Checking The Timing Chain Tensioner
timing chain tensioner Cracks damage Replace. Rough movement Replace the timing chain tensioner housing. timing chain tensioner rod Damage wear Replace the defective part -s .
A Warning Cen
Securely support the motorcycle so that there is no danger of it falling over. Both wheels should be on the ground without rider on the motorcycle. 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. drive chain slack a Out of specification Adjust. b. Turn both adjusting nuts in direction or until the specified drive chain slack is obtained.
Adjusting The Shift Pedal
The end of the shift pedal is above the shift rod. The angle should be approximately 90o. Incorrect Adjust. b. Turn the shift rod 3 in direction or to obtain the correct shift pedal position. Direction a shift pedal is raised. ADJUSTING THE DRIVE CHAIN SLACK NOTE _ The drive chain slack must be checked at the tightest point on the chain.
General Tightening Torque Specifications
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.
Checking The Fuses Replacing The Headlight Blubs
b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.
A Warning 1
The engine, muffler and engine oil are extremely hot. 5. Measure engine oil pressure at the following conditions Approx. 10,000 r min Engine oil temperature 115 C Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Leaking oil passage Faulty oil filter Oil viscosity too high
Changing The Engine Oil
1. Start the engien, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. engine oil drain bolt 2 along with the gasket 5. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge with an oil filter wrench lt 2. b. Apply a thin coat of engine oil onto the O-ring of the new oil filter cartridge.
Eb205000
Handlebar switch lead left Starting circuit cut-off relay Battery positive lead Seat lock cable AC magneto lead Starter motor lead Air filter drain hose Sidestand switch Neutral switch Oil level switch To front brake switch To battery negative - lead To starter relay AC magneto coupler Pickup coupler Sidestand switch coupler Oil level neutral switch coupler A Use a plastic clamp to fasten the handlebar switch lead left , main switch lead, clutch cable and starter cable to the frame. B Use a...
Lubricating The Drive Chain
The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only ker-osine to clean the drive chain. Wipe the drive...
Measuring The Compression Pressure
The following procedure applies to all of the cylinders. Insufficient compression pressure will result in a loss of performance. 2. Start the engine, warm it up for several minutes, and then turn it off.
Adjusting The Rear Brake
1. Check brake pedal position distance from the top of the rider foot-rest to the top of the brake pedal Out of specification Adjust. Brake pedal position below the top of the rider footrest 36.6 mm Brake pedal position below the top of the rider footrest 36.6 mm b. Turn the adjusting bolt 2 in direction or until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction Brake pedal is lowered.
Caution Uhe
Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD or higher and do not use oils labeled ENERGY CONSERVING II or higher. Do not allow foreign materials to enter the carankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil...
A Warning Gxv
Bleed the hydraulic brake system whenever the system was disassembled, a brake hose was loosened or removed, the brake fluid level is very low, Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the...
Bleeding The Hydraulic Brake System Adjusting The Shift Pedal
2. Bleed hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm brake master cylinder reservoir or brake fluid reservoir . c. Connect a clear plastic hose tightly to the bleed screw 0. d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. This will release the tension and cause the brake lever to contact the throttle...
Caution Iwb
Make sure that the crankcase breather hose is routed correctly. CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. muffler 2 Cracks damage Replace.
Info Tnr
Pass the main switch lead under the throttle cables, headlight lead, handlebar switch lead right and speed sensor lead, then insert it right side of the box. Pass the reservoir tank over flow hose, fuel tank breather hose and fuel tank drain hose through the cable holder. Pass the battery negative - lead inside of the reservoir hose. Throttle cable Handlebar switch lead right Headlight lead Speed sensor lead Carburetor heater hose Reservoir tank hose Fuel pump Fuel filter T.P.S lead Fuel...
Engine
Cylinder Bore size Taper limit Out of round limit Camshaft Drive method Cam cap inside dia. Camshaft out side dia. Camshaft to cap clearance Cam dimensions Intake A B C Chain drive center 23.000 - 23.021 mm 23.967 - 22.980 mm 0.020 - 0.054 mm 32.75 - 32.85 mm 25.0 - 25.1 mm 7.65 - 7.85 mm 32.45 - 32.55 mm 24.95 - 25.05 mm 7.4 - 7.6 mm 32.7 mm 24.95 mm 7.5 mm 32.4 mm 24.9 mm 7.25 mm 0.03 mm Cam chain Cam chain type No. of links Cam chain adjustment method Valve, valve seat, valve guide Valve...
Adjusting The Clutch Cable Free Play
1. Check clutch cable free play Out of specification Adjust. Clutch cable free play at the end of the clutch lever 10 - 15 mm Clutch cable free play at the end of the clutch lever 10 - 15 mm 2. Adjust clutch cable free play b. Turn the adjusting bolt 0 in direction or until the specified clutch cable free play is obtained. Direction a Clutch cable free play is increased. Direction Clutch cable free _play is decreased. If the specified clutch cable free play cannot be obtained on the handlebar...
Info Ecu
a. Turn the crankshaft counterclockwise. b. When piston 1 is at TDC on the compression stroke, align the TDC mark on the generator rotor with the mark on the crankcase. TDC on the compression stroke can be found when the camshaft lobes are turned c. Measure the valve clearance with a thickness gauge . If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder 1 2 4 3 d. For each cylinder,...
Adjusting The Valve Clearance
The following procedure applies to all of the valves. Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center TDC on the compression stroke. Refer to FRONT COWLING SEAT, SIDE COVER AND FUEL TANK in chapter 3 2. Drain the coolant Refer to COOLANT REPLACEMENT in chapter 3 Refer to RADIATOR in chapter 5 5. Measure valve clearance Out of specification Adjust. 0.11 0.20 mm Exhaust...
A Warning Alv
A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly rotate the radiator cap counterclockwise towrd the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap, while still pressing down...
Adjusting The Throttle Cable Free Play
Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly. 1. Check throttle cable free play d Out of specification Adjust. Throttle cable free play at the flange of the throttle grip 3 5 mm Throttle cable free play at the flange of the throttle grip 3 5 mm When the motorcycle is accelerating, throttle cable 1 is pulled and throttle cable 2 lt 2 is pushed. a. Loosen the locknut on throttle cable 2. b. Turn the adjuster or...
Synchronizing The Carburetors
Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE Place the motorcycle on a suitable stand. Vacuum gauge 90890-03094 Engine tachometer 90890-03113 Vacuum gauge 90890-03094 Engine tachometer 90890-03113 4. Start the engine and let it warm up for several minutes. engine idling speed Out of specification Adjust. Refer to ADJUSTING THE ENGINE...
V
Ignition system Ignition timing B.T.D.C. Advanced timing B.T.D.C. Advance type 10 1,250 r min 50 4,500 r min TPS and electrical type T.C.I. Pickup coil resistance T.C.I. unit model manufacturer Ignition coil Model manufacturer Primary winding resistance Secondary winding resistance J0313 DENS0 1.87 2.53 W at 20 C 12 18 kW at 20 C Model manufacturer Standard output Stator coil resistance A.C. magneto F4T359 MITSUBISHI 12 V 18 A at 5,000 r min 0.36 0.44 W at 20 C W-W Model manufacturer No load...
Info Lhg
Bearings and oil seals Pivot shaft bearing Front wheel bearing left Front wheel bearing right Rear wheel bearing left Rear wheel bearing right Rear wheel oil seal right Clutch hub bearing Clutch hub oil seal TA2428Z 24 x 31 x 28 6203LLU 2A 17 x 40 x 12 6204 2RS 20 x 47 x 14 6204 2RS 20 x 47 x 14 SD-28-47-7-1 62062RS 30 x 62 x 16 MHSA-40-62-8-B