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SERVICE MANUAL - Sarner Trading AB

1. 1 5 Cylinder amp Piston I 20 Crankcase amp Crankshaft I 27 Cooling System 1 33 Transmission amp Gear 1 38 Chapter 2 Fuel System amp Carburetion Carburetor Il 3 Fuel Tank Il 7 Air Cleaner Il 10 Exhaust System Il 12 Chapter 3 Ignition and Starting System Ignition System III 1 Starting System III 4 Recoil Backup Starting System IIl 7 Chapter 4 Frame amp Cover Frame amp Cover IV 2 Chapter5 Wheel Tyres amp Brakes Handlebar amp Steering V 2 Front amp Rear Wheel V 6 Suspension System V 9 Hydraulic Brake V 14 Chapter 6 Electrical Equipment Alternator amp Starter Gear VI 2 Electrical Equipment VI 10 Wire Diagram VI 13 F 3 Gener
2. Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Cylinder head Leaking or damaged head gasket Warpedor cracked cylinder head Cylinder and piston Compression Too High o Excessive carbon build up on piston or combustion chamber Excessive Noise Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn camshaft Loose or worn cam chain Worn or damaged cam chain tensioner o Worn cam sprocket teeth o Worn rocker arm and or shaft Chapter 1 Engine Transmission amp Gear Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove blow by hose on cylinder head cover N Blow by tube _ Remove four cylinder head cover bolts on Camshaft ead cover bolts CAMSHAFT REMOVAL Remove the cam chain adjuster sealing bolt and spring Remove the two cam sprocket holder bolts m En cn 1 E il Baur NE A a a NOTE se gt Be careful not to drop the bolts into the Folder bolt A crankcase Derail the cam chain from the cam sprocket teeth and remove the cam sprocket NOTE e Suspend the cam chain with a piece of wire to keep it from falling to the crankcase Remove rocker arm cam shaft bearing holder plate mounting bolt and holder plate Remove rocker arm shaft by using a M6 bolt 3 screw in shaft then pull out the shaft Holder Dolt Remove r
3. Check the moveable drive face for wear or damage Measure the drive face depth with the straight edge and feeler gauge Service Limit 0 4 mm 0 0016 in Max 0 4mm 42 Chapter 1 Engine Transmission amp Gear ASSEMBLY Lubricate the inside of the moveable drive face with grease then install the weight rollers NOTE o Use 25 30g of grease and apply to the inside of the moveable drive face evenly Specified grease Lithium based grease Install the ramp plate Apply grease to the drive pulley collar Install the drive pulley face collar with the spline side facing out Clean off any grease or oil from the drive pulley faces INSTALLATION Install the moveable drive face onto the crankshaft Install the drive belt Clean the drive pulley face and install it Set the recoil dish onto the crankshaft and loosely install the drive pulley nut Apply engine oil to the threads of the drive pulley nut Hold the drive pulley and tighten the drive pulley nut Torque 90 100 N m 65 72 ft Ib CAUTION Do not allow oil or grease on the drive belt or pulley face Reinstall the removed parts in the reverse order of removal 1 43 Chapter 1 Engine Transmission amp Gear Clutch Driven Pulley REMOVAL Remove the left crankcase cover drive pulley face and drive belt Hold the clutch outer with drive pulley holder and remove the drive pulley nut and clutch outer Remove the driven pulley clutch
4. Apply greases on both of axle holder oil seal before installation V 11 Chapter 5 Wheels Tires amp Brakes Rear Suspension SWING ARM REMOVAL CAUTION Support the vehicle frame steady when servicing or inspecting Remove L and R foot pad and rear tires Disconnect drive chain and remove the chain Remove rear shock absorber mounting bolts both upper and lower then remove shock from axle Remove rear caliper and pull back caliper set with brake line and parking brake cable aside the swing arm assemble Remove rocker arm to chassis mounting bolt Remove foot brake pedal Loosen the swing arm bolt and remove it Pull back the swing arm assembly with axle and remove it from chassis INSPECTION Check swing arm bushing and oil seal for broken or damage replace it if necessary Check rocker arm bushing and roller bearing The bearing must turn smoothly and quietly Check shoe slider for unusually wear replace it if necessary INSTALLATION Install rear wheel axle in the reverse order of removal V 12 Chapter 5 Wheels Tires amp Brakes REAR WHEEL AXLE RMOVAL Loosen brake disk flange tighten nuts and remove the nuts Remove brake disk flange assembly Push wheel axle to right side and remove axle with rear sprocket assembly from axle holder Remove rear sprocket assembly from axle SPROCKET INSPECTION Check sprocket teeth replace if show as illustration REAR AXLE H
5. BODY 320U IV 3 Chapter 4 Frame amp Cover BODY COVER amp SEAT 320S y E amp SPA gt nh i N Sy 77 N u AN a A n See gt gt IV 4 Chapter 4 Frame amp Cover BODY COVER amp SEAT 320U IV 5 Chapter 4_ Frame amp Cover REAR FENDERS REMOVAL Remove the seat by flip back the latch level and lift the back end of seat Remove left and right floor panels Remove rear carrier Disconnect tail light and L R indicator light connector Remove upper fender to frame mounting bolts and front to rear fender joint bolts Remove two lower mount bolts Remove tail light fender 320S Open the rear luggage box and remove the mounting bolt 320S Raise up the fender and pull to back to remove the rear fender INSTALLATION Install the rear fender in the reverse order of removal NOTE Be sure to insert floor panel tabs to front and read fenders corresponding slots IV 6 Chapter 4 Frame amp Cover FRONT FENDER REMOVAL 320S NOTE The aid of an assistant will be required when removing front panel Remove L R floor panel Remove front fascia and disconnect headlight wire Disconnect indicator light and main switch wire Remove L R side cover and front to rear joint bolts Remove speedometer cover and handle bar supporter then
6. EX 27 5 mm 1 08 in Outer IN EX 30 4 mm 1 20 in VALVE STEM Inspect each valve for bending burning or abnormal stem wear Check valve movement in the guide and measure and record each valve stem O D Service Limit IN 4 9 mm 0 193 in EX 4 9 mm 0 193 in VALVE GUIDE NOTE o Remove the guides to remove any carbon build up before checking clearance Measure and record each valve guide I D using a ball gauge or inside micrometer Service Limit 5 03 mm 0 198 in Subtract each valve stem O D from the corresponding guide 1 D to obtain the stem to guide clearance Service Limit IN 0 08 mm 0 003 in EX 0 10 mm 0 004 in 1 14 Chapter 1 Engine Transmission amp Gear NOTE If the stem to guide clearance exceeds the Valve stem seal service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace any guide as necessary and to fit If the stem to guide clearance exceeds the service limits with new guide replace the valve also NOTE o Reface the valve seats whenever the valve guide are replace CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil then insert the valves into the valve guides Install new valve stem seals Install the valve spring seat springs and retainers The springs tightly wound coils should face in toward the combustion chamber NOTE There has paint marked on
7. Faulty ignition system o Faulty fuel valve Faulty components in the evaporative emission control system US version only Lean mixture Clogged fuel jet Stuck vacuum piston Faulty float valve Low float level Blocked fuel cap vent clogged fuel line Restricted fuel line Clogged air vent tube Intake air leak Faulty fuel valve Rich mixture Clogged air jets Faulty float valve Float level too high Improper choke operation Dirty air cleaner Chapter 2 Fuel System amp Carburetion CARBURETOR Il 3 3 Chapter 2 Fuel System amp Carburetion Carburetor CARBURETOR REMOVAL Loosen the air filter tube and intake manifold bands Disconnect the throttle cable on carburetor side Remove the choke cable with choke piston Leave the throttle cable and choke cable on vehicle NOTE Do not damage jet needle on the throttle piston Disconnect the heater component on carburetor Disconnect the fuel tube from the carburetor Remove the carburetor Vacuum Chamber DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Remove the four vacuum chamber cover screws and cover Remove the compression spring and the vacuum piston Needle jet Turn the vacuum piston upside down then remove the needle holder and jet needle Il 4 4 Chapter 2 Fuel System amp Carburetion Float Float valve Jets DISASSEMBLY Remove the fo
8. Install the starter driven gear onto the crankshaft Install the set plate and set plate bolt Check that the starter driven gear rotates freely Install the starter idle gear shaft Install the starter idle gear on the shaft VI 6 Chapter 6 Alternator Electrical Equipment FLYWHEEL INSTALLATION Install starter gear to crankshaft apply some grease onto crankshaft for easily insert Install starter gear holding plate by slight raise the starter gear and insert the holding plate Fasten the holding plate tighten blot Wipe off oil and grease from the tapered section of the crankshaft and flywheel Install the oil orifice drive pin in the crankshaft Install the woodruff key into the crankshaft slot Install the flywheel onto the crankshaft aligning the key on the crankshaft with the groove in the flywheel Apply oil to the washer and install onto the crankshaft Apply molybdenum disulfide grease to the flywheel nut and crankshaft threads then install and tighten the flywheel nut while holding the flywheel Torque 105 115 N m 76 83 ft Ib Install the spring and oil orifice onto the crankshaft aligning the slot in the orifice with the drive pin in the crankshaft VI 7 Chapter 6__Alternator Electrical Equipment ____ STATOR INSTALLATION Install the stator on the right crankcase cover with the three bolts Install the ignition pulse generator and breather plate with two bolts Install
9. make handle bar freely for moving Remove fender to frame mounting bolts Remove shaft nob and shaft rod plate fixing bolts Remove fuel cap With an assistant to help to raise the front fender and let it passed the handle bar and remove it from frame IV 7 Chapter 4_Frame amp Cover _ 320U Remove L R floor panel Remove front carrier optional accessory Disconnect headlight indicator light and main switch connector Remove shaft nob and shaft rod plate fixing bolts Remove two fender to frame mounting bolts Remove four bumper cover to bumper and headlight to bumper mounting bolts Remove fuel cap then remove fuel tank dash board NOTE o Lock the fuel cap to fuel tank as soon as removed fuel tank dash board With an assistant to help to raise the front fender and pull forward to passed the handle bar and remove it from frame INSTALLATION Install the rear fender in the reverse order of removal NOTE Be sure to insert floor panel tabs to front and read fenders corresponding slots IV 8 Chapter 4_ Frame amp Cover FRONT REAR CARRIER 320U ONLY FRONT CARRIER REMOVAL Loosen two carrier to bumper mounting bolts Loosen two carrier to cover fixed pole bolts Remove the front carrier INSTALLATION Install the front carrier in the reverse order of removal NOTE Attached all four bolts first and after aligned the carrier tighten the bolts INS
10. required to support and maneuver the engine SPECIFICATION Engine dry weight 32 kg 72 Ib Oil capacity Engine 1 0 liter 1 06 US qt at disassembly 0 8 liter 0 85 US qt at change Transmission 0 6 liter 0 74 US qt at disassembly 0 5 liter 0 63 US qt at change Coolant capacity Engine and radiator 1 1 liter 1 16 US qt Reserve tank 0 3 liter 0 31 US qt Total 1 4 liter 1 47 US qt TORQUE VALUES Engine upper hanger plate 18 24 N m 13 16 ft lb Engine mounting nut 40 55 N m 29 40 ft Ib Step bar rear bolt 40 55 N m 29 40 ft Ib Step bar front bolt 18 24 N m 13 16 ft Ib Chain cover bolt 10 14 N m 7 10 ft lb Chapter 1 Engine Transmission amp Gear Engine Removal amp Installation ENGINE REMOVAL Park the vehicle on the level ground and pull parking lever to park the vehicle Disconnect the battery ground cable Remove left and right floor panel and step bar Remove foot brake pedal Remove front chain cover then disconnect drive chain Disconnect gear selection rod then remove muffler ass y Disconnect coolant hose Disconnect spark plug and generator wire connector and coupler Disconnect blow by tube at cylinder head cover and crankcase Disconnect carburetor on intake manifold and vacuum tube The engine is held in the frame by three point two at bottom an on at rear upper Loosen the all nuts on fixing studs and move all studs Remove
11. seconds Coolant Replacement WARNING The engine must cool before removing the radiator cap or severe scalding may result Remove the front light fender 280AS or front fender assy 280AU Remove the radiator cap Place a drain pan under the water pump and drain the coolant from the system by removing the coolant tube Reinstall the coolant tube Fill the system with a 50 50 mixture of distilled water and ethylene glycol Capacity 1 1 L 1 16 US qt Bleed air from the system Start the engine and run until there are no air bubbles in the coolant and the level stabilizes Stop the engine and add coolant up to the proper level if necessary I 35 Chapter 1 Engine Transmission amp Gear Check the level of coolant in the reserve tank and fill to the correct level if the level is low Install the front light fender 280AS or front fender assy 280AU Radiator INSPECTION Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with low pressure air If insects etc are clogging the radiator wash them off with low pressure water REMOVEAL Remove the front light fender 280AS or front fender assy 280AU Drain the coolant Remove the radiator grill Disconnect the radiator upper and lower hoses from the radiator Disconnect the fan switch wire Remove two mounting screws and radiator INSTALLATION Install the radiator in the reverse o
12. springs loosely wound coils both inner and outer springs Compress the valve springs using the valve spring compressor then install the valve cotters I 15 Chapter 1 Engine Transmission amp Gear CAUTION To prevent loss of tension do not compress the valve spring more than necessary Tap the valve stems gently with a plastic hammer to firmly seat the cotters CAUTION Support the cylinder head above the working bench surface to prevent possible valve damage Install the carburetor insulator with two bolts and tighten the bolts CYLINDER HEAD INSTALLATION Install the dowel pins and a new gasket onto the cylinder Install the cylinder head onto the cylinder Install four copper washers and cap nuts and tighten the cap nuts Torque 22 26 N m 16 19 ft Ib NOTE Tighten the cap nuts in a crisscross pattern in 2 3 steps Install the cylinder base bolt Install a new O ring onto the thermostat housing Install the thermostat housing to the cylinder head and tighten the bolt I 16 Chapter 1 Engine Transmission amp Gear CAMSHAFT INSTALLATION Remove the timing hole oil filling cap from the right crankcase cover Turn the drive pulley counterclockwise and align the T mark on the flywheel with the index mark on the right crankcase cover Insert the camshaft into camshaft holding house and turn down the intake and exhaust lobe OSTIA I ia ae Install i
13. the flywheel and starter idle and driven gears Remove the attaching bolt and oil separator cover Remove the circlip then remove the oil pump drive chain and driven sprocket Remove the two oil pump mounting bolts and remove the oil separator and oil pump OIL PUMP DISASSEMBLY Unscrew the pump cover attaching screw and disassemble the oil pump OIL PUMP INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 25 mm 0 010 in Measure the outer rotor to inner rotor tip clearance Service Limit 0 20 mm 0 008 in Check the rotor to pump body clearance Service Limit 0 12 mm 0 005 in OIL PUMP ASSEMBLY Install the outer and inner rotor into the pump body Insert the pump shaft by aligning the flats of the shaft and inner rotor Install the dowel pin Install the pump cover by aligning the hole of the cover with the dowel pin Tighten the screw Make sure that the pump shaft rotates freely without binding Chapter 1 Engine Transmission amp Gear Contents Engine Removal amp Installation Cylinder Head amp Valve Cylinder amp Piston Crankcase amp Crankshaft Cooling System Transmission amp Gear GENERAL SAFETY WARNING If the engine must be running to do some work make sure the area is well ventilated Never run the engine in a closed area The exhaust contains carbon monoxide gas that may cause loss of consciousness and lead to death WARNING Gasoline is ext
14. wear or damage Turn the water pump shaft to check the bearing it should turn smoothly and quietly Inspect ignition pulse generator soldering and check the sealing rubber for any deficient INSTALLATION Use solvent to clean right crankcase Install the dowel pins and a new gasket Apply silicon sealing on ignition pulse generator sealing rubber Align water pump shaft gap toward oil pump shaft then install the right crankcase and tighten the mounting bolts Turn the water pump impeller to ensure shaft alignment then install water pump cover 1 32 I 33 Chapter 1 Engine Transmission amp Gear Cooling System Service Information GRENERAL WARNING Do not remove the radiator cap when the engine is hot The coolant is under pressure and severe scalding could result The engine must be cool before servicing the cooling system Use only distilled water and ethylene glycol in the cooling system A 50 50 mixture is recommended for maximum corrosion Do not use alcohol based antifreeze Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system The cooling system service can be done with the engine on frame Avoid spilling coolant on painted surface After servicing the system check for leaks with a cooling system taster SPECIFICATION 55 distilled water 45 ethylene glycol 32 C 26 F Freezing point Hydrometer test 50 distilled water
15. 0 0 16 3 0 0 14 Disc thickness Front l l 4 0 0 16 3 5 0 14 0 3 0 012 Disc runout Brake padthickness 1 0 0 04 TORQUE VALUES Bleed valve 4 7 N m 3 5 ft lb Caliper mounting bolt 30 N m 22 ft Ib Brake fluid line bolt 34 N m 25 ft lb Master cylinder holder bolt 10 14 N m 7 10 ft Ib Troubleshooting Brake lever soft or spongy Brakes grab or pull to one side Air bubbles in hydraulic system Pads contaminated Low fluid level Disc or wheel misaligned Hydraulic system leaking Brake chatter or squeal Brake lever too hard Pads contaminated Sticking piston s Excessive disc runout Clogged hydraulic system Caliper installed incorrectly Pads glazed or excessively worn Disc or wheel misaligned Brake drag Hydraulic system sticking Sticking piston s V 16 Chapter 5 Wheels Tires amp Brakes Brake Fluid Replacement Bleeding BRAKE FLUID DRAINING WARNING A contaminated brake disc or pads reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent CAUTION Do not allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced With the fluid reservoir parallel to the ground remove the reservoir cap and diaphragm plate Connect a hose to the bleed valve Loo
16. 3 6 14 3 V Replaced the regulator if it s not heated or charging volts not in range when engine is running REMOVAL INSTALLATION Disconnect alternator wire couplers and connector on right side then loosen two mounting bolts and remove regulator Install the regulator in the reverse order of removal VI 12 Chapter 6 Alternator Electrical Equipment Wire Diagram LRT fit Co ES EN HTT TA LL TH KAENI Hl PERRI HH Udit i i VI 13
17. 50 ethylene glycol 37 C 35 F 45 distilled water 55 ethylene glycol 44 5 C 48 F Coolant capacity Radiator and engine 11 10 liter 1 16 US qt Reserve tank 0 30 liter 0 31 US qt Total system 1 40 liter 1 47 US qt Begin to open 60 C to 65C 140 F to 149 F Valve lift 3 5 4 5mm 0 14 0 18in at 80 C 176 F Un pressurized 107 7 C 226 F Cap on pressurized 125 6 C 258 F Thermostat Boiling point with 50 50 mixture TORQUE VALUES Water pump impeller left hand threads 10 14N m 7 10 ft lb Oil pipe bolt 8mm 8 12 N m 6 9 ft lb 12 mm 18 22 N m 13 169 ft lb Troubleshooting Engine temperature too high Engine temperature too low Faulty temperature gauge or gauge sensor Faulty temperature gauge or gauge sensor Faulty radiator cap o Thermostat stuck open Thermostat stuck closed Insufficient coolant Coolant leaks Passages blocked in radiator hoses or water Faulty pump mechanical seal jacket Deteriorated O ring Faulty water pump Damaged or deteriorated hoses Faulty fan motor 1 34 Chapter 1 Engine Transmission amp Gear System Testing COOLING SYSTEM LEAK TEST Remove the front luggage rack Remove the radiator cap Install special plug radiator cap and hose pincher on overflow hose Pressurize all system through coolant reservoir to 103 kPa 15 PSI Repair or replace components if system will not hold the specified pressure for at least six
18. 9 Chapter 6 __Alternator Electrical Equipment Electrical Equipment Service Information GENERAL INFORMATION The machines covered by this manual are equipped with a 12 volt electrical system The components include a three phase permanent magnet alternator and a regulator rectifier unit The regulator rectifier unit maintains the charging system output within the specified range to prevent overcharging and converts the AC alternating current output of the alternator to DC direct current to power the lights and other components and to charge the battery Electrical problems often stem from simple causes such as loose or corroded connections or a blown fuse Prior to any electrical troubleshooting always visually check the condition of the fuse wires and connections in the problem circuit If testing instruments are going to be utilized use the diagrams to plan where you will make the necessary connections in order to accurately pinpoint the trouble spot One method of finding short circuits is to remove the fuse and connect a test light or voltmeter in its place to the fuse terminal There should be no load in the circuit Move the wiring harness from side to side while watching the test light If the bulb light there is a short to ground somewhere in that area probably where insulation has rubbed off a wire The same test can be performed on other components in the circuit including the switch A ground check should be d
19. 9 ft lb Cylinder stud bolt 7 11 N m 5 8 ft lb Troubleshooting Overheating Low compression or uneven compression e Excessive carbon build up on piston o Worn cylinder or piston rings Excessive smoke o Worn cylinder piston or piston rings o Blocked or restricted flow of coolant Sticking thermostat Knocking or abnormal noise Improperly installed piston rings o Worn piston and cylinder Damaged piston or cylinder Excessive carbon build up on piston head l 21 Chapter 1 Engine Transmission amp Gear Cylinder CYLINDER REMOVE Remove the cylinder head Disconnect the water hose from the cylinder Remove the cam chain guide Remove the cylinder base bolt and cylinder Remove the cylinder gasket and dowel pins Place rags in the crankcase openings Clean off any gasket material from the cylinder surface of the crankcase NOTE o Gasket material will come off easier if it is soaked in solvent Remove the cam chain adjuster base and gasket from the cylinder Clean any material from the cylinder surface NOTE o Gasket material will come off easier if it is soaked in solvent I 22 Chapter 1 Engine Transmission amp Gear Piston PISTON REMOVE Place clean shop towels in the crankcase opening to keep the piston pin clips or other parts from falling into the crankcase Remove the piston pin clips with pliers Pull the piston pin out of the piston and remove the
20. Feeler gauge o Start with the intake valves Valve Clearance IN 0 15 mm 0 006 in EX 0 15 mm 0 006 in When the clearances are correct for all four valves install the cylinder head cover The remainder of installation is the reverse of removal I 18 Chapter 1 Engine Transmission amp Gear CYLINDER HEAD COVER INSTALLATION Check the cylinder head cover seal for any buckle or broken Replace a new one if necessary Coating engine oil on seal face before install Install the cylinder head cover to cylinder and tighten four 6mm head cover bolts crisscross pattern in two or more steps Torque 8 12 N m 6 9 ft Ib I 19 Chapter 1 Engine Transmission amp Gear Cylinder Piston Crankshaft I 20 Chapter 1 Engine Transmission amp Gear Cylinder Piston Crankshaft Service Information GENERAL It is recommended to remove the engine from frame body for cylinder and piston service If the crankshaft bearing oil pump drive sprocket or timing sprocket need to replacement the crankshaft assembly must be replaced STANDARD mm in SERVICE LIMIT mm in CT wena nm SPECIFICAIONS ter T_T sese _ owowa sese Ring to groove Top 0 015 0 050 0 0006 0 0020 0 09 0 004 Piston Ring end gap 0 15 0 35 0 006 0 014 0 05 0 002 Piston Oil Side rail 0 2 0 7 0 01 0 03 Crans run Gres TORQUE VALUES Cam chain adjuster base bolt 8 12 N m 6
21. OLDER INSPECTION Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the outer race fits tightly in the holder Remove and discard the bearing if the races do not turn smoothly quietly or if they are fit loosely in the holder NOTE Replace holder bearing in pairs INSTALLATION Install rear wheel axle in the reverse order of removal NOTE Apply greases on bushing before installation NOTE Apply Loctite on brake disk flange tighten nuts when installation V 13 Chapter 5 Wheels Tires amp Brakes HYDRAULIC BRAKE SYSTEM V 14 Chapter 5 Wheels Tires amp Brakes BRAKE CALIPER V 15 Chapter 5 Wheels Tires amp Brakes Service Information GENERAL The brake calipers can be removed without disconnecting the hydraulic system Bleed the hydraulic system if it has been disassembled or if the brake feels spongy Do not allow foreign material to enter the system when filling the reservoir Brake fluid will damage painted plastic and rubber parts Whenever handling brake fluid protect the painted plastic and rubber parts by covering them with a rag If fluid does get on the parts wipe if off with a clean cloth Always check brake operation before riding the motorcycle SPECIFICATION ITEM STANDARD mm in SERVICE LIMIT mm in Front 4
22. SERVICE MANUAL ATV 320 S U 2002 24 JUNE 30 2007 High Power Liquid Cooled Engine HER CHEE INDUSTRIAL CO LTD Foreword This service manual contains information on servicing ATV 320 S U This manual is written for use as a guideline only It is recommended that any mechanic with or without sufficient experience thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual For fully qualified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manual in full before attempting service on ATV 320 All the data and diagrams provided in this service manual are valid at the time of publication Information may be updated without notice due to improvements or upgrades No quotation reproduction or reprint of the service manual as a whole or in part will be permitted without the express written consent from ADLY Motor sports CONTENTS General Information amp Lubrication General Information F 4 Information for Preparation F 5 Lubrication F Chapter1 Engine Transmission amp Gear Engine Removal amp Installation I 2 Cylinder Head amp Valve
23. TALLATION Install the front carrier in the reverse order of removal REAR CARRIER REMOVAL Remove two carrier to plate bracket bolts and two carrier to rear bumper bolts Remove the rear carrier INSTALLATION Install the front carrier in the reverse order of removal IV 9 Chapter 4 Frame amp Cover FRONT BUMPER REMOVAL Remove the front carrier Remove four bumper mounting bolts Remove the front bumper NOTE Attached all four bolts first and after aligned the bumper then tighten the bolts INSTALLATION Install the front bumper in the reverse order of removal REAR BUMPER REMOVAL Remove the rear carrier Remove four bumper mounting bolts NOTE The right side front bolt also tighten the muffler bracket For easily removing the rear bumper loosen another bracket mounting bolt too Remove the rear bumper INSTALLATION Install the rear bumper in the reverse order of removal IV 10 Chapter 5 Wheels Tires amp Brakes Contents Handlebar amp Steering Front amp Rear Wheel Suspension System Hydraulic Brake Service Information Specification ITEM STANDARD mm in SERVICE LIMIT mm in Axle round out e 0 2 0 008 Rma 20008 Rim round out ma 20008 Torque Values Steering shaft nut Steering shaft holder bolt Handle bar holder clamp nut Handle bar holder clamp bolt Tie rod end Ball joint Upper Lower Front wheel hub nut Rear wheel hu
24. al Information MODEL IDENTIFICATION The frame serial number is stamped on the The engine serial number is stamped on the lower front right side of frame upper rear right crankcase dio ich i 0 ii Perret iat yeast pitt isis Er ae i nii indire stout x2002 24 1365 01 4 JO saFLCK25207A000105 82 3500 i Ta The VIN Vehicle Identification Number is The carburetor identification number is attached to the lower front right side of frame stamped on the right side of the carburetor behind the frame number Information for Preparation ATTENTION ON OPERATION All washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted O O Locking of all screws nuts cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks All items must use original parts pure oil and greases La All service shall use special tools and general tools to repair All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated F 5 Information for Preparation ATTENTION ON OPERATION Certified lubricants in cans shall be used on all the elements to be lubricated E After assembly performance of all elements shall be duly checked and the locking shall be duly verified Incas
25. assembly INSPECTION Check the clutch outer for wear or damage Measure the clutch outer I D Service Limit 154 0 mm 6 063 in Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 0 5 mm 0 02 in NOTE o Replace the clutch as a set 44 ion amp Gear ISS Transm ine En Chapter 1 ission Transm NV SS Ni 7 J YY UM UL 7 N J 1 45 Chapter 1 Engine Transmission amp Gear Transmission Service Information SPECIFICATION Specified gear oil SAE 85W 90 or equivalant Oil capacity 0 5 liter 0 52 US qt at change 0 6 liter 0 63 US qt at disassembly TORQUE VALUES Transmission case cover 6 mm 8 12 N m 6 9 ft Ib 8 mm 20 24 N m 14 18 ft Ib 10 mm 10 15 N m 7 11 ft Ib Troubleshooting Engine starts but vehicle won t move Damaged or seized transmission Abnormal noise e Worn seized or chipped gear Worn bearing Oil leak o Oil level too high Worn or damaged oil seal 1 46 Chapter 1 Engine Transmission amp Gear Gearbox DISASSEMBLY Drain the gear oil by loosen drain bolt Remove drive sprocket Remove shaft lever Loosen eight gearbox attaching bolts Remove right side gearbox cover dowel pins and gasket Remove gear shaft arm Remove shift rod guide rod Remove shaft drum Remove gear set I 47 Chapter 1 Engine Transmission amp Gear INSPECTION Inspect drive shaf
26. b nut Wheel nut Brake disk bolt Shock absorber Front Rear Upper Lower Troubleshooting Hard steering Steering shaft nut too tight Steering shaft bearing damage Steering shaft holder too tight Insufficient tire pressure Soft suspension Damper oil leaks o Weak shock absorber spring 80 120 N m 58 87 ft lb 50 60 N m 36 43 ft lb 30 40 N m 22 29 ft lb 24 30 N m 17 22 ft lb 45 N m 33 ft lb 55 N m 40 ft lb 55 N m 40 ft lb 59 79 N m 43 58 ft lb 140 160 N m 101 116 ft lb 64 N m 17 22 ft lb 30 N m 22 ft lb 45 N m 33 ft lb 108 N m 80 ft lb 59 N m 43 ft lb Steers to one side or do not tract straight Insufficient toe in setting Bend A arm Insufficient tire pressure Front wheel wobbling Bent rim Faulty or unevenly worn tire Excessive wheel bearing play V 1 Chapter 5 Wheels Tires amp Brakes HANDLE BAR Chapter 5 Wheels Tires amp Brakes STEERING Chapter 5 Wheels Tires amp Brakes Handlebar REMOVAL Remove the speedometer assembly mounting SCrews Loosen L R hand brake master cylinder holder mounting bolts and remove brake cylinder from handlebar Loosen L handle switch mounting bolts and remove switch from handlebar Disconnect brake switch wire overdrive switch wire throttle and choke cable Loosen four handle clamp hex socket bolts and remove handlebar NOTE Do not remove the brake hose bolt f
27. e Transmission amp Gear INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 23 0 mm 0 9055 in Min 23 mm INSTALLATION Lay the drive belt on the driven pulley Squeeze the driven pulley to widen its faces then set the drive belt on the drive pulley face collar Reinstall the drive pulley face and recoil dish hold the drive pulley and tighten the nut Torque 80 100 N m 58 72 ft Ib Reinstall the left crankcase cover Drive Pulley REMOVAL Remove the left crankcase cover Remove the drive belt Remove the moveable drive face assembly NOTE If the spline fitting is tight use a commercially available bearing puller DISASSEMBLY Remove the ramp plate Remove the weight rollers 41 Chapter 1 Endine Transmission amp Gear INSPECTION Check the face seal for wear or damage Replace the face seal with a new one if necessary Check each roller for wear or damage Measure the weight roller O D Service Limit 22 4 mm 0 8819 in Measure the moveable drive face bushing D Service Limit 27 06 mm 1 065 in Max27 06mm Check the drive face collar for wear or damage Measure the O D at the drive face sliding surface Service Limit 26 94 mm 1 061 in Check the driver face for wear or damage Measure the drive face depth with the straight edge and feeler gauge Service Limit 0 4 mm 0 0016 in
28. e first then the other INSTALLATION Installation is the reverse of removal Using a C clamp depress the piston back into the caliper bore to provide enough room for the new pads to clear the disc Insert brake pads fixation bolts and tighten the bolts Tighten the caliper mounting bolts Torque 30 N m 25 ft Ib V 20 Chapter 5_ Wheels Tires amp Brakes REAR BRAKE PADS Remove the caliper mounting bolts and remove caliper from rear swing arm Push caliper piston back into the caliper bore to provide enough room for remove pads Remove the inner pad first then outer pad NOTE For easily remove the outer pad pull the pad apart with align pin one side first then the other Installation is the reverse of removal Using a C clamp depress the piston back into the caliper bore to provide enough room for the new pads to clear the disc Tighten the caliper mounting bolts Torque 30 N m 25 ft Ib BRAKE DISC INSPECTION REMOVAL AND INSTALLATION INSPECTION Visually inspect the surface of the disc for score mark and other damage Light scratches are normal after use and won t affect brake operation but deep grooves and heavy score marks will reduce braking efficiency and accelerate pad wear If the disc is badly grooved it must be machined or replaced Check the thickness of the disc with a micrometer If the disc is thinner than service limit replace it The minimum thickness is also stamped i
29. e fuel tube and vacuum tube on fuel valve Disconnect the petrol gauge connector Remove the fuel tank from frame body FUEL VALVE INSPECTION Disconnect vacuum tube from fuel valve and fuel tube from carburetor Connect a commercially brake bleeder to vacuum tube then pump the brake bleeder Check the fuel flow thru fuel tube if it s block or intermittently replace the fuel valve INSTALLATION Install the fuel tank in the reverse order of removal Petrol Gauge Sensor REMOVAL Remove fuel tank Loosen four petrol gauge mounting bolts Remove petrol gauge from the fuel tank NOTE Do not damage or bend the float and float arm Il 8 8 Chapter 2_ Fuel System amp Carburetion _ _ INSPECTION Check the petrol gauge seal for damage or deterioration and replace if necessary Use a ohmmeter connect to gauge terminal to check the ohm reading from upper to lower float level of petrol gauge Ohm reading 10 QO 90 Q Replace petrol gauge if the ohm reading is discontinuousness or the reading is INSTALLATION Install the petrol gauge onto the fuel tank Install the mounting bolts Il 9 9 Chapter 2 Fuel System amp Carburetion AIR CLEANER ASSEMBLY 10 Il 10 Chapter 2 Fuel System amp Carburetion Air Cleaner Assembly REMOVAL Remove the seat Loosen the air cleaner case to air camber connecting tube band Remove the four air cleaner case mounting bolts and remove
30. e of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority et _ Tr De IO pre e gt 45 Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation OIL Lubrication by designated lubricant GREASE Lubrication by grease Special Tool Parts on which special tools shall be used General Tool General tools shall be used New Replace by new items after dismounting Attention Dangerous and important operations F 6 Lubrication GENERAL The maintenance of the oil pump and engine oil can be done with the engine install in the frame When removing and install the oil pump use care not to allow dust or dirt to enter the engine and oil line SPECIFICATION ITEM STANDARD mm in SERVICE LIMT mm in Rotor tip clearance 0 15 0 006 0 20 0 008 Oil pump Body clearance 0 15 0 20 0 006 0 008 0 25 0 010 Rotor end clearance 0 04 0 09 0 002 0 004 0 12 0 005 TORQUE VALUES Oil drain plug 20 25 N m 15 18 ft lb Oil filter screen cap 18 22 N m 13 16 ft lb Transmission oil check bolt 10 15 N m 7 11 ft lb Transmission oil drain bolt 10 15 N m 7 11 ft lb Troubleshooting Oil level too low e External oil leaks Worn valve guide or seal Worn piston rings Oil contamination Oil not changed often enough Head gasket faulty worn piston rings Low o
31. emove the oil orifice from the end of the crankshaft Hold the flywheel with a flywheel holder and remove the flywheel nut and washer NOTE Be careful not to drop the drive pin into the crankcase Remove the flywheel with a flywheel puller Remove the woodruff key from the crankshaft VI 4 Chapter 6 __Alternator Electrical Equipment Starter Gear STARTER IDLE DRIVEN GEAR REMOVAL Remove the starter idle gear Remove the set plate Remove the starter driven gear and idle gear shaft STARTER GEAR INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limit I D 22 10 mm 0 870in O D 42 15 mm 1 659in Inspect the starter idle gear and shaft for wear or damage Install the starter driven gear onto the one way clutch and check for proper operation by turning the starter driven gear The starter driven gear should only turn in one direction VI 5 Chapter 6 Alternator Electrical Equipment Starter Clutch DISASSEMBLY Remove the hex socket bolts using an impact driver and 6 mm socket bit Measure the one way clutch outer I D Service Limit 58 98 mm 2 322in ASSEMBLY Install the one way clutch into the one way clutch outer Install the one way clutch assembly to the flywheel and tighten with 6 mm socket bolts Torque 28 32 N m 21 24 ft lb NOTE Apply a locking agent to the socket bolt threads INSTALLATION
32. ervice Information GENERAL The alternator and starter clutch can be serviced with the engine installed in the frame SPECIFICATION ITEM STANDARD mm in SERVICE LIMIT mm in Starter driven gear I D 22 026 22 045 0 8672 0 8679 22 10 0 870 Starter Driven gear O D 42 195 42 208 1 6612 1 6617 42 15 1 659 One way clutch outer D 58 897 58 927 2 3187 2 3200 58 98 2 322 TROQUE VALUES Flywheel nut 105 115 N m 76 83 ft Ib Oil pipe bolt 8 mm 8 12 N m 6 9 ft Ib 12 mm 18 22 N m 13 16 ft Ib One way clutch bolt 28 32 N m 21 24 ft Ib VI 1 Chapter 6 Alternator Electrical Equipment Alternator amp Starter Gear VI 2 Chapter 6 Alternator Electrical Equipment Right Crankcase Cover REMOVAL Remove right foot pad Drain the coolant by disconnecting the water hoses of the water pump Remove the two pipe bolts two 8 mm oil pipe bolts 12 mm oil pipe bolt and washer then remove the pipe Disconnect the pulse generator and alternator wire connectors Disconnect the crankcase breather tube from the right crankcase cover Remove the right crankcase cover attaching bolts and right crankcase cover Remove the dowel pins and gasket Chapter 6__Alternator Electrical Equipment ____ STATOR REMOVAL Remove the wire grommet from the groove in the Pd cover Remove the breather plate and ignition pulse generator Remove the three stator attaching bolts and stator FLYWHEEL REMOVAL R
33. ght bulb CAUTION Do not put finger prints on the headlight bulb they may create hot sports on the bulb If you touch the bulb with your hands clean it with c cloth moistened with alcohol to prevent its early failure Do not try to replace the bulb with light ON Position the headlight bulb rubber dust seal NOTE Install the dust seal securely Speedometer REMOVAL INSTALLATION Loosen two mounting bolts of speedometer cover Disconnect speedometer connectors and pull out the soeedometer cover with speedometer Loosen three speedometer mounting screws and remove the speedometer Install the speedometer in the reverse order of removal VI 11 Chapter 6 _Alternator Electrical Equipment Regulator Rectifier GENERAL Regulator rectifier was located on left front side of front fender The regulator rectifier unit maintains the charging system output within the specified range to prevent overcharging and converts the AC alternating current output of the alternator to DC direct current to power the lights and other components and to charge the battery INSPECTION During the regulator normally function the alloy body of regulator will became heated Started the engine use your hand to touch the alloy body to check it s functional When engine is running turnoff the light and other electrical accessory and use a voltmeter to check the volts of battery Battery volts 1
34. gnition and Starting System Ignition System Service Information GENERAL Ignition timing cannot be adjusted since the ignition control module is factory present A continuity check can usually be made without removing the parts from the vehicle Simply disconnect the wires and use a continuity tester or ohmmeter at the terminals Inspect should be made sequence referring for troubleshooting of the system SPECIFICATION ITEM STANDARD Without plug cap 7 4 11 KQ Ignition pulse generator at 20 C 68 F 50 170 Q Ignition coil With plug cap 3 7 4 6 KQ iik o mno TROUBLESHOOTING No spark at plug Engine starts but runs poorly Poorly connected broken or shorted wire o Ignition primary circuit Between ignition pulse generator and ignition Faulty ignition coil control module CDI Loose or bare wire Between CDI and ignition coil Poor connection at ignition switch Between CDI and ignition switch Ignition secondary circuit Between ignition coil and spark plug Faulty ignition coil Faulty Faulty spark plug Ignition switch Faulty spark plug wire Ignition control module CDI Poorly insulated plug cap Ignition pulse generator Improper ignition timing Spark plug Faulty ignition pulse generator Stator not installed properly Faulty ignition control module CDI 1 1 Chapter 3 Ignition and Starting System Ignition Coll INSPECTION Disconnect the ignition co
35. h the engine installed o Avoid getting grease and oil on the drive belt and pulley faces SPECIFICATION Clutch lining thickness 0 5 002 Clutch outer I D 153 0 153 3 6 023 6 035 153 5 6 043 40 96 40 98 1 612 1 613 Drive Driven face depth 0000 Torque Values Left crankcase cover bolt 8 12 N m 6 9 ft lb Drive face nut 90 100 N m 65 72 ft lb Clutch outer nut 50 60 N m 36 43 ft Ib Moveable driven face nut 70 90 N m 51 65 ft Ib Troubleshooting Engine starts but vehicle won t move Worn or damaged drive belt Damaged ramp plate Worn or damaged clutch lining Engine stalls or vehicle creeps Broken clutch weight spring Poor performance at high speed or lack of power o Worn drive belt o Weak driven face spring Faulty driven face 1 39 Chapter 1 Engine Transmission amp Gear Left Crankcase Cover REMOVAL INSTALLATION Remove left foot bar Remove front and rear air tube on left crankcase Remove the crankcase cover attaching bolts and remove the crankcase cover dowel pins and gasket Inspect the gasket for crankcase cover and replace it if necessary Install the left crankcase cover in the reverse order of removal Torque 8 12 N m 6 9 ft Ib Drive Belt REMOVAL Remove the left crankcase cover Hold the drive pulley with the drive pulley holder and remove the drive pulley nut washer and drive face Remove the drive belt 1 40 Chapter 1 Engin
36. i No continuity when Ignition switch BI W G switch ON If the harness and all other components are all okay the CDI is probably defective But before replace a new one It s a good idea to substitute a known good CDI IIl 3 Chapter 3 Ignition and Starting System Starting System Service Information SPECIFICATION ITEM STANDARD SERVICE LIMIT Starter motor brush length 12 0 12 5 mm 0 47 0 49in 6 5 mm 0 26 in Starter motor brush spring tension 680 920 g 1 49 2 03 Ib 680 g 1 49 Ib TROUBLESHOOTING Starter won t turn Burned out fuse Weak battery Poorly connected broken or shorted wire Faulty Ignition switch starter switch Rear brake light switch Starter motor Lack of power Weak battery o Loose or bare wire Faulty starter gear Starter turns but engine does not start Faulty starter clutch Faulty starter pinion 1 4 Chapter 3_ Ignition and Starting System Starter Relay GENERAL The relay coil is normal if you hear a click when starter button is depressed with the ignition switch ON and brake lever pressed x gt Starter switch Li REMOVAL INSPECTION Remove the seat Disconnect the negative battery cable from the battery Disconnect the positive cable and starter motor cable from the starter relay Disconnect starter relay terminal and remove the starter relay Connect an ohmmeter between the positive and starter motor terminal Connect the yel
37. il haft Repeat about mentioned process till the engine starting After engine start release the recoil haft the wire should return into the recoil body and the haft Stay to it s original position NOTE If the recoil haft can t back to original position slightly pull out the recoil wire till it can retract If the recoil haft still can t return to it s original position replace the recoil set REMOVAL INSTALLATION Remove foot pad Loosen five mounting bolts on recoil cover Remove recoil set Check starting dish edge for wear or damage Install the starter motor in the reserve order of removal 111 8 Chapter 4 Frame amp Cover GENERAL INFORMATION This Chapter covers the procedures necessary to remove and install the body panels and other body parts Since many service and repair operations on this vehicle require remove of the panels and or other parts the procedure are grouped here and referred to from other Chapter In the case of damage to the panels or other parts it is usually necessary to remove the broken component and replace it with a new or used one The material that the plastic body parts are composed of doesn t lend itself to conventional repair techniques There are however some shops that specialize in plastic welding so it would be advantageous to check around first before throwing the damaged parts away NOTE When attempting to remove any body panel first st
38. il pressure Oil level too low Clogged oil filter oil passage and or oil pipe Faulty oil pump Engine Oil OIL LEVEL Warm up the engine Stop the engine and park the vehicle on level ground i Check the oil level through the oil window Min Level_ If the level is near the lower of the window fill to SE ie oe ip ee FR e the middle level with the recommended engine oil OIL CHANGE NOTE Drain the oil from the crankcase while the engine is warm This ensures complete and rapid draining Place the oil pan under the engine Remove the oil filler cap and oil drain plug and drain the engine oil Remove the oil filter screen cap spring and filter screen and clean the filter screen After the oil has been completely drained be sure the O ring on the filter screen cap is in good condition and install the filter screen with the closed end facing out Install the spring and cap Torque 18 22 N m 13 16ft Ib Make sure that the sealing washer is in good condition install the drain plug and tighten it Torque 20 25 N m 15 18 ft lb Fill the engine with recommended engine oil through the oil filler hole ENGINE OIL CAPACITY 0 8 Liter 0 85 US qt at change Reinstall the oil filler cap and start the engine and let it idle for a few minutes Recheck the oil level Check that there are no oil leaks Oil Pump OIL PUMP REMOVAL Remove the right crankcase cover Remove
39. il primary wires and measure the resistance between the terminals Resistance 0 1 0 3 Q Remove the spark plug cap from the spark plug and measure the resistance between the ignition coil primary terminal and spark plug cap Resistance 7 4 11 KQO If the resistance is out of the specification remove the spark plug cap from spark plug wire and measure the resistance of the secondary coil Resistance 3 7 4 5 KQO REMOVAL INSTALLATION Disconnect the ignition coil primary wires connectors and remove the spark plug cap from the spark plug Remove the ignition coil mounting bolt and remove the ignition coli Install the ignition coil in the reverse order of removal Ignition Pulse Generator Disconnect the ignition pulse generator wire connectors and measure the resistance between the terminals Resistance 50 1700 IIl 2 Chapter 3 Ignition and Starting System Capacitive Discharge Ignition C D I GENERAL The CDI unit was located on front right of frame about the right front shock absorber There are three electrical connectors for the CDI the two pin connector and a four pin connector on CDI body and a four pin gear position coupler k INSPECTION Disconnect the CDI coupler and connectors and check each circuit according to the table below CIRCUIT COLOR CORRECT Ignition Puler Bu Y G 50 170 Q BI Y G 0 1 0 3 Q Ignition coil w cap 7 4 11kQ PIRGRIUGICSR w o cap 3 7 4 5kQ
40. ion amp Gear Cylinder Head Valves Service Information GENERAL This section covers maintenance of the cylinder head valves camshaft and rocker arms SPECIFICATION Service Limit Item Standard mm in mm in 34 590 34 34 700 1 3618 1 3661 34 54 1 3598 Camshaft Cam height 34 460 34 680 1 3567 1 3654 34 41 1 3547 680 1 3567 1 Rocker arm I D 11 000 11 018 0 4330 0 4337 11 10 0 4370 984 0 Rocker arm Shaft O D 10 966 10 984 0 4318 0 4324 10 91 0 4295 Roller O D 17 00 0 6693 16 95 0 6673 IN 4 975 4 970 0 1959 0 1965 4 90 0 193 Valve stem EX 4 955 4 970 0 1951 0 1957 4 90 0 193 X clearance E 0 10 0 004 Valve spring free Inner Oyinsernesd wapage o Valve guide I D 5 00 5 012 0 1969 0 1973 5 03 0 198 TORQUE VALUES Cylinder head cover screw 3 5 5 0 N m 2 5 3 6ft lb Apply a locking agent Cylinder cover bolt 8 12 N m 6 9 ft Ib Cylinder head cap nut 22 28 N m 16 19 ft Ib Camshaft holder bolt 8 12 N m 6 9 ft Ib Cam chain tensioner sealing bolt 8 12 N m 6 9 ft Ib Oil pipe bolt 8 mm 8 12 N m 6 9 ft Ib Exhaust pipe stud bolt 7 11 N m 5 8 ft Ib Spark plug 15 20 N m 11 15 ft lb Chapter 1 Engine Transmission amp Gear Troubleshooting Engine top problems usually affect engine performance These can be diagnosed by a compression test or by tracing noises with a sounding rod or stethoscope Low Compression Valves
41. low red wire terminal to the positive battery terminal and green wire to the negative battery terminal by using a jumper wire Check for continuity between the starter relay terminal Replace the starter relay with a new one if there is no continuity INSTALLATION Install the ignition coil in the reverse order of removal II 5 Chapter 3 Ignition and Starting System Starter Motor REMOVAL Remove the negative battery cable from the battery Disconnect the starter cable from the starter motor Remove the two mounting bolts then remove the starter motor INSTALLATION NOTE Before installing the starter motor check the operation by connecting the starter motor wire to the starter relay Install the starter motor in the reserve order of removal Tighten the starter motor cable attaching nut Torque 10 14 N m 7 10 ft Ib Install and tighten the starter motor mounting bolts Torque 10 14 N m 7 10 ft Ib NOTE Place the starter motor cable cover securely III 6 Chapter 3 nition and Starting System Recoil Backup Starting System e CN IIl 7 Chapter 3 Ignition and Starting System Recoil Backup Starting System CHECK NOTE Pull the recoil haft rapidly to have enough kinetic energy for engine starting Park the vehicle on a level ground Put the gear shaft to Neutral Turn the ignition switch ON Pressed the brake lever then pull the reco
42. nstall the water hose to the cylinder Install the cam chain guide NOTE Push the guide in until it bottoms in the crankcase guide hole Install the cylinder head Tighten the cylinder base bolt I 26 Chapter 1 Engine Transmission amp Gear Crankcase IN I 27 Chapter 1 Engine Transmission amp Gear Crankcase CEANKCASE SEPARATION Remove the cam chain adjuster by removing the bolt Remove the cam chain Remove the nine crankcase attaching bolts Remove the crankcase with the left side crankcase down and remove the right crankcase CAUTION Never pry the crankcase mating surfaces apart Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Remove the oil pipe from the right crankcase by removing the bolt Check the oil seal for wear or damage Replace the oil seal if necessary I 28 Chapter 1 Endine Transmission amp Gear CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge Service Limit 0 05 mm 0 002 in Set the crankshaft on a stand or in V blocks and using a dial indicator to read run out at the points shown Service Limit 0 10 mm 0 004 in Turn the outer race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing inner race fits tightly in the crankshaft Replace the crankshaft assembl
43. ntake and exhaust rocker arm to cylinder head Tighten the rocker arm camshaft bearing holder plate mounting bolt Push the cam chain adjuster push rod back into the adjuster body by pressing the tab down Rail the cam chain to the cam sprocket teeth and install the cam sprocket to camshaft as shown Tighten the two cam sprocket holder bolts Install the cam chain adjuster spring and sealing bolt and tighten the sealing bolt Torque 8 12 N m 6 9 ft Ib Install the timing hole cap to the right rear cover I 17 Chapter 1 Engine Transmission amp Gear VALVE CLEARANCE NOTE Pa Inspect and adjust valve clearance while the engine is cold below 35 C 95 F Remove the cylinder head cover Remove the left crankcase recoil cover Remove the timing hole plug oil filling plug from the right crankcase cover Remove the spark plug this will make it easier to turn the crankshaft Rotate the recoil drive pulley counterclockwise and align the punch mark on the flywheel with the index mark on the right crankcase cover to bring the position to TDC Top Dead Center on the compression stroke With the engine in this position all four valves can be checked Loosen the valve adjuster locknut and insert a feeler gauge of the thickness as specified between the valve stem and valve adjuster Turn the adjusting screw until the clearance is correct then tighten the locknut t NOTE 0 15mm 0 000 a
44. nto disc Service limit Front 3 5 mm Rear 3 5 mm V 21 Chapter 5_ Wheels Tires amp Brakes REMOVAL AND INSTALLATION Front disc removal installation Remove the wheel hub Remove the disc retaining bolts on hub Installation is the reverse of removal Tighten the disc retaining bolts Torque 43 N m 31 ft Ib NOTE Used pre coating anti loosen bolts Rear disc removal installation Remove the left rear wheel hub Remove the rear caliper Remove the disc retaining bolts and remove the disc Installation is the reverse of removal Tighten the disc retaining bolts Torque 43 N m 31 ft Ib NOTE o Used pre coating anti loosen bolts V 22 Chapter 5 _ Wheels Tires amp Brakes Parking Brake ADJUSTMENT Park the vehicle on a level ground Pull the parking lever to left side Loosen the parking brake adjust bolt fixing nut u Ze g k i li ie o cd m ala J and then turn in the adjust bolt until you can feel it touch the piston wall Turn out the adjust bolt half turn and hold the adjust bolt then tight the fixing nut NOTE o Pull the parking lever to right side and push the vehicle to check it s movable or not If it could easily moving the adjustment is not in position Re adjust and check to confirm V 23 Chapter 6 __Alternator Electrical Equipment Contents Alternator amp Starting Motor Battery Lights amp Horn Wire Diagram Alternator Starter Clutch S
45. ocker arm pe K Remove the cam shaft from cylinder head CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the intake and exhaust cam lobe height Service Limit 34 54 mm 1 3598 in Turn the outer race of each camshaft bearing with your finger The bearing should turn smoothly and quietly Replace the camshaft assembly if the races do not turn smoothly or quietly PE i a Chapter 1 Engine Transmission amp Gear Rocker Arm ROCKER ARM REMOVAL Remove rocker arm cam shaft bearing holder plate mounting bolt and holder plate Remove rocker arm shaft by using a M6 bolt screw in shaft then pull out the shaft Remove rocker arm ROCKER ARM INSPECTION Measure the rocker arm shaft O D Service Limit 16 96 mm 0 6677 in 106mm Measure the rocker arm bore I D Service Limit 17 04 mm 0 6709 in Turn the outer race of each rocker arm roller with your finger The roller should turn smoothly and quietly Replace the rocker arm assembly if the races do not turn smoothly or quietly Measure the rocker arm roller O D Service Limit 16 95 mm 0 6673 in I 11 Chapter 1 Engine Transmission amp Gear Cylinder Head CYLINDER HEAD REMOVAL Remove the thermostat housing bolt and thermostat housing from the cylinder head Remove the cam chain adjuster sealing bolt and spring Remove the two cam sprocket holder bolts Derail the cam chain from the cam sprocket teeth and rem
46. one to see if a component is grounded properly Disconnect the battery and connect one lead of a self powered test light such as a continuity tester to a known good ground Connect the other lead to the wire or ground connection being tested If the bulb lights the ground is good If the bulb does not light the ground is not good A continuity check is performed to see if a circuit section of circuit or individual component is capable of passing electricity through it Disconnect the battery and connect one lead of a self powered test light such as a continuity tester to one end of the circuit being tested and the other lead to the other end of the circuit If the bulb lights there is continuity which means the circuit is passing electricity through it properly Switched can be checked in the same way Remember that all electrical circuits are designed to conduct electricity from the battery through the wires switches relays etc to the electrical component light bulb motor etc From there it is directed to the frame ground where it is passed back to the battery Electrical problems are basically an interruption in the flow of electricity from the battery or back to it VI 10 Chapter 6 __Alternator Electrical Equipment Headlight BULB REPLACEMENT Remove headlight panel 280AS only Disconnect the headlight coupler Remove headlight bulb rubber dust seal Remove the bulb socket Remove the clip and replace the headli
47. ove the cam sprocket Remove the cylinder head base bolt Remove the four cylinder head cap nuts and four copper washer Remove the cylinder head Remove the cylinder head gasket and dowel pins Remove the two bolts and carburetor insulator Remove all gasket material from the cylinder head mating surface NOTE Careful not to drop the gasket material into cylinder I 12 Chapter 1 Engine Transmission amp Gear CYLINDER HEAD DISASSEMBLY Compress the valve spring and remove the valve cotters retainers springs spring seat and valves CAUTION To prevent loss of tension do not compress the valve springs more than necessary to remove Be Valve stem seal ne fi the cotters NOTE Mark all disassembled parts to ensure correct reassembly Remove the valve stem seals Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head gasket surface NOTE Avoid damaging the gasket surface o Gasket will come off easier if soaked in solvent INSPECTION CYLINDER HEAD Check the camshaft bearing house for wear or damage Check the spark hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm 0 002in I 13 Chapter 1 Engine Transmission amp Gear VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limit Inner IN
48. piston PISTON PISTON PIN AND PISTON RING INSPECTION Measure the piston pin bore 1 D Service Limit 17 04 mm 0 6709 in Measure the piston pin O D Service Limit 16 96 mm 0 6677 in Calculate the piston pin to piston clearance Service Limit 0 02 mm 0 001 in Measure the piston ring to groove clearance Service Limits TOP 0 09 mm 0 004 in 2nd 0 09 mm 0 004 in Measure the connecting rod small end 1 D Service Limit 17 06 mm 0 6716 in Remove the piston rings Inspect the piston for damage and ring grooves for wear I 23 Chapter 1 Engine Transmission amp Gear CAUTION Piston rings are easily broken take care not to damage them during removal Insert each piston ring into the cylinder 20 mm 0 75 in in from the bottom To ensure that it s square in the bore use a piston to push it in Measure the ring end gap Service Limits TOP 0 50 mm 0 020 in Max 0 50mm 2nd 0 50 mm 0 020 in Measure and record the piston O D at a point 10 mm 0 4 in from the bottom and 90 to the piston pin bore Service Limit 75 90 mm 2 9882 in Compare this measurement against the service limit and calculate piston cylinder clearance CYLINDER INSPECTION Inspect the cylinder walls for scratches and wear Measure and record the cylinder D at three levels in both and X Y axis Take the maximum reading to determine the cylinder wear Service Limit 76 10 mm 2 996 in Calculate the piston to c
49. r certain condition Work in a well ventilated area Do not smoke or allow flames or sparks in the work area When disassembling the fuel system parts note the location of the O ring and gasket Replace them with new ones if necessary on reassembly Before disassembling the carburetor drain the fuel in the float chamber by turning the drain screw US version only Refer to the sticker on vehicle for the hose connections of the evaporative emission control system CAUTION Do not bend or twist control cable Damaged control cable may stick or bind SPECIFICATIONS cme I E Chapter 2 Fuel System amp Carburetion Troubleshooting Engine cranks but won t start No fuel in tank No fuel to carburetor Engine flooded with fuel No spark at plug faulty ignition system o Clogged air cleaner Intake air leak Improper choke operation Improper throttle operation Faulty fuel valve Hard starting or stalling after starting Improper choke operation Ignition malfunction Faulty carburetor Contaminated fuel Intake air leak Incorrect idle speed Faulty fuel valve Rough idle Faulty ignition system Incorrect idle speed Faulty carburetor e Contaminated fuel Misfiring during acceleration Faulty ignition system Backfiring Faulty ignition system Faulty carburetor Il 2 Poor performance and fuel economy Clogged fuel system
50. rder of removal Fill and bleed the coolant system 1 36 Chapter 1 Engine Transmission amp Gear Thermostat REMOVAL Disconnect the thermo sensor wire connector from the housing Drain the coolant Remove the thermostat housing from the cylinder head by removing the mounting bolt Remove the cover attaching bolts and separate the thermostat housing Remove the O ring from the thermostat housing Remove the thermostat from the housing INSPECTION Inspect the thermostat visually for damage Suspend the thermostat in heated water to check Its operation NOTE If the thermostat or thermometer touches the pan you ll get a false reading Replace the thermostat if the valve stays open at room temperature or if it responds at temperature other than those specified Technical Data Start to open 60 C to 65C 140 F to 149 F 3 5 4 5mm 0 14 0 18in when Fully open heated to 90 C 176 F for 5 minutes INSTALLATION Install in the reverse order of removal NOTE Replace the O ring with a new one and apply grease to it Tighten the thermostat housing mounting bolt Fill the coolant system with the specified coolant l 37 ion amp Gear ISS Transm ine En Chapter 1 Left Crankcase Cover 1 38 Chapter 1 Engine Transmission amp Gear Drive Pulley Clutch Driven Pulley Service Information GENERAL The drive pulley clutch and driven pulley can be service wit
51. remely flammable and is explosive under certain condition Do not smoke or allow flames or sparks in your working area WARNING The battery electrolyte contains sulfuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and call a doctor if electrolyte gets in your eyes WARNING The battery generates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it SERVICE RULES 1 Use genuine ADLY or ADLY recommended parts and lubricants or the equivalents Parts that do not meet ADLYSs design specifications may damage the vehicle 2 Use the special tools designed for this product Use only metric tools when service the vehicle Metric bolts nuts and screws are not interchangeable with English fasteners The use of incorrect tools and fasteners may damage the vehicle Install new gaskets O ring cotter pin lock plates etc when reassembling 5 When tightening a series of bolts or nuts begin with large diameter or inner bolts first and tighten to the specified torque diagonally unless a particular sequence is specified 6 Clean parts in clean solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation Chapter 1 Engine Transmission amp Gear Engine Removal Installation GENERAL A floor jack or other adjustable support is
52. rom the brake cylinder INSTALLATION Install handlebar onto lower holders and aligning the punch mark on the handlebar with the upper surfaces surface of the lower holders Install the handlebar upper holders and tighten four hex socket bolts Torque 24 30 N m 17 22 ft Ib Install the L R hand master cylinder holder with the UP mark facing up and aligning the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then tighten the lower bolt Torque 24 30 N m 17 22 ft Ib Install the L handle switch housing aligning the locating pin on the housing with the hole in the handlebar Connect the throttle and choke cable Connect the brake switch and overdrive wire Insert soeedometer assembly to the handlebar and tighten the mounting screw Chapter 5 Wheels Tires amp Brakes Steering STEERING SHAFT REMOVE Remove the front fender NOTE Raise the front frame and secure with stable stand for easily working Remove the handlebar Remove tie rod end nuts on steering shaft side Remove the steering shaft nut Remove the steering shaft holder bolts Remove the steering shaft holder basket and pull out the steering from frame INSPECTION Inspect tie rod end mounting plate for wear or damage and replace if necessary Inspect steering shaft bush and holder bush for wear and damage Replace if necessary NOTE Apply grease to steering shaft bush and holder b
53. sen the caliper bleed valve and pump the brake lever until no more fluid flows out of the bleed valve Close the bleed valve V 17 Chapter 5 Wheels Tires amp Brakes BRAKE FLUID FILLING BLEEDING Fill the reservoir with DOT 3 or DOT 4 brake fluid from a sealed container CAUTION Do not mix different types of fluid They are not compatible Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve Bleeding front wheel first by bleeding front brake shunt then left and right brake caliper After completed bleeding front wheels calipers then bleeding the rear brake shunt and caliper Add fluid when the fluid level in the master cylinder reservoir is low NOTE Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system When using a brake bleeding tool follow the manufacture s operating instruction If air is entering the bleeder from around the bleed valve threads seal the threads with Teflon tape Repeat the above procedures until air bubbles do not appear in the plastic hose Close the bleed valve and operate the brake lever If it feels spongy bleed the system by performing BLEEDING procedure V 18 Chapter 5_ Wheels Tires amp Brakes BRAKE FLUID FILLING BLEEDING If a brake bleeder is not available perform the following procedure Pump up the system pressure wi
54. t main shaft and final gear set for abnormal wear or broken teeth Driver Shaft Inspect gear shaft arm for abnormal wear or broken teeth Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check engine mounting rubber bush 1 48 Chapter 1 Engine Transmission amp Gear INSTALLATION Install gear set to gear case NOTE Do not forget install main shaft washer Install shaft drum Install gear shaft fork Install gear shift arm NOTE Aligned shift forks to shift drum groove gear shift arm to shift drum and shift drum retainer in correct position Install the dowel pins and a new gasket add specified gear oil to gear box Install right side gear box cover and tighten the mounting bolts Toque Value 6mm 8 12 N m 6 9 ft Ib 8 mm 10 15 N m 7 11 ft Ib 1 49 Chapter 2 Fuel System amp Carburetion Contents Carburetor Fuel Tank Air Cleaner Exhaust System Service Information GENERAL The fuel system comprises a petrol tank from which petrol is fed by gravity to the float chamber of the Mikuni carburetor A vacuum control tap with build in gauze filter is located beneath the rear end of the fuel tank An electrical fuel level sensor which provision single to speed meter and shows fuel level on it WARNING Gasoline is extremely flammable and is explosive unde
55. th the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt 1 Squeeze the brake lever and hold it down then open the bleed valve half turn and then close the valve NOTE Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever slowly and wait several seconds after it reaches the end of its travel Repeat steps 1 and 2 until bubbles cease to appear in the fluid Tighten the bleed valve Torque 4 7 N m 3 5 ft Ib Fill the fluid reservoir to the upper level mark Reinstall the diaphragm diaphragm plate and reservoir cap V 19 Chapter 5 Wheels Tires amp Brakes BRAKE PAD REPLACEMENT WARNING Never blow out brake dust with compressed air and don t inhale it NOTE Always replace the brake pads in pair to assure even disc pressure FRONT BRAKE PADS Remove the front wheel Remove the caliper mounting bolts and remove caliper from knuckle NOTE o It s unnecessary to remove the brake line for brake pads replacement Loosen two brake pad fixation bolts and pull out the bolts Push brake pads against caliper piston to let it back into the caliper bore then remove inner brake pad from caliper house Press caliper mounting plate toward bore side then push outer brake pad out of the caliper NOTE For easily remove the outer pad pull the pad apart with align pin one sid
56. the air cleaner case INSPECTION AND CLEAN OUT Disconnect the air filter assembly mounting clamp Remove the air filter element cover Drain the accumulated water or dust Clean the air cleaner case and filter element with compress air Inspect the filter element A and B replace it if necessary Install the filter assembly to air cleaner case NOTE Tighten the mounting clamp screw securely INSTALLATION Install the air cleaner case in the reverse order of removal NOTE Tighten the connecting tube band screw securely 11 11 11 Chapter 2 Fuel System amp Carburetion EXHAUST SYSTEM m f n i O a SZ ge 4 L v es L WV N ag 7 fa Il 12 12 Chapter 2 Fuel System amp Carburetion Exhaust System REMOVAL Disconnect the shaft selecting rod nut Loosen exhaust pipe front section to cylinder head mounting nuts Loosen muffler silencer hanger mounting bolts Pull back the muffler assembly for removal Bend the exhaust pipe front section to release pipe springs INSPECTION Check the exhaust pipe gasket replace it if necessary INSTALLATION Install the muffler assembly in the reverse order of removal NOTE Tighten the exhaust pipe front section to oat cylinder head mounting nuts properly ms S gt A gt t u HERE LEER we Start the engine to check any leak thru gasket Ya Il 13 13 Chapter 3 I
57. the front engine bracket Slightly raise the engine and pull it toward front frame then pull out the engine thru right side ae p i dl pl a i ro t engine bracket L Chapter 1 Engine Transmission amp Gear ENGINE INSTALLATION Move the engine into the frame Insert the front engine bracket to correct position then insert the bolts Insert all other engine mounting bolts and tighten the nuts by following steps A Rear lower engine mount Torque value 40 55 N m 29 40 ft Ib B Front engine mount C Front engine bracket Torque value 40 55 N m 29 40 ft Ib D Rear upper hanger plate Torque value 18 24 N m 13 16 ft Ib E Rear engine mount Torque value 40 55 N m 29 40 ft Ib Install the removed parts in the reverse order of removal Refill coolant to specified volume and connect battery terminals NOTE o Checked all connect points and oil level before restart the engine ion amp Gear ISS Transm ine En Chapter 1 Cvlinder Head Cover I 5 Chapter 1 Engine Transmission amp Gear Camshaft Valve Cam T SA N AR 7 N TI g NG A Va Y CO A e nes n n SSX n 0 GY R H DD SS 2 f jA ae ae NZZ 7 b A n es eee a A N A BAS fs x sa a ni WE N N fe I Chapter 1 Engine Transmiss
58. the wire grommet in its groove in the cover securely NOTE Be sure to route the stator wire under the pulse generator Make sure that the breather plate is in position securely RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Install the right crankcase cover attaching bolts and tighten them Connect the crankcase breather tube to the right crankcase cover Connect the ignition pulse generator and alternator wire couplers and connector Connect the water hoses to the water pump Make sure that the oil pipe is not clogged Install the oil pipe with oil bolts and sealing washers VI 8 Chapter 6 Alternator Electrical Equipment CAUTION o The 8 mm oil pipe bolt for the cylinder head cover side is black because its oil hole differs from the oil pipe bolt for the right crankcase cover side Install the oil pipe bolts in the correct position o If the 8 mm oil pipe bolts are interchanged engine damage may result NOTE Make sure that the sealing washer tab at the right crankcase cover faces the right crankcase side Install the oil pipe stay bolts on the right crankcase cover and water pump Tighten the 8 mm and 12 mm oil pipe bolts Torque 8mm 8 12 N m 6 9 ft Ib 12mm 18 22 N m 13 16 ft Ib Tighten the oil pipe stay bolts VI
59. udy the panel closely noting any fasteners and associated fittings to be sure of returning everything to its correct place on installation In some cases the aid of an assistant will be required when removing panels to help avoid damaging the surface Once the visible fasteners have been removed try to lift off the panel as described but DO NOT FORCE the panel if it will not release check that all fasteners have been removed and try again Where a panel engages another by means of tabs and slots be careful not to break the tabs or to damage the bodywork Remember that a few moments of patience at this stage will save you a lot of money in replacing broken panels FRAME All models use a double cradle frame made of steel tubing The frame shouldn t require attention unless accident damage has occurred In most cases frame replacement is the only satisfactory remedy for such damage A few frame specialists have the jigs and other equipment necessary for straightening the frame to the required standard of accuracy but even then there is no simple way of assessing to what extent the frame may have been over stressed After the machine has accumulated a lot of miles the frame should be examined closely for signs of cranking or splitting at the welded joints Corrosion can also cause weakness at these joint IV 1 Chapter 4 Frame amp Cover FRAME BODY 320S IV 2 Chapter 4 Frame amp Cover FRAME
60. ur chamber screws and the float chamber Remove the main jet needle jet holder idle jet and choke jet Remove the float pin float and float valve FLOAT VALVE INSPECTION Inspect the float valve for grooves and nicks Inspect the operation of the float valve Blow open all passages with compressed air before assembling ASSEMBLY Clean main jet needle jet holder needle jet and idle jet in cleaning solvent and blow them open with compressed air Install the needle jet and needle jet holder Install the main jet and idle jet Install the float valve float and float pin Reinstall the float chamber Il 5 5 Chapter 2 Fuel System amp Carburetion CARBURETOR INSTALLATION Tighten the drain screw Connect the drain tube to the carburetor Install the throttle cable Install the choke cable with choke piston Install the carburetor aligning the tab on the carburetor with the groove in the intake manifold and tighten the band screw Install the air filter tube and tighten the connecting bands Adjust the following throttle lever free play idle speed Il 6 6 Chapter 2 Fuel System amp Carburetion FUEL TANK Il 7 Chapter 2 Fuel System amp Carburetion Fuel Tank REMOVAL WARNING Do not smoke or allow flames or spark in the work area Remove the seat Remove the front fender Remove fuel tank to frame mounting bolts Disconnect th
61. ush when replace and reassembling INSTALLATION Install the steering shaft in the reverse order of removal Chapter 5 Wheels Tires amp Brakes FRONT amp REAR WHEEL Chapter 5_ Wheels Tires amp Brakes Front amp Rear Wheel WHEEL REMOVAL NOTE Use a hydraulic jacket for easily serving Use parking brake to locked rear wheel slightly loosen wheel nuts Raise the frame to let wheel leave ground Loosen and remove wheel nuts then remove wheel INSPECTION Check the tires for cuts or embedded object Check the front and rear wheels rim for trueness Service Limits Radial 2 0 mm 0 08in Axial 2 0 mm 0 08in Replace if the reading exceeds the service limit Measure the tread depth at the center of tires Replace the tires if the tread depth reaches the following limits Minimum tread depth Front 1 5 mm 0 06in Rear 2 5 mm 0 08in INSTALLATION Align wheel to hub studs and install wheel nuts Down the vehicle to ground and tighten wheel nuts to specified torque Torque 64 N m 47 ft Ib Chapter 5 Wheels Tires amp Brakes _ _ HUB REMOVAL Remove the wheel Remove the hub to axle mounting nut cotter pin Loosen the hub to axle mounting nut and remove nut and plane washer Remove the hub from axle INSPECTION Front hub Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The bearing should turn smoothl
62. y and quietly Check the outer race fits tightly in the hub Remove and discard the bearing if the races do not turn smoothly quietly or if they are fit loosely in the hub NOTE Replace the hub bearing in pairs INSTALLATION Install front and rear hub in the reverse order of removal Torque Front 59 79 N m 43 58 ft Ib Rear 140 160 N m 101 116 ft Ib NOTE Use a new axle mounting nut cotter pin Chapter 5 Wheels Tires amp Brakes FRONT SUSPENSION Chapter 5 Wheels Tires amp Brakes REAR SUSPENSION amp SWING ARM SUB ASS Y V 10 Chapter 5_ Wheels Tires amp Brakes Front Suspension A arm REMOVAL CAUTION Support the vehicle frame steady when servicing or inspecting Remove front tire Remove tie rod end on knuckle Remove upper and lower ball joint on knuckle and apart the knuckle with brake clipper from ball joint Remove lower shock absorber mounting bolt Remove upper and lower a arm mounting bolts and remove a arm from vehicle frame INSPECTION Inspect ball joint rubber and joint for wear or damage Replace ball joint upper and lower at same time Inspect a arm bushing replace it if necessary Inspect a arm for any crushed or bended INSTALLATION Install upper and lower a arm in the reverse order of removal Torque Ball joint 55 N m 40 ft Ib Mounting bolts 30 N m 22 ft Ib Tie rod end nuts 45 N m 33 ft Ib NOTE
63. y if the races do not turn smoothly quietly or if they fit loosely in the crankshaft CRANKSHAFT ASSEMBLY Remove all gasket materials from crankcase being careful not to damage the mating surfaces Apply grease to the lip of a new oil seal and install it into the left crankcase Wash the oil pipe in clean solvent and install new oil seals on both ends of the pipe I 29 Chapter 1 Engine Transmission amp Gear Install the oil pipe into the right crankcase and secure it with the bolt Install the crankshaft into the left crankcase being careful not to damage the oil seal Install the dowel pins and a new gasket Place the crankcase over the crankshaft and onto the left crankcase Install the nine crankcase attaching bolts Torque 8 12 N m 6 9 ft Ib Install the cam chain cam chain adjuster slipper and secure it with the bolt Torque 8 12 N m 6 9 ft Ib l 30 ion amp Gear ISS Transm ine En Chapter 1 Right Crankcase Cover 1 31 Chapter 1 Engine Transmission amp Gear Right Crankcase REMOVAL Drain the coolant by disconnected coolant tube Remove oil tube Drain the engine oil thru oil filter cover or oil draining bolt Remove right case mounting bolts Remove right crankcase Remove the crankcase gasket and dowel pins IMSPECTION Remove water pump cover and inspect the pump impeller for deficient or damage Inspect the mechanical seal for
64. ylinder clearance Take the maximum reading to determine the clearance Service Limit 0 10 mm 0 004 in 24 Chapter 1 Engine Transmission amp Gear PISTON RING INSTALLATION Clean the piston head ring lands and skirts Carefully install the piston rings onto the piston Marking Stagger the ring end gaps as shown NOTE Be careful not to damage the piston rings during assembly All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking PISTON INSTALLATION Install the piston and piston pin Position the piston IN mark on the intake valve side Install a new piston pin clips NOTE Do not align the piston pin clip end gap with the piston cut out Place a shop towel around the piston skirt and in the crankcase to prevent the piston pin clips from falling into the crankcase I 25 Chapter 1 Engine Transmission amp Gear CYLINDER INSTALLATION Install the cam chain adjuster base onto the cylinder with a new gasket Tighten the two adjuster base bolts Torque 8 12 N m 6 9 ft Ib Coat the cylinder bore piston and piston rings with fresh engine oil Carefully lower the cylinder over the piston by compressing the piston rings one at a time CAUTION Do not force the cylinder over a ring you may damage the piston and piston rings Loosely install the cylinder base bolt and seal washer I

SERVICE MANUAL - Sarner Trading AB

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