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    16 views14 pages

    004

    Uploaded by

    Jose Antonio Lomba

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 14
    Chapter 4 et Fuel and exhaust systems Contents Arfiter cleaning and renewal ..... Arfiter housing - removal and instalation . Anifue mixture aduustment ~ general information Carburetor overhaul ~ general information . Carburetor synchronisation... Garpuretiors~ removal and instaliatix Exhaust system ~ removal and installation Fuel hoses ~ check and renewal Fuel system— check . Fuel tank ~cleaning and repair... eee. Fuel tank and fuel tap = removal and installation nora exometon and precautions Caturtiors—deansembl, deaning eid inepacion 7) lo speed check - Caurttors = rnssombly end loa eight check 8 Subalrcleaner Caburetiors seperation anddning Trott ander ces“ aan se Chaph Crake cabo emovel end instalcton 11 Trot coble-romovaland instalation ss--rsssccernicrs eet Degrees of difficulty Eagy, suitable for Fairty easy, suitable & Difficult, suitable for 3. rove with tle & forbegirner witn << suttablaforcompetent | experianced DY = sthetceonby exmence S| some exerence DYYmechanic mechanic Ro Specifications Note: Where applicable, models are identified by their production code letter = refer to ‘Identificaiton numbers" atthe frat of this manual for dota. Fuel Grade Unleaded, minimum 91 RON esearch Octane Numbe?) Find tk capacty sites Carburetors Troe Keihin VP 34 mm ‘Pot screw setting Cums out). Torque settings {Bbuietor ening nut (upp) CapuretorJoning nut fower Eehaust downpipe nute: EEgaust and slencer mounting bolts . Shocer clamp bok = 10 2 tums out 13,7 mm 1900 rpm (x 100 rpm) 38, 122 4#2 Fuel and exhaust systems 4 General information and precautions General information The fuel system consists of the fuel tank, fuel tap, Fiter, earburettors, fual hoses and ‘control cables The fuel fier Is part of the tap and Is fitted Incido tho fuel tank The carburettors used on al mode's are OV types with one carburettor for each cylinder. For cold starting, a choke laver is mounted on ‘the lett-hand handlebar, and is connected to the carburetiors by a cable. To prevent carburettor icing, coolant Is routed via a small-bors hoae from the union on the back of the eylinder head to the carburettor bodies fang than Back to the cooling systam via a union an the water pump cover. Air |s drawn into the cerburettors through fan alr filter which is housed undar the carburettors. The exhaust system is a two-into-one design Many cf the fuel systom cervice procedures are considered routine maintenance items land for that reason ave included in Chapter 1 Precautions Warning: Petrol (gasoline) is extremely flammable, so take ‘extra precautions whon you work 2.1 On SW, SX and SY models, release the screws holding the fering to the brackets ‘on tho front of the tank ‘and the vacuum hose from the inlet ‘manitole ‘on any part of the fuel system. Don't smoke oF allow open flames or bare light bulbs near the work area, and dom't work in 2 ‘garage where a natural gas-type appliance is present. i you spi! any fuel on your skin, rinse it off immeatately with soap and water. When you perform any kind of work ‘on the fuel system, wear safety glasses and have a fire extinguisher sultable for a class 8B typo fire (ammable liquids) on hand. Always perform service procedures in a wall-ventlated area to prevent a bulld-up of fumes. Nover work in a building containing a ges ‘appliance with a plot light, or any other form fof naked flame Ensure that there are no naked Faht bulbs or eny sources of flame or spatks nearby. Do not smoxe (or allow anyone else to ‘emoke) while in the vicinity of potral (gasoling) oF of components containing It. Remember the possi presence of vapour trom these sources and move wal cear before smoking. Greck ail elecrical equipment batonging to the house, gatage or workshop where work is being undertaken (eee the Safety frst! section. ‘of this menua). Remember that certain electrical apaliances such as drills, cutters fete. create sparks in the normal courso of ‘poration and must not be used near petrol (Gasoline) or any component containing it ‘Again, romomber tho possiblo presence of fumes belore ushig electrical equipment. ‘Always mop up any split fuel and Safely ‘depose ofthe rag used. tank ‘Any stored fuel that is drained off curing servicing work must be kept in sealed Containers that are suitable for holding patra (gasoline), and clear'y marked as such; the containers themselves should be keot ine Safa piace. Note that this last point applies equally 10 the fuel tank if I is removed rom the machine; also remember to keen its filer cap closed et all times. Read the Safely fist section ofthis manual carefully before starting work. ‘2 Fuel tank and fuel tap ~ removal and installation Warning: Refer to the precautions given in Section { before starting work. Fuel tank Removal 1 Moke sure the fue! filer cap is secure and fual tap is in the OFF position. Remove the ‘eat and the trame sido panels; on FT, Vs X and ¥ mocels remove the radiator side ‘panels and on SYV, SK and SY models cetach the lover edge of the fairing from the fue! tank (so Chaco’ 8} (see illustration), 2 Piace a ta under the fue! tap to catch any residual (uel as the hose is cetached. Release the ciip securing the fuel hose to the tap and detect the hose (see llustration). Note: // fs necessary to arain the tank , connect @ Tength of fyo! hose to the tao and place the {ree end of the hase In @ sultable container ‘belew tne fave! oF tha fuel in tne tank. Tum ihe tap to the FES position and draw vacuum the vacuum hase: fuel should few fror the tank. Clamp the vacuum hose until sufciert fuel has bean drawn from tho tank, thon tury the tap OFF end aisconnact the fuel hose 3 Rolease the olp securing the vacuurn hose to the let-hand inlet manifold ane detach te hose (see illustration), 44 Unscraw tha Dolt sacuring the rar of tha tank to the tramp and lift the tank to galt ‘access to the clips securing the drain hoae land breather hose under the ght-hand side Of the tank. Release the clips anc cetach the hhoses (see llustrations), 2b... and detach the drain and breather hoses Fuel and exhaust systems 4+3 25a Remove the tank . 45 Remove the tank (see illustration). Note the postion of the two rubber bushes on the fort and the roar tank mounting breckets and ths two tank mounting rubbers on the frame {0 tub96 (see ilustration).. 6 Inspect the tank mounting bushes and rubbers for signs of damage or deterioration and tenew ther f necoscary (600 illustration). Installation T.Chock that the tank mounting bushes are fitec, then carefully lower the fuel tank into poston 8 Fit the drain hose and breather hose and Isa the hose clips (see ilustration). Ensure the hoses are socuro in thelr guides on the side ofthe air fter housing (see illustration). 8 Install the tank rear mounting bolt and washer and tighten it securely (see stration), 282 Secure the drain and breather hoses ‘othe tank with their clips (arrowed) 25b + +-noling the mounting rubbers (arrowed) on the trame tubes 40 Fit the fuel hose onto fs union on the tap and secure it with the clip (see illustration). 11 Fit the vacuum hoae to the left-hand inlet manifold and secure it with the clip (see IMustration) 42 Turn the fuel tap ON. Start the engine and ‘check that there's no sign of fuel leakage. 1G Install the sont and tne frame sido panois (G00 Cnapter 8). Fuel tap 14 The tap should not be removed from the tank unless the fiker needs cleaning or the ‘O-ring between the tap and tank is leaking. Remove tha tank (see Stops 1 to 6) and refer {to Chapter 1, Section 11 for dotais of these operations. 45 If fuel fow problems are experianced and this is not due to blockage of the filter, the tap ddigphragm could be faulty or the vacuum pipe 2.6 Remove and inspect the tank ‘mounting bushes (arrowed) ‘could be at ‘aul; chack thatthe vacaaam pipe at it connection peints are air tight belore

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