User manual ETON YXL-150 - SERVICE MANUAL

CONTENTS 1.INFORMATION............................................................2 2.MAINTENANCE...........................................................6 3.ENGINE REMOVAL AND INSTALLATION.......................14 4. CYLINDER HEAD / VALVES........................................16 5. LUBRICATION..........................................................26 6. CYLINDER / PISTON..................................................34 7. TRANSMISSION / KICK STARTER...............................42 8. STEERING AND SUSPENSION....................................52 9. FRONT WHEEL AND BRAKE SYSTEM.........................59 10. REAR WHEEL AND BRAKE SYSTEM.........................68 11. FENDERS AND EXHAUST PIPE.................................83 12. ELECTRICAL SYSTEM.............................................89 13. TROUBLE SHOOTING............................................108 1 1. INFORMATION 1.1 1.2 1.3 SAFTY NOTES SPECIFICATION 1.4 1.5 SERIAL NUMBER TORQUE VALUE 1.1 SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run. Wear insulated gloves before handling these parts. USED ENGINE/GEAR OIL Used engine oil and gear oil may cause skin disease if repeatedly contact with the skin for long periods. Keep out of reach of children. 1.2 NOTES All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission. 2 1.3 SPECIFICATION ENGINE This service manual have six models, it is YXL-150, CXL-150, EXL-150 / 150 (2004 two-passengers) RXL-150 and EXL-150 (VIPER) in this service manual. Type Displacement Bore and Stroke Compression Maximum Torque (Nm/rpm) Carburetor Ignition Starting Lubrication Transmission Air-Cooling 4-Stroke with oil cooler 149.5 c.c. 57.4X57.8mm 9.7:1 11.7 / 5000 ± 500 Capacitor Discharge Electric and kick starter Auto oil injection Automatic (C.V.T. V-belt) YXL-150 CHASSIS Overall Length Overall Width Overall Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity CXL-150 EXL-150 EXL 150 (2004) RXL-150 1665 mm 1010 mm 1070 mm 1090 mm 120 mm 168 kg EXL-150 (VIPER) 1670 mm 1010 mm 1070 mm 1090 mm 120 mm 170 kg 8.0 Liters 1730 mm 980 mm 1070 mm 1115 mm 130 mm 172 kg 6.5 Liters 1750 mm 1010 mm 1065 mm 1115 mm 130 mm 176 kg 6.5 Liters YXL-150 SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear PRESSURE Front Rear Drum EXL-150 CXL-150 EXL 150 (2004) RXL-150 EXL-150 (VIPER) Dual Arm Swing arm Drum Disc Disc Drum Drum Disc 21"*7"-10" 20"*11"-9" 4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23) Disc Drum 21"*7"-10" 20"*11"-9" 20"*7"-8" 21"*7"-10" 22"*10"-8" 22"*10"-10" psi ( kgf/cm2) MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23) MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23) 21"*7"-10" 22"*10"-10" 4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23) 21"*7"-10" 22"*10"-10" 12(0.8) 12(0.8) 12(0.8) 12(0.8) COLORING Specifications subject to change without notice. 3 1.4 SERIAL NUMBER (For YXL 150, EXL 150 / EXL 150(2004 two-passengers) and CXL 150 in this service manual) The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Side frame serial number --only in EXL 150 / 150 (2004 two-passengers) Engine serial number RXL / EXL150 (Viper. St) 4 1.5 TORQUE VALUES STANDARD 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 N.m (3.5 lbf.ft) 10 N.m (7.2 lbf.ft) 22 N.m (16 lbf.ft) 35 N.m (25 lbf.ft) 55 N.m (40 lbf.ft) ENGINE Cylinder head nut Spark plug Cylinder head bolt Alternator bolt 28 N.m (20.7 lbf.ft) 12 N.m (8.9 lbf.ft) 20 N.m (14.8 lbf.ft) 8 N.m (5.9 lbf.ft) FRAME Handlebar upper holder bolt Throttle housing cover screw Steering shaft nut Steering shaft holder bolt Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle castle nut Front brake arm nut Rear brake arm nut Rear axle castle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt Rear axle holder bolt Swing arm pivot nut Rear shock absorber mounting nut 24 N.m (17.7 lbf.ft) 4 N.m (2.9 lbf.ft) 50 N.m (36.9 lbf.ft) 33 N.m (24 lbf.ft) 18 N.m (13.3 lbf.ft) 35 N.m (25.8 lbf.ft) 40 N.m (29 lbf.ft) 40 N.m (29.5 lbf.ft) 24 N.m (17.7 lbf.ft) 40-60 N.m (30-45 lbf.ft) 4 N.m (3.0 lbf.ft) 7 N.m (5.2 lbf.ft) 40-60 N.m (30-45 lbf.ft) 24 N.m (17.7 lbf.ft) 30 N.m (22.1 lbf.ft) 30 N.m ( 22 lbf.ft) 90 N.m (65 lbf.ft) 90 N.m (65 lbf.ft) 45 N.m (33 lbf.ft) 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBLE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE AJUSTMENT 2.6 AIR CLEANER 2.7 SPARK PLUG 2.8 IDLE SPEED 2.9 DRIVE CHAIN 2.10 BRAKE SYSTEM 2.11 WHEELS AND TIRES 2.12 STEERING SYSTEM 2.13 TOE-IN 2.14 GEAR OIL 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG SPARK PLUG CAP RECOMMENDED SPARK PLUGS THROTTLE LEVER FREE PLAY IDLE SPEED BRAKE LEVER FREE PLAY DRIVE CHAIN SLACK TOE-IN 5-10 mm 1600±100rpm 15-25 mm 10-25 mm 5±10 mm 0.6-0.7 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT ENGINE OIL GEAR LUBRICATION OIL 12-19 N.m 35-43 N.m Viscosity: SAE 10W-40 API service classification SF or SG SAE 90 6 2.2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing. INITIAL SERVICE (First week) I I REGULAR SERVICE (Every 30 operating days) I C I I I, L I I I I I I I I I R R C EVERY YEAR I FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG CARBURETOR IDLE SPEED DRIVE CHAIN BRAKE SHOE WEAR BRAKE SYSTEM NUT, BOLT, FASTENER WHEEL/TIRES STEERING SYSTEM SUSPENSION SYSTEM GEAR OIL ENGINE OIL ENGINE OIL FILTER I I, L R C I Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. 2.4 THROTTLE OPERATION Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever. Disconnect the throttle cable at the upper end. Lubricate the cable with commercially lubricant to prevent premature wear. 7 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER Unscrew the air cleaner cover screws. Remove the air cleaner case cover. Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil. Install the element into air cleaner in the reverse order of removal. 2.7 SPARK PLUG This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the spark plug electrodes for wear. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.6-0.7mm. With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading. Tighten the spark plug with 12-19 N.m 2.8 IDLE SPEED Connect an engine speed meter. Warm up the engine, 10 minutes are enough. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) will get higher speed. "Turn out" (counter clockwise) will get lower speed. IDLE SPEED: 1700±100 rpm 8 2.9 DRIVE CHAIN Stop the ATV and shift the transmission into neutral. Measure the drive chain slack midway between the sprockets. Chain slack =15~25mm (5/8~1 inch) Adjust the chain slack. Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack. Tighten the axle holder bolts. Torque = 90N.m (65 lbf.ft) If your ATV has the tensioner inside the drive chain. You don't need to follow the procedure of chain slack adjustment. The drive chain will be adjusted by tensioner. When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged. Inspect the sprocket teeth, if it is excessive wear or damage, replace it. 2.10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. (The right side picture is for YXL 150) 9 (The right side picture is for CXL / RXL / EXL-150 they have a parking brake on the top of hand brake.) Only for EXL 150 (2004 two-passengers) / EXL-150 (VIPER) Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 10-20 mm. (The right side picture is for YXL 150 / EXL-150 (2004 two-passengers) / EXL-150 (VIPER)) (The right side picture is for CXL / RXL-150) 10 Adjust the free play of the rear brake lever by turning the adjuster on the rear axle. (Only for YXL 150 / EXL 150 (2004 two-passengers), / EXL-150 (VIPER)) Because of the CXL / EXL / RXL-150 are both disc brake system, so they don't need to adjust the free play. They will be discussed in chap10. BRAKE SHOE WEAR FRONT BRAKE (The YXL / CXL / EXL / RXL 150 have the same model of front brake) Release the front wheel and inspect the brake lining thickness. Service Limit: 2.0mm(0.08 inch) If either lining is worn beyond the service limit, replace Both brakes shoes. REAR BRAKE This system is for YXL / EXL 150 (2004 two-passengers) / EXL-150 (VIPER). Replace the brake shoes if the indicator plate aligns with the brake index mark when the parking brake lever is applied. 11 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition. *The standard of tire pressure is on chap 1. 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. STEERING SHAFT HOLDER BUSHING Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage. If the bushing is worn or damaged, change a new one. Grease the steering shaft bushing and install the parts in the reverse order of removal. Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft) 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. 12 Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m 2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. Unscrew this release bolt and can let the dirty oil flow out. (STEP1) STEP1 The re-add oil hole is on the engine case beside gearbox. (STEP2) STEP2 13 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 3.2 ENGINE REMOVAL 3.3 ENGINE INSTALLATION 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3.2 ENGINE REMOVAL Remove the seat, front fender and rear fender (see chapter 11). Remove the footrest. Remove the spark plug cap from the spark plug. Remove the exhaust muffler. Disconnect the carburetor cable by unscrew two screws on top of the carburetor. Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively. Remove the drive chain cover. Remove the drive chain retaining clip and master link, and remove the drive chain. Remove the engine hanger bolts under the engine. Remove the three bolts and air cleaner together. 14 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly. 15 4.CYLINDER HEAD / VALVES 4.1 SERVICE INFORMATION 4.2 TROUBLESHOOTING 4.3 CAMSHAFT COMPOSITION REMOVAL 4.4 CYLINDER HEAD REMOVAL 4.5 CYLINDER HEAD INSTALLATION 4.1 SERVICE INFORMATION GENERAL This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case. Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place. SPECIFICATIONS ITEM CYLINDER COMPRESSION CAM LOBE HEIGHT ROCKER ARM I.D. ROCKER ARM SHAFT O.D. CYLINDER HEAD WARPAGE VALVE SPRING FREE LENGTH IN OUT IN EX IN/EX IN EX IN EX IN EX STANDARD 12±0.5 kg/cm2 29.795 29.560 10.000-10.018 9.972-9.987 -------32.3 35.0 4.975-4.990 4.955-4.970 5.000-5.012 0.010-0.037 0.030-0.057 1.0 1.0 SERVICE LIMIT -------29.395 29.160 10.10 9.91 0.05 31.2 34.1 4.90 4.90 5.30 0.08 0.10 1.8 1.8 VALVE STEM O.D. VALVE GUIDE I.D. STEM-TO-GUIDE CLEARANCE VALVE SEAT WIDTH TORQUE VALUES Cylinder head bolts Camshaft holder flange nuts Tappet adjusting nut 8 ~ 12 n-m (0.8 ~ 1.2 kg-m) 20 ~ 24 n-m (2.0 ~ 2.4 kg-m) 9 ~ 12 n-m (0.9 ~ 1.2 kg-m) 16 4.2 TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope. LOW COMPRESSION Valve Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect valve timing Weak valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Excessive smoke Damaged valve stem seal Faulty cylinder or piston rings 4.3 CAMSHAFT COMPOSITION REMOVAL Remove the rubber tube of gas waste recovery. RUBBER TUBE GAS WASTE RECOVERY Remove the cylinder head cover. CYLINDER HEAD COVER 17 Remove the air cleaner and carburetor. Remove the inlet pipe assy. Remove the shroud compositions. CARBURATOR SHROUD COMPOSITIONS INLET PIPE ASSY Relax the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam chain adjusting bolt with clockwise direction. CAM CHAIN ADJUSTING BOLT CAM CHAIN ADJUSTER SCREW Remove the nuts and washers. Remove the camshaft holder and dowel pins. CAMSHAFT HOLDER NUTS Relax the camshaft gear from cam chain and remove the camshaft. CAMSHAFT CAMSHAFT GEAR 18 INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. SERVICE LIMIT: IN 29.395 mm EX 29.160 mm CAM LOBES Inspect the camshaft and bearings for wear or damage and replace them if necessary. BEARINGS Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms. ROCKER ARMS Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage. CAMSHAFT HOLDER ROCKER ARM SHAFTS 19 Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10 mm Measure the O.D. of each rocker arm shaft. SERVICE LIMIT: 9.91 mm 4.4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head. FLANGE BOLTS CYLINDER HEAD Remove the cylinder head gasket and dowel pins. DOWEL PINS CYLINDER HEAD GASKET Remove the cam chain guide. CAM CHAIN GUIDE 20 CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor. INSPECTION Clean off all carbon deposits from the combustion chamber. Check the spark plug hole and valve area for cracks. Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm Measure the free length of the inner and outer valve springs. OUTER VALVE SERVICE LIMITS: Inner 31.2 mm Outer 34.1 mm INNER VALVE 21 Inspect each valve for turning, burning, scratches or abnormal stems wear. INLET VALVE EXHAUST VALVE Check the valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.30 mm Calculate the stem-to-guide clearance. SERVICE LIMITS: IN 0.08 mm EX 0.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit. If the valve guide is replaced, the valve guide is replaced; the valve seat must be refaced. CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil. Insert the valves into guides. Install the valve springs, retainers and the cotters. NOTE: To prevent loss of tension, don't compress the valve springs more than necessary. 22 INSTALLATION Install the new gasket and dowel pins. DOWEL PINS Install the cam chain guide. CAM CHAIN GUIDE Install the cylinder head. CYLINDER HEAD CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder. 23 Align the "T" mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise. "T" MARK Position the camshaft gear with cam chain so that its "I" mark aligns with the cylinder head surface and the circle hole forwards front. "I" MARK CIRCLE HOLE Install the dowel pins and camshaft holder. Tighten the washers and nuts. TORQUE: 20 n-m (2.0 kg-m) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge. STANDARD VALVE: 0.08 mm 24 Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw. Install the cylinder head cover. CYLINDER HEAD COVER 25 5. LUBRICATION 5.1 SERVICE INFORMATION 5.2 TROUBLESHOOTING 5.3 ENGINE OIL LEVEL 5.4 ENGINE OIL & FILTER CHANGE 5.5 OIL PUMP 5.1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump. Fill the oil pump with clean oil when reassembling the pump. SPECIFICATION ENGINE OIL CAPACITY API service classification: SF or SG 0.8-1.0 liter ENGINE OIL RECOMMENDATION VISCOSITY: SAE 20w-40 When the average temperature in your riding area is within the indicated range, you should use the other engine oil viscosities that are shown in the chart. ENGINE OIL VISCOSITIES SAE 20W-50 SAE 20W-40 SAE 10W-40 SAE 10W-30 SAE 5W -20 -10 0 10 20 30 40 o C ITEM OIL PUMP COVER-TO-ROTOR CLEARANCE ROTOR TIP CLEARANCE END CLEARANCE STANDARD ------------------0.05 ­ 0.10 SERVICE LIMIT 0.12 0.12 0.2 TORQUE VALUE OIL DRAIN BOLT 20-30 n-m (2.0~3.0 kg-m) 26 5.2 TROUBLESHOOTING Oil lever too low-high oil consumption Normal oil consumption. External oil leaks. Oil not changed often enough. Worn piston rings. Faulty heat gasket. Oil contamination Worn piston rings. Faulty heat gasket. Oil or filter not changed often enough. 5.3 ENGINE OIL LEVEL Place the engine on the level plane. Check the oil level with the oil level gauge, but do not screw it in when making this check. OIL LEVEL GAUGE Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge. LOWER UPPER LEVEL 5.4 ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. NOTE: Drain the oil while the engine is warm to ensure complete draining. 27 OIL DRAIN Remove the oil filter cap, spring and oil filter screen. Check the O-ring for damage or fatigue. Install a new oil filter screen and spring then install the cap. OIL FILTER SCREEN OIL FILTER SPRING O-RINING Install the oil drain bolt with sealing washer. TORQUE: 20~30 n-m (2.0 ~ 3.0 kg-m) Fill the crankcase with recommended oil. ENGINE OIL CAPACITY: 0.8 liter at draining. Install the oil filter cap. Install the oil level gauge. Start the engine and let it idle speed for 2 or 3 minutes. Stop the engine and check that the oil level at the upper line on the gauge. Make sure there is no oil leaks. OIL FILTER CAP 5.5 OIL PUMP REMOVAL Remove the fan cover assy. FAN COVER ASSY. 28 Remove the cooling fan composition. COOLING FAN COMPOSITION Remove the A.C.G generator assy. A.C.G GENERATOR ASSY Remove the right crankcase cover. CRANKCASE COVER Remove the starting clutch outer and gear assy. STARTING CLUTCH OUTER 29 STARTING CLUTCH GEAR Remove the flange bolts and oil separator. OIL SEPARATOR FLANGE BOLTS Remove the oil pump chain and oil pump driven sprocket. OIL PUMP CHAIN OIL PUMP DRIVEN SPROCKET Remove the oil pump assy. OIL PUMP ASSY. Disassemble the oil pump. OIL PUMP ASSY. 30 INSPECTION Measure the oil pump rotor-to-body clearance. SERVICE LIMIT: 0.12 mm OIL PUMP BODY Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm. OIL PUMP SHAFT Remove the oil pump shaft and measure the pump end clearance. OIL PUMP OUTER ROTER SERVICE LIMIT: 0.2 mm. OIL PUMP INNER ROTER OIL PUMP ASSEMBLY / INSTALLATION Install the outer rotor, inner rotor and oil pump shaft onto the body. NOTE: Pour a drop of clean engine oil inside the oil pump. OIL PUMP SHAFT 31 Install the oil pump assy. Install the oil pump driven sprocket and oil pump chain. PS: The tighten torque of driven sprocket nut is 80~120 kgf-cm. OIL PUMP DRIVEN SPROCKET Install the oil separator. OIL SEPARATOR Install the starting clutch outer and gear assy. 32 Install the new gasket, dowel pins and right crankcase cover. Install the A.C.G generator assy. and cooling fan composition. 33 6.CYLINDER / PISTON 6.1 SERVICE INFORMATION 6.2 TROUBLESHOOTING 6.3 CYLINDER REMOVAL 6.4 PISTON REMOVAL 6.5 PISTON INSTALLATION 6.6 CYLINDER INSTALLATION 6.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head make sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place. ITEM I.D. TAPER OUT OF ROUND WARPAGE ACROSS TOP Piston PISTON O.D. Piston pin PISTON PIN BORE Piston rings PISTON PIN O.D. PISTON-TO-PIN CLEARANCE PISTON-TO-PIN CLEARANCE PISTON RING-TO-RING GROOVE CLEARANCE PISTON RING END GAP CYLINDER-TO-PISTON CLEARANCE CONNECTING ROD SMALL END I.D. Cylinder TOP SECOND TOP/SEC OIL STANDARD 57.400 - 57.410 ---------------------------------57.3075 - 57.3095 15.002 - 15.008 14.994 ­ 15.000 0.002 ­ 0.014 0.015 ­ 0.050 0.015 ­ 0.050 0.10 ­ 0.25 0.2 ­0.7 0.0005 ­ 0.1025 15.010 ­ 15.028 SERVICE LIMIT 57.50 0.10 0.10 0.10 56.500 15.04 14.960 0.02 0.12 0.12 0.5 -----------0.1 15.06 6.2 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings. Overheating Excessive carbon build-up on piston or combustion chamber wall. Knocking or abnormal noise Worn piston and cylinder. Excessive carbon build-up. Excessive smoke Worn cylinder, piston, or piston rings. Improper installation of piston rings. Scored or scratched piston or cylinder wall. Damaged valve stem seal. 34 6.3 CYLINDER REMOVAL Remove the cylinder head. CYLINDER HEAD Remove the cylinder. CYLINDER Remove the cylinder gasket and dowel pins. GASKET DOWEL Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface. CYLINDER SURFACE 35 6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase. PISTON PIN CLIP Remove the piston pin from the piston. Remove the piston. PISTON Spread each piston ring and remove it by lifting up at a point opposite the gap. PISTON PIN PISTON INSPECTION Inspect the cylinder walls for scratches or wear. 36 Measure and record the cylinder I.D. at three levels in both an X and Y-axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 57.50 mm Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm Calculate cylinder taper at three levels in an X and Y-axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.10 mm Calculate the cylinder out-of-round at three levels in an X and Y-axis. Take the maximum reading to determine the out-of ­round. SERVICE LIMIT: 0.10 mm Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.10 mm PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance. SERVICE LIMITS: TOP 0.12 mm SECOND 0.12 mm 37 Inspect the piston for wear or damage. PISTON Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder. SERVICE LIMITS: TOP 0.5 mm SECOND 0.5 mm Measure the piston pin O.D. SERVICE LIMIT: 14.960 mm PISTON PIN Measure the piston pin bore. SERVICE LIMIT: 15.04 mm 38 Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm Measure the connecting rod small end I.D. SERVICE LIMIT: 15.06 mm CONNECTING ROD 6.5 PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up. NOTE: Don't interchange the top and second rings. Avoid piston and piston ring damage during installation. Space the piston ring end gaps 120 degrees apart. 39 PISTON INSTALLATION Install the piston with it's "IN" mark on the intake valve side. "IN"MARK Install the piston pin with new pin clips. Do not align the piston pin clip end gap with the piston cutout. NOTE: Do not allow the clip to fall into the crankcase. PISTON PIN 6.6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface. NOTE: Be careful not to damage the gasket surface. Install the dowel pins and a new gasket. 40 GASKET