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service manual 125-250 XMOTION

1. T 1T 5 PDF created with pdfFactory Pro trial version www pdffactory com above maintenance schedule is established by taking the monthy 1000 kilometers as areference which ever comes first Code Inspection cleaning and adjustment R Replacement Cleaning replaced if necessary L Lubrication Remark 1 Clean or replace the air cleanr element more often whe the scooter is operated on dusty roads or in the Heavily polluted environment 2 Maintenance should be performed more often if the scooter is frequently operated in high speed and after the scooter has accumulated a higher mileage 1 4 General Inspection General Inspection and Adjustment means adjustable Note The ignition of this scooter by the use of crank shaft which is 4 ignitions revolution Special attention should be paid while setting the turning speed of Engine by Tachometer Brake Disc _ Fuses Tail Light Turn Signal Light Air Filter Gear Oil Head Light Spark Plug Raer Brake Tire _ Brake Disc 6 PDF created with S pdfFactory Pro trial version www pdffactory com Head Lig jhe Tail Light Turn Signal Light Ar Filter Spark Phog Gear Raer 1 5 Notes for Inspection ITEM INSPECTION DETAILS Be aware of smoke and fire while performing maintenance New Packing Gask
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4. absciutn PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Troubleshooting Table Engine Throtile mte ms e rs sere Notes 1 Integrated test motorcycle according Ig the Comprehensive Maintenance list implementation 2 Spare parts according lo the System components description implementation PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Comprehensive Maintenance List Rut pirni iel g Rel pump faul rector faul specifications Venetber e Wan tarina fou Mo 8 rri fait plur wayi col taut Notes 1 Fuel pressure gauge connected between the fuel tank and injector open the main switch to repeatedly shut down fuel system makes pressure stability 2 Injector and injector cap tightly by hands fuel spills should not be the case PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System injection System for Use diagnosis W70 Gable connector cartridge slots Note When problems arise be used for diagnosis tool cf the rs detected and exclusion a addition to testing troubleshooting another of the operation can be cared out data analysis type monitor Method of Use 1 2 3 4 Main
5. walue PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fuel Pump Functional Description Powered DC B 18V 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 major component is a driving fan pump that equipped with low electrical consuming DC motor Powered by 12V voltage and keep fuel pressure inside the fuel pump in 204 about 3 kg cm The fuel pump is located inside of the fuel tank and installed a filter in front of its eo that can prevent from foreign materials sucking inte Fial pump the fuel pump damage it and the fuel injector G Testing Procedures 1 Fuel pump working voltage confirmed S9 0 apy Fuel pump coupler to property using the probe tool or can be n removed coupler working voltage measurements direct Fuel pump amp fusi uni coupler plan measurement ge Open the main switch but not to start engine Use volteg meter DC stalls DCW to check fuel pump voltage Confirmed working valiage Volteg meter negate access to the wire hamess fuel pump coupler 2nd pin Green Voltage metor positive access fo the wire harness fual pump couplar first pin Black Purple A Cautions Gonducting fuel pump voltage measurement if the
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7. 126 Qaa 1 1 UUUjf 4 DISASSEMBLY REPAIRMENT 4 1 Notice for Disassembly Repairment 137 4 2 Removal and Installation of Engine 138 4 3 Removal and Inspection of Electric Items 199 4 4 Removal and Inspection of Body Parts 206 4 5 Brake System 214 i PDF created with pdfFactory Pro trial version www pdffactory com CHAPTER REGULAR INSPECTION 1 1 Delivery Introduction 1 4 General Inspection 1 2 Inspection Before Running 1 5 Notes for Inspection 1 3 Regular Maintenance Schedule 1 1 Delivery Introduction To inform customers of correct methods to use To practically and correctly ride a scooter according to the Instruction of Manual and Maintenance Handbook Customers should also try in person according to this manual 1 Starting A Turn the power switch to ON Hold the front or rear brake and press the START button If the scooter is not started release the START button and try again after a few minutes Each start should be less than five seconds to avoid battery consumption Note This is an AUTO CHOKE scooter thus there is no choke lever The fuel is controlled only by throttle grip The accelerator has to return to its original place when the scooter is not in use D If the scooter can not be started by
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9. 9100200 RET jHKT516 _ 9100400 6206 22 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS Bearing puller 8303 Drive shaft seal 25 40 E socket Meere eem wo Bearing driver 8201 Crankcase bush pulle wo 9814000 8201 1120310 0 1120320 Water pump bearing driver Water mechanical seal 4 BUT m ena pump saai drier 23 PDF created with pdfFactory Pro trial version www pdffactory com 2 4 List of Grease amp Oil Adopted TGB Supper Grease No 0 Apply in Oil Seal 1104 Sealing Three Bond Apply on Right Hand Crank Surface TGB Genuine EXTRA 4X OIL Engine Oil Apply in oil tank TGB Supper Grease No Apply in Oil Seal TGB Supper Grease No 2 Apply in Kick Starter Cemedine 575 Apply in Handle Grip Supper Grease No 3 Apply in Axle Shaft inside of Oil Seal TGB Gear Oil 85w 140 Transmission Gear Oil for Scooters Three Bond 1322 Under M10 Screw For medium fixing for Flywheel Magneto DOT 3 Brake Oil For Brake TGB Supper Grease No 4 For Movable Drive Face Comp 24 PDF created with pdfFactory Pro trial version www pdffactory com 0405 1 Wimmk CRITICAL CHARACTERIST
10. janj pe WSLSAS FUEL SYSTEM Adjustment of pilot scrow Throttle cable adjust nut Caution Pilol screw wae set at factory adjustment is needed Nate the n mber af tma take TO a8 howay for ease of inmsiallabon main stand mus used support ta ta pertarm the adjustments Lise tachometer when adjusting engine AIPM Screw in adjustment screw gently back up to standard Standard turns LA12W 2 1 4 turns LA1EW 1 2 turns LATE 4 1 2 turns Caution Dip not screw m forceful to avoid damaging serew face Warm up engine acusi be stopper screw of throtie valve to standard RPM idle speed rpm 1500 100 rpm Connect the hose nf exhaust analyzer to axhauel trant end Press test key on the analyzer Adjust the pilot crew and read CO reading on the analyzer CO standard value 1 01 5 5 in grad uad incrermenis make sure rpm and CO value in gtandand value after engine running in and value fluctusted repeat the pracedures deseri ed above for adjusting to valise 48 PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM FUEL TANK Fuel unit removal Open the sal Remove luggage B bolts and 1 screw Remove rear canter bolts Remo
11. place acid Ty farma when working wit g salina Cautions net band off throttle cable Damaged throtle cable will make unviable drive ability When Tuo parta pay attention to O ring position taplace wilh naw one 3s There is a drain screw in ite float chamber for dreining rasitual gasoline Dio not disassemble auto by starter and cut valve arbitrary Specification mm uw uw Tomme oas 2 aas Idle 16002100 rem 18002100 mm 15002100 rpm Taratia handla eane 26mm mum Torque value Fuel valve tightening nut 1 5 2 0Kgf m Teal Special servicn tools pure General service bool Fuel level gauge PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM TROUBLE DIAGNOSIS Poor eniin start Tone Clogged pei tube Too much fuel in cylinder spark from spark plug maifurietn of ignition system Clepged air cleaner Maece n al auto pysstarter ef throtile of perge control valua Stall after started auto cer starter Incorrect ignition Timing of carburetor Darty angina ol Abr Intake system Incorrect ole speed HiaFiunctipn of purge como vale Rough Idla of ignites system
12. 10 LU ariga Saaai jawas Due AOD JRL LUNDA jo SWSJ3E 7 yea EN Pe ING pug 088004 UES po dus dweep durs dum nu 1929 50 15800005 ASO Bid ESOL eC Due Bug jo inu Eun pue nu gueuqsnipe aui uesa acu EACEA 5 WALSAS 1903 FUEL SYSTEM Installation ingtall needin spring ard seat fo waciium piston Install vacuum pisimn to carburetor body and align the inde an Ihe diaphragm install compress spring Install vacuum chamber cover and then 2 AN Caution Do not damage vacuum diaphragm When lightening the vacuum chamber screw hoki down vacuum piston 45 PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM FLOAT CHAMBER Remove 4 mounting sors and remove fost chamber cover Remove the feat pin Checking Check Boat valve and valve sist for damage Check Float valve for wearing and check valve Seat lace for wear dirt Caution Nalve seat will not cioe increase and as
13. ES Use of the meter Chm stalls 0 measurement of the ignition coil First circuit coil resistance resistance value mens srgmeart Detection judge s Ignition first circuit 3 0 30420 C Treatment of abnormal phenomena 1 Ignition internal disconnection damaged or plugs bad contact 2 Ignition coil ignition ts not abnormal proposes to replace the ignition cod Crankshaft position sensor Functional Description Long tooth u Do not need for an extemal power supply has bwo pin of signal plug oot Constitutes a major change in its reluctance induction coil c m The spacing of flywheel and sensor should be 0 7 to 1 1 mm Magnetic induction sensor is the use of flywheel on the Gear 23 1 long tooth rotary cutting Induction changes in the magnetic held sensor with the inductive voage signal for ECU judgement calculated at the engine speed and crankshaft position and with a mast appropriate tine of fuel injection and bgnition control Testing Procedures Resistance Confirmation Removed crankshaft position sensor coupler Blue Yellow amp Green White Use of the meter Ohm stalls 07 measurement of the crankshaft position sensor resistance value Detection judge Resistance value 80 18006 20 6 Treatment of abnormal phenomena 1 Sensor intemal internupted damaged or coupler bad contact 2 Check whether the abnormal wire harness lines
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15. PDF created with pdfFactory Pro trial version www pdffactory com 00 5 9 U W IBU OCT qe ped FE ari JESS Mi segue 20S SAMA Ly pinid aj seu pasada peu anpa Jayy Jagno JOYS 1886 esr pagina JO 01 pees GAPE up se Gu Bu pub jeas pepiop ayi 45047 jeas GAJEA ufnas jo amp j 1098 jl 1685 ajada ssaugfino sj E E RN RN a BUO quA BAIA sonde uogne2 BOE FELT sp pus TEGS GABA OMEA jo po euius La Adde pus papanga aye aug dr pue ways eua jap jou OC e t Burpuui genug SCN une pDuejuos ama opua AYES up SAAMA
16. PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Cra ring sng aes PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Remove fuel pump fuel unit Remove side cower Remove rear carrier Remove rear bodycover Remove floor panel Remove under cover refer to chapter 14 Remove fine pamp Enes Raines te fuel tube folder ramorod tho fuel ruba Remove the fuel jank fixed bolts Boll 4 remove the Remeve Install fuel pump and fuel unit Remove fuel pump fixed balta Bolt 6 remove fuel Pressure Fegul ting Walwa pump Install n ihe order A Cautions Then remove fuel pump fuel in fuel tank interrial to confirm not excessive Then instal fuel pump and fuel unit attention direction Gonfirm whether the fuel filter cart obstructive Final pump instaltation to confirm whether it is normal to the fuel aut the pressure about 3 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Air Cleaner Remove Remove loft side body cover and luggage Dox Ramove rear carrier and body cover Remove fuel gas recover tube Remove waste gas purification system pipes Remove intake Temperahbure sensor coupler Remove intake tube fied bol 1 Remove air clearer fixed bolts bolt 2 Remove air cleaner
17. af 3 pages are able to use eit and right button view inpecton system Cn the any sereen press tha EXIT budton the function can rebum to the directory screen 07 03 TEN IT T PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Data stream 1 3 LEFT 4s The screen showed the ECU captured by the engine of the state immediately The following data for the benchmark idling state Engie BSPD Sree dle 1650 1750 idle speed FAULT Normal 7 number VOLT 52V Above 12V Battery voltage s FUEL PUMP z ON Fuel pump actuator state die 32 38kPa Manitold pressure TPS 1 idle 1 5 Throttle opening TPS postion _ Idig 0 58 0 82 Throttle sensor voltage 0 SENSOR mV ole 50 200m O sensor voltage s HEATER 3500rpmeON heater actuator state ENGINE 7 Stable B5 65 C Engine temperature cooling water temperature the DATA STREAM of the screen use A Y bution to move the left side of the project symbol seieacted lems press the ENTER buttom lock af the project and press the Fa button showed that ihe wave of projects Able to 4 DAP and right button transtorm View wave numerical siz
18. clearance adjustment hole cap with 3 bolts and tighten the bolla Clean up all residues and materials onto ihe machin surfaces of both cylinder and cylinder head Install chain guide Install 2 set pins and cylinder head gasket Caution Dono damage the matching surfaces of cylinder and cylinder haad Ayold residues of gasket or foreign materiak falling into crankcase 85 cleaning PDF created with pdfFactory Pro trial version www pdffactory CYLINDER HEAD VALVE Install cylinder head Tighten 4 and washers on thi cylinder head upper sede and thin tighten 2 cylinder head mounting bolts of cylinder head side Torque value 2 0 2 4 kgf m install and tighten spark plug Torque value 2 0 24 kgf m Caution This model is equipped with more precision 4 valve mechanism sp its Bbghiern terque can not be exceedad standard value in order causing cylinder head deformation engine noise and leaking so that performance effected Install cam chain on to sprocket and align the timing mark on the sprockel with Inat of head Align sprocket bolt hole with camshaft bolt hole Tighten the sprocket mounting bolt Caution Make sure timing marks are matched Install a now O ring onto thermostat and tighten ita mounting bols Loosen sprocket chain tensioner amd let contact with chain plate tight
19. Analysis of potential causes See page 19 works RPM Poor too slow Check battery charging and contact of pins oosen the carburetor leakage screw to check Bright light 5 Dim light or light off Fair Poor Check the echarge the battery Check the solenoid switch Charge the battery or Check for existence nd be sure the starting moter of the starting replace it In case of poor Of water or other Ghea roperly secured In the switch motor for noise charging in addition to Impurities in the pu ase of poor during work recharging check the carburetor buoyant uel tank harging proceed charging system of the power ith a new charging J lant for failure nd check the oO L fal harging system of No noise Fair power plant for Check contac of Noise the starting Peck the starting Check for fuel Clean the switch gear and speeding spill inthe carburetor wit No fuel b Starting gear of the starting carburetor and the relay motor for abnormal fuel filter Add in ne breaks or engagement designated others in short circuit Poor Fair heck the fuel ae Loose Repair or Check skips aa and the ubin contact or replace in spark g wiring P 5001 Fair Fair Poor Check fuel tank zl ventilation skip tubing for aT obstruction and needle valve Replacement
20. given tame limit or Ihe opening Pressure is too high too low The specified pressure ehall be maintained al ieget for seconde the test Relief pressure Tor tha filler cap 0 75 1 05 Apply pressure lo the radiator engine and water hose to check for any leakage fy Caution Pressure which ix too high may damage the radutor Never pressure which 1 08 If he system fads to maintain the specified for at least seconds repair replace purs Change of coolant AN Warning to Garry oul work on the cooling sysiem unless the engine complotaly comed down otherwise you may get scalded Ramove the fiar cover and tha filler Place water pon uncer ihe water pump loosen the drain bolt to drain aut the coolant Haimistall the dram bell system wiih coolant and bleeding ihe air bubbles Run the engine umil the eanalsnt surface becomes StS and there iz bubble coming nut Stop the engine Add coolant to proper level if necessary Screw and tighten up the filler 117 PDF created with pdfFactory Pro trial version www pdffactory com LUOOm Ajojo amp ypa UOJSJGA leu 811 paseo Bund eenBpnui gio p pue su Z sanas juega ups
21. pue pear epos bpn uopaneg jean jo eur aujBus ueg apoa jo 204 8 jo uuo g uogrogdde exui 7 jo ONES 001 sisouBelc ueo joo sisoubeip eu pue n3 eujus jou ING uo Aay 7 uo aggsoubaerp 01 joo pauvo San pasta siouDmp ques pur ADayeis up Tey weud ABagens amp 8i sasun je s duind pany pue aug dagenge Bujaup pug Bursuas uomipuoa auibus jo janua 53 5 jueuoduna qun aq Jayoos Uid gc pue 01 8 Aq pauswog 5 5149445813 uondu sa wasis 43 wasg jang Fuel Injection System Functional Description ThrotBe body is fuel inject system inlet flow regulating body
22. uoqies ge dn veng 5 ONY NOLLO3dSNI 1735 3ATVA 151 PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE Use 60 cutter to cut a quarter lower part cul Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified wicth 1 0mm 0 04 in Make sure that all roughness and uneven faces had bean ground Grind valve seat again if necessary Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve slightly press down the valve but do not rotate that seal track will be created on contact surface A Caution The contact surfaces of valve and valva seat are very important to the valve sealing capacity the contact surface too high grind the valve seal with cutter Then grind the valve seat 10 specified width if the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat to specified width PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE After the valve sent ground coa valve soat surface with emer and then slighth press the ground surface Clean up all emery coated onto cylinder and valve after ground CYLINDER HEAD REASSEMBLY Lubricate valve stem with engine od and then insert the valve into valv
23. 0 pana mo SAL pariu uaa 7950 Auaedes po aufus po eee papasus Loren WIS go 970 17 NA Mie ep pesn eq ug eygen 0000 ump sou pug ADOC apun ued 9259 Agir poco pue AOS prump WED mp aues augus i6 de papa suus ee pe uis eBueu Io dA FAD gt Tija sag mers jor os go puts Weu iu up SAS open au pue wn TIO W31SAS NOY Sam LUBRICATION SYSTEM Pump Removal Remove generator and staring gear Remove nap ring and take out oll pump driving chain and sprocket value 8 1 2 dur that pump shaft can be rotated freely Remove on the pump and then remore nil Oil Pump Disassembly Ramowa the soewe on pump cover and disassemble the pump illustration shown 110 PDF created with pdfFactory Pro trial version www pdffactory com LUBRICATION SYSTEM Oil Pump Inspection Check tha clearance between all pump body and outer rotor Lamm 0 25 Chec
24. Install Install the andi demolition orter Clean air cleaner filter Remove mr cleaner cover bolt amp B Remove air cleaner filter Use compressed air lo remove the adhesion of dirt if nat too much dirt cleared please mew replacement Cautions Air cleaner filter for paper products must not soak or cleaning by walter Install air cleaner filter Install In the anti demokbon order A Cautions cleaner filter and air filter cover should be covered fonmation me not to skew seam resulting dust foreign body aspiration in the angina PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System _ nnn Fault Diagnosis Note When the motorcycle injection system in the wrong signal causing abnormal functioning of the engine or start engine warning ight at the meter will be lighting to inform drivers to aut maintenance Overhaul the diagnosis tool can be used for troubleshooting refer to diagnosis tool use guide manually by the meter warning light inspection revealed that the fault codes refer to checking signal fault codes discriminant method the two methods for maintenance the fault has been ruled out or repair after the inspection light will be extinguished but fault code will be recorded 50 the need to get rid of fault codes fault exists this system has two kinds of
25. Lisussenby 1000 Charge 500 Gear cil Disessembhy 110 SOW 40 Change 100 EAE 10W 4d Od SEA 10W 30 T S Recommended King oik Gear nil Geur dil vscosdy SEA 140 Recommended SYM Hypold gear items Standard mm immer ry clearance is il pump between outer rotor and body a 15 0 20 Clearance between and 004 008 Limitimm 0 30 Torgus oil strainer 1 3 1 7 Gear oil drain plug 1 27 4 Egf m Gear ail inspection Goll 1 1 1 4 Oi pump bait 0 8 1 2 Kgf m TROUBLESHOOTING Low atl ere Dirty change in periodical guide seat worn Cylinder head gasxe damage Piston ring worn gul Pisten ring warn eut Low oil pressura gt Lowy engine oil evel Gagged in alt sirainer circuits of pipes CH pump damage 108 PDF created with pdfFactory Pro trial version www pdffactory com LUOOm Ajojo amp ypa UOJSJGA leu 601 pa puisse Duj amp n pepuauaipae GANG See Aes uo po ue jg rperianpgesenbaa des jeg Dunda pue gens pisn aq funda qne go
26. Xmotion 125 250 OWNER MANUAI MAINTENANCE HANDBOOK TAIWAN GOLDEN BEE CO LTD PDF created with pdfFactory Pro trial version www pdffactory com TABLE OF CONTENT 1 REGULAR INSPECTION 1 1 Delivery Introduction 2 1 2 Inspection Before Running 4 1 3 Regular Maintenance Schedule 5 1 4 General Inspection 6 1 5 Notes for Inspection 7 2 MAINTENANCE INFORMATION 2 1 Specification Sheet 8 2 2 Safety PrecautionS 10 2 3 Special Tools 11 2 4 List of Grease amp Oil Adopted 24 2 5 Circuit Drawings 25 2 6 Troubleshooting 27 2 7 Tighting Torque of Screws 27 2 8 Troubleshooting 30 3 DESCRIPTION OF PARTS AND COMPONENTS 3 1 Engine 39 3 2 Electric System
27. the injector can be different engine load conditions Fuel Injector width time to control the fuel injection quantity Fuel pum pap mounted inside the fuel tank Rely on battery power supply from the EGU control opening and closing idling at the fuel pressure 294 about 3 kg PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Ignition System Outlined Principle The engine used computer program is when the ignition control from the Crank position sensor Throttle position sensor O2 Sensor Inlet pressure sensor Intake temperature sensor Engine temperature sensor issued by the signal With engine speed B bit microcomputer by the appropriate decision when the ignition is fram a current transistor control of intermittent 25000 30000 V is a secondary hypertension flashover triggered spark plug This way not only can be the engine to achieve the maximum output power but also help improve fuel consumption rates Specifications 1 Ignition timing 13 BTDC 1050RPM 2 Spark plug Clearance 0 6 10 0 7 mm Blue Yellow Ignition coll primary circuit 3 6 10 20 C Red Yellow Black Yellow 5 Battery Type Capacity YTX12A BS or GTX12A BS 12V 12Ah 25 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Sensors and Drives Outlined Crankshaft Position Senso
28. 10 hours 20 hours 30 hours Pour electrolyte after made into battery Lay 30 minutes then begin to use 6 Connect the black lead to the pole of battery red to pole put the battery to the location and clamp the rubber band 7 For the connected plastics long tube to the air vent hole of battery the other end of the tube must be setted through into the square hole in the plastic leg shield rightly to discharge the erosive air or sulfuric acid to avoid eroding the body The tube must be without plugging or straight bending to avoid exploding CAUTION It s important to use open long tube to instead of close short tube to assure normal output of gas to prohibite of exploding 4 BATTERY MAINTENANCE FOR WATER ADDING BATTERY 1 Use the same key of main switch to trun right or left 128 PDF created with pdfFactory Pro trial version www pdffactory com to open inner box lid then disconnect the battery band and take out the battery finally take off cable 2 Checking electrolyte add distilled water to refill and adjust to upper level in case of adding distilled water frequently checking the over charging of the battery No voltage indicated on the terminal or no action on rectifier means short on the battery the voltage will higher than normal and the life will shorten 3 Inspect charged condition Add electrolyte to the upper level and check by battery hyprometer as attached drawing The
29. Care be taken when instaling piston Into cylinder Press piston rings in by as matalalta A Caution mot push piston into cylinder forcefully because piston and piston rings will ba damaged install coolant hose onto cylinder Install cylinder haad refer to Chapter PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER PDF created with pdfFactory Pro trial version www pdffactory com LUOOm Ajojoewpa NMM UOJSJGA IBUI Odd uaan E guercxnsu 7 4 paeds yy 2008 10 Jamodasuoy DY priu Lir Inu Ly Japnd 1001 saag 5 090 vt 520 06 6 000 Zz __ we 1 ___ ___ Buuds jo said 000 00565 o ____ SSC wn tienen piping YSN 2 yana ua Jappnus uaap Gio C BOR aaup WOM 7 weg 71 jou jnq papes SISONOVIO 318n08 1
30. circuit 4 3 4 STARTER MOTOR 1 Please place main stand to park the motorcycle for inspection 2 Turn the main switch to OFF position before maintenance Disconnect the battery ground circuit To ensure safety turn the main switch to ON position and check if the motor has operated Disassembly Remove starter motor cable 2 starter motor attaching screws O 2 motor case attaching bolts O Starter motor Check Starter Commutator Inspection 1 Check continuity between segments Note A If continuity is good then it is normal B If no continuity then it is broken 2 Check continuity between segments and armature shaft Note A If no continuity then it is normal B If continuity is good then it is broken 3 Clean the commutators if there is metal powder between segments 4 Check the removed parts for damaging burning discoloration and wearing Replace with a new if necessary 5 Check brush length Note A Initial standard brush length is 112 5 mm B If brush length is smaller than 8 5 mm please replace with new brush Inspection Check continuity of the brush holder Note A If there is no continuity it is normal B If there is continuity it is broken Please replace with new one Installation install in reverse order of disassembly procedures 204 PDF created with pdfFactory Pro trial version www pdffactory com 4 3 5 RESISTOR Disassembly Remove front windshield cover Measure A Us
31. peoscular sey 1 LI euo mau 3 ul paseia y jou og uogne 068 no ej Burreeq episyna jepu qe SOL AA Hoa juBu eur cquo ps paz suoja sa Cupei juspeas pajinbas 14 OL eg oque peers eng Y Biuriacaner sae pas Anu e uognnez Busigeg pane spo MEL eus je ino pue proe exu jeog sap jo 3ueure2ed agg WALSAS ONlIOO2 P91B9J0 LUOO U0JSJ9A NT BU P91B9J0 a si eu f 57 L 0 L anjeA wan pue ouo ESS jpartu un jeujeBc paveida eq renw uognej 010 OSE su Pou dund Jawu prou peui au jauur jets duund Japa WALSAS COOLING SYSTEM Install the right crankcase cover bolt 8 install the dowel pin
32. similar to the role carburator a valve shaft of The driven synchronous positon sensor ECU immediately to detect the throttle opening Throite positioning screw and the factory has been adjusted at Chatham positioning in principle Shall not adjust Above configuration idle bypass control valve role when engine cold compensation air tn easily siart vehicles hot engine after the engine by reducing demand for air pipe Treatment of abnormal phenomena fuel Injection associated components identified no adversae and other tradiBonal engine components normal the engine is stil smooth please confirm whether the throttle body coke serious If coke serous please clean throttle body and then adjust the injection system PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System intake Pressure Sensor Functional Description Powered by 5V DC from ECU It hae 3X pin socket on ihe sensor One terminal is for power and 1 terminal are for signal output And the rest one is for ground The major component of the intake pressure sensor is a variable transistor IC reference voltage is DC 5V and output voltage range is DC 0 5V asansor by sensing pressure and can measure the absolute pressure in intake process t also conducts fuel injection quantity corectian based environmental postion l Function
33. uj 079 076 3nu gt Wb 079 06 nu ua ug anbua m GAD jo gi Gay eq 15nu Aegnd pue yeg Bu 9 uo aq pue UENO eo e ug uj NOILdIH2S3O0 39NYN3 LNIVIN 4314915 42I4 W315AS ONIAING L138 A PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER LEFT CRANKCASE COVER Left crankcase cover removal Remove body cover Remove air cleaner 2 bolts Remove kick starter 1 boll Remove L crankcase cover B bolts Disassembly of Kick Starter Remove snap ring and thrust washer from L Starter spindle crankcase cover Install kick starter arm rotate the arm slightly and then remove driven gear and washer ae Remove the kick starter arm starter spindle and f return spring as well as socket m oO E Return spring Inspection of Kick Starter Check if starter spindle driven gear socket and bearing hole for wear or damage Retum spring Starner shaft Friction spring PDF created with pdfFactory Pro trial version www pdffactory com LUOO U0JSJ9A BU P91B9J0 42 4 JE SU J A0S SSEONUEID yaj eu esu BSEDYULID Yo au jo OLY jo eab uonau eur 8u ajpurds
34. Clean fuel of new filter and fuel starting motor tubing or replacement and check for work Correct the engagement of the starting motor with the speeding clutch Refer to 1 8 3 Skip in Spark Plugs for checking PDF created with pdfFactory Pro trial version www pdffactory com Fair Fair Adjustment or replacement of carburetor buoyant needle valve Refer to 1 Replace the 8 2 Poor original skip in starting motor Spark or repair it Plugs for checking ventilation tubing Check spark plug for cleanliness normal gap pollution by gasoline If yes check the choke of the carburetor Fair Poor Check if the adjustment screws of the carburetor need to be regulated Clean and adjust spark plug gap or replace with new Readjustment Check choke of the carburetor for troubles L Check if the slop nozzle of Adjust or the carburetor is replace new obstructed or the choke parts threshold fails Fair Poor Test the Clean or replace the slow nozzle or correct replace compression with new threshold Fair Poor Check air filter gril Check cylinder washer for leakage for obstruction check cylinder piston piston ring for wear with correction adjustment or replacement PDF created with pdfFactory Pro trial version www pdffactory com Check item No fuel Dirty fuel filter Obstructed ventilation tubing of th efuel tank Poo
35. Electrolyte 1 280 1 250 1 220 1 190 1 120 Specific Gravity Charge Level rol 3 4 1 2 14 Totally Charged Charged Charged Discharg B Charge by generator Connecting battery and gener terminals by with and L with Warning Battery releases explosive gas during charging or use battery Therefore it is dangerous to do so in concealed location Please put battery in good ventilation location during charging and forbid fire Note 1 Standard charging current 0 6 A for 5 10 hours 2 Quick charging current 6 0 A for 30 minutes 3 Please do not use quick charge except for emergency 4 Measure the battery voltage 30 minutes after battery is charged The battery voltage should be higher than 12 8 V C Battery manufactured month and charge time comparison inufactue Within After3 amp 1000 Within Over Months mo mo yr yr Charge Add electrolyte 10 20 30 hr 40 60 Time And wait 30 m hr hr 5 hr hr 4 3 3 SHORT CIRCUIT TEST Disassembly Disconnect battery negative terminal cable Measure method A Connect megga meter terminal to battery terminal 203 PDF created with pdfFactory Pro trial version www pdffactory com B Connect megga meter terminal to circuit negative cable Note User megga meter A current position m Turn main switch to OFF position Inspection Check if there is electrical current If no current check the main switch and wire harness for short
36. LJVHSHNYHO2 CRANKSHAFT CRANKCASE D lt Crank shaft puller FJL crank case disas install tool Clutch nut wrench Install new dowel pin and new gasket Install the right crankcase onto the laft crankcase Tighten seven bolts on the crankcase Torque value 0 8 1 2 kgf m PDF created with pdfFactory Pro trial version www pdffactory com LUOOm NWM UOJSJGA IBlJl Ajopejpd WES WED g ZL eu pue Jaucrsus pereu ges eu dip o jou Bug ui ASEJE eu ui ess eu DOSLZLE INAS g8 0F Sz 100 12995 usnjos UES uu eu ueaj Bes po jo dij uo asee Addy FESS au 3JSVOMNHNVHHO LJVHSMHNYVYH 2 4 3 REMOVAL AND INSPECTION OF ELECTRIC ITEMS 4 3 1 Operating Cautions amp Troubleshooting Operating Cautions 1 Warning a The liquid in the battery is diluted sulfuric acid that is dangerous If your skin or eye unfortunately get contact with it please wash with water abundantly and consult immediately a doctor lest you should lose vision b If your clothes is touched by the electrolyte your skin would also be touched Therefore you should get it off and wash with water abundantly 2 Check if electrolyte in the battery is sufficient If not add distilled water till the liquid level reach the upper
37. Nut M16x10 600 900 Rear Brake Connecting Rod Bolt 16 32 50 80 8 Rear Brake Pin Self lock Nut 250 270 Li Rear Upper Cushion Tightening Bolt M10 46 200 300 EA Rear Lower Cushion Tightening Bolt M8 35 200 300 Torque Values of Engine components 8 195 5 Cylinder Intake Pipe Stud Bolt 6 50 500 800 Muffler and Exhaust Pipe Tightening Screw 100 120 Muffler amp Right Crankcase Upper Tightening Maxaa 300 490 Screw Muffler amp Right Crankcase Lower Tightening 300 400 Screw Valve Gap Adjust Lock Bolt 50 90 30 Fuel Filter Nut Cap M 150 200 Cooler Fan Lock CR M6x18 500 800 Wire Assembly Lock Screw M6x20 800 1000 ELEM Start Clutch Gear ightening Nut M22 R T 800 1000 Driven Belt Pully Assembly 400 600 28 PDF created with pdfFactory Pro trial version www pdffactory com Gearbox Cover Tightening Bolt M6x28 100 1200 22227 Clutch Side Cover Screw 6 40 50 80 Starter Arm Tightening Screw M6x22 100 120 29 PDF created with pdfFactory Pro trial version www pdffactory com 2 8 TROUBLESHOOTING 2 8 1 Troubleshooting for failure in starting the engine Does not work Check if the starting motor works Does not work Check if the starting gear and th if the battery is speeding clutch of the startin properly charged motor suffer critical wear if yes for inlet of fuel replace them Works Engine does not start Check if the crank shaft works
38. System 3 Used the diagnosis tool to confirm of sensor work situations Connected the diagnosis tool 16 diagnosis coupler and open the main switch to start the engine Engine t be completely warm up idling state operation 5 minutes above Screen will switch to the diagnosis tool of DATA STREAM 01 01 screen select Sensor project and switches to wave of images turn the throttle engine speed to about 4500 rom Observation O2 Sensor actuator circumstances Observation OZ Sensor voltage values that the situation changes Humecical voltage changes the Detection judge Working voltage value above 10 value 6 7 10 60 Sensor amendment in tha voltage value of between 100 900 mV beating representatives pollution closed loop control system to normal contrary maintain a fixed value for abnormalities Treatment of abnormal phenomena sensor damage heater damaged or couplers to poor contact Check whether the abnormal wire harness limes O2 Sensor anomaly the proposed replacement of the Sensor and measurements again PDF created with pdfFactory Pro trial version www pdffactory com 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 85 degrees over sensor will be the implementati
39. amp RH HANDLE BAR ASSY GRIP CABLE CABLE THRORRLE PDF created with pdfFactory Pro trial version www pdffactory com CU8 amp CUB Remove upper and lower bolts on the shock absorber assy Shock absorber assy Remove the bolts on the suspension ram Suspension ram CU8 B amp CUB B Remove the bolts on the fork comp Remove 4 nuts Fork comp front LH amp RH 4 4 3 Removal and Assembly of Wheel and Shock absorber Front wheel Watch Please place main stand to park the motorcycle for maintenance Removal Remove 2 bolts on the caliper Caliper Remove bolt and collar Remvoe speed meter cable nut Note Do not apply brake when removing caliper from brake disk Otherwise the lining can contact Front wheel Inspection Check eccentricity and wear condition Note If eccentricity is higher than 0 2mm please replace with new one to ensure driving safety Speed meter gear assembly Inspection of Wheel Rim Put wheel rim on rotation stand Rotate the wheel slowly and use dial gauge to measure eccentricity Note 1 The transverse eccentricity should be within 3 0 mm If the condition is poor please replace with new one 2 The lateral eccentricity should be within 3 0mm If the condition is poor please replace with new one 211 PDF created with pdfFactory Pro trial version www pdffactory com Rear wheel Watch Please place main stand to par
40. any protection D The Seat has to be locked If the Seat is not locked during riding it will affect the safety and even cause injury Please pay attention not to let fuel or oil drop into the compartment F The cover of the compartment can be cleaned with vacuum cleaner It can also be washed and put back after dried Please do not wash with volatile fluid such as gasoline The seat is controlled by the seat lock on the side 2 Helmet Holder There is a Helmet Holder at the position of Seat Hinge open the Seat to hook or unhook Helmet 134 PDF created with pdfFactory Pro trial version www pdffactory com 3 3 3 Front amp Rear Suspension System 1 Front Suspension A No suspension on Front Fork For B Type B Brake Con rod and Bracket of Brake Lining are equipped between Front Fork and Disc Brake Resistant Torque occurrs toward the revolving direction when acting brake The Torque will become the force to push Front Fork up by using connection Rod Therefore the sink of Front Fork is stopped and decreases the change of sitting gesture while the brake is used 2 Rear Suspension A Suspension Mechanism is composed of single telescopic absorber between the crank case and scooter body Rear Axle Movable by telescopic shock absorber 3 3 5 Tire amp Tire pressure Inspection Check if tire has been cracked damage worn inclusions stone nail glass etc If tire is in poor condition please
41. density of charged battery must be 1 26 1 28 above 20 if the density below 1 2 20 it means fully dis charged and must be recharged The battery must be checked electrolyte level density and the voltage after charging 5 RECHARGING OF THE BATTERY To Take off the fixing plugs of the battery before charging Use 1 10 current intensity of the capacity to recharge the battery about 15 20 hours at normal condition connect pole of the battery to pole of the charger and with CAUTION 1 Keep the battery away from flames sparks and cigarettes 2 If the temperature of the electrolyte is higher than 456 it must to change to half of the current intensity or stop to charge until decrease to get under 35 C 3 After charging the battery adjusting the electrolyte to upper level and recharge 1 2 hours again then put into the fixing plugs washing and protect with vaseline 4 Disassemble the pole terminal at first before taking out the battery from scooter begin to assemble the pole terminal reversely 5 If it couldn t reach to 12v after charging the battery for 15 20 hours it s necessary to replace new battery 6 REGULAR MAINTENANCE OF THE BATTERY 1 Keep the battery clean and dry 2 Protect the terminals with vaseline 3 It can reduce the time to 5 6 hours to charge battery at urgent case 4 Don t use fuse which above standard otherwise it ll cause broken of scooter or even firing 5 It must to char
42. limit line 3 The battery is rechargeable after discharging If it is unused after discharge it may deteriorate and shorten service life It will become less efficient After usage of 2 3 years battery capacity will decrease It can be regained by recharging several times 4 When there is other loads while igniting if the voltage will rise again after an abrupt falling it is normal 5 If a battery is unused during a long time its energy storage will decrease by its auto discharge Therefore a recharging is necessary around every 3 months 6 To charge a battery it shall be removed from the car and its filler plugs removed To put the charging current or OFF you must operate at the charger s switch You shall not connect or pull off directly on the battery because electric spark may provoke hydrogen explosion 7 During battery charging hydrogen is produced It is an inflammable gas Fire must be forbidden 8 At recharging a battery the temperature of electrolyte shall be lower than 45 lt 9 To test if a battery is fully charged please use a voltmeter Never use Spark method 10 When there is current in an electrical installation please do not pull off a contact then connect it again because resulting over voltage may damage electronic parts in the commuter Therefore this operation must be done after the main switch is put OFF 199 PDF created with pdfFactory Pro trial version www pdffactory com
43. the START button try the kick starter 2 Fuel Inform customers to refill the fuel to no more than 80 of the tank capacity only PDF created with pdfFactory Pro trial version www pdffactory com 1 1 Delivery Introduction 3 Lubricant Adopted A WARNING The engine oil must be refilled when the oil warning lamp lights otherwise the engine will be burned out due to insufficient lubrication Recommended oil TGB Genuine EXTRA 4X OIL Genuine HYPOID GEAR OIL or SAE85W 140 will be adopted as gear oil to be changed on a periodical basis Gear oil and engine oil are different in their nature Attention should be paid to avoid mistake when used 4 Regular Inspection and Maintenance Inform customers of the importance of inspection before running and regular inspection A Inspection Before Running Riders should perform nspection by themselves before running B Regular Inspection Regular inspection should be performed after the first month and the sixth month and every six months afterwards 5 Description of Warranty System Clearly identify the content of warranty in accordance with the warranty paper A Content and term of warranty Maintenance items not guaranteed C Items should be followed by customers Instruct customers to carry the OWNER S Manual with them when they come for regular inspection and maintenance It is because such inspection should be recorded onto the Manual PDF created with pdfF
44. the temperature sensor PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System O2 Sensor Functional Description Use 6 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 O2 for a signal pin 02 Sensor output feedback signal to the ECU fuel ratio control in the vicinity of 14 5 14 7 a closed loop fuel control When the air fuel ratio control in the near equivalent CO HC Nox to have the highest conversion efficiency Testing Procedures 1 oe confirmed Removed O2 Sensor and the wire hamess between the coupler Open the main switch but not to start engine Use meter DC stalls DOW to check inlet pressure sensor voltage Confirmed working vollage meter negative access to the wire harness sensor coupler 2nd pin Red Orange Voltage meter positive access to the wire harness sensor coupler first pin Red Yellow 2 Resistance Confirmation Removed 02 Sensor and the wire harness between the coupler of the meter Ohm stalls Measurement OZ Sensor heater a Measurement resistance value Ohm meter negative access to the O2 sensor coupler 2nd pin White Ohm meter negative access to the O2 sensor coupler first pin White Resistance Confirmation PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection
45. to minimize the exhaust pollution PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fuel System Outlined System Description 1 The fuel tank of fuel pumps in the Key on the sensors signal 10 be sent to the ECU control fuel pump relay fuel pump to start operationm if not start the engine fuel pump will be 2 to 3 seconds after the closure in order to save power Pressure regulating valve to the fuel manifold pressure maintained 204 6kpa about 3 kg 2 injector according to operating conditions and environment appropriate compensation coefficient fuel emissions Key off or engine stopped operating the fuel stop moving 2 Gasoline filter Impurities in the fuel filter should be regularly replaced err 3 When the engine could not start do not start motor for continuous moverent which led to lack of battery power less than 10 V the electric fuel pump will not be able to move the correct way is a new battary lap munem injector to provide two intake valve fuel injection quantity increase fogging effect AS be easily fired injector and receiving fuel from the fuel pump fixator limit injector rotation sliding injector fuel injection quantity from the ECU signal control Pressure Regulating Valve Regulator the use of the diaphragm spring and fuel manifold vacuum pressure and maintain pressure in 294 Gkpa about 3 cm 7
46. voltage Cautions Attentions to the tools required close to the probe wire waterproof penetrate skin and internal terminal before measurements to the correct value Throtie output signal measurement full closed Detection judge Working voltage value 5 030 1V Full throttle voltage value 0 620 D2V Full throttle closed voltage value 3 770 1 Throtthe output signal full PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Engine Temperature Sensor Functional Description Powered by 5V DC from ECU IL has the two pin socket on the sensor One terminal is for power output and 1 terminal are for ground lis main component is a negative bemperature coefficient resistance temperature rise smaller thermistor Installad in the cylinder head tha engine Temperature sensor resistance with the induction to the temperature change and converted into voltage signals sent to the ECU was calculated engine temperature ECU accordance with the engine warm up to amendment the injection time and ignition angle Testing Procedures Dismantled engine temperature sensor Use of the meter Ohm stalls inspection sensor resistance Troatment of abnormal phenomena Temperature sensor damage or couplers poor contact Check whether the abnormal wire harness lines Temperature sensor anomaly the proposed replacement of
47. xe speed e of carburetor Dirty fuel rtarmitt ntiy as of griion system Late 13nitio n Wabunciinn af gation system Haslunctian of Power insufficiency and fuel consuming system zlozged Mallunctian of ignitien system Mixture too lean Clogged fuel Injector Vacuum piston stigi and closed of last valve Fuad too tow in foal chamber furi tank cap veri fuel fer Ofscructed fusil pips air vant howe Aa ating in intake Syete Mixture to riet Clogged air injector kisbunctian af value Furl tevel too nigh ost chimie gf aute Diny af clearer ELE g 41 PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM AIR CUT OFF VALVE Inspection Disconnect vacuum hose and vent hose irem ihe air cut aft valve Connect a hose from vacuum hose connector to pump Connect air pump ta alr vent Apply wih specified vacuum 1o ai cut off wahe Vacuum value 420 800 mm Hg Fump compressed air from air pump te air vent hose Caution he vacuum can not be over 600 mm Hg Or amp gir cut olT wal damaged is in i will restrict gir tcw is restrict replace carburetor assem 42
48. 0 Torque value Fhywheel nut 5 0 8 0 Starting clutch hexagon bolt 1 01 4 kgf m with adhesive 8 mm bolts 0 8 1 2 12 mm bolts 1 01 4 Tools Special tools A C G fhrwheel puller Universal holder 185 PDF created with pdfFactory Pro trial version www pdffactory com ALTERNATOR STARTING CLUTCH Right Crankcase Cover Removal Remove 7 bolts from the right crankcase cover Remove the nghl crankcamse cover Remove dowel and gasket A C G Set Removal Remove 2 mounted bolts from pulse generator and then remove it Remove 3 screws from crankcase cover and ACG sat Flywheel Removal Remove pil through from crankshaft Remove the pin from crankshaft PDF created with pdfFactory Pro trial version www pdffactory com ALTERNATOR STARTING CLUTCH Hold with holder and then remove fhyrwneel nut Tool Multi functional holder Pull out flywheel with ACG flywheel puller Tool A C G Flywheel puller Starting Clutch Removal Remove starting driven gear Remove mounting plate starter reduction gear and the shaft PDF created with pdfFactory Pro trial version www pdffactory com ALTERNATOR STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage Measure the ID and OD of the starting clutch pes Service Limit ID 20 1 mm 00 42 10 mm Check the starting reduction gear and shaf
49. 11 fresh electrolyte is poured a new battery a voltage will be generated after a certain lapse of time If the voltage is not sufficient then a recharging is necessary A recharged new battery has necessarily a longer lifetime 12 The C D I of the ignition system shall not fall swinging and be shocked It is a cause of frequent breakdown Therefore a special precaution is necessary in its dismounting and remounting 13 Bad contact between plug and jack causes often the breakdown of the ignition system Therefore before undertaking repair the contact is to be checked at first 14 Spark plugs of a suitable heat value and gap are to be used Otherwise engine will not work smoothly or break Troubleshooting Battery Recharging System No voltage 1 Battery cable fallen or disconnected 2 Fuse fused 3 Defective of flywheel magneto 4 Excessive battery discharging a Electrolyte leaked b Chemical reaction in battery c Short circuit in battery d Defective rectifier Low voltage 1 Insufficient recharging Leaking of electrolyte Defective separator causing short circuit between positive and negative plates 2 3 1 Defective battery terminals 2 Defective recharging system 3 Defective rectifier Excessive specific weight of electrolyte 1 Insufficient recharging 2 Leaking of electrolyte 3 Reaction between sulfuric acid and pole plates 200 PDF created with pdfFactory Pro trial version www pdffa
50. 16 COVER SET LEG SHIELD 17 FRONT LUGGAGE BOX 18 LEG SHIELD REAR 19 COVER RIB LH amp RH 20 LEG SHIELD SIDE LH 4 RH 21 CUSHION LEG SHIELD LH amp RH 22 FRONT FENDER INNER 23 LEG SHIELD LOWER 24 FENDER REAR TANK FUEL 25 FRONT FENDER FOR CUB 26 FRONT FENDER UNDER 2 FRONT FENDER FOR CUB B ONoa PWN 131 PDF created with pdfFactory Pro trial version www pdffactory com 132 PDF created with pdfFactory Pro trial version www pdffactorv com Dismount floor panels following the sequence shown in the list Carrier Cove Handle Bar Upper Bottom Plate Leg Shield Front Right and Left Side Front Fender Cover Cover Set Leg Shield Fender Fixed Front Cover Handle Bar Leg Shield Side Under Lower Leg Shield Rear Leg Shield Lower Cautions 1 Do not damage cover of body panels while dismounting 2 Handle with care regarding lugs of to avoid damage dismounting 3 When remounting do not scratch or crash wiring 4 While assembling every lug shall be fixated effectively 5 While assembling make matching panels and their slots 133 PDF created with pdfFactory Pro trial version www pdffactory com 3 3 2 Compartment and Seat 1 Compartment A Located in the center of scooter body there is a Personal Space for helmet and other etc The maximum load capacity of compartment is 10kg C Please don t store precious or easy to break articles in the compartment without
51. 300 kg cm Installation Install in reverse order of removal procedures e 213 PDF created with pdfFactory Pro trial version www pdffactory com 4 5 Brake system CU8 amp CUB 1 MASTER CYLINDER e WS 2 HOSE ASSY 3 CALIPER 4 PAD ASSY 5 DISC BRAKE 6 REAR FORK ASSY 214 PDF 5 created with pdfFactory Pro trial version www pdffactory com CU8 B amp CUB B 1 MASTER CYLINDER fn BE d M 2 HOSE ASSY 3 CALIPER 4 PAD ASSY 5 DISC BRAKE 6 REAR FORK ASSY PDF created with pdfFactory Pro trial version www pdffactory com A Check of braking fluid level Inspection The front brake fluid level should above LOWER If it is below refill the brake fluid and check leakage of the brake system Adding of braking fluid Stand the scooter at its main rest a leveled floor Turn open the fuel tank cap and add in designated braking fluid to the maximum Warning 1 Add in designated braking fluid a different fluid would cause hazardous chemical reaction leading to failure in braking 2 Keep water off the fluid cup or the boiling point would drop to produce air block leading to failure in braking 3 In case of spill of braking fluid to plastic parts wipe it off with a rag for aestheticism B Checking and adjustment of free braking gaps Note front brake free gap of 10 20 mm Adjustment of braking gap Remove Front windshield Turn los
52. 5 0 4 02 Sensor amendment in the voltage of between 100 900 mV beatings PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Throttle position sensor TPS Basic Principle TPS a rotary variable resistor when the resistance values at the moment will change voltage values glso change the resulting voltage value to reflect the throttle position Function Measurements throttle valve position feedback to control the engine ECU as the basis PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Idle Air Control Valva ISC stepper motor Function Stepper motor canirol to move forward or backward to maintain the engine running for air Figure 1 the stepper motor rotor on currents generated by cutting the stator magnetic line rotary torque generated resulting in moter rotor rotation Figure 2 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Secondary Air Inject Solenoid Valve AISV Function In the low engine load into appropriate to air in the exhaust pipe to reduce the emission of pollutants Basic Principle When the closed he engine speed and throttle opening greater than the setting the ECU can control open or PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Precautions In Operation G
53. ACG eet onio right cover 3 scraws Install pulse generator 2 screws Tie the wire harness securely onto the indent of crankcase A Caution Right Crankcase Cover Installation Install dowel pin and new gasket inated right crankcase cover anto erankcass Note thal align ihe water pump shaft indent with the ail pump shaft Install right crankcase cover 9 screws Connect water to the right crankcase COVEF Install ihe water pump cover onto crankcase PDF created with pdfFactory Pro trial version www pdffactory com CRANKSHAFT CRANKCASE G nerai information Crankshaft Trouble diaqnosis Assembly of crankcase Disassemblv of crankcase 1 2 1 6 kgf m J 1 0 1 5 kgf m 0 SS 1 5 3 0 kgf m o PDF created with pdfFactory Pro trial version www pdffactorv com CRANKSHAFT CRANKCASE General information Operational precautions This Section concerns disassembly of the crankcase for repair purpose a Remove following components before disassembling crankcase Engine Section 5 Cylinder head Section 6 Cylinder and piston Section 7 Drive pulley and driven pulley Section B generator Gtart driven gear Section 10 Starting motor Section 16 Incase it requires replacing the crankshaft bearing the driving chain of engine pump or the timing chain it i amp preferably to replace crankshaft as a unit Torque value Bolts
54. Black Signal output Green Red Ground Testing Procedures 1 Inlet pressure sensor connector to properly using the probe tool 2 Open the main switch but nal to start engine 3 Use volteg meter DC stalls to check inlet pressure sensor voltage 4 Confirmed working voltage Volteg mater negative access to the pressure sensor third pin Green Red Voltage meter positive access In the inlet pressure sensor first pin Yellow Black 5 Confirmed plains output voltage values meter negative access to the inlet pressure sensor third pin Green Red Voltage meter positive access to the inlet pressure sensor second pin Black Red Cautions Attentions to the toala required close to the probe wire waterproot apron penetrate skin and intemal terminal before measurements to the comedi value Detection judge a Working voltage value 5 0 0 1V Plains output voltage values 2 87 0 03V Conditions In the plains 101 3 kpa Measurement cautions The higher the altitude the measurement value to the lower voltage Sea lovel atmospheric pressure TAim 101 3kpa 7B0UmmHg 1013mbar E 1 Output plains Treatment of abnormal phenomena Inlet pressure sensor damaged or poor contact couplers Check whether the abnormal wire hamess lines inet pressure sensor anomaly the proposed replacement of the
55. IC gt Ifffitt SIGNIFICANT CHARACTERISTEC moss Br ope EB T TL T a T0 E e H3 T T3 556 is i cere a 5 u mE beer Green ___ GREENBLUE a 37 5 7 BLACRGREEN 35 EO A 00 CTN Pet Cam emne 4t eeno Lees fee e mU s ORANGE WHITE YELLOW GREEN ere BLACK RED SKYBLUECRANGE GREENWHITE 5 faw Toe eo WH BLACK YELLOW WHITEIBLUE 590 2 6 Troubleshooting Complaint Possible Reason No action for starter motor 1 Fuse breaks 2 No power in battery 3 Defective action of brake switch 4 Short circuit of starter relay No sparking or poor sparking 1 Defective spark plug 2 Defective CDI amp ignition coil unit 3 Defective magneto stator coil 4 Loose connection of lead wire Unable or Plug not sparking Replace Clean amp Difficult to start 1 Damaged spark plug or spark plug cap 2 Replace Dirty or wet spark plug 3 Defective CDI Replace Replace amp ignition coil unit or stator coil 4 Open or Replace Clean short in high tension cord 5 Defective Clean or replace ignition switc
56. IVER BEARING 6801 INNER OIL SEAL MEGHANICL SEAL 16 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS arid AMT lrarermission aide CRANK CASE I TRANSMISSION OIL SEAL DRIVER OIL SEAL 2574048 CHL SEAL 20 32 6 SEAL 25742771 17 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS 2 2 VALVE COTTER REMOVE AC G FLYWHEEL PULLER INSTALL DRIVER 18 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS 19 PDF created with pdfFactory Pro trial version www pdffactory com woom 5 1 TIVLSNI H3AONSH HSDH 5 5 HNYHO d D d A 2 1001 7192345 LUOOm Ajojoewpa Nwm UOJSJGA BU Odd jojoejpd Kauessy 001591001 ow LSM 80 1029 VAH DOOSI T51 urs ny mu mm x quas Buueeq asia HUIS H ____00 60 on 0001006 1 on youu vadde usu awn 51001 1Vi23dS SPECIAL TOOLS e fre sno 07 Bearing driver 1516
57. Measurement resistance value 3 Sensor anomaly the proposed replacement of the new PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Secondary air injection solenoid valve Functional Description Control power has two pin socket one for tha power supply one for grounding Secondary air inpection solenoid valve at the Idle 3500 rpm below actuator At idling ECU control solenoid valve by the grounding circuit to be moving closing Testing Procedures Resistance Confirmation Use of the meter Ohm stalls 0 measurement of the secondary air injection solenoid valve resistance value Detection Judge Resistance value 260 2 60 Treatment of abnormal phenomena Secondary air injection solenoid valve internal short circull or open circuit or coupler bad contact Check whether ihe abnormal wine hamess lines Secondary air injection solenoid valve anomaly the proposed replacement of the new one TH PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fuel Injection System Circuit oa 20A R kas 5 a Dy 0 s Charging Indicator 79 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fault Diagnosis EFi Circuit inspection Bulbs broken 27 Fuse broken NG 3 Battery wollag
58. OLD 15 374 000 2 Charging Device Power is given by flywheel magneto The voltage is controlled by voltage regulator Power is charged to battery A Flywheel Magneto Flywheel rotor includes four poles crossed N poles and S poles The stator consists of one high tension ignition coil and three low tension coils for charging and lighting to create change of magnetic field by rotating the flywheel to generate electricity 126 PDF created with pdfFactory Pro trial version www pdffactory com B Battery 1 Battery Caution 1 The electrolyte contains sulphuric acid is poisonous avoid to contact with eye skin and clothes Immediately wash with abundant water and call a doctor at once in case of contact with the eyes or skin Immediately drink beaten eggs or vegetable oil call a doctor at once in case of drink 2 batteries release explosive gases prohibit to closed to sparks flames or cigarettes 3 When charging or using the battery in a closed location make sure that ventilation is good 4 Keep off children hands 2 Instruction for Filling Electrolyte For Water adding Free Battery 1 Remove the Aluminum Seal on the filling hole of battery 2 Remove the cover bar and battery sealing bolt 3 Insert the filling hole of electrolyte container into the filling hole of battery Try not to spillage it 4 There are three pipes on each side Tap the bottom of container lightly when the electrol
59. PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM AUTO BY STARTER Inspection Turn off engine and waitirg for over 10 minutes for cooling Chock resisbinos acrags ihe two baemingis of tho auto by starter Resistance value Max 100 Measured after engine slopped for more than 10 minutes Replace the auto with new one if resistance value exceeds standard Riamowe carburetor allow it ta of for 20 minutes pressure lester rom sir Connect by starter circuit Pump compressed air to circuit Replace the aute by starter tha circuit chagged Connect betten posts 12v to starter amp connectors After 5 minutes test the Greuil with compressed air air flows through the ciculi then replace the sterber Removal Fixing plabe screw ard then rarnave Lhe plabe and muta fren carburetor Valve inspection Check if auto by starter and vaia needa for damage or wear cut Installation install aute by starter to the bottom of carburetor body Install plate to the upper groove ef auta by starter and install its flat surface to carburetor install screw and lighten 43 PDF created with pdfFactory Pro trial version www pdffactory com LUOOm Ajojo amp ypa AMMI UOJSJGA 180 Odd jojoejpd 1717 40 ei JO MSGS pne
60. PS eq uo gy OE suu uwd pue uajsid jou 00 uanne xy uus umep se voysed ja surado ayy sony uojgxd Buu uopsed eu Tapuna Buu doy uojsid ues NOLLYTTIVLSNI DNIH NOLSId apuja pue uoisid SOUETES aj meye GNA aJeduo unu 808 695 AAS LT T oj BUR apis ungsid aguna sr 0051500 ERLE SL ml amp Jano eso NOLSId HS0NNAD CYLINDER PISTON PISTON INSTALLATION Install piston and piston pin and place the marks the piston top side forward to intake Install pea piston pin enap ring O Go not let the opening of piston pin snap ring align with the apenina piston ring a Piece pece of cloth between piston and crankcase order prevent snap ring from falling into crankcase as operation CYLINDER INSTALLATION Clean up all readies and foreign malerials the matching surface of crankcase Pay atbention to not lel thse residues and l oneign materials fall inta crankcase Caution Soap ihe residues mta solvent so that tne residues be removed more easily instal dowe pins and new gasket Coat engine oil to inside of cylinder piston and piston rings
61. RTER Clutch lining Measure each clutch weight thickness Replace it if exceeds service limit Service limit 2 0 mm Driven pulley spring Measure the length of driven pulley spring Replace it if exceeds service limit Service limit B3 2 mm Driven pulley Check following ibems s If both surfaces are damaged or worn e If guide pin groove damaged or worn Replace damaged ar worn components Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing inspection Check if the inner bearing seal is damage Replace it if necessary Check if needle bearing is damage too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER Clutch weight Replacement Remove snap and washer and then remove 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 giasticity Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with gre
62. Torque value 5 0 6 0 kgf m DRIVE FACE Removal Remove crankcase cover Hold generator fhywheel with universal holder and then remove drive face nul Remove dive face PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER Removal Remove movable drive face comp and driving belt from crankshaft Remove ramp plata Remove weight rollers from movable drive face Inspection The weight rollers are to press movable drive face by means of centrifuge force Thus if weight rollers are worn out or damaged the centrifuge force will be effected Check rollers are wear aut or damage Replace it if necessary Measure each tallers outer diameter Replace it if exceed the service limit Service limit 19 50 mm PDF created with pdfFactory Pro trial version www pdffactory com U0JSJ9A BU P91B9J0 sage purae BOLE apus ewes peaaxe p jj pug BAUS Jeuur else pi ear us passes y jo japsujslp fuessanau pue WOM 51 5504 ji 39807 5 XODI W31SAS SNIAIda LT38 A MEN V BELT DRIVING SYSTEM KICK STARTER Install movable drive face comp ont
63. actory Pro trial version www pdffactory com 1 2 Inspection Before Running Items to be Inspected Before Running by Customers CONTENT GUIDELINE 1 NN em the oil volume 1 EE NN Oil Warning Lamp to see if the oil proper volume is proper 2 Fuel Is the fuel volume 1 Check fuel volume to see if it is enough sufficient to the destination 3 Lamp amp Is the lamp condition 1 Check if the lighting condition of head Direction well Is there any lamp tail lamp licence lamp brake lamp Indicator dirt direction indicator and other lamp is well 2 Lamps should be kept clean and undamaged 4 Back Mirror Is the reflecting 1 Look at the back mirror from the image well seat to check if the rear view is clear 5 License Plate amp dirt and damage 1 License plate should be installed letters Reflector should appear and numbers should be kept clear and clean 2 Dirt and damage should not appear on the reflector Check the distance of 1 Operate the handle lever slowly to the brake handle lever brake begin to effect in order to inspect the and the brake effect moving distance 2 Test the brake with low speed running to see the brake effect of front and rear brakes 1 Check if the air p of tire is proper sufficient with a sig ht deep enough 3 Unusual wear is not 1 Check landing flat of tire to see if desired any unusual wear appears 4 Breaking and damage 1 Check landing flat and si
64. and naw gasket Install the water pump cover wiih bos Temperature sensor Please refer to chapter 17 for inspection of Temperature sensor Removal Remove the body cover Drain out he coolant Disconnect the cable of termperalure sensar the temperature sensor Installation Apply coni of 3 Bond 1212 sealant equivalent to the thread of temperature sensor and install li on the holder Connect cable to the temperature Refil te coolant and bleed eut the air bubble 12 4 the right rear cover 123 PDF created with pdfFactory Pro trial version www pdffactory com COOLING SYSTEM Thermostat Removal Remove the rear cower Drain out the coolant Disconnect the cable from the thermostat Remove the woier hose from the tharmastat holder Remove the vent hase from ihe holder Romeve the holder and lock bolt From the cylinder head Remove the temperature sensor ard O ring from the holder Remove two and eeparalm the holder from Gover Remove the thermostat Inspection Visually inspect thermostat for amy damage Place the thermostat inta healed water te check ita operation Caution Whenever the and the lhermrinmeter in contact ta the wall of heated water container the reading displayed incorrect H the valve of the thermostat remains open at dom temperature or the valve aperalian ie ca
65. ar Lamp Brake Lamp Direction Lamp mm 2130 System Height mm 1380 Wheelbase mm 1500 120 70 14 140 60 13 0 12 0 02 mm Electric system Centrifugal type 2 o o ez H o 5 m s 8 lt Ignition Pointgap mm Transmission type Air Filter Paper Type Fuel Battery Type Gear Box 0 79 2 72 Gear Ratio Clutch type raked angle R1 R2 9 67 Transmis sion Motion system Braking system Frame Type Tire Pressure psi Turn angel Disk Disk Suspension Hydraulic pressed Spring type Hydraulic pressed Spring type Buffer Hydraulic pressed Spring Hydraulic pressed Spring Welding Tube PDF created with pdfFactory Pro trial version www pdffactory com CUB X Motion 250 E kg 1500 Dimension Total Engine Type 4 Lubrication system Liquid Forced circulation amp splashing Reference and setting 0 1 0 02 mm range IN Reference and setting 0 1540 02 mm range EX ie a Fuel System FuelCapacty Electric system 7 Point LN 5 Battery Type GTX14 BS Transm ission Clutch type Centrifugal type Transmission ps _ 8 2 30 Gear 7 42 raked 9 csi NN Box Motion System Tire Pressure D 0 s Braking system Foto ee Hydraulic pressed Spring type pe Hydraulic pressed Spri
66. ark plug Spark plug covered by carbon ll Electric leakage in ceramic part of spark plug d Electric leakage from spark plug rubber screen 3 Defective ignition timing a Defective flywheel magneto b Defective C D I Too large gap of spark plug d Too high electric resistance of spark plug Starter System Starter motor unable to run 1 MON Damaged battery Battery circuit broken bad contact or too large resistance at connections Fuse fused Defective main switch Defective front and rear brake switches Defective starter motor switch Defective starter motor relay Defective starter motor Circuitry conductor defective or broken 10 Starter motor drive pinion locked with the over speed clutch gear Weak drive of starter motor 1 NOOR WN Insufficient recharging of battery Bad contact on circuit conductors Strange object introduced in the starter motor pinion Armature shaft bent Commutator unclean or worn Brush worn or spring too weak Starting motor of relay defective 202 PDF created with pdfFactory Pro trial version www pdffactory com 4 3 2 BATTERY A Cautions in battery inspection and generator charging Inspection Use gravity gauge to measure electrolyte White is fully charged yellow means charge is required and red is broken or almost totally discharged Note Electrolyte s specific gravity and charge level comparison table 205
67. ase ante setting pins Install new clutch weight onte setting pin and then push to the specified location Apply with grease onto setting pins But the cluteh block should not be greased If so replace it A Caution Grease or lubricant will damage the clutch weight and effect the block s connection capacity Install the spring into groove with pliers 8I PDF created with pdfFactory Pro trial version www pdffactory com 181 PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER Install snap ring and mounting plate onto setting pin Roplacement of Driven Pulley Bearing Remove inner bearing Caution If the inner bearing equipped with seal on side the driven pulley then remove the oil seal firstly If the pulley equipped with ball bearing it has bo remove snap ring and then the bearing Remove snap ring and then push bearing forward to other side of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified sealing end should be forwarded to outside as bearing installation presser Install bali bearing by means of hydraulic presser Install snap ring inta the groove of driving face Align seal lip with bearing and then install tha new oll seal necessary PDF created with pdfFactory Pro trial version www pdffactory com LUOO
68. ce limit 0 05 mm PISTON REMOVAL Plug opening with cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling Hold another snap rng with pers Push out the piston pin from the side thal not the snap ning Inspection Measure clearance between piston ring amd its grooves Service Limit Top ring 0 09 mm 2 ring 0 09 mm Remove piston rings Check if the piston mmga ane damaged or ifs grooves are worn A Caution Pay attention io remove piston nngs because they are fragile PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER PISTON Place piston rings respective inio cylinder below 20 of cylinder In order to keep the piston nngs in horizontal evel in cylinder push the rings with piston Service Limit Top ring 0 50 mm 2 ring 0 65 mm Measure the outer diameter af piston pin Service Limit 14 93 mm Measure the inner diameter of connecting rod small end Service Limit 15 06 mm Measure the inner diameter of piston hole Service Limit 15 04 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm PDF created with pdfFactory Pro trial version www pdffactory com LUOO U0JSJ9A U MM BU P91B9J0 pegajsu Jays ue sur Jeu ams ape dn jenu LO
69. ces new valve guide is within service limit or not if so replace valve guida Correct iE with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too Caution It has to correct valve seat when replacing valve guide VALVE STEM REPLACEMENT Heat up cylinder head to 100 150 with heated plate or toaster Caution Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating Wear on of glove to protect your hands when operating Hold the cylinder head and then press out old valve guide from combustion chamber side Tool Valve guide driver 6 0 mm amp Caution Check new valve guide is deformation after pressed it in When pressing in the new valve guide cylinder head still have to be kept in 100 1502 Adjust the valve guide driver and let valve guide height is in 13 Press in new valve guide from rocker arm side Tool Valve guide driver 6 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with teamet Caution Using cutting of when correcting valve guide with reamer Turn the reamer in same direction when be inserted or rotated Valve guide driver 5 0 mm AS UN Correct valve seal and clean up all metal residues from cylinder head Tool Valve quide reamor 6 0 mm
70. ctory com Too low capacity 1 Insufficient recharging 2 Pole plates react with sulfuric acid 3 Insufficient electrolyte 4 Active matter fallen from pole plates because of excessive recharging Inefficient recharging system 1 Bad contact at connectors short circuitry or broken circuit 2 Defective rectifier 3 Defective of flywheel magneto a Armature winding short circuited or broken b Magneto coil short circuited or broken Bad electric continuity 1 Bad contact at battery connection 2 Ignition system short circuit or bad contact at connectors 3 Lighting system short circuit or bad contact at connections Ignition System Dysfunctioning of spark plugs 1 Defective of flywheel magneto Defective high tension coil Defective C D I Defective spark plugs amp Defective conductor contact breaking or short circuit for example a Conduction between flywheel magneto C D I b Conduction between C D I and the main switch c Conduction between C D I and the high tension coil Engine not running smoothly 1 Defective ignition first circuit a Bad contact in circuitry or cable b Defective of flywheel magneto 2 Bad ignition secondary circuit 1 The ignition coil insulation defect causing electric leakage 2 Defective magneto coil Short circuit between coil layers Defective coil 201 PDF created with pdfFactory Pro trial version www pdffactory com c Defective sp
71. de to see if are not desired any breaking or damage appear 5 Metal stone and 1 Cneck if any cracking stone or any other articles are other article sticks into the tire not desired PDF created with pdfFactory Pro trial version www pdffactory com 1 3 Regular Maintenance Schedule The chart below lists the recommended intervals for all the returned periodic service work necessarily to keep the motorcycle operating at peak performance and utmost efficiency Mileages are expressed in terms of kilometers and months These intervals judged by odometer reading or month whichever comes first Maintenance 300KM Every Every Every Every Remarks kilometer 1000KM 3000KM 6000KM 12000KM Maintenance Interval 1 Month 2 Month 3 Month 4 Month puer mer cleaner element Remark element Remark __ filter Screen pf a i o i e MERE __ _ ELO MEN Jer aJ qp cae AL gg c4 E Replacement for every 5000 p Month LITE T 1T __ 7 Dwpesumm L T apm LL eee
72. der washer Serious damage of cylinder piston piston ring Check for normal Cleaning or replacement fluid level in the buoyant Poor low level Fair Check of needle Check the valve and buoyant compression Poor Fair Check for leakage in cylinder washer check cylinder piston piston ring for wear Correct Adjustment or Check fuel pipe P replacement carburetor for Yustment or obstruction replacement when necessar Cleaning or replacement 37 PDF created with pdfFactory Pro trial version www pdffactory com CHAPTER 3 DESCRIPTION OF COMPONENTS AND ASSEMBLY 3 1 ENGINE 3 1 1 Fuel system For 125c c 3 1 2 Fuel injection system For 250c c 3 1 3 Lubrication System 3 1 4 Cooling System 3 1 5 Spark Plug 3 2 ELECTRIC SYSTEM 3 2 1 Ignition amp Charging Device 3 2 2 Lamps 3 3 BODY 3 3 1 Frame amp Cover 3 3 2 Compartment and Seat 3 3 3 Front amp Rear Suspension System 3 3 4 Brake System 3 3 5 Tire amp Tire pressure 38 PDF created with pdfFactory Pro trial version www pdffactory com 3 1 ENGINE 3 1 1 Fuel system For 125c c FUEL SYSTEM Auto by startor Carburetor removal Vacuum chamber 39 PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM PRECAUTIONS IM OPERATION General information A Warning is a bow grition point and explosive matetials so always work
73. dfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE P o 4 a OC 0 7 4 1 PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE PRECAUTIONS IN OPERATION General Information This chapter is contained maintenance and servica for cylinder head valve and camshaf as well as rocker arm Cylnder head service can carried out when engine Ig in frame Specification Compression pressure Camshaft Height of cam lobe Exhaust 30411 90851 ID of valve rocker arm 12 000 12 018 o OD of valve rocker arm shaft 11910 Valve OD of valve stem ss 4 875 4 590 4 955 4 070 Guide seat 5000 5012 Sa Clearance betwean 0 010 0 037 0 080 valve stem and guide re Valve seat with I Tilt angle of cylinder head Torque Value Cylinder head bolt LIM 2 0 2 4 Cylinder head Nut 20 24 kgm Sealing bolt of cam chain auto tongioner 0 8 1 2 kg m Bolt of cam chain auto tensioner 1 2 1 8 Cam sprocket cover bolts 0 8 1 2 Cam sprocket bolt 1 0 1 2 kg m 142 PDF created with pdfFactory Pro trial version www pdffactory com 143 PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE TOOLS Special service tools Valve reemer 0mm guide driver 5 0mm Valve spring compressor Troubleshooting Engine performance will affected by troubles on engine t
74. e Engle SPD BATT VOLT position position Voltage SENSOR Voltage ENGINE TEMP 1 100 PDF created with pdfFactory Pro trial version www pdffactory com 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 BARD kPa Above SBkPa Atmospheric pressure a Intake Outside Temp Intake air temperature 2nd AIR Idle ON Secondary air solenoid valve actuator siate INJECT TIME msldie 1 Injection time s IGN ANGLE Idia 12 14 timing STEP MOTOR air control valve sten motor actuator stale CRANKSHAFT Idle CAM Crankshalt functioning direction TEST TERMINAL idle Test terminal state s IDLE SET RPM 21650 RPM Idle speed goal ser value 150 STEP idle 75 95 Idle Ab Control Valve simpper motor step In the DATA STREAM of the screen use A Y button to move the leit side of the project symbol selected items press ihe ENTER bultom lock of the project and press the F4 button showed that the wave of prapacts Able to use 4 left and night button can transform View wave numarical 02 03 Dara sirean J Ti analysis of images 2 3 tha wavef
75. e too low IR 4 Power lina bad contact Poor contact the main power OK ECU faul 7 gt OK Ban volage meter measurement of Ihe E voltage difference Gonfirmad ECU and battery supply voltage differential pressure within the D 2 V voltage OK Battery voltage drive parts voltage of less than 0 2 I 1 Main gwitch OFF 2 the injector fuel pump Oz sensor HG over sensor ignition couplers lt 3 Measurement of the voltage between the couplers and ground of the voltage difference 4 Confirmed volage diferance and batiery voltage of 0 2 V gap within ECU 54 voltage sensor voltage of less than 0 2 Vv 1 Main switch OFF 2 Use probe inserted throttle sensor engine temperature the inlet pressure sensar power connector 3 switch ON 4 Use voltage mater measurement of the sensor connector 5 Vollage standard value 5 020 1V 1 Lines anomaly HG 1 Lines anomaly E 2 ECU anomaly Battery voltage fual pump voltage of less than 0 2 1 switch OFF 6 Confirmed pump and battery supply voltage differential pressure within the 0 2 voltage 8i PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection Syste Can not Start the engine or difficult to start inspection Warning lights extinguished after 2 MG 1 inspection pr
76. e C D I or plugs coils main switches replacement of PICK UP distributor C D I and mount coil for normality properly the plug Normal Abnormal Check for Poor high voltage correct main coils main wiring contacts switches PICK and terminals if Ups distributor necessary coils correct them 33 PDF created with pdfFactory Pro trial version www pdffactory com 2 8 3 Troubleshooting for no skip of spark plugs Analysis of potential causes No skip of spark plugs gt Check for proper loading of the spark plug cap Loose spark plug cap Poor spark plug Loose C D adapter Fair Poor Poor C D I Load properly the spark Poor PICK UP Replacement spark plug and test the Poor distributor 8 intensity of the spark plugs high voltage wiring Weak sparks Poor main switch Weak sparks Replacement of Main wiring broken or in poor spark plugs Intense sparks short circuit Ignition coil broken or in Check for loose C D I short circuit contacts X 1 Poor adapter contact Loose Normal Load properly the Check C D I terminals passage and testing of C D I adapter resistance Normal Abnormal Use C D I tester Poor PICK UP Poor main switch Poor contact of adapter Broken main wiring of short circuit for checks of C D I d Normal Abnormal _ Check ignition coil f
77. e guide Install new valve slom oll seal install valve springs and retainers Caution The closed coils of valve spring should face down to combustion chamber Lite valve spring compressor to press valve spring instal valve cotter and release the valve compressor Caution In order to avoid loosing spring elasticity do not press the spring too much Thus presa length based an tha cotter in which can be removed Tool valve spring compressor Tap valve stem to make valve retainer and valve stem sealing property Caution Place and hold cylinder head on to working table so that can prevent from valve damaged PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE CYLINDER HEAD INSTALLATION install new O ring inta the indent of carburetor insulator and then insted the insulator onto cylinder head with 2 bolts camshan into cylinder head and align rocker with rocker hale Then ingert ihe rocker arm Install rocker arm mounting plate Loosen valve ciesranos adjustment nuts and bals located valve rocker arm Measure and adjust valve clearance with thickness gauge valve clearance had been adjusted t standard value hold adjustment bok and then tighten the adjustment nut Valve clearance Intake 0 12 0 02 Exhaust 0 12 0 02 mm Install
78. e megga meter s positive terminal to connect resistor wire B Connect the megga meter s negative terminal with frame ground and measure the resistance Note Resistor standard 20 W 5 9 Ohm 5 0 7 0 Ohm 5W 5 0 Ohm 4 0 6 0 Ohm 4 3 6 CDI Use megga meter to check the following items A Exciting Coil Inspection Disassembly The exciting coil connector Measure A Use megga meter s positive terminal to connec t exciting coil s black red terminal B Connect the megga meter s negative terminal with frame ground and measure the resistance B Pulse Coil Inspection Disassembly The pulse coil connector Measure A Use megga meter s positive terminal to connect pulse coil s blue yellow terminal B Connect the megga meter s negative terminal with body ground and measure the resistance 205 PDF created with pdfFactory Pro trial version www pdffactory com 4 4 Removal and Installation of body 4 4 1 Removal and Installation of Seat and Cover Seat Remove the nuts and pin Seat Remove 6 bolts on the helmet case Helmet case Note There is a coupler under the helmet case And remove it Additions of side cover Remove the handles Remove the bolts on the side cover Leg shield Remove the bolts on the leg shield each side leg shield Installation Install in reverse order of removal procedures 206 PDF created with pdfFactory Pro trial version www pdffactory co
79. e the securing nuts tighten the screws Remark 1 Turn it clockwise to enlarge the gap 2 Turn it counterclockwise to reduce the gap 3 Keep the free gap at between 10 20 mm and tighten the nut C Inspection of the Return Spring of Brake Lining a Testing the free length of the spring with a vernier caliper b Check for any wear and crack on the spring Free Length of the Return Spring of Brake Lining mm Standard 32 6 33 0 Limit Exchanged over 35 0 D Inspection of the Brake Cam a Check for any rust or unusual wear on the brake cam 216 PDF created with pdfFactory Pro trial version www pdffactory com b Make sure the brake cam runs smoothly c Make sure to apply sufficient grease to the brake cam and lining anchor pin E Inspection of Front Brake a Check the gap between the ends of front brake lever Gap of Front Brake Lever 10 20mm 10 20 mm b Add brake oil c Check the brake lining F Inspection of Rear Brake a Check the gap between the ends of rear brake lever b Move the adjusting nut of brake cable clockwise to proper gap Gap of Rear Brake Lever 10 20 mm 217 PDF created with pdfFactory Pro trial version www pdffactory com
80. eneral information Warning a Gasoline is a low ignition paint and explosive materials always work ina well ventilated place are prohibit flame when working with gasoline Dismantling fuel pipeline the first of the fuel systam in leak in addition to the fuel pressure or tubing surraunde the folder of twel io prevent fuel splash Do not bend cr twist throtile cable Damaged cable will make unstable drive When deassembling Muel system parts pay attention to O ring position renlace with mew one as ra acsiembiy Specification Item Specifications handle free play mm Fuel pressure about 3 0kg om Torque value Engine Temperature sensor 0 74 0 68 kgf m O2 Sensu 3 6 4 6 Special Tools Viacuurn air pressure pump Injection system diagnostic Data Scan Fuel pipeline faldar PDF created with pdfFactory Pro trial version www pdffactory com LUOO U0JSJ9A BU P91B9J0 ugue euaega BGunonugssqnaoa Jo sued 17 3 16sdde qned E UES aj sped Jo Sed Aes 2 Sued aau pO Leeda MOR POYY EUSLE 2 na3a eno aq jou jo inazo jou epoo
81. er 2 sonos Remove moun bols for crankcase and gear 12 Remove ait claaner B screws Remove air chennmer set 4 sews Caution The alr cleaner mamani ia made of papa eo oe not somp d inda water ar wash it wilh water 50 PDF created with pdfFactory Pro trial version www pdffactory com 3 1 2 Fuel injection system For 250c c Fuel Injection System Fuel Injection System Components Integrated Fault Diagnosis Program Operation of The Fuel Injection System Air Cleaner The Fuel Injection System Introduction Fault Diagnosis Note Fuel System Outlined Check Light Fault Codes Discriminant ignition System Outlined Precautions Operation Fault Code and Check Light Flashing EFI System Components Description Lighting Identification Tables Fuel Injection System Circult Injection System for Use diagnosis ECU Pin Configurations Fault Diagnosis Diagnosis Use Note Troubleshooting Table Comprehensive Maintenance List Fuel Injection System Components PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Operation of The Fuel injection System Crank Position Manifold Absolute Pressure Sensor INJECTOR Throttle Position Engine ETS Sensor 5 FUEL PUMP 02 Sensor Roll Over ___ Air Inject es ew an js Isc uos m Contr
82. es and Tereign malprials on cylinder hag matching surface 4 Caution Do not damage the matching surface of cylinder head PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE INSPECTION CYLINDER HEAD Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Savica limit 0 5 mm Valve spring free length Mensura the free length of intake and exhaust valve springt Service limit 31 5 mm Valve stem Check if valve stems bend crack or burn Check the operation condition of valve stem in valye guide and moasure amp the valve Stem outer diameter Service Limit IN 4 80 mm EX 4 90 mm Valve guide A Caution EE measuring the valve guide clean carbon deposits with Tool 5 0 mm valve quide eame Measure and record each guide inner diameters Service limit 5 03 mm The thal the inner diameter of valve guide deducts the outer of valve stem is the clearance between the valve stem and valve guida Service Limit IN 0 08 mm EX 0 10 mm L A PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE A Caution if clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only repla
83. et O Ring locking pin should be used while assembling 3 Only designated oils should be used on spare parts Clean the vehicle before maintenance to avoid dirt or mud on disconnected parts The locking sequence of Bolt and Nut should be from inside to outside or in diagonal step Reverse the sequence to loose Special tools should be used when necessary Reconfirm each function after the assembly Special attention should be paid to the battery s electrolyte and brake oil which will stam clothes 7 Attention should be paid to avoid damage or loss of disconnected parts Clean and grease properly before the assembly No grease on Bolt s Thread PDF created with pdfFactory Pro trial version www pdffactory com CHAPTER 2 MAINTENANCE INFORMATION 2 1 Specification Sheet CU8 X Motion 125 Length Front 9 Total Unload mass Total mass Front Rear 40 5 5 50 02 98 2 00 Total 150 kg Front Rear Engine Engine Type 4 Stroke 4V electroplated ceramic cylinders engine Fuel Type Number of Cylinder Bore X Stroke mm Cylinder Capacity Starter Cooling System Lubrication system Reference and setting range Reference and setting range EX MaxSpeed km hr 5W 12V 21W 12V 21W 12V Idle speed rpm Max Power Kw rpm Max Torque Nm rpm Compression Ratio Oil Spec Oil Capacity L Gear Oil Spec Capacity Front Lamp Re
84. for crankcase D B 1 2kgf m Bolts for cam chain adjuster 1 2 1 6kgf m Tools Special tools Trouble diagnosis Engine noise Loose crankshaft baaring Loose crankshaft pin bearing a Wom cut piston and pin hole 192 PDF created with pdfFactory Pro trial version www pdffactory com CRANKSHAFT CRANKCASE Disassembly of crankcase Remove the chain Loosen the bolt and nemows the tension er Loosen seven bolle on the right crankshaft case downward and up crankcase Caution 1 Gare should be taken not to damage tha cantact surfaces Refer to chapter 18 Special tools Special tool RL crank case disassembhie instal tonl SYM 1120000 H8A PDF created with pdfFactory Pro trial version www pdffactory com CRANKSHAFT CRANKCASE Remove crankshaft from right crankcase Remove gasket and Scrape gasket residues of th contact A Caution Do not damage contact surface of the gasket It is betlar to moisten the gasket residue far _ Sy Boe _______ Check any damage in saal Replace with new one if damaged PDF created with pdfFactory Pro trial version www pdffactory com CRANKSHAFT CRANKCASE Mageiring poled fer ihe big amil of Crankshaft Use a thickness gauge to measure left right clearance of connecting rod big end Service 0 6 mm Measure the clea
85. ge before using new battery to keep the maximum performance if don t charging adequately or the electrolyte under the low level it may cause broken before normal life 129 PDF created with pdfFactory Pro trial version www pdffactory com 6 Tap or drinking water contain mineral will reduce the battery s life it must to use distilled water For Water Adding battery 7 1 scooter is stay a long time it required charged periodically otherwise it ll fully discharged by itself above three months 3 2 2 Lamps Head lamp Remove the bolts of the cover Cover Remove the head lamp couples Rear lamp Remove the bolts of the cover Cover Remove the rear lamp couples Inspection Check if the lamps is damage please replace with new one Installation Install in reverse order of removal procedures 130 PDF created with pdfFactory Pro trial version www pdffactory com 3 3 BODY 3 3 1 Frame amp Cover 1 Frame A steel pipe and steel sheet are adopted to compose reinforced frame A compartment as Personal space for Helmet is set in the Frame center 2 Cover SEAT SET HELMET CASE BRKT SEAT CAP HELMET CASE COVER SIDE LH amp RH COVER TAIL UPPER amp UNDER HANDLE LH amp RH ORNAMENTAL HANDLE BAR COVER HANDLE BAR UPPER amp UNDER 10 WIND SHIELD 11 FRONT SPEEDOMETER COVER 12 SPEEDOMETER COVER 13 SPEEDOMETER COVER 14 COVER LEG SHIELD FRONT 15 LEG SHIELD FRONT
86. h No fuel reaching the Clean or replace carburetor 1 No gasoline in fuel tank Replace Tighten 2 Clogged hole in the fuel tank cap Replace 3 Clogged or defective fuel cock 4 Clogged fuel hose or defective vacuum hose Compression too low 1 Excessively worn cylinder or piston rings 2 Spark plug too loose 3 Broken cracked or otherwise failed piston Noisy engine 1 Piston or cylinder worn down 2 Combustion chamber fouled with carbon 3 Piston pin bearing or piston pin worn 4 Worn or burnt crankshaft bearings Engine idles poorly 1 Stiff piston ring in place 2 Excessively Replace Replace worn cylinder or piston rings 3 Gas leaks Replace Replace from crankshaft oil seal 4 Defective CDI amp Clean or adjust ignition coil unit 5 Clogged jets in carburetor 2 7 Tighting Torque of Screws Standard Torque Values of Bolts and Nuts Specification Torque kg cm Specification Torque kg cm 5 mm Flange Bolt and Nut 8 mm Flange Bolt and Nut 6 mm Flange Bolt and Nut 10 mm Flange Bolt and Nut 27 PDF created with pdfFactory Pro trial version www pdffactory com Torque Values of Chassis Components Tightening Location Specification kg cm Front Wheel Axle Self lock Nut 500 600 Brake Disk Hex Bolt 180 280 Brake Clipper Tightening Bolt M 8x35 210 250 Speed Meter Cable Nut 5 Front Fork Bearing Tightening Nut 25 1 0 600 650 Rear Wheel Axle Self lock
87. he motorcycle from the CHE lights flashing signal interpretation and then the basis for the diagnosis of dynamic information on the priorities of light and prompts you to the motorcycle to the emergence af some warning or FLASH CODE is te determine what kind of fault and exclusion 1 Nn Unit second UL U LL Fault code 22 Fault coda 12 Continuous repeatad Fault Code manual removal procedure When there is without diagnosis tool canbe manually Geared Fault Code the implementation of the following steps 1 Main switch OFF 2 5 the test switch for interconnection access and without opening up cross access movement must indeed 3 Full throttle and do not open up 4 Main switch ON 5 Described above the Mo with the 4 movements continued liberalization of 8 seconds iater about B seconds after inspections at carnivals lash twica to complete the removal of fault cada Then remove the cross wiring g 5 Nol io Full 1 Full throttle closed LAL least 5 seconds ee eee ON 3 OFF OFF Lighting USSG ong inspection lights flash Not lit PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fault Code And The Sensors Of The Table NE No Fault Description Parts Inspection Throttle position sensor fault Throttle posit
88. hermistor to the outside temperature sen amp or when the high temperature resistance values the smaller low temperature temstance Insiamsd of change the temperature of the engine ECU to provide signals to control spray fuel applications inet pressure sensor copepod D IM T absolute pressure deterred by the Winston bridge circuit to the sensor atmospheric pressure and intake manifold pressure ECU feedback as to the basis for the control of the engine 58 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System O2 Sensor ping Concentrated 14 7 Dilute Function Measurement cylinder emissions of oxygen 02 concentration oxygen content and will neturn tha computar signal change the injector fuel injection tima the mixing ratio adjusted diluted concentrabian if the cxygen level is too low that the mixture footprint HC and CO emissions in the concentration will be higher if the axygen content is too high that the mixture tog lean lean more mixed than the combustion temparature will increase emissions of NOx and the higher the concentration 1 O2 Sensor output feedback signal to the ECU fuel ratio control in the vicinity of a 14 7 fuel closed loop control 2 When the air fuel ratio control in the near equivalent CO HC Nox had the highest conversion 3 Heating resistor two while line 8 7 10
89. i pa ger go pede 2 anpa HOG uonaedsu go person Gury Buren seas pps sss BITES cq ep Auguenb qo Jane UO o pu H plumes dae irae pns yes uo La paesi 1825 W3lSAS NOLLVOIHEITI LUOO AMMI U0JSJ9A U M BU P91B9J0 WALSAS 5 6ullooo p i LUOOm Ajojo amp ypa AMMI UOJSJGA BU Odd duind sre pres duind 1088 dund aog 1012905 soo 3090 dod AB zL perunessud d ognuui GE 208 14 sunbed 772 Der jdn Song dea uomearjroeds aug Lies JOS BUH aur WCE Loe Aug 20 Buana SIBLING Gy juegos gids
90. il engine is cooled 10 PDF created with pdfFactory Pro trial version www pdffactory com 2 3 Special Tools 125 ce Crank case transmission off seal driver Crank ACG pullar Outer remover ins driver NAME aa SPY Poon BC NE 9100210 NAME etann oann 6203 6004LLZ 6901 MAME Dene 11 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS 4774477 MALER DRIVER 31 10400 SEAL DRIVER NO 0020200 Tcn 2301000 PRICE USO PRICE USD PRICE 12 PDF created with pdfFactory Pro trial version www pdffactory com LUOO U0JSJ9A U M BU 91 9 0 1 BSL ON SWVN 57001 1 12448 SPECIAL TOOLS How to use special tools gt RIL CRANK CASE PISASS TOOL Disassemble the Install the loft crank crankcase case bearing install the crankshaft 14 PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS BEARING DRIVER PDF created with pdfFactory Pro trial version www pdffactory com SPECIAL TOOLS WATER PUMP _ BEARING DRIVER WATER PUMP OIL SEAL DR
91. inder piston piston ring and other elements with correction 35 adjustment replacement PDF created with pdfFactory Pro trial version www pdffactory com 2 8 5 Poor acceleration and horse power Breakdown of potential causes Poor acceleration and horse power Check for drag of braking drum by braking plate Fair Poor Adjust or replace braking plate Check for 11 air filter Fair Poor Check for burn of spark Replacement of the plugs and the gap Fair p Check for normal ignition timing Cleaning adjustment of replacement of new spark plugs Poor Fair Test of spark plugs Timing sparks Poor skip Intense T sparks See 2 8 2 poor skip of spark plug for proper adjustment checking methods Check carburetor for Poor Fair Adiustment Check for normal choke valve action Poor Fair Check for obstructed injection nozzle Correction or replacement 36 PDF created with pdfFactory Pro trial version www pdffactory com Braking plate retaining braking drum Air filter grill obstructed Dirty spark plugs Incorrect gap in spark plugs Incorrect ignition timing Poor skip in spark plugs Incorrect adjustment of carburetor adjustment screw Poor choke valve in carburetor Dirty or obstructed carburetor injection nozzle Poor carburetor buoyant needle valve Dirty fuel filter Obstructed fuel circuitry Poor engagement of cylin
92. ion sensor and wire Manifold absolute pressure sensor fault MAP sensorand wire Engine temperature sensor fault water Engine temperature Sensor and wire 4 06 Engine oil temperature sensor fault oll Engine temperature sensor and wire Intake temperature sensor fault Intake temperature sensor and wire 1610 Roll over sensor fault Roll over sensor and wire 0130 Os sensor fault 32 Sensorand wire VN J 1 fault IG 1 fault E Fuel pump faul Fuel pump and wire _____ ISC Idle speed control motor fault Exes 2 air control solenoid valve fault 2 air control valve and wire oponon sorserion Omas 10511 Ignition and wire PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System ED ao ong so 1 Fault detection procacees refer Sytem components description O2 sensor chapter gring tong a shona _ Fault detection procedures Please refer to the EFI System components descritiont tuai injector chapter et faut igh ng ionga snot lgn oncolandwme Fault detection procedures io adhere bo they radigan way Fusi pump fault onga stony Fualpumpand wie TUM 9 ET ae nc
93. irmed hydraulic pressure the proposed replacement fuel pump to confirm A Warninc Gasoline is lower ignited explosive materials in n the ventilation premises operations and prohibited fire Inthe inspection injector fuel injection state the outflow of gasoline usual Injecton state unus and the application of appropriate collection containers so as to avoid danger PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Transistor ignition coil Functional Description Use 8 18V DC power supply has the two pin socket Two pin socket for the power supply and grounding components forthe high conversion ratio transformer Through computer programs when the ignitian m controlled fram ignition timing TDIC crank position sensor the throttle valve position sensor engine temperature sensor the inlet pressure sensor and O2 Sensor issued by the signal with the engine Speed through the ECU lo determine tha appropriate ignition is by the current of a enystal intermittent control 25000 30000 volts of secondary hypertension flashover triggered spark plug this approach will not only enable the engine to achieve maximum output function also help to improve the efficiency of fuel consumption and pollution improvements Testing Procedures Resistance Confirmation Removed first circuit plugs an the ignition Red Yellow amp Black Yellow
94. k elaarance between inner and outer robora Lirnit 0 20 mm Check clearance bebveen rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft wiih That af inner install ive driving shaft Install fring pin 111 PDF created with pdfFactory Pro trial version www pdffactory com LUBRICATION SYSTEM instal the oll pump cover and fixing properly SCREW x 1 Tighten screw Make sure that ail pump shaft can be rotated haet Oil Pump Installation the oll pump and then tighten Torgue value 0 8 1 2 sure thal pump shaft be rotated freely install oll pump driving chain and sprocket aad then ing snap ning anta oll pump shaft Install starting gear and 112 PDF created with pdfFactory Pro trial version www pdffactory com LUOO AMMI U0JSJ9A U M BU P91B9JO 11 cour aun 1283102 amp JY ax Lu Lun sym 2 2 Jog maua auus Ves pue Taamal ect agna Bupyegdas pop AU io ie tay uonasedsu Ayguenb ej ppy pa n ei a See ami enbao peaspap au
95. k the motorcycle for maintenance Removal Remove 2 bolts on the caliper Caliper Remove the nut Rearwheel Note 1 Please use vacuum to clean wheel ri m and lining Try to reduce the contamination of asbestos fiber which may affect the human breath system or lead to cancer 2 The transverse eccentricity should be within 3 0mm If the condition is poor please replace with new one 3 The lateral eccentricity should be within 3 0 mm If the condition is poor please replace with new one Installation Install in reverse order of removal procedures Shock absorber Front Watch Please place main stand to park the motorcycle for maintenance Removal Remove upper and lower attaching bolts on front shock absorber each side 2 bolts Shock absorber Inspection Check if the shock absorber is worn scratched leaking or bent If its condition is poor please replace with new one Note Torque of shock absorber upper and lower attaching bolts 200 300 kg cm Rear Remove 2 attaching bolts on air filter Airfilter Remove upper and lower attaching bolts on rear shock absorber each side 2 bolts Shock absorber 212 PDF created with pdfFactory Pro trial version www pdffactory com Inspection Check if the shock absorber is worn scratched leaking or bent If its condition is poor please replace with new one Note Torque of shock absorber upper and lower attaching bolts 200
96. ly Tighten the bolt cap of tensioner adjustment hole PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE Install carburetor insulator onio carburetor and tighten clamp strip bot Install the vacuum hese af carburetor insulator Remove the intake vale adjustment hole cap Start engine and make sure that lubricant flows fo cylinder head Turn elf engine after confirmed and install tha intake valve adjusiment hole cap install seat cushion and body center cover Caution lubricant does not flow to cylinder haad engine components will be worn out seriously Thus it must be confirmed When checking lubricant flowing condition fun the engine speed accelerate engine speed PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER PISTON 157 PDF created with pdfFactory Pro trial version www pdffactory com PDF created with pdfFactory Pro trial version www pdffactory com U0JSJ9A U MM otl MOL yaoua you edid Guyoo5 ape doy uo mpes uo uoqIES 1n Jo 10 Apada uomegeisu Guu Jo ino worm B
97. m Front fender Remove the bolts on the front fender each side Mud guard Remove the bolts on the mud guard each side Installation Install in reverse order of removal procedures Raer leg shield Remove the bolts on the rearleg shield each side 207 PDF created with pdfFactory Pro trial version www pdffactory com Fronnt leg shield cover Remove the nuts and screw on the fronnt leg shield cover Fronnt leg shield cover Fronnt leg shield Remove the bolts on the fronnt leg shield each side Fronnt leg shield Leg shield cover set Remove the bolts on the leg shield cover set Installation Install in reverse order of removal procedures 208 PDF created with pdfFactory Pro trial version www pdffactory com Wind shield Remove the bolts on the wind shield each side Wind shield Front speedometer cover Remove the screws on the Front speedometer cover each side Speedometer cover Remove the screws on the speedometer cover each side Installation Install in reverse order of removal procedures 209 PDF created with pdfFactory Pro trial version www pdffactory com 4 4 2 Removal and Inspection of Front Fork amp Steering CU8 amp CUB 1 FORK COMP FRONT 2 SHOCK ABSORBER ASSY 3 SUSPENSION ARM LH amp RH 4 FIXED PLATE LH amp RH CU8 B amp CUB B 1 FORK COMP FRONT 2 FORK COMP FRONT LH
98. main switch to open three seconds after the engine did not started the ECL will automatically cui off the fuel pump power supply Detection judge 1 1 Working voltage value Above 10V 2 Resistance value 1 50 50 wi 3 Fuel pressure 28446kPa about kg cm Testing Procedures 2 Resistance Confirmation Removed caupler on the fuel pump Use of the meter Ohm stalls Measurement fuel unit resistance Yellow White amp Green Detection judge 2 a Fuel unit rostetance value 4 107 50 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Testing Procedures 3 Fuel pressure measurement Use fuel pressure gauge connected in series between the injector and the fuel tank A Cautions In the implementation of the fuel pressure measurement will go to the demolition of the fuel hose such as injector fuel pump hose hydraulic measurements after be sure to confirm whether there is leakage of fuel situation in order to avoid danger Detection judge 3 1 Fuel pressure 204 GkPa about Jkgicm M Treatment of abnormal phenomena 1 Fuel pump damage internal break or coupler bad contact 2 Fuel filter blockage 3 Fuel pump anomaly the proposed replacement of the fuel pump 4 Fuel unit anomaly the proposed replacement of the fuel unit Fuel pressure measurement demolition injector Fuel pressure measurgrmen demolition fuel p
99. methods to eliminate fault codes respectively in the diagnosis tool removal and manual removal Diagnosis tool for overhaul Diagnosis tool will connect to the motorcycle for coupler diagnosis according to the use of diagnesti tool testing methods when belong fuel injection system fault or parts fault according to the diagnosis trol of the fault code display messages do describe parts of the inspection testing maintenance and replacement parts When after the maintenance the need to get rid of fault codes Please refer 10 detailed steps diagnosis tool of instructions or fault code will always be stored in the ECU Maintenance Manual Use of cross wiring wire or paper clips etc to cross Joints Test Switch for grounding in the meter of this check light are flashing it means that the injection system or parts of abnormal situations bul not in the diagnosis tool can be for the detection inspection can enjoy for a lang time flashing lights flashing and the short period of time to inform the cause of the malfunction refer to check light fault information code table Test switch coupler _ Diagnosis tool coupler Diagnosis too coupler and test switch coupler plani PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Check Light Fault Codes Discriminant Method Check light flashing mode If problem without diagnosis too ta be detected it can be eraas acocss the test switch coupler t
100. ng type Front Hydraulic pressed Spring pe Hydraulic pressed Spring Buffer Suspension Buffer Oil Capacity L Frame Type Welding Tube Direction Lamp 21W 12V PDF created with pdfFactory Pro trial version www pdffactory com 2 2 Safety Precautions Warning Engine Exhaust Please keep good ventilation during engine operation Do not operate engine in closed room The toxic carbon oxygen CO in exhaust may lead human to loss conscious and even death Warning Gasoline The gasoline is very easy to burn or explode Forbid any fire during inspection of gasoline tank or gasoline leak Warning Battery and Battery Liquid 1 The battery liquid is toxic sodium liquid Please do not contact the liquid with skin or eye If any contact happens please wash with massive clean water and contact with doctor 2 The released from battery is explosive Please keep good ventilation during charging battery and forbid any fire Watch Brake Fluid The brake fluid can damage the painting on plastic Please cover the plastic parts with towel or cloth during maintenance of brake disk If the brake fluid is split on plastic component please remove the fluid and wash the surface with water right away Watch High Temperature of Engine The engine cover cylinder and exhaust pipe have high temperature after starting of engine Please wear glove in maintenance of parts during engine operation or maintenance should be waited unt
101. o erankshaft s dr Driven pulley installation Press driving belt into pulley groove and then pull the onto drive shaft Install driven pulley washer and nut Caution sure thal two sides of pulley surfaces have to free of grease Clean it with cleaning solvent Hold crankshaft wih universal holder Tighten nut to specified torque Torque value 5 0 6 0 kgf m Install left crankcase cover PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER CLUTCH OUTER DRIVEN PULLEY Disassembly Remove driving belt and clutch outerdrven pulley Install clutch apring compressor onto the pulley assembly and operate ine compressor to let the wrench be Installed more easily A Caution Do not press the compressor too much Hold the clutch spring compressor anto bench vise and then remove mounting nut with special service tool Release the clutch spring compressor and clutch weight and spring from drivan pulbery Remove collar from driven pulley Remove guide pin guide pin roller and mavable driven face and then remove O ring amp oll geal seat from movable driven face Inspection Clutch outer the inner diameter of clutch outer Replace the clutch outer if exceed service limit Service limit 130 5 mm PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STA
102. ocess in accordance with seconds gt inspaetion 1 usa dignas tool 10 view EMS fault Display warring lights Fault Code gt 2 with Troubleshooting procedures on troubleshooting 1 Fuel tank inadequate z Fuel injector pressures 284 expr AG 3 Pipeline fuel 4 Pressure Regulating Valve anomaly Fual system anomaly 5 Fuel pump pipe leakage 5 The high vokage power ines pose ECU anomaly Leaking oxygen senso connecior corrasibn sheri circuit 4 valve clearance 2 Valve timing is mol connect gt NG 3 jam Engine anomaly gt 4 Cylinder and piston ring wear pie amp Throes adjustment screw adjusimani OK of tha air improper al PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System idle fameout diagnosis 1 Link diagerosis tool to view tall conbeni 2 In accordance wih Troubleshaohrg procedures on troubleshooting 52 PDF created with pdfFactory Pro trial version www pdffactory com value set bavond scape of 1 5 Thratlle body poke sargus Actuation wheather or failure EF gystem more relevant institution each rezognized by detection d stl unable te rule tha Idling problem amp is recermimandad that engine checks whether there e
103. oject press the ENTER lo ihe implenmentatian Conditions Tha main swibch or in the SYM KEIHIN gine running state the faull code can be removed UF LJ Fault code removed namely showing the ERASE TB SUCC Presa the EXIT button the Tunctiun can fo directory seren 105 PDF created with pdfFactory Pro trial version Fuel Injection System 6 CO ADAPTION In the directory functions used A Y button select CO ADAPTION project press the ENTER into the CO adjustment screen 2 STREAM J FREEZED DATA 4 TROUBLE COD ENTER confirm UP DOWN EXIT Exit lt LEFT gt lt RIGHI Use 4 left and right gt or A Y button CO value can be adjusted CO ADAPT CO adjusted value CO Read CO read back value Press the EXIT button the function can return to the directory screen CO ADAPT CO Read PDF created with pdfFactory Pro trial version www pdffactory com LUOO 5 BU 9189 0 SEAT ucgeaugrr AO Wit SATA WALSAS LUBRICATION SYSTEM PRECAUTIONS IN OPERATION General Information This chapter conlains maintenance operation for le engine pil pamp and ge ail replacement Specifications Engine oil
104. ol Voge PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System The Fuel Injection System Introduction Based 4 stroke SOHC engine displacement 250 c c Electronically controfied fuel injection fuel vapor absorbed by carbon canisters The engine bums off the blow by fuel gas in the crankcase through the fuei air separating device The OZ sensor enhances the efficiency af the catalyzer by dynamically cantralling the ratio Electronic Fuel Injection Device Consisting of fuel supply devices Fuel tank fuel pump fuel filter and pressure regulating valve And fuel controller devices fuel injector and fuel is pumped from electrical fuel pump in the fuel tank to the injector on the inlet pipe The pressure regulating valve keeps the pressure around 294 6kpr The signals fram ECU enable the injector lo spray fuel into the combusting chamber once each two crankshaft revolutions The excessive fual flows back to the fuel tank through the pressure regulating valve Fue pump is placed within the tank to reduce the working noise and the complicity of fuel pipes Electrically controlled ignition and injection system effectively reduce fuel consumption rate and pollution In traditional gasoline engine carburetor supplies the fuel The process done by engine vacuum and the negative pressure in the carburetor mixes fuel with air Under this conditi
105. om Fuel Injection System Throttle Position Sensor Functional Description Use ECU provided DC SV power supply has the three pin coupler one for the power supply pin one for a voltage output pin for a grounding pin its main component a sophisbcated type of variable resistor Installed on the throttle body beside the throttle through the accelerator rotates the output of linear voltage signal provided ECU perception and judgement then throttle position opening and this signal with have Ehe most appropriate fuel injection and ianitian timing drown Signal output Center Yellow Black 5 voltage input Linder Green Red Ground Testing Procedures 1 Sensor connector to property using the probe tool can be removed connector to voltage measurements direct Measurement 2 Opened the main switch but not to start engine 3 Use volteg meter DC stalls to check sensor voltage 4 Confirmed working voltage meter access to the inlet pressure sensor third pin Green Red Voltage mater positive access to the inlet pressure sensor first pin Yellow Black 5 Throtile output signal recognition using the probe tol meter negative access 10 the sensor third pin Green Red Voltage meter positive access the sensor first pin white Brown Measurements were full throttle at full throttle closed the values of the output
106. om to the implementation tai BJ PDF created with pdfFactory Pro trial version Fuel Injection System Options main functional areas 1 ECU ID 7 DATA STREAM 3 FREEZED DATA 4 TROUBLE CODE 5 TB CODE 5 CO ADAPTION Use A Y button select mobile anti white subtitles implementation of the project and then press tha ENTER key to the implementation 96 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System 1 ECU ID In the directory functions used A Y 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 ECU Pin Assign KIT ER gt confirm UP DOWN Exit LEFT RIGHT 1 1 ECU ID Datas Use A T button select ECU ID projects press the EMTER bultem to the imgpsenmentation A total of 2 page use left and right button view EC LU information DIAG 0002000000020 Diagnosis IL S H VER 001 Software version VER Hardware version VER 001 Software Version DIAG VER 03 Diagnosis Version CALI ID Correction ID Code MODEL SYM GT8250 ECU 001 HML 00203 97 PDF created with pdfFactory Pro trial version LUOO OND wysig Od 9 OND wasis 9 Lod SE vt 79 abed 1 LIA dais NESSI ze
107. on three major processes done simultaneously in the carburetor 1 Alr quantity measurement 2 Tha determination of fuel quanbty 3 Mix of fuel and air Electric Fuel Injection System separates ihe three major processes into three different devices 1 gauges the air quantity and temperature and sends the signa tc ECU as a reference 2 ECU decides the amount of fuel to be injected according to the default A F rate 3 ECU enables the injector to spray appropriate fuel amount The independence of these three functions will raise Ihe accuracy of the whole process Our EFI engine uses cemputer programrmed tuel injaction the main features 1 The quantity of fuel injected is decided according the condition of lhe engine The engine RPM and throtila position determines the fuel quantity and injection time length This throttle canitralled fuel injection is better responding and more accurate 2 The quantity of fual injection and the determination of injection tima length sre all controled by E bit microcomputer 3 The pressure regulating valve maintains 234 6 pressure difference between Inlet pipe and fuel pipe raising the accuracy of fuel injection 4 By measuring the air pressure of inlet pipa this system gives the vehicie better accommodation to the environment 5 die air by pass system supplies fuel and air to the idle running and cold starting 6 O2 sersor feeds back the signal
108. on af ECU system power off this point once again to restart the engine the need to re open a main switch This as safety device when the dumping of vehicles be cul off power supply of ECU and engine stop Testing Procedures Because of the roll over sensor for the electronic control agencies not against removed alter a singla measurement Normal state after power is tumed on the main switch measurement of ECU power relays red yellow line to the Green Line ground the power supply voltage measurement can determine whether is normal for the roll over sensor Detection Judge Voltage Supply voltage Battery voltage Treatment of abnormal phenomena Vehicle state vertical power relays or ECU without electricity supply Roll over sensor internal short circuit open circuit or coupler bad contact Check whether the abnormal wire hamess lines Rell over sensor anomaly the proposed replacement of the over Sensor PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Idle Speed Control Valve stepper motor y Functional Description a Use 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 contral and management of this stepper motor actuators if it s mainly low power DC motors drives idie speed control valve of the movemen
109. ons 6 Dust dirt and unusual articles should be avoided while reassembling 7 While assembling the main lip of oil seal should face inwards oil chamber and the antidust sub lip should face outwards Apply an even layer of specified grease onto the lip before it is pressed to its location with balanced force by specified jigs 8 While pressing the bearing into the hole apply balanced force to the outer ring of bearing by specified jigs While pressing the bearing into the main shaft apply balanced force to the inner ring of bearing by specified jigs 137 PDF created with pdfFactory Pro trial version www pdffactory com 4 2 REMOVAL AND INSTALLATION OF ENGINE Removal of Engine Remove Seat and Cover Remove Exhaust Muffler Remove Clamp of Air Filter and Air Filter 138 PDF created with pdfFactory Pro trial version www pdffactory com Remove Mud Guard Remove Ignition Coil Lead Flywheel Magneto Lead Engine Earth Ground Lead Remove the Throttle Cable on Carburetor Piston Remove Oil Hose Remove Negative Pressure Hose and Remove rear belt cooling duct Remove Fuel Hose Remove Water Hose Remove the engine mounting bolts and nuts 139 PDF created with pdfFactory Pro trial version www pdffactory com Remove the rear axle shaft bolts and remove rear wheel lnstallation Install in reverse order of removal procedures 140 PDF created with p
110. op parts The trouble usually can be determined or by performing cylinder compression test and judging the abnormal generated Low compression pressure Valve improper valve adjusiment Burnt bert valve improper valve timing Valve spring damage Cylinder head Cylinder head gasket leaking or Tilt ar crack cylinder High compression pressure i Too much carbon deposit on combustion chamber or piston head Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft woar out or damage Chain wear out loogeness Auto tensioner wear out or damage Camshaft sprocket Rocker arm or rocker arm shaft wear out PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE CYLINDER HEAD REMOVAL Remove cushion and body center cover Remove the clamp strip bolt of carburetor and disconnect vacuum tube from the carburetor insulator Remove 1 of thermostat and then namora the thermostat Remove the side cover mounting blot af cylinder head and then take out side cover Remove hole cap for the adjustment bolt of cam chain tensioner and then loosen the tensioner by turning flat driver in C W directeon Remove cam sprocket bolt and than remove th sprocket by prying chain out PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE Remove the 2 cylinder head moun
111. or Replacement of the poor breaking or short circuit replace when C D I necessary 34 PDF created with pdfFactory Pro trial version www pdffactory com 2 8 4 Troubleshooting for slow run troubled engine Analysis of potential causes Poor slow run gt Check for contamination in spark plugs and excessive gap Dirty spark plugs Incorrect spark plug gaps Fair Poor Incorrect ignition Cleani d zm anita Hin eaning an M Alarmina abnormalitv of ianition timina Obstructed airfilter adjustment grill Poor carburetor Poor Fair buoyant needle valve adiustment Is the air filter grill Poor carburetor choke obstructed valve Poor engagement of Por ______ carburetor and inlet Replacement of Is the carburetor buoyant tube Obstructed carburetor the filter grill level normal slow injection Poor engagement of cylinder head washer Check if the choke Severe wear of valve fails valve replacement of the does not open buoyant needle valve Psion piston ring Poor Fair Check of for air between the Correction carburetor and the air inlet Poor Fair Add tightening force or replacement of the washer Check for obstruction in the carburetor slow injection Fair Cleaning Test the compression Check for air leakage in the cylinder washer check wear of cyl
112. orm can be dapiayed as shown in the folowing items BARO Air INJECT TIME IGN ANGLE IDLE SET 15 STEP 101 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Data stream 3 3 screen showed the ECU captured by the engine of the state immediately The following data for the benchmark idling state LEARNED STEP Set by Idle Air Control Valve stepper motor learning In the DATA STREAM of the screen use Y bution to move the left side of the project symbol salected items press the CENTER buttom of the proiect and press the F4 button showed that the wave of projects Able to use 4 left and right button can transform View wave numerical size 1 f ED 4 1348 Numarical analysis of images 3 3 he waveform can be displayed shown in the following LEARNED STEP 102 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System 3 FREEZED DATA Objective Ven sensor fault the system will record all ihe parameters of fault aignals in ander t facilitate fault diagnosis In the directory functions used A Y bution select FREEZED DATA project press the ENTER key to the implementation Only one page al screen precs the EXIT button the funcion can mium to ihe direc
113. r CPS Function Induction sequence teeth on the flywheel voltage signals will transmitted to ECU ECU normal work Note By receiving signals from the various sensors ECU to speed output control perspective Idle Air Control Valve opened the adjustment to the inlet manifold idle air bypass pipe to amend idle speed engine operation chemokine normal When starting TOC are not yet known location so by crankshaft position sensor to dataci the long tooth of flywheel calculated to identify the position a fixed point of ignition timing to the ignition when the engine speed reach Software set speed and then the ignition timing will change to the software 55 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Roll Over Sensor Function a safely device when the molocycle to overturned it will be cut off power supply of ECU and engine flameout Note For tha haavy hammar dumping sensor when vehicles dumping mare than 95 degree angle the executlve power of system At this point once again to restart tha engine the need to re Kay on the main switch PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Manifold Absolute Pressure MPS Engine Water Temperature WTS Air Temperature TAS Sensors water temperature Air temperature sensor Lise negative cooficient of the variable resistor t
114. r carburector buoyant needle valve Carburetor buoyant with impurities Poor carburetor buoyant No skip in spark plugs Poor skip in spark plugs Dirty spark plugs Incorrect spark plugs gap Dirty and wet spark plugs Loose adjustment screws in the carburetor Carburetor choke Obstructed carburetor slow nozzle Ailing carburetor threshold Obstructed air filter grill Leakage in cylinderwasher Seriously damaged cylinder piston Dead batte ry Poor contact of batte ry pin and conductors Starting switch with poor or failure Starting relay with broken wire or short circuit Loose contact and wiring Starting gear and speeding clutch gear seriously worn Starting gear and speeding clutch gear in poor engagement Poor starting motor 32 PDF created with pdfFactory Pro trial version www pdffactory com 2 8 2 Troubleshooting for poor skip of spark plugs Analysis of potential causes Poor skip of spark plugs Check for spark plug cap ignition coil Loosen spark plugs Poor spark plugs Poor high voltage wiring Poor Normal Loose distributor coils Poor Load in the spark plu Replacement of new spark plug and try skip park plug switches Wiring relay PICK Ups Poor main again cap Poor skip High sparks Check for loose C D I Replacement of poor Son and resistance values Abnormal Normal Poor or abnormal Check high voltag
115. rance of the big end at fhe vertical directions Sarvice limit 0 05 mm Place the ona back measure run out of the crankshnaft Service limit 0 10 mm Checking crankshaft bearing Wee hand to crank the bearing to see it moves freely smoothly and noisaless Chock the inner ring to see It links firmty en the Dearing If any roughness noise and loose linkage detected replace the bearing with new one Caution Th The bearing shalt be replaced in pair Special tool cuter bearing puller 8204010 PDF created with pdfFactory Pro trial version www pdffactory com woom AJopB pa ftmm UOJSJGA EI Gig 4Ipd Lar Jad 02 OLZ00L6 WAS jawoas Buy Buueag S BH DOOOE EL E 1N AS 19jnd yeys yumg joo jje1 amp urajquiass esp 1007 BSEINUBID eig cuo quedo 2 100 sesip ese Agora jnu ung WAS qna VEH O0O00ELEI WAS yeys yuris W6EH OOOOELL MAS 1 joo TH W6H O0Z00L6 WAS yuma yH oo aque jo Ajquiessy 3SVOXWNYH2
116. replace with new one Note Tire specifications See specification table Tire pressure Watch Please measure cool tire pressure Note Tire pressure Front tire 28 PSI Rear tire 32 PSI Warning Don t over load the motorcycle The tire may explode with over load and it is dangerous 135 PDF created with pdfFactory Pro trial version www pdffactory com CHAPTER 4 DISASSEMBLY REPAIRS 4 1 NOTICE FOR DISASSEMBLY REPAIRS 4 2 REMOVAL AND INSTALLATION OF ENGINE 4 3 REMOVAL AND INSPECTION OF ELECTRIC ITEMS 4 3 1 OPERATING CAUTIOS amp TROUBLESHOOTING 4 3 2 BATTERY 4 3 3 SHORT CIRCUIT TEST 4 3 4 STARTER MOTOR 4 3 5 RESISTOR 4 3 6 CDI 4 4 REMOVAL AND INSPECTION OF BODY PARTS 4 4 1 Removal and Inspection of Front Fork and Steering 4 4 2 Removal and Assembly of Wheel and Shock Absorber 4 5 BRAKING SYSTEM 136 PDF created with pdfFactory Pro trial version www pdffactory com 4 1 NOTICE FOR DISASSEMBLY INSPECTION 1 In order to avoid mixing and loss of disassembled parts before reassembling the disassembled parts have to be arranged according to their function during the process 2 The damage to Cover and Frame should be avoided while disassembling and assembling 3 Remove the negative terminal of Battery before working 4 While reassembling make sure that all parts are normal 5 Specified oil should be adopted on turning and sliding parts Specified grease should also be applied on specified positi
117. result fuel flooding A nut 07 daty Float valve must be replaced h rura new ong Remove main jet fuel needle jut nokder need jet slow jet pilot sere Sec Caution Take care not to damage jets and adjust screwy Before removing adjustment screw tum it all the vu down and note Ehe number of turris Do turm adjust screw forcefully to avald damaging valve seat Clean jate wih cleaning fluid Then usa compressed alr to blow Iha dirl off SEA Mt body passages with compressed A Caution vacuum chamber and valve sah 46 PDF created with pdfFactory Pro trial version www pdffactory com 5 U M IBU P91B9J0 LG Typ sus ape 63 yamu quacum ug JOPAN GIES JO ax 85 8 JOY os ANA YORE JOY ucqieod 1360 3 Gun j0j jgoj GEA aure Qi uonne 57 Eun jn degunu ens JOU jag uopne Xy pui paf qal apasi janj apja pa
118. rraspanding ta tha jomperature change then it must raplacen 124 PDF created with pdfFactory Pro trial version www pdffactory com COOLING SYSTEM Technical Data Valve begins to open 71 Valve stroke 35 45 2180 installation Install ini reverse order of removal Caution Always use new oll ring and apply a cost of grease on it before installing Refil tha specified coolant as nacessary 125 PDF created with pdfFactory Pro trial version www pdffactory com 3 1 5 Spark Plug Disassemble Spark plug cap Note Please blow away deposits around spark plug with blower before removing spark plug Otherwise the dust may drop into cylinder and it can damage engine Inspection Check if spark plug has carbon deposits burned or cracked Use steel brush to remove carbon deposits and adjust spark plug gap Replace burned or cracked spark plug with new one Note Spark plug specification Spark plug gap 0 6 0 7 mm Warning First 0620 7 install the spark plug with hand and then tighten it with spark plug wrench Please do not over twist the spark plug Note Torque of spark plug 100 120 kg cm Remove Carbon __ 3 Deposits 3 2 1 Ignition amp Charging Device Adjust Gap Check Washer Damaged 3 2 ELECTRIC SYSTEM 1 Ignition Device CDI Unit of two ignitions per revolution is adopted The ignition Lead is 18 374 000rpm
119. sensor to measure the output voltage ECU anomaly the proposed replacement of the ECU 10 measure the working voltage PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Intake Temperature Sensor Functional Description Use ECU power supply provided has the bwo pin coupler Fi voltage output another one for grounding main component 5 a negative temperature coefficient resistance temperature rise smaller thermistor Installed in the air cleaner on the intake temperalure sensor within the resistance with Ihe induction to the temperature change and converted into voltage signals sent to ihe ECU then calculated the temperature and in accordance with the ECU temperature and state amancdments injection time and ignition angle Testing Procedures Rasistance Value Measurement Disrnantied inlet temperature sensor connector the Ohmmelter Ohm stalls inspection sensor resistance Detection judge Resistance value and the rature between relationships as follows Resistance value 188224 1 135120 _____ 0 1583 0 007 Treatment of abnormal phenomena Temperature sensor damage connector poor contact Check whether the abnormal wire harness lines Temperature sensor anomaly the proposed replacement of the lemperature sensor PDF created with pdfFactory Pro trial version www pdffactory c
120. t for wear damage Install one way clutch onto starting clutch gear Hold fhraheel and roiste starting clutch gear The siarting clutch gear should be rotated in CCW direction freely but not C VY direction View as shown in this figure Disassembly Remove 3 haxagorn bolts with air and hex socket wrenches PDF created with pdfFactory Pro trial version www pdffactory com ALTERNATOR STARTING CLUTCH Remove the spring caps and springs of clutch on the clutch that located on the back of flywheel Check each roller and plug for wear damage install rollers plugs and springs Installation Install the components in the reverse procedures of removal A Caution _ Tape tightening tape onto the thread of hexagon bolt Torque value 1 0 1 4 kg m Installation Install reduction gear shaft and reduction gear Install starting clutch gear onto crankshaft PDF created with pdfFactory Pro trial version www pdffactory com ALTERNATOR STARTING CLUTCH Flywheel Installation inert this onto sure that ihare is other material stack on it if so clean if up Align tha key on crankshaft with the flywheel groove and then install the flywheel Hold the fheatseeld with holder arid tighten its nut Torque value 5 06 0 kg m Tool Flywheel holder Install spring and cil through Set Installation Install tha
121. t to adjust the idie air flow channel sime control of idle speed of the engine in the cold or hot Testing Procedures 1 Resistance Confirmation die Air Control Valve will be demolished down coupler directly in the body can also measure Use of the meter Ohm stalls 2 measurement of the two step motor coil resistance values A phase ISCAP and ISTAN B phase IGCBP and IS CEN Inspection of the actuation testing can only be on engine not a single test Closure of the main switch Use hand touch Idle Air Control Valve boxy Open the main switch Feeling the dle Air Control Valve Actuation A Cautions Dynamit checking for idie Air Control valve can only be tested on the engine not a single test Detection judge 1 Fesistance value A phase 100 Environmental conditions 15 25 17 B phase 80 100 Environmental conditions 15 25 2 Actuator inspection the above steps Ar Control Valve idling motor actuator control of inspection ISC will be slightly vibration or da continuous voc A phase measunement of teur resistance value Treatment of abnormal phenomena idle air control valve damage or poor coupler contact Check whether the abnormal wine harness lines ldie Air Control valve anomaly the proposed replaceme nt of the Idle Air Control Valve further inspection of its actuator B phase measurement of the
122. tain angine flameout state do not open main switch Opened the luggage box fighting light cover screw x2 connected to the diagnostic connector diagnosis tool Then open the main switch and the diagnosis wol power switch affer diagnosis display screen anpaared the words connection Press iha ENTER button into the screen there are 6 major functions ECU ID DATA STREAM FREEZED DATA TROUBLE CODE ERASE TB CODE and CO ADAPTION Use Y select bution under the function press the ENTER button access into various functions Example select DATA STREAM by the ENTER button the screen showed that the existing fault codes indicates no faut system 5 OK Press EWIT buttom to leave of the various functions Must to close the main switch or power switch of the diagnosis tool after and than can removal of diagnosis tool coupler 54 PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Diagnosis Use Note Diagnosis of connectivity 1 the diagnosis tool coupler access to the motorcycle injection system diagnostic signal coupler main switch ON Open the diagnosis left power switch which turn on the LCD sereen the screen brightness adjustment knob to the appropriate brightness 4 and cartridge content display on screen such as icon by the beginning of the implamantatian of any bution Lheplay diagnostic software release press the ENTER butt
123. te other traditional abnormal Throttle line mint 100 jammed revert ta full aloe ina Idle Control Vale Fuel Injection System value revised anomaly O2 Sensor equipped with Ine system in principle not adgusbed CO value such as value deviated from the normal range check O2 Sensor and other agencias anarmaly Link diagnosis tool view EF facit content i s idle CO value amend E Gasoline whether enough Whether loose battery connecter Voltage it adequacy Throttle line iz not tod jammed revert to closure Conneet with the disgnosis tool into to View data steam screen Bilan engine and warm te 70 65 C confirmed engine spese vile valve ard fuel injection timing sensor is abnormal idle CC value is set beyond the scope of 1 5 2 596 Idle functioning of 3 5 minutes 10 confim the engine 15 manning marmay after engine elimingting fault operations wysimm more relevant inst utipng each recognized by the detection if sill unable To out fhe idling fiameout problem it is recommended angina checks whether here ane cler traditional instiutions abnormal PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fault ats Program M m
124. ting bolts from cylinder head side cover and then remove 4 nuts ond washers from cylinder head upper side Remove the cylinder lead Remove 2 bolts of carburetor insulator and then take ihe insulator Remove cylinder head gasket and 2 dowel pins Remove chain guide Clean up residues from the matching surfaces of and cylinder head Caution De not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER HEAD VALVE CYLINDER HEAD DISASSEMBLY Remove tha hole cap of intake A exhaust valve clearance adjustment There are 6 bolts Then remove cap Remove the rocker arm pin stopper plate and then screw a 5mm boll inte the rocker arm pin Finally remove the pin and ihe rocker arm Screw a 6 mm inta cam sprockel mounting hole and then pull the carmahalt out Use a valve compressor to press ihe valve spring After removed valve cotter mileage tha compressor ond then take out spring valve spring and valves Caution in order to avokd loosing spring elasticity do nat press the spring too much Thus press is based on ihe valve cotter in whith can removed Tool Valve spring compressor Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residu
125. tory screen in the FREEZED DATA of tha screen use A Y bulton to move the left side of the project symbol selected items press the ENTER buttem lack of the project and press the F4 button shoved thal the wave of projects Able to use legt and right i button can transform View wave numerical PDF created with pdfFactory Pro trial version Fuel Injection System 4 TROUBLE CODE in the funational directory select TROUBLE CODE project press the ENTER button mplementation the message began to read Fault Code electronic injection system that had happened fault of the message whether or nat completion of repar Without fault is that showing System OK Press the EXIT bution the function tan return bo the directory screen if the system has faulty code that is showing the fault code that can be used 4 lef and nghi button selected the fault code selected before the code tags thal press the ENTER button the code can be read descriptions and fault handling SYM KEIHIN Fault code in the nate and treatment of the pages il the first one page did End they can press the A Y bution turn the pages to read all that B i o4 PDF created with pdfFactory Pro trial version Fuel Injection System 5 ERASE TB CODE In the directory functions used A Y button select ERASE T8 CODE pr
126. ump PDF created with pdfFactory Pro trial version www pdffactory com Fuel Injection System Fuel Injector Functional Description Powered by 8 1 and has two pin socket on fhe injector major component is the solenoid valve of high resistance driven by electronic current The two terminals are connected power source and ground respective It is controlled by ECU te decide the injection timing and the injector pulse width Td Procedures 1 Resistance Confirmation Use of the meter Ohm stalls D measurement of the injector resistance vals 2 Injector injection state examination Removed the injector fixed bolt and removed the injector from intake manifold but nat removal of hamess coupler Injector and injector cap tightly by hands fuel spills should not be case Key on and start the engine injector injection state examination Injector resistsnce confirmation Detection judge 1 Between the two pin resistance values 11 730 561 2 injection state Fuel atomizing good wilh clear scattering angle judged normal Injector state such as water no obvious scattering angle found abnormal Treatment of abnormal phenomena 1 Injector abnormal the proposed replacement of the new one injector 2 Injection state abnormal for the following reasons injector obstructive the proposed replacement of the naw one injector Fuel pressure shortage conf
127. uo 1825 uiye pue APOIO Jayma x9 esu Buuds 2241235 Ajquiesseoy YALYVLS 49DI WSISAS SNIAPIO LTIS A V BELT DRIVING SYSTEM KICK STARTER DRIVING BELT Hold clutch outer with universal holder and Caution Using special service tools for tightening Push the driving belt into belt groove as diagram shown thal the belt can be loosened and then remove driven pulley Remove driven Do not remove driving Remove the driving belt from the groove of driven pulley Inspection Check the driving belt for crack or wear Replace it if necessary Measure the width of driving belt as diagram Service Limit 17 5 mm Replace the belt if exceeds the service limit Caution Using tha genuine parts for rapiscernent The surfaces of driving belt ar pulley must be free of grease Clean up all grease dirt before installation Installation caution Install driving belt onto driven pulley Install the driven pulley that has installed the ento drive shaft PDF created with pdfFactory Pro trial version www pdffactory com 173 PDF created with pdfFactory Pro trial version www pdffactory com V BELT DRIVING SYSTEM KICK STARTER Install the clutch with universal holder and then tighten nut to amp pacified terque value
128. uy saputo adig uj Guyyows 21155214 uossaJduio7 10 Mo 81019 68 09 090 5 vto 51 90 Sk 09 200 DEB vL 5 5 i 9 uopnegagisedg uei UO pajunoui INO aq ue pue yog peuaoz NOLLYH3dO NI SNOLL nVO3Hd NOLSId H3QNI1A2 PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER PISTON CYLINDER REMOVAL Remove cylinder head refer to chapter 6 Remove coolant hose from cylinder head Remove cylinder Remove cylinder gasket and dowel pin Cover the holes of crankcase and chain with piace af clath Cikan up all residues or foreign materials from the two matching surfaces of cylinder and A Caution Soap the residues into solvent so thal the dues con be removed more easily Inspection Check if the inner diameter of cylinder is wear out ar damaged In tha 3 positions tap center and bottom af cylinder measure the X and values respective in the cylinder Service limit LA12W A LA15W 57 016 mm LA18W 61 016 mm PDF created with pdfFactory Pro trial version www pdffactory com 162 PDF created with pdfFactory Pro trial version www pdffactory com CYLINDER PISTON Check cylinder if warp Servi
129. ve rear bracket 2 bolts Remoye the central cover 4 gongwa Remove the left and ighi pedals 1 bol Remove the lett and right covers 4 boks Remove the central cover 8 screws Remove left right body covers and the upper cover 4 screws md 2 bolts Remove pedal 4 bolts and 4 screws Desconrect fuel unit connector Remove fuel und 3 screws A Caution Da not bend the float arm of fuel unit a nat fill cul teo much bo fue tenk Fuel unit inspection Rele to electrical equipment 17 18 Fuel unit installation install the gauge in the reverse order of removal Caution Do not target tn mstall the gasket of fuel unit or damage Fuel tank romoval Open ihe seal 3 liogage box 8 bolts and 1 screw she rear central cover 4 screws Remove tre left and right pedals 1 bok Remove tre left and covers 4 bois Remove fe central cover 6 Remove pedal 4 bolts and 4 screws Disconnect fuel unit connector Remove tual unit 4 straws Remove fuel pure 2 bolts Remove tank bracket 4 bolis Remove vacuum and fuel filter Remove tuel tank Installation Install te Tank 3 the reverse order of nemayal PDF created with pdfFactory Pro trial version www pdffactory com FUEL SYSTEM AIR CLEANER sest LOOSEN tha clamp strip of air cleaner Remove left cov
130. yte bubbles Pulling it out will be unnecessary 5 Remove the container from the battery after all electrolyte is filled into battery 6 Insert the fixing plug in the filling hole of battery and press the fixing plug until itis not higher than the top of cover Note The Battery is completely ready to use thus do not remove the Aluminum Seal on the closed filling hole until it is to be used Electrolyte except those specified is absolutely forbidden While filling the electrolyte only regulated volume of electrolyte can be adopted The seal plug should not be removed after the electrolyte is added 127 PDF created with pdfFactory Pro trial version www pdffactory com 3 THE PROCEDURE OF USING NEW BATTERY FOR WATER ADDING BATTERY 1 Use the open long plastics tube to instead of the L Type closed rubber tube adjacent to the pole of the battery 2 Cut off the tip of the electrolyte s bottle and put on the open rubber tube Take off the fixing plugs on the battery 3 Pour the electrolyte into battery carefully to reach the upper level and the density must be1 28 20T 4 The battery must be stay to decrease the temperature of the electrolyte to under 35 Then begin to charge 5 Lay the battery for 30 minutes if battery stay long time it must recharge again also according to the table Time Within 3 months within above interval 1 year 1 year Unnecessary to 10 months 40 hours 60 hours charge

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