Servicemanual Blade 500-600

SERVICE MANUAL
TAIWAN GOLDEN BEE CO.,LTD.

FORWARD
This service manual contains the technical data of each component inspection
and repairs for the ATV. 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 ATV 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
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for ATV. 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 and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
CONTENT
Page Content Index
1-1 ~ 1-18 GENERAL INFORMATION 1
2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-6 LUBRICATION SYSTEM 3
4-1 ~ 4-12 FUEL SYSTEM 4
5-1 ~ 5-18 ENGINE REMOVAL 5
6-1 ~ 6-16 CYLINDER HEAD/VALVE 6
7-1 ~ 7-8 CYLINDER/PISTON 7
8-1 ~ 8-12 “V” TYPE BELT DRIVING SYSTEM/KICK STARTER 8
9-1 ~ 9-12 DRIVE SYSTEM 9
10-1 ~ 10-10 ALTERNAOTOR/STARTING CLUTCH 10
11-1 ~ 11-20 CRANKSHAFT/CRANKCASE 11
12-1 ~ 12-10 COOLING SYSTEM 12
13-1 ~ 13-10 BODY COVER 13
14-1 ~ 14-12 FRONT BRAKE AND FRONT WHEEL 14
15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15
16-1 ~ 16-14 REAR BRAKE/REAR WHEEL/REAR CUSHION 16
17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17
18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

SERIAL NUMBER
Frame Number
Engine Number
1. GENERAL INFORMATION
Symbols and Marks............................. 1-1 Torque Values ................................... 1-10

General Safety ................................... 1-2 Troubles Diagnosis.......................….. 1-12
Service Precautions ........................... 1-3 Lubrication Points. ............................. 1-17
Specifications ...................................... 1-9
Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service are needed,
in case supplemental information is procedures needed for these symbols and marks, explanations will
be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are
not followed.
Caution Means that equipment damages may result if procedures are not
followed.
Engine oil Limits to use SAE 10W-40 API SG class oil.Warranty will not cover
the damage that caused by not apply with the limited engine oil.
Grease
King Mate G-3 is recommended.
Oil seal
Apply with lubricant.
Renew
Replace with a new part before installation.
Brake fluid
Use recommended brake fluid DOT4 or WELLRUN brake fluid.
Special tools
Special tools
Indication
Indication of components.
Directions
Indicates position and operation directions
1-1
General Safety
Carbon monoxide Battery
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a Caution
closed area. Run your engine in an open area,
‧ Battery emits explosive gases; flame is
if you have to run your engine in a closed area,
strictly prohibited. Keeps the place well
be sure to use an extractor.
ventilated when charging the battery.
‧ Battery contains sulfuric acid (electrolyte)
Caution which can cause serious burns so be
Exhaust contains toxic gas, which may cause careful do not be spray on your eyes or
one to lose consciousness and even result in skin. If you get battery acid on your skin,
death. flush it off immediately with water. If you
get battery acid in your eyes, flush it off
Gasoline immediately with water and then go to
Gasoline is a low ignition point and explosive hospital to see an ophthalmologist.
material. Work in a well-ventilated place, no ‧ If you swallow it by mistake, drink a lot of
flame or spark should be allowed in the work water or milk, and take some laxative such
place or where gasoline is being stored. as castor oil or vegetable oil and then go
to see a doctor.
Caution ‧ Keep electrolyte beyond reach of children.
Gasoline is highly flammable, and may explode Brake shoe
under some conditions, keep it away from Do not use an air hose or a dry brush to clean
children. components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.
Used engine oil
Caution
Caution
Inhaling brake shoe or pad ash may cause
Prolonged contact with used engine oil (or disorders and cancer of the breathing system.
transmission oil) may cause skin cancer
although it might not be verified. Brake fluid
We recommend that you wash your hands with
soap and water right after contacting. Keep the
Caution
used oil beyond reach of children.
Spilling brake fluid on painted, plastic, or rubber
Hot components parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
Caution protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.
1-2
Service Precaution
● Always use with TGB genuine parts and ● Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts for unsmooth control and premature worn out.
TGB ATV may damage the ATV.
● Rubber parts may become deteriorated when

● Special tools are designed for remove and install
old, and prone to be damaged by solvent and
of components without damaging the parts being
oil. Check these parts before installation to
worked on. Using wrong tools may result in parts
make sure that they are in good condition,
damaged.
replace if necessary.
● When loosening a component, which has

different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
● Store complex components such as

transmission parts in the proper assemble
● When servicing this ATV, use only metric
order and tie them together with a wire for
tools. Metric bolts, nuts, and screws are not
ease of installation later.
interchangeable with the English system,
using wrong tools and fasteners may
damage this vehicle.
● Clean the outside of the parts or the cover

before removing it from the ATV. Otherwise,
dirt and deposit accumulated on the part's
surface may fall into the engine, chassis, or
brake system to cause damage.
● Note the reassemble position of the important
● Wash and clean parts with high ignition point components before disassembling them to
solvent, and blow-dry with compressed air. ensure they will be reassembled in correct
Pay special attention to O-rings or oil seals dimensions (depth, distance or position).
because most cleaning agents have an
adverse effect on them. ● Components not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.
1-3
● The length of bolts and screws for ● Remove residues of the old gasket or sealant
assemblies, cover plates or boxes is different before re-installation grind with a grindstone if
from one another, be sure they are correctly the contact surface has any damage.
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.
● The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can
go to their connections so that there is
enough room below the enlarged ends for
tightening the clamps.
Groove
Clamp
● Tighten assemblies with different dimension
fasteners as follows: Tighten all the Connect
fasteners with fingers, then tighten the big or
ones with special tool first diagonally from
inside toward outside, important components
should be tightened 2 to 3 times with ● Rubber and plastic boots should be properly
appropriate increments to avoid warp unless reinstalled to the original correct positions as
otherwise indicated. Bolts and fasteners designed.
should be kept clean and dry. Do not apply
oil to the threads.
Boots
● The tool should be pressed against two (inner

and outer) bearing races when removing a
● When oil seal is installed, fill the groove with ball bearing. Damage may result if the tool is
grease, install the oil seal with the name of pressed against only one race (either inner
the manufacturer facing outside, and check race or outer race). In this case, the bearing
the shaft on which the oil seal is to be should be replaced. To avoid damaging the
installed for smoothness and for burrs that bearing, use equal force on both races.
may damage the oil seal.
Manufacturer's name
Both of these examples can

result in bearing damage.
1-4
● Lubricate the rotation face with specified ● After service completed, make sure all
lubricant on the lubrication points before connection points is secured.
assembling.
Battery positive (+) cable should be connected
firstly.
● And the two posts of battery have to be

greased after connected the cables.
● Check if positions and operation for installed

parts is in correct and properly.
● Make sure that the battery post caps are

located in properly after the battery posts had
● Make sure service safety each other when been serviced.
conducting by two persons.
● Note that do not let parts fall down.

● If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
Capacity
verification
● Before battery removal operation, it has to

remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not
contact with body to prevent from circuit
short and create spark.
● When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
1-5
● Do not pull the wires as removing a ● Insert the terminal completely.
connector or wires. Hold the connector body. Check if the terminal is covered by the boot.
Do not let boot open facing up.
● Make sure if the connector pins are bent,

extruded or loosen.
● Secure wires and wire harnesses to the frame

with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
● Insert the connector completely. If there are

two lockers on two connector sides, make
sure the lockers are locked in properly.
Check if any wire loose.
● Wire band and wire harness have to be

clamped secured properly.
● Check if the connector is covered by the twin

connector boot completely and secured
properly.
● Do not squeeze wires against the weld or its

clamp.
● Before terminal connection, check if the boot is

crack or the terminal is loose.
● Do not let the wire harness contact with ● Protect wires or wire harnesses with electrical
rotating, moving or vibrating components as tape or tube if they contact a sharp edge or
routing the harness. corner. Thoroughly clean the surface where
tape is to be applied.
● Keep wire harnesses far away from the hot

parts. ● Secure the rubber boot firmly as applying it on
wire harness.
Never Touch
● Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of
bolts and screws. ● Never use wires or harnesses which insulation
has been broken. Wrap electrical tape
around the damaged parts or replace them.
● Route harnesses so that they neither pull too

tight nor have excessive slack. ● Never clamp or squeeze the wire harness as
installing other components.
Never clamp or squeeze the

wire harness
Never too tight
1-7
● Do not let the wire harness been twisted as ● With sand paper to clean rust on connector
installation. pins/terminals if found and then conduct
connection operation later.
Clean rust
● Wire harnesses routed along the handlebar

should not be pulled too tight or have
excessive slack, be rubbed against or
interfere with adjacent or surrounding parts in
all steering positions.
● Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set

the instrument to its
measurement position and
the insert locations of its
two probes?
1-8
Specifications
500 cc
FBH FLH
Overall Length 2120 2365 [mm]
Overall Width 1240 1230 [mm]
Overall Height 1502 1460 [mm]
Wheel Base 1290 1450 [mm]
Front 236 247 [kg]
Mass of vehicle in running
Rear 201 201 [kg]
order (without driver)
Total 437 448 [kg]
Type 4-Stroke Engine
Installation and arrangement Vertical, below center, incline
Fuel Used Above 92 unleaded
Cycle/Cooling 4-stroke/Water cooled
Bore 92 [mm]
Cylinde
Stroke 75.6 [mm]

r
Number/ Arrangement Single Cylinder

Displacement 503 [㏄]
Compression Ratio 9.1/- 0.5
Max. HP 14.8 (7000) [kw/rpm]
Max. Torque 33.3 (5000) [Nm/rpm]
Ignition ECU
Starting System Electrical starter
Air filtration Sponge
Front Double A-Arm
Suspension System
Rear Double A-Arm
Front 25X8-12, 26X8-14, 26X9-14
Tire Specifications
Rear 25X8-12, 26X10-14, 26X11-14
Rim Aluminum / Steel
Brake Front Disk (Ø 190) [mm]
System Rear Disk (Ø 200) [mm]
Max. Speed 55 / 90 km/hr
Performance
Climb Ability ＜25 ﾟ
Primary Reduction Belt
Secondary
Gear / Sprocket
Reduction Reduction
Clutch Centrifugal, dry type
Transmission C.V.T., auto speed change
Speedometer 0 ~ 300 [km/hr]
Horn 93 ~ 112 [dB/A]
Fuel capacity 18 +/- 0.3 [l]
Lubrication System Forced circulation & splashing
Engine oil SAE 10 W/ 40
Engine oil
Capacity 1.2 [l]
Front Spec. SAE 85W-90
Gear
Differential Capacity 350 [ml]
lubrication
Rear Gear Spec. SAE 85W-90
1-9
Capacity 500 [ml]
Spark Plug NGK DCR8E
Battery 12/18 V/AH
Front Lamps 55×2
[W]
(HI/LO) 55×2
Lamps Rear Lamps 5×1 [W]
Brake Lamps 21×1 [W]
Turn Lamps 10×4 [W]
1-10
600cc
FBH VSH FLH
Overall Length 2120 1950 2365 [mm]
Overall Width 1240 1240 1230 [mm]
Overall Height 1502 1412 1460 [mm]
Wheel Base 1290 1290 1450 [mm]
Front 236 212 247 [kg]
Mass of vehicle in running
order (without driver) Rear 201 214 201 [kg]
Total 437 426 448 [kg]
Type 4-Stroke Engine
Installation and arrangement Vertical, below center, incline
Fuel Used Above 92 unleaded
Cycle/Cooling 4-stroke/Water cooled
Bore 95 [mm]
Cylinde
Stroke 79.2 [mm]

r
Number/ Arrangement Single Cylinder

Displacement 561 [㏄]
Compression Ratio 10.2+/- 0.5
Max. HP 16 (6000) / 28.3 (6500) [kw/rpm]
Max. Torque 33.4 (4000) / 43.1 (5500) [Nm/rpm]
Ignition ECU
Starting System Electrical starter
Air filtration Sponge
Front Double A-Arm
Suspension System
Rear Double A-Arm
25X8-12 25X8-12
Front 26X8-14 25X8-12 26X8-14
26X9-14 26X9-14
Tire Specifications
25X8-12 25X8-12
Rear 26X10-14 25X10-12 26X10-14
26X11-14 26X11-14
Rim Aluminum / Steel
Brake Front Disk (Ø 190) [mm]
System Rear Disk (Ø 200) [mm]
Max. Speed 55 / 90 km/hr
Performance
Climb Ability ＜25 ﾟ
Primary Reduction Belt
Secondary
Gear / Sprocket
Reduction Reduction
Clutch Centrifugal, dry type
Transmission C.V.T., auto speed change
Speedometer 0 ~ 300 [km/hr]
Horn 93 ~ 112 [dB/A]
Fuel capacity 18 +/- 0.3 15 +/- 0.3 18 +/- 0.3 [l]
Lubrication System Forced circulation & splashing
Engine oil Engine oil SAE 10 W/ 40
1-11
Capacity 1.2 [l]
Front Spec. SAE 85W-90
Gear Differential Capacity 350 [ml]
lubrication Spec. SAE 85W-90
Rear Gear
Capacity 500 [ml]
Spark Plug NGK DCR8E
Battery 12/18 V/AH
Front Lamps 55×2
[W]
(HI/LO) 55×2
Lamps Rear Lamps 5×1 [W]
Brake Lamps 21×1 [W]
Turn Lamps 10×4 [W]
1-12
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see
standard values for not listed in the table.
Standard Torque Values for Reference

Type Tighten Type Tighten
5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
6 mm bolt、nut 0.8~1.2kgf-m 6 mm screw、SH nut 0.7~ 1.1kgf-m
8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m
10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m
5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m
12 mm bolt、nut
Engine Torque Values

Thread Dia. Torque Values
Item Q’ty Remarks
(mm) (kgf-m)
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 8 3.6~4.0
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head side cover bolt 2 6 1.0~1.4
Cylinder head cover bolt 4 6 1.0~1.4
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Tensioner lifter bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 3 0.1~0.3
Water pump impeller 1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 1.1~1.5
Mission filling bolt 1 12 3.5~4.5
Shift drum fixing bolt 1 14 3.5~4.5
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 18 16~18
Drive face nut 1 16 11.5~12
ACG. Flywheel nut 1 18 16~18
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
1-13
Frame Torque Values
Thread Dia. Torque Values

Item Q’ty Remarks
(mm) (kgf-m)
Handlebar upper holder bolt 4 6 2.40
Steering shaft nut 1 10 5.00
Steering tie-rod nut 4 10 5.00
Knuckle nut 2 10 5.00
Steering shaft holder bolt 2 8 3.40
Tie rod lock nut 4 10 3.60
Handlebar under holder nut 2 8 4.00
Front wheel nut 8 10 2.40
Front axle castle nut 2 14 5.00
Rear axle castle nut 2 14 5.00
Rear wheel nut 8 10 2.40
Engine hanger nut 4 12 8.50
Rear axle holder bolt 4 12 9.20
Drive gear bolt 2 10 4.60
Driven gear nut 4 10 4.60
Swing arm pivot bolt 1 14 9.20
Front suspension arm nut 4 10 5.00
Front / Rear cushion mounting bolt 6 10 4.60
Brake lever nut 2 6 1.00
Brake hose bolt 13 10 3.50
Brake caliper bolt 6 6 3.25
Brake disk mounting bolt 11 8 4.25
Air-bleed valve 3 5 0.50
Exhaust muffler mounting bolt 2 8 3.00
Exhaust muffler connection nut 2 7 1.20
Troubles Diagnosis
1-14
A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to

check if there is gasoline inside
the carburetor ● No fuel in fuel tank
● Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
● Float valve clogged
Fuel supplied tom No fuel is supplied to ● Lines in fuel tank evaporation
carburetor sufficient carburetor system clogged
● Malfunction of fuel pump
● Loosen or damaged fuel pump
Remove spark plug, install it into vacuum hose
spark plug cap, and perform a ● Fuel filter clogged
spark test against engine
ground.
● Malfunction of spark plug
● Spark plug foul
Check if sparks Weak sparks, no spark ● Malfunction of Ignition Coil set
at all
● Malfunction of AC generator
● Ignition coil is in open or short circuit
Perform cylinder compression ● Ignition coil leads open or short circuit
pressure test. ● Malfunction of main switch
Cylinder compression Low compression

pressure normal pressure or no pressure ● Piston ring seized
● Malfunction of cylinder valves
● Worn cylinder and piston ring
● Cylinder gasket leak
Re-start by following the ● Sand hole in compression parts
starting procedures
● Malfunction of throttle valve operation

No ignition There are some signs of ● Air sucked into intake manifold
ignition; nut engine can ● Incorrect ignition timing
not be started
Remove the spark plug again

and check it.
● Fuel level in carburetor too high

Dry spark plug Wet spark plug ● Malfunction of throttle valve operation
● Throttle valve opening too wide
Remove carburetor after 30

minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Blowing in normal Blowing clogged ● Malfunction of automatic by- starter
1-15
B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration and

check engine speed
● Air cleaner clogged

● Poor fuel supply
Engine speed can be
increased.
Engine speed can not be ● Lines in fuel tank evaporation system
increased. clogged
● Exhaust pipe clogged
● Fuel nozzle clogged in carburetor.
Check ignition timing (Using ● Fuel nozzle clogged in carburetor.
ignition lamp)
Ignition timing correct Incorrect ignition timing

●Malfunction of Ignition Coil
●Malfunction of AC alternator
Check cylinder compression

pressure (using compression
pressure gauge)
Compression pressure No compression ● Cylinder & piston ring worn out

correct pressure
● Cylinder gasket leaked
● Sand hole in compression parts
Check if carburetor jet is ●Valve deterioration
clogged ● Seized piston ring
No clogged Clogged ● Remove foreign
Remove spark plug
No foul or discoloration Fouled and discoloration ●Remove dirt

●Incorrect spark plug heat range
● Piston and cylinder worn out
●Lean mixture
Check if engine over heat ● Poor fuel quality
● Too much carbon deposited
Normal Engine overheat in combustion chamber
● Ignition timing too advanced
● Poor circuit on the cooling system
Continually drive in
acceleration or high speed
● Too much carbon deposited in
combustion chamber
● Lean mixture
No knock Knock ● Poor fuel quality
C. Engine runs sluggish (especially in low speed and idling)
1-16
Check ignition timing (using

ignition lamp)
Normal Abnormal ● Incorrect ignition timing (malfunction

of Ignition Coil or AC alternator)
Adjust the airscrew of

carburetor
● Rich mixture (loosen the screw)

Good Poor
● Lean mixture (tighten the screw)
Air sucked through carburetor

gasket ● Poor heat insulation gasket
● Carburetor lock loose
No air sucked Air sucked ● Poor intake gasket
● Poor carburetor O-ring
● Vacuum hose crack
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
● Spark plug fouled
engine ground
● Malfunction of Ignition coil
● Malfunction of AC generator
Good spark Poor ● Malfunction of ignition coil
● Open or short circuit in spark plug
leads
● Malfunction of main switch
D. Engine runs sluggish (High speed)
Check ignition timing
Normal Abnormal ● Malfunction of CDI

● Malfunction of AC alternator
Check for fuel supplying

system in automatic fuel cup
● Insufficient fuel in fuel tank

Good Abnormal ● Fuel filter clogged
● Restricted fuel tank vent
Check if carburetor clogged
No clogged Clogged ●Cleaning
1-17
E. Clutch, driving and driving pulley
FAULT CONDITIONS PROBABLE CAUSES
● Drive belt worn out or deformation

● Ramp plate of movable drive face damaged
Engine can be started but motorcycle
● Driving pulley spring broken
cannot be moved.
● Clutch weights broken
● Drive slide-shaft gear groove broken
● Transmission gear damaged
Engine running and misfire as ● Clutch weights spring broken

motorcycle initial forward moving or ● Clutch outer stuck with clutch weights
jumping suddenly (rear wheel rotating ● Connection parts in clutch and shaft worn out or burned
as engine in running)
● Drive belt worn out or deformation

● Weight roller worn out
Poor initial driving (Poor climbing
performance) ● Movable drive face shaft worn out
● Driven pulley spring deformation
● Driven pulley shaft worn out
● Greased in drive belt and driven face.
F. Poor handling
FAULT CONDITIONS PROBABLE CAUSES
Steering is heavy ● Damaged steering bearing

● Damaged steering shaft bushing
● Bent rim
● Improperly installed wheel hub
One wheel is wobbling ●Excessive wheel bearing play
● Bent swing arm
● Bent frame
● Swing arm pivot bushing excessively
● Worn
● Bent tie-rod
● Incorrect tie-rod adjustment
Vehicle pulls to one side
● Rear tie air pressure incorrect
● Improper wheel alignment
● Bent frame
G. Loss power
1-18
Raise wheels off ground and

spin by hand
● Brake dragging
Spin freely Abnormal ● Drive chain too tight
● Damaged wheel bearing
● Wheel bearing needs lubrication
Check tire pressure
Normal Abnormal ● Punctured tire

● Faulty tire valve
Accelerate lightly, engine

speed can be increase ● Fuel / air mixture ratio too rich or lean
● Clogged in air cleaner
Normal Abnormal ● Clogged in muffler
● Restricted fuel flow
● Clogged fuel tank cap breather hole
Check ignition timing
Normal Abnormal ● Faulty pulse generator

● Faulty Ignition coil
Test cylinder compression
Normal Abnormal ● Leaking head gasket

● Worn cylinder and piston rings
Check carburetor
Normal Clogged ● Clean
Check spark plug
Normal Fouled or discolored ● Clean the spark plug

● Spark plug is incorrect heat range
Check for engine overheating

● Excessive carbon deposited in
combustion chamber
Normal Overheating ● Wrong type of fuel
● Fuel / air mixture ratio is lean
● Use of poor quality fuel
Accelerate or run at high speed
● worn piston and cylinder
● Fuel / air mixture ratio is lean
Normal Knocks ● Wrong type of fuel
● Excessive carbon deposited in
combustion chamber
1-19
Oil and Lubrication Points
Brake Fluid
Grease
1-20
Gear Oil
1-21
2. MAINTENANCE INFORMATION
Precautions in Operation ······················ 2-1 Brake System (Disk Brake) ················· 2-8
Periodical Maintenance Schedule ·········2-2 Brake Light Switch/Starting Inhibitor
Fuel Lines ············································· 2-3 Switch ·················································· 2-9
Acceleration Operation ························· 2-3 Headlight Beam Distance ···················· 2-10
Air Cleaner············································ 2-3 Clutch Disc Wear ································· 2-10
Spark Plug ············································ 2-3 Cushion················································· 2-10
Valve Clearance ··································· 2-4 Steering Handle···································· 2-11
Carburetor Idle Speed Adjustment········ 2-5 Wheel/Tire············································· 2-11
Ignition System ······································2-6 Nuts, Bolts Tightness ··························· 2-11
Cylinder Compression Pressure ·········· 2-6 Special Tools List ································· 2-12
Drive Belt ·············································2-7
Precautions in Operation
Specification
Model 500 cc 600 cc
Fuel Tank Capacity 18000 c.c.
With Oil Radiator 3850 c.c.
Capacity
Blade Without Oil radiator 3500 c.c.
Model Oil & Filter Change 3300 c.c..
Oil change 3000 c.c.
Engine Oil
Capacity With Oil Radiator 3800 c.c.
Target Without Oil radiator 3500 c.c
Model Oil & Filter Change 3300 c.c.
Oil change 3000 c.c
Front Capacity 350 c.c.
Differential Change 350 c.c.
Transmission Gear oil
Rear Capacity 500 c.c.
Differential Change 500 c.c.
Engine + Radiator 2200 c.c.
Capacity of coolant
Reservoir upper 1200 c.c.
Clearance of throttle valve 1~3 mm
Type NGK DCR7E NGK DCR8E
Spark Plug
Gap 0.7~0.8 mm
Idling speed 1500±100 rpm
Cylinder compression pressure 9.2 kgf/cm² 10.2 kgf/cm²
Front 25X8-12, 26X8-14, 26X9-14
Tire dimension
Rear 25X8-12, 26X10-14, 26X11-14
Tire pressure (cold) 7 psi
Battery 12V18Ah (type : MF battery)
2-1
Periodical Maintenance Schedule
MONTHS 1 3 6 12
INTERVAL
ITEM Kms INITIAL 200 EVERY 1000 EVERY 2000 EVERY 4000
MILES INITIAL 120 EVERY 600 EVERY 1200 EVERY 2400

Muffler Bolts and Exhaust Pipe Nuts T T T T
Valve Clearance I - I I
Air Cleaner - C C R
Engine Idle RPM I I I I
- - I I
Spark Plus
Replace Every 6000KM (4000 MILES)
Engine Oil R - R R
Oil Filter R - R R
R - R R
Front Differential Set Oil
Replace Every 6000KM or Every 6 Months
R - R R
Final Gear Oil
Replace Every 6000KM or Every 6 Months
C.V.T Belt - - I I
- I I I
Fuel Tube
Replace Every 4 Years
Throttle Cable Play I I I I
Brakes I I I I
- - I I
Brake Hose
- I I I
Brake Fluid
Tires - I I I
Suspensions - - I I
Steering System I I I I
Chassis Bolts and Nuts T T T T
General Lubrications - L L L
Grease nipple (TOOL 552304)
- - R R
(Universal Joint Assy)
Code: C ~ Cleaning (replaced if necessary) I ~ Inspection, cleaning, and adjustment

L ~ Lubrication R ~ Replacement T ~ Tighten
Have your ATV checked, adjusted, and recorded maintenance data periodically by your TGB
Authorized Dealer to maintain the ATV at the optimum condition.
The above maintenance schedule is established by taking the monthly 1000 kilometers as a
reference which ever comes first.
Remarks:
1. Clean or replace the air cleaner element more often when the ATV is operated on dusty
roads or in the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high
speed and after the ATV has accumulated a higher mileage.
3. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition,
misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads,
exhaust system when power is obviously lower than normal.
2-2
Fuel Lines
Remove the seat .Loosen 2 screws and 2 bolts.
Remove the tank cover.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind
of fire is strictly prohibited as dealing it.
Acceleration Operation
Have a wide open of throttle valve as handle in
any position and release it to let back original
(full closed) position.
Check handle 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 the throttle lever free play in its flange
part.
Remove rubber boot, loosen fixing nut, and
then adjust it by turning the adjustment screw.
Tighten the fixing nut, and check acceleration
operation condition.
Free play: 1~3 mm.
Air Cleaner
Remove seat.
loosen 4 hooks from the air cleaner cover
and then remove the cover.
Loosen the clamp strip and 1 screw of air
cleaner element, and then remove the air
cleaner element. Clean the element with
non-flammable or
high-flash point solvent and then squeeze it
for dry.
Caution
Never use gasoline or acid organized solvent
to clean the element.
Soap the element into cleaning engine oil and
then squeeze it out. Install the element onto
the element seat and then install the air cleaner
cover.
Spark Plug
Recommended spark plug:
CR7E Remove spark plug
cap.
Clean dirt around the spark plug hole. Remove
spark plug.
Measure spark plug gap.
Spark plug gap：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
2-3
Valve Clearance
Caution
Checks and adjustment must be performed
when the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel
tank. Remove cylinder head cover.
Turn camshaft bolt in C.W. direction and let the
“T” mark on the camshaft sprocket align 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.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut
for adjustment.
Caution
Re-check the valve clearance after tightened
the fixing nut.
2-4
Carburetor Idle Speed Adjustment

Caution
● Inspection & adjustment for idle speed have
to be performed after all parts in engine that
needed adjustment have been adjusted.
● Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV with onto neutral and warm up
engine.
Connect tachometer (the wire clamp of
tachometer is connected to the high tension
cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1700 ± 100 rpm
Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and
let engine runs in 1700±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust
pipe. Adjust the air adjustment screw so that
emission value in idle speed is within
standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for
2~3 times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm
2-5
Ignition System
Caution
● C.D.I ignition system is set by manufacturer
so it cannot be adjusted.
● Ignition timing check procedure is for
checking whether CDI function is in normal or
not.
Connect tachometer and ignition light.
Start engine.
As engine in idle speed: 1600 rpm, aim at the
mark “F” with the ignition light. Then, it is means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located
within the ignition advance degrees, it is means
that the ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set,
pulse rotor and pulse generator. Replace it if
malfunction of these parts is found.
Cylinder Compression Pressure

Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the 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: 9.2 ± 2 Kg/cm²

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.
2-6
Drive Belt
Loosen the 2 clamp strips of clutch cover, and
then remove the clutch cover vapor hose.
Remove 14 bolts of the clutch 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: 26.8 mm or above
2-7
Brake System (Disk Brake)

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
contents inside the brake system hoses.
Air Bleed Operation

Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding
valve. Perform this operation alternative until
there is no air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not
release the brake lever.
Added Brake Fluid

Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4
WELL RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent
from damage brake system or reducing brake
performance.
2-8
Brake Lining Wear

The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.
Caution
● To check front brake lining must be remove
front wheel first.
● It is not necessary to remove brake hose
when replacing the brake lining.
Brake Lining Replacement (refer chapter

14)
Make sure the brake lining condition. Replace
the lining if the brake lining wear limitation
groove close to the brake disc.
Caution
● Do not operate the brake lever after the
clipper removed to avoid clipping the brake
lining.
● In order to maintain brake power balance, the
brake lining must be replaced with one set.
Brake Light Switch/Starting

Inhibitor Switch
The brake light switch is to light up brake light as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.
2-9
Headlight Beam Distance

Turn on main switch.
Headlight beam adjustment.
Turn the headlight adjustment screw to adjust
headlight beam high.
Caution
●To adjust the headlight beam follows related
regulations.
● Improper headlight beam adjustment will
make in coming driver dazzled or insufficient
lighting.
Clutch Shoe Wear

Run the ATV and increase throttle valve opening
gradually to check clutch operation.
If the ATV is in forward moving and shaking,
check clutch disc condition. Replace it
Cushion
Warning
●Do not ride the ATV 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 damage
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
Press down the rear cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
2-10
Steering Handle
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
check the handle top bearing.
Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.
Check if tire surface is ticked with nails, stones

or other materials.
Appointed tire pressure

Tire size Front Tire Rear Tire
Tire pressure as cold 7 psi 7 psi
Check if front and rear tires’ pressure is in

normal. Measure tire thread depth from tire
central surface. Replace the tire if the depth is
not come with following specification:
Front tire: 1.5 mm
Rear tire: 2.0 mm
Nuts, Bolts Tightness

Perform periodical maintenance in accord with
the Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamp,
and wire holders for security.
2-11
Special Tools List
PARTS NO. : 440649 PARTS NO. : 440650

PARTS NAME : EXTENSION PULLER / REMOVER PARTS NAME : BUSHING(924739) REMOVER
PARTS NO. : 440651 PARTS NO. : 440652

PARTS NAME : BEARING(924384) REMOVER φ15 PARTS NAME : BEARING(924384) REMOVER
φ20
PARTS NO. : 440653 PARTS NO. : 440654

PARTS NAME : BEARING(924384) REMOVER φ45 PARTS NAME : BUSHING(924739)
REMOVER
PARTS NO. : 440655 PARTS NO. : 440656

PARTS NAME : R CRANK CASE OIL SEAL (924168) PARTS NAME : L CRANK CASE OIL SEAL
INSTALLER REMOVER
2-12
PARTS NO. : 440657 PARTS NO. : 440658

PARTS NAME : CRANK SHAFT HOLDER PARTS NAME : STARTER (924136)
HOLDER
PARTS NO. : 440659 PARTS NO. : 440660

PARTS NAME : FLYWHEEL REMOVER PARTS NAME : CHAIN WHEEL(925094)
& WASHER(924718)INSTALLER
PARTS NO. : 440661 PARTS NO. : 440662

PARTS NAME : PISTON & ROD PARTS NAME : CYLINDER HEAD
CONNECTING HOLDER VALVE GAP ADJUSTER
PARTS NO. : 440663 PARTS NO. : 440664

PARTS NAME : GEAR SHAFT (924253) PARTS NAME : FLYWHEEL PULLER
INSTALLER
2-13
PARTS NO. : 440665 PARTS NO. : 440666

PARTS NAME : IDLER GEAR (924187) PARTS NAME : CLUTCH AND CVT
PULLER HOLDER
PARTS NO. : 440667 PARTS NO. : 440668

PARTS NAME : CYLINDER HEAD VALVE PARTS NAME : UNIVERSAL JOINT
AND SPRING INSTALLER/REMOVER HEAD (924646)
INSTALLER
PARTS NO. : 440669 PARTS NO. : 440670

PARTS NAME : CHAIN WHEEL (925094) & PARTS NAME : ENGINE OIL FILTER
WASHER (924718) REMOVER (924153) INSTALLER / REMOVER
PARTS NO. : 440671 PARTS NO. : 924941

PARTS NAME : WET CLUTCH SCREW NUT PARTS NAME : MAINTENANCE TOOL
FIXER PACKAGE
2-14
PARTS NO. : 552302 PARTS NO. : 552301

PARTS NAME : FINAL DRIVE NUT (N33701) PARTS NAME : OIL SEAL INSTALLER
INSTALLER/REMOVER
2-15
Note :
2-16
3.LUBRICATION SYSTEM
Engine
Mechanism Diagram ······························
Oil ··············································· 3-3
3-1
Engine Oil Strainer Clean ······················
Precautions in Operation ······················
3-3
3-2
Oil
Troubleshooting ····································
Pump ·················································
3-2
3-4
Mechanism Diagram
3-1
General Information
This chapter contains maintenance operation
for the engine oil pump and gear oil replacement.
Specifications
Engine oil quantity
Overhaul:
Blade Model: with oil radiator: 3850 c.c.
without radiator: 3500 c.c.
Target Model: with oil radiator: 3800 c.c.
without radiator: 3500 c.c.
Filter change: 3300 c.c.

Change: 3000 c.c.
Oil viscosity SAE 10W-40
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Oil pump Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil filter 1.2 kgf-m
Engine oil drain bolt 2.3 kgf-m
Troubleshooting
Low engine oil level

● Oil leaking
● Valve guide or seat worn out
● Piston ring worn out
Low oil pressure

● Low engine oil level Dirty oil
● Clogged in oil strainer, circuits or pipes ● No oil change in periodical
● Oil pump damage ● Cylinder head gasket damage
● Piston ring worn out
3-2
Engine Oil
 Turn off engine, and park the ATV in flat
surface
 Turning the dipstick counter clockwise and
release.
 Wipe dipstick clean.
 Reinstall dipstick into crankcase. Turn dipstick
clockwise to the end and remove dipstick again
to check oil level on dipstick.
 If oil level is at or below lower mark, add only
enough oil to bring the level to a point
between the two arrows on the dipstick.
Caution
4screws
 Do not overfill oil. Doing so can affect the
engine performance or malfunction.
 Always check the oil level after refill or
change.
Caution
Drain oil as engine warmed up so that makes
sure oil can be drained smoothly and
completely.
Drain bolt
Place an oil pan under the ATV, and remove oil
drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
O-ring
Torque value：2.3 kgf-m
Engine Oil Strainer Clean
Drain engine oil out.
Remove oil strainer cap.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer cap.
Torque value：1.0~1.2 kgf-m
Engine oil capacity: 3000c.c. when replacing
Replace The Oil Filter
3-3
Same as oil change, drain the oil out.
Remove the oil filter by special tool.
Apply engine oil lightly to the gasket of the new
oil filter when installation.
Torque value：1.2 kgf-m
Oil and filter change:3300c.c. when replacing
Install dipstick, start the engine for running

several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Oil Pump
Oil Pump Removal One way clutch
Remove the one way clutch.
Remove the clutch shoe.
Remove the snap ring.
Remove the washer.
Remove the oil pump driver gear.
Caution
The clutch shoe nut has left-hand threads.
Remove the snap ring.

Remove the washer.
Remove the oil pump driver gear.
Snap
Remove the pin.
Remove the washer. ring
Make sure that pump shaft can be rotated freely.

Remove 3 screws on the oil pump, and then
remove oil pump. 3 screws
Pin
3-4
Oil Pump Disassembly
Remove the screws on oil pump cover and 1 screw
remove the cover.
Remove oil pump shaft roller and shaft.
Oil Pump Inspection

Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer rotors.

Limit: 0.20 mm
Check clearance between rotor side face and

pump body
Limit: 0.12 mm
3-5
Oil Pump Re-assembly
Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner
rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.
Tighten the oil pump screw.
Oil Pump Installation

Install the oil pump, and then tighten 3 screws.
Torque value：1.0kgf-m
Make sure that oil pump shaft can be rotated
freely.
Install the washer.

Install the pin.
Install the oil driven gear.
Install the washer.
Install the snap ring.
3-6
4-1. FUEL INJECTION SYSTEM
EFI system components inspection……..13
Fuel Injection System Components………..1
Fuel line inspection……………………..…26
Precautions in servicing……………………..2
Fuel flow inspection……………………….27
General………………………………………..2
Fuel pump………………………………..…28
Fuel system………………………..…………2
Fuel pump relay……………………………29
Connector/coupler……………….…….…….3
Sensor circuit malfunction
Fuse……………………………….…….…….3
troubleshooting…………………..…………31
ECU/various sensors…………………..……3
Fault diagnosis………………………..……54
Electrical circuit inspection procedure. ……4
Integrated fault diagnosis program. …..…57
Parts location………………………………...8
Fault diagnosis note………………….……58
Wiring diagram…………………………..…..9
Use diagnosis tool..……………………..…60
ECU terminal…………………………..……10
Troubleshooting table…………………...…68
Customer complaint analysis…………..….11
Comprehensive maintenance list…………69
Fuel Injection System Components
Throttle Body Idle Speed Controller
ECU
Temperature Manifold Air

Pressure
Throttle Position Sensor
Fuel Pump
Injector
Ignition Coil Engine Coolant

Temperature Sensor
Roll Over Switch
Crank Position Sensor
4-1-1
PRECAUTIONS IN SERVICING
When handling the Fuel Injection component parts or servicing the Fuel Injection system,
observe the following points for the safety of the system.
GENERAL
Be sure to relieve the fuel pressure while the engine is OFF.
Bending or twisting the control cables will impair smooth operation and could cause the cables
to stick or bind, resulting in loss of vehicle control.
Work in a well-ventilated area. Smoking or allowing flames or sparks in the work area or where
gasoline is stored can cause a fire or explosion.
FUEL SYSTEM
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore,
which is coated with molybdenum.
• Do not snap the throttle valve from full open to full close after the throttle cable has been
removed. It may cause incorrect idle operation.
• Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from
entering the intake ports after the throttle body has been removed.
• Do not apply excessive force to the fuel pipe on the throttle body while removing or installing
the throttle body.
• Do not damage the throttle body. It may cause incorrect throttle and idle valve
synchronization.
• Prevent dirt and debris from entering the throttle bore, fuel tube and return tube, clean them
using compressed air.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this
manual.
• Do not loosen or tighten the white painted bolts and screws of the throttle body. Loosening or
tightening them can cause throttle and idle valve synchronization failure.
• Do not push the fuel pump base under the fuel tank when the fuel tank is stored.
• Always replace the packing when the fuel pump is removed.
• Fuel injection system location, see page 8.
• A faulty EFI system is often related to poorly connected or corroded connectors. Check those
connections before proceeding.
• When disassembling the EFI parts, note the location of the O-rings. Replace them with new
ones upon reassembly.
• Before disconnecting the fuel hose, release the fuel pressure.
• Always replace the clamp when the fuel hose is removed or loosened.
• Use a diagnosis tool for EFI system inspection.
4-1-2
CONNECTOR/COUPLER
• When connecting a connector, be sure to push it in until a click is felt.
• With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to
engage the lock when connecting.
• When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead
wires.
• Inspect each terminal on the connector/coupler for looseness or bending.
• Inspect each terminal for corrosion and contamination. The terminals must be clean and free
of any foreign material, which could impede proper terminal contact.
• Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace.
• When taking measurements at electrical connectors using a tester probe, be sure to insert
the probe from the wire harness side (backside) of the connector/coupler.
• When connecting meter probe from the terminal side of the coupler where (connection from
harness side not being possible), use extra care not to force and cause the male terminal to
bend or the female terminal to open. Connect the probe as shown to avoid opening of
female terminal. Never push in the probe where male terminal is supposed to fit.
• Check the male connector for bend and female connector for excessive opening. Also check
the coupler for locking (looseness), corrosion, dust, etc.
FUSE
• When a fuse blows, always investigate the cause to correct it and then replace the fuse.
• Do not use a fuse of a different capacity.
• Do not use wire or any other substitute for the fuse.
ECU/VARIOUS SENSORS
• Since each component is a high-precision part, great care should be taken not to apply any
sharp impacts during removal and installation.
• Be careful not to touch the electrical terminals of the ECU. The static electricity from your
body may damage this part.
• When disconnecting and connecting the ECU couplers, make sure to turn OFF the ignition
switch, or electronic parts may get damaged.
• Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will
damage the components of the FI system instantly when reverse power is applied.
• Removing any battery terminal of a running engine is strictly prohibited. The moment such
removal is made, damaging counter electromotive force will be applied to the ECU, which
may result in serious damage.
• Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V
or higher. Terminal voltage check with a low voltage battery will lead to erroneous diagnosis.
• Never connect any tester (voltmeter, ohmmeter, or whatever) to the ECU when its coupler is
disconnected. Otherwise, damage to the ECU may result.
4-1-3
• Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to
the ECU or sensors may result.
• Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not
be obtained and personal injury may result.
ELECTRICAL CIRCUIT INSPECTION PROCEDURE

While there are various methods for electrical circuit inspection, described here is a general
method to check for open and short circuit using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows.
As the cause can exist in the connector/coupler or
terminal, they need to be checked carefully.
• Loose connection of connector/coupler.
• Poor contact of terminal (due to dirt, corrosion or
rust, poor contact tension, entry of foreign object
ECU
etc.)
• Wire harness being open
• Poor terminal-to-wire connection
• Disconnect the negative cable from the battery. 1. Check for loose connection
• Check each connector/coupler at both ends of the
circuit being checked for loose connection. Also
check for condition of the coupler lock if equipped.
• Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact
(possibly caused by dirt, corrosion, rust, entry of
foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact
to increase tension or replace.
The terminals must be clean and free of any foreign
material, which could impede proper terminal
contact.
• Using continuity inspect or voltage check

procedure as described below, inspect the wire 1. Looseness of crimping
harness terminals for open circuit and poor 2. Open
connection. Locate abnormality, if any. 3. Thin wire (a few strands left)
4-1-4
CONTINUITY CHECK
• Measure resistance across coupler B (between A
and C in the figure).
• If no continuity is indicated (infinity or over limit),
ECU
the circuit is open between terminals A and C.
• Disconnect the coupler B and measure resistance

between couplers A and B.
• If no continuity is indicated, the circuit is open
between couplers A and B. If continuity is indicated, ECU
there is an open circuit between couplers B’ and C
or an abnormality in coupler B’ or coupler C.
VOLTAGE CHECK
• If voltage is supplied to the circuit being checked,
voltage check can be used as circuit check.
• With all connectors/couplers connected and
voltage applied to the circuit being checked,
measure voltage between each terminal and body
ground.
• If measurements were taken as shown in the figure
at the right and results are as listed below, it means
that the circuit is open between terminals A and B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 0 V
• Also, if measured values are as listed below, a

resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals A and
B.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 3 V
(2 V voltage drop)
4-1-5
SHORT CIRCUIT CHECK (WIRE HARNESS TO GROUND)

• Disconnect the negative cable from the battery.
• Disconnect the connectors/couplers at both ends of
the circuit to be checked.
NOTE:
If the circuit to be checked branches to other parts
as shown, disconnect all connectors/couplers of
those parts. Otherwise, diagnosis will be misled.
• Measure resistance between terminal at one end of

circuit (A terminal in figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals A and C.
• Disconnect the connector/coupler included in

circuit (coupler B) and measure resistance between
terminal A and body ground. ECU
If continuity is indicated, the circuit is shorted to the
ground between terminals A and B.
4-1-6
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle body identification number
Starter valve vacuum difference
Idle speed 1500+/- 100 rpm
Throttle grip free play 2~4 mm
Intake air temperature sensor resistance Ω
Engine coolant temperature sensor
Ω
resistance
Fuel injector resistance Ω
Ignition pulse generator peak voltage V
Manifold absolute pressure at idle 420 +/- 30 mm Hg
Fuel pressure at idle 300 kPa
TORQUE VALUES
ECT sensor
Pressure regulator mounting bolt
Fuel pump mounting nut
4-1-7
PARTS LOCATION
1 ECU 8 Fuel Pump (Reservoir)

2 Roll Over Sensor 9 Fuel Filter x 2
3 Injector 10 Ignition Coil
4 Speed Sensor 11 Throttle Position Sensor
5 Engine Coolant Temperature 12 Idle Speed Controller
6 Crank Position Sensor 13 Temperature Manifold Air Pressure
7 Pressure Regulator 14 Throttle Body
4-1-8
WIRING DIAGRAM
4-1-9
ECU TERMINAL
HARNESS ECU PLUG
Pin Pin Wire Pin Pin Wire

Circuit Note Circuit Note
No. Code Color No. Code Color
A1 1 Y/B VSENS Sensor voltage G1 7 Br/W
A2 13 Blank G2 19 Gr/R SGND2 Signal ground
A3 25 Blank G3 31 W/Br TPS Throttle position sensor
A4 37 Br/L VBK Key SW voltage G4 43 Blank
B1 2 P/W CAN_H Diagnosis Tool H1 8 Blank
B2 14 W/G RPM H2 20 W Gear B
B3 26 Y/G MIL Engine Check H3 32 Pu VEH Speed sensor
B4 38 R/W VBD Battery Voltage H4 44 L Gear C
C1 3 P/G CAN_L Diagnosis Tool J1 9 B Fuel Pump relay
C2 15 B/Y Temp. Temperature LED J2 21 Blank
C3 27 Gr/R SGND1 Signal Ground J3 33 R Gear A
C4 39 Br/B Stepper B J4 45 R/Gr Override switch
D1 4 LG/R CPS- Crank position sensor (-) K1 10 O/W Main relay
D2 16 Pu/B K2 22 B/W Fan relay
D3 28 G/B Stepper D K3 34 Blank
D4 40 L/B Stepper A K4 46 Blank
E1 5 L/Y CPS+ Crank position sensor (+) L1 11 R VBR Start relay voltage
E2 17 Blank L2 23 Blank
E3 29 Blank L3 35 B/W Starter
E4 41 B/Y Stepper C L4 47 L/G Injector
F1 6 G/Y Brake SW M1 12 B/Y Ignition
F2 18 W/Y MAP Manifold Air Pressure M2 24 Blank
F3 30 G/Br TIA Temperature Intake Air M3 36 Gr PGND Ground
F4 42 Y/R ECT E/G Temperature sensor M4 48 Gr PGND Ground
4-1-10
SYSTEM TROUBLSHOOTING CUSTOMER COMPLAINT ANALYSIS

Record details of problem (failure, complaint) and how it occurred as described by the
customer. For this purpose, use of an inspection form such as below will facilitate collecting
information required for proper analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM

User name: Model: VIN:
Date of issue Date Reg. Date of problem: Mileage:
Malfunction lamp
□Always ON □Sometimes ON □Always OFF □Good condition
condition (LED)
Malfunction code Malfunction code（）
PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Drivability
□ No cranking □ Hesitation on acceleration
□ No initial combustion □ Back fire / □ After fire
□ No combustion □ Lack of power
□ Poor starting at □ Surging
（□cold □warm □always） □ Abnormal knocking
□ Other_______________ □ Engine rpm jumps briefly
□ Other _______________
□ Poor Idling □ Engine Stall when
□ Poor fast idle □ Immediately after start
□ Abnormal idling speed □ Throttle valve is opened
（□ High □ Low）（ rpm） □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting（ rpm to rpm） □ Other __________
□ Other ________________
□ OTHERS:
4-1-11
ATV ENVIROMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □Fair □Cloudy □Rain □Snow □Always □Other __________
Temperature □Hot □Warm □Cool □Cold( ℃) □Always
Frequency □Always □Sometimes ( times/ day, month) □Only once
□Under certain condition
□Urban □Suburb □Highway □Mountainous (□Uphill □Down hill)
Road □Tar macadam □Gravel □Other __________
ATV condition
□Cold □Warming up phase □warmed up □Always
□Other at starting
Engine condition
□Immediately after start □Racing without load
□Engine speed ( rpm)
During driving: □Constant speed □Accelerating □Decelerating
□Right hard corner □Left hand comer
ATV condition
□At shop □ATV speed when problem occurs ( km/h, mile/h)
□ Other _____________
NOTE:
The above form is a standard sample. The form should be modified according to conditions
and characteristics of each market.
4-1-12
EFI SYSTEM COMPONENTS INSPECTION

T-MAP SENSOR
• Turn the ignition OFF.
• Disconnect the T-MAP sensor 4P connector.
• Check for loose or poor contact on the MAP sensor
connector.
• Connect the T-MAP sensor connector.

• Start the engine and check that the MIL light.
2.Vrev 3.Vout (℃)
1.Vout (p) 4.GND
MIL
• Turn the ignition switch OFF.

• Disconnect the MAP sensor 4P connector.
• Turn the ignition switch ON.
• Measure the voltage at the wire harness side
connector.
Connection: Yellow/Black (+)－Ground(-)
Standard: 5.0 +/- 0.1V
• Measure the voltage between the connector

terminals of wire harness side.
Connection: Yellow/Black (+)－Gray/Red(-)

• Connect the TMAP sensor 4P connector.
4-1-13
ECT SENSOR
INSPECTION
• Disconnect ECT sensor 2P connector.
• Check for loose or poor contact on the ECT sensor
connector.
• Connect the ECT sensor connector.

• Check the MIL light.

• Disconnect the ECT sensor connector.
• Measure the resistance at ECT sensor terminals.
Connection:
Standard:2.3~2.6 kΩ (at 20℃)

• Measure the voltage between the ECT sensor
connector terminal of the wire harness side and
ground.
Connection: Yellow/Red (+)－Ground(-)
• Measure the voltage at ECT sensor connector of the

wire harness side.
Connection: Yellow/Red (+)－Gray/Red(-)
4-1-14
REMOVAL / INSTALLATION
• Disconnect the ECT sensor 2P connector from the
sensor
• Remove the ECT sensor.
• Install the new ECT sensor.
TORQUE: 120 kgf/cm
• Connect the ECT sensor 2P connector.
Standard:
RESISTANCE
TEMPERATURE(℃) TOL. (OHM)
VALUES(OHM)
20 3500 ±250
60 704 ±45
90 260 ±20
4-1-15
TP SENSOR
INSPECTION
• Disconnect the TP sensor 3P connector.
• Check for loose or poor contact on the TP sensor
connector.
• Connect the TP sensor connector.

• Start the engine and check the MIL light.

• Disconnect the TP sensor 3P connector.
• Measure the voltage between the wire harness side
connector terminal and ground.
Connection: Yellow/Black (+)－Ground(-)
• Measure the voltage at TP sensor terminals of the

wire harness side.
Connection: Yellow/Black (+)－Gray/Red(-)
B.OUTPUT A.GROUND(-)
• Working voltage value: 5.0±0.1V
C.INPUT(+) 5V
• Full throttle open voltage: 3.9±0.2V
• Full throttle closed voltage: 0.5±0.05V
• WARNING!
Never loosen the screw of TPS, result the
unsteady idle.
• Using diagnosis tool to confirm the throttle output screw

signal.
1. Connected to the "diagnosis tool", and open
the main switch, but not to start engine.
2. "Diagnosis tool" selects to a "Live Data"
screen.
3. Rotations throttle and check voltages.
4-1-16
VEHICLE SPEED SENSOR

• Disconnect the vehicle speed sensor 3P connector.
• Check for loose or poor contact on the vehicle
speed sensor connector.
• Connect the vehicle speed sensor 3P connector.

• Start the engine.
• Ride the vehicle and keep the engine more than
5,000 RPM about 20 seconds or more.

• Disconnect the vehicle speed sensor 3P connector.
• Measure the voltage at the wire harness side
connector.
Connection: Red (+)－Black/White(-)
Standard: 12 V
4-1-17
INJECTOR
• Disconnect the injector 2P connector.
• Check for loose or poor contact on the injector 2P
connector.
• Connect the injector 2P connector.


• Disconnect the injector 2P connector and measure
the resistance of the injector.
Connection: Red (+) － Blue/Green(-)
Standard:12.0+/-1Ω
• Check for continuity between the injector and

ground.
Connection: Red (+) － Ground(-)
Standard: continuity

• Measure the voltage between the injector connector
of the wire harness side and ground.
Standard: battery voltage
4-1-18
INSPECTION
• Start the engine and let it idle.
• Confirm the injector operating sounds with a
sounding rod or stethoscope.
• If the injector does not operate, replace the injector.
REMOVAL
• Disconnect the injector 2P connector.
• Remove the bolts and fuel rail assembly.
• Remove the injector from the intake pipe.
INSTALLATION
• Install injector on the intake pipe.
• Being careful not to damage the O-ring of injector.
• Install fuel rail assembly and tighten the bolt.
TORQUE: 120 kgf-cm
• Connect the injector 2P connector.
4-1-19
CRANK POSITION SENSOR

• Disconnect the crank position sensor 2P connector.
• Check for loose or poor contact on the crank
position sensor 2P connector.
• Connect the crank position sensor 2P connector.

• Turn the starter motor more than 10 seconds and
then check that the MIL light.

• Disconnect the crank position sensor 2P connector.
• Check for continuity between the crank position
sensor connector terminal and ground.
Connection: Blue (+) － Ground(-)
Standard: No continuity
• Crank the engine with the starter motor, and

measure the crank position sensor peak voltage at
the crank position sensor 2P connector.
Connection: Blue (+) － Sky Blue(-)
Standard: 0.7V
4-1-20
IGNITION COIL
• Disconnect the ignition coil 2P connector.
• Check for loose or poor contact on the ignition coil
2P connector.
• Connect the ignition coil 2P connector.

• Turn the starter motor more than 10 seconds and
then check that the MIL light.

• Disconnect the ignition coil 2P connector.
• Check for continuity between the ignition coil
Standard: No continuity
• Crank the engine with the starter motor, and

measure the ignition coil peak voltage at the
ignition coil 2P connector.
Connection: Red (+) － Black/Yellow(-)
Standard: 0.7V
• Check for resistance between the ignition coil

Standard: 0.63±0.05Ω
4-1-21
THROTTLE BODY
REMOVAL
NOTE:
• Before disconnecting the fuel hose, release the fuel
pressure by loosening the clamp.
• Always replace the clamp when the fuel hose is
removed or loosened.
DISASSEMBLY
• Disconnect the TP sensor, T-MAP sensor and ISC
sensor connector from the throttle
• Disconnect intake pipe rubber tube from the throttle
body.
• Disconnect the throttle body from the air cleaner
case.
NOTE:
• Do not damage the throttle body. It may cause
incorrect throttle and idle valve.
• The throttle body is factory pre-set. Do not
disassemble in a way other than shown in this
manual.
• Do not loosen or tighten the white painted bolts
and screws of the throttle body. Loosening or
tightening them can cause throttle and idle
valve failure.
• Disconnect the throttle cable end from the throttle

drum.
ASSEMBLY
• Connect the throttle cable end to the throttle drum.
• Connect the TP, T-MAP and ISC sensor connector
on the throttle body.
• Install and tighten the intake pipe rubber tube on the
throttle body.
• Install the throttle body to the air cleaner case.
4-1-22
PRESSURE REGULATOR
NOTE:
• Remove the pressure regulator mounting bolts and
cover then remove the pressure regulator.
• Disconnect injector fuel hose (2) to release

fuel pressure.
• Disconnect fuel supply hose (1).
• Disconnect fuel return hose (3).
NOTE:
• Recommends that hose clamp be discarded and
replaced each time they are removed or loosened.
They are one time usage only.
Special Tool:
• Install the pressure regulator in the reverse order of

removal.
TORQUE: 100kgf-cm
4-1-23
ROLL OVER SENSOR

INSPECTION
• Remove the seat set.
• Turn the ignition switch ON and measure the voltage
between the following terminals of the Roll Over
sensor connector with the connector connected.
Angle STANDARD
0∘ 1.0~1.4 V
65∘ 3.7~4.4 V
• Remove the screws, washers, nuts and roll over
sensor.
• Place roll over sensor horizontal as shown and turn
the ignition switch ON.
• The roll over sensor is normal if the power supply is
closed.
• Incline the roll over sensor approximately 65
degrees to the left or right with the ignition switch
ON.
• The roll over sensor is normal if the power supply is
open.
• If you repeat this test, first turn the ignition switch
OFF then turn the ignition switch ON.
• Disconnect the roll over sensor 2P connector.
• Remove the two screws, nuts and roll over sensor.
• Installation is in the reverse order of removal.
• Tighten the mounting screws securely.
NOTE: Install the roll over sensor with its

“UP” mark facing up.
4-1-24
ECU
• Remove the seat set.
• Disconnect the ECU 48P connectors.
POWER INPUT LINE

• Measure the voltage between the ECU and ground.
• There should be battery voltage.
• If there is no voltage, check for an open circuit in
Black/White wire between the ECU and roll over
sensor/relay.
• If the wire is OK, check for the roll over sensor/relay.
4-1-25
FUEL LINE INSPECTION
FUEL PRESSURE INSPECTION

NOTE:
• Before disconnecting fuel hose, release the fuel
pressure by loosening the pressure regulator fuel
hose clamp on the injector hose.
• Always replace the clamp when the hose is
• Disconnect the battery negative cable from the

battery terminal.
4-1-26
• Disconnect the pressure regulator output hose and

plug the hose.
• Slowly catch the remaining fuel using an approved
gasoline container.
• Install the 3-way connector and attach the fuel

pressure gauge as shown.
• Connect the battery negative cable.

• Start the engine.
• Read the fuel pressure at idle speed.
IDLE SPEED: 1500+/-100 RPM
STANDARD:300 kPa
• If the fuel pressure is higher than specified, inspect

the following:
- Pinched or clogged fuel return hose.
- Pressure regulator
- Fuel pump
• If the fuel pressure is lower than specified, inspect

the following:
- Fuel line leaking.
- Clogged fuel filter
- Fuel pump
• After inspection, remove the fuel pressure gauge

and reinstall and tighten the fuel hose clamp using
the new clamp.
• Connect the pressure regulator output hose.
• Install the removed parts in reverse order of
removal.
4-1-27
FUEL FLOW INSPECTION

• Disconnect the fuel pump relay.
• Jump the Black/Purple and Red/Orange wire
terminals of the wire harness side using a jumper
wire.
• When the fuel return hose is disconnected, gasoline
will spill out from the hose. Use an approved
gasoline container to drain the gasoline.
• Wipe off spilled gasoline.
• Disconnect the fuel return hose on the top of fuel
tank; plug the fuel tank inlet joint.
• Turn the ignition switch ON for 10 seconds.
• Measure the amount of fuel flow.
Amount of fuel flow:
300 cm3 minimum/*10 seconds at 12V
• If the fuel flow is less than specified, inspect the
following:
- Pinched or clogged fuel hose and fuel return hose
- Clogged fuel filter
- Fuel pump
• After inspection, connect the fuel return hose.
• Start the engine and check for leaks.
FUEL PUMP
INSPECTION
• Turn the ignition switch ON and confirm that the fuel
pump operates for a few seconds.
• If the fuel pump does not operate, inspect as follow:
• Disconnect the fuel pump 2P connector.
• Turn the ignition switch ON and measure the voltage
between the terminals. 12 V.
• There should be battery voltage for a few seconds.
• If there is battery voltage, replace the fuel pump.
• If there is no battery voltage, inspect the following:
- Main fuse 30A
- Fuel pump relay
- Roll Over sensor
- ECU
4-1-28
REMOVAL
NOTE:
• Before disconnecting the fuel hose, release the fuel
pressure.
• Remove the fuel tank
• Remove the fuel pump mounting nuts.
• Remove the fuel pump assembly and packing.
FUEL FILTER REPLACEMENT

• Disconnect the fuel hose from the fuel filter.
• Remove the screw, clamp and fuel filter.
• Install the fuel filter in the reverse order of removal.
NOTE: The direction of fuel filter with “IN” mark.
INSTALLATION
• Place new packing onto the fuel tank.
• Install the fuel pump, being careful not to damage
the fuel pump wire.
• Install and tighten the fuel pump mounting nuts in
the sequence shown.
TORQUE: 120 kgf/cm.
FUEL PUMP RELAY

• Disconnect the fuel pump relay 5P connector,
remove the fuel pump relay.
• Connect the ohmmeter to the fuel pump relay
connector terminals 30 and 87.
CONNECTION:
• Connect the 12V battery to the fuel pump relay
connector terminals 85 and 86.
CONNECTION:
• There should be continuity only when the 12V
battery is connected.
• If there is no continuity when the 12V battery is
connected, replace the fuel pump relay.
4-1-29
FUEL TANK/RESERVOIR (FUEL PUMP ASSEMBLY)

ROMOVAL
• Loosen the fuel tank mounting bolt/nut.
• Release the fuel pressure.
Gray
• Disconnect the fuel tank air vent hose and supply
hose. Air Vent hose
• Remove the clamp then disconnect the fuel hose.
• Remove the following: To Regulator
- Fuel tank supply hose Black/Purple
- Fuel tank air vent hose
- Fuel pump/reserve sensor 2 P connector
NOTE: The clamp for one time use only.
• Clamp the fuel return hose.
• Disconnect the fuel return hose at the pressure
regulator.
• Install the following:
- Fuel hose (with “▲” mark)
- Air vent hose
- Fuel pump/reserve sensor 2P connector
NOTE:
• Always replace new clamp while disassemble or
loosen.
• Connect the fuel hose to the pressure regulator.
• Connect the fuel pump/reserve sensor 2P
connector.
• Connect the fuel output hose to the fuel rail with new
clamp.
• While pushing the fuel hose to the fuel rail, install
and tighten the clamp.
NOTE: Do not apply excessive force to the fuel
pipe.
4-1-30
SENSOR CIRCUIT TROUBLESHOOTING

CPS SENSOR CIRCUIT MALFUNCTION
DETECTED CONDITION POSSIBLE CAUSE
The signal does not reach ECU for 3 sec. or • Metal particles or foreign material being
more, after receiving the starter signal. stuck on the CPS sensor and rotor tip
• CPS sensor circuit open or short
• CPS sensor malfunction
• ECU malfunction
INSPECTION
Step 1
1) Remove the seat set.
2) Remove the left side cover.
3) Turn the ignition switch OFF.
4) Check the CPS sensor coupler for loose or
poor contacts.
If OK, then measure the CPS sensor
resistance.
5) Disconnect the CPS sensor coupler and
measure the resistance.
CPS sensor resistance: 115 +/- 10 Ω
(Blue –Sky Blue)
6) If OK, then check the continuity between
each terminal and ground.
CPS sensor continuity: ∞ Ω (Infinity)
(Blue – Ground)
(Green – Ground)
4-1-31
Are the resistance and continuity OK?

YES Go to next step 2
NO Replace CPS sensor with new one
7) After repairing the trouble, clear the DTC
using Diagnosis Tool.
Step 2
1) Crank the engine a few seconds with the
starter motor, and measure the CPS sensor
peak voltage at the coupler.
2) Repeat the above test procedure a few times
and measure the highest peak voltage.
CPS sensor peak voltage: 4.0 V and more
(+ Blue – - Sky-Blue)
Is the voltage OK?

•Blue or Sky-Blue wire open or
shorted to ground
• Loose or poor contacts on the CPS
sensor coupler or ECU coupler
(terminal 4 or 5)
• If wire and connection are OK,
YES
intermittent trouble or faulty ECU.
• Recheck each terminal and wire
harness for open circuit and poor
connection.
• Replace the ECU with a known good 4 5
one, and inspect it again.
• Inspect that metal particles or foreign
material stuck on the CPS sensor
and rotor tip.
NO
• If there are no metal particles and
foreign material, then replace the
CPS sensor with a new one.

using Diagnosis tool.
4-1-32
TMAP SENSOR CIRCUIT MALFUNCTION

T-MAP sensor voltage low or high • Clogged vacuum passage between throttle
(0.1 V Sensor voltage < 4.8 V) body and T-MAP sensor
NOTE: • Air being drawn from vacuum passage
Note that atmospheric pressure varies between throttle body and T-MAP sensor
depending on weather conditions as well as • T-MAP sensor circuit open or shorted to
altitude. ground
Take that into consideration when inspecting • T-MAP sensor malfunction
voltage. • ECM malfunction
INSPECTION
Step 1
1) Loosen and lift up the fuel tank.
3) Check the T-MAP sensor couple for loose or
poor contacts.
If OK, then measure the T-MAP sensor input
voltage.
4) Disconnect the T-MAP sensor coupler.
5) Turn the ignition switch ON.
6) Measure the voltage at the Yellow/Black wire
and ground.
7) Also, measure the voltage at the
Yellow/Black wire and Gray/Red wire.
T-MAP sensor input voltage: 4.5 – 5.5 V
(+Yellow/Black – - Ground)
(+Yellow/Black – - Gray/Red)
4-1-33
Is the voltage OK?

• Loose or poor contacts on the ECU
coupler terminal 1 or 27
NO
• Open or short circuit in the
Yellow/Black wire or Gray/Red wire
Step 2
1) Connect the T-MAP sensor coupler.
2) Insert the needle pointed probes to the lead
wire coupler.
3) Start the engine at idle speed and measure
the T-MAP sensor output voltage at the wire
side coupler.
T-MAP sensor output voltage: Approx. 2.6 V
at idle speed
Is the voltage OK?
YES •Yellow/Black or Gray/Red wire open
or shorted to ground, or poor 18, 30
or 1 connection.
connection.
• Replace the ECU with a known
good one, and inspect it again.
• If check result is not satisfactory,
NO
replace new T-MAP (throttle body).
4-1-34
TP SENSOR CIRCUIT MALFUNCTION

Output voltage is not within the following • TP sensor maladjusted
range. • TP sensor circuit open or short
Difference between actual throttle opening • TP sensor malfunction
and opening calculated by ECU is larger • ECU malfunction
than specified value.
0.1 V Sensor voltage < 4.8 V
Sensor voltage is higher than specified • TP sensor circuit shorted to VSENS or
value. ground circuit open
Sensor voltage is lower than specified value. • TP sensor circuit open or shorted to ground
or VSENS circuit open
INSPECTION
Step 1
(When output voltage is out of specified)
3) Check the TP sensor coupler for loose or
poor contacts.
If OK, then measure the TP sensor input
voltage.
4) Disconnect the TP sensor coupler.
6) Measure the voltage at the Red wire B and
ground.
7) Also, measure the voltage at the
Yellow/Black wire and Gray/Red wire.
TP sensor input voltage: 4.5 – 5.5 V
(+Yellow/Black – - Ground)
4-1-35
Is the voltage OK?

coupler (terminal 1 or 27)
NO
• Open or short circuit in the
Yellow/Black wire or Gray/Red wire
Step 1
(When sensor voltage is higher than specified)
poor contacts.
If OK, then check the TP sensor lead wire
continuity.
5) Check the continuity between W/Br wire and
Y/B wire.
If the sound is not heard from the tester, the
circuit condition is OK.
6) Disconnect the ECU coupler.
terminal 31.
8) Also, check the continuity between Gr/R wire
and terminal 27.
TPS lead wire continuity: Continuity (sound)
Is the continuity OK?
W/Br wire shorted to VSENS or
NO
SGND1 wire open
Step 1 31
(When sensor voltage is lower than specified)
poor contacts.
If OK, then measure the TP sensor lead wire
continuity.
4-1-36

ground.
6) Also, check the continuity between W/Br wire
and Gr/R wire
C. If the sound is not heard from the tester, the
terminal 31.
31
9) Also, check the continuity between Y/B wire
and terminal .
TPS lead wire continuity: Continuity (sound)
YES Go to step 1 and step 2
Y/B wire or Gr/R wire open, or Gr/R
NO
wire shorted to ground
Step 2
ground.
TP sensor continuity: ∞ Ω (Infinity)
(White/Brown – Ground)
4) If OK, then measure the TP sensor
resistance at the terminals (between Bottom
and Center pin).
5) Turn the throttle grip and measure the
resistance.
TP sensor resistance
Throttle valve is closed: Approx. 1.1 kΩ
Throttle valve is opened: Approx. 4.4 kΩ
6) If OK, then measure the TP sensor
resistance at the terminals (between Upper
and Center pin).
TP sensor resistance: Approx. 4.66 kΩ
(Upper pin – Center pin)
4-1-37
Are the continuity and resistance OK?

YES Go to step 3
• Reset the TP sensor position
correctly.
NO
• Replace the new TP sensor (throttle
body).
Step 3
1) Connect the TP sensor coupler.
wire coupler.
4) Measure the TP sensor output voltage at the
coupler (between W/Br wire and Gr/R wire )
by turning the throttle grip.
TP sensor output voltage
Throttle valve is closed: Approx. 1.1 V
Throttle valve is opened: Approx. 4.4 V
Is the voltage OK?
• Y/B, W/Br or Gr/R wire open or
shorted to ground, or poor 1, 31 or
27 connection
YES
connection.
If check result is not satisfactory,
NO replace new TP sensor (throttle
body).
4-1-38
ECT SENSOR CIRCUIT MALFUNCTION

Output voltage is not within the following • ECT sensor circuit open or short
range. • ECT sensor malfunction
0.1 Sensor voltage < 4.6 V • ECU malfunction
Sensor voltage is higher than specified
value. • ECT sensor circuit open or ground circuit
Sensor voltage is lower than specified value. open
• ECT sensor circuit shorted to ground
INSPECTION
Step 1
2) Check the ECT sensor coupler for loose or
poor contacts.
If OK, then measure the ECT sensor voltage
at the wire side coupler.
3) Disconnect the ECT sensor coupler and turn
the ignition switch ON.
4) Measure the voltage between Y/R wire
terminal and ground.
5) Also, measure the voltage between Y/R wire
terminal and Gr/R wire terminal.
ECT sensor input voltage: 4.5 – 5.5 V
(+Y/R – - Ground)
(+Y/R – - Gr/R)
4-1-39
Is the voltage OK?

YES Go to step 2
coupler (terminal 42 or 27)
NO
• Open or short circuit in the Y/R wire
or Gr/R wire
Step 1
poor contacts.
If OK, then check the ECT sensor lead wire
continuity.
3) Remove the left side cover.
4) Disconnect the ECT sensor coupler.
5) Remove the ECU coupler.
6) Check the continuity between Y/R wire and
42
terminal 42.
7) Also, check the continuity between Gr/R wire
and terminal 27.
ECTS lead wire continuity: Continuity (sound)
YES Go to step 2
NO Y/R or Gr/R wire open
Step 1
poor contacts.
If OK, then check the ECT sensor lead wire
continuity.
4) Check the continuity between Y/R wire and
ground.
5) If the sound is not heard from the tester, the
Tester knob indication: Continuity (sound)
4-1-40
6) Connect the ECT sensor coupler.

8) Measure the voltage between Y/R wire and
ground.
Output voltage: 0.1 – 4.6 V
(+ Y/R – - Ground)
Are the continuity and voltage OK?
YES Go to step 2
NO Y/R wire shorted to ground.
Step 2
3) Measure the ECT sensor resistance.
ECT sensor resistance:
Approx. 2.3 – 2.6 kΩ at 20 °C (68 °F)
(Terminal – Terminal)
Is the resistance OK?
• Y/R or Gr/R wire open or shorted to 42
ground, or poor 42 or 27 connection 27
YES • Recheck each terminal and wire
connection.
NO Replace ECT sensor with a new one.
ECT sensor specification

Engine Coolant
Resistance
Temperature
20 °C (68 °F) Approx. 2.45 kΩ
40 °C (104 °F) Approx. 1.148 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.322 kΩ
4-1-41
IGNITION SYSTEM MALFUNCTION
TROUBLESHOOTING
No spark or poor spark
NOTE:
Check that the transmission is in neutral and check that the fuse is not blown and the battery
is fully charged before diagnosing.
Step 1
1) Check the ignition system couplers for poor
connections.
Is there connection in the ignition switch couplers?
YES Go to step 2
NO Poor connection of couplers
Step 2
1) Measure the battery voltage between input
lead wires at the ECU with the ignition switch
in the “ON” position.
Is the voltage OK?
YES Go to step 3
• Faulty ignition switch
• Broken wire harness or poor
NO
connection of related circuit
couplers
11 12
4-1-42
Step 3
1) Measure the ignition coil primary peak voltage.
NOTE:
This inspection method is applicable only with the multi circuit tester and the peak volt
adaptor.
Is the peak voltage OK?
YES Go to step 4
NO Go to step 5
Step 4
1) Check the plug caps for poor contacts.
2) If OK, then inspect the spark plugs.
Are the spark plugs OK?
YES Go to step 5
NO Faulty spark plug (-s)
Step 5
1) Inspect the ignition coils.
Are the ignition coils OK?
YES Go to step 6
NO Faulty ignition coil (-s)
Step 6
1) Measure the CPS sensor peak voltage and its resistance.
NOTE:
The CPS peak voltage inspection is applicable only with the multi-circuit tester and peak volt
adaptor.
Are the peak voltage and its resistance OK?
• Faulty ECU
YES • Open or short circuit in wire harness
• Poor connection of ignition couplers
• Faulty CPS sensor
• Metal particles or foreign material
NO
being stuck on the CPS sensor and
rotor tip
4-1-43
FUEL INJECTOR CIRCUIT MALFUNCTION

CPS signals produced but fuel injector • Injector circuit open or short
signal is interrupted continuous by 4 times • Injector malfunction
or more. • ECU malfunction
Step 1
2) Check the injector coupler for loose or poor
contacts.
If OK, then measure the injector resistance.
3) Disconnect the injector coupler and measure
the resistance between terminals.
Injector resistance:
Approx. 11.7 Ω at 20 °C (68 °F)
(Terminal – Terminal)
4) If OK, then check the continuity between
each terminal and ground.
STP sensor continuity: ∞ Ω (Infinity)
Are the resistance and continuity OK?
YES Go to step 2
NO Replace the injector with a new one.
Step 2
2) Measure the injector voltage between R wire
and ground.
Injector voltage: Battery voltage
(+ R – - Ground)
4-1-44
NOTE:
Injector voltage can be detected only 3
seconds after ignition switch is turned ON.
Is the voltage OK?

• L/G wire open or shorted to ground,
or poor 47 connection (cylinder
side)
YES
harness for open circuit and poor 47
connection.
NO Open circuit in the R wire
4-1-45
FP RELAY CIRCUIT MALFUNCTION

No voltage is applied to fuel pump although • Fuel pump relay circuit open or short
fuel pump relay is turned ON, or voltage is • Fuel pump relay malfunction
applied to fuel pump, although fuel pump • ECU malfunction
relay is turned OFF.
INSPECTION
Step 1
1) Remove the seat.
2) Turn the main switch OFF.
3) Check the FP relay coupler for loose or poor
contacts.
If OK, then check the FP relay.
Is the FP relay OK?
• Blue wire open or shorted to
ground, or poor 9 connection
• Red wire open or poor 11
connection
YES intermittent trouble or faulty ECU. Battery

connection.
NO Replace the FP relay with a new one.
9 11
4-1-46
ROLL OVEWR SENSOR CIRCUIT MALFUNCTION

The sensor voltage should be the following • TO sensor circuit open or short
for 2 sec. and more, after ignition switch is • TO sensor malfunction
turned ON. • ECU malfunction
0.2 Sensor voltage < 4.6 V
Sensor voltage is higher than specified •TO sensor circuit open or shorted to
value. VSENS or ground circuit open
Sensor voltage is lower than specified value. •TO sensor circuit shorted to ground or
VSENS circuit open
INSPECTION
Step 1
3) Check the Roll over sensor coupler for loose
or poor contacts.
4-1-47

or poor contacts.
If OK, then check the Roll over sensor lead
wire continuity.
4) Disconnect the Roll over sensor coupler.
5) Check the continuity between Y/B wire and
Pu/B wire.
If the sound is not heard from the tester, the
7) Check the continuity between Pu/B wire and
terminal 16.
YES Go to step 2
NO Pu/B wire shorted to VBR 16

or poor contacts.
If OK, then check the Roll over sensor lead
wire continuity.
4) Disconnect the Roll over sensor coupler.
5) Check the continuity between Pu/B wire and
ground. If the sound is not heard from the
tester, the circuit condition is OK.
8) Check the continuity between Y/B wire and
terminal 1.
9) Also, then check the continuity between Pu/B
wire B and terminal 16.
1
Roll over sensor lead wire continuity:
Continuity (sound)
4-1-48
YES Go to step 2
Y/B or Pu/B wire open or Pu/B wire
NO
shorted to ground
Step 2
1) Connect the Roll over sensor coupler.
wire coupler.
4) Measure the voltage at the wire side coupler
between Pu/B and B wires.
Also, measure the voltage when leaning the
vehicle.
Roll over sensor voltage (Normal): 1.0– 1.4 V
(+ Pu/B – - B)
5) Dismount the Roll over sensor from its
bracket and measure the voltage when it is
leaned 65° and more, left and right, from the
horizontal level.
Roll over sensor voltage (Leaning): 3.7 – 4.4
V (+ Pu/B – - B)
Is the voltage OK?
• Y/B or Pu/B wire open or shorted to
ground, or poor 1 or 16 connection
YES • Recheck each terminal and wire
1 16
connection.
coupler
NO • Open or short circuit
• Replace the Roll over sensor with a
new one.
4-1-49
IDLE SPEED CONTROLLER CIRCUIT MALFUNCTION

The operation voltage does not reach the • ISC malfunction
ISC. • ISC circuit open or short
ECU does not receive communication signal • ISC motor malfunction
from the ISC.
INSPECTION
Step 1
1) Remove the fuel tank.
3) Check the ISC lead wire coupler for loose or
poor contacts.
4) Remove the air cleaner rubber tube.
5) Turn the ignition switch ON to check the ISC
operation.
(ISC operating order: 95% open → full open
→ 95% open)
Is the operating OK?
YES Go to step 2.
• Loose or poor contacts on the ISC
coupler
• Open or short circuit in the Br/B,
NO
G/B, Y/B or B/Y wires
• If wire and connection are OK, go to
Step 2.
Step 2
2) Disconnect the ISC lead wire coupler.
3) Check the continuity between each terminal
and ground.
4-1-50
ISC continuity: ∞ Ω (Infinity)
(Terminal – Ground)
4) If OK, then measure the ISC resistance
(between Br/B, G/B, Y/B and B/Y wires).
ISC resistance: Approx. 6.5 Ω
Is the resistance OK?
•Br/B, G/B, Y/B and B/Y wire open or
shorted to ground, or poor 28, 39,
40 and 41 connection
YES
connection.
NO coupler
• Replace new ISC (throttle body).
• Measure the resistance between A-D and B-C

as below
• The standard are all follow 50.5±0.5Ω.
A D B C
4-1-51
Fault Diagnosis
EFI Circuit inspection
4-1-52
Can not Start the engine or difficult to start inspection
4-1-53
Idle flameout diagnosis
4-1-54
Integrated Fault Diagnosis Program
4-1-55
Fault Diagnosis Note
When the motorcycle injection system in the wrong signal, causing abnormal functioning of
the engine or can not start engine, MIL light at the dashboard will be lighting, to inform drivers
to carry out maintenance.
Overhaul, the diagnosis tool can be used for troubleshooting. If the fault has been ruled out or
repair after the MIL light will be extinguished, but ECU fault code will be recorded, so the need
to get rid of fault codes.
Diagnosis tool for overhaul

Diagnosis tool will connect to the motorcycle for coupler diagnosis, according to the use of
diagnostic tool testing methods, when belong fuel injection system fault or parts fault,
according to the diagnosis tool of the fault code display messages do describe parts of the
inspection testing maintenance and replacement parts. When after the maintenance, the need
to get rid of fault codes.
4-1-56
Fault Code And The Sensors Of The Table
No. Fault codes Fault Description

1 XXXXX Un define
2 B2225 Tilt switch diagnosis (SCP)
3 B2226 Tilt switch diagnosis (SCG_OL)
4 P0000 No DTC
5 P0031 Sensor heater diagnosis #0 (SCG/OL)
6 P0032 Sensor heater diagnosis #0 (SCP)
7 P0051 Sensor heater diagnosis #1 (SCG/OL)
8 P0052 Sensor heater diagnosis #1 (SCP)
9 P0107 MAP sensor diagnosis (SCG_OL)
10 P0108 MAP sensor diagnosis (SCP)
11 P0112 Intake air temperature sensor diagnosis (SCG)
12 P0113 Intake air temperature sensor diagnosis (SCP_OL)
13 P0114 Electrical intake air temperature intermittent diagnosis (failure)
14 P0117 Coolant Temperature Sensor (SCG)
15 P0118 Coolant Temperature Sensor (SCP_OL)
16 P0119 Coolant temperature intermittent diagnosis (failure)
17 P0121 TPS position sensor adaptation diagnosis (out of range)
18 P0122 Throttle Position Sensor 1 (SCG_OL)
19 P0123 Throttle Position Sensor 1 (SCP)
20 P0131 Lambda sensor #0 diagnosis (SCG)
21 P0132 Lambda sensor #0 diagnosis (SCP)
22 P0133 Lambda sensor #0 diagnosis (OL)
23 P0151 Lambda sensor #1 diagnosis (SCG)
24 P0152 Lambda sensor #1 diagnosis (SCP)
25 P0153 Lambda sensor #1 diagnosis (OL)
26 P0171 Lambda control diagnosis #0 (too high)
27 P0172 Lambda control diagnosis #0 (too low)
28 P0174 Lambda control diagnosis #1 (too high)
29 P0175 Lambda control diagnosis #1 (too low)
30 P0217 Engine coolant over temperature protection diagnosis
31 P0219 Engine over speed detection diagnosis
32 P0231 Electric fuel pump diagnosis (SCG/OL)
33 P0232 Electric fuel pump diagnosis (SCP)
34 P0261 Injection valve diagnosis #0 (SCG/OL)
35 P0262 Injection valve diagnosis #0 (SCP)
36 P0264 Injection valve diagnosis #1 (SCG/OL)
4-1-57
37 P0265 Injection valve diagnosis #1 (SCP)

38 P0351 Ignition diagnosis #0 (SCP)
39 P0352 Ignition diagnosis #1 (SCP)
40 P0370 Loss of synchronization diagnosis
41 P0371 Crankshaft sensor diagnosis
42 P0373 Crankshaft sensor diagnosis
43 P0462 FUEL sensor diagnosis (SCG)
44 P0463 FUEL sensor diagnosis (SCP_OL)
45 P0484 Cooling fan diagnosis (SCP)
46 P0485 Cooling fan diagnosis (SCG/OL)
47 P0530 Light relay diagnosis
48 P0560 Battery voltage diagnosis (too low)_VBR
49 P0561 Battery voltage diagnosis (too high)_VBR
50 P0562 Battery voltage diagnosis (too low)_VBK
51 P0563 Battery voltage diagnosis (too high)_VBK
52 P0608 Reference voltage diagnosis (SCP)
53 P0609 Reference voltage diagnosis (SCG_OL)
54 P0615 Starter 1 diagnosis (OL)
55 P0616 Starter 1 diagnosis (SCG)
56 P0617 Starter 1 diagnosis (SCP)
57 P0630 VIN coherence
58 P0651 MIL diagnosis (SCG/OL)
59 P0652 MIL diagnosis (SCP)
60 P1352 Ignition diagnosis #0 (SCG_OL)
61 P1353 Ignition diagnosis #1 (SCG_OL)
62 P1508 Stepper motor diagnosis (SCG_OL)
63 P1509 Stepper motor diagnosis (SCP)
64 P1615 Starter 2 diagnosis (OL)
65 P1616 Starter 2 diagnosis (SCG)
66 P1617 Starter 2 diagnosis (SCP)
67 U1600 IMMO sensor diagnosis (exist)
68 U1601 BUS error handling (OFF)
69 U1602 Frame 20 diagnosis
70 U1603 IMMO sensor diagnosis (aerial)
71 U1604 IMMO sensor diagnosis (unknown)
4-1-58
Use diagnosis tool
Note:
● When problems arise, 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. Connected to the diagnostic connector for diagnosis tool.
NACS→TGB interface→Transfer Cable→TGB 3 pin/6 pin Diagnosis Cable→Vehicle.
2. When the IG of the motorcycle is on, the system starts to run, entering into boot screen.
3. Key ON and the diagnosis display screen appeared the words connection.
4. Press the “ENTER” button and the system will identify the vehicle model automatically and
display the vehicle info on the screen, as following picture
4-1-59
5. Press “ENTER” button again for more detailed vehicle information. Press ▲▼ button to
view all information.
Diagnosis Use Note

Press ”ENTER” button to the function menu.
Options main functional areas:

1. Vehicle Info
2. Diagnostic Trouble Code
3. Live Data
4. Actuator
5. Special Function
Press ▲▼ button to choose one function.
1. Vehicle Info
Move the cursor to ”Vehicle Info” and press ENTER to see the content
This is the page of “Vehicle Info”, press ▲▼ button to view all vehicle info.
4-1-60
2. Diagnostic Trouble Code

Move the cursor to “Diagnostic Trouble Code” and press ENTER to see the content.
2-1. Current
Current” is for the Diagnostic Trouble Code occurred at the time
2-2. History
“History” is for Diagnostic Trouble Code occurred in the past.
Move the cursor to ”Current” and press “ENTER” to continue

After entering the page, press ▲▼ to view all the Diagnostic Trouble Code.
After viewing the Diagnostic Trouble Code, press ESC to return to the previous page.
4-1-61
Move the cursor to “History” and press “ENTER” to continue
After entering the page, press ▲▼ to view all the Diagnostic Trouble Code occurred in the
past.
After viewing the Diagnostic Trouble Code, press ESC to return to the previous page.
※
After viewing the content of “Current” or “History” Diagnostic Trouble Code, press ESC to
return to the previous page, you will see two more items on the screen - “Freeze Data” and
“Erase DTC”.
“Freeze Data” is the data recorded when FIRST Diagnostic Trouble Code occurred, and one
time only record one Diagnostic Trouble Code freeze data, it’s for saving the engine dynamic
data for further analysis.
“Erase DTC” is the function to erase all Diagnostic Trouble Code in both “Current” and
“History”.
2-3. Freeze Data

This is the content you will see when entering into the “Freeze Data”. Press ▲▼ to view the
Freeze Data.
★ NOTE: not all ECU support this function.

Numerical analysis of images (1 / 3), the waveform can be displayed as shown in the
following items:
4-1-62
Freeze Data (01/03)
Number of data
DTC
Engine speed
Throttle valve volt
Intake pressure MAP
Freeze Data (02/03)

Engine temp
Lambda Control volt
Battery volt
Atmospheric pressure
Intake air temp
2-4. Erase DTC

Move the cursor to “Erase DTC” item and press ENTER to EARSE ALL DIAGNOSTIC
TROUBLE CODE DIRECTLY!
When you see the following picture on the screen, the Diagnostic Trouble Code erasure is
completed. Press ESC button back to the main menu.
4-1-63
3. Live Data
Back to the main menu, move the cursor to “Live Data” and press ENTER to view the
content.
Press ▲▼ button to view all Live Data
4. Actuator
Move the cursor to “Activator” and press ENTER to see the content (To perform this function,
IG must be ON and engine stop running.)
4-1-64
This is the page after entering the “Activator” function
Take one activation function for example: move the cursor to “Ignition coil” item and press
ENTER to continue.
When pressing “Actuating “▲ button, the test is activated and the “Value” column shows
Open.
When pressing “Stop Actuating” ▼ button, the test is de-activated and the “Value” column
shows close.
5. Special Function
Move the cursor to “Special Function” and press ENTER to view the content
4-1-65
There are two items under “Special Function”: “Reset TPS” and “Reset Adaptive”.
Move the cursor to “Reset TPS” and press ENTER. Then you will see the following picture,
which means the RESET is completed. Press ESC button to return to the previous page.
4-1-66
Troubleshooting Table
Notes: 1. Integrated test motorcycle, according to the "Comprehensive Maintenance list"

implementation.
2. Spare parts, according to the "EFI System components description" implementation.
4-1-67
Comprehensive Maintenance List
Maintenanc
No. Testing Procedures Test items Determine benchmarks Fault reasons
e Project
 Use meter direct  Battery  Battery voltage = 10 V  Battery electricity
measurement battery above  Battery connector
voltage loose
Power and
1  Use diagnosis tool  Harness circuit
voltage
detection of battery opening
voltage  ECU coupler not
connected properly
 Use fuel pressure  Open the main  Open main switch but not  Fuel not enough
gauge connected in switch but not to start:  Fuel pump relay
series between the start the engine of Pressure = 250 kPa (stable fault
injector and the pressure value)  Fuel pump fault
pressure regulating  Pressure in Idle  Idle state:  Injector fault
valve  Rotating throttle, Pressure = 300+/-6 kPa  ECU fault
 Main switch ON but situation of (Beating situation from top
Fuel not start engine pressure changes to bottom)
2
pressure  Check fuel pressure  Rotating throttle moment:
 Start engine (Idle) Pressure=300+/-6kPa(sligh
 Check change of fuel tly beating)
pressure
 Throttle several
rotation
 Check to the change
of fuel pressure again
 The spark plug  Spark plug  Specifications: NGK-CR7H  Spark plug fault
removed from the specifications  Ignition conditions:  Roll over sensor
cylinder head but the  Whether the With traditional engines fault
3
Ignition power lines still ring spark plug ignition found ways  ECU No. 12 pin fault
state  Start engines or use  Spark plug sparks  Ignition coil fault
for the diagnosis tool of whether it is  Crankshaft position
output view spark plug normal strength sensor fault
ignition conditions
 Diagnosis tool to  Manifold pressure Manifold pressure = 32~38  Valve clearance
Engine
4 detect the use of of diagnosis tool kPa abnormal
vacuum
 Intake system leak
 The injector removed  Open the main  Not started, Injector not  Fuel pump relay
from the throttle body switch but did not leaking fuel fault
but not dismantle start engine the  In started, the injection  Fuel pump fault
pipeline injection situation state must show fan shape  Injector fault
 Main switch ON but  Injector state  ECU fault
not start engine when start
 Investigation the
Injection
5 injector it’s leaking
state
fuel?
 Start engines again or
use for the diagnosis
tool of output function
 Check injector fuel
injection and the
injection situation
 Use of diagnosis tool  Diagnosis toll of  Without any residual Fault  Throttle position
existing fault detection the fault code is it Code sensor fault
code or historical Fault can be eliminated  If residual Fault Code,  Engine temperature
Code  Start engine, the according to the “Fault Code sensor fault
 Eliminated of the fault is it will Maintenance Form”  Intake temperature
Fault Code
6 implementation of fault happen again implementation of sensor fault
Detection
codes, check can be troubleshooting  Manifold pressure
eliminated sensor fault
 Start engine again  CPS fault
 Check fault is it  ECU fault
happen again  Tilt sensor fault
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.
4-1-68
5. ENGINE REMOVAL
Precautions in Operation ..................... 5-1 Engine Installation ................................ 5-9

Removal of Engine .............................. 5-2 Engine Disassembly........................... 5-12
General Information
● The engine has to be supported with special service tools that can be lifted or adjustable.
● Engine shall be removal in the conditions of necessary repair or adjustment to the only.
● The following parts can be serviced as engine mounted
on frame: Carburetor.
Drive pulley, drive belt, clutch, and movable drive face
assembly. Start motor.
AC. Generator, oil pump and start one way
clutch.
Crankcase RH cover.
Clutch housing assy.
Unidirectional clutch.
Clutch assy.
Specification
Item Capacity
Replacement 3100 c.c.
Engine oil capacity Oil and oil filter change 3300 c.c.
Disassembly (Engine & Oil radiator) 3500 c.c.
Engine& radiator 2200 c.c.
Coolant capacity Reservoir 1200 c.c.
Total 3400 c.c.
Torque Value
Engine hanger bolt 5.4~5.9kgf-m
Exhaust muffler mounting bolt 2.8~3.2kgf-m
Exhaust muffler connection nut 1.0~1.4kgf-m
5-1
5. ENGINE REMOVAL
Engine Removal
Before taking the engine out of the frame.
Clean and wash the engine using A steam
cleaner.
Engine removal is explained in the following.
Steps.
Reinstall the engine by reversing the removal
procedure.
‧Before removal the engine. Drain engine oil
‧Remove the seat.
‧Remove the seat lock plate.
‧Remove battery negative post (－).
‧Remove battery positive post (＋).
Remove the starter motor wire.
Remove the front fender side cover. (L and R)
Remove the footrest nut guard. (L and R)

Remove the Fuel tank cover
5-2
5. ENGINE REMOVAL
Remove the gearshift lever.
Remove the fuel hose and vacuum hose.

Fuel pipe
Vacuum pipe
Remove the air cleaner.
Remove the cover of throttle body.
5-3
5. ENGINE REMOVAL
Remove the speedometer cable.
Remove the gearshift mud.
Remove the connector of lead wire.

Remove the signal generator lead wire
connector and generator lead wire connector.
Remove the spark plug cap.
5-4
5. ENGINE REMOVAL
Remove the right footrest.
Remove the brake pedal.
Remove the muffler.
Remove the exhaust pipe.
5-5
5. ENGINE REMOVAL
Remove the front and rear tube.
Remove the front shaft bolts and springs.
Remove the selflock nut and take out the bolt.
Note: Install the selflock nut with specified

torque
(540~590 kgf-cm).
Remove the nut onto the bush and take down

engine bolster.(each side)
5-6
5. ENGINE REMOVAL
Remove the nut under the bush and take out

the bush from first hole.(each side)
Front hole
Longer
Remove the selflock nut and take out the bolt.

torque
(540~590 kgf-cm).
Take down the bush (each side).
Note: The flange of bush points to inside.

Inside
5-7
5. ENGINE REMOVAL
Remove the nut and selflock nut.
Take out the engine bolster, bolt and washers.

torque
(540~590 kgf-cm).
Remove the nut.
Take out the bush.
Longer
Remove the bolt and take out the engine

bolster.
5-8
5. ENGINE REMOVAL
Engine installation
Remove the engine in the reverse order of
engine removal.
Caution
The engine mounting nuts are self-locking
once the nut was been removed it is no longer
of any use.
Be sure to use new nuts. For every time engine Torque value：5.4~5.9 kgf-m
installation and tighten them according the
torque standard.
Install the spring (shorter N/P 925334) into front

differential assy. Front Differential Assy.
Install the spring into rear differential assy.
5-9
5. ENGINE REMOVAL
Rear Differential Assy.
Torque value:
Front and rear propeller shaft flange coupling
bolt:
45N-m(4.5kgf-m, 32.5lb-ft)
Install the gasket.

Check if the gasket has been damage.
Please replace with the new one.
Apply sealant to the muffler mounting bolt

Install muffler. Pay attention don’t damage the
connector.
Tighten the exhaust pipe nuts and muffler bolts
with
specified torque.
5-10
5. ENGINE REMOVAL
Exhaust pipe nut:
Connector bolt:
Muffler mounting bolt: 25N-m (2.5kgf-m,
16.5lb-ft)
Apply sealant to the muffler mounting bolt to the

muffler fixed bolts and tighten them.
Apply sealant to the muffler mounting bolt to the

muffler fixed bolts and tighten them. (N/A)
Install 2 muffler’s bolt comp. from the rear

frame.
At first, install blot,washer and bush with
specified torque
(30~40 kgf-cm).
Then, install the nut with specified torque
(250~300 kgf-cm).
5-11
5. ENGINE REMOVAL
Engine Disassembly
Remove starter motor wire.
Remove oil pressure switch’s wire.
Remove the hose.
Remove the spark plug cap.

Remove the wire.
Spark Plug Cap
Remove the thermostat.
Remove the spring bolt and remove the cam

chain tensioner adjuster assy.
5-12
5. ENGINE REMOVAL
Remove the engine oil pipe nuts.
Remove the outlet water hose.
5-13
6. CYLINDER HEAD/VALVE
Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10

Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11
Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13
Cylinder Head Removal ······················ 6-4 Cylinder Head Installation ················· 6-14
Cylinder Head Inspection ···················6-7 Valve Clearance Adjustment ············· 6-16
Mechanism Diagram
6-1
General Information
● This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
● Cylinder head service can be carried out when engine is in frame.
Specification
500 cc 600 cc
Item Standard Limit Standard Limit
Compression pressure 6~10 bar --- 9-11 bar ---
Intake 33.842 33.892 33.07 33.12

Camshaft Height of cam lobe
Exhaust 33.727 33.777 32.95 33.10
Rocker ID of valve rocker arm 12~12.018 12.080 12~12.018 12.080
arm OD of valve rocker arm shaft 11.966~11.954 11.936 11.984~11.966 11.954
Intake 4.975~4.990 4.900 4.975~4.990 4.900

OD of valve stem
Exhaust 4.950~4.975 4.900 4.950~4.975 4.900
ID of valve guide 5.000~5.012 5.030 5.000~5.012 5.030
Clearance between Intake 0.010~0.037 0.080 0.010~0.037 0.080
valve stem and guide Exhaust 0.025~0.062 0.100 0.025~0.062 0.100

Valve
Free length of valve Inner 36 32.5 --- ---
spring Outer 39.5 36.0 41.1 37.6
Valve seat width 1.600 --- 1.600 ---
Intake 0.10±0.02mm --- 0.10±0.02mm ---

Valve clearance
Exhaust 0.15±0.02mm --- 0.15±0.02mm ---
Torque Value
Cylinder head cover bolt 1.0~1.2kgf-m
Exhaust pipe stud bolt 2.4~3.0kgf-m
Cylinder head bolt M6 1.0~1.2kgf-m
Cylinder head bolt M10 First torque M10 cylinder head bolts with Loctite in cross sequence to 20
Nm+/- 1 Nm two times then finish by tightening to 180° +/- 5°.
Sealing bolt of cam chain auto-tensioner 1.0kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cylinder side nut 1.0~1.2kgf-m
Cam sprocket bolt 1.0~1.2kgf-m
Tappet adjustment screw nut 0.7~1.1kgf-m
Spark plug 1.0~1.2kgf-m
Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-2
Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can
be determined or by performing cylinder compression test and judging the abnormal noise
generated.
Low compression pressure

1. Valve
● Improper valve adjustment
● Burnt or bent valve
● Improper valve timing
● Valve spring damage
● Valve carbon deposit.
2. Cylinder head
● Cylinder head gasket leaking or damage
● Tilt or crack cylinder
3. Piston
● Piston ring worn out.
High compression pressure

● Too much carbon deposit on combustion chamber or piston head
Noise
● Improper valve clearance adjustment
● Burnt valve or damaged valve spring
● Camshaft wear out or damage
● Chain wear out or looseness
● Auto-tensioner wear out or damage
● Camshaft sprocket
● Rocker arm or rocker arm shaft wear out
6-3
Cylinder Head Removal Remove

engine. (Refer to chapter 5) Remove the inlet
pipe (2 bolts)
Bolts
Remove 1 bolt of thermostat and then remove

Thermostat bolts
the thermostat. Tensioner bolts
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Remove spark plug
Remove the screws of cylinder head.(2 bolts)

Remove the nuts of cylinder.(2 nuts)
6-4
Remove cylinder head cover, and hole

bolts(4 bolts)
Remove fix stand for spindle .cam (6 bolts)
Remove cam sprocket bolts and then remove

the sprocket by prying chain out.
Remove cam chain tensioner and hole bolt.
Remove cam shafts.

Remove Rocker arm and cam shaft puller
6-5
Remove the 4 cylinder head mounting bolts from

cylinder head right side, and then remove 4 bolts
and washers from cylinder head upper side.
Remove the cylinder head.
Remove cylinder head gasket and 2 dowel pins.

Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Caution
● Do not damage the matching surfaces of

● Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.
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
6-6
Remove valve stem seals.
Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of cylinder

head.
Cylinder Head Inspection
Check if spark plug and valve holes are cracked.

Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 33.12mm
EX: Replacement when less than 33.10mm
Inspect the camshaft bearing for looseness or
wear out.
If any damage, replace whole set of camshaft
and bearing.
6-7
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.
Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm
shaft and cam rocker arm.
11.954 mm.
Calculate the clearance between the rocker arm

shaft and the rocker arm.
0.10 mm.
Valve spring free length

Measure the free length of intake and exhaust
valve springs.
Service limit: 37.6mm
spring 41.1 mm
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
6-8
Valve guide
Caution
Before measuring the valve guide, clean carbon

deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner

diameters.
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.10 mm
EX→0.15 mm
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
Valve Stem Replacement

Heat up cylinder head to 100~150 ℃ with
heated plate or toaster.
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
℃.
Adjust the valve guide driver and let valve guide

height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room

temperature, and then correct the new valve
guide with reamer.
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
Valve Seat Inspection and

Service
Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other
manual grinding tool.
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, wears out, or incomplete contacted
with valve seat.
Valve seat width
Valve seat inspection
If the valve seat is too width, narrow or rough,
corrects it.
Valve seat width

Service limit: 1.6mm
Check the contact condition of valve seat. Roughness
Valve seat grinding

The worn valve seat has to be ground with valve
seat chamfer cutter. 45°
Refer to operation manual of the valve seat
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any
rough or uneven surface from valve seat.
Caution
After valve guide had been replaced, it has to be

Old Valve seat width
ground with 45° valve seal chamfer cutter to
correct its seat face.
Use 32° cutter to cut a quarter upper parts out.
32°
6-11
Use 60° cutter to cut a quarter lower parts out.
Remove the cutter and check new valve seat.
Old Valve seat width
60°
Use 45° cutter to grind the valve seat to

specified width.
Caution Old Valve seat width
Make sure that all roughness and uneven faces

had been ground.
Grind valve seat again if necessary.
45°
Coat the valve seat surface with red paint.

Install the valve through valve guide until the
valve contacting with valve seat, slightly press Contact surface too high
down the valve but do not rotate it so that a seal
track will be created on contact surface. Old Valve seat width
Caution
The contact surfaces of valve and valve seat are 32°

very important to the valve sealing capacity.
If the contact surface too high, grind the valve

seat with 32° cutter.
Then, grind the valve seat to specified width.
Contact surface too low
If the contact surface too low, grind the valve
seat with 60° cutter. Old Valve seat width
Then, grind the valve seat to specified width.
60°
6-12
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and
valve after ground.
Cylinder Head Reassembly

Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal. Install valve
springs and retainers.
Caution
The closed coils of valve spring should face

down to combustion chamber.
Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.
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
Tap the valve stems gently with a plastic hammer

to make sure valve retainer and valve cotter is
settled.
Caution
Place and hold cylinder head on to working table

so that can prevent from valve damaged.
6-13
Cylinder Head Installation

Cylinder head Installation
For installation, reverse the removal procedure.
NOTE: Never invert front and rear cylinder
heads.
▪ Ensure dowel pins and key are in place.
NOTICE: Timing chain guide (fixed) has to be

fixed between cylinder and cylinder head.
▪ Install a NEW cylinder head gasket.

1
▪ First torque M10 cylinder head bolts with
3
LOCTITLE in cross sequence to 20 Nm+/- 1
Nm two times then finish by tightening to 180°
+/- 5°.
Caution
4
Do not damage the matching surfaces of 2
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
M6 screws
Screw: M6:1.0~1.2kgf-m
Nut: M6: 1.0~1.2kgf-m

M6 nut
Install camshaft into cylinder head.

Install rocker arm, rocker arm shaft.
Install cam chain tensioner into cylinder head
Install 6 bolts on the stand for spindle,cam.
Bolt: 1.0~1.2 kgf-m.
6-14
Install cam chain on to sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.
Caution
Make sure timing marks are matched.

Install the lock washer so that it is covering the
locating pin.
Bend up the washer tongue positively to lock

bolts.
A B
Align the line Ⓐ on the generator rotor with the

index mark Ⓑ on the crankcase.
Loosen auto tensioner adjustment bolt and

remove bolt and spring.
Install tensioner and install spring and
adjustment bolt.
Install thermostat(2 bolts)
Install cylinder cover (4 bolts).

Tighten cylinder head cover retaining bolts to
specified torque in a criss-cross sequence.
TORQUE: 1.0~1.2 kgf.m
6-15
Install and tighten spark plug
Torque value: 1.0~2.0kgf-m
ten the sprocket mounting 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 motorcycle’s
performance be effected.
Install the engine onto frame (refer chapter 5).
Valve Clearance Adjustment

Remove cylinder head cover.(3 bolts)
Align the line Ⓐ on the generator rotor with the A B
index mark Ⓑ on the crankcase.
Loosen valve clearance adjustment nuts and

bolts located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to

standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Start the engine and make sure that engine oil

flows onto the cylinder head.
Stop the engine after confirmed, and then install
the cylinder head cover.
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
7. CYLINDER/PISTON
Mechanism Diagram ···························· 7-1 Piston Ring Installation ···················7-6

Precautions in Operation ···················· 7-2 Piston Installation ····························7-7
Trouble Diagnosis································ 7-2 Cylinder Installation ·························7-7
Cylinder and Piston Removal ············· 7-3
Mechanism Diagram
7-1
7. CYLINDER/PISTON
General Information
Specification
500 cc 600 cc
Item Standard Limit Standard Limit
ID 92.022~92.052 92.100 95.022~95.052 95.100
Cylinder
Bend - 0.050 - 0.050
Clearance Top ring 0.04~0.075 0.011 0.04~0.075 0.011
between
piston 2nd ring 0.02~0.055 0.090 0.02~0.055 0.090
rings
Top ring 0.150~0.300 0.500 0.30~0.50 0.70
Ring-end
2nd ring 0.300~0.450 0.650 0.45~0.65 0.85
Camshaft gap
Oil ring side rail 0.200~0.700 - 0.20~0.70 -
Rocker arm nd
OD of piston (2 ) 92.30~92.50 92.25 95.30~95.50 95.25
Clearance between piston and
0.04~0.058 0.12 0.04~0.058 0.12
cylinder
ID of piston pin boss 22.001~22.006 22.020 22.001~22.006 22.020
OD of piston pin 21.996~22.000 21.960 21.996~22.000 21.960
Clearance between piston and piston pin 0.001~0.010 0.020 0.001~0.010 0.020
ID of connecting rod small-end 22.002~22.01 22.040 22.002~22.01 22.040
Trouble Diagnosis
Low or Unstable Compression Pressure
● Cylinder or piston ring worn out
Knock or Noise
● Cylinder or piston ring worn out
● Carbon deposits on cylinder head top-side
● Piston pin hole and piston pin wear out
Smoking in Exhaust Pipe

● Piston or piston ring worn out
● Piston ring installation improperly
● Cylinder or piston damage
Engine Overheat
● Carbon deposits on cylinder head top side
● Cooling pipe clogged or not enough in coolant flow
7-2
7. CYLINDER/PISTON
Cylinder and Piston Removal

Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder. Remove
cylinder.
Cover the holes of crankcase and cam chain with

a piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.
Remove cylinder gasket and dowel pin.

Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.
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.
7-3
7. CYLINDER/PISTON
Check cylinder if warp.
Service Limit: 0.09 mm
Measure clearance between piston rings and

grooves.
Service Limit: Top ring: 0.09 mm

2nd ring: 0.09 mm
Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.
Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm

2nd ring: 0.65 mm
7-4
7. CYLINDER/PISTON
Measure the outer diameter of piston pin.
Measure the inner diameter of connecting rod

small end.
Measure the inner diameter of piston pin hole.

Calculate clearance between piston pin and its
hole.
Service Limit: 0. 2 mm
Measure piston outer diameter.
Caution
The measurement position is 8 mm distance
from piston bottom side, and 90° to piston
pin.
Service limit：85.850 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.
110˚
Top ring(N)
125˚ 125˚
2nd ring(2R)
Oil ring
7-6
7. CYLINDER/PISTON
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.
Piston Installation
Install piston and piston pin, and place the
marks on the piston topside forward to exhaust
valve.
Install new piston pin clip.
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.
Cylinder Installation
Install dowel pins and new gasket.
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
Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).
7-8
8. V-BELT DRIVING SYSTEM
Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-5

Maintenance Description ···················· 8-2 Drive Face·············································8-7
Trouble Diagnosis ·······························8-2 Clutch Outer/Driven Pulley···················8-10
Clutch Cover ······································ 8-3
Mechanism Diagram
8-1
Maintenance Description
General Information
● Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
● Drive belt and drive pulley must be free of grease.
Specification
Item Standard value Limit
Driving belt width 28.500 mm 27.000 mm
OD of movable drive face boss 26.946~26.980 mm 26.926 mm
ID of movable drive face 27.000~27.040 mm 27.060 mm
OD of weight roller 25.800~26.000 mm 25.000 mm
ID of clutch outer 140.000~140.200 mm 140.500 mm
Free length of driven pulley spring 230.000 mm 225.000 mm
OD of driven pulley boss 44.965~44.985 mm 40.935 mm
ID of driven face 45.000~45.035 mm 45.600 mm
Weight of weight roller 13.300~13.500 g 13.800 g
Torque value Special Service Tools

Clutch spring compressor:
● Drive face nut: 10~12kgf-m
Inner bearing puller: TGB-
● Clutch outer nut: 10~12.0kgf-m
Clutch nut wrench 27 x 15 mm: TGB-
● Drive plate nut: 10~12kgf-m Universal holder: TGB-
Bearing driver: TGB-
Trouble Diagnosis
Engine can be started but motorcycle Insufficient horsepower or poor
can not be moved high speed performance
1. Worn drive Belt 1. Worn drive belt
2. Worn drive face 2. Insufficient spring force of driven pulley
3. Worn or damaged clutch weight 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly
Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight
8-2
Clutch Cover
Clutch cover removal
Release the 2 clamp strips of clutch cover ducts,
and then remove the ducts.
Remove clutch cover. (14 bolts)
Remove 2-dowel pin and gasket.
Clutch cover install

Install left clutch cover in the reverse procedures
of removal.
Clutch over inspection

Check bearing on clutch cover.
Rotate bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
8-3
Drive Belt
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and
remove nut and drive face.
Special Tool：Clutch And CVT Holder (440666)
Hold clutch outer with universal holder, and

remove nut, and clutch outer.
Caution
● Using special service tools for tightening
or loosening the nut.
● Fixed rear wheel or rear brake will
damage reduction gear system.
Push the drive belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive
belt. Remove the drive belt from the groove of
driven pulley.
Inspection
Check the drive belt for crack or wear.
Replace it if necessary.
Measure the width of drive belt as diagram
shown.
Replace the belt if exceeds the service limit.
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.
8-4
Installation
Caution
●Pull out driven face to avoid it closing.
●Cannot oppress friction plate comp in
order to avoid creates the distortion or
the damage.
●Install drive belt onto driven pulley.
Install the driven pulley that has installed the belt

onto drive shaft.
On the drive belt another end to the movable
drive face.
Install the clutch outer . Hold the clutch outer whit

universal holder, and then tighten nut to specified
torque value.
Torque value: 10~12kgf-m
Special Tool：Clutch And CVT Holder (440666)
Install the drive face, washer and drive face nut.

Hold drive face with universal holder, and then
tighten nut to specified torque value.
8-5
Drive Face
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Remove movable drive face comp and drive face

boss from crankshaft. Movable drive face
Drive face boss
Remove ramp plate.
Remove weight rollers from movable drive face.
8-6
Inspection
The weight rollers are to press movable drive
face by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged.
Replace it if necessary.
Measure each roller’s outer diameter.
Replace it if exceed the service limit.
Weight: 13.5g
Check if drive face boss is worn or damaged and

replace it if necessary.
Measure the outer diameter of movable drive
face boss, and replace it if it exceed service limit.
Measure the inner diameter of movable drive
face, and replace it if it exceed service limit.
Service limit:27.060 mm
Reassembly/installation
Install weight rollers.
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.
Install ramp plate.
8-7
With 4~5g grease spreads wipes drives in the

movable drive face axis hole.
Install drive face boss.
Caution
●The movable drive face surface has to be
free of grease.
●Clean it with cleaning solvent.
Driven pulley installation (By 2 screw)

Press drive belt into pulley groove, and then pull
the belt onto drive shaft.
Install Movable drive face, and nut.

Loosen the 2 screws.
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.

Install left crankcase cover.
8-8
Clutch Outer/Driven Pulley Clutch nut wrench

Disassembly
Remove drive belt, 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. Clutch spring compressor
Hold the clutch spring compressor onto bench

vise, and then remove mounting nut with special
service tool.
Release the clutch spring compressor and
remove movable driven sheave and spring from
driven pulley.
Remove seal collar from driven pulley. Collar
Remove guide pin, guide pin roller, and movable

Seat Guide Pin
driven face, and then remove O-ring & oil seal
seat from movable driven face.
Guide Pin Roller

O-ring Guide Pin
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
8-9
Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 225 mm
Free Length
Driven pulley
Check following items:
If both surfaces are damaged or worn. Driven Face
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 44.93 mm
Inner diameter 45.60 mm
Driven Face
Guide Pin Groove
8-10
Installation of Clutch OUTER/Driven Pulley

Oil Seal
Assembly
Install new oil seal and O-ring onto movable
driven face.
Apply with specified grease to lubricate the
inside of movable driven face.
Special Grease
O-ring
Install the movable driven face onto driven face.

Install the guide pin and guide pin roller.
Install the collar.
Install friction plate, spring and into clutch spring

compressor, and press down the assembly by
turning manual lever until mounting nut that can
be installed.
Hold the compressor by bench vise and tighten

the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.

Install driven pulley and drive belt onto drive
shaft.
8-11
Notes :
8-12
9-1. FRONT DIFFERENTIAL
FRONT DRIVE (FRONT DIFFERENTIAL)
825 +/- 25 kgf-cm

Apply Loctite
#263
9-1-1
DRIVE SYSTEM
FRONT DRIVE
GENERAL
During assemble/installation, use torque values and service products as in the exploded views.
Clean threads before applying thread locker.
WARNING
Torque wrench tightening specifications must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, cotter pin, etc.)
must be replaced.
Hoses, cables or locking ties removed during a procedure must be reinstalled as per factory
standards.
WHEEL HUB
Wheel Hub Removal
▪ Lift and support vehicle.
▪ Place the transmission lever on “P”.
▪ Remove caliper from knuckle.
▪ Remove the following parts:
- Wheel
- Cotter pin.
- Castellated nut.
- Washer.
▪ Remove wheel hub.
Wheel Hub Inspection

▪ Check wheel hub for cracks or other damages.
▪ Check inner splines for wear or other damages.
▪ If any damage is detected on wheel hub, replace it
with a new one.
Wheel Hub Installation

▪ For installation, reverse the removal procedure.
▪ Install washer with its concave side towards
outward.
TORQUE: 225 Nm.
NOTE: Tighten further castellated nut if required to
align grooves with drive shaft hole.
▪ Install a NEW cotter pin.
9-1-2
DRIVE SHAFT
REMOVAL
▪ Lift and support vehicle.
▪ Remove the wheel hub.
▪ Remove the knuckle.
▪ Apply special tool # 440649 strongly pull drive
shaft out of differential.
▪ Discard the stop ring at the end of the shaft.
INSPECTION
▪ Inspect the condition of boots. If there is any
damage or evidence of leaking lubricant,
replace them.
▪ Check splines for excessive wear. Replace if
necessary.
NOTE: If the splines on plunging joint are worn,
a check of differential inner splines should be
done.
INSTALLATION
▪ For installation, reverse the removal
procedure.
▪ Install a NEW stop ring.
▪ Apply SYNTHETIC GREASE to the splines.
▪ The wear ring should be closed to the
differential.
▪ Reinstall all removed parts.
DRIVE SHAFT BOOT

REMOVAL
▪ Remove the drive shaft from the vehicle.
▪ Remove drive shaft boot clamps using special
tools.
▪ Dislodge the large boot end.
▪ Separate the joint from the shaft.
▪ Remove boot from drive shaft.
▪ Remove and discard the circlip.
9-1-1
INSTALLATION
procedure.
▪ Install new circlip.
▪ Pack bearing area with grease.
NOTE: Do not use or add other grease.
▪ Install new drive shaft clamps.
FRONT DIFFERENTIAL
REMOVAL
Caution
Be sure the differential set temperature below
35℃
▪ Drain the differential oil.
▪ Remove both drive shafts.
▪ Detach vent hose from front differential.
▪ Remove 2WD/4WD mode select cables.
▪ Remove LOCK mode select cables.
▪ Remove securing the differential bolts and

nuts.
9-1-2
▪ Lift up the differential and slide forward to

detach from the propeller shaft.
▪ Remove the front differential by pulling it from
the RH side.
NOTICE: Be careful not to knock or to bend
vent hose fitting while removing front
differential.
▪ Loose and remove six bolts on the LOCK

cover.
▪ Check the shift fork oil seal, replace if damage.
▪ Check the LOCK cover bearing, replace if

necessary.
FRONT DIFFERENTIAL DISASSEMBLY

▪ Loose and remove six differential housing
bolts then separate half housings.
9-1-1
▪ Check the oil seal, replace if necessary.
▪ Remove the anti-slip gear set (A) and shim

(B), check the bearing, replace if necessary.
B
A
▪ Remove the “C” clip.
▪ Remove the oil seal and discard, replace new

one when reassemble.
9-1-2
▪ Using special tool pull out the bearing. Check

the bearing replace if necessary.
▪ Using plier remove the “C” clip.
▪ Using rubber hammer lightly knock out the

pivot gear.
▪ Remove the “C” clip (as shown) and pull out

the shift shaft.
▪ Remove the oil seal and pull out the shift shaft.
9-1-1
ASSEMBLY
▪ Apply the Loctite #510 on the contact surface
of half case.
NOTE: Before apply Loctite, clean the old glue.
▪ Cross tighten the bolts as shown.
Torque : 120~150kgf-cm)
▪ Apply the Loctite #510 on the contact surface

of LOCK cover.
NOTE: Before apply Loctite, clean the old glue.
▪ Install the dowel pin.
▪ Cross tighten the LOCK cover bolts as shown.
Torque : 120~150kgf-cm)
9-1-2
Torque :
A : gear oil levelcheck bolt 70~90kgf-cm) B
B : Gear oil filling bolt 300~350kgf-cm
CABLE ADJUSTING
LOCK MODE CABLE ADJUSTMENT.
▪ Loose jam nut to adjust the cable length.
▪ Adjust the suitable length by the rotate the
nuts as shown.
▪ Apply special tool #552309-1 on the position

as shown and adjust the cable length.
2WD/4WD MODE CABLE ADJUSTMENT.

▪ Apply special tool #552309-2 on the position
as shown and adjust the cable length.
9-1-1
INSTALLATION
procedure.
▪ Fill the gear oil and tighten the bolt.
Caution
Oil standard:SAE#90 hypoid gear oil
Oil capacity: 350c.c.
Bolt Torque : 33N-m
DIFFERENTIAL MOTOR
▪ Disconnected the wiring connector.
▪ Unscrew three differential motor bolts.
INSTALLATION
procedure.
9-1-2
9-2.REAR DIFFERENTIAL
REAR DRIVE (REAR DIFFERENTIAL)
A:4.2~4.4 kgf-m
B:3.0~3.5 kgf-m
C:0.7~0.9 kgf-m
D:2.0~2.2 kgf-m
E、F:1.2~1.5 kgf-m
G: 11~12kgf-m
9-2-1
9-2. REAR DIFFERENTIAL
REAR DIFFERENTIAL
REMOVAL
Caution
Be sure the differential set temperature below
35℃
▪ Drain the differential oil.
▪ Remove both drive shafts.
▪ Detach vent hose from rear differential.
▪ Remove the lock mode cables.
▪ Remove the four bolts and bracket as shown.
▪ Remove the upper front end three bolts from

the frame as shown.
▪ Remove front end upper and bottom bolts as

shown.
▪ Lift up the differential and slide backward to
detach from the propeller shaft.
▪ Remove the rear differential by pulling it from
the RH side.
NOTICE: Be careful not to knock or to bend
vent hose fitting while removing front
differential.
9-2-2
INSTALLATION
Reverse the removal procedure install the rear
differential.
▪ Apply grease into the propeller shaft end.
▪ Install the rear differential and insert the

differential shaft into the connecting shaft, put
the boot on the position as shown.
▪ Install rear brackets and tighten with bolts,

washers and nuts as shown.
Torque : 4.5~5.5kgf-m
▪ Assemble the upper bracket and tighten with

three bolts on the front top of rear differential
as shown.
Torque : 2.2~2.5kgf-m.
9-2-1
▪ Tighten the upper and bottom front end bolt as

shown.
▪ Install and fixed the vent hose as shown.
NOTE: keep the vent hose away from the

exhaust.
▪ Install the cable, apply special tool #560023 to

adjust the length.
▪ Tighten the nut.
▪ Reverse the removal procedure; install the

relative parts.
▪ Refill the gear oil to 500 cc and tighten the bolt
and washer.
Caution
Oil standard:SAE#90 hypoid gear oil
Oil capacity: 500 c.c.
Torque: 3.0~3.5 kgf-m
9-2-2
REAR DIFFERENTIAL DISASSEMBLY

▪ Remove the differential housing eight bolts.
▪ Apply rubber hammer lightly knock the case

(red area as shown) to separate the half case.
▪ Check “O” ring, replace if necessary.
▪ Remove the anti-slip limited gear assy. and the

shims.
9-2-1
▪ Check the two bearing, replace if necessary.
NOTE: beware the foreign object falling into the

slip limited gear assy.
▪ Check the bearing on the left half case,

replace if necessary.
▪ Check oil seal, replace if necessary.
NOTE: Apply grease on rear area as shown

before install oil seal.
9-2-2
REAR DIFFERENTIAL ASSEMBLE

▪ Install shim into the case as shown.
▪ Install anti slip limited gear assy. into the case

and apply rubber hammer lightly knock to the
position as shown.
▪ Install two dowel pin on the left half case.
▪ Apply Loctite #263 on the eight bolts and cross

tighten.
NOTE: Ensure the O-ring install properly.
Torque: 2.0~2.2kgf-m.
9-2-1
LOCK MODE ASSY. DISASSEMBLE

▪ Remove five bolts.
▪ Apply rubber hammer light knock to separate

the case.
▪ Check the oil seal, replace if necessary.
NOTE: shift shaft seal recommend replace after
assemble.
▪ Check bearing, replace if necessary.
▪ Remove shift rod assy. and other parts.
9-2-2
LOCK MODE ASSY. ASSEMBLE

▪ Install the two dowel pin as shown.
▪ Install the lock sleeve and shift rod.
▪ Clean the old glue and apply Loctite #510 on

the contact surface as shown.
▪ Assemble the case.
9-2-1
▪ Apply Loctite #263 on the three bolts and

cross tighten as shown.
NOTE: S70810 is shortest bolt.
.
Torque : 1.2~1.5kgf-m。
NOTE: Check and test the shift rod function.
▪ Install shift rod oil seal.
▪ Install bracket and tighten the two bolts.
▪ Install the LOCK cable.
REAR DIFFERENTIAL ADJUSTMENT

▪ Using special tool to adjust the cable.
▪ Adjust the suitable length by the rotate the

nuts
9-2-2
PIVOT GEAR DISASSEMBLE

▪ Remove four bolts and lightly knock out the
housing.
▪ Check the oil seal and O ring, replace if
necessary.
▪ Using special tool #560010 to remove the ring

snap.
▪ Apply rubber hammer from the inside of case

lightly knock out the gear to remove the shaft
from the case.
NOTE: Beware the knocking might damage the

bearing.
▪ Check the bearing, replace if necessary.
▪ Before install new bearing, apply some

lubricate oil inside the bearing.
9-2-1
PIVOT GEAR ASSEMBLE

▪ Reverse the disassemble procedure install the
shaft and bearing into case.
▪ Apply Loctite #263 on the ring snap, and Apply
special tool #560010 to install.
Torque : 11~12kgf-m
▪ Apply Loctite #263 on the four bolts, and install

the housing and tighten.
Torque : 4.2~4.4kgf-m
DIFFERENTIAL MOTOR
REMOVAL
Disconnected the wiring connector.
Unscrew three differential motor bolts.
INSTALLATION
9-2-2
10. ALTERNATOR/STARTING CLUTCH
Mechanism Diagram ···························10-1 Flywheel Removal ································10-4

Precautions in Operation····················10-2 Starting Clutch ·····································10-5
Right Crankcase Cover Removal ·······10-3 Flywheel Installation ····························10-7
A.C.G. Set Removal ·····························10-3 A.C.G. Set Installation·························· 10-8
Lift Cover Bearing································10-3 Right Crankcase Cover Installation····10-8
Mechanism Diagram
4.0~5.0kgf-m
1.0~1.5kgf-m
1.0~1.5kgf-m
0.8~1.2kgf-m 3.0~3.5kgf-m
16~18kgf-m
10-1
General information
● Refer to chapter 17: The troubleshooting and inspection of alternator
● Refer to chapter 17: The service procedures and precaution items of starter motor
Specification
Item Standard value (mm) Limit (mm)
ID of starting clutch gear 29
OD of starting clutch gear 52.548~52.445
Torque value
Flywheel nut 16~18kgf-m

Not to be reused should be replaced when disassembled
Starting clutch hexagon bolt 1.2~1.5kgf-m with adhesive
8 mm bolts 2.8~3.0kgf-m
12 mm bolts 1.0~1.4kgf-m
Tools
Special tools
A.C.G. flywheel puller: 440659
10-2
Left Crankcase Cover Removal
15 bolts
Remove left footrest.
Drain out the engine oil and coolant, and then
remove coolant hoses.
Remove water pump (2 bolts).
Remove 15 bolts from the left crankcase cover. Water pump bolts
Remove the left crankcase cover.
Remove dowel pin and gasket.
A.C.G. Set Removal

Remove 3 mounted screws from pulse
generator and then remove it. Wire
Prized open three fixed-points.
Remove 3 screws from left crankcase cover and
then remove generator coil set.
Left Cover Bearing

Inspection
Rotate the bearing with finger to check if the
bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Remove the bearing.
10-3
Check the oil seal for wear or damage.
Replace it if necessary. Oil seal
Install a new one bearing (16005) by bearing

driver.
Bearing
Flywheel Removal
Remove left crankcase cover. Flywheel nut
Remove starter reduction gear and shaft. Pull

out flywheel with A.C.G. flywheel puller.
Special tool:
A.C.G. Flywheel puller (440659)
Remove flywheel and starting driven gear.
10-4
Starting Clutch
Starting Clutch Inspection
Remove starting clutch driven gear. ID
Check the gear for wear or damage.
Measure the ID and OD of the starting clutch
driven gear.
Service Limit: ID: 29 mm
OD: 52.54mm
OD
Check the starting reduction gear and shaft for

wear or damage.
Check each roller for wear or damage.
Install starting clutch driven gear onto one way

clutch.
Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
(View as shown in this figure.)
10-5
One way clutch removal
Remove starting driven gear.
Starting driven gear
Remove 6 socket bolts, and then remove one

way clutch.
6 socket bolts
One way clutch
One way clutch Installation

Install the components in the reverse procedures 6 socket bolts
of removal.
Caution
Tape a tightening tape onto the thread of
hexagon bolt.
10-6
Install starting driven gear.
Flywheel Installation
Align the key on crankshaft with the flywheel
groove, and then install the flywheel. Groove
Hold the flywheel by drive face with

universal holder, and tighten flywheel nut.
Caution
Flywheel nut not to be reused should be
replaced when disassembled
Torque value:16~18kgf-m
Special tool: Flywheel Puller (440664)
Install reduction gear shaft and reduction gear.

Reduction gear
10-7
A.C.G. Set Installation
Put the new gasket on.
Install the A.C.G. coil set onto left crankcase
cover (3 screws). Torque value:1.7kgf-m
Bend up the gasket tongue positively to lock
screws.
Install pulse generator (3 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed
under pulse generator.
Left Crankcase Cover Installation

Install dowel pin and new gasket.
Dowel pin
Remove water pump cover.

Install left crankcase cover onto the crankcase.
Note: Align the water pump shaft indent with the

water pump gear shaft.
10-8
Install left crankcase cover (15 screws).
Install the dowel pin, new gasket and water pump 15 bolts
cover onto left crankcase cover.
Water pump bolts
Install the water pipe.

Install the recoil starter assy.(4 bolts).
10-9
Note:
10-10
11. CRANKSHAFT / CRANKCASE
L CASE
R CASE
11-1
Oil SEAL
Remove the oil seal with the special tool.
Oil seal remover 440656
Install the oil seal with the special tool.
Bearing installer set 440655
Caution
Change the new oil seal to prevent oil
leakage.
NOTE:
Be sure the stamped mark on the oil seal faces
outside.
OIL SEPARATOR
When installing the oil guide plate, apply a small
quantity of Loctite 262TM (Thread locker) to the
screw.
11-2
BEARING REASEMBLY
Install the bearing.
NOTE:
Be sure The sealed cover of the bearing must
face outside.
Install the chuck,Bearing.
NOTE:
When installing the Bearing chuck,apply a small
quantity of Loctite 262TM (Thread locker) to the
screws.
11-3
DRIVE BELT COVER
Remove the snap ring with the snap ring pliers.
NOTE:
If any damage the bearing, replace the new
one.
Remove the bearing.
REASSEMBLY
Install the snap ring with snap ring pliers.
11-4
L CRANK CASE COVER
Remove the oil pressure valve
When installing the oil valve, tighten it to the
specified Torque.
Oil pressure value:25N．M(2.5kgf-m,17lb-ft)
Using an shaped tool to check the oil pressure

valve
Operation. If the piston does not operate, replace
the new one.
ASSEMBLY
Remove the generator stator.
Remove the oil seal retainer of crank case cover.
NOTE:
If the bearing is not abnormal noise, these is not
necessary to replace the new one.
11-5
Remove the oil seal.
REASSEMBLY
Apply Grease to the bearing,O-ring and Oil seal

lip.
Install the oil seal.
NOTE:
When installing the oil seals, be sure the
stamped mark
on the oil seal faces outside.
Apply a small quantity of Loctite 262TM (Thread

locker) to the screws and install the bearing
retainer.
11-6
CRANKSHAFT
Mounting the crankshaft in the crankcase.
NOTE:
Use the front fork oil seal installer as an
attachment.
Front fork oil seal installer 440655
Apply a small quantity of Loctite 262TM (Thread

locker) to the thread and install and the
gearshift cam stopper.
BALANCER
Install the balancershaft.
Install the key.
Install the balancershaft driven gear.

Install the driven gear balancershaft by aligning
the punched marks.
11-7
Apply Loctite 510 (Flange sealant) to the mating

surface of the left crankcase.
L CASE
R CASE
11-8
Assemble the crankcase within few minutes.
NOTE:
After crankcase screws have been tightened,
check if crankshaft rotate smoothly.
Fit the clamp to the bolt.
Check the each shaft rotates smoothly after the

crankcase bolts have been tightend.
OIL PUMP
Install the oil pump.
Install the washer and pin.
Install the oil pump driven gear.
Install the snap ring with snap ring pliers.
NOTE:
Assemble the oil pump gear as show.
11-9
OIL PUMP DRIVE GEAR
Install the pin.
Install the oil pump drive gear and washer.
Apply lock tail to the oil pump drive gear bolt.
NOTE:
Flange side of the gear is positioned inside.
Tighten the oil pump drive gear bolt to the

specified torque.
Oil pump drive gear bolt: 50 N．M( 5.0 kgf-

m,37 lb-ft)
Idler Gear Puller (440665)
CAM CHAIN
Install the cam chain.
CLUTCH SHOE
Install the clutch shoe assembly.
Apply Loctite 262TM (Thread locker) to the
clutch shoe nut.
Tighten nut to the torque with the special tool.
Shoe nut torque: 160 N．M( 16 kgf- m, 116
lb-ft)
Clutch And CVT Holder (440666)
Caution
The nut of clutch shoe has left-hand threads.
11-10
Install the one way clutch outside.
Caution “OUTSIDE”
The one way clutch outside facing must on the
shaft outside.
NEUTRAL SWITCH
Install the springs and switch contacts.
Install the neutral switch.
CLUTCH CASE
Install the dowel pins and put the new gasket.
Tighten the clutch case bolts.
Install the collar.
11-11
AIR DEFECTOR&FIXED DRIVE

FACE
Install the air defector.
Install the fixed drive face.
MOVABLE DRIVE/DRIVEN FACE

AND DRIVE BELT
Install the drive belt,between the movable
driven face and fixed driven face by tapping with
a plastic mallet.
Caution
The drive belt contact surface of the driven
face should be thoroughly cleaned.
Install the movable driven face assembly.
11-12
Tighten the movable drive face nut to the
specified torque with the special tool.
Movable drive face nut: 115 N．M( 11.5 kgf-

m,85 lb-ft)
Clutch And CVT Holder (440666)
NOTE:
Turn the fixed drive face until the belt is seated
in and both the drive and driven faces check the
belt without slip.
CLUTCH COVER
Install the dowel pins and new gasket.
Install the clutch cover.
OIL FILTER
Apply engine oil lightly to the O-ring.
Install the oil filter turning it by hand until feeling
that the filter gasket contacts the surface of
case. Then Tighten it 2 turns using the oil filter
wrench.
Oil filter Installer/Remover (440670)
11-13
WATER PUMP GEAR
Install the pin.
Install the water pump chain to the two water
pump gears as show.
Install the water pump gears with special tool.

Install the washer.
Chain Wheel & Washer Installer
(440660)
Install the water pump gears and tighe the nut
NOTE:
Make sure the crankshaft can turning smoothly.
If any resistance remove the screw,
re-associate the screw again.
Install the wash.
11-14
GENERATOR
Install the key.
Install the one way clutch and generator rotor

sets.
Caution
Be sure the one way clutch on the crankshaft is
fitted into the generator rotor properly.
Tighten the generator rotor nut to the specified

torque with the special tool.
Generator rotor nut: 160 N．M( 16.0 kgf- m,
125 lb-ft)
Flywheel Puller (440664)
Install the output drive gear by installing the

snap ring.
11-15
GEARSHIFT
Install the cam driven gear.
Reassemble the gearshift shaft.
Install the gearshift shaft by aligning the

punched mark with the center of the cam driven
gear.
STARTER DRIVEN GEAR/IDLE

GEAR
Install the starter idle gear and driver gear.
LEFT CRANKCASE COVER

Install the dowel pins and put the new gasket.
11-16
Tighten the left crankcase cover bolt.
NOTE:
Fit the clamp to the bolt.
SPEEDOMETER GEARBOX
Fit a new gasket and install the speedometer
gearbox.
WATER PUMP
Check the water pump shaft position with water
pump gear shaft.
Apply engine oil on the O-ring of water pump.
Install water pump.
Tighten the screw.
11-17
STARTER CUP
Apply engine oil to the O-ring and lip of the oil
seal.
Install the starter cup.
Tighten the starter cup nut by using a suitable

bar.
Starter cup nut: 35 N．M( 3.5 kgf- m, 25 lb-ft)
Cup, Starter Holder (440658)
Install 4 studs, and then put 2 gaskets and 2

O-rings.
Install the oil pipe.
Gasket
Stud
O-ring
Put 4 spring washers and tighten 4 nuts. Spring Washer

Special torque: 1.2 kgf- m
Nut
Oil pipe
11-18
GEARSHIFT for Parking

Install the Gear Stopper 925735.
Torque: 2.7 kgf-m
Assemble the Secondary dial pole 925742.
Install the Secondary dial pole by aligning the

punched mark with the center of the cam driven
gear.
11-19
NOTE：
11-20
12. COOLING SYSTEM
General Information
General
Warning
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant
may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the
engine is completely cooled down.
Refill the radiator with distilled water or specified additives.

● Add coolant to the reservoir.
● The cooling system can be serviced on the ATV.
● Never spill the coolant to the painted surface.
● Test the cooling system for any leakage after the repair.
● Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.
Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 2200c.c.
Reservoir upper 1200c.c.
Begins to activate at 65~72℃
Thermostat
Stroke: 0.05~5mm
Cooling fan switch Begins to activate at 85±3℃
Not-pressure: 107.7℃
Boiling point
Pressurized: 125.6
Torque Value
For water pump impeller 1.0~1.4kgf-m
Trouble Diagnosis The engine temperature is too low

The engine temperature is too high ● The water thermometer and the
● The water thermometer and the temperature temperature sensor malfunction.
sensor do not work properly. ● The thermostat is stuck to open.
● The thermostat is stuck to close.
● Insufficient coolant. Coolant is leaking
● The water hose and jacket are clogged. ● The water pump mechanical seal does
● Fan motor malfunction. not function properly.
● B et we en cylinder head and cylinder do not be ● The O ring is deteriorated.
tighten. ● The water hose is broken or aged.
12-1
12. COOLING SYSTEM
Trouble Diagnosis for Cooling System
The temperature indicated is too high
A. Stop and waiting for the

engine is completely A1.Refill the radiator with Y
cooled down, open cap to
N coolant then check for any Water leaking problem
check the capacity of leakage?
coolant in radiator.
N
B. Turn on main switch and

check the water N B-1. Measure thermo unit to N
confirm voltage 6V↑? Replace thermo unit
temperature indicator
back to zero?
B-2. Inspect the circuits of water Y

temperature have short or
Short or earth handle
Y earth?
N
Meter problem
C-1. Eng. stop and remove

C. Open radiator cap and water pump cover, N
softly throttle, inspect N
coolant have circulated? start the motor to Water pump repair
inspect pump
its rotation?
Y Y
Water hose clogged
D. Close radiator cap,

measure thermo unit to
confirm voltage reduced N
Replace thermo unit
comply with temperature
rise?
Next Page
12-2
12. COOLING SYSTEM
Preceding page
E. Keep eng. 3000~4000 rpm E-1. Measure cooling fan switch

and inspect cooling fan was N to confirm voltage be N Replace cooling
operating after the changed (12→0V)? fan switch
temperature gauge over 3
checks?
Y
Y
E-2. Connect cooling fan
F. Confirm the cooling fan was terminals with battery N
convulsion? Replace cooling
(12V) directly to inspect fan
its operation?
Y
Y
Meter unusual
E-3. Keep eng. 3000~4000 rpm

and inspect coolant flow into
reserve tank after the
If circuit connects reverse temperature gauge over 3
cooling fan will forward, checks?
correct and check again.
E-4. Remove thermostat from

holder then heats it by water N Replace
directly to check its
operation? thermostat
Y Refill with
coolant then
check again
For bleed the air bubbles

completely, open radiator cap
Notice the water hose
and start engine while engine is
can’t any unsuitable
cool then press water hose
bend or twist and bleed
softly by hand to bleeding. Turn
the air bubbles
the throttle repeatedly until the
completely.
coolant surface becomes
stable.
12-3
12. COOLING SYSTEM
System Test
Test on the filler cap
Hermetically seal the filler cap, apply water
and pressure to the filler cap. Replace it with
new one if found failing to maintain the
specified pressure
within a given time limit, or the opening
pressure is too high or too low. The specified
pressure shall
be maintained at least for 6 seconds in the
test Relief pressure for the filler cap:
Pressure Tester Filter Cap
0.9-0.15 kgf/cm2
Apply pressure to the radiator, engine and water
hose to check for any leakage
If the system fails to maintain the specified

pressure for at least 6 seconds, repair or
replace parts.
Change of coolant
Remove the front center cover, and then

remove filler cap.
Place a water pan under the water pump;
loosen the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Refilling system with coolant and bleeding the

air bubbles.
● Run the engine, and remove by-pass pipe.
● Check by-pass hole whether has the air
bubble to emit.
● If emits without the air bubble, only has the
coolant to flow out, then backflow pipe joint
on, engine flameout.
● Remove radiator filler cap.
● Starts the engine, inspects does not have the
air bubble in the radiator coolant, also the
coolant liquid level is stable.
● Stop the engine. Add coolant to proper
level if necessary.
● Screw and tighten up the radiator filler cap.
Coolant recommended: TGB Bramax radiator

agent. Drain Bolt
Concentration: 50%
By pass pipe
12-4
12. COOLING SYSTEM
Check reserve tank
● Remove the front center cover, and
then remove reserve tank filler cap.
● Check the liquid level in the front fender Upper
right side. Add coolant to proper level if too
low.
● Reinstall the reserve tank filler cap.
Lower
Caution er
The reserve tank liquid level coca too is not
high, after avoids the water temperature
elevating, in the cooling system the
refrigerant backflow floods.
Radiator
Check
Remove the front center cover, side covers and
front fender. (refer chapter 13), 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.
Removal
Place a water pan under the water pump.
Remove coolant filler pipe.
12-5
12. COOLING SYSTEM
Loosen the radiator 4 bolts. Remove coolant

upper side pipes.
Remove coolant outlet pipe.

Disconnect the couplers for the cooling fan
switch and fan motor, and then remove radiator
and cooling fan.
Disassembly
Loosen the 4 bolts from the fan duct, and
then remove the fan duct.
Loosen 4 screws from the fan motor, and take
off the fan motor.
Remove nut to remove the fan from fan motor.
Assembly
Install fan motor onto fan duct and insert the
fan into the motor shaft.
Apply a coat of the adhesive to the shaft thread
of the motor, and then install the washer and the
lock nut.
Tighten the fan duct onto the radiator with 4 bolts.

Please refer to chapter 17 for the inspection of
the cooling fan switch.
Caution
Liquid packing must be applied to the cooling
fan switch before installing to avoid
damaging the radiator.
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.
12-6
12. COOLING SYSTEM
Water Pump
Check water pump seal / cooling system
divulges inspection
● Disassembles the refrigerant drain bolt,
overflows little buckles the N actually fluid,
confirmed overflows the refrigerant whether
has the greasy dirt.
● Turns on lathe the engine oil gauge rule, the

inspection engine oil whether does have
bleaches situation of the emulsified.
If has the above two kind of interior to divulge the

phenomenon, possibly for the water pump inner
two seal damages, the engine cooling system
damages or the cylinder and the cylinder head
gasket damages, please first dismantles the right
crank case to say A confirms the replacement
water pump seal, if does not have the question to
take apart for overhaul cooling system of system
again the cylinder head, the cylinder.
Removal of water pump

Loosen the drain bolt to drain out the
coolant. Remove the water hose.
Loosen 2 bolts and remove the water pump.
Caution
Check the water pump shaft position with
water pump gear shat.
Install water pump and tighten the screw.
12-7
12. COOLING SYSTEM
Thermostat
Please refer to chapter 17 for inspection of
temperature sensor.
Removal
Drain out the coolant.
Remove the thermostat set. (2 bolts)
Inspection
Visually inspect thermostat for any damage.
Place the thermostat into heated water to check

its operation.
Caution
Whenever the thermostat and the thermometer
are in contact to the wall of heated water
container, the reading displayed is incorrect. If
the valve of the thermostat remains open at
room temperature or the valve operation is not
corresponding to the temperature change, then
it must be replaced.
Technical Data
Valve begins to open 65~72℃
Valve stroke 0.05 ~ 5mm
Installation
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out the air bubble
(Page 12-5).
12-8
12. COOLING SYSTEM
Oil Radiator
Check
Remove the protector, and check for any
leakage from weld seam.
Blow oil radiator clean using compressed

air.
If the oil radiator is blocked by dirt, use low
pressure water jet to clean it.
Remove two oil pipes.
Remove 3 bolts from the water radiator.

Remove the bolt of protector’s upper right
corner and take down clip “P”.
Installation
Install the removed parts in the reverse

order of removal.
Note：
Oil radiator’s capacity is 170 ml.

Two oil pipes’ total capacity is 190 ml.
If the oil content is empty in the engine

internal, oil pipe, and oil radiator, must to
add 3.86 L engine oil.
12-9
12. COOLING SYSTEM
Note :
12-10
13. BODY COVER
BLADE MODEL
Mechanism Diagram
13-1
13. BODY COVER
Maintenance
Body covers dissemble sequence
Fuel tank cover
Right and left foot board
Right and left foot board
Right and left front internal fender
Right and left front shock mount, front bumper
Front air inlet plate
Right and left head lamp support, body cover
Rear body cover
Front protector
Rear protector
Upper bracket assembly
Be careful not to damage various covers in assembly or disassembly operation.

Never injure hooks molded on the body covers.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the quad and the covers during assembly.
13-2
13. BODY COVER
Remove seat
Remove 2 bolts from battery fixed.
Remove cable and battery fixed.
Remove 1 screw and take off shift lever
Remove fuel cap.
Remove 4 screws，and then remove fuel tank

cover.
Installation
Install in reverse order of removal procedures.
13-3
13. BODY COVER
Remove screws from right or left foot board

(each side 4 screws).
Remove screws from right or left foot board

(each side 9 screws).
Remove M6 bolts from right or left foot board
remove right or left foot board (each side 3
bolts).
Remove bolts from right or left front internal

fender (each side 5 bolts)，and then remove
right or left front internal fender.
Remove 4 bolts from front bumper
Remove 2 screws from front bumper
Installation
13-4
13. BODY COVER
Remove screws from front bumper (each side 3

screws).
Remove head lamp couplers，and then remove

front bumper.
Remove bolts from right and left headlamp

support (each side 2 bolts).
Remove bolts from front air inlet plate (each

side 2 bolts) ，and then remove front air inlet
plate
Remove bolts from front body cover (each side

1 bolts)
Installation
13-5
13. BODY COVER
Remove lock cap.
Remove power source couplers，and then

remove front body cover.
Remove bolts (each side 1 bolts).
Remove 2 couplers
Installation
13-6
13. BODY COVER
Remove 1 couplers and 1 nut from starting

motor relay，and then remove starting motor
relay.
Remove 1 bolts from rear body covert.
Remove 1 nut from rear reflector assembly

(each side 1 bolts).
Remove number-plate lamp couplers 、rear

lamp assembly couplers (L/R) and turn signal
lamp couplers (L/R).
Installation
13-7
13. BODY COVER
Remove screws from rear body covert (each

side 2 screws) ，and then remove rear body
covert.
Remove 2 bolts from front protector.
Remove 2 bolts from front protector，and then

remove front protector.
Remove bolts from bear protector (each side 1

bolts).
Installation
13-8
13. BODY COVER
Remove bolts from bear protector (each side 1

bolts)，and then remove bear protector.
Remove 7 screws from upper bracket

assembly.
Remove speedometer assembly couplers，and

then remove upper bracket assembly.
Installation
13-9
13. BODY COVER
TARGET MODEL
13-10
13. BODY COVER
Body covers dissemble sequence
Seat, battery fixed
Fuel cup
Feont body cover, front cover ornamental
Right / left side cover
Right / left foot board
Tail carrier, Tail carrier ornamental
Rear body cover
Bumper, number-plate bracket, first housing
Front / rear protector
Handle bar front cover
Upper bracket assembly
 Be careful not to damage various covers in assembly or disassembly operation.

 Never injure hooks molded on the body covers.
 Align the buckles on the guards with slot on the covers.
 Make sure that each hook is properly installed during the assembly.
 Never compact forcefully or hammer the quard and the covers during assembly.
13-11
13. BODY COVER
Remove seat.
Remove battery fixeds.
Remove 2 wire from battery.

Remove battery.
Remove 2 bolts from battery fixed.Then,remove

cable.
Remove 1 couplers from starting motor relay ,
and then remove starting motor relay.
Remove bolts (each side 1 bolts) and 2

couplers
Remove fuse box.
Installation
13-12
13. BODY COVER

Remove battery fixed.
Remove 1 screw and take off shift lever.

Remove fuel cap.
Remove bolts (each side) from front body cover.
Installation
Install in reverse order of removal procedures
13-13
13. BODY COVER
Remove screws (each side) from the part of

front body cover,and then remove front body
cover.
Remove front cover ornamental.
Remove 8 screws from right or left side cover.

(each side 4 screws)
Remove right or left side cover.
Installation
13-14
13. BODY COVER
Remove bolts and screws from right or left foot

board.(each side 5 bolts)
Remove right or left foot board.
Remove screw from tail carrier.
Then,remove tail carrier ornamental.
Remove 3 bolts from tail carrier,then remove tail

carrier.
Remove the bolts from rear body cover.

(each side)
Installation
13-15
14. BRAKE SYSTEM
BRAKE
FRONT BRAKE
14-1
14. BRAKE SYSTEM AND BODY COVER
REAR BRAKE
14-2
14. BRAKE SYSTEM
BRAKE SPECIFICATIONS
FRONT BRAKES
Item Standard Service Limit
Bake Pad Thickness 1.5 mm
Brake Disc Thickness 4.75 mm 4.24 mm
Brake Disc Run out 0.25 mm
Caliper Piston Diameter 14” tire 25.3 mm 25.25 mm
Caliper Bore Diameter 14” tire 25.4 mm 25.45 mm
Caliper Piston Diameter 12” tire 33.86 mm 33.81 mm
Caliper Bore Diameter 12” tire 33.96 mm 34.01 mm
REAR BRAKES
Item Standard Service Limit
Bake Pad Thickness 1.5 mm
Brake Disc Thickness 3.75 mm 3.24 mm
Brake Disc Run out 0.25 mm
Caliper Piston Diameter 33.86 mm 33.81 mm
Caliper Bore Diameter 33.96 mm 34.01 mm
TORQUE SPECIFICATIONS
Item Torque kgf-cm
Front Caliper Mounting Bolts 280-320
Rear Caliper Mounting Bolts 500~600
Handlebar Master Cylinder Clamp Bolts 70-90
Hand Master Cylinder Reservoir Cover 8
Brake Line Flare Fitting 160-200
Brake Line Banjo Bolt Fitting 320
Bleeder Screw 40-70
Caliper bracket Bolts 14” tire only 300
Caliper bracket Nuts 14” tire only 220-250
BRAKE FLUID：DOT4
14-3
BRAKE SYSTEM SERVICE NOTES

Disc brake systems are lightweight, low maintenance and perform well in the conditions this vehicle
will routinely encounter. There are a few things to remember when replacing disc brake pads or
performing brake system service to ensure proper system function and maximum pad service life.
▪ Do not overfill the master cylinder fluid reservoir.
▪ Make sure the brake lever/pedal returns freely and completely.
▪ Adjust stop pin on caliper after pad service.
▪ Check and adjust master cylinder reservoir fluid level after pad service.
▪ Make sure atmospheric vent on reservoir is unobstructed.
▪ Test for brake drag after any brake system service and investigate cause if brake drag is evident.
▪ Make sure caliper moves freely on guide pins (where applicable).
▪ Inspect caliper piston seals for foreign material that could prevent caliper piston from returning freely.
▪ Perform a brake burnishing procedure after installing new pads to maximum service life.
▪. DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only
approved brake cleaning products..
▪ .DO NOT allow brake-cleaning products to contact painted surfaces. Painting damage will occur as a
result.
14-4
14. BRAKE SYSTEM
BRAKE LIGHT SWITCH

Brake Light Switch Location
There are two brake light switches, which
located on the brake liquid distributor, one at
front and other at LH rear.
Brake Light Switch Continuity Test

1. Disconnect brake light switch connector.
2. Using multimeter check switch operation:
Firmly pushed switch = continuity.
Release switch = Open.
▪. If switch is defective, replace with a new one.
▪. If the switch is good, verify wire continuity
between harness connector and ECU
connector.
Brake Light Switch Replacement

1. Disconnect brake light switch connector.
2. Drain rear brake line.
3. Remove brake light switch from distributor.
NOTE: Use shop rag to catch any spilled brake
fluid.
4. Install new sealing washers.
5. Install brake light switch on distributor.
TORQUE: 300~350kgf-cm
6. Connect brake light switch connector.
7. Refill and bleed brake system.
14-5
MASTER CYLINDER
Master Cylinder Removal (Hand Brake)
1. Drain brake system.
2. Remove master cylinder.
3. Unscrew brake hose from master cylinder.
Master Cylinder Removal (Pedal Brake)

4. Disconnect master cylinder rod from brake
pedal.
5. Remove master cylinder rod from master
cylinder.
6. Remove master cylinder retaining bolts and
nuts.
7. Remove master cylinder from vehicle.
Master Cylinder Inspection

▪. Check boot for crack.
▪. Check rod for wear and scratch.
▪. Check master cylinder housing for leak or
damage.
Master Cylinder Installation

▪. For installation, reverse the removal
procedure.
▪. Tighten brake light switch and front brake
hoses to specification.
TORQUE:
Pedal Master Cylinder bolts:280-320kgf-cm.
Pedal reservoir bolt: 100-120 kgf-cm.
Banjor bolt (A)= 80 kgf-cm.
Pedal pivot bolt (B)= 100-120 kgf-cm.
▪. Lubricate push rod end and inside master A

cylinder boot.
▪. Install new sealing washers.
▪. Refill and bleed brake system.
▪. Adjust master cylinder rod.
B
14-6
14. BRAKE SYSTEM
CALIPER
Caliper Removal
1. Safety lift and support the vehicle.
2. Remove wheels.
3. If caliper is removed from vehicle for
replacement:
3.1 Drain brake system.
3.2Unscrew brake hose from caliper.
4. Remove fasteners retaining brake hose to
knuckle.
5. Remove screws securing caliper support
knuckle.
6. Place caliper assembly onto a support.
NOTICE: Do not let caliper hangs the hose and
do not stretch or twist hose.
Caliper Installation
If caliper was removed for replacement:
- Refill and bleed brake system.
- Install new sealing washers.
Apply thread locker (LOCTITE 243)on caliper
retaining screws.
Tighten caliper retaining screws to specification.
TORQUE: 300-320 kgf-cm.
14-7
BRAKE PADS
Brake Pads Replacement
1. Remove caliper from knuckle.
2. Remove brake pad pins from caliper.
3. Remove brake pads.
4. Clean pistons end using brake cleaner.
5. Push caliper pistons inward.
NOTE: To avoid damaging pistons, use an old
pad to push it into the caliper using a C-clamp.
6. Ensure brake pad spring is properly
positioned onto caliper.
7. Install new brake pads.
8. Clean then lubricate brake pad pins using
grease.
9. Install brake pad pins on caliper.
10. Install caliper on knuckle.
BRAKE DISC
Brake Disc Inspection
1. Check disc surfaces for scratch or grooves
on both sides.
2. Measure thickness of the disc.
THICKNESS: 4.1 mm.
NOTICE: Brake discs must never be machined
3. Check warpage of disc.
Maximum disc warpage : 0.2 mm.
Brake Disc Replacement

1. Remove caliper.
2. Remove brake disc mounting bolts.
3. Replace brake disc.
4. Install new brake disc.
5. Apply thread locker (LOCTITE 243) on disc
retaining bolts and tighten with torque.
6. Install caliper and install NEW cotter pin to
secure wheel hub castle nut.
TORQUE:
Brake Disc:250-300 kgf-cm.
Castle Nut:1600-1800 kgf-cm
14-8
15-1-1. STEERING SYSTEM AND SUSPENSION
STEERING SYSTEM
EPS MODEL
15-1-1
15-1-1. STEERING AND SUSPENSION
NON EPS MODEL
15-1-2
STEERING SYSTEM
GENERAL
During assembly/installation, use the torque
values and service products as in the exploded
view.
Clean threads before applying thread locker.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pin,
etc.) must be replaced.
Hoses, cables or locking ties removed during a
procedure must be reinstalled as per factory
standards.
15-1-1
PROCEDURES
HANDLEBAR COVER
Handlebar Cover Removal
1. Loosen six screws on the dashboard cover.
2. Remove the two screws on the both rear

mirror bracket.
3. Remove the top cover screws and pull out

the cover from the handlebar.
Handlebar Cover Inspection

Check covers for cracks or other damages.
Replace if necessary.
Handlebar Cover Installation

The installation is the reverse of removal
procedure.
15-1-4
Handlebar Removal
1. Remove handlebar cover.
NOTE: Remove handlebar grips, throttle lever,
brake lever and switch only if the handlebar is
defective and requires replacement.
2. Remove four bolts from the dashboard

bracket.
3. Remove the dashboard.
4. Remove four handlebar mounting bolts.

5. Remove handlebar
Handlebar Inspection
Inspect the handlebar for damage, cracks or
bending. Replace if any of these problems is
detected.
Handlebar Installation
For the installation, reverse the removal
procedure.
15-1-1
Steering Shaft Removal (without EPS)

2. Remove dashboard support.
3. Loosen handlebar mounting bolts and
remove handlebar.
4. Remove the body top cover.
5. Remove steering shaft bracket and bolts.
6. Remove the inner fender.
7.Remove the cotter pin and castle nut at the
arm plate. Discard the cotter pin.
8. Disconnect the tie-rods from the arm plate.
9. Remove the steering shaft cotter low end pin,
washer and castle nut. Discard the cotter pin.
NOTE: Always install new cotter pin after
removal.
10. Pull off the steering shaft from the vehicle.
Steering Shaft
Steering Shaft Removal (with EPS)
2. Remove dashboard support.
3. Loosen handlebar mounting bolts and
remove handlebar.
4. Remove the body top cover.
5. Remove steering shaft bracket and bolts.
6. Remove the inner fender.
7.Remove steering shaft secure bolt and pull
out the shaft.
Torque: 280~320 kgf-cm
NOTE: For detail of the EPS system please
refer to chapter EPS.
15-1-6
Steering Tie-Rod Assembly (w/EPS)
Steering Tie-Rod Assembly (w/o EPS)
15-1-1
WHEEL AND TIRE TIRES

GENERAL
WARNING
WARNING Do not rotate tires. The front and rear tires
Torque wrench tightening specifications have a different size. Respect direction of
must strictly be adhered to. rotation when applicable.
Castle Nut
Torque: 1600-1800 kgf-cm TIRE PRESSURE
Wheel Nut WARNING
Torque: 680-720 kgf-cm
Tire pressure greatly affects vehicle
handling and stability. Insufficient pressure
WHEELS may cause tire to deflate and rotate on
Removal wheel. Excessive pressure may burst the
tire. Always follow recommended pressure.
1. Position the vehicles on a level surface.
Checks pressure when tires are cold before
2. Stop the engine, place the transmission in
using the vehicle. Tire pressure changes with
PARK and lock the parking brake.
temperature and altitude. Recheck pressure if
3. Loosen the wheel nuts slightly.
one of these condition has changed.
4. Elevate the appropriate side of the vehicle by
TIRE PRESSURE
placing a suitable stand or jack under the
FRONT: 7 psi
frame.
REAR: 7 psi
5. Remove the wheel nuts and remove the
wheels.
Tire Inspection
Check tire for presence of slits, bulges, wear or
Installation
other damage. Replace if necessary.
1. Verify the transmission is still in PARK and
the parking brake is locked.
Tire Replacement
2. Place the wheel in the correct position on the
wheel hub. Be sure the valve stem is toward WARNING
the outside and rotation arrows on the tire - Replace tires only with the same type and
point toward forward rotation. size as original tires.
- For unidirectional thread pattern, ensure
3. Install the wheel nuts and finger tighten them
that the tires are installed in the correct
to align center of the wheel holes with the direction of rotation.
center of the tapered nuts.
4. Carefully lower the vehicle to the ground.
5. Torque the wheel nuts to the proper torque
specification.
WARNING
Do not rotate tires. The front and rear tires
have a different size. Respect direction of
rotation when applicable.
15-1-8
FRONT SUSPENSION
15-1-1
FRONT SUSPENSION
GENERAL
▪ The procedure explained below is the same
for the RH and LH sides unless otherwise
noted.
▪ During assembly/installation, use the torque
values and service products as in the
exploded view.
▪ Clean threads before applying a thread locker.
WARNING
Locking devices when removed (e.g.:
locking tabs, cotter pins, etc.) must be
replaced.
NOTICE: hoses, cables and locking ties
removed during a procedure must be reinstalled
as per factory standards.
PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
1. Safety lifts and supports the vehicle of the
ground.
2. Remove bolts and nuts retaining shock
absorber.
3. Remove shock absorber.
Shock Absorber Inspection
▪ Remove spring from shock absorber.
▪ Secure the end of shock body in a vise with its
rod upward.
NOTICE: Do not clamp directly on shock body.
▪ Extend and compress the piston several times
over its entire stoke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
▪ Check the following conditions that will denote
a defective shock:
- A skip or a hang back when reversing stroke
at mid travel.
15-1-10
- Seizing or binding condition except at

extreme end of either stroke.
- Oil leakage.
- A gurgling noise, after completing one full
compression and extension stroke.
▪ Replace if any faults are present.
Shock Absorber Installation

▪ Make sure to install the proper type of shock
absorber on vehicle.
TORQUE: 48 Nm +/- 6.
LOWER A ARM
Lower A Arm Removal
1. Safety lifts and supports the vehicle off the
ground.
2. Remove wheel.
3. Remove bolts and nut securing lower ball
joint to knuckle.
4. Remove bolts and nuts securing A arm to
frame.
5. Remove A arm.
Lower A arm installation
15-1-1
UPPER A ARM
Upper A Arm Removal
ground.
2. Remove wheel.
3. Remove fasteners retaining brake hose to
vehicle.
4. Remove and discard cotter pin retaining ball
joint.
5. Remove ball joint nut and washer.
6. Carefully move brake hose aside.
7. Using a plastic hammer, carefully hit on the
knuckle side to separate ball joint from
knuckle.
NOTE: A ball joint remover can be used if
the ball joint is jammed into knuckle.
NOTICE: Never hit on A arm to avoid to
damage it permanently.
8. Remove bolt and nut securing A arm to
shock absorber.
9. Remove fasteners securing A arm to frame.
10. Remove A arm.
Upper A Arm Installation

Install a new cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
15-1-12
REAR SUSPENSION
15-1-1
REAR SUSPENSION
GENERAL
The procedure explained below is the same for
the RH and LH sides unless otherwise noted.
During assembly/installation, use the torque
values and service products as in the
exploded view.
Clean threads before applying a thread
locker.
WARNING
Locking devices when removed (e.g.:
locking tabs, cotter pins, etc.) must be
replaced.
NOTICE: hoses, cables and locking ties
removed during a procedure must be reinstalled
as per factory standards.
PROCEDURES
SHOCK ABSORBER
Shock Absorber Removal
1. Safety lifts and supports the vehicle of the
ground.
2. Remove bolts and nuts retaining shock
absorber.
3. Remove shock absorber.
Shock Absorber Inspection
▪ Remove spring from shock absorber.
▪ Secure the end of shock body in a vise with its
rod upward.
NOTICE: Do not clamp directly on shock body.
▪ Extend and compress the piston several times
over its entire stoke. Check that it moves
smoothly and with uniform resistance with its
rod upward.
▪ Check the following conditions that will denote
a defective shock:
- A skip or a hang back when reversing stroke
at mid travel.
15-1-14
- Seizing or binding condition except at

extreme end of either stroke.
- Oil leakage.
- A gurgling noise, after completing one full
compression and extension stroke.
▪ Replace if any faults are present.
Shock Absorber Installation

▪ Make sure to install the proper type of shock
absorber on vehicle.
TENSION BAR
Tension Bar Removal
ground.
2. Loosen and remove the bolts, washer and
bushing from the frame.
3. Remove ball joint nut from the A arm or
tension bar.
Tension Bar Installation

TORQUE: 280-300 kgf-cm.
TORQUE: 450-500 kgf-cm
15-1-1
UPPER A ARM
Upper A Arm Removal
ground.
2. Remove wheel.
frame.
4. Remove bolts and nut securing upper
knuckle.
5. Carefully move brake hose aside.
6.. Remove A arm.
Upper A Arm Installation

Install a new cotter pin to secure ball joint nut.
Both end of cotter pin must be folded.
15-1-16
LOWER A ARM
Lower A Arm Removal
ground.
2. Remove wheel.
frame.
4. Remove bolts and nut securing lower
knuckle.
5. Remove ball joint nut to tension bar rod.
6. Remove shock absorber lower bolt.
7. Remove A arm.
Lower A arm installation

15-1-1
15-2. ELECTRIC POWER STEERING
EPS (Electric Power Steering)
15-2-1
(EPS) Electric Power Steering When electrical system is under high load
GENERAL (battery not at full charge, operating the vehicle
During assembly/installation, use the torque for prolonged periods of time at slow speed and
values and service products as in the exploded low RPM which, requires higher power steering
view. assist), the battery power reserve will gradually
Clean threads before applying thread locker. decrease. This further increase the load on the
charging system and the electrical system
WARNING
voltage will drop. As system voltage drops, so
does power steering assist.
Locking devices (e.g.: locking tabs, elastic NOTE: It is important to maintain the battery at
stop nuts, self-locking fasteners, cotter pin, a full state of charge to ensure proper EPS
etc.) must be replaced. operation. The magneto output is 650 watts to
Hoses, cables or locking ties removed during a
minimize battery drain and system voltage
procedure must be reinstalled as per factory
drop.
standards.
EPS Assist Mode

SYSTEM DESCRIPTION
The EPS system provides two rider selectable
The Electric Power Steering (EPS) provides a
modes of operation.
computer controlled, variable power assist,
ESP MAX provides maximum steering assist
achieved by an electric motor to optimize the
for technical low speed riding in rough or
amount of steering input required by the rider.
muddy terrain or for touring.
The EPS system uses the following parameters
EPS MIN provides less steering assist for
to determine how much steering assist it
increased feedback and trail riding.
provides:
- Electrical system voltage.
De-rating Explanation
- Vehicle speed.
De-rating is an internal protection system
- EPS shaft torque sensor input.
integrated in the EPS electrical module.
The amount of steering assist provided is
This system protects the electrical components
dependent on the handlebar effort (steering
when EPS works too hard and internal
torque), electrical power available, and vehicle
temperature reaches a critical level.
speed.
It also protects electronics when current ripples
When handlebar is in the straight ahead
in the system are too high. These current
position, there is no steering assist.
ripples can be caused by:
Steering torque may also come from the wheels
- Bad grounds.
due to rough terrain. Steering kickback is
- Defective stator or bad stator output wires
reduced while providing feedback to the driver.
connection.
The greater the power steering assist, the
- Failed regulator.
greater the load on the electrical system.
- High electrical loads.
15-2-2
The internal protection system decreases the Steering Torque Sensor

assistance level available to protect its The steering column is connected to the shaft
electronic board. The normal assistance level on the EPS unit. A small area of the EPS shaft
will return when riding conditions are back to is magnetized. Inside the EPS unit, a torque
normal and the internal temperature decrease sensor surrounds the magnetized area of the
and/or when the ripples in the electric circuit EPS shaft.
decrease. When the handlebar is turned, torque is applied
NOTE: This reaction is a normal protective to the shaft, which tends to twist the shaft
behavior of the unit and it does not necessary slightly, deforming the magnetic field in the
raise a fault in the cluster. shaft. The sensor detects the torque by
measuring the deviation of the magnetic field.
EPS SYSTEM DESCRIPTION The torque sensor is very sensitive and can
EPS Unit detect very small changes in the magnetic field.
The EPS unit is a self contained unit that The harder the handlebar is turned, the greater
includes the steering gear, the EPS module, the the magnetic deviation, the greater the power
EPS motor and the torque sensor. steering assist.
The EPS module provides DC power to the
motor. The amount and duration of that DC
power is determined by the inputs to the EPS
module. The direction in which the motor turns
is changed by reversing the polarity of the
EPS Mode
circuit current.
The EPS system normally provides two rider
The EPS motor does not “spin”, but rather turns selectable modes of operation.
in very small increments based on the amount, MAX provides maximum steering assist for
duration, and direction of DC power delivered technical low speed riding in rough or
by the EPS module. muddy terrain or for touring.
MIN provides less steering assist for increased
EPS Unit protection feedback and aggressive trail riding.
When the EPS unit temperature is above 100
℃, all the EPS function will stop but the steering
can operate without power assist, when the
EPS internal board temperature decrease
below 90℃, the power steering will back to
normal and steering assist should resume
normal operation.
15-2-3
How to View EPS Mode Selection
1. To view the active EPS assist mode, press
MODE button from the dashboard and move
to EPS select page, the EPS page will
blinking then press the RESET button to
engage the EPS assist.
2. The active EPS mode will display in the
middle right portion of speedometer.
How to Change EPS Mode

To change EPS mode, press the RESET button
on the EPS function page, The EPS system will
engage or disengage and display “MIN”,
“MAX” and blank (OFF).
When EPS system is malfunction, the function
block will displayed “FAIL”. And the bottom of
dashboard will show DTC code with “Cxxxx”.
Code Problem Caused
C1511 Torque sensor connector poor contact
C1512
C1513
Torque sensor abnormal
C1514
C1515
C1521 Motor connector poor contact
C1522
C1523
C1524 Motor abnormal
C1525
C1526
C1532 Controller current sensor abnormal
C1531
Controller abnormal
C1533
C1536 Controller voltage too high
C1538 Controller overheat
15-2-4
SYSTEM DESCRIPTION (COMPONENTS)

EPS Unit
▪ The EPS unit is a self-contained unit that
includes the steering gear, the EPS module,
the EPS motor and the torque sensor.
▪ The EPS module provides DC power to the
motor. The amount and duration of that DC
power is determined by the inputs to the EPS
module. Reversing the polarity of the circuit
current changes the direction in which the
motor turns.
▪ The EPS motor does not “spin”, but rather
turns in very small increments based on the
amount, duration and direction of DC power
delivered by the EPS module.
ADJUSTMENT
TORQUE OFFSET RESET
When replacing the following parts or adjusting
steering alignment, the sensor torque offset
must be reset to zero for proper system
operation.
- EPS unit
- Steering shaft bearing
- Tie Rod
- Knuckle
- Ball joint
- Front suspension A-arm
- Steering alignment
1. Connect vehicle to the Diagnostic tool.
2. Select „Special Function” →”ESP reset”→
3. Follow the instruction and procedure of the
screen till “setting success” the reset is
completely.
NOTICE: Ensure handlebar is free and

centered position. There MUST NOT be any
effort applied to the steering shaft.
15-2-5
TROUBLESHOOTING LOW POWER STEERING ASSIST
NO POWER STEERING 1. Low battery voltage.
1. EPS malfunction. - Check battery terminals. Clean, repair,
- If the CHECK ENGINE light is on and a EPS replace or tighten as required.
FAULT message is visible in the dashboard, - Test battery voltage. Recharge or replace
check for fault code at the bottom of battery as required.
dashboard. - Carry out an EPS unit INPUT VOLTAGE test
2. No power to EPS unit. (POWER SIDE) as detailed in this
- Carry out an EPS unit FUSE test. Replace subsection. Ensure power connector pins
as required. are clean, corrosion free, tight and make
- Carry out an EPS unit INPUT VOLTAGE good contact. Repair or replace
test (POWER SIDE). Repair or replace wiring/connectors as required.
wiring/connectors as required. - Carry out an EPS SYSTEM LOAD TEST as
- Carry out an EPS unit INPUT VOLTAGE detailed in this subsection.
test (CONTROL SIDE). Repair or replace 2. Low input voltage to EPS unit.
wiring/connectors as required. - Carry out an EPS unit INPUT VOLTAGE test
3. NO ground to EPS unit. (POWER SIDE) as detailed in this
- Carry out an EPS unit GROUND CIRCUIT subsection. Ensure power connector pins
test. Repair or replace wiring/connectors as are clean, corrosion free, tight and make
required. good contact. Repair or replace
4. No engine RPM signal from ECU. wiring/connectors as required.
- If engine RPM can be displayed in the 3. Faulty EPS ground circuit.
dashboard when the engine is running, carry - Carry out an EPS GROUND CIRCUIT test.
out an EPS unit COMMUNICATION LINK Ensure EPS ground connector pins and
(can) CONTINUITY test. Repair or replace frame ground post are clean, corrosion free,
wiring/connectors as required. tight and make good contact. Repair or
- If engine RPM cannot be displayed in the replace wiring/connector as required.
dashboard, use diagnostic tool to check for
applicable fault codes. Carry out service ASYMMETRICAL POWERT STEERING
actions. ASSIST (SIDE TO SIDE)
1. Torque sensor not reset to zero.
- Ensure steering alignment is within
specification and carry out the TORQUE
OFFSET RESET procedure detailed in this
subsection.
15-2-6
EPS unit Power Fuse Test

A 40 A EPS fuse located at the right side under
the passenger seat in the EPS fuse box
provides power for the EPS motor.
1. To remove fuse box cover, simultaneously

squeeze tabs inwards on each end of fuse
box cover as you pull upward on the cover.
2. Using voltmeter set to Ω selection, remove

and test the EPS fuse.
40A 30A 30A

3. Replace fuse as required.
NOTE：The color and function of fuse.

① EPS power fuse (Green 40A). ③
①
② MAXI fuse (Pink 30 A).
③ Charger fuse (Pink 30A).
15-2-7
EPS unit Input Voltage Test (Power Side) ①

1. Disconnect the EPS power connector. ③
2. Test for 12 VDC EPS motor power at pin as
per following table.
EPS power connector pin 1 + Battery GND ②
The voltage should be battery voltage
▪ If NO voltage is measured, test the 40 A EPS
fuse. If good, check wires and connector pins.
Replace or repair defective parts and reset
faulty codes.
▪ If battery voltage is measured, carry out the
following EPS UNIT INPUT VOLTAGE TEST Red Red/White Blued
(CONTROL SIDE).
EPS Unit Input Voltage Test (Control Side)

1. Disconnect EPS control connector and turn
ignition switch ON.
2. Set the ignition switch to ON.
3. Test for 12 VDC power to the EPS module pin
as per following table.
EPS control connector (pin A) + battery GND
The voltage should be battery voltage
▪ If NO voltage is measured, check wires and
connector pins from EPS unit to the
Relays/Speedo fuse in front fuse box.
faulty codes.
▪ If battery voltage is measured, carry out the
following EPS UNIT GROUND CIRCUIT
TEST.
15-2-8
EPS Unit Ground Circuit Test
1. Disconnect the EPS ground connector (GDN)
2. Test for continuity between PINS to battery
ground.
EPS GND connector pin A + Battery GND
EPS GND connector pin B+ Battery GND
The voltage should be Continuity (close to 0
Ω)
▪ If there is NO continuity or a high resistance is
measured, check wires and connector pins
from EPS unit to chassis ground post.
faulty codes.
▪ If there is good continuity, carry out the
following EPS UNIT COMMUNICATION LINK
(CAN) CONTINUITY TEST.
EPS Unit Communication Link (CAN)

Continuity Test
NOTE: EPS unit must receive an RPM signal to
provide power steering assist.
▪ Disconnect the EPS control connector and the
diagnostic connector.
▪ Test continuity of CAN Bus Wires at PINS.
EPS control connector (pin C) + diagnostic
connector (pin 1) = Below 1 Ω
EPS control connector (pin D) + diagnostic

connector (pin 2) = Below 1 Ω
▪ If resistance measured is out of specification,
check wires and connector pins. Carry out
repairs as required and reset faulty codes.
▪ If resistance measured is good, replace the
EPS unit and reset faulty codes.
15-2-9
EPS System Load Test

If the charging system cannot sustain normal
voltage when the EPS is operating, EPS may
be greatly reduced or nonexistent. Carry out the
following steps.
1. Connect the red lead of voltmeter set to VDC
to the EPS fuse box battery terminal.
2. Connect the black voltmeter lead to the
battery ground.
3. Measure the battery voltage.
NOTE: If battery voltage is low, recharge
battery.
4. Ensure the vehicle transmission is set to N.
5. Start the engine.
6. Note the voltage on the voltmeter with the
engine running (charging system voltage).
7. Press the RANGE button repeatedly to select
Manual Range 60.
8. Press the MIN MAX button on the voltmeter
to engage the MIN function.
9. Turn the handlebar momentarily against the
steering frame stops to each side.
NOTE: Do not hold steering against frame stops
for and extended period of time.
10. Read the MIN charging system voltage
recorded while the handlebar was turned
against each stop.
Battery (-) terminal + fuse box battery
terminal = at least 12 VDC (Steering position
LH stop/ RH stop)
NOTE: Turning the handlebar momentarily
against the frame stops generates maximum - EPS unit power and ground connections.
EPS load (maximum current draw on electrical - Charging system.
system). Electrical system must sustain at least - Frame and engine ground studs.
12 VDC for proper EPS operation. ▪ If the previously listed items, carry out the
following EPS UNIT CURRENT TEST.
▪ If the electrical system cannot sustain at least
12 VDC, check the following:
- Battery.
- Battery connections.
15-2-10
EPS Unit Current Test
1. Connect vehicle to the latest BUS software.
2. Click on the Rear Data button.
3. Choose the Monitoring page tab.
4. At the bottom of the Monitoring page, choose
the EPS tab.
5. With the vehicle engine running in N, turn the
handlebar side to side, momentarily against
each stop and observe the indications on the
BUS EPS Monitoring page.
▪ The EPS Torque Sensor Nm increase with

torque applied to the handlebar.
▪ The EPS Current ammeter should increase
proportionately to the torque applied and
decrease with the torque as steering assist is
provided.
NOTE: Increase and decrease in torque and
current readings is very brief as steering assist
is quickly provided. Current draw should remain
within green scale but may momentarily peak to
60 amps, then drop off close to 0 amps as
torque applied is nulled out by steering assist. A
residual torque of 2 NM with a corresponding
current draw is acceptable.
▪ If current draw tends to remain high, carry out

the following:
- Steering alignment check.
- Steering column shim adjustment at half
bushings as described in the EPS UNIT
INSTALLATION procedure detailed in this
section.
- TORQUE OFFSET RESET procedure detailed
in this section.
- Replace EPS unit.
15-2-11
EPS Unit Removal
Remove the following items:
• Both internal fender.
• The front bumper.
• Disconnect the wiring of headlamp and power
source.
• The front cover.
• The inlet tube.
▪ Loose the handle steering lock nut.

▪ Lift up and dismounting the steering shaft.
▪ Disconnect the wiring on the motor.

▪ Disconnect the wiring on the controller.
Remove the three mounting bolts ① of EPS

body. ①
15-2-12
Loose the clamp of anti-dust rubber.
Lift up and dismounting the EPS unit.

Take out the EPS unit from the left side of
vehicle.
NOTE: Be careful do not damage the cable of

torque sensor.
Remove the four bolts ① and the bracket ②.

Remove the two bolts ③ and dismounting the ②
brake distributor.
③
①
Remove the three bolts ①.

Lift up and remove the steering lower bearing
①
seat ②.
Installation
Install the EPS in the reverse order of removal.
②
15-2-13
Steering lower Bearing Seat

Refer to the picture for install new bearing and
seal into the bearing seat then assemble the
bearing seat assembly.
① Steering Pad.
② Bearing Seat
③ Oil Seal
④ Bearing x 2
⑤ Cap
⑥ Washer
⑦ Plate Nut
⑧ Circlip
⑧
⑦
⑥
⑤
② ④
③
①
Control Unit Removal

Remove four mounting bolts.
Disconnect the wiring as follow:.

1. To fuse box. ① ② ⑤
2. To ECU, Speed Sensor and Ignition.
④
3. To Motor Power.
4. To Torque Sensor.
5.To Motor Control.
③
Remove the control unit.
Installation
Install the control in the reverse order of
removal.
15-2-14
Fuse Removal
Simultaneously squeeze tabs inwards on each
end of fuse box cover as you pull downward on
the cover.
Replace the damage fuse.
Installation
Install the control in the reverse order of
removal.
15-2-15
16. ELECTRICAL SYSTEM
/Mechanism Diagram ····························17-1 Meters ················································ 17-12

Maintenance Data ································17-2 Light / Bulb·········································17-13
Technical Specification··························17-2 Switch / Horn······································ 17-16
Trouble Diagnosis ································17-3 Fuel Unit ············································ 17-19
Battery ···················································17-4 Cooling Fan Switch ···························· 17-20
Charging System ··································17-5 Thermo unit········································ 17-21
Ignition System······································17-8 Water Temperature Indicator Light ······17-21
Starting System ····································17-10
Mechanism Diagram
Main switch
Hazard control
Front brake switch
Rear brake switch
Shift gear
C.D.I
Pedal Brake switch
Cooling fan switch
DC. Power outlet
Winker relay
Headlight relay Regulator
Fan relay
AC.Generator
Ignition coil
Horn
Oil pressure switch
16-1
Maintenance Data
Operational precaution
● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
● The model of the spark plug and the tightening torque.
● The ignition timing.
● Adjustment of headlight.
● Removal and installation of AC generator.
● The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.
● To recharge the battery, remove the battery from rack without removing ventilation caps.
● Unless in emergency, never rapid charge the battery.
● The voltage must be checked with the voltmeter while charging the battery.
● As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check
C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary.
Technical Specification
Charging system
Description Specification
Capacity 12V18Ah
Battery 1.4A / 5 ~ 10 hours (standard)

Charging rate
14A / 0.5 hour (fast charging)
Leak current < 1mA
Charging current 1.2 A / 1500rpm
Control voltage in charging 14.5 + 0.5 V / 1500rpm
Ignition system
Description Specification
Model NGK CR7E / NGK DCR8E

Spark plug
Gap 0.8mm
Primary winding 2.9 ± 10%Ω

Ignition coil and
Without cap: 15. ± 10KΩ
resistance Secondary winding
With cap:20 ± 10KΩ
16-2
Trouble Diagnosis
No voltage Charging system does not
● Battery discharged operate properly
● The cable disconnected ● Burnt fuse
● The fuse is blown ● Poor contact, open or short circuit
● Improper operation of the main switch ● Poor regulator
● Poor ACG
Low voltage
● The battery is not fully charged Engine does not crank smoothly
● Poor contact ● Primary winding circuit
● Poor charging system - Poor ignition coil
● Poor voltage regulator - Poor connection of cable and connectors
- Poor main switch
● Secondary winding circuit
- Poor ignition coil
No spark produced by spark plug - Poor spark plug
● The spark plug is out of work - Poor ignition coil cable
● The cable is poorly connected, open or
- Current leakage in the spark plug
short-circuited
● Incorrect ignition timing
- Between AC.G. and C.D.I. - Poor AC.G.
● Poor connection between C.D.I. and ignition
- Improper installation of the pulse sensor
coil
- Poor C.D.I.
- Poor connection between C.D.I. and the
main switch
● Poor main switch
● Poor C.D.I. Weak starter motor
● AC.G. is out of work ● Poor charging system
● The battery is not fully charged
● Poor connection in the windings
● The motor gear is jammed by foreign material
Starter motor does not work
● The fuse is blown
● The battery is not fully charge
● Poor main switch Starter motor is working, but engine
● Poor starter switch
● The front and rear brake switches do not does not crank
operate correctly ● Poor starter motor pinion
● Starter relay is out of work ● The starter motor run in reverse direction
● The ignition coil is poorly connected, open or ● Poor battery
short-circuited
● The starter motor is out of work
Intermittent power supply

● The connector of the charging system
becomes loose
● Poor connection of the battery cable
● Poor connection or short-circuit of the
discharging system
● Poor connection or short-circuit of the power
generation system
16-3
Battery
Removal
Remove the seat, and then you can see the
battery.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery clamp, and then remove
battery.
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 12.0~12.2 V at 20℃
Undercharged: Below 11.3 V at 20℃
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 1.8A 9.0A
Charging time 5~10H 1H
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.
16-4
Charging System
Charging circuit
Main Switch
Black Blue
Yellow
Fuse 20 A Black/Red
Yellow Yellow
Battery
AC Generator
Current Leakage Inspection

Turn the main switch to OFF position, and
remove the negative cable terminal (-) from the
battery.
Connect an ammeter between the negative

cable terminal and the battery negative terminal.
Caution
● In the current leakage test, set the current
range at the largest scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.
●Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified value,

it may indicate a short circuit.
Allowable current leakage: Less than 1mA
Disconnect each cable one by one and take

measurement of the current of each cable to
locate the short circuit.
16-5
Inspection on Charging Voltage

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 + 0.5 V / 2000 rpm
Caution
Caution To replace the old battery, use a new battery
●Before conducting the inspection, be sure with the same current and voltage.
that the battery is fully charged. If
undercharged, the current changes The following problems are related to the
dramatically. charging system; follow the instructions
●Use a fully charged battery having a provided in the checking list to correct it if any
voltage larger than 13.0 V. one of the problems takes place.
● While starting the engine, the starter motor (1) The charging voltage can not exceed the
draws large amount of current from the voltage between two battery terminals
battery. and the charging current is in the
After the engine is warmed up, replace discharging direction.
original battery with a fully charged battery. (2) The charging voltage and current are too
Connect a digital voltmeter to the battery much higher than the standard values.
terminals.
Connect an ammeter between both ends of the The following problems are not related to the
main fuse. charging system; correct it if any by following
steps indicate in the checking list.
Caution (1) The standard charging voltage and
When the probe is reversibly connected, use current can only reach when the
a voltmeter having an indication that the revolution of the engine exceeds the
current flows from the positive or the specified rpm.
negative direction and the measurement - Bulbs used exceed their rate and
should be at zero, ammeter at one direction consume too much power.
only. - The replacement battery is aged and
does not have enough capacity.
(2) The charging voltage is normal, but the
Caution current is not.
- The replacement battery is aged and
●Does not use short-circuit cable.
does not have enough capacity.
●It is possible to measure the current by
- Battery used does not have enough
connecting an ammeter between the
electricity or is over charged.
battery positive terminal and the cable
position terminal, however, while the starter - The fuse of the ammeter is blown.
motor is activated, the surge current the - The ammeter is improperly connected.
motor draws from the battery may damage (3) The charging current is normal, but the
the ammeter. Use the kick-starter to start voltage is not.
the engine. - The fuse of the voltmeter is blown.
●The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing
through. It may damage the ammeter.
16-6
Inspection on regulator rectifier

Remove the seat, rear carrier and rear fender.
Disconnect two 3 pin couplers of the regulator
rectifier.
Inspection the rectifier coupler to the wire
harness passes the condition.
Item Check Points Standard Value
Main switch Battery voltage
Bl – B
connection (ON)
Battery
Bl – B Battery voltage
connection
Charging coil B–B 0.1 ~ 0.5Ω
If the readings measured are not normal, check

parts in the circuit.
If the parts are normal, then trouble is in the
wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
16-7
Ignition System
B Black
Ignition circuit diagram
R Red
G Green
W White
Y Yellow
C.D.I unit
L Blue
B
BR/B B/W
B1/Y
G/R
B Ignition
Main Fuse LG/R Coil
20A
Spark
Battery Plug
Main Switch G
Pulse Generator
C.D.I unit
Disconnect connectors of the C.D.I unit.
Check the following connectors as indicated in the table at the harness side.
Item Points to check Result
Main switch turn to “ON” position Br/Bl ~ B Battery voltage
Pulse generator Bl/Y ~ G/R 50~170Ω
Primary circuit G/R ~ B 2.9±10%Ω
Ignition coil TERMINAL-B ~ with no cap 15.0±10%Ω

Secondary circuit
TERMINAL-B ~ with cap 20.0±10%KΩ
16-8
Inspection on Ignition Coil
Disengage the connector of the ignition coil
and the spark plug cap.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 2.9Ω ± 10%
Remove the cap from the spark plug and
measure the resistance between the spark plug
and the primary winding.
Standard resistance:
With no cap: 15.0Ω ± 10%
With cap: 20.0±10%KΩ
Ignition Coil Replacement

Loosen the lock bolt and replace the ignition coil
if necessary.
Inspection of Pulse Generator

Disconnect the coupler of the pulse generator
and measure the resistance between the
terminals of green/white and blue/yellow.
Standard resistance: 50~170Ω
16-9
Starting System
Starting circuit diagram B Black
B1 Blue
R Red
C.D.I Main Switch G Green
BR/B Fuse 20A W White
B R Y Yellow
W R Main Fuse 30 A
B/W BR Brown
B
Brake
F Switch Battery
N
R G/Y
Change Switch
Starter Relay Starter Motor

B1/W
G
Starter Switch Brake light
G/Y
Inspection on starter relay

Open the main
switch. Press the
brake.
Push down the starter switch.
If a sound of “Looh Looh” is heard, it indicates
the relay function normally.
Remove the seat.

Disconnect the negative cable terminal of
the battery.
Disconnect the cable positive terminal from
the relay.
Disconnect the positive cable of the starter motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal end.
Connect the yellow/red cable to the battery
positive terminal and the black / blue cable to the
battery negative terminal.
Check the continuity of the large terminal end. If
there is no continuity, replace the relay.
16-10
Removal of Starter motor

Remove the seat.
Disconnect the cable negative terminal (-), then
the cable positive terminal (+).
Remove starter motor cable.

Loosen the lock bolts and remove the starter
motor.
Installation of Starter motor

16-11
Meters
Removal
Loosen 7 screws of the meter stay.
Remove the front center cover, and then remove

meter couplers and main switch coupler.
Remove speedometer cable.
Main Switch coupler
Remove speedometer cable, and then remove

meter set, main switch and handle cover.
Speedometer Cable
Remove 4 nuts and meter wire, and then remove

speedometer and fuel meter.
16-12
Light / Bulb
Replacing Bulb for Headlight
Remove waterproof cover for the headlight.
Remove 2 coupler.
Remove bulb setting hook.
Take out the bulb connector and the bulb.

Replace with new bulb if necessary.
(Main beam H3 12V 55W)
(Dipped 12V 55W)
Caution
● Never touch the bulb with finger, which will
create a heat point.
●Clean the fingerprint left on the bulb with
alcohol.
Install the bulb of the headlight in reverse order
of removal.
Upon completion of replacement, turn on the
main switch to ensure the headlight works well.
Adjust the beam and distance of the headlight if
necessary.
16-13
Replacing the Front winker light Bulb

Pull out the front winker light bulb seat.
Replace with new front winker light bulb.

(12V 21W)
Replacing Bulb of Position Light

Pull out the position light bulb seat.
Replace with new position light bulb.

(12V 5W)
16-14
Replacing Bulb of Taillight

Turn the taillight and rear winker light bulb
connectors by CCW.
Replace with new taillight bulb.

(12V 5W/21W)
Rear Winker Light

Replace with new rear winker light bulb.
(12V 21W)
Replacing Bulb of License Light

Turn the license light bulb connectors by CCW.
Replace with new license light bulb.
16-15
Switch / Horn
Main Switch
Inspection
Remove the front center cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below:
Pin
BAT1 BAT2
Position
OFF
ON
Wire Color Red/White Brown/Blue
Replacement of main switch

Disconnect the coupler of the main switch.
Push out the main switch.
Align the main switch stopper with the meter
cover groove, and install main switch.
Install the main switch coupler.
Handle switches
Disconnect the coupler of handle from front
fender left side.
Check the continuity between two points as
indicated in the table below.
Start Switch
Pin
ST SG
Position
FREE
Wire Color Blue/White Black
16-16
Headlight Switch
Pin
BAT3 LO HI PL
Position
Red/ Red/ Blue/

Wire Color Red
Green Yellow Brown
Winker switch
Pin
L WR R
Position
N PUSH OFF
Wire Color Brown Brown/White Green
Horn switch
Pin
BAT3 HO
Position
FREE
Wire Color Brown/White Pink
Hazard switch
Pin
HD E
Position
Wire Color Brown/White Black
16-17
Lock switch
Pin
1 39 44 45
Position
LOCK
Wire Color Black W/L W/O Pu/W
Remove three bolts from the frame.
Remove the transfer shift cables of right and left

side from the front differential assy.
Note：
Check if the servomotor„s condition is poor,
please replace with the new one.
Remove the wire from the lock controller.

Then, remove the servomotor.
Check：
Be sure that lock controller should not be
damaged.
If happening, please replace with the new one.
Installation
Install the removed parts in the reverse

order of removal.
16-18
Front Brake Switch

While grasp the brake lever firmly, the terminals
of brown/blue and green/yellow of the brake
should have continuity.
Replace the switch if damaged.
Rear Brake Switch

While grasp the brake lever firmly, the terminals
of white/black and Brown/White of the brake
should have continuity.
Replace the switch if damaged.
Horn
Remove the horn from front fender.
Apply 12 V power source to two terminals of the

horn, the horn should sound.
Replace the horn if necessary.
16-19
Fuel Unit
Remove the seat.
Remove the fuel tank cap.
Remove the fuel tank cover and front fender
(refer chapter 13).
Disconnect the coupler of the fuel unit. Remove
the fuel unit (4 bolts).
Caution
● Great care shall be taken not to damage or
bend the float arm of the gauge.
When the float arm shifts to the F position or the

E position, the resistance measured shall be as
follows:
Position Resistance
Full
E (Empty) 97.5~107.5 Ω
F (Fuel) 4~10 Ω
Connect the wiring to the fuel unit and the

ohmmeter as shown. Empty
Connect the fuel unit coupler to the wire harness.

Turn on the main switch.
Move the float arm to verify the proper position
the fuel gauge needle indicates.
Arm Position Bargrahpic Position
Up (Full) 7 Bargrahpic (Full)
Down (Empty) E (Empty)
Caution
While conducting the test, turn on the
direction indication lamp to make sure that
the battery is in serviceable condition.
Function of Over-ride
Remove the over-ride button from the handle.
Remove it„s coupler.
Check it. Replace the switch if damaged
16-20
Cooling Fan Switch

The cooling fan switch mounted on the radiator
controls the operation of the cooling fan motor.
In case that the fan motor fails to work, disconnect

the green and black/blue leads and connect jump
wires to the terminals, then, turn on the main switch,
the fan motor should operate.
If the fan motor still fails to run, measure battery

voltage between the green and black/blue leads. If
there is no voltage, check for blown fuse, loose
connection or short-circuit.
If the fan motor runs, check the cooling fan switch in

the manner as described below:
Hang the cooling fan switch on the bowl filled with

coolant to check the switch‟s opening and closing
temperatures, confirm the switch is open circuited at
room temperature, increase the coolant
temperature gradually. The switch should have
continuity at 85±3℃.
Caution
Thermometer
● Keep the coolant at a constant temperature
at least for three minutes. Sudden
increase the coolant temperature will
cause the thermometer and the tester to
indicate wrong readings.
● Never let the thermometer and the cooling
fan switch contact the wall of the bowl,
which may result in wrong readings.
● The cooling fan switch shall be placed in
the coolant until the teeth are completely
submerged.
16-21
Thermo unit
Remove the thermo unit.
Hang the thermo unit in an oil heater, heat the oil
and measure the resistance at each temperature.
Temperature 50°C 80°C 100°C 120°C
Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2
Caution
●Wear gloves and goggles when performing
this test.
Caution
● Engine oil should be used as a heating
medium as the test temperature must be
higher than 100℃.
● Contacting the container wall by the
thermometer and the thermo unit may
result in wrong readings.
Thermometer
Water Temperature Indicator Light

Disconnect the water temperature meter and
connect it to engine ground.
Turn on the main switch.
The indicator light of the fuel meter should be
lighting.
16-22
15A 10A 10A
15A 10A 10A
10A 10A
10A 20A
65
9400uf
+12V
ECU
+12V
15A 10A 10A
15A 10A 10A
10A 10A
10A 20A
65
9400uf
+12V
ECU
+12V

Servicemanual Blade 500-600

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Servicemanual Blade 500-600

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SERVICE MANUAL

TAIWAN GOLDEN BEE CO.,LTD.

The first chapter covers general information and trouble diagnosis.

Page Content Index

1-1 ~ 1-18 GENERAL INFORMATION 1

2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 2

3-1 ~ 3-6 LUBRICATION SYSTEM 3

4-1 ~ 4-12 FUEL SYSTEM 4

5-1 ~ 5-18 ENGINE REMOVAL 5

6-1 ~ 6-16 CYLINDER HEAD/VALVE 6

7-1 ~ 7-8 CYLINDER/PISTON 7

8-1 ~ 8-12 “V” TYPE BELT DRIVING SYSTEM/KICK STARTER 8

9-1 ~ 9-12 DRIVE SYSTEM 9

10-1 ~ 10-10 ALTERNAOTOR/STARTING CLUTCH 10

11-1 ~ 11-20 CRANKSHAFT/CRANKCASE 11

12-1 ~ 12-10 COOLING SYSTEM 12

13-1 ~ 13-10 BODY COVER 13

14-1 ~ 14-12 FRONT BRAKE AND FRONT WHEEL 14

15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15

16-1 ~ 16-14 REAR BRAKE/REAR WHEEL/REAR CUSHION 16

17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17

18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

Symbols and Marks............................. 1-1 Torque Values ................................... 1-10

Symbols and Marks

● Rubber parts may become deteriorated when

● When loosening a component, which has

● Store complex components such as

● Clean the outside of the parts or the cover

● The ends of rubber hoses (for fuel, vacuum, or

● The tool should be pressed against two (inner

Both of these examples can

● And the two posts of battery have to be

● Check if positions and operation for installed

● Make sure that the battery post caps are

● Note that do not let parts fall down.

● Before battery removal operation, it has to

● Make sure if the connector pins are bent,

● Secure wires and wire harnesses to the frame

● Insert the connector completely. If there are

● Wire band and wire harness have to be

● Check if the connector is covered by the twin

● Do not squeeze wires against the weld or its

● Before terminal connection, check if the boot is

● Keep wire harnesses far away from the hot

● Route wire harnesses to avoid sharp edges or

● Route harnesses so that they neither pull too

Never clamp or squeeze the

Never too tight

● Wire harnesses routed along the handlebar

● Before operating a test instrument, operator

Do you know how to set

Stroke 75.6 [mm]

Number/ Arrangement Single Cylinder

Stroke 79.2 [mm]

Number/ Arrangement Single Cylinder

Standard Torque Values for Reference

Engine Torque Values

Thread Dia. Torque Values

Steering shaft nut 1 10 5.00

Steering tie-rod nut 4 10 5.00

Knuckle nut 2 10 5.00

Steering shaft holder bolt 2 8 3.40

Tie rod lock nut 4 10 3.60

Handlebar under holder nut 2 8 4.00