battery Step Function ECU controls ISC stepper motor to adjust the bypass intake air quantity and stabilized the idle speed. 4-11… -
Page 55
To this chapter contents 4. Fuel Injection System Air Injection Solenoid Valve (AISV) Function AISV introduces appropriate air quantity to reduce pollutant emission. Basic Principle When the engine RPM and throttle opening are higher than the default value, ECU controls AISV opening or closure. -
Page 56: Precautions In Operation
To this chapter contents 4. Fuel Injection System Precautions in Operation General information Warning Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and flame is ● strictly prohibited when working with gasoline. Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to prevent ●…
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Page 57: Efi System Components Description
To this chapter contents 4. Fuel Injection System EFi System Components Description ECU (Electronic Control Unit) Functional Description: Powered by DC 8~16V, and has 33-pin socket on the unit. ● The hardware component consists of a 16-bit microcomputer that is its ●…
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Page 58
To this chapter contents 4. Fuel Injection System Throttle Body Functional Description: Throttle body is the inlet air flow regulating device (similar to the ● carburetor). Throttle valve pivot drives the throttle position sensor synchronously ● and makes ECU detect the throttle opening immediately. Throttle valve positioning screw has been adjusted and marked on the ●… -
Page 59: Map Sensor
To this chapter contents 4. Fuel Injection System MAP Sensor Functional Description: Powered by 5V DC from ECU. It has 3-pin sockets on the sensor. One ● terminal is for power, and 1 terminal are for signal output. And, the rest one is for ground.
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Page 60
To this chapter contents 4. Fuel Injection System TA Sensor Functional Description: Use ECU DC 5V power supply provided, has the two-pin coupler, a voltage output pin; another one for a grounding pin. Its main component is a negative temperature coefficient (resistance ●… -
Page 61
To this chapter contents 4. Fuel Injection System Functional Description: Use ECU provided DC 5V power supply, has the three-pin coupler, one ● for the power supply pin; one for a voltage output pin; one for a grounding pin. Its main component is a sophisticated type of variable resistor. ●… -
Page 62
To this chapter contents 4. Fuel Injection System Also, can be used for diagnosis tool confirm to the throttle output signal. 1. Connected to the «diagnosis tool», and open the main switch, but not to start engine. 2. «Diagnosis tool» screen switches to a «data analysis (01 / 03)» screen. 3. -
Page 63
To this chapter contents 4. Fuel Injection System TW Sensor Functional Description: Powered by 5V DC from ECU. It has the two-pin socket on the sensor. ● One terminal is for power output, and 1 terminal are for ground. Its main component is a negative temperature coefficient (resistance ●… -
Page 64
To this chapter contents 4. Fuel Injection System Sensor Functional Description: Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply ● pins for heater; for a heater control pin; signal for a grounding pin; O for a signal pin. -
Page 65
To this chapter contents 4. Fuel Injection System 1. Used the diagnosis tool to confirm of O sensor work situations: Connected the «diagnosis tool» to diagnosis coupler and open the ● main switch to start the engine. Engine to be completely warm-up (idling state operation «5 minutes» ●… -
Page 66: Roll Over Sensor
To this chapter contents 4. Fuel Injection System Roll over sensor Functional Description: Control power of the power relay coil, has the three-pin socket. ● When vehicles tilt angle greater than 65 degrees, roll over sensor will ● be the implementation of ECU system power off. At this point once again to restart the engine, the need to re-open a main switch.
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Page 67
To this chapter contents 4. Fuel Injection System ISC (stepper motor)： ： ： ： Functional Description: Use ECU provided power, has the four-pin socket. ● 4-pin coupler for the two motor coils of the power supply and ● grounding wire, grounding ECU power through the control and management of the stepper motor actuators. -
Page 68: Fuel Pump
To this chapter contents 4. Fuel Injection System Fuel Pump Functional Description: Powered by DC 8~16V, and has four-pin socket 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.
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Page 69
To this chapter contents 4. Fuel Injection System Testing Procedures 3: Fuel pressure measurement: Use fuel pressure gauge, connected in series between the injector ● and the fuel tank. Cautions In the implementation of the fuel pressure measurement, will go to ●… -
Page 70: Fuel Injector
To this chapter contents 4. Fuel Injection System Fuel Injector Functional Description: Powered by DC 8~16V, and has two-pin socket on the injector. ● Its major component is the solenoid valve of high resistance driven by ● electronic current. The two terminals are connected to power source and ground ●…
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Page 71
To this chapter contents 4. Fuel Injection System Transistor ignition coil Functional Description: Use 8 ~ 16V DC power supply, has the two-pin socket. ● Two-pin socket for the power supply and grounding. Its main ● components for the high conversion ratio transformer. Through computer programs when the ignition is controlled, from ●… -
Page 72
To this chapter contents 4. Fuel Injection System AISV Functional Description: Control power, has two-pin socket, one for the power supply pin, one ● for grounding pin. Secondary air injection solenoid valve at the Idle (3500 rpm below) ● actuator. At Idling, ECU control solenoid valve by the grounding circuit to be ●… -
Page 73: Efi System Circuit
To this chapter contents 4. Fuel Injection System EFi System Circuit 4-30…
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Page 74: Ecu Pin Configuration
To this chapter contents 4. Fuel Injection System ECU Pin Configuration (ON ECU) ECU Pin Note Pin NO. Pin code Wire color Note IGNITION POWER LOGIC GROUND HEGO O2 SENSOR SENSOR GROUND W/BR THROTTLE POSITION SENSOR SENSOR POWER OUTPUT (+5V) BATT BATTERY POWER GROUND1…
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Page 75: Troubleshooting
To this chapter contents 4. Fuel Injection System Troubleshooting EFi Circuit inspection Main switch on Bulbs broken? Fuse broken? Battery voltage is too low? Warning lights extinguished after 2 seconds? ECU Power line bad contact? Poor contact the main power switch? ECU fault？…
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Page 76
To this chapter contents 4. Fuel Injection System Can not Start the engine or difficult to start inspection Difficulties or can not to start engine Warning lights extinguished after 2 Inspection process in accordance with seconds? circuit inspection 1. Use diagnosis tool to view EMS fault content Display warning lights Fault Code? -
Page 77
To this chapter contents 4. Fuel Injection System Idle flameout diagnosis Idle flameout Throttle line is not too jammed to revert to full closure? 1. Link diagnosis tool to view EFI fault content 2. In accordance with Troubleshooting procedures on troubleshooting Idle CO value is set beyond the scope of (1.5% ~… -
Page 78
To this chapter contents 4. Fuel Injection System CO value revised anomaly Sensor equipped with the system, in principle, not adjusted CO LLLvalue; such as CO value deviated from the normal range, check O Sensor and other agencies anomaly. Idle flameout Throttle line is not too jammed to revert to full closure? Link diagnosis tool to view EFI fault… -
Page 79: Integrated Troubleshooting Procedure
To this chapter contents 4. Fuel Injection System Integrated Troubleshooting Procedure Checking, Detection of Fault status Fault reasons Parts specifications adjusting determination maintenance projects Project and steps Battery Use meter direct Battery voltage Battery electricity Diagnosis tool ● ● ● ●…
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Page 80
To this chapter contents 4. Fuel Injection System Continued from previous page Closed-loop Observation O2 O2 sensor O2 sensor fault O2 sensor ● ● ● ● systems for senslor voltage voltage is ECU fault voltage beating ● mobility changes (Standed maintained in a specifications: motorcycle so that… -
Page 81
To this chapter contents 4. Fuel Injection System Remove fuel pump/fuel unit Remove side cover. Remove rear carrier Remove rear body cover. Remove floor panel. Remove under cover. (Refer to chapter 14) Fuel pump Remove fuel pump lines coupler. coupler Release the fuel tube folder, removed the fuel tube. -
Page 82: Air Cleaner
To this chapter contents 4. Fuel Injection System Air Cleaner Bolt × 6 Air catheter fixed bolts × 1 Clean air cleaner element Remove air cleaner cover (bolt×8). Remove air cleaner filter (bolt×6). Use compressed air to remove the adhesion of dirt, if not too much dirt cleared, please new replacement.
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Page 83: Efi System Diagnosis Methods
To this chapter contents 4. Fuel Injection System EFi System Diagnosis Methods When the motorcycle injection system in the wrong signal, causing abnormal functioning of the engine or can not start engine, warning light at the meter will be lighting, to inform drivers to carry out maintenance. Overhaul, the diagnosis tool can be used for troubleshooting (refer to diagnosis tool use guide), or manually by the meter warning light inspection revealed that the fault codes (refer to checking signal fault codes discriminate method), the two methods for maintenance.
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Page 84: Check Light Flault Codes Differentiation
To this chapter contents 4. Fuel Injection System Check Light Fault Codes Differentiation Check light flashing mode If problem without diagnosis tool to be detected, it can be cross-access the test switch coupler, the motorcycle from the CHK lights flashing signal interpretation, and then the basis for the diagnosis of dynamic information tables on the priorities of light, and prompts you to the motorcycle to the emergence of some warning, or FLASH CODE is to determine what kind of fault, and exclusion.
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Page 85: Fault Code And Sensors Table
To this chapter contents 4. Fuel Injection System Fault Code and Sensors Table Fault Fault Description Parts Inspection codes Throttle position sensor fault TP Sensor and wire 0120 0105 Manifold absolute pressure sensor fault MAP sensor and wire 0115 Engine temperature sensor fault (water) TW Sensor and wire 0195 Engine oil temperature sensor fault (oil)
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Page 86: Fault Code And Check Light Flashing Lighting Identification Table
To this chapter contents 4. Fuel Injection System Fault Code and Check Light Flashing Lighting Identification Table Fault Check Check light flashing Fault Description Parts Inspection codes light state Throttle position sensor fault Lighting Throttle position sensor and wire long 0，short 6 0120 Fault detection procedures Please refer to the «EFI System components description»…
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Page 87: Efi System Diagnostic Tool — V70
To this chapter contents 4. Fuel Injection System EFi System Diagnostic Tool — V70 Cable connector monitor Link cable Information transmission indicator Function set Button Button to turn the pages, and numerical adjustment Leave Executive button Function button Digital button Software cartridge Software cartridge slots…
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Page 88: Diagnostic Tool Note
To this chapter contents 4. Fuel Injection System Diagnostic Tool Use Note Diagnosis of connectivity 1. For the diagnostic tool coupler access to the motorcycle injection system diagnostic signal coupler. 2. main switch ON. 3. Open the diagnosis left power switch, which turn on the LCD screen, the screen brightness adjustment knob to the appropriate brightness.
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Page 89
To this chapter contents 4. Fuel Injection System Options main functional areas: 1. ECU ID 2. DATA STREAM 3. FREEZED DATA 4. TROUBLE CODE 5. ERASE TB CODE 6. CO ADAPTION Use «▲» «▼» button, select mobile anti-white subtitles implementation of the project, and then press the «ENTER»… -
Page 90
To this chapter contents 4. Fuel Injection System 1. ECU ID In the directory functions used «▲» «▼» button, select ECU ID project, press the «ENTER» buttom to the implementation of information systems function. ECU ID containing two functions: 1-1. ECU ID Datas 1-2. -
Page 91
To this chapter contents 4. Fuel Injection System 1-2. ECU Pin Assign Use «▲» «▼» button, select the ECU pin project, and press the «ENTER» button to the implementation of the ECU pin functions. ECU pin assign total of 5 pages that can be used «◄ left» and «right ►» button, view the page note. -
Page 92
To this chapter contents 4. Fuel Injection System 2. DATA STREAM In the directory functions used «▲» «▼» button, select «DATA STREAM» project, press the «ENTER» key to the implementation. A total of 3 pages, are able to use «◄ left» and «right ►» button, view injection system information. On the any screen, press the «EXIT»… -
Page 93
To this chapter contents 4. Fuel Injection System Data stream (1/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: Engine SPD— RPM (Idle:1550~1750) →Engine idle speed ● FAULT NO.——— (Normal:0) →Fault code number ●… -
Page 94
To this chapter contents 4. Fuel Injection System Data stream (2/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: BARO———— kPa (Above 98kPa) →Atmospheric pressure ● Intake Air———- ºC (Outside Temp.) →Intake air temperature ●… -
Page 95
To this chapter contents 4. Fuel Injection System Data stream (3/3) The screen showed the ECU captured by the engine of the state immediately. The following data for the benchmark idling state: LEARNED STEP————— (Set by ECU) →Idle Air Control Valve stepper motor learning ●… -
Page 96
To this chapter contents 4. Fuel Injection System 3. FREEZED DATA Objective: When a sensor fault, the EMS system will record all the parameters of fault signals, in order to facilitate fault diagnosis. In the directory functions used «▲» «▼» button, select «FREEZED DATA» project, press the «ENTER» key to the implementation. -
Page 97
To this chapter contents 4. Fuel Injection System 4. TROUBLE CODE In the functional directory select «TROUBLE CODE» project, press the «ENTER» button implementation, the message began to read fault. Fault Code: electronic injection system that had happened fault of the message (whether or not completion of repair). -
Page 98
To this chapter contents 4. Fuel Injection System 5. ERASE TB CODE In the directory functions used «▲» «▼» button, select «ERASE TB CODE» project, press the «ENTER» key to the implementation. Conditions: The main switch «ON», or in the engine running state, the fault code can be removed. Fault code removed, namely showing the «ERASE TB SUCC.!». -
Page 99
To this chapter contents 4. Fuel Injection System 6. CO ADAPTION In the directory functions used «▲» «▼» button, select «CO ADAPTION» project, press the «ENTER» button into the CO adjustment screen. Use «◄ left» and «right ►» or «▲» «▼» button, CO value can be adjusted. CO ADAPT: CO adjusted value. -
Page 100: Troubleshooting Table
To this chapter contents 4. Fuel Injection System Troubleshooting Table Test items Comprehensive testing program Parts closed- Throttle Engine Fault Power Fuel Ignition Engine Injection loop Abnormal Code position temp. control voltage press. state vacuum state phenomena Detection sensor sensor system Can’t start Start…
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Page 101: Comprehensive Maintenance List
To this chapter contents 4. Fuel Injection System Comprehensive Maintenance List Maintenance Testing Procedures Test items Determine benchmarks Fault reasons Project Power and ● Use meter direct ● Battery voltage ● Battery voltage = 10V Above ● Battery electricity measurement battery voltage ●…
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Page 102: Engine Removal
Homepage Contents 5. Engine Removal Precautions in Operation ……5-1 Engine Installation ……5-4 Removal of Engine………5-2 Precautions in Operation The engine has to be supported with special service tools that can be lifted or adjustable. The following parts can be serviced as engine mounted on frame. Carburetor.
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Page 103
To this chapter contents 5. Engine Removal Removal of Engine Disconnect the seat dampers. Remove the air box cover. Disconnect the air temperature sensor coupler. Air temperature sensor coupler Remove the air box. Disconnect the starter motor wire. Starter motor wire Remove the spark plug cap. -
Page 104
To this chapter contents 5. Engine Removal Remove fuel pipe, vacuum tube and throttle valve wire from the throttle body. Disconnect the EFi system coupler. Remove water hose from water pump. Water hose Remove the thermo-sensor wires. Water pump Remove the muffler (3 bolts, 2 nuts). Bolt X3… -
Page 105
To this chapter contents 5. Engine Removal Remove the parking brake cable. Rear right cushion bolt Remove the rear brake caliper (2 bolts). Caution Do not operate brake lever after the caliper is removed to avoid clipping the brake pad. Remove the mounting bolt of rear right cushion. -
Page 106: Cylinder Head / Valve
Home page Contents . Cylinder Head / Valve Mechanism Diagram····························6-1 Valve Stem Replacement ··················· 6-10 Precautions in Operation ····················6-2 Valve Seat Inspection and Service ···· 6-11 Troubleshooting ··································6-3 Cylinder Head Reassembly················ 6-13 Cylinder Head Removal·······················6-4 Cylinder Head Installation·················· 6-14 Cylinder Head Disassembly················6-6 Valve Clearance Adjustment··············…
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Page 107: Precautions In Operation
To this chapter contents 6. Cylinder Head / Valve Precautions in Operation This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Remove the engine from the frame before repairing the cylinder head. Specification Item Standard…
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Page 108: Troubleshooting
To this chapter contents . Cylinder Head / Valve Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1.
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Page 109: Cylinder Head Removal
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Removal Remove engine. (Refer to chapter 5) Tensioner bolts Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.
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Page 110
To this chapter contents . Cylinder Head / Valve Remove the side cover mounting blots of cylinder 3 bolts head, and then take out the side cover. Remove left crankcase cover, and turn the Timing mark Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. -
Page 111: Cylinder Head Disassembly
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Disassembly Cam shaft setting plate 1 bolt Remove cam shaft setting plate (1 bolt). Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller SYM-1445100 Rocker arm shaft and cam shaft puller Cam shafts…
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Page 112
To this chapter contents . Cylinder Head / Valve Remove valve cotters, spring retainers, springs Inlet valve Inner spring Spring retainer and valves. Exhaust valve Cotter Outer spring Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. -
Page 113: Cylinder Head Inspection
To this chapter contents 6. Cylinder Head / Valve Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.05 mm Camshaft Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm…
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Page 114
To this chapter contents . Cylinder Head / Valve Valve spring free length Measure the free length of intake and exhaust valve springs. Service limit: Inner spring 35.20 mm Outer spring 36.90 mm Valve stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure &… -
Page 115: Valve Stem Replacement
To this chapter contents 6. Cylinder Head / Valve Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated Valve guide driver 5.0mm plate or toaster. Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it.
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Page 116: Valve Seat Inspection And Service
To this chapter contents . Cylinder Head / Valve Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.
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Page 117
To this chapter contents 6. Cylinder Head / Valve Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. -
Page 118: Cylinder Head Reassembly
To this chapter contents . Cylinder Head / Valve After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Valve spring retainer Lubricate valve stem with engine oil, and then Valve stem seal…
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Page 119: Cylinder Head Installation
To this chapter contents 6. Cylinder Head / Valve Install camshaft into cylinder head. 2 bolts Cam shaft setting plate Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head.
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Page 120
To this chapter contents . Cylinder Head / Valve Install cylinder head side cover (3 bolts). 3 bolts Tensioner bolts Install thermostat (2 bolts). Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt. -
Page 121: Valve Clearance Adjustment
To this chapter contents 6. Cylinder Head / Valve Valve Clearance Adjustment 4 bolts Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover. Remove the cylinder head side cover. 3 bolts Timing mark Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position.
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Page 122
Home page Contents 7. Cylinder / Piston Mechanism Diagram ···························· 7-1 Piston Ring Installation ······················· 7-6 Precautions in Operation ···················· 7-2 Piston Installation ································ 7-7 Troubleshooting··································· 7-2 Cylinder Installation····························· 7-7 Cylinder / Piston Removal··················· 7-3 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m 1.2~1.6kgf-m 1.0~1.4kgf-m… -
Page 123: Precautions In Operation
To this chapter contents 7. Cylinder / Piston Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Unit： ： ： ： mm Specification LM25W5 LM30W Item Standard Limit Standard Limit I.D.
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Page 124: Cylinder / Piston Removal
To this chapter contents 7. Cylinder / Piston Cylinder / Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
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Page 125
To this chapter contents 7. Cylinder / Piston Measure the cylinder upper surface for warpage. Service limit: 0.05 mm Measure the clearance between piston rings and ring grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. -
Page 126
To this chapter contents 7. Cylinder / Piston Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole. -
Page 127: Piston Ring Installation
To this chapter contents 7. Cylinder / Piston Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
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Page 128: Piston Installation
To this chapter contents 7. Cylinder / Piston Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve. Install new piston pin clip. Clip end gap Caution Do not let the opening of piston pin clip align with the piston cutout.
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Page 129
To this chapter contents 7. Cylinder / Piston Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged. -
Page 130: V-Belt Drive System
Home page Contents . V-Belt Drive System Mechanism Diagram···························· 8-1 Drive Belt·············································· 8-5 Precautions in Operation ···················· 8-2 Drive Face ············································ 8-7 Troubleshooting ·································· 8-2 Clutch Outer / Driven Pulley ··············· 8-10 Left Crankcase Cover·························· 8-3 Mechanism Diagram 8.5~10.5kgf-m 6.0~7.0kgf-m 0.7~1.1kgf-m 0.7~1.1kgf-m…
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Page 131: Precautions In Operation
To this chapter contents 8. V-Belt Drive System Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Drive belt and drive pulley must be free of grease. Specification Item Standard value Limit Drive belt width 24.000 mm…
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Page 132: Left Crankcase Cover
To this chapter contents . V-Belt Drive System Left Crankcase Cover Left crankcase cover removal Loosen 4 bolts from left side crank out cover & remove it. Remove left crankcase cover. (8 bolts) Remove 2 dowel pin and gasket. 8 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
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Page 133
To this chapter contents 8. V-Belt Drive System Left crankcase cover inspection 2 bolts Remove 2 bolts to remove left crankcase cover bearing setting plate. Check bearing on left crankcase cover. Rotate bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly. -
Page 134: Drive Belt
To this chapter contents . V-Belt Drive System Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool： ： ： ： Universal holder Bearing stay collar Universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
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Page 135
To this chapter contents 8. V-Belt Drive System Installation Caution Pull out driven face to avoid it closing. Cannot oppress friction plate comp in order to Driven face avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. -
Page 136: Drive Face
To this chapter contents . V-Belt Drive System Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Movable drive face Remove movable drive face comp and drive face boss from crankshaft.
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Page 137
To this chapter contents 8. V-Belt Drive System Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. -
Page 138
To this chapter contents . V-Belt Drive System With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Install movable drive face comp. -
Page 139: Clutch Outer / Driven Pulley
To this chapter contents 8. V-Belt Drive System Clutch Outer / Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily.
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Page 140
To this chapter contents . V-Belt Drive System Clutch weight Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.400 mm Free length Driven pulley… -
Page 141
To this chapter contents 8. V-Belt Drive System Clutch weight Replacement Remove snap ring and washer, and then remove Spring Driving plate clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity. -
Page 142
To this chapter contents . V-Belt Drive System Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Caution Clipper If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. -
Page 143
To this chapter contents 8. V-Belt Drive System Installation of Clutch Outer/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face. -
Page 144: Final Drive Mechanism
Homepage Contents 9. Final Drive Mechanism Mechanism Diagram ……9-1 Final Drive Mechanism Inspection ..9-3 Precautions in Operation ….9-2 Bearing Replacement ……9-4 Troubleshooting……..9-2 Final Drive Mechanism Reassembly ..9-6 Final Drive Mechanism Disassembly . 9-3 Mechanism Diagram Radial ball bearing 6206 UU Oil seal 45*65*10 Radial ball bearing 6204 Final shaft…
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Page 145: Precautions In Operation
To this chapter contents 9. Final Drive Mechanism Precautions in Operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4 kg-m Tools Special tools Bearing (6203/6004UZ) driver Bearing (6204) driver…
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Page 146: Final Drive Mechanism Disassembly
To this chapter contents 9. Final Drive Mechanism Final Drive Mechanism Disassembly Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover. Remove gasket and dowel pin. 7 bolts Remove drive shaft. Remove final driving gear and shaft.
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Page 147: Bearing Replacement
To this chapter contents 9. Final Drive Mechanism Check bearings on gear box. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
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Page 148
To this chapter contents 9. Final Drive Mechanism Remove oil seal, and then remove final shaft bearing from left crankcase. Install new final shaft bearing. Press the bearing in with hydraulic presser. Tool: Bearing (6203/6004UZ) driver (27*42*7) driver (27*42*7) driver (27*42*7) driver (27*42*7) driver Oil seal… -
Page 149: Final Drive Mechanism Reassembly
To this chapter contents 9. Final Drive Mechanism Install a new final shaft bearing onto gear box cover. Tool: Bearing (6203/6004UZ) driver Press the bearing in with hydraulic presser. Install the driving shaft onto gear box cover and then place it to proper position. Apply with grease onto new oil seal lip, and then install the oil seal.
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Page 150
To this chapter contents 9. Final Drive Mechanism Install dowel pin and new gasket. dowel Gasket Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4 kgf-m Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase. -
Page 151
To this chapter contents 9. Final Drive Mechanism NOTE:… -
Page 152: Ac Generator / Starting Clutch
Homepage Contents 10. AC Generator / Starting Clutch Mechanism Diagram ….. 10-1 Flywheel Removal……10-3 Precautions in Operation ….. 10-2 Flywheel Installation……10-7 Right Crankcase Cover Removal. 10-3 A.C.G. Set Installation ….10-7 A.C.G. Set Removal……. 10-3 Right Crankcase Installation..10-7 Mechanism Diagram 0.7~1.1 kgf-m 0.7~1.1 kgf-m 8.5~10.5 kgf-m 2.8~3.2 kgf-m…
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Page 153: Precautions In Operation
To this chapter contents 10. AC Generator / Starting Clutch Precautions in Operation ‧ Refer to chapter 5: Engine removal and installation ‧ Refer to chapter 16: The troubleshooting and inspection of alternator ‧ Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm)
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Page 154: Right Crankcase Cover Removal
To this chapter contents 10. AC Generator / Starting Clutch Right Crankcase Cover Removal 12 bolts Remove 12 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. A.C.G. Set Removal 2 screws Remove 2 screws from pulse generator and then remove it.
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Page 155: Flywheel Installation
To this chapter contents 10. AC Generator / Starting Clutch Flywheel Installation Insert the pin onto crankshaft. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 5.0~6.0 kg-m Tool: Flywheel holder…
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Page 156: Crankshaft / Crankcase
Homepage Contents 11. Crankshaft / Crankcase Mechanism Diagram …… 11-1 Crankshaft bearing replacement .. 11-5 Precautions in Operation ….11-2 Crankshaft bearing installation ..11-5 Troubleshooting……11-2 Crankcase Assembly …… 11-6 Crankcase Disassembly ….11-3 Mechanism Diagram 0.7~1.1 kgf-m 6.0~7.0 kgf-m 2.0~2.4 kgf-m 1.0~2.0 kgf-m 1.0~1.4 kgf-m…
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Page 157: Precautions In Operation
To this chapter contents 11. Crankshaft / Crankcase Precautions in Operation • This Section concerns disassembly of the crankcase for repair purpose. • Remove following components before disassembling crankcase. ─Engine Section 5 －Cylinder head Section 6 －Cylinder and piston Section 7 －Drive pulley and driven pulley Section 8 －AC generator/Start driven gear…
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Page 158
To this chapter contents 11. Crankshaft / Crankcase Tensioner Crankcase Disassembly Remove the cam chain. Loosen the bolt and remove the tensioner. Remove the water pump shaft locknut. Cam chain Water pump shaft locknut Remove the oil separator (bolt x 2). boltsX2 Remove the oil pump drive sprocket, driven Oil pump drive sprocket… -
Page 159
To this chapter contents 11. Crankshaft / Crankcase Remove the left crankcase bolts (bolt x 11). Bolt x 11 Remove the right crankcase from the left crankcase. Remove the crankshaft and balancer shaft from the left crankcase. Check the main bearing on the crankcase for any wear. -
Page 160: Crankshaft Bearing Replacement
To this chapter contents 11. Crankshaft / Crankcase Crankshaft bearing replacement Align the main bearing remover with the main bearing. Fix the remover with the universal holder and press out the main bearing. Crankshaft bearing installation Use the crankshaft main bearing holder to fasten the upper and lower main bearing.
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Page 161: Crankcase Assembly
To this chapter contents 11. Crankshaft / Crankcase Crankcase assembly Install the crankshaft and balancer shaft to the left crankcase. Marks on the crankshaft and The marks on the crankshaft and balancer shaft balancer shaft must be aligned. Assemble the right crankcase to the left crankcase.
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Page 162
To this chapter contents 11. Crankshaft / Crankcase Install the oil separator (bolt x2). Tighten the bolts on the left crankcase ( bolt x 11). Bolt x 11 Tighten the water pump shaft locknut. Install the cam chain and tensioner. 11-7… -
Page 163
To this chapter contents 11. Crankshaft / Crankcase NOTE: 11-8… -
Page 164: Cooling System
Home page Contents 12. Cooling System Mechanism Diagram…… 12-1 Radiator ……….12-5 Precautions in Operation ….12-2 Steps to fill coolant after engine service …………12-7 Troubleshooting ……12-3 System Test ……..12-4 Mechanism Diagram Reserve tank inlet pipe Reserve tank Radiator filler cap Thermo switch (fan) Radiator Cooling fan…
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Page 165: Technical Specification
To this chapter contents 12. Cooling System Precautions in Operation Warning: ˙While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.
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Page 166
To this chapter contents 12. Cooling System Troubleshooting The engine temperature is too high The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to close. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. -
Page 167
To this chapter contents 12. Cooling System System Test Warning Never attempt to carry out service work on the cooling system unless the engine is completely cooled down, otherwise, you may get scalded. Remove the reserve tank cap cover, and then remove tank cap. -
Page 168
To this chapter contents 12. Cooling System Check reserve tank Open the inner box lid. Check the liquid level in the tank. Add coolant to proper level if necessary. Caution Add too much coolant in the reserve tank might cause overflow when the temperature increased. -
Page 169
To this chapter contents 12. Cooling System Thermo switch coupler Disconnect the couplers for the thermo switch and fan motor. Remove engine coolant inlet pipe, reserve tank inlet pipe and radiator inlet pipe. Engine coolant. Remove reserve tank coolant inlet pipe. Remove the radiator and the cooling fun. -
Page 170
To this chapter contents 12. Cooling System Technical Data Valve begins to open 71 ~ 80℃ Valve stroke 3.5 ~ 4.5 mm at 80℃ Installation Install in reverse order of removal. Caution Always use a new oil ring and apply a coat of grease on it before installation. -
Page 171
To this chapter contents 12. Cooling System Remove the engine circulation pipe, and pump in high pressure air to the pipe. Pump in high pressure Based on the above steps, coolant could be drained out. Steps to fill coolant: Open this tube Remove the tube connecting to thermostat(19320) cover. -
Page 172
To this chapter contents 12. Cooling System Close the fuel tube (95001-08550) loop. Close this tube Fill up the coolant from filler neck (19039) without interruption. 12-9… -
Page 173
To this chapter contents 12. Cooling System Check the air exhausted through the thermostat tube head until coolant come out. Thermostat tube head Thermostat cover joint end Check the air exhausted through the thermostat cover joint until coolant come out. Reconnect thermostat tube Reconnect thermostat tube(19320) to thermostat cover joint(19315) -
Page 174
To this chapter contents 12. Cooling System Open the radiator cap, and turn on the engine. Overflow is normal. Continue adding water to radiator until equilibrant if the amount of water diminished. Maintain the liquid level in reserve tank between upper and lower limit. -
Page 175
To this chapter contents 12. Cooling System NOTE: 12-12… -
Page 176: Body Cover
Home page Contents 13. Body Cover Mechanism Diagram···························13-1 Side Cover ·········································· 13-11 Maintenance ········································13-4 Rear Carrier ········································ 13-12 Handle Cover·······································13-5 Luggage Box ······································ 13-13 Front Cover ·········································13-6 Rear Body Cover ································ 13-14 Meter Panel··········································13-8 Floor Panel ········································· 13-15 Inner Box ·············································13-9 Front Fender·······································…
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Page 177: Mechanism Diagram
13. Body Cover Mechanism Diagram Upper handle cover Double seat Left lower handle cover Right lower handle cover Rear back seat Right side cover Right floor panel Right body cover Inner box lid stiffener RH. RR. grip Inner box lid LH.
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Page 178
13. Body Cover Mechanism Diagram Maintenance cover Left floor panel Left side cover RR. luggage box FR. luggage box Left body cover Rear cover Under cover Rear fender 13-3… -
Page 179: Maintenance
13. Body Cover Maintenance Body covers disassemble sequence: R/L. lower handle covers Double seat Upper handle cover Wind screen Rear back seat Front upper cover Front fender R/L. grip Meter visor Under cover R/L. body cover Meter panel R/L. side cover Air box Front under spoiler Luggage box…
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Page 180: Handle Cover
To this chapter contents 13. Body Cover Handle Cover Remove Loosen the 2 screws from handle upper cover front end. 2 screws Loosen the 2 screws from handle upper cover rear end. Remove right and left handle side cover. 2 screws Installation Install in reverse order of removal procedures.
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Page 181: Front Cover
To this chapter contents 13. Body Cover Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Each side 2 screws Loosen 6 screws from the wind screen and remove the wind screen. 6 screws Loosen 4 screws from the meter visor and remove the meter visor.
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Page 182
To this chapter contents 13. Body Cover Loosen 2 bolts from the front cover under side. 4 bolts Loosen 2 screws and 2 bolts from the front cover upper side. Each side 1 screw Each side 1 bolt Disconnect the headlight, foggy light and winker Headlight coupler light couplers. -
Page 183: Meter Panel
To this chapter contents 13. Body Cover Meter Panel Remove Remove wind screen garnish, wind screen, meter visor and front cover. Remove reserve tank cap. Loosen 4screws from right & left side of the meter panel. Each side 1 screws Loosen 2 screws from in side of meter panel.
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Page 184: Inner Box
To this chapter contents 13. Body Cover Inner Box Reserve tank Remove Remove wind screen garnish, wind screen, meter visor, front cover, meter panel, R/L side cover and front under spoiler. Loosen 1 screw from reserve tank stay. 1 screw 1 screw Loosen 1 screw from fuse box and remove it.
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Page 185
To this chapter contents 13. Body Cover Loosen 2 bolts from inner box under side. Each side 2 bolts Loosen 2 bolts from inside of the inner box. Disconnect the hazard light and foggy light switch couplers. Remove inner box. Installation Install in reverse order of removal procedures. -
Page 186: Side Cover
To this chapter contents 13. Body Cover Side Cover Remove Loosen 2 screws from the side cover side end. 1 screw Loosen 2 screws from the side cover upper end. 2 screws Remove the side cover. Installation Install in reverse order of removal procedures. 13-11…
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Page 187: Rear Carrier
To this chapter contents 13. Body Cover Rear Carrier Remove Loosen 4 bolts from the rear carrier and remove it. Installation Install in reverse order of removal procedures. 13-12…
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Page 188: Luggage Box
To this chapter contents 13. Body Cover Luggage Box 3 screws Remove Open the seat. Loosen 3 screws from the luggage box rear cover. Disconnect the luggage box light and switch coupler. Remove the luggage box rear cover. 2 bolts Loosen 2 bolts from luggage box front side 4 bolts Loosen 4bolts from luggage box rear side.
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Page 189: Rear Body Cover
To this chapter contents 13. Body Cover Rear Body Cover Remove Loosen right and left side screws from rear end of floor panel. Remove the cover Loosen right, left side and middle screws from rear side of the body cover. 3 screws Disconnect the tail light coupler.
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Page 190: Floor Panel
To this chapter contents 13. Body Cover Floor Panel Each side 1 screw Remove Remove wind screen garnish, wind screen, meter visor, front cover, R/L side cover, front under spoiler, inner box, luggage box and body cover. Loosen 4 bolts and 2 screws from floor panel. Each side 2 bolts Remove floor panel.
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Page 191
To this chapter contents 13. Body Cover NOTE: 13-16… -
Page 192: Brake System
Home page Contents 14. Brake System Mechanism Diagram···························· 14-1 Brake Fluid Replacement / Air-bleed·· 14-6 Precautions in Operation ···················· 14-2 Front Brake Caliper······························ 14-7 Troubleshooting ·································· 14-3 Rear Brake Caliper······························· 14-8 Disk Brake System Inspection············ 14-4 Brake Disk ············································ 14-9 Adding Brake Fluid ······························…
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Page 193: Precautions In Operation
To this chapter contents 14. Brake System Precautions in Operation Caution Inhaling asbestos may cause disorders of respiration system or lung cancer; therefore, never use compressed air 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.
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Page 194: Troubleshooting
To this chapter contents 14. Brake System Troubleshooting Slack brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8.
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Page 195
To this chapter contents 14. Brake System Disk Brake System Inspection Inspection Examine for leaking or damage visually. Inspect brake tube seam with spanner to check if it becomes loose. Checking if there is any interferes, contacts between protected pipeline and other parts by turning the handle bar right or left, pressing the cushion up and down. -
Page 196: Adding Brake Fluid
To this chapter contents 14. Brake System Adding Brake Fluid Front brake master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintain the brake system, it is supposed to cover the surface of rubber parts by rags.
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Page 197: Brake Fluid Replacement / Air-Bleed
To this chapter contents 14. Brake System Brake Fluid Replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay valve, hold and release the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.
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Page 198: Front Brake Caliper
To this chapter contents 14. Brake System Front Brake Caliper Brake hose bolts Removal Place a container under the brake caliper, and loosen the brake hose bolts and finally remove the brake hoses. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.
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Page 199: Rear Brake Caliper
To this chapter contents 14. Brake System Rear Brake Caliper Caliper mounting bolts Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Remove two caliper mounting bolts and the caliper.
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Page 200: Brake Disk
To this chapter contents 14. Brake System Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: Front brake disk 2.5 mm Micrometer…
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Page 201
To this chapter contents 14. Brake System Remove the rubber pad. Remove the circlip. Cir clip Rubber Remove the piston and the spring. boot Clean the master cylinder with recommended Piston brake fluid. Piston Spring Master cylinder Master Cylinder Inspection Check the master cylinder for damage or scratch. -
Page 202
To this chapter contents 14. Brake System Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. 2 bolts Connect brake hoses with 2 new washers. -
Page 203
To this chapter contents 14. Brake System NOTE: 14-12… -
Page 204
Home page Contents Mechanism Diagram···························· 15-1 Front Wheel ·········································· 15-5 Precautions in Operation ···················· 15-2 Front Cushion ······································ 15-8 Troubleshooting ·································· 15-2 Steering Stem······································· 15-9 Steering Handle ··································· 15-3 Mechanism Diagram 2.9~3.5kgf-m 6.0~8.0kgf-m 2.4~3.0kgf-m 6.0~8.0kgf-m 2.4~3.0kgf-m 2.4~3.0kgf-m 5.0~7.0kgf-m 15-1… -
Page 205: Precautions In Operation
To this chapter contents Precautions in Operation General Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of the tire. Torque Values Nut for the front wheel axle 5.0 ~ 7.0kgf-m Nut for the steering handle 4.0 ~ 5.0kgf-m Lock nut for the steering handle stem 1.0 ~ 2.0kgf-m…
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Page 206: Steering Handle
To this chapter contents Steering Handle Master cylinder Remove Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake. 2 bolts Holder Fixing nut Loosen the deceleration throttle cable fixing nut.
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Page 207
To this chapter contents Loosen 2 bolts from the master cylinder of the rear Master cylinder brake. Remove holder and master cylinder. Holder 2 bolts Loosen left handle switch connecter. Loosen 2 screws from left side handle switch holder. Remove the right handle switch. 2 screws Switch connecter Loosen handle mounting nut. -
Page 208: Front Wheel
To this chapter contents Front Wheel 2 screws Loosen 2 bolts from the front brake caliper and remove it Caution Care shall be taken not to push the brake lever to avoid the brake pad being squeezed out. In case that the brake pad is accidentally squeezed out, use a screwdriver to force it back to the place.
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Page 209
To this chapter contents Inspection Wheel axle Place the wheel axle on a V block, measure its displacement. Service limit: 0.2 mm Bearing Use finger to move the inner ring of each bearing, Free play it shall move smoothly and quietly. Check the outer ring is securely attached on the wheel hub. -
Page 210
To this chapter contents Assembly Dist collar Dust seal Fill out the block of bearing by grease. Drive the left bearing, dust seal and install the dist collar. Bearing Install the right side bearing. 6201U Caution Carefully install the bearing in correct and evenly. -
Page 211: Front Cushion
To this chapter contents Front Cushion 3 bolts at both Remove side Remove front cover, front under spoiler and front fender. Remove three bolts at both sides. Remove front wheel. Remove front brake caliper. Remove speedometer cable. 15-8…
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Page 212: Steering Stem
To this chapter contents Steering Stem Stem mounting nut Steering stem top thread Remove wrench Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Top cone race Top cone race Remove top cone race and steering stem. Caution Place the steel ball onto a parts container to prevent from missing.
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Page 213
To this chapter contents Lubricate the top cone race seat with grease. Steering lock nut Screw the cone race into top ball bearing seat till touching, and then screw out the cane race 1/4~3/8 turn. Return 1/2 turn Torque value: 0.25kgf-m Caution Check the steering stem that should be rotated freely, and no clearance in vertical… -
Page 214
To this chapter contents NOTE: Steering stem adjustment: When the steering stem is too tight. Steps: please refer to figure 1 Stay front wheel on the ground, and make sure that the component ①,②,③,④ are connected all together appropriately. Lock the component 53220-HMA-00(STRG. HEAD TOP THREAD COMP.) with the torque of 350 ±… -
Page 215
Home page Contents 16. Rear Wheel / Rear Fork / Rear Cushion Mechanism Diagram···························16-1 Rear Wheel ········································· 16-3 Operational Precautions ····················16-2 Rear Fork ············································ 16-5 Troubleshooting ·································16-2 Rear Cushion······································ 16-6 Muffler··················································16-3 Mechanism Diagram 3.5~4.5kgf-m 2.8~3.2kgf-m 3.5~4.5kgf-m 11.0~13.0kgf-m 1.0~1.4kgf-m 2.9~3.5kgf-m 16-1… -
Page 216: Operational Precautions
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Operational Precautions General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit…
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Page 217: Muffler
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Muffler Removal Loosen the 2 nuts from exhaust muffler front side. 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side. Remove exhaust muffler. Installation Install in reverse order of removal procedures.
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Page 218
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Remove rear wheel axle nut. 1 nut Remove rear fork and both side collars. Remove the rear wheel. Inspection rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. -
Page 219: Rear Fork
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Rear Fork Free play Inspection rear fork bearing Rotate the inner ring of the bearing with a finger. Free play The bearing should move smoothly and quietly. Check the fit of the bearing and rim.
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Page 220: Rear Cushion
To this chapter contents 16. Rear Wheel / Rear Fork / Rear Cushion Install the bearing lock cir clip. Cir clip Outside collar Bearing (6303UU) Inside collar Rear Cushion Left Upper bolt Removal Remove the luggage box, rear carrier and body covers.
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Page 221: Electrical System
Home page Contents 17. Electrical System Mechanism Diagram ··························17-1 Starting System ································· 17-11 Precautions in Operation···················17-2 Meter ··················································· 17-13 Specification ·······································17-2 Light / Bulb········································· 17-15 Troubleshooting ·································17-3 Switch / Horn······································ 17-17 Battery ·················································17-4 Fuel Unit ············································· 17-19 Fuse ·····················································17-5 Cooling Fan Thermo Switch ············· 17-20 Charging System ································17-6 Thermo Unit ·······································…
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Page 222: Precautions In Operation
To this chapter contents 17. Electrical System Precautions in Operation When removing the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.
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Page 223
To this chapter contents 17. Electrical System Troubleshooting No voltage Intermittent power supply Battery over discharged The connector of the charging system becomes The cable disconnected loose The fuse is blown Poor connection of the battery cable Improper operation of the main switch Poor connection or short-circuit of the Low voltage discharging system… -
Page 224
To this chapter contents 17. Electrical System Battery Removal Loosen 1 screw and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery. Voltage Check Use the digital voltmeter to check the voltage of the battery. -
Page 225
To this chapter contents 17. Electrical System Fuse Fuse circuit diagram 17-5… -
Page 226
To this chapter contents 17. Electrical System Charging System Black Green Yellow Regulator rectifier Inspection (K ) ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞… -
Page 227
To this chapter contents 17. Electrical System Inspection on AC. Generator coil Remove the luggage box, rear carrier and body covers. Disconnect 3 pin couplers of the generator coil. Connect an ohmmeter to the each terminal end. Check the continuity of the each terminal end, and engine ground with short circuit. -
Page 228
To this chapter contents 17. Electrical System Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm… -
Page 229
17. Electrical System ECU. coupler (ECU. side) 01 pin(R/Y): Drive components Power. 03 pin(L/O): Crankshaft position sensor positive 09 pin(G): Crankshaft position sensor negative 18 pin(Y/G)： Ignition coil 17-9… -
Page 230
To this chapter contents 17. Electrical System Inspection on ignition coil Remove the right floor garnish. Disengage the connector of the ignition coil. Measure the resistance between the terminals of the primary winding. Standard resistance: 2.8 ±15% (20ºC) Replacement of ignition coil Remove the cap from the spark plug. -
Page 231: Starting System
To this chapter contents 17. Electrical System Starting System White Black Blue Green Sky blue Yellow Orange Inspection of starter relay Open the main switch. Press the brake. Push the starter switch. If a sound of “Looh Looh” is heard, it indicates the relay is working properly.
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Page 232
To this chapter contents 17. Electrical System Disconnect the positive cable of the starter motor. Disconnect the coupler of the relay. Connect an ohmmeter to the large terminal end. Connect the yellow/red cable to the battery positive terminal and the green/yellow cable to the battery negative terminal. -
Page 233: Meter
To this chapter contents 17. Electrical System Meter Meter circuit diagram Meter (Ignition) Fuse 10A Turn right indicator Main switch Fuse 20A Turn left indicator Charge High beam indicator indicator REG. REC. Side stand warning light Eng. temperature indicator Thermo sensor Battery Parking right indicator Fuel injection indicator…
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Page 234
To this chapter contents 17. Electrical System Removal of meter Remove wind screen garnish, wind screen, meter visor, front cover, meter visor. (Refer chapter 14) Disconnect the coupler of the speedometer, and take off the meter panel and meter. Meter coupler 4 screws Loosen 4 screws from meter panel. -
Page 235: Light / Bulb
To this chapter contents 17. Electrical System Light / Bulb Headlight and foggy light circuit diagram (Headlight) White Fuse 15A Black Blue Green Brown Position & meter illumination light Lo-beam light Lo-beam relay Light switch Beam switch Hi-beam light Hi-beam relay Main switch Fuse 20A Passing switch…
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Page 236
To this chapter contents 17. Electrical System Headlight bulb replacement Pull out the rubber socket, and press the 2 springs, then remove light bulb. Specification: Lo-beam bulb 12V 55W (H11) Hi-beam bulb 12V 55W (H11) Caution It would be much easier to replace the light bulb if dismounting the front cover. -
Page 237: Switch / Horn
To this chapter contents 17. Electrical System Switch / Horn Main switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below BAT1 BAT2 Position LOCK Main switch coupler Wire Color Black Blake Replacement of main switch…
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Page 238
To this chapter contents 17. Electrical System Left handle switch High and low beam switch Remove the handle cover and front cover. Disconnect the coupler of left handle switch. Check the continuity between two points as indicated in the table below High and low beam switch Position Winker switch… -
Page 239: Fuel Unit
To this chapter contents 17. Electrical System Fuel Unit Fuel Pump and unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove right & left side cover. Remove the body cover Remove the floor panel. Disconnect the coupler of the fuel unit. Loosen 4 bolts from fuel unit and remove it.
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Page 240: Cooling Fan Thermo Switch
To this chapter contents 17. Electrical System Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails working, disconnect the green and black/blue leads, and connect jump wires to the terminals, then turn on the main switch.
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Page 241: Thermo Unit
To this chapter contents 17. Electrical System Thermo Unit Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (Ω Ω Ω Ω ) 134~149 47.5~57.0 26~29 14.8~17.2 Caution Wear gloves and goggles when performing this test.
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Page 242
To this chapter contents 17. Electrical System NOTE: 17-22… -
Page 243: Wiring Diagram
Homepage Contents 18. Wiring Diagram 18-1…
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Page 244
Homepage Contents 18. Wiring Diagram NOTE: 18-2…
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Manuals and User Guides for Sym MAXSYM 400i. We have 2 Sym MAXSYM 400i manuals available for free PDF download: Service Manual
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Detail Specifications: 704/704961-maxsym_400i.pdf file (22 Feb 2023) |
Accompanying Data:
Sym MAXSYM 400i Motorcycle, Scooter PDF Service Manual (Updated: Wednesday 22nd of February 2023 07:30:30 PM)
Rating: 4.8 (rated by 36 users)
Compatible devices: MaxSym 600i ABS, Wolf Classic 150, Mio 50, Fiddle II 50 SYM Series, Jet4 AD12W1-6; Jet4 AD12W1-6C, DD 50, HD2 125, Joyride S 125i.
Recommended Documentation:
Text Version of Service Manual
(Ocr-Read Summary of Contents, UPD: 22 February 2023)
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54, Sym MAXSYM 400i 4. Fuel Injection System 4-11 Idle Speed Control Valve (ISC stepper motor) Function ECU controls ISC stepper motor to adjust the bypass intake air quantity and stabilized the idle speed. I SC ECU B attery +Va -Va +Vb -Vb S tep S N S S N N Va Vb To this chapter contents
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16, 1. General Information 1-11 Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value (Kg-m) Remarks Mounting bolt for steering handle post 1 10 4.0~5.0 Lock nut for steering stem 1 BC1 1.0~2.0 Steering top cone race 1 BC1 2.0~3.0 Front wheel axle nut 1 12 5.0~7.0 Rear wheel axle nut 1 16 11.0~13.0 Front cus…
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118, 6 . Cylinder Head / Valve 6-13 After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem o…
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228, 17. Electrical System 17-8 Inspection on Charging Voltage Caution Before conducting the inspection, be sure that the battery is fully charged. If undercharged, the current changes dramatically. Use a fully charged battery having a voltage larger than 13.0 V to prevent the current fluctuation. While starting the engine, the starter motor draws la…
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214, 15-11 NOTE: Steering stem adjustment: When the steering stem is too tight. Steps: please refer to figure 1 1. Stay front wheel on the ground, and make sure that the component ①,②,③,④ are connected all together appropriately. 2. Lock the component 53220-HMA-00(STRG. HEAD TOP THREAD COMP.) with the torque of 50350 ± Kgf-cm. 3. Turn the steering stem…
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200, 14. Brake System 14-9 Brake Disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: Front brake disk 2.5 mm Rear brake disk 3.5 mm Remove the brake disk from wheel. Check the disk for deformation and bend. Allowable limit: 0.30 mm…
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71, Sym MAXSYM 400i 4. Fuel Injection System 4-28 Transistor ignition coil First circuit coil resistance measurement Functional Description: ● Use 8 ~ 16V DC power supply, has the two-pin socket. ● Two-pin socket for the power supply and grounding. Its main components for the high conversion ratio transformer. ● Through computer programs when the ignition…
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110, 6 . Cylinder Head / Valve 6-5 Remove the side cover mounting blots of cylinder head, and then take out the side cover. Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying…
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48, 4. Fuel Injection System 4-5 Fuel System System Description 1. After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in order to save electricity. Fuel pressure regulator maintains fuel …
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123, Sym MAXSYM 400i 7. Cylinder / Piston 7-2 Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit： ：： ：mm LM25W5 LM30W Item Standard Limit Standard Limit I.D. 70.995~71.015 71.100 72.995~73.015 73.100 Out of round — 0.050 — 0.050 Taper — 0.050 -…
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194, Sym MAXSYM 400i 14. Brake System 14-3 Troubleshooting Slack brake lever 1. Air inside the hydraulic system 2. Hydraulic system leaking 3. Worn master piston 4. Worn brake pad 5. Poor brake caliper 6. Worn brake lining/disk 7. Low brake fluid 8. Blocked brake hose 9. Deformed/ bent brake disk 10. Bent brake lever Malfunction of the brake lever 1. Blocked brake syste…
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109, 6. Cylinder Head / Valve 6-4 Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove 2 bolts of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts). Remove Air Injection system (AI) pipe…
Recommended Instructions:
BTE300, B300m, LZ-30, XHDART, FR-C150
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Owner’s Manual Read and understand this entire manual BEFORE riding!For assistance contact Razor. DO NOT RETURN TO STORE.Please have product with you when calling for assistance.Item Number:13114501NOTE: Manual illustrations are for demonstration purposes only. Illustrations may not reflect exact appearance of actual product. Specifications subject to chang …
Ecosmart metro 12
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“Quantum Jazzy 1420”Owners ManualATTENTION:Please read the contentof your owners manualbefore operating yourpower chair.Includes 1420 and 14001-800-800-8586 (Exeter, PA) • 1-888-570-1113 (St. Catharines, ON) • www.quantumrehab.com …
Quantum Jazzy 1420 47
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1INTRODUZIONE• Congratulazioni per l’ottima scelta ed un “grazie” per la fiducia, dai tecnici della Malaguti. Fiducia ben riposta in quanto il tuo nuovoScooter è il frutto di lunghe esperienze e severissimi collaudi ed è l’espressione di una tecnologia d’avanguardia nel settore. La sualongevità ed il buon funzionamento da questo momento dipendono mol …
CIAK 125 134
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Operating Impressions, Questions and Answers:
Руководство по эксплуатации
SYM MAXSYM 400i
1. Оглавление 1
2. Контрольные функции 3
3. Перед поездкой 4
4. Безопасность 4
5. Езда 5
6. Оригинальные запчасти 5
7. Назначение каждого компонента 6
Приборная панель 6
Замок зажигания 9
Назначение кнопок 10
Блокировка двигателя 13
Багажник 13
Подножки пассажира 13
Крышка топливного бака 14
Тормоза 15
Парковочный тормоз 15
8. Безопасность при запуске 16
9. Управление и парковка 17
Управление дросселем 17
Способы парковки 17
10. Inspection and Maintenance before Riding 18
Регулярный осмотр 18
Моторное масло инспекция и замена 18
Топливо 20
Трансмиссионное масло инспекция и замена 20
Инспекция и регулировка свободного хода рычагов 21
Тормозная жидкость 21
Проверка дискового тормоза 22
Регулировка ручки газа 22
Инспекция батареи 23
Инспекция колес 24
Проверка передней вилки 24
Настройка заднего амортизатора 25
Проверка и замена предохранителей 25
Проверка освещения и звукового сигнала 26
Проверка передних и задних габаритов 26
Проверка стоп-сигнала 26
Проверка герметичности топливной системы 26
Проверка и смазка основных механизмов 26
Проверка свечи зажигания 26
Инспекция охлаждающей системы 27
Заправка антифриза 27
Таблица содержания концентрации антифриза в зависимости от температуры 28
Вентиляция картера 28
Проверка воздушного фильтра 29
11. Диагностика неисправностей 30
Если двигатель не заводится 30
12. Рекомендации по выбору топлива 31
13. Tрансмисcионное масло 31
14. Рекомендации по управлению скутером 31
15. Таблица периодического обслуживания 32
16. Спецификация 33
Стоп двигатель/стартер
Крышка бензобака
Моргание/ Дальний & Ближний свет / Звуковой сигнал / открывание сиденья
Рычаг переднего тормоза
Рычаг переднего и заднего тормоза
Боковая подножка
Центральная подножка
Багажная емкость
Глушитель
Крышка
расширительного бачка
Замок зажигания
Предохранители
Указатели поворота
Головной свет
Задний габарит/
Сигналы поворота
Замок сиденья
Номер двигателя
Номер рамы
Эта инструкция описывает правильное использование этого скутера, включая безопасность езды, методы проверки и т.д..
Для более комфортной и безопасной езды внимательно изучите данное руководство.
Внимательно изучите руководство пользователя, и особое внимание уделите пунктам:
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| Спасибо за вашу лояльность к мототехнике SYM!
В целях обеспечения высокой производительности вашего скутера должны быть выполнены все рекомендации данного руководства. Чтобы ваш скутер работал надежно и долговечно, необходимо хорошо обкатать его и пройти обязательное техническое обслуживание после первых 300 км пробега, так же необходимо проверять скутер каждые 1000 км.. |
- Производитель оставляет за собой право производить изменения конструкции данного скутера, не отражая это в спецификации, данные изменения направлены на улучшение потребительских качеств.
4. Езда
Очень важно за рулем быть предельно собранным, правильно одетым, соблюдать правила дорожного движения.
Очень часто бывают случаи, когда водитель на недавно купленном скутере ездит очень
аккуратно, но по мере освоения навыков управления начинает вести себя безрассудно, и это может
привести к аварии с тяжелыми последствиями.
| Помните:
Пожалуйста, носите защитный шлем и застегивайте его. Одежда, парусящая на ветру, а так же со свободными манжетами может попасть в движущиеся детали Скутера, и таким образом повлиять на безопасность езды. Надевайте одежду с плотными рукавами. Крепко держите руль во время езды двумя руками. Никогда не ездите, держа руль одной рукой. Соблюдайте ограничение скорости. Носите обувь с низким каблуком. Выполняйте периодическое техническое обслуживание в соответствии с графиком обслуживания. |
 ВНИМАНИЕ!!
Для того чтобы избежать ожогов от выхлопной трубы при посадке пассажира -убедитесь что пассажир поставил ноги на подножки. После запуска выхлопная труба очень горячая! Будьте осторожны, чтобы не обжечься при проведении обслуживания. Выбирайте подходящее место для парковки скутера, т.к. труба после остановки горячая -о нее могут обжечься посторонние люди. |
| ПРЕДУПРЕЖДЕНИЕ:
Модифицирование скутера может повлиять на его производительность и безопасность, привести к ухудшению работы двигателя и сокращению срока службы скутера. Кроме того, данные изменения являются незаконными и не соответствуют оригинальным спецификациям. Скутер с такими изменениями снимается с гарантии. |
Правильно располагайте руки и ноги на скутере.
Поза водителя в значительной степени влияет на безопасность движения, водитель должен
быть в состоянии быстро реагировать на дорожную обстановку, когда это необходимо.
Не переносите вес тела на заднюю часть сиденья, это может вызвать разгрузку переднего колеса и
Потерю управления. В поворотах переносите вес тела внутрь поворота, это повысит устойчивость
скутера при проведении маневра.
| ВНИМАНИЕ:
Нагруженный и не нагруженный скутер ведет себя по разному. Перегрузка сильно влияет на ездовые характеристики, поэтому не перегружайте скутер. |
| ВНИМАНИЕ:
Не размещайте тряпки и др. горючие материалы в зоне двигателя и глушителя, это может вызвать пожар. Не располагайте груз на не предназначенных для этого элементах, это может вызвать их повреждение. |
| РЕКОМЕНДАЦИЯ
Чтобы максимально повысить эффективность работы скутера, первые 1000 километров необходимо «обкатать» его для приработки основных движущихся частей. Не разгоняйте скутер свыше 60 км/ч. |
6. ИСПОЛЬЗУЙТЕ ОРИГИНАЛЬНЫЕ ЗАПЧАСТИ
В целях поддержания скутера в технически исправном состоянии необходимо использование только оригинальных запасных частей. Оригинальные запасные части SYM проходят строгий контроль качества, и поэтому надежны и долговечны. Использование неоригинальных запасных частей может привести к поломке скутера и повлиять на вашу безопасность. Кроме того, скутер будет снят с гарантийного обслуживания.
(Ниже приведены основные операции с SYM 4 тактным скутером жидкостного охлаждения,они могут варьироваться в зависимости от модификации).
Table of Contents for Sym MAXSYM 400i:
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17. Electrical System 17-11 Starting System Inspection of starter relay Open the main switch. Press the brake. Push the starter switch. If a sound of “Looh Looh” is heard, it indicates the relay is working properly. Open the inner box lid, and remove battery cover. Disconnect the negative cable terminal of the battery. Remove the luggage box. D
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4. Fuel Injection System 4-34 Idle flameout diagnosis Idle Air Control Valve Actuation whether or failure? EFi system more relevant institutions, each recognized by the detection, if still unable to rule out the idling flameout problem, it is recommended that engine checks whether there are other traditional institutions abnormal. Idle flameout 1. Link diagnosis tool to view EFI fault content 2. In accordance with Troublesho
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10. AC Generator / Starting Clutch 10-2 Precautions in Operation ‧ Refer to chapter 5: Engine removal and installation ‧ Refer to chapter 16: The troubleshooting and inspection of alternator ‧ Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear 20.026~20.045 20.100 OD of starting cl
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4. Fuel Injection System 4-56 6. CO ADAPTION In the directory functions used «▲» «▼» button, select «CO ADAPTION» project, press the «ENTER» button into the CO adjustment screen. Use «◄ left» and «right ►» or «▲» «▼» button, CO value can be adjusted. CO ADAPT: CO adjusted value. CO Read: CO read-back value. Press the «EXIT» button, the function can retur
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15-3 Steering Handle Remove Remove the right and left handle side cover, handle upper cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake. Loosen the deceleration throttle cable fixing nut. Loosen 1 screw from the acceleration throttle fixing plate. Loosen 2 screws from the throttle holder. Remove throttle holder, handle switch, cables and
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10. AC Generator / Starting Clutch 10-4 Flywheel Installation Insert the pin onto crankshaft. Align the key on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 8.5~10.5 kg-m Tool: Flywheel holder A.C.G. Set Installation Install the A.C.G. set onto right cran
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15-6 Inspection Wheel axle Place the wheel axle on a V block, measure its displacement. Service limit: 0.2 mm Bearing Use finger to move the inner ring of each bearing, it shall move smoothly and quietly. Check the outer ring is securely attached on the wheel hub. If the motion of the inner ring of the bearing is not smooth, or noisy and loose when being moved, replace with a new one. Caution The bearing shall be replaced in pair. W
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14. Brake System 14-6 Brake Fluid Replacement / Air-bleed Connect drain hose to air-bleed valve. Open the drain valve on the calipers and delay valve, hold and release the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder. Recommended brake fluid: WELLRUN DOT 3 brake fluid Connect one end of transparent hose to the drain valve, and put the other end into a container. Open the drain valve around 1/4 tu
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9. Final Drive Mechanism 9-3 Precautions in Operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4 kg-m Tools Special tools Bearing (6203/6004UZ) driver Bearing (6204) driver Bearing (6301) driver Oil seal (27*42*7) driver Oil seal (20*32*6) driver Inner bearing puller Outer bearing puller Troubleshooting Engine can be starte
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8 . V-Belt Drive System 8-7 Installation Caution Pull out driven face to avoid it closing. Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face. Install the clutch outer and bearing stay colla
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2. Maintenance Information 2-7 Spark Plug Recommended spark plug: CR8E Remove luggage box Remove central cover. Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap. Spark plug gap: 0.6~0.7 mm Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwin
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6. Cylinder Head / Valve 6-14 Install camshaft into cylinder head. Install valve rocker arm, rocker arm shaft and cam shaft setting plate. Cylinder Head Installation Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or f
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13. Body Cover 13-6 Front Cover Remove Loosen 4 screws from the wind screen garnish and remove the wind screen garnish. Loosen 6 screws from the wind screen and remove the wind screen. Loosen 4 screws from the meter visor and remove the meter visor. Loosen 4 screws (2 screws on each side) from the inner box. Each side 2 screws 6 screws 4 screws Each side 2 screws To thi
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12. Cooling System 12-12 NOTE: To this chapter contents
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