MaxSym400 - Service Manual PDF
MaxSym400 - Service Manual PDF
MaxSym400 - Service Manual PDF
SERVICE MANUAL
FOREWORD
CONTENTS
MECHANISM ILLUSTRATION
20120303
Homepage
Contents
Foreword
This service manual contains the technical data of each component inspection
and repair for the Sanyang MAXSYM 400i scooter. The manual is shown with
illustrations and focused on Service Procedures, Operation Key Points, and
Inspection Adjustment so that provides technician with service guidelines.
If the style and construction of the motorcycle, MAXSYM 400i, are different
from that of the photos, pictures shown in this manual, the actual vehicle shall
prevail. Specifications are subject to change without notice.
Service Department
Sanyang Industry Co., LTD.
Homepage
Contents
This service manual describes basic information of different system parts and
system inspection & service for Sanyang MAXSYM 400i scooter. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information.
Th third to the twelfth chapter covers the engine and driving systems.
The thirteenth to the sixteenth is contained the parts set of assembly body.
The seventeenth chapter is electrical equipment.
The eighteenth chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, Foreword, Contents, How to Use This Manual and
Mechanism Illustration in the PDF version, and can be access to these items
by clicking on the buttons.
If user wants to look for the content of each chapter, selecting the words of
each chapter on the contents can reach to each chapter. There are two buttons,
Homepage and contents, on the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back
the homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the
content. In addition, there is a To this Chapter Contents button at the second
page of each content so that clicking the button can back to the contents of this
chapter.
Homepage
Contents
Contents
Page
Content
Index
1-1 ~ 1-16
General Information
2-1 ~ 2-16
Maintenance Information
3-1 ~ 3-6
Lubrication System
4-1 ~ 4-58
5-1 ~ 5-4
Engine Removal
6-1 ~ 6-16
7-1 ~ 7-8
Cylinder / Piston
8-1 ~ 8-14
9-1 ~ 9-8
10-1 ~ 10-4
10
11-1 ~ 11-8
Crankshaft / Crankcase
11
12-1 ~ 12-12
Cooling System
12
13-1 ~ 13-16
Body Cover
13
14-1 ~ 14-12
Brake System
14
15-1 ~ 15-11
15
16-1 ~ 16-6
16
17-1 ~ 17-22
Electrical System
17
18-1 ~ 18-2
Wiring Diagram
18
Contents
Home page
Mechanism Illustration
Start / engine stop switch
Front winker
Luggage box
Fuel tank /
fuel pump
Taillight /
rear winker
Headlight
Air cleaner
Reserve tank
cap
Main stand
Side stand
Back mirror
Engine number
Muffler
Homepage
Contents
1. General Information
Symbols and Marks1-1
Troubleshooting 1-12
Before Servicing1-3
Specifications 1-9
Warning
Caution
Means that serious injury or loss of life may happen if procedures are not
correctly followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil.
Engine oil
damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
Grease
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Special tools
Correct
Wrong
Indication
Indication of components.
Directions
1-1
1. General Information
General Safety
Carbon Monoxide
Before you start the engine, make sure the place
is well ventilated. Never start the engine in an
unventilated place. If you have to start the engine
in an unventilated place, an exhaust fume
extractor is needed.
Caution
Exhaust fume contains toxic gas which may
cause one to lose consciousness and even result
in loss of life.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from the
children.
Hot Components
Caution
Components of the engine and exhaust system
can be extremely hot after engine running. They
remain very hot even after the engine has been
stopped for a period of time. Before performing
service work on these parts, wear the heat
insulation gloves or wait until the temperature
drops.
1-2
Battery
Caution
Battery emits explosive gases; flame is strictly
prohibited. Keep the place well ventilated
when the battery is being charged.
Battery contains sulfuric acid (electrolyte)
which can cause serious burns, be careful not
to spill it on your skin or eyes. If you get
battery fluid on your skin, flush it off with water
immediately. If you get battery fluid in your
eyes, flush it off immediately with water and
go to hospital to see an ophthalmologist
doctor.
If you swallow the battery fluid by mistake,
drink a lot of water or milk, and take some
laxative such as Epsom salts or vegetable oil
and then go to see a doctor.
Keep the battery and battery fluid beyond
reach of the children.
Brake Shoes
Do not use compressed air or brush to clean the
components of the brake system. Use a vacuum
cleaner or the equivalent to avoid dust drifting in
the air.
Caution
Inhaling brake shoes dust may cause disease or
even cancer of the respiratory system.
Brake Fluid
Caution
Brake fluid spilled on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the top of the parts for protection
when servicing the brake system. Keep the brake
fluid beyond reach of the children.
1. General Information
Before Servicing
Always use SANYANG genuine parts and
recommended oil. Using improper parts may
cause damage to or destruction of the vehicle.
1-3
1. General Information
The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole to
compare its length with other bolts, if its length
out side the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.
Clamp
Connector
Boots
Manufacturer's name
1-4
1. General Information
Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
1-5
1. General Information
1-6
1. General Information
Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
Never Touch
1-7
1. General Information
Do not let the wire harness been twisted as
installation.
Clean rust
1-8
1. General Information
Specifications
Overall Length
2270 mm
Overall Width
825 mm
Overall Height
1410 mm
Wheel Base
1555 mm
Weight
Curb
Weight
Front
94 kg
Rear
135 kg
Total
229 kg
Passengers/Weight
Cylinder
Total
Weight
Engine
SANYANG
Two / 150 kg
Front
131 kg
Rear
248 kg
Total
379 kg
MODEL
Suspension
System
Tire
Specifications
Brake System
Performance
Reduction
LX40A1-6 / F
Front
TELESCOPIC FORK
Rear
UNlT SWING
Front
Rear
Front
DOUBLE DISK
( 275 mm)
Rear
Max. Speed
>152 km/hr
Climb Ability
<24
Primary
Reduction
Secondary
Reduction
Belt
Gear
Type
4-STROKE ENGINE
Clutch
Installation and
arrangement
Vertical, below
center, incline 80
Transmission
CVT
Fuel
Above 92 unleaded
Speedometer
0 ~ 180 km/hr
Cycle/ Cooling
4-stroke/
Liquid-cooled
Horn
93~112 dB/A
Bore
83.0 mm
Muffler
Stroke
73.8 mm
Number/Arrange
ment
SINGLE CYLINDER
Lubrication System
Exhaust
Concentration
Dimension
MAKER
Displacement
399 cc
CO
<2.0 g/km
Compression Ratio
10.6 : 1
HC
<0.3 g/km
Max. HP
NOx
<0.15 g/km
Max. Torque
E.E.C.
Ignition
P.C.V.
Starting System
Electrical starter
1-9
1. General Information
Torque Values
The torque values listed in below are for more important tightening torque values. Please see standard
values for those not listed in the table.
Tighten Torque
0.45~0.6kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
Type
5 mm screw
6 mm screwSH nut
6 mm boltnut
8 mm boltnut
10 mm boltnut
Tighten Torque
0.35~0.5kgf-m
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
1-10
10
8
8
6
6
6
8
6
3
5
10
6
6
3
7
6
12
30
8
10
28
14
14
14
6
8
10
8
1.0~1.4
3.6~4.0
2.0~2.4
1.0~1.4
1.0~1.4
1.0~1.4
2.4~3.0
1.0~1.4
0.07~0.09
0.7~1.1
1.0~1.2
1.0~1.4
0.7~1.1
0.1~0.3
1.0~1.4
1.1~1.5
3.5~4.5
1.3~1.7
0.8~1.2
1.0~1.4
5.0~6.0
5.0~6.0
8.5~10.5
5.0~6.0
0.8~1.2
2.6~3.0
3.2 ~3.8
1.0 ~1.2
Remarks
1. General Information
Frame Torque Values
Item
Mounting bolt for steering handle
post
Lock nut for steering stem
Remarks
10
4.0~5.0
BC1
1.0~2.0
BC1
2.0~3.0
12
5.0~7.0
16
11.0~13.0
10
3.5~4.5
10
3.5~4.5
2.4~3.0
10
4.0~5.0
10
3.0~4.0
0.8~1.0
4.0~4.5
4.0~4.5
2.9~3.5
12
7.5~9.5
On frame side
12
7.5~9.5
On engine side
10
4.0~5.0
1.0~1.4
1-11
1. General Information
Troubleshooting
A. Engine cannot be started or
difficult to be started
Check and adjustment
Fault condition
Probable causes
3. Malfunction of ECU
4. Malfunction of the AC Generator
5. Ignition coil is in open or short circuit
Low or no compression
pressure
No ignition
1-12
1. General Information
B. Engine runs sluggish (Speed
does not pick up, lack of power)
Check and adjustment
Fault condition
Probable causes
1.
2.
3.
4.
Incorrect ignition
timing
1. Malfunction of ECU
2. Malfunction of AC Generator
Check cylinder
compression pressure
(using compression
Abnormal compression
pressure
Not clogged
Clogged
1.
2.
3.
4.
5.
No contamination or
discoloration
Contaminated or
Engine overheated
1.
2.
3.
4.
Continually drive in
acceleration or high
speed
No knocking
Knocking
1-13
1. General Information
C. Engine runs sluggish (especially
in low speed and idling)
Check and adjustment
Fault condition
Probable causes
Normal
Abnormal
No air sucked in
Good spark
Poor spark
1.
2.
3.
4.
5.
Fault condition
Probable causes
Normal
Abnormal
1.
2.
Malfunction of ECU
Malfunction of AC Generator
Good
Poor
1-14
Clogged
1. General Information
E. CLUTCH AND DRIVING PULLEY
FAULT CONDITION
PROBABLE CAUSES
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
1-15
1. General Information
Lubrication Points
Acceleration cable/
Front & rear brake lever pivot
Seat locker
1-16
Home page
Contents
2. Maintenance Information
Precautions in Operation 2-1
Cushion 2-9
Battery 2-13
Precautions in Operation
Model
Fuel Tank Capacity
Engine Oil
Transmission
Gear oil
LX40A1-6 / F
14,200500 c.c.
capacity
change (with oil filter
replaced)
2,000 c.c.
change
1,800 c.c.
capacity
350 c.c.
change
330 c.c.
Capacity of
coolant
1,900 c.c.
Engine + radiator
1400 c.c.
Reservoir upper
350 c.c.
2~6 mm
CR8E (gap:0.6~0.7 mm)
Idling speed
1,550100 rpm
12.5 2 kgf/cm
IN
0.100.02 mm
EX
0.120.02 mm
Tire dimension
Front
120/70-15 56S
Tire dimension
Rear
160/60-14 65H
Tire pressure
(cold)
single
Valve clearance
Battery
2-1
2. Maintenance Information
Periodical Maintenance Schedule
No
item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Tire pressure
Battery inspection
Brake free play check
Steering handle check
Cushion operation check
Every screw tightening check
Gear oil check for leaking
Spark plug check or change
Gear oil change
Frame lubrication
Exhaust pipe
Ignition timing
Emission check in Idling
Throttle operation
Engine bolt tightening
CVT driving device(belt
CVT driving device(roller)
Lights/electrical equipment/multi-meters
Main/side stands & springs
Fuel lines
Cam chain
Valve clearance
Crankcase evaporative control system
Evaporative control system
Lines & connections in cooling system
Coolant reservoir
Coolant
ECU input voltage
EFi sensor coupler
1 month
every
1,000KM
I
First replacement
at 1000 km
I
First replacement
at 1000 km
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
3 months
every
5,000KM
C
6 months
every
10,000KM
R
I
1 year
every
15,000KM
R
I
I
I
I
I
I
I
I
I
I
R
Replacement for every 10,000 km
L
L
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
R
I
I
I
I
I
I
I
I
I
I
C
I
I
I
I
I
R
I
I
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1,000 kilometers as a reference which ever comes first.
Remarks: 1. These marks
in the schedule are emission control items. According to EPA regulations, these items must be
performed normally periodical maintenance following the user manual instructions. They are prohibited to be
adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition systemPerform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removalRemove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious
lower.
c. Replace worn out pistons, cylinder head.
2-2
2. Maintenance Information
Engine Oil
Turn off engine, and park the vehicle in a flat
surface with main stand.
Check oil level with oil dipstick
Do not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that to make
sure oil can be drained smoothly and
completely.
Place an oil pan under the vehicle, and remove oil
drain bolt.
After draining, make sure washer can be re-used.
Install oil drain bolt.
Torque value: 3.5~4.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-40)
Recommended using King serial oil.
Engine oil capacity:
Disassembly - 2000c.c.
Replacement (oil filter replaced) - 1900c.c.
Replacement 1800c.c.
Install dipstick, start the engine for running several
minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
2-3
2. Maintenance Information
Gear Oil
Warning
2~6 mm
Acceleration Operation
Have a wide open of throttle valve as handle bar in
any position and release it to let back original (full
closed) position.
Check handle bar if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure handle bar free play in its flange part.
Free play: 2~6 mm.
Rubber
Adjustment nut
2-4
2. Maintenance Information
Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
Adjustment nut
Air Cleaner
Air Cleaner Element
Remove 6 screws from the air cleaner cover.
6 screws
Caution
The air cleaner element is made of paper so
do not soap it into water or wash it with water.
2-5
2. Maintenance Information
P.C.V. system
Remove the plug from lower of the breather
chamber hose.
Release the dry internal deposit.
Every 5,000 kilometers release oil
Caution
In releases the breather chamber hose in the
transparent section is worthy of looking at as
any deposit
In the multi-rain or the accelerator in the
situation rides, must reduce the maintenance
traveling schedule
In releases the breather chamber hose in the
transparent section is worthy of looking at as
any deposit
Valve Clearance
Caution
Checks and adjustment must be performed
when the engine temperature is below 35.
Remove luggage box.
Remove cylinder head cover & side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover
Turn camshaft bolt in C.W. direction and let the T
mark on the camshaft sprocket aligns with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to
prevent from camshaft bolt looseness.
Valve clearance inspection and adjustment:
Check & adjust valve clearance with feeler gauge.
Valve clearance (IN)
0.100.02 mm.
Valve clearance (EX)
0.150.02 mm.
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened
the fixing nut.
Special tool: Tappet adjuster
SYM-9001200-08
SYM-9001200-09
SYM-9001200-10
Special tool: Tappet adjuster wrench
SYM-9001200
2-6
2. Maintenance Information
Spark Plug
Recommended spark plug: CR8E
Remove luggage box
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap: 0.6~0.7 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0~1.2kgf-m
Connect spark plug cap
Spark plug
Ground electrode
Central electrode
0.6~0.7mm
2-7
2. Maintenance Information
Cylinder Compression Pressure
Warm up engine.
Turn off the engine.
Remove luggage box and central cover
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the
gauge no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure
12.52 Kg/cm
Check following items if the pressure is too low:
Incorrect valve clearance.
Valve leaking.
Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
Compression gauge
Drive Belt
Remove mounting bolt located under air cleaner.
Remove the engine left side cover and the cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.
Width limit: 22.5 mm or above
Teeth
Width
Clutch lining
Clutch weight
2-8
2. Maintenance Information
Steering Handle Top Bearing
Caution
Check all wires and cables if they are
interfered with the rotation of steering handle
bar.
Lift the front wheel out of ground.
Turn handle from right to left alternative and check
if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
adjust the handle top bearing.
Cushion
Caution
Do not ride the motorcycle with poor cushion.
Looseness, wear or damage cushion will
make poor stability and drive-ability.
Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damaged.
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Park motorcycle with main stand.
Turn the rear wheel forcefully and check if engine
bracket bushing worn out
Replace the bushing if looseness found.
Tighten all nuts and bolts.
2-9
2. Maintenance Information
Disk Brake System
Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid to UPPER limit. Also check brake
system for leaking if low brake level found.
Caution
In order to maintain brake fluid in the
reservoir in horizontal position, do not remove
the cap until handle stop.
Do not operate the brake lever after the cap
had been removed. Otherwise, the brake
fluid will spread out if operated the lever.
Do not mix non-compatible brake fluid
together.
Filling Out Brake Fluid
Tighten the drain valve, and add brake fluid.
Operate the brake lever so that brake fluid fulfilled
inside the brake system hoses.
Diaphragm
LOWER
Brake
Fluid
Caution
Never mix or use dirty brake fluid to prevent
from damaging brake system or reducing brake
performance.
Air bubble
Drain valve
Caution
Before closing the air bleeding valve, do not
release the brake lever.
Transparent hose
2-10
2. Maintenance Information
Brake Lining Wear
Lining
Caution
It is not necessary to remove brake hose when
replacing the brake lining.
Brake caliper
Brake disk
2 bolts
Caution
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
Cotter pins
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set.
2-11
2. Maintenance Information
Brake Light Switch / Start Switch
The brake light switch is to light up brake lamp as
brake applied.
Make sure that starter motor can be operated only
under brake applying.
Wheel / Tire
Caution
Tire pressure check should be done as cold
engine.
Appointed tire pressure
Tire size
Load for
Tire pressure as
under 90 Kg
cold engine
(Kg/cm)
Full loaded
2.25
2.00
2.50
2-12
Stop switch
2. Maintenance Information
Battery
Open the inner box lid.
Loosen screw & remove the battery cover
Caution
If there is rust on the posts very serious,
spray some hot water on the posts. Then,
clean it with steel brush so that can remove
rust for more easily.
Apply some grease on the posts after rust
removed to prevent from rust again.
2-13
2. Maintenance Information
Special Tools List
NAME
NO
NAME
NO
NAME
NO
NAME
NO
2-14
NAME
NO
NAME
NO
NAME
NO
NAME
NO
NAME
NO
NAME
NO
NAME
NO
NAME
NO
2. Maintenance Information
NAME
NO
NAME
NO
NO
NAME
NO
NAME
NAME
NO
SYM-9615000-L4A A6206
NO
NAME
NO
NAME
NO
SYM-9100420-A6305
Universal holder
SYM-2210100
NAME
NO
NAME
NO
SYM-3110000-HMA
NO
SYM-9100100-L4A
2-15
2. Maintenance Information
NAME
NO
NAME
NO
NAME
NO
2-16
NAME
NO
NAME
NO
NAME
NO
NAME
NO
Vehicle circuit test harness kit NAME EFi System Diagnostic tool
Multi-meter
SYM-HE170008-01
SYM-HE07007-01
NO
Contents
Homepage
3. Lubrication System
Precautions in Operations ........... 3-1
Troubleshooting............................ 3-1
Precautions in Operation
This chapter contains maintenance operation for the engine oil pump and gear oil replacement.
SAE
Specifications
Engine oil quantity
Gear oil
Oil
Gear oil
Items
Inner rotor clearance
Oil pump Clearance between outer rotor and body
Clearance between rotor side and body
Torque value oil strainer
1.3~1.7 Kgf-m
1.1~1.4 Kgf-m
1.1~1.4 Kgf-m
0.8~1.2 Kgf-m
Standard (mm)
Limit (mm)
0.15
0.20
0.15~0.20
0.25
0.04~0.09
0.12
Troubleshooting
Low engine oil level
Oil leaking
Valve guide or seat worn out
Piston ring worn out
Dirty oil
No oil change in periodical
Cylinder head gasket damage
Piston ring worn out
3-1
3. Lubrication System
Engine Oil
Turn off engine, and park the vehicle in a flat
surface with main stand.
Check oil level with oil dipstick
Do not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that to
make sure oil can be drained smoothly and
completely.
Place an oil pan under the vehicle, and remove
oil drain bolt.
After draining, make sure washer can be
re-used. Install oil drain bolt.
Torque value: 1.1~1.5 Kgf-m
Fill out engine oil (oil viscosity SEA 10W-40).
Recommended using King serial oil.
3-2
Drain bolt
3. Lubrication System
Oil Pump Removal
Remove generator and starting gear.
Remove the oil separator (bolt x 2).
Oil separator
BOLT
3
3-3
3. Lubrication System
Oil Pump Inspection
Check the clearance between oil pump body
and outer rotor.
Limit: 0.25 mm
3-4
PIN
3. Lubrication System
Install the oil pump cover and fixing pin properly
SCREW
1
Tighten screw
Make sure that oil pump shaft can be rotated
freely.
3-5
3. Lubrication System
Gear Oil
Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off the engine and remove oil inspection
bolt.
Gear oil
drain plug
3-6
Home page
Contents
Troubleshooting 4-32
Diagnostic tool
Ignition coil
AISV
TPS
Roll over
sensor
TA
Sensor
Injector
O2
Sensor
Power
relay
ISC
(Stepper motor)
MAP
Sensor
TW
Sensor
Battery
ECU
CPS
4-1
TPS
ISC
Injector
MAP Sensor
ECU
CPS
O2 Sensor
TW Sensor
Left
Rollover sensor
Diagnostic coupler
Test switch
4-2
TA Sensor
AISV
Fuel pump
Crankshaft Position
Sensor
CPS
Manifold Absolute
Pressure Sensor
MAP
INJECTOR
Throttle Position
Sensor
Engine Coolant
Temperature Sensor
O2 Sensor
TPS
TW
(ECU)
IGN COIL
Engine Control
Unit
FUEL PUMP
LAMBDA
CHECK LIGHT
K/S
AISV
Intake Air
Temperature Sensor
TA
ISC
Battery Voltage
Air Injection
Solenoid Valve
Idle Speed Control
Valve
(Stepper motor)
VBATT
Tuning tools
Diagnostic tool
4-3
4-4
Fuel pump
Injector
ECU
Fuel pump
relay
Power relay
Battery
System Description
1. After Key-on, the sensors signal to be sent to the ECU. ECU controls the fuel pump relay to make the
fuel pump operate. If the engine is not started, the fuel pump will be shut down within 2 to 3 seconds in
order to save electricity.
Fuel pressure regulator maintains fuel pressure at 294 6kPa (about 3 kg / cm). According to the
operating conditions and environmental compensation coefficient, appropriate fuel will be injected. After
Key-off or engine stopped operating, the fuel pump stops running.
2. Fuel impurities filtered by the fuel filter should be cleaned regularly.
3. When the engine can not be started, do not keep start motor running continuously which may lead to
lack of battery power (less than 10 V) and the fuel pump will not be able to operate. The correct way is
to use a new battery.
Injector
Eight-hole type injector provides two intake valves fuel injection quantity, enhances the effect of fuel
atomization, and reduces HC emissions. Short-type injector cap can easily fix the injector, receive the fuel
from the fuel pump, and limit injector rotation sliding. The signals from ECU control the fuel pressure
regulator, using the diaphragm and spring to maintain the fuel pressure in 294 6kPa (about 3 kg / cm),
and determine the fuel injection quantity by adjusting injection time width under different engine
conditions.
Fuel Pump
Electrical fuel pump is placed inside the fuel tank, powered by the battery and controlled by ECU.
Fuel pressure: 294 6kPa (about 3 kg / cm)
4-5
ECU
Throttle position
Ignition coil
Spark plug
Oxygen content
ACG/ Flywheel Gear
(23+1 Long teeth)
Crankshaft
position
sensor
Power relay
Battery
REG. REC.
Principle
The computer programmed ignition system receives the signals from the Crankshaft position sensor,
Throttle position sensor, O2 Sensor, MAP sensor, Intake air temperature sensor, Engine coolant
temperature sensor. Calculating the engine RPM, the 16-bit microcomputer determines the appropriate
ignition timing, controls the ignition coil and triggers the spark plug. This way can not only make the
engine achieve the maximum power output, but also help improve fuel consumption rate.
Specifications
1.
2.
3.
4.
5.
4-6
Flywheel
Description
The magnetic field type sensor generates a voltage
signal to calculate engine speed with ACG gear ring
(18-1 tooth).
There is one tooth every 20 degree on the gear ring.
But, one of the teeth is blank for the TDC calculating
base.
4-7
ECU
MAP Sensor
TA Sensor
TW Sensor
Inlet
pressure
sensor
Output voltage
4-8
Output voltage
Power relay
O2 Sensor
ECU
Battery
O2 Sensor
3
Output voltage
4
1.
2.
3.
4.
Ceramics tube
Electrode
Emissions
Atmosphere
Function
O2 Sensor measures the proportion of oxygen in the exhaust gas, sending signals to ECU which adjusts
the air-fuel ratio by changing the fuel injection time. If the proportion of oxygen is too low, it means the rich
air-fuel mixture with higher HC & CO concentration in the exhaust gas. If the proportion of oxygen is too
high, it means the lean air-fuel mixture with higher temperature and higher NOx concentration.
1. O2 Sensor outputs feedback signal to ECU which keeps the air-fuel mixture near the stoichometric ratio
4-9
ECU
TPS
Battery
TPS
EC
U
5V
VC
6
Voltage
VTA
4
2
0
50
100
150
Throttle valve opening angle
Basic Principle
TPS is a rotary variable electric resistor. When it is rotated, both electric resistance and voltage value
change, determining the throttle position.
Function
TPS determines the throttle valve position and sends signal to ECU as reference of engine control.
4-10
ISC
ECU
Battery
+Va
-Va
+Vb
-Vb
N
N
S
N
Vb
Step
Va
Function
ECU controls ISC stepper motor to adjust the bypass intake air quantity and stabilized the idle speed.
4-11
Basic Principle
When the engine RPM and throttle opening are higher than the default value, ECU controls AISV opening
or closure.
Fresh air
AISV
Reed valve
Power relay
ECU
Battery
Power relay
Air Injection
Solenoid Valve
ECU
4-12
Gasoline is a low fire point and explosive material. Always work in a well-ventilated place and flame is
strictly prohibited when working with gasoline.
Before dismantling fuel system parts, leak fuel out first, or grip the fuel pipe by using pliers to prevent
fuel from splashing.
Cautions
Do not bend or twist the throttle cable. Damaged cable will lead to unstable driving.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly.
Specification
Item
Specifications
Idle RPM
1550100 rpm
2~6 mm
Fuel pressure
Torque value
Engine Temperature sensor
O2 Sensor
0.74~0.88 kgf-m
3.6~4.6 kgf-m
Special Tools
Vacuum Gauge
Fuel Pressure Gauge
EFi System Diagnostic Scanner
Fuel Pipe Pliers
4-13
Testing Procedures:
1. Connect the diagnostic scanner to the diagnostic coupler on the
vehicle.
2. Key-on but not to start engine, confirm ECU and the diagnostic
scanner can be connected or not.
3. Diagnostic scanner will automatically display Version "certification" of
the screen.
4. Confirm the application model, version is correct or not.
5. Check if the fault codes exist.
6. Remove the fault codes.
7. Start engine and check the parameters which shown on the diagnostic
scanner.
Detection judge:
Fault codes can be read and cleaned, and the fault codes will not
appear again after re-start.
4-14
Throttle body is the inlet air flow regulating device (similar to the
carburetor).
Throttle valve pivot drives the throttle position sensor synchronously
and makes ECU detect the throttle opening immediately.
Throttle valve positioning screw has been adjusted and marked on the
production line. Readjustment is not suggested.
4-15
Testing Procedures:
Y/B
B/R
G/R
Cautions
Detection judge:
Cautions
4-16
The higher the altitude, the measurement value to the lower voltage.
Sea-level atmospheric pressure = 1Atm = 101.3kPa = 760mmHg =
1013mbar
Inlet pressure sensor damaged, or poor contact couplers.
Check whether the abnormal wire harness lines.
Inlet pressure sensor anomaly, the proposed replacement of the
sensor to measure the output voltage.
ECU anomaly, the proposed replacement of the ECU to measure the
working voltage.
Testing Procedures:
Resistance Value Measurement:
Dismantled inlet temperature sensor connector.
Use of the "Ohmmeter" Ohm stalls, inspection sensor resistance.
Detection judge:
Resistance value and the temperature between relationships as follows
Temperature ()
Resistance value (K)
-20
18.8 2.4
40
1.136 0.1
100
0.1553 0.007
4-17
W/BR
Y/B
Pins
Upper
Center
Under
G/R
Wire color
White / Brown
Yellow / Black
Green / Red
Function
Signal output
5V voltage input
Ground
Testing Procedures:
Cautions
4-18
Detection judge:
Warning
4-19
Testing Procedures:
Detection judge:
Resistance value and the temperature between relationships as follows:
Temperature ()
Resistance value (K)
-20
18.8 2.4
40
1.136 0.1
100
0.1553 0.007
Resistivity measurements
4-20
G/R
Use 8 ~ 16V DC power supply, has the 4-pin coupler, a power supply
pins for heater; for a heater control pin; signal for a grounding pin; O2
for a signal pin.
O2 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.
L/O
Testing Procedures:
R/O
R/Y
1. Voltage confirmed:
Removed O2 Sensor and the wire harness between the coupler.
Open the main switch, but not to start engine.
Use "voltage meter" DC stalls (DCV) to check inlet pressure sensor
voltage.
Confirmed working voltage:
Voltage 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).
GR
2. Resistance Confirmation:
Remove O2 Sensor and the wire harness between the coupler.
Use of the "meter" Ohm stalls, Measurement O2 Sensor heater
resistance.
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
4-21
Detection judge:
4-22
Control power of the power relay coil, has the three-pin socket.
When vehicles tilt angle greater than 65 degrees, roll over sensor will
be the implementation of ECU system power off. At this point once
again to restart the engine, the need to re-open a main switch.
This as a safety device, when the dumping of vehicles, be cut off
power supply of ECU, and engine stop.
Testing Procedures:
Because of the roll over sensor for the electronic control agencies, not
against removed after a single measurement.
Normal state, after power is turned 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 it is normal
for the roll over sensor.
Detection judge:
Voltage: Supply voltage = Battery voltage
4-23
Functional Description:
Testing Procedures 1:
Resistance Confirmation:
Idle Air Control Valve will be demolished down coupler (directly in the
body, can also measure).
Use of the "meter" Ohm stalls (), measurement of the two step
motor coil resistance values.
A phase: ISCAP and ISCAN
B phase: ISCBP and ISCBN
ISCBP
ISCBN
ISCAP
ISCAN
ISC PINS
Cautions
Dynamic checking for Idle Air Control valve, can only be tested on
the engine, not a single test.
Detection judge:
1. Resistance value:
A phase: 80 10 (Environmental conditions: 15 ~ 25 )
B phase: 80 10 (Environmental conditions: 15 ~ 25 )
2. Actuator inspection:
In the above steps Idle Air Control Valve (ISC) Idling motor actuator
control of inspection, ISC will be slightly vibration or " da da"
continuous sound.
4-24
Testing Procedures 1:
Fuel pump working voltage confirmed:
Fuel pump coupler to properly (using the probe tool), or can be
removed coupler working voltage measurements (direct
measurement).
Open the main switch, but not to start engine.
Use "voltage meter" DC stalls (DCV) to check fuel pump voltage.
Confirmed working voltage:
Voltage meter negative access to the wire harness fuel pump coupler
2nd pin (Green).
Voltage meter positive access to the wire harness fuel pump coupler
first pin (Black / Purple).
Cautions
Confirmed working voltage
Detection judge 1:
1. Working voltage value: Above 10V
2. Resistance value: 1.50.5
3. Fuel pressure: 2946kPa (about 3kg/cm2)
4-25
Cautions
Detection judge 3:
1. Fuel pressure: 2946kPa (about 3kg/cm2)
4-26
1.
2.
3.
4.
Testing Procedures:
1. Resistance Confirmation:
Use of the "meter" Ohm stalls (), measurement of the injector
resistance value.
2. Injector injection state examination:
Removed the injector fixed bolt and removed the injector from intake
manifold, but not removal of harness coupler.
Injector and injector cap tightly by hands, fuel spills should not be
the case.
Key-on and start the engine, injector injection state examination.
Injector resistance confirmation
Detection judge:
1. Between the two pin resistance values: 10.50.53
2. injection state:
Fuel atomizing good, with a clear scattering angle judged as
normal.
Injection-state such as water, no obvious scattering angle found
abnormal.
Warning
Injection-state unusual
4-27
Testing Procedures:
Resistance Confirmation:
Removed coil first circuit plugs on the ignition coil (Red / Yellow &
Black / Yellow).
Use of the "meter" Ohm stalls (), measurement of the ignition coil
resistance value.
Detection judge:
Do not need for an external power supply, has two-pin of signal plug.
Constitutes a major change in its reluctance induction coil.
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 (18-1
tooth) rotary cutting induction coil changes in the magnetic field sensor
with the inductive voltage signal for ECU judgment, calculated at the
engine speed and crankshaft position, and with a most appropriate
time of fuel injection and ignition control.
Testing Procedures:
Resistance Confirmation:
Removed crankshaft position sensor coupler (Blue / Yellow & Green /
White).
Use of the "meter" Ohm stalls (), measurement of the crankshaft
position sensor resistance value.
Detection judge:
4-28
Control power, has two-pin socket, one for the power supply pin, one
for grounding pin.
Secondary air injection solenoid valve at the Idle (3500 rpm below)
actuator.
At Idling, ECU control solenoid valve by the grounding circuit to be
moving or closing.
Testing Procedures:
Resistance Confirmation:
Use of the "meter" Ohm stalls (), measurement of the secondary air
injection solenoid valve resistance value.
Detection judge:
Resistance value = 26 2.6 (20)
4-29
4-30
Pin code
Wire color
Note
1
2
IGP
LG
R/Y
G
IGNITION POWER
LOGIC GROUND
3
4
HEGO
SG
L/O
G/R
O2 SENSOR
SENSOR GROUND
5
6
TH
VCC
W/BR
Y/B
BATT
BATTERY
8
9
PG1
POWER GROUND1
10
11
PG2
IG
G
B/Y
POWER GROUND2
IGNITION COIL
12
CRK-P
L/Y
13
14
TA
G/BR
15
16
TEST
INJ
P/W
L/G
TEST SW
INJECTOR
17
18
MIL
Y/G
19
FLPR
O/W
20
ISCBP
G/B
21
ISCAP
L/B
22
HEGO HT
R/O
O2 SENSOR HEATER
23
CRK-M
G/W
24
25
TW
-
R/GR
-
26
27
ROLL
PM
Y/P
B/R
28
SOL
O/L
AISV
29
30
K-LINE
W/G
DIAGNOSTIC TOOL
31
ICSBN
B/W
32
ISCAN
BR/B
33
RPM
B/Y
RPM SIGNAL
4-31
Main switch on
NG
switch?
OK
6. ECU fault
NG
1. Bulbs broken?
2. Fuse broken?
3. Battery voltage is too low?
4. ECU Power line bad contact?
5. Poor contact the main power
3. Short-circuit leakage?
Battery voltage & ECU of voltage less than 0.2 V?
1. Main switch OFF
2. Removed ECU coupler
3. Main switch ON
4. Use voltage meter measurement of the power-pin
voltage difference
5. Confirmed ECU and battery supply voltage
differential pressure within the 0.2 V voltage
OK
NG
1. Lines anomaly?
OK
NG
1. Lines anomaly?
OK
NG
1. Lines anomaly?
2. ECU anomaly?
NG
1. Lines anomaly?
2. Relay fault?
3. ECU anomaly?
3. Main switch ON
4. Use voltage meter measurement of the sensor
connector voltage
OK
OK
values
End
4-32
NG
OK
NG
OK
1. Fuel tank inadequate?
2. Fuel injector pressure-less than 294
6kpr?
NG
OK
NG
Is Circuit anomaly?
Circuit
NG
OK
OK
Is Engine anomaly?
End
4-33
Idle flameout
4-34
Idle flameout
4-35
Detection of
maintenance projects
and steps
Battery
voltage
Fault reasons
Fault status
determination
Battery voltage
is 10 V above?
Diagnosis tool
show whether
the voltage of 10
V above?
NO
Battery electricity
Battery connector
loose
Harness circuit
opening
ECU coupler not
connected properly
Parts specifications
Diagnosis tool
display voltage
required to
achieve more
than 10 V
The sensor
detection
methods and
specifications,
please refer to
repair manual
YES
Diagnosis
fault code
inspection
Use of the
diagnosis tool
detection fault
code
Elimination of
fault codes, and
then start engine
Diagnostic tool
TPS fault
show whether or
ETS fault
not a fault code?
CPS fault
YES MAP fault
Fault Code
cleared after
O2 sensor fault
show again?
ROS fault
ECU fault
NO
Fuel
quantity and
fuel
pressure
Removed the
injector on the
intake manifold,
but not removal of
harness coupler.
(Injector and
injector cap tightly
by hands, fuel
spills should not
be the case)
Start the engine
Examine whether
injector fuel
injection
Between the tank
and injector
installation the
pressure gauge
check fuel
pressure
adequacy
Injector whether
injection?
Injector spray
angle is normal?
Fuel pressure
enough?
NO
Pressure fuel
specifications:
Open the main
switch three
seconds after
but not start
engine more
than 250 kPa
Idle
2946kPa
Injector
resistance
specifications:
11.70.6
YES
Ignition
situation
Removed the
spark plug from
the cylinder
head, but then
power lines still
ring
Examine
whether the
spark plug
ignition?
Check spark
plug sparks
strength is
normal?
sparks
YES
Continued next page
4-36
NO
Spark plug
specifications:
NGK-CR8E
YES
Closed-loop
systems for
mobility
Observation
O2
senslor voltage
changes (Standed
motorcycle so that
engine speed
refueling between
4500 to 5500 rpm
O2 sensor
voltage is
maintained in a
long time within
a certain range
beating
O2 sensor fault
ECU fault
O2 sensor
voltage beating
specifications:
100 ~ 900 mV
from the two
groups within
the interactive
beating
Valve clearance is
not normal
Intake system leak
Manifold
pressure
Specifications:
32~38 kPa
NG
YES
Engine
vacuum
Use diagnosis
tool to detect of
the manifold
pressure
Diagnosis tool
manifold
pressure for
compliance with
specifications?
NG
YES
Normal starting
Finish
4-37
Fuel pump
coupler
Bolt 2
Cautions
4-38
Fuel filter
Bolt 6
Cautions
Cautions
4-39
Manual inspection
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, but not in
the diagnosis tool can be - for the detection, inspection can enjoy for a long time flashing lights flashing
and the short period of time to inform the cause of the malfunction (refer to check light fault information
fault code table).
4-40
0.5
Fault code 22
0.5
Unit: second
Fault code 12
Continuous repeated
Cross-access
Not to cross-access
Throtrtle
Full throttle
Full throttle closed
At least 5 seconds
Main
switch
ON
OF
F
OF
F
Lighting
Check
light
Not lit
Lighting
4-41
Fault
codes
Fault Description
Parts Inspection
0120
0105
0115
0195
0110
1630
0130
O2 sensor fault
0201
#1 fault
0351
IG #1 fault
10
0230
11
0135
12
1505
13
1410
14
0335
15
1205
16
0603
EEPROM fault
EEPROM
4-42
Fault
codes
0120
0105
0115
0195
0110
1630
0130
0201
0351
10
0230
11
0135
12
1505
13
1410
14
0335
15
1205
16
0603
lighting
long 1short 7
O2 Sensorand wire
Fault detection procedures Please refer to the "EFI System components description" O2 sensor chapter.
#1 fault
lighting
long 3short 3
Fault detection procedures Please refer to the "EFI System components description" fuel injector chapter.
IG #1 fault
lighting
long 3short 7
lighting
long 4short 1
Fault detection procedures Please refer to the "EFI System components description" fuel pump chapter.
O2 sensor heater fault
lighting
long 4short 5
O2 Sensorand wire
Fault detection procedures Please refer to the "EFI System components description" O2 Sensor chapter.
ISC motor fault
lighting
Step motor and wire
long 4short 9
Fault detection procedures Please refer to the "EFI System components description" idle speed control valve
(ISC) chapter.
nd
nd
Exhaust 2 air solenoid valve fault
lighting
2 air control valve and wire
long 5short 4
nd
Fault detection procedures Please refer to the "EFI System components description" 2 air solenoid valve
chapter.
Crankshaft position sensor fault
lighting
Crankshaft position sensor and wire
long 6short 6
Fault detection procedures Please refer to the "EFI System components description" Crankshaft position
sensor chapter.
Manifold absolute pressure sensor
PM wire fault
lighting
long 6 short 8
and wire
Fault detection procedures Please refer to the "EFI System components description" Manifold absolute
pressure sensor (MAP) chapter.
EEPROM fault
Not lit
EEPROM
long short
This fault Please direct replacement ECU
4-43
LCD
monitor
Link cable
Information
transmission indicator
Function
set Button
Leave
button
Executive
Function button
Digital
button
Software
cartridge
Note:
When problems occurred, can be used for diagnosis tool of the fault is detected, and exclusion.
In addition to testing, troubleshooting, another of the operation can be carried out data analysis-type
monitor.
Method of Use:
1. Maintain engine flameout state, do not open main switch.
2. Opened the luggage box lighting light cover (screw x2), connected to the diagnostic connector for
diagnosis tool.
3. Then open the main switch and the diagnosis tool power switch after diagnosis display screen
appeared the words connection.
4. Press the "ENTER" button into the main screen (there are 6 major functions: ECU ID, DATA STREAM,
FREEZED DATA, TROUBLE CODE, ERASE TB CODE and CO ADAPTION)
5. Use , select button 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 fault "system is OK."
6. Press "EXIT" button to leave of the various functions.
7. Must to close the main switch or power switch of the diagnosis tool after, and then can removal of
diagnosis tool coupler.
4-44
Test switch
coupler
Diagnostic coupler
4-45
4-46
4-47
4-48
A total of 3 pages, are able to use " left" and "right " button, view injection system information.
On the any screen, press the "EXIT" button, the function can return to the directory screen.
4-49
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
Engine SPD--RPM (Idle:1550~1750) Engine idle speed
FAULT NO.-------(Normal:0) Fault code number
BATT. VOLT---V (Above 12V) Battery voltage
FUEL PUMP--------(Idle:ON) Fuel pump actuator state
MAP-----------kPa (Idle:32~38kPa) Manifold pressure
TPS position-----% (Idle: 1.5%) Throttle opening
TPS position---V (Idle:0.58~0.62) Throttle sensor voltage
O2 SENSOR---mV (Idle:50~200mV) O2 sensor voltage
O2 HEATER--------(Idle: 3500rpm=ON) O2 heater actuator state
ENGINE TEMP-C (Stable:85~95C) Engine temperature (cooling water temperature)
In the "DATA STREAM" of the screen use "" "" button to move the left side of the project ""
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use " left" and "right " button, can transform View wave numerical size.
Numerical analysis of images (1 / 3), the waveform can be displayed as shown in the following items:
Engine SPD
BATT. VOLT
MAP
TPS position %
TPS position Voltage
O2 SENSOR Voltage
ENGINE TEMP
4-50
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
BARO-----------kPa (Above 98kPa) Atmospheric pressure
Intake Air---------C (Outside Temp.) Intake air temperature
2nd AIR VALVE-----V (Idle:ON) Secondary air solenoid valve actuator state
INJECT TIME---mS(Idle:1~3mS) Injection time
IGN. ANGLE-----------(Idle:12~14) Ignition timing
STEP MOTOR -----Idle air control valve step motor actuator state
CRANKSHAFT ---------(Idle:CW) Crankshaft functioning direction
TEST TERMINAL-(Idle:OPEN) Test terminal state
IDLE SET----------RPM (=1650 RPM) Idle speed goal set value
ISC STEP--------------(Idle:75~95) Idle Air Control Valve stepper motor learning step
In the "DATA STREAM" of the screen use "" "" button to move the left side of the project ""
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use " left" and "right " button, can transform View wave numerical size.
Numerical analysis of images (2 / 3), the waveform can be displayed as shown in the following items:
BARO
Intaje Air
INJECT TIME
IGN. ANGLE
IDLE SET
ISC STEP
4-51
The screen showed the ECU captured by the engine of the state immediately.
The following data for the benchmark idling state:
LEARNED STEP--------------(Set by ECU) Idle Air Control Valve stepper motor learning
step
In the "DATA STREAM" of the screen use "" "" button to move the left side of the project ""
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use " left" and "right " button, can transform View wave numerical size.
Numerical analysis of images (3 / 3), the waveform can be displayed as shown in the following items:
4-52
Only one page, at any screen, press the "EXIT" button, the function can return to the directory screen.
In the "FREEZED DATA" of the screen use "" "" button to move the left side of the project ""
symbol selected items, press the "ENTER" button lock of the project, and press the "F4" button
showed that the wave of projects.
Able to use " left" and "right " button, can transform View wave numerical size.
4-53
If the system has faulty code, that is showing the fault code, that can be used " left" and "right " or
"" "" button to select the fault code (selected before the code "" tags) that, press the "ENTER"
button, the code can be read descriptions and fault handling.
Fault code in the note and treatment of the pages, if the first one page did End, they can press the
"" "" button to turn the pages to read all content.
4-54
4-55
Use " left" and "right " or "" "" button, CO value can be adjusted.
CO ADAPT: CO adjusted value.
CO Read: CO read-back value.
Press the "EXIT" button, the function can return to the directory screen.
4-56
Fuel
press.
Cant start
Difficult to
start
Abnormal
phenomena
Start
state
Without
idle
Idle
state
Parts
closedFault
loop
Ignition Engine Injection
Code
control Detection
state
state
vacuum
system
Idle not
smooth
RPM NG
Acceleration
Flameout
Engine
temp.
sensor
Throttle
position
sensor
CO NG
Not smooth
Inability
and slow
Idle
flameout
ECU
Acceleratio
n flameout
Roll over
Fuel pump
sensor
Ignition
coil
Inlet pipe
Injector
O2 sensor
Secondary
air
Fuel pump injection
solenoid
valve
Fuel
pressure
Spark plug
adjustment
valve
Cylinder
head
Security
unit
Fuel pump
relay
Fuel
Inlet
pressure
pressure
adjustment
sensor
valve
Main
switch
Fuel filter
Power
relay
Battery
Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list" implementation.
2. Spare parts, according to the "EFI System components description" implementation.
4-57
Maintenance
Project
Testing Procedures
Test items
Battery voltage
Power and Use meter direct
measurement battery voltage
voltage
Determine benchmarks
Battery voltage = 10V Above
Battery electricity
Battery connector loose
Harness circuit opening
ECU coupler not connected
properly
Spark plug
specifications
Whether the spark
plug ignition
Spark plug sparks
whether it is normal
strength
Specifications: NGK-CR8H
Ignition conditions:
With traditional engines found
ways
4
5
Fuel
pressure
Engine
vacuum
Idle state:
pressure = 2946kPa
(Beating situation from top to
bottom)
rotation throttle moment:
pressure = 2946kPa (Slightly
beating)
Injection
state
Fault reasons
eliminated
If residual Fault Code,
Start again, the fault
according to the "Fault Code
is it will happen again
Maintenance Form"
implementation of
troubleshooting
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
4-58
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Contents
5. Engine Removal
L
Removal of Engine.................................5-2
Precautions in Operation
The engine has to be supported with special service tools that can be lifted or adjustable.
The following parts can be serviced as engine mounted on frame.
Carburetor.
Cylinder head, cylinder, and piston.
Driving pulley, driving belt, clutch, and driving disc assembly.
Final gear reduction mechanism.
Specification
Item
Capacity
Replacement
1800 c.c.
Disassembly (oil
filter replaced)
1900 c.c.
Disassembly
2000 c.c.
Replacement
330 c.c.
Disassembly
350 c.c.
1400 c.c.
Coolant capacity
Reservoir
Total
350 c.c.
as indicator shown
1750 c.c.
Torque Value
Engine mounting bolt
Engine hanger bolt
Rear shock absorber connection bolt (under)
Engine hanger stopper nut
Engine bracket nut
4.0~5.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
1.8~2.2kgf-m
4.0~5.0kgf-m
5-1
5. Engine Removal
Removal of Engine
Disconnect the seat dampers.
Remove the air box cover.
5-2
5. Engine Removal
Remove fuel pipe, vacuum tube and throttle valve
wire from the throttle body.
Disconnect the EFi system coupler.
Water hose
l
Water pump
Bolt X3
5-3
5. Engine Removal
Remove the parking brake cable.
Remove the rear brake caliper (2 bolts).
Caution
Do not operate brake lever after the caliper is
removed to avoid clipping the brake pad.
Remove the mounting bolt of rear right cushion.
Bolts X2
Engine Installation
Check if the bushings of engine suspension parts
and shock absorber for damage.
Install engine in the reverse procedures of
removal.
Caution
Pay attention of foot & hand safety as engine
installation to avoid hurting.
Do not bend or twist wires.
Cables wires have to be routed in
accordance with normal layout.
Engine Mounting Bolt:
Torque value: 4.0~5.0 kgf-m
Rear shock absorber bolt:
Torque value: UPPER: 3.5~4.5 kgf-m
LOWER: 2.4~3.0 kgf-m
5-4
Home page
Contents
Troubleshooting 6-3
Mechanism Diagram
1.0~1.4 kgf-m
1.0~1.4 kgf-m
2.0~2.4 kgf-m
3.6~4.0 kgf-m
1.0~1.2 kgf-m
1.0~1.4 kgf-m
0.7~1.1 kgf-m
6-1
Specification
Item
Standard
Limit
12+/2 kg/cm2
---
Intake
30.800~30.920
3.075
Exhaust
30.411~30.531
30.26
12.000~12.018
12.10
11.966~11.984
11.910
Intake
4.975~4.990
4.900
Exhaust
4.955~4.970
4.900
5.000~5.012
5.030
Intake
0.010~0.037
0.080
Exhaust
0.030~0.057
0.100
35.000
31.500
1.000
1.6
---
0.05
Compression pressure
Camshaft
Rocker
arm
Valve
OD of valve stem
Guide seat
Clearance between
valve stem and guide
Torque Value
Cylinder head bolt (LH)
Cylinder head Nut
Sealing bolt of cam chain auto-tensioner
Bolt of cam chain auto-tensioner
Cam sprocket cover bolts
Cam sprocket bolt
6-2
2.0~2.4 kg-m
2.0~2.4 kg-m
0.8~1.2 kg-m
1.2~1.6 kg-m
0.8~1.2 kg-m
1.0~1.2 kg-m
Noise
6-3
Tensioner bolts
Thermostat bolts
6-4
4 bolts
4 bolts
3 bolts
Timing mark
2 bolts
Bolt 2
4 nuts
2 dowel pins
Caution
Do not damage the matching surfaces of
cylinder and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Cam chain guide
6-5
1 bolt
Cam shafts
Rocker arm
shaft and cam
shaft puller
Caution
In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.
Special Service Tool:
Valve cotter remove & assembly tool
SYM-1471110-SY125
6-6
Inlet valve
Exhaust valve
Inner spring
Spring retainer
Outer spring
Cotter
Caution
Do not damage the matching surface of
cylinder head.
6-7
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm
EX: Replacement when less than 34.725mm
Inspect the camshaft bearing for looseness or
wear out. If any damage, replace whole set of
camshaft and bearing.
Rocker Arm
Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?
Service Limit: Replace when it is less than
12.080 mm.
6-8
Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
Valve guide
Caution
Before measuring the valve guide, clean
carbon deposits with reamer.
Tool: 5.0 mm valve guide reamer
Caution
If clearance between valve stem and valve
guide exceeded service limit, check whether
the new clearance that only replaces new valve
guide is within service limit or not. If so,
replace valve guide.
Correct it 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.
6-9
Caution
Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Caution
Check if new valve guide is deformation after
pressed it in.
When pressing in the new valve guide, cylinder
head still have to be kept in 100~150.
Caution
Using cutting oil when correcting valve guide
with a reamer.
Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-10
Caution
Do not let emery enter into between valve stem
and valve guide.
Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and
valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is
roughness, wear out, or incomplete contacted
with valve seat.
Valve seat width
Caution
Roughness
45
32
6-11
60
Caution
Make sure that all roughness and uneven faces
had been ground.
Grind valve seat again if necessary.
45
Caution
32
60
6-12
Valve cotter
Inlet valve
Caution
The closed coils of valve spring should face
down to combustion chamber.
Valve spring
Exhaust valve
Caution
In order to avoid damaging the valve stem and
the cylinder head, in the combustion chamber
place a rag between the valve spring
remover/installer as compressing the valve
spring directly.
Special Service Tool:
Valve cotter remove & assembly tool
SYM-1471110-SY125
Caution
Place and hold cylinder head on to working
table so that can prevent from valve damaged.
6-13
2 bolts
Gasket
Caution
Do not damage the matching surfaces of
cylinder and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide
Dowel pins
Bolt 2
4 nuts
Timing mark
Caution
Make sure timing marks are matched.
2 bolts
6-14
3 bolts
Tensioner bolts
Thermostat bolts
4 bolts
4 bolts
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can
not be exceeded standard value in order to
avoid causing cylinder head deformation,
engine noise and leaking so that motorcycles
performance be effected.
Install the engine onto frame (refer chapter 5).
6-15
4 bolts
Caution
If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.
6-16
3 bolts
Timing mark
2 bolts
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Contents
7. Cylinder / Piston
Mechanism Diagram 7-1
Troubleshooting 7-2
Mechanism Diagram
0.8~1.2kgf-m
1.0~1.4kgf-m
1.2~1.6kgf-m
1.0~1.4kgf-m
7-1
7. Cylinder / Piston
Precautions in Operation
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
Unit
mm
Specification
LM25W5
Item
Standard
Limit
Standard
Limit
70.995~71.015
71.100
72.995~73.015
73.100
Out of round
0.050
0.050
Taper
0.050
0.050
Warpage
0.050
0.050
Top
0.015~0.050
0.090
0.015~0.050
0.090
2nd
0.015~0.050
0.090
0.015~0.050
0.090
Too
0.150~0.300
0.500
0.150~0.300
0.500
nd
0.300~0.450
0.650
0.300~0.450
0.650
0.200~0.700
0.200~0.700
70.430~70.480
70.380
72.430~72.480
72.380
0.010~0.040
0.100
0.010~0.040
0.100
17.002~17.008
17.020
17.002~17.008
17.020
16.994~17.000
16.960
16.994~17.000
16.960
0.002~0.014
0.020
0.002~0.014
0.020
17.016~17.034
17.064
17.016~17.034
17.064
I.D.
Cylinder
Clearance
between
piston ring and
ring groove
Piston/
Piston
ring
LM30W
Oil
(side rail)
Troubleshooting
Low or Unstable Compression Pressure
Knock or Noise
Engine Overheat
7-2
7. Cylinder / Piston
Cylinder / Piston Removal
Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.
Coolant hose
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective in
the cylinder.
Service limit:
LM25W5: 71.100 mm
LM30W: 73.100 mm
Top
Center
Bottom
7-3
7. Cylinder / Piston
Measure the cylinder upper surface for warpage.
Service limit: 0.05 mm
Caution
Pay attention to remove piston rings because
they are fragile.
7-4
7. Cylinder / Piston
Measure the outer diameter of piston pin.
Service Limit: 16.96 mm
Caution
The measurement position is 10 mm distance
from piston bottom side, and 90 to piston pin.
Service limit
LM25W5: 70.380 mm
LM30W: 72.380 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
7-5
7. Cylinder / Piston
Piston Ring Installation
Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
Do not damage piston and piston rings as installation.
All marks on the piston rings must be forwarded to up side.
Make sure that all piston rings can be rotated freely after installed.
Top ring
2nd ring
Oil ring
Top groove
2nd groove
Oil groove
7-6
7. Cylinder / Piston
Piston Installation
Install piston and piston pin, and place the IN
marks on the piston top side forward to inlet valve.
Caution
Do not let the opening of piston pin clip align
with the piston cutout.
Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.
Cutout
Cylinder Installation
Clean up all residues and foreign materials on the
matching surface of crankcase. Pay attention to
not let these residues and foreign materials fall
into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
Dowel pins
7-7
7. Cylinder / Piston
Coat some engine oil to inside of cylinder, piston
and piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because piston and piston rings will be
damaged.
7-8
Home page
Contents
Troubleshooting 8-2
Mechanism Diagram
8.5~10.5kgf-m
6.0~7.0kgf-m
0.7~1.1kgf-m
0.7~1.1kgf-m
8-1
Specification
Item
Drive belt width
Standard value
Limit
24.000 mm
22.500 mm
29.946~29.980 mm
29.926 mm
30.000~30.040 mm
30.060 mm
OD of weight roller
19.500~20.000 mm
19.000 mm
144.850~145.150 mm
145.450 mm
6.000 mm
3.000 mm
102.400 mm
97.400 mm
40.950~40.990 mm
40.930 mm
ID of driven face
41.000~41.050 mm
41.070 mm
17.700~18.300
17.200
ID of clutch outer
Thickness of clutch weight
Free length of driven pulley spring
Torque value
Troubleshooting
Engine can be started but motorcycle can
not be moved
8-2
8 bolts
8-3
Bearing replacement
Remove bearing with special service tools
Special tools:
Inner bearing puller
SYM-6204022
8-4
2 bolts
Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.
Special Tool
Universal holder
Universal holder
Caution
Using special service tools for tightening or
loosening the nut.
Fixed rear wheel or rear brake will damage
reduction gear system.
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
Service Limit: 22.5 mm
Replace the belt if exceeds the service limit.
Belt tooth
Width
Caution
Using the genuine parts for replacement.
The surfaces of drive belt or pulley must be
free of grease.
Clean up all grease or dirt before installation.
8-5
Driven face
Universal holder
Universal holder
8-6
Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Crankshaft
Ramp plate
Weight roller
8-7
Weight roller
Reassembly/installation
Install weight rollers.
Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Closure surface
Ramp plate
Guide collar
8-8
Caution
The movable drive face surface has to be free
of grease. Clean it with cleaning solvent.
Crank shaft
Press down
Drive belt
Caution
Make sure that two sides of pulley surfaces
have to be free of grease. Clean it with
cleaning solvent.
Hold drives face with universal holder.
Tighten nut to specified torque.
Torque value: 8.5~10.5kgf-m
Install left crankcase cover.
8-9
Disassembly
Remove drive belt, clutch outer and driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.
Caution
Do not press the compressor too much.
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
friction plate, clutch weight and spring from driven
pulley.
Collar
Guide pin
Seal
Guide pin
O-ring
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 145.450 mm
Inner
diameter
8-10
Clutch outer
Replace
Clutch weight
Free length
Driven pulley
Check following items:
If both surfaces are damaged or worn.
If guide pin groove is damaged or worn.
Replace damaged or 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 40.93 mm
Inner diameter 41.07 mm
Driven face
Needle bearing
8-11
Spring
Driving plate
Caution
Some of models are equipped with one
mounting plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight
Caution
Grease or lubricant will damage the clutch
weight and affect the blocks connection
capacity.
Clutch weight
8-12
Snap ring
Caution
Outer bearing
Clipper
Inner needle
bearing
Snap ring
Outer bearing
Bearing end
Caution
Its sealing end should be forwarded to outside
as bearing installation.
Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of drive face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
Inner bearing
8-13
Oil seal
Specified grease
O-ring
Guide pin
Oil seal
Guide pin
O-ring
8-14
Homepage
Contents
Troubleshooting................................... 9-2
Mechanism Diagram
Radial ball bearing 6206 UU
Oil seal 45*65*10
Final gear
Counter shaft
Radial ball bearing 6204
Needle bearing NK18/20R
Drive shaft
2.4~3.0 kgf-m
Needle bearing HKS 25*33*18
9-1
Torque value
Gear box cover
1.0~1.4 kg-m
Tools
Special tools
Bearing (6203/6004UZ) driver
Bearing (6204) driver
Bearing (6301) driver
Oil seal (27*42*7) driver
Oil seal (20*32*6) driver
Inner bearing puller
Outer bearing puller
Troubleshooting
Engine can be started but motorcycle
can not be moved.
Noise
9-2
7 bolts
9-3
Caution
Bearing Replacement
Caution
9-4
Bearing puller
9-5
Final shaft
Countershaft
Final driving gear
9-6
dowel
pin
Gasket
7 bolts
9-7
9-8
Homepage
Contents
Flywheel Removal..........................10-3
Flywheel Installation......................10-7
Mechanism Diagram
0.7~1.1 kgf-m
0.7~1.1 kgf-m
8.5~10.5 kgf-m
2.8~3.2 kgf-m
10-1
10
Specification
Item
Limit (mm)
20.026~20.045
20.100
42.175~42.200
42.100
Torque value
Flywheel nut
5.0~6.0 kgf-m
8 mm bolts
0.8~1.2 kgf-m
12 mm bolts
1.0~1.4 kgf-m
Tools
Special tools
A.C.G. flywheel puller
Universal holder
10-2
12 bolts
2 screws
3 bolts
Flywheel Removal
Remove the flywheel nut.
Install the shaft protector to the crankshaft.
Shaft protector
10-3
2 screws
Caution
Make sure that the wire harness is placed
under pulse generator.
3 bolts
10-4
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Contents
Troubleshooting............................. 11-2
11
Mechanism Diagram
0.7~1.1 kgf-m
6.0~7.0 kgf-m
2.0~2.4 kgf-m
1.0~2.0 kgf-m
1.0~1.4 kgf-m
1.0~1.4 kgf-m
1.1~1.5 kgf-m
3.5~4.5 kgf-m
1.0~1.4 kgf-m
0.7~1.1 kgf-m
1.0~1.4 kgf-m
11-1
In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the
timing chain, it is preferably to replace crankshaft as a unit.
Service data
Crankshaft
Item
Connecting rod side clearance of the big end
Vertical clearance of the big end of the connecting
rod
Run-out
Torque value
Bolts for crankcase
Bolts for cam chain adjuster
Tools
Special tools
R/L. crank disassemble/ install tool
L. crank shaft bearing driver
Crank shaft bearing fixing socket
Crank shaft puller
Outer bearing puller
Inner bearing puller
Troubleshooting
Engine noise
Loose crankshaft bearing
Loose crankshaft pin bearing
Worn out piston pin and pin hole
11-2
0.8~1.2kgf-m
1.2~1.6kgf-m
Standard
0.100~0.400
Unit: mm
Limit
0.600
0~0.008
0.050
0.100
Crankcase Disassembly
Remove the cam chain.
Loosen the bolt and remove the tensioner.
Remove the water pump shaft locknut.
Cam chain
boltsX2
Bolt x 3
11-3
11-4
Bolt x 11
SYM-9100310-L4A
11-5
11-6
11-7
11-8
Home page
Contents
Radiator ..........................................12-5
12
Mechanism Diagram
Reserve tank
Cooling fan
Thermo unit
(temp meter)
Thermostat
Water pump
12-1
Technical Specification
Specification
Item
0.90.15 Kg/cm
850c.c.
420c.c.
Torque Value
For water pump rotor
Tools Requirement
Special tools
Water pump bearing driver (6901)
Water pump oil seal driver (Inner)
Water pump mechanical seal driver
Inner bearing puller
12-2
1.0~1.4kgf-m
The water thermometer and the temperature sensor do not work properly.
The thermostat is stuck to close.
Insufficient coolant.
The water hose and jacket are clogged.
Fan motor malfunction.
The malfunction of the radiator filler cap.
Coolant is leaking
12-3
Drain bolt
By-pass pipe
Caution
12-4
Caution
Radiator
Check
Check for any leakage from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure
water jet to clean it.
Care shall be taken when straightening the sink
fan.
Remove
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Drain bolt
12-5
Engine coolant.
Cooling fun
3 bolts
Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.
Caution
12-6
Thermo switch
Installation
Install in reverse order of removal.
Caution
Always use a new oil ring and apply a coat of
grease on it before installation.
Refill the specified coolant as necessary.
Remove
3:
Pump in high pressure air from the water hole in
order to vent out the water from the pipe.
12-7
5:
Based on the above steps, coolant could be
drained out.
12-8
3:
Fill up the coolant from filler neck (19039)
without interruption.
12-9
5:
Check the air exhausted through the thermostat
cover joint until coolant come out.
6:
Reconnect thermostat tube(19320) to thermostat
cover joint(19315)
7:
Loosen flange bolt ( 8X12) on the water pump
cover(19221) for exhausting air until coolant
come out.
Tighten the flange bolt when finish.
12-10
9:
Maintain the liquid level in reserve tank between
upper and lower limit.
12-11
12-12
Home page
Contents
Mechanism Diagram13-1
Maintenance 13-4
Handle Cover13-5
Meter Panel13-8
Mechanism Diagram
Meter visor
Meter panel
13-1
13
Double seat
Left lower handle cover
13-2
Rear cover
Under cover
Rear fender
13-3
Double seat
Wind screen
Front fender
R/L. grip
Under cover
Meter visor
Meter panel
Air box
Luggage box
Inner box
Rear fender
Maintenance cover
13-4
2 screws
2 screws
Installation
Install in reverse order of removal procedures.
13-5
6 screws
4 screws
13-6
4 bolts
Headlight coupler
Installation
Install in reverse order of removal procedures.
13-7
Meter coupler
Installation
Install in reverse order of removal procedures.
13-8
Reserve tank
Remove
Remove wind screen garnish, wind screen, meter
visor, front cover, meter panel, R/L side cover and
front under spoiler.
Loosen 1 screw from reserve tank stay.
1 screw
1 screw
1 screw
Positive
13-9
Installation
Install in reverse order of removal procedures.
1 bolts
13-10
1 screw
2 screws
Installation
Install in reverse order of removal procedures.
13-11
Installation
Install in reverse order of removal procedures.
13-12
3 screws
Remove
Open the seat.
Loosen 3 screws from the luggage box rear cover.
Disconnect the luggage box light and switch
coupler.
Remove the luggage box rear cover.
2 bolts
4 bolts
3 bolts
Installation
Install in reverse order of removal procedures.
13-13
3 screws
2 screws
Installation
Install in reverse order of removal procedures.
13-14
Remove
Remove wind screen garnish, wind screen, meter
visor, front cover, R/L side cover, front under
spoiler, inner box, luggage box and body cover.
Loosen 4 bolts and 2 screws from floor panel.
Installation
Install in reverse order of removal procedures.
Front Fender
Remove
Loosen 4 screws from front cushion.
Installation
Install in reverse order of removal procedures.
13-15
13-16
Home page
Contents
Troubleshooting 14-3
Mechanism Diagram
14
0.8~1.0 kgf-m
3.0~4.0 kgf-m
Delay valve
3.5~4.5 kgf-m
3.5~4.5 kgf-m
2.4~3.0 kgf-m
14-1
The brake caliper can be removed without removing the hydraulic system.
Air should be bled from the hydraulic system when remove it or the brake system is slack.
While refilling brake fluid, avoid mixing any other substances.
Do not spill brake fluid on the painted surfaces, because plastic or rubber parts might be damaged.
Check the operation of the brake system before riding.
Specifications
unit: mm
Item
Standard
Limit
4.000
2.500
5.000
3.500
< 0.100
0.300
11.000~11.043
11.055
10.957~10.984
10.945
14.000~14.043
14.055
13.957~13.984
13.945
240.000
220.000
5.000
2.000
.1
6.000
2.000
Torque values:
Brake hose bolts
3.0~4.0kgf-m
2.9~3.5kgf-m
0.8~1.0kgf-m
Air-bleed valve
0.8~1.0kgf-m
14-2
Uneven brake
1.
2.
3.
4.
Tight brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or bent brake disk
Dirty lining
Deformed brake disk
Poor brake caliper installation
Imbalance of brake disk or wheel
14-3
Caution
Inclined or just stopped vehicles could not be
measured oil level accurately. For accuracy,
vehicles should stay in still position for 3-to
minutes.
In order to prevent chemical change, please do
not use counterfeiting or other uncertified brake
fluid.
Please use the same brand of brake fluid
consistently for brake efficiency.
14-4
Brake caliper
Brake disk
Caution
Please do not refill the brake fluid over upper
limit. Overflow may result in damages on painted
surface such as rubber or plastic parts.
Caution
Dirty brake lining or disk will reduce the brake
performance.
Mix incompatible brake fluid will reduce brake
performance.
Other substance will block the brake fluid
system, and lead to reduce the brake
performance or lose brake ability completely.
Diaphragm
Upper level
Brake
Fluid
14-5
Air-bleed valve
Delay valve
Air-bleed valve
Caution
Air-bleed valve
Bubble
Air-bleed valve
Caution
Divulges the air to have to pump by the minute
first divulges, then to caliper.
May use fluid the replacement machine, the
replacement fluid, the time is quicker, the air
bubble also Compared with cannot remain
Transparent hose
14-6
Removal
Place a container under the brake caliper, and
loosen the brake hose bolts and finally remove the
brake hoses.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper mounting bolts and the
caliper.
Installation
Caution
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of brake
disk.
Pin clips
14-7
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper mounting bolts and the
caliper.
Installation
Install the brake caliper and tighten the mounting
bolts.
Torque: 2.9~3.5kgf-m
Caution
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of brake
disk.
Use two seal washers and hose bolts to lock the
hoses and brake caliper in place.
Torque: 3.0~4.0kgf-m
Refill the brake fluid to the reservoir and bleed the
air if necessary.
14-8
Socket bolt
Brake disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit:
Front brake disk 2.5 mm
Rear brake disk 3.5 mm
Micrometer
Caution
Master Cylinder
Brake hose
Caution
The whole set of master cylinder, piston, spring,
diaphragm and circlip should be replaced as a
set.
Brake switch
2 bolts
14-9
Cir clip
Rubber
boot
Piston
Piston
cup
Spring
Master cylinder
Master cylinder
Allowable limit:
Front brake: 10.945 mm
Rear brake: 13.945 mm
Piston
Caution
Never install cup lip in the opposite direction.
Make sure the cir clip is seated securely in
the groove.
Install the rubber pad into groove properly.
14-10
Cir clip
Rubber
boot
Piston
cup
Spring
Master cylinder
2 bolts
Washers
Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Brake light
switch
Brake hose
14-11
14-12
Home page
Contents
Troubleshooting 15-2
Mechanism Diagram
2.9~3.5kgf-m
6.0~8.0kgf-m
2.4~3.0kgf-m
6.0~8.0kgf-m
2.4~3.0kgf-m
2.4~3.0kgf-m
5.0~7.0kgf-m
15-1
15
Precautions in Operation
General
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of
the tire.
Torque Values
Nut for the front wheel axle
5.0 ~ 7.0kgf-m
4.0 ~ 5.0kgf-m
1.0 ~ 2.0kgf-m
0.2 ~ 0.3kgf-m
0.15 ~0.3kgf-m
2.4 ~ 3.0kgf-m
4.0~4.5kgf-m
Special Tools
Steering handle top thread wrench
SYM-5320000SYM-5321100
SYM-6204020
SYM-6204010
Driver 32*35mm
Driver 42*47mm
Troubleshooting
Hard to steer
15-2
Master cylinder
Steering Handle
Remove
Remove the right and left handle side cover,
handle upper cover and front cover. (Refer to
chapter 13)
Loosen the lock bolts for the master cylinder of the
front brake.
2 bolts
Holder
Fixing nut
1 screw
2 screws
Throttle cables
15-3
Master cylinder
Holder
2 bolts
Switch connecter
2 screws
Installation
Install handle and align with bolt hole.
Install bolt and nut and then tighten it.
Torque value: 4.0~5.0kgf-m
15-4
Front Wheel
2 screws
Caution
Care shall be taken not to push the brake
lever to avoid the brake pad being squeezed
out. In case that the brake pad is accidentally
squeezed out, use a screwdriver to force it
back to the place.
Axle nut
Speedometer cable
15-5
Inspection
Wheel axle
Place the wheel axle on a V block, measure its
displacement.
Service limit: 0.2 mm
Bearing
Use finger to move the inner ring of each bearing,
it shall move smoothly and quietly. Check the
outer ring is securely attached on the wheel hub.
If the motion of the inner ring of the bearing is not
smooth, or noisy and loose when being moved,
replace with a new one.
Free play
Free play
Caution
The bearing shall be replaced in pair.
Wheel
Place the wheel on to a rotation seat to check its
rim wobbling.
Turn the wheel with hand and measure its rim
wobbling value with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Disassembly
Remove brake disk (5 bolts).
Remove dust seal, bearing and dist collar from left
side.
Remove dust seal and bearing from right side.
Special tools:
Inner bearing puller
SYM-6204020
Inner
bearing puller
15-6
Assembly
Fill out the block of bearing by grease.
Drive the left bearing, dust seal and install the dist
collar.
Install the right side bearing.
Dust seal
Dist collar
Bearing
6201U
Caution
Carefully install the bearing in correct and
evenly.
Bearing outer face should be faced up as
bearing installation.
Dust seal
Bearing 6201U
15-7
Front Cushion
Remove
3 bolts at both
side
15-8
Steering Stem
Remove
Caution
Place the steel ball onto a parts container to
prevent from missing.
Special tools:
Steering stem top thread wrench SYM-5320010
Handle stand nut wrench SYM-5321100
Caution
Do not damage the steering stem.
Installation
Install a new bottom cone race onto the steering
stem.
Push the cone race until to mounted position.
Caution
Do not tilt the ball bearing seats as
installation.
Apply with grease onto the ball bearing seats, and
install steel balls onto the seats. (Top: 26 balls,
bottom: 29 balls)
Steel balls
Bottom cone race
15-9
Caution
Check the steering stem that should be
rotated freely, and no clearance in vertical
direction.
Locking to
1/4~3/8 turn
Top cone-race
15-10
NOTE:
Steering stem adjustment: When the steering stem is too tight.
Steps: please refer to figure 1
1.
Stay front wheel on the ground, and make sure that the component ,,, are connected all
together appropriately.
2.
Lock the component 53220-HMA-00(STRG. HEAD TOP THREAD COMP.) with the torque of
350 50 Kgf-cm.
3.
Turn the steering stem right to left for 5-6 times in order to make the bearing fit in.
4.
Keep the front wheel on the ground, loosen the component 53220-HMA-00 over 1/4 turn, and make
the lock torque to zero.
5.
Start second lock procedure. To begin with the component 53220-HMA-00. Make sure that the lock
torque is between 100~130 Kgf-cm.
Turn the steering stem, and adjust it to appropriate position.
6.
Lock the component 50306-M9Q-00 with the torque of 300~350 Kgf-cm. Please be aware that
component 53220-HMA-00 is not allowed to rotate along with the component 50306-M9Q-00 during
this lock procedure.
7.
15-11
Home page
Contents
Troubleshooting 16-2
Muffler16-3
Mechanism Diagram
3.5~4.5kgf-m
2.8~3.2kgf-m
3.5~4.5kgf-m
11.0~13.0kgf-m
1.0~1.4kgf-m
2.9~3.5kgf-m
16-1
16
Service data
Unit: mm
Item
Standard
Allowable Limit
Radial
2.0
Axial
2.0
Torque Value
Rear wheel axle nut
Rear cushion upper bolt
Rear cushion under bolt
Rear fork mounting bolt
Exhaust muffler mounting nut
Exhaust muffler mounting bolt
Brake clipper mounting bolts
Brake disc mounting bolt
11.0~13.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
4.0~5.0kgf-m
1.0~1.2kgf-m
3.2~3.8kgf-m
2.9~3.5kgf-m
4.0~5.0kgf-m
Troubleshooting
Run-out of rear wheel
Soft Cushion
The spring is too weak.
Noisy Brake
16-2
2 nuts
Installation
Install in reverse order of removal procedures.
Caution
Replace the front side muffler pipe gasket if
worn or deformed.
Torque Value:
Muffler mounting bolt 3.2 ~ 3.8kgf-m
Muffler mounting nut 1.0 ~ 1.2kgf-m
3 bolts
Rear Wheel
Hose clamp
Removal
Remove the exhaust muffler.
Remove the rear brake caliper (2 bolts) and brake
hose clamp (1 bolt).
Caution
Care shall be taken not to push the brake
lever to avoid the brake pad being squeezed
out. In case that the brake pad is accidentally
squeezed out, use a screwdriver to force it
back to the place.
2 bolts
2 bolts
1 bolt
16-3
1 nut
Installation
Install in reverse order of removal procedures.
Torque Value:
Rear wheel axle nut
11.0~13.0kgf-m
Rear cushion under bolt
2.4~3.0kgf-m
Rear fork mounting bolt
4.0~5.0kgf-m
Brake clipper mounting bolts 2.9~3.5kgf-m
16-4
Free play
Free play
Cir clip
Assembly
directs puller
16-5
Cir clip
Outside collar
Bearing
(6303UU)
Inside collar
Rear Cushion
Left
Upper bolt
Removal
Remove the luggage box, rear carrier and body
covers.
Loosen the mounting bolts of the air cleaner (2
bolts).
Remove the exhaust muffler (3 bolts, 2 nuts).
Remove the under bolts by left and right rear
cushions.
Remove the upper bolts by left and right rear
cushions, and then remove the cushion.
Installation
Install in reverse order of removal procedures.
Under bolt
Right
Upper bolt
Caution
The rear cushion must be replaced as a unit.
Never disassemble the rear cushion as that
would damage the structure.
Torque Value
Rear cushion upper bolt: 3.5~4.5kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Under bolt
16-6
Home page
Contents
Precautions in Operation17-2
Meter 17-13
Specification 17-2
Troubleshooting 17-3
Battery 17-4
Fuse 17-5
Ignition System17-9
Mechanism Diagram
Speed sensor
Horn
Headlight lo-beam relay
Rollover sensor
Winker & Hazard
control unit
Headlight hi-beam relay
Thermo switch
(Cooling fan)
Power relay
Key relay
Engine stop relay
Battery
Fuse box
Main switch
Start relay
Passing / Beam / Winker /
Horn / Seat open switch
AISV
Side stand switch
Start / Headlight /
Engine stop switch
Fuel pump / fuel unit
O2 Sensor
Spark plug
Ignition coil
Fuel injector
MAP Sensor
Thermo unit
TW Sensor
ISC
TPS
CPS
TA Sensor
A.C. Generator
ECU
Reg. Rec.
17-1
17
Specification
Charging system
Description
Specification
Capacity
12V10Ah
Charging rate
Battery
Leak current
Below 10mA
Charging current
Ignition system
Description
Model
Specification
NGK CR8E (Recommended)
Spark plug
Gap
Primary winding
Ignition coil and
resistance
0.6~0.7 mm
2.815%
Without cap:9 K 20%
Secondary winding
With cap:14.1 K 20%
80~160
At idle speed
Full advanced
BTDC 30
17-2
Burnt fuse
Poor contact, open or short circuit
Poor regulator rectifier
Poor ACG
17-3
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 12.8V at 20
Warning
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by battery
cables.
Charging
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard
Maximum
Charging current
1.2A
5A
Charging time
10 hr
1 hr
Warning
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by battery
cables.
Caution
Never rapid charge the battery unless in
emergency.
Verify the battery is recharged with current and
duration prescribed above.
Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable terminal
with grease.
17-4
17-5
R
B
G
Y
Y1
Y1
(K)
Y2
Y3
Y/L
5~30
1~10
Y2
Y3
5~30
5~30
5~30
2~20
2~20
2~20
B
Y/L
G
Check Points
1~10
R B
Battery voltage
(ON)
R G
Battery voltage
Charging coil
Y Y
0.2~0.4
5~30
Standard Value
Main switch
connection
Battery
connection
17-6
Red
Black
Green
Yellow
Regulator rectifier
Y1
70~80
0.2~0.4
Y2
70~80
0.2~0.4
Y3
70~80
0.2~0.4
Y1
Y2
Y3
Y1
V
Y2
V
V
Y3
Caution
17-7
Connect a tachometer.
Turn on the headlight to high beam and start the
engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 V/1650 rpm
Caution
Fuse connector
Caution
17-8
17-9
17-10
Ignition coil
Coupler
R
B
G
Y
Red
Black
Green
Yellow
W
L
SB
O
White
Blue
Sky blue
Orange
17-11
17-12
2 bolts
(Ignition)
Fuse 10A
R
O
Main switch
Fuse 20A
SB
Charge
indicator
REG. REC.
Y/L
L/W
Eng. temperature
indicator
Thermo sensor
Battery
W/B
G/L
Y/G
Fuel indicator
Fuel unit
Y/W
BR
Speed sensor
GR/W
O/B
G/P
Meter illumination
R/G
Transistor ignition
Speedometer
Meter coupler
BATT+
11
20
Green
GND.
EFI
Blue /
White
Side
stand
R
B
G
Y
P
BR
Red
Black
Green
Yellow
Pink
Brown
W
L
SB
O
GR
White
Blue
Sky blue
Orange
Gray
10
Tachometer
10
11
20
Green
Green /
Pink
Green
Red /
Green
Yellow
/ White
Gray /
White
Orange
/ black
IGN+
BATT-
SP-
BATT-
RPM
Fuel+
SP+
SP
Blue
Yellow
/ Blue
Brown
Sky
Blue
Orange
White /
Black
Green /
Blue
Hi-beam
Charge
ILLUMI.
Turn-R
Turn-L
Foggy
TEMP.
17-13
Meter coupler
Installation of meter
Install in reverse order of removal procedures
17-14
4 screws
R
B
G
R/W
Position & meter
illumination light
Light switch
Red
Black
Green
Lo-beam relay
BR
Beam switch
W
L
BR
White
Blue
Brown
Lo-beam light
W
G
L/W
Hi-beam relay
Main switch
Hi-beam light
L
Fuse 20A
Passing switch
Hi-beam indicator
B
( fan)
Fuse 20A
Foggy switch
R/L
W/B
Key relay
Foggy right
G
R/L
B/L
Thermo switch
G
Fan
Battery
R
B
G
Red
Black
Green
O
SB
GR
Orange
Sky blue
Gray
R. winker indicator
Main switch
Fuse 20A
O
B
SB
R
G
Winker
switch
GR
Hazard
switch
Battery
Winker &
Hazard control
unit
SB
17-15
Caution
Installation
Install the bulb of the headlight in reverse order of
removal.
Installation
Install the bulb of the headlight in reverse order of
removal.
17-16
2 springs
OFF
ON
Wire Color
Red
Black
Blake
CI
HL
CI
Black
Blue
/White
blot
Headlight switch
Wire Color
Brown Black
Start switch
Right handle switch coupler
ST
FREE
Wire Color
Black
17-17
Wire color
White
HL
Blue /
White
HI
Horn switch
Blue
Left handle switch coupler
Winker switch
Pin
Position
WR
Sky blue
Gray
Orange
FROM R
N PUSH OFF
FROM L
Wire color
Brake Switch
While grasp the brake lever firmly, the terminals of
white/green and green/yellow of the brake should
have continuity.
Replace the switch if damaged.
Horn
Remove the front cover and front under spoiler.
Apply 12 V power source to two terminals of the
horn, the horn should work.
Replace the horn if necessary.
Horn
17-18
Brake switch
Winker switch
Resistance
E (Empty)
90~100
F (Full)
4~8
Needle Position
Up (Full)
F (Full)
Down (Empty)
E (Empty)
Full
Caution
Empty
17-19
17-20
Thermo switch
Thermo switch
Thermometer
Thermo unit
50C
80C
100C
120C
Standard (
) 134~149 47.5~57.0 26~29 14.8~17.2
Caution
17-21
17-22
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Contents
18
18-1
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18-2
Contents