General information

A-7

A-6

A-5

INDEX

CYLINDER HEAD …………………………………………………………………………………………F-4 CYLINDER HEAD ……………………………………………………………………………………F-4 CYLINDER HEAD REMOVAL………………………………………………………………………F-5 CYLINDER HEAD INSPECTION …………………………………………………………………F-5 CYLINDER HEAD INSTALLATION ………………………………………………………………F-5 CAMSHAFT AND ROCKER ARMS ……………………………………………………………………F-7 CAMSHAFT AND ROCKER ARMS ………………………………………………………………F-7 CAMSHAFT AND ROCKER ARM SHAFT REMOVAL …………………………………………F-7 CAMSHAFT INSPECTION …………………………………………………………………………F-7 CAMSHAFT AND ROCKER ARM SHAFT INSPECTION ………………………………………F-8

CAMSHAFT AND ROCKER INSTALLATION ……………………………………………………F-8 VALVES AND VALVE SPRINGS …………………………………………………………………………F-9 VALVES AND VALVE SPRINGS …………………………………………………………………F-9 VALVES AND VALVE SPRINGS REMOVAL ……………………………………………………F-9 VALVES AND VALVE SPRINGS INSPECTION …………………………………………………F-9 VALVE SEAT INSPECTION ………………………………………………………………………F-10 VALVE AND VALVE SPRINGS INSTALLATION ………………………………………………F-11 CYLINDER AND PISTON ………………………………………………………………………………F-12 CYLINDER AND PISTON …………………………………………………………………………F-12 PISTON AND PISTON RINGS REMOVAL………………………………………………………F-12 CYLINDER INSPECTION …………………………………………………………………………F-12 PISTON/PIN INSPECTION ………………………………………………………………………F-13 PISTON RINGS INSPECTION ……………………………………………………………………F-13 PISTON RINGS, PISTON AND CYLINDER INSTALLATION …………………………………F-14

V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAF …………………………………………F-15 CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT) ………………………F-15 V BELT, CLUTCH AND SECONDARY/PRIMARY SHEAF ……………………………………F-15

SECONDARY SHEAVE ……………………………………………………………………………F-16 PRIMARY SHEAVE REMOVAL …………………………………………………………………F-16 SECONDARY SHEAVE AND V BELT REMOVAL ……………………………………………F-16 SECONDARY SHEAVE DISASSEMBLY …………………………………………………………G-1 CLUTCH INSPECTION ……………………………………………………………………………G-1 V BELT INSPECTION ………………………………………………………………………………G-1 WEIGHT INSPECTION ……………………………………………………………………………G-1 SECONDARY SHEAVE INSPECTION ……………………………………………………………G-1 PRIMARY SHEAVE ASSEMBLY …………………………………………………………………G-2 SECONDARY SHEAVE INSTALLATION …………………………………………………………G-2

AC MAGNETO AND STARTER CLUTCH ……………………………………………………………G-4 COVER AND STATOR COIL ………………………………………………………………………G-4 STARTER CLUTCH …………………………………………………………………………………G-4 ROTOR REMOVAL …………………………………………………………………………………G-5

ROTOR INSTALLATION ……………………………………………………………………………G-5 STARTER DRIVE GEAR REMOVAL ……………………………………………………………G-5 STARTER DRIVE GEAR INSPECTION …………………………………………………………G-5

OIL PUMP …………………………………………………………………………………………………G-6 OIL PUMP ……………………………………………………………………………………………G-6 OIL PUMP INSPECTION …………………………………………………………………………G-6

TRANSMISSION …………………………………………………………………………………………G-7 TRANSMISSION ……………………………………………………………………………………G-7 CRANKCASE AND CRANKSHAFT ……………………………………………………………………G-7 CRANKCASE AND CRANKSHAFT ………………………………………………………………G-7 CRANKSHAFT REMOVAL …………………………………………………………………………G-8 CRANKSHAFT INSPECTION ……………………………………………………………………G-8 CRANKSHAFT INSTALLATION ……………………………………………………………………G-9

CHAPTER 5 COOLING SYSTEM

RADIATOR …………………………………………………………………………………………………H-2 RADIATOR ……………………………………………………………………………………………H-2 INSPECTION …………………………………………………………………………………………H-2 WATER PUMP ……………………………………………………………………………………………H-3 WATER PUMP ………………………………………………………………………………………H-3 INSPECTION …………………………………………………………………………………………H-4 WATER PUMP INSTALLATION ……………………………………………………………………H-4 THERMOSTAT ……………………………………………………………………………………………H-5 THERMOSTAT ………………………………………………………………………………………H-5 INSPECTION …………………………………………………………………………………………H-5 INSTALLATION ………………………………………………………………………………………H-5

CHAPTER 6 CARBURETION

CARBURETION ……………………………………………………………………………………………I-2 CARBURETION ………………………………………………………………………………………I-2 CARBURETTOR DISASSEMBLY …………………………………………………………………I-2 ASSEMBLY ……………………………………………………………………………………………I-3 FUEL LEVEL ADJUSTMENT ………………………………………………………………………I-4 AUTO CHOKE INSPECTION ………………………………………………………………………I-4 FUEL COCK INSPECTION …………………………………………………………………………I-5

INDEX

INDEX

CHAPTER 7 CHASSIS

FRONT WHEEL AND BRAKE DISC ……………………………………………………………………J-2 FRONT WHEEL AND BRAKE DISC ………………………………………………………………J-2 FRONT WHEEL DISASSEMBLY …………………………………………………………………J-2 INSPECTION …………………………………………………………………………………………J-3 BRAKE DISC INSPECTION ………………………………………………………………………J-3 FRONT WHEEL ASSEMBLY ………………………………………………………………………J-3 FRONT WHEEL INSTALLATION …………………………………………………………………J-4 WHEEL STATIC BALANCE ADJUSTMENT ………………………………………………………J-4 REAR WHEEL AND REAR BRAKE ……………………………………………………………………J-5 REAR WHEEL AND REAR BRAKE ………………………………………………………………J-5 REAR WHEEL INSPECTION ………………………………………………………………………J-6 FRONT BRAKE ……………………………………………………………………………………………J-6 FRONT BRAKE ………………………………………………………………………………………J-6 BRAKE PAD REPLACEMENT ……………………………………………………………………J-7 MASTER CYLINDER ………………………………………………………………………………J-7 MASTER CYLINDER INSPECTION ………………………………………………………………J-8 MASTER CYLINDER INSTALLATION ……………………………………………………………J-8 CALIPER ………………………………………………………………………………………………J-9 CALIPER DISASSEMBLY …………………………………………………………………………J-9 REAR BRAKE ……………………………………………………………………………………………J-10 BRAKE PAD …………………………………………………………………………………………J-10 BRAKE PAD REPLACEMT ………………………………………………………………………J-10 CALIPER ……………………………………………………………………………………………J-11 CALIPER DISASSEMBLY …………………………………………………………………………J-11 CALIPER INSTALLATION …………………………………………………………………………J-12 MASTER CYLINDER ………………………………………………………………………………J-12 MASTER CYLINDER INSPECTION ……………………………………………………………J-13 MASTER CYLINDER INSTALLATION……………………………………………………………J-13 FRONT FORK ……………………………………………………………………………………………J-14 FRONT FORK ………………………………………………………………………………………J-14 FRONT FORK EXTRACTION ……………………………………………………………………J-14 FRONT FORK DISASSEMBLY……………………………………………………………………J-14 FRONT FORK REMOVAL …………………………………………………………………………J-15 FRONT FORK DISASSEMBLY……………………………………………………………………J-15 FRONT FORK INSPECTION ……………………………………………………………………J-15 FRONT FORK ASSEMBLY ………………………………………………………………………J-15 FRONT FORK INSTALLATION ……………………………………………………………………K-1 HANDLEBAR ………………………………………………………………………………………………K-1 HANDLEBAR …………………………………………………………………………………………K-1 HANDLEBAR REMOVAL……………………………………………………………………………K-2 HANDLEBAR INSPECTION ………………………………………………………………………K-2 HANDLEBAR INSTALLATION ……………………………………………………………………K-2

STEERING …………………………………………………………………………………………………K-3 STEERING ……………………………………………………………………………………………K-3 LOWER BRACKET REMOVAL ……………………………………………………………………K-4 LOWER BRACKET INSPECTION …………………………………………………………………K-4 LOWER BRACKET INSTALLATION ………………………………………………………………K-5 REAR SHOCK ABSORBER AND SWING ARM ………………………………………………………K-5 REAR SHOCK ABSORBER AND SWING ARM …………………………………………………K-5

CHAPTER 8 ELECTRICAL

ELECTRICAL COMPONENTS …………………………………………………………………………L-2 WIRING DIAGRAM …………………………………………………………………………………L-2 CHECKING OF CONNECTIONS …………………………………………………………………………L-3 CHECKING SWITCHES ……………………………………………………………………………L-3 CHECKING STEPS …………………………………………………………………………………L-3 SWITCH CONNECTION AS SHOWN IN THIS MANUAL ………………………………………L-3 SWITCH POSITION AND TERMINAL CONNECTION …………………………………………L-4

IGNITION SYSTEM ………………………………………………………………………………………L-4 CIRCUIT DIAGRAM …………………………………………………………………………………L-4 TROUBLESHOOTING ………………………………………………………………………………L-5 CHARGING SYSTEM ……………………………………………………………………………………L-8 CIRCUIT DIAGRAM …………………………………………………………………………………L-8 TROUBLESHOOTING ………………………………………………………………………………L-8 ELECTRIC STARTING SYSTEM ………………………………………………………………………L-10 CIRCUIT DIAGRAM ………………………………………………………………………………L-10 TROUBLESHOOTING ……………………………………………………………………………L-10 STARTER MOTOR ………………………………………………………………………………………L-12 INSPECTION AND REPAIR ………………………………………………………………………L-12 ASSEMBLY …………………………………………………………………………………………L-13 LIGHTING SYSTEM ……………………………………………………………………………………L-13 CIRCUIT DIAGRAM ………………………………………………………………………………L-13 TROUBLESHOOTING ……………………………………………………………………………L-14 LIGHTING SYSTEM CHECK ……………………………………………………………………L-14 SIGNAL SYSTEM ………………………………………………………………………………………L-16 CIRCUIT DIAGRAM ………………………………………………………………………………L-16 TROUBLESHOOTING………………………………………………………………………………M-1 SIGNAL SYSTEM CHECK …………………………………………………………………………M-2 COOLING SYSTEM ………………………………………………………………………………………M-5 CIRCUIT DIAGRAM…………………………………………………………………………………M-5 TROUBLESHOOTING………………………………………………………………………………M-5 COOLING SYSTEM CHECK ………………………………………………………………………M7

INDEX

AUTO CHOKE AND CARBURETTOR HEATER SYSTEM …………………………………………M-8

CIRCUIT DIAGRAM…………………………………………………………………………………M-8 TROUBLESHOOTING………………………………………………………………………………M-9

CHAPTER 9 TROUBLESHOOTING

STARTING FAILURE/HARD STARTING ………………………………………………………………A-2 FUEL SYSTEM ………………………………………………………………………………………A-2 COMPRESSION SYSTEM …………………………………………………………………………A-2 IGNITION SYSTEM …………………………………………………………………………………A-2 POOR IDLE SPEED PERFORMANCE …………………………………………………………………A-2 POOR IDLE SPEED PERFORMANCE……………………………………………………………A-2 POOR MEDIUM AND HIGH SPEED PERFORMANCE ………………………………………………A-3 POOR MEDIUM AND HIGH SPEED PERFORMANCE ………………………………………A-3

POOR SPEED PERFORMANCE ………………………………………………………………………A-3 POOR SPEED PERFORMANCE …………………………………………………………………A-3 FAULT Y CLUTCH …………………………………………………………………………………………A-3 WHEN ENGINE IS RUNNING, SCOOTER DOES NOT MOVE ………………………………A-3

POOR SPEED PERFORMANCE …………………………………………………………………A-3 CLUTCH SLIPPING …………………………………………………………………………………A-3 POOR STARTING PERFORMANCE ……………………………………………………………A-3 OVERHEATING OR OVER COOLING …………………………………………………………………A-4 OVERHEATING ……………………………………………………………………………………A-4 OVERCOOLING ……………………………………………………………………………………A-4 FAULTY BRAKE …………………………………………………………………………………………A-4 POOR BRAKING EFFECT …………………………………………………………………………A-4 FRONT FORK MALFUNCTION ……………………………………………………………………A-4 UNSTABLE HANDLING …………………………………………………………………………………A-5 UNSTABLE HANDLING ……………………………………………………………………………A-5 STARTER MOTOR DOES NOT OPERATE ……………………………………………………………A-5 STARTER MOTOR DOES NOT OPERATE ………………………………………………………A-5 FAULTY SIGNAL AND LIGHTING SYSTEM …………………………………………………………A-5 HEADLIGHT GIVES POOR LIGHT ………………………………………………………………A-5 BULB BURNT OUT …………………………………………………………………………………A-5 FLASHER DOES NOT BLINK ……………………………………………………………………A-5 FLASHER STAYS ON ………………………………………………………………………………A-5 FLASHER BLINKS SLOWER ………………………………………………………………………A-5 FLASHER BLINKS QUICKER ……………………………………………………………………A-5 HORN DOES NOT SOUND ………………………………………………………………………A-5

GEN INFO

Дата добавления: 2014-12-23