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Санкт-Петербургский государственный университет технологии и дизайна

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Мануал по Suzuki gsx r 600 k1.docx

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Iacautioni

*Neveruseanythingexceptthespecifiedbattery.

*Onceinstallthecapstothebattery;donotremovethecaps.

•Donottapthecapswithahammerwheninstalling

_them.

^?-2.⁼^~^e;

0^~⁰

•Usingmulticircuittester,measurethebatteryvoltage.Thetestershouldindicatemorethan12.5-12.6V(DC)asshownintheFig.Ifthebatteryvoltageislowerthanthespecification,chargethebatterywithabatterycharger.(Refertotherechargingop•eration)

Iacautioni

_Donot_r_e_m_o_v_ethecaps_o_nthe_battery_top_w_hilecharg•

(V)

~;::;:=-30seconds

(at25'C)

ing.

NOTE:

Initialchargingforanewbatteryisrecommendediftwoyearshaveelapsedsincethedateofmanufacture.

SERVICING

Visuallyinspectthesurfaceofthebatterycontainer.Ifanysignsofcrackingorelectrolyteleakagefromthesidesofthebatteryhaveoccurred,replacethebatterywithanewone.Ifthebatteryterminalsarefoundtobecoatedwithrustoranacidicwhitepow•derysubstance,thenthiscanbecleanedawaywithsandpaper.

O 246810(Minutes)Time

RECHARGINGOPERATION

•Usingthemulticircuittester,checkthebatteryvoltage.Ifthevoltagereadingislessthanthe12.0V(DC),rechargethebat•

_tery_w_i_thabattery_charge_r_.

Chargingperiod

⁽^V₎_-1..._...--Sto_p_c_harg_i_ng

¹⁷_-

₁₆

ACAUTIONI

*Whenrechargingthebattery,removethebatteryfromthemotorcycle.

¹⁵_'

.........

*Donotremovethecapsonthebatterytopwhilere•

charging.

Rechargingtime:4Aforonehouror0.9Afor5to10hours

IACAUTIONI

Becarefulnottopermitthechargingcurrenttoexceed

₄_Aatan_y_time_.

(V)

⁰¹⁰²⁰³⁰⁴⁰⁵⁰⁶⁰

Time(Minutes)

(ato·-40°C)

•Afterrecharging,waitformorethan30minutesandcheckthebatteryvoltagewithamulticircuittester.

•Ifthebatteryvoltageislessthanthe12.5V,rechargethebat•

teryagain.

•Ifbatteryvoltageisstilllessthan12.SV,afterrecharging,re•

placethebatterywithanewone.

•Whenthemotorcycleisnotusedforalongperiod,checkthebatteryevery1monthtopreventthebatterydischarge.

1o~-+---4--o1----1----1

1007550250(%)

Batterychargedcondition

SERVICINGINFORMATION

_FlSYSTEM_M_{ALFUNCTIONCODEAND} DEFECTIVECONDITION..............................................................	8-2
ENGINE..........................................................................................	8-4
RADIATOR(COOLINGSYSTEM).................................................	8-9
CHASSIS........................................................................................	8-10
BRAKES	8-11
ELECTRICAL.................................................................................	8-12
BATTERY.......................................................................................	8-13
WIREHARNESS,CABLEANDHOSEROUTING..........................	8-14
WIREHARNESSROUTING	8-14
CABLEROUTING	8-17
FUELTANKDRAINHOSEROUTING	8-18
COOLINGSYSTEMHOSEROUTING..........................................	8-19
FRONTBRAKEHOSEROUTING................................................	8-20
REARBRAKEHOSEROUTING..................................................	8-21
PAIR(AIRSUPPLY)SYSTEMHOSEROUTING.........................	8-22
FUELTANKSET-UP.........................................................................	8-23
COWLINGSET-UP............................................................................	8-24
FRAMECOVERSET-UP..................................................................	8-25
SIDE-STANDSET-UP.......................................................................	8-26
GEARSHIFTPEDALSET-UP	8-26
SPECIALTOOLS	8-27
TIGHTENINGTORQUE.....................................................................	8-30
SERVICEDATA	8-34

CONTENTS~~~~~~~~~~TROUBLESHOOTING8-2

TROUBLESHOOTING

_FlS_Y_ST_EMM_ALFUNCTI_O_N_CODE_A_N_DDE_F_EC_TI_VE_CO_N_DIT_I_ON

_MALF_U_NC_T_IO_N

_D_E_T_E_CTED_ITEM_--_-_-_-_-

_D_E_TECT_E_D_FAI_L_UR_E_CONDI_T_ION

^CODE

_cooNO_FAUL_T

---------------

^CHECK^F^O^R

^Cams^h^aft^posⁱ^tⁱ^on^ThesignaldoesnotreachECMformorethan2sec.afterre-^{sensorceiving}thestartersignal.

^-^---^-^--^-^-^-^---^-^---^-----^-

^c11^Thecamshaftpositionsensorwiringandmechanicalparts.

(Camshaftpositionsensor,intakecampin,wiring/couplercon-nection)

^C^r^aⁿ^ksha^ft^position^ThesignaldoesnotreachECMformorethan2sec.afterre-^sensor^ceivingthestartersignal.

_c12^-^--^-^-^-^-^-^-^-^---^---^-^-^--^-^-^-

^T^he^c^r^anksha^ft^positⁱ^onsensor^wⁱ^rⁱ^ngandmechanⁱ^cal^parts^.

(Crankshaftpositionsensor,wiring/couplerconnection)

^{Intakeairpressure}^Thesensorshouldproducefollowingvoltage._c13^sensor⁽0.5V~sensorvoltage<4.85V)

_Withou_t_t_h_e_above_range_,_c₁₃_i_s_i_n_dica_t_ed.

~----------------------

^In^t^{akeairpressure}^s^e^nsor^,^wi^r^ing^/^coupler^connec^tⁱ^on^.

^Throt^t^l^e^posⁱ^tⁱ^on^Thesensorshouldproducefollowingvoltage._c₁₄^senso^r⁽0.2V~sensorvoltage<4.8V)

_W_i_thout_theabove_range_,_c₁₄_i_s_i_ndicate_d_.

^--^-^-^-^-^--^-^--^--^-----^-^-^-^-^-

Throttlepositionsensor,wiring/couplerconnection.

^E^ngⁱ^ne^co^ol^antThesensorvoltageshouldbethefollowing._c₁₅^t^empera^tu^resenso^r⁽0.15V~sensorvoltage<4.85V)

Enginecoolanttemperaturesensor,wiring/couplerconnection.

Intakeairtemperature

sensor

Thesensorvoltageshouldbethefollowing.(0.15V~sensorvoltage<4.85V)

^-^W^-ⁱ^t^h^-^o^u^-^t^-^t^h^-^e^-^a^b^-^o^v^-^e^-^r^aⁿ^-^g^e^-^,^c^-¹⁵^-ⁱ^s^-ⁱⁿ^-^dⁱ^c^a^-^t^e^-^d^.^-^-^-^-^-

c21

_W_it_hou_t_theabove_r_ange_,_c21_i_s_i_nd_i_cated_.

^-^--^--^-^--^--^-^-^-^-^--^-^-^--^-^---

Intakeairtemperaturesensor,wiring/couplerconnection.

Atmospheric_The_sen_s_o_r_v_olt_age_shou_l_db_e_the_f_ollowing.

_c22^p^r^essu^r^e^sensor⁽^0.5^V^s^senso^r^vo^l^tage<4.85^V⁾

_Wi_t_hou_t_theabo_v_e_r_ange_,_c22_i_s_i_nd_i_ca_t_ed_.

~----------------------

^A^t^m^.^press^ur^esensor^,^w^irⁱⁿ^g^/^coupler^connec^t^ion^.

^Tⁱ^p^{oversensorThe}sensorvoltageshouldbelessthanthefollowingformorethan3sec.afterignitionswitchturnsON.

^c²³⁽0.25V~sensorvoltage<4.85V)

^~^-^-^-^-^-^-^-^---^-^-----^-^-^-^---

Withouttheabovevalue,c23isindicated.Tipoversensor,wiring/couplerconnection.

^Igni^tⁱ^oⁿ^sⁱ^gⁿ^a^l_Cran_k_sha_ft_pos_it_i_o_n_se_n_so_r₍_p_i_ck-up_co_i_l₎_s_i_gna_l_isprod_uc_edb_ut

_c24_,_c25_,^sⁱ^gna^l^from^ignⁱ^tioⁿ^c^o^ilⁱ^sⁱ^nt^e^r^r^upted^contⁱ^nuousbytwo^tⁱ^mesor

c26orc27

more.Inthiscase,thecodec24,c25,c26orc27isindicated.

i--------------------------

Ignitioncoil,wiring/couplerconnection,powersupplyfromthebattery.

c28

c29

^S^e^c^o^ndaryt^h^r^o^ttleWhennoactuatorcontrolsignalissuppliedfromECMorcom-^v^a^lv^e^actua^t^o^r^municationsignaldoesnotreachECMoroperationvoltage

doesnotreachSTYactuator.

Withouttheabovevalue,c28isindicated.STYactuatorcannotoperate.

~----------------------

^STYactuator^l^ead^wi^r^e^/^cou^p^l^er^.

^S^e^condary^t^h^ro^ttle^Thesensorshouldproducefollowingvoltage.positionsensor(0.2V~sensorvoltage<4.8V)

^L--^Withouttheaboverange,c29isindicated.

Secondarythrottlepositionsensor,wiring/couplerconnection.^Secondary^t^h^rottle^WhennocommunicationsignalissuppliedfromtheECMor

_c₃₀_contro_l_u_nit_whenpower_so_u_rce_stops,c30_i_s_ind_i_cated_.

_~_-_-_-_-_--_--_---_-_-_--_-_--_--_-_-

^STC^uⁿⁱ^t^,^wⁱ^ring^/^coup^l^er^connectⁱ^on^,^po^w^er^supp^l^y^toSTCunit.

^Gear^pos^itⁱ^on^signa^l^Gearpositionsignalvoltageshouldbehigherthanthefollow-ingformorethan3seconds.

(Gearpositionsensorvoltage>0.60V)

_c31_W_i_thoutt_h_e_above_va_l_ue_,_c31_i_s_indicated.

^!---^--^--^-^---^--^---^-^-^-^-^-^-^--

^Gea^r^{positionsensor}^,^wⁱ^r^ing^/^co^u^pler^connection^.^Gearshiftca^m

etc.

c32,c33,c34

^Fuelⁱⁿ^j^ector^sⁱ^gⁿ^a^l^Whenfuelinjectionsignalstops,thec32,c33,c34orc35isindicated.

^L----^-^--^-^-----^---^--^-^--^-^-^-

orc35^Injec^t^or^,^wⁱ^ring^/^coup^l^er^connec^ti^on^,^powe^r^supp^l^y^to^t^h^eⁱ^n-

_jector.

Fuelpumprelay

_L._Whenno_s_i_gna_l_is_s_u_pp_l_i_ed_f_rom_fue_l_pump_r_e_l_a_y_,_c₄₁_is_in_d_i_cated.

c41 ^sⁱ^gna^l^F^ue^l^pump^re^l^ay^,^coⁿ^nec^tⁱ^ng^l^ead^,^p^o^wersource^to^f^u^e^l^p^u^m^p^relay.

Ignitionswitchsignal_~n_it_i_on~_i_tc~i_g_~_~notinput_~_t_h~CM_~_-_-_-_--_-

c42

Ignitionswitch,leadwire/coupler.

_ENGINE

Complaint Enginewillnotstart,		Symptomandpossiblecauses Compressiontoolow	Remedy
orishard	tostart.	1.Outofadjustmentvalveclearance. 2.Wornvalveguidesorpoorseatingofvalves.	Adjust. Repairorreplace.
		3.^Mⁱ^stimⁱⁿ^g^v^a^lve^s^.	Adjust.
		4.^Exce^s^sⁱ^vely^wo^rn^pis^t^oⁿ^rⁱ^ng^s^.	Replace.
		5.^Worn^-^d^own^cy^li^nder^b^o^r^es^.	Replace.

6.^T^oo^s^l^o^wl^y^starte^r^m^o^t^o^r^cr^an^ks^.^See^e^l^e^c^t^rⁱ^ca^l^sec^t^ioⁿ^.

7.^Poorseatingo^f^spa^r^k^p^l^ugs^.^R^e^t^ighten^.^Plugsnotsparking

¹^.^F^ou^l^ed^spa^r^k^plugs^.^C^l^ean^.

2.Wetsparkplugs.^C^l^eanand^dry^.

3.^Defect^iv^eⁱ^gnⁱ^t^ioⁿ^co^il^/pl^ug^cap^.^R^ep^l^ace.

4.DefectiveCKPsensor.^R^e^place^.

5.^De^f^ectⁱ^ve^E^CM^.^Re^p^lace^.

1.	Cloggedfuelfilterorfuelhose.	Cleanorreplace.
2.	Defectivefuelpump.	Replace.
3.	Defectivefuelpressureregulator.	Replace.
4.	Defectivefuelinjector.	Replace.
5.	Defectivefuelpumprelay.	Replace.
6.	DefectiveECM.	Replace.
₇_.	Open-circuitedwiringconnections.	Checkandrepair.
Incorrectfuel/airmixture
1.	Outofadjustmentthrottlepositionsensor.	Adjust.
2.	Defectivefuelpump.	Replace.
3.	Defectivefuelpressureregulator.	Replace.
4.	Defectivethrottlepositionsensor.	Replace.
5.	Defectivecrankshaftpositionsensor.	Replace.
6.	Defectiveintakeairpressuresensor.	Replace.
7.	Defectiveatmosphericpressuresensor.	Replace.
8.	DefectiveECM.	Replace.
9.	Defectiveenginecoolanttemp.sensor.	Replace.
10.	Defectiveintakeairtemp.sensor.	Replace.

6.^O^p^en-cⁱ^r^c^ui^t^ed^wⁱ^ring^connectⁱ^ons.^R^ep^ai^r^o^r^r^e^p^l^ac^e.^Nofuelreachingintakemanifold

ComplaintSymptomandpossiblecauses_Re_m_edy

Engine	idlespoorly.	1.	Outofadjustmentvalveclearance.	Adjust.
		2.	Poorseatingofvalves.	Replaceorrepair.
		3.	Defectivevalveguides.	Replace.
		4.	Worndowncamshaft.	Replace.
		5.	Toowidesparkpluggaps.	Adjustorreplace.
		6.	Defectiveignitioncoil/plugcap.	Replace.
		7.	Defectivecrankshaftpositionsensor.	Replace.
		8.	DefectiveECM.	Replace.
		9.	Defectivethrottlepositionsensor.	Replace.
		10.	Defectivefuelpump.	Replace.
		11.	Imbalancedthrottlevalve.	Adjust.
		12.	Damagedorcrackedvacuumhose.	Replace.
Engine	stallseasily.	Inc	rrectfuel/airmixture
		1.	Defectiveintakeairpressuresensororcircuit.	Repairorreplace.
		2.	Cloggedfuelfilter.	Cleanorreplace.
		3.	Defectivefuelpump.	Replace.
		4.	Defectivefuelpressureregulator.	Replace.
		5.	Defectiveenginecoolanttemp.sensor.	Replace.
		6.	Defectivethermostat.	Replace.
		7.	Defectiveintakeairtemp.sensor.	Replace.

_I_mp_r_o_p_er_l_y_work_ing_f_u_e_l_in_j_ector

1.	Defectivefuelinjector.	Replace.
2.	NoinjectionsignalfromECM.	Repairorreplace.
3.	Openorshortcircuitedwiringconnection.	Repairorreplace.
4.	Defectivebatteryorlowbatteryvoltage.	Replaceorrecharge.

_I_mproperly_worki_n_gcontro_l_c_i_rcui_t_o_r_se_n_sors

1.	DefectiveECM.	Replace.
2.	Defectivefuelpressureregulator.	Replace.
3.	Defectivethrottlepositionsensor.	Replace.
4.	Defectiveintakeairtemp.sensor.	Replace.
5.	Defectivecamshaftpositionsensor.	Replace.
6.	Defectivecrankshaftpositionsensor.	Replace.
7.	Defectiveenginecoolanttemp.sensor.	Replace.
8.	Defectivefuelpumprelay.	Replace.

Improperlyworkingengineinternalparts

1.Fouledsparkplugs.Clean.

²^.^D^efe^c^ti^v^e^cr^aⁿ^k^shaft^po^sⁱ^ti^onsenso^r^orECM.^Replace.

³^.^Clogged^fue^l^hose.^Clean.

^4.^Outofad^j^ustme^nt^tappe^t^c^l^earance.Adjust.

^Comp^l^aint^Symptomand^possib^l^e^causesRemedy

Noisyengine.^{Excessivevalvechatter}

¹^.^Toola^r^ge^va^l^ve^c^learaⁿ^c^e^.^Adjust.

2.^Weaken^ed^o^r^b^rok^en^v^a^l^v^e^s^p^rⁱ^ngs^.^Replace.

3.^W^o^rn^ta^ppet^or^c^a^m^s^urface.^Replace.

⁴^.^Wornan^d^b^u^rn^t^cams^h^aft^j^ournal.^Replace.

_{Noiseseemstocomefrompiston}

1.	Worndownpistonsorcylinders.	Replace.
2.	Fouledwithcarboncombustionchambers.	Clean.
3.	Wornpistonpinsorpistonpinbore.	Replace.
4.	Wornpistonringsorringgrooves.	Replace.

Noiseseemstocomefromtimingchain

1.Stretchedchain.Replace.

2.Wornsprockets.Replace.

3.Notworkingtensionadjuster.Repairorreplace.

_{Noiseseemstocomefromclutch}

1.	Wornsplinesofcountershaftorhub.	Replace.
2.	Wornteethofclutchplates.	Replace.
3.	Distortedclutchplates,drivenanddrive.	Replace.
4.	Wornclutchreleasebearing.	Replace.
5.	Weakenedclutchdampers.	Replacetheprimarydrivengear.

Noiseseemstocomefromcrankshaft

1.	Duetowearrattlingbearings.	Replace.
2.	Wornandburntbig-endbearings.	Replace.
3.	Wornandburntjournalbearings.	Replace.
4.	Toolargethrustclearance.	Replacethrustbearing.

Noiseseemstocomefromtransmission

¹^.^{Wornorrubbing}^gea^r^s^.^Replace.

²^.^Worn^sp^l^ines^.^Replace.

³^.^Worn^o^r^r^u^b^bing^prⁱ^ma^ry^gears.^Replace.

	1.Toomuchplayonpumpshaftbearing. 2.Wornordamagedimpellershaft. 3.Wornordamagedmechanicalseal.		Replace.Replace.Replace.
	4.Touchespumpcaseandimpeller.		Replace.
Enginerunspoorly	Defectiveengineinternal/electricalparts
inhighspeedrange.	1.	Weakenedvalvesprings.	Replace.
	2.	Worncamshafts.	Replace.
	3.	Valvetimingoutofadjustment.	Adjust.
	4.	Toonarrowsparkpluggaps.	Adjust.
	5. 6.	Ignitionnotadvancedsufficientlyduetopoorlyworkingtimingadvancecircuit. Defectiveignitioncoil.	ReplaceECM. Replace.
	7.	Defectivecrankshaftpositionsensor.	Replace.
	8.	DefectiveECM.	Replace.
	9.	Cloggedaircleanerelement.	Clean.
	10.	Cloggedfuelhose,resultingininadequatefuel	Cleanandprime.
		supplytoinjector.
	11.	Defectivefuelpump.	Replace.
	12.	Defectivethrottlepositionsensor.	Replace.
	13.	DefectiveSTCunitorSTVactuator	Replace.

⁴^.^Worn^b^earings.^Replace.Noiseseemstocomefromwaterpump

^C^o^{mplaintSymptoma}ⁿ^d^possible^causes^Remedy

Enginerunspoorly^D^efecti^v^e^a^irflow^s^y^s^t^em

ⁱⁿ^hⁱ^gh^sp^e^e^d^r^ange.¹^.^C^l^{oggedaircleanerelement.}^Cleanorreplace.

^2.^Defective^throt^t^l^e^valve^.^Adjustorreplace.

³^.^Defectⁱ^vesecoundary^t^h^rott^l^e^va^l^ve^.^Adjustorreplace.

^4.^Suckingair^f^rom^throt^t^l^e^bo^d^y^j^oⁱⁿ^l^Repairorreplace.

^5.^Defectⁱ^veECM.^Replace.

1.	Lowfuelpressure.	Repairorreplace.
2.	Defectivethrottlepositionsensor.	Replace.
3.	Defectiveintakeairtemp.sensor.	Replace.
4.	Defectivecamshaftpositionsensor.	Replace.
5.	Defectivecrankshaftpositionsensor.	Replace.
6.	Defectivegearpositionsensor.	Replace.
7.	Defectiveintakeairpressuresensor.	Replace.
8.	Defectiveatmosphericpressuresensor.	Replace.
9.	DefectiveECM.	Replace.
10.	lmbalancingthrottlevalvesynchronization.	Adjust.
11.	DefectiveSTPsensorand/orSTVactuator.	Replace.
12.	DefectiveSTCunit.	_Rep_l_ace.
Defectiveengineinternal/electricalparts
1.	Lossofvalveclearance.	Adjust.
2.	Weakenedvalvesprings.	Replace.
3.	Outofadjustmentvalvetiming.	Adjust.
4.	Wornpistonringsorcylinders.	Replace.
5.	Poorseatingofvalves.	Repair.
6.	Fouledsparkplug.	Cleanorreplace.
7.	Incorrectsparkplug.	Adjustorreplace.
8.	Cloggedinjector.	Clean.
9.	Outofadjustmentthrottlepositionsensor.	Adjust.
10.	Cloggedaircleanerelement.	Clean.
11.	lmbalancingthrottlevalvesynchronization.	Adjust.
12.	Suckingairfromthrottlevalveorvacuumhose.	Retightenorreplace.
13.	Toomuchengineoil.	Drainoutexcessoil.
14.	DefectivefuelpumporECM.	Replace.
15.	Defectivecrankshaftpositionsensorand	Replace.
	ignitioncoil.

_D_e_fe_c_ti_veco_ntrolcircui_to_r_sens_o_r

_Enginela_c_ks_pow_e_r.

Defectivecontrolcircuitorsensor

¹^.^Lowfue^l^pressure.^Repairorreplace.

^2.^De^f^ectivethro^tt^le^p^osition^sen^s^or^.^Replace.

^3.^De^f^ectⁱ^ve^inta^k^e^aⁱ^r^t^e^m^p.^sensor.^Replace.

^4.^{Defectivecamsh}^aft^posⁱ^tion^senso^r.^Replace.

^5.^{Defectivecranksh}^a^{ftpositionsensor.Replace.}

⁶^.^Defectⁱ^vegear^p^osition^senso^r^.^Replace.

^7.^{Defectiveintake}^aⁱ^rpressu^r^{esensor.Replace.}

^8.^{Defectiveatmospheri}^cpr^ess^u^{resensor.Replace.}

^9.^Defective^E^CM.^Replace.

¹^0.^lmbalancingthrottlevalvesynchronization.Adjust.

^11.^Defec^ti^veST^P^sensorand^/^o^r^STVactuato^r^.^Replace.

12.DefectiveSTCunit.Replace.

^Com^p^laⁱ^nt^S^y^mp^t^o^mand^p^o^ssⁱ^b^l^e^ca^u^ses^Remedy

_E_ngi_n_e_ove_r_h_e_a_t_s_._De_fec_t_i_v_e_e_n_g_i_nein_t_e_r_n_al_p_arts

1.	Heavycarbondepositonpistoncrowns.	Clean.
2.	Notenoughoilintheengine.	Addoil.
3.	Defectiveoilpumporcloggedoilcircuit.	Replaceorclean.
4.	Suckingairfromintakepipes.	Retightenorreplace.
5.	Useincorrectengineoil.	Change.
6.	Defectivecoolingsystem.	Seeradiatorsection.

Leanfuel/airmixture

1.Short-circuitedintakeairpressuresensor/leadRepairorreplace.wire.

2.^S^h^o^r^t-^ci^rcu^it^e^dⁱⁿ^t^ake^aⁱ^rtemp^.^sensor^/^l^eadwi^r^e.Repairorreplace.

3.^Sucking^aⁱ^r^f^r^omⁱⁿ^t^a^k^e^pⁱ^pejoint.^Cleanorreplace.

4.Defectivefuelinjector.Repairorreplace.

5.Defectiveenginecoolanttemp.sensor.Replace.

Theotherfactors

¹^.^I^gnitⁱ^on^timⁱ^ngⁱ^s^tooad^v^{ancedduetodefec}^t^ive^Replace.timingadvancesystem(enginecoolanttemp.

sensor,gearpositionsensor,crankshaftpositionsensorandECM.)

²^.^{Drivechainistoo}^tⁱ^ght.^Ad^j^us^t^.

^Dⁱ^r^tyorhe^a^v^y¹^.^Toomuchengineoilintheengine.Checkwithinspection

^exhaust^sm^o^k^e^.^windowdrainoutexcessoil.

^2.^Worn^pi^ston^ri^ngsor^cy^lⁱ^nders^.^Rep^l^ace.

^3.^Worn^va^l^ve^g^uⁱ^des.^Replace.

⁴^.^{Scoredorscuffed}^cy^lⁱ^nder^wa^l^l^s.^Replace.

^5.Worn^va^l^ves^s^t^ems^.^Replace.

6.^De^f^ectⁱ^vestem^sea^l.^Replace.

7.^Worn^o^il^ri^ngside^raⁱ^l^s^.^Replace.

2.Wornordistortedpressureplate. 3.Distortedclutchplatesorclutchplate.

			Replace.
Draggingclutch.	1.	Someclutchspringweakenedwhileothers	Replace.
		arenot.
	2.	Distortedpressureplateorclutchplate.	Replace.
Transmissionwill	1.	Brokengearshiftcam.	Replace.
notshift.	2.	Distortedgearshiftforks.	Replace.
	3.	Worngearshiftpawl.	Replace.
Transmissionwill	1.	Brokenreturnspringonshiftshaft.	Replace.
notshiftback.	2.	Rubbingorsticklyshiftshaft.	Repairorreplace.
	3.	Distortedorworngearshiftforks.	Replace.
Transmissionjumps		Wornshiftinggearsondriveshaftor	Replace.
outofgear.		countershaft.
	2.	Distortedorworngearshiftforks.	Replace.
	3.	Weakenedstopperspringongearshiftstopper.	Replace.
	4.	Worngearshiftcamplate.	Replace.

^S^lⁱ^p^ping^c^l^utch.^1.^Weakened^c^lu^t^ch^sp^rⁱ^ngs.^Replace.

_R_e_p_l_ace.

_,_.

RADIATOR(COOLINGSYSTEM)

Complaint^Symptom^and^{possiblecauses}^Remedy

Engineoverheats.	1. 2.	Notenoughenginecoolant. Cloggedwithdirtortrashesradiator	core.	Addcoolant.Clean.
	3.	Faultycoolingfan.		Repairorreplace.
	4.	Defectivecoolingfanthermo-switch.		Replace.
	5.	Cloggedwaterpassage.		Clean.
	6.	Airtrappedinthecoolingcircuit.		Bleedoutair.
	7.	Defectivewaterpump.		Replace.
	8.	Useincorrectcoolant.		Replace.
	9.	Defectivethermostat.		Replace.
Engineovercools.	1.	Defectivecoolingfanthermo-switch.		Replace.
	2.	Extremelycoldweather.		Putontheradiator
	3.	Defectivethermostat.		cover.Replace.


Noisyfront	1.	Nolenoughforkoil.		Replenish.
suspension.	2.	Looseboltsonsuspension.		Retighten.
Wobblyrearwheel.	1.	Distortedwheelrim.		Replace.
	2.	Wornrearwheelbearingorswingarm	bearings.	Replace.
	3.	Defectiveorincorrecttire.		Replace.
	4.	Wornswingarmandrearsuspensionbearings.		Replace.
	5.	Loosenutsorboltsonrearsuspensions.		Retighten.
Rearsuspension	1.	Weakenedspringofshockabsorber.		Replace.
toosoft.	2.	Leakageoilorgasofshockabsorber.		Replace.
	3.	Improperlysetrearspringunitadjuster.		Adjust.
	⁴^.	Improperlysetrearsuspensiondampingforce		Adjust.
		adjuster.
Rearsuspension	1.	Bentshockabsorbershaft.		Replace.
toostiff.	2.	Bentswingarm.		Replace.
	3.	Wornswingarmandrearsuspensionbearings.		Replace.
	4.	Improperlysetrearsuspensionadjuster.		Adjust.
	5.	Improperlysetrearsuspensiondampingforce		Adjust.
		adjuster.
Noisyrear	1.	Loosenutsorboltsonrearsuspension.		Retighten.
suspension.	2.	Wornswingarmandsuspensionbearings.		Replace.

CHASSIS

Complaint Heavysteering.	1.	Symptomandpossiblecauses Overtightenedsteeringstemnut.	Remedy Adjust.
	2.	Brokenbearinginsteeringstem.	Replace.
	3.	Distortedsteeringstem.	Replace.
	4.	Notenoughpressureintires.	Adjust.
Wobblyhandlebars.	1.	Lossofbalancebetweenrightandleftfrontforks.	Replace.
	2.	Distortedfrontfork.	Repairorreplace.
	3.	Distortedfrontaxleorcrookedtire.	Replace.
	4.	Loosesteeringstemnut.	Adjust.
	5.	Wornorincorrecttireorwrongtirepressure.	Adjustorreplace.
	6.	Wornbearing/raceinsteeringstem.	Replace.
Wobblyfrontwheel.	1.	Distortedwheelrim.	Replace.
	2.	Wornfrontwheelbearings.	Replace.
	3.	Defectiveorincorrecttire.	Replace.
	4.	Looseaxleoraxlepinchbolt.	Retighten.
	5.	Incorrectfrontforkoillevel.	Adjust.
Frontsuspension	1.	Weakenedsprings.	Replace.
toosoft.	2.	Notenoughforkoil.	Replenish.
	3.	Wrongweightforkoil.	Replace.
	4.	Improperlysetfrontforkspringadjuster.	Adjust.
	5.	Improperlysetfrontforkdampingforceadjuster.	Adjust.
Frontsuspension	1.	Tooviscousforkoil.	Replace.
toostiff.	^2. 3.	Toomuchforkoil. Improperlysetfrontforkspringadjuster.	Drainexcessoil. Adjust.
	4.	Improperlysetfrontforkdampingforceadjuster.	Adjust.
	5.	Bentfrontaxle.	Replace.

_BRAKES

Complaint Insufficientbrake	1.	Symptomandpossiblecauses Leakageofbrakefluidfromhydraulicsystem.		Remedy Repairorreplace.
power.	2.	Wornpads.		Replace.
	3.	Oiladhesionofengagingsurfaceofpads/shoe.		Cleandiscandpads.
	4.	Worndisc.		Replace.
	5.	Airinhydraulicsystem.		Bleedair.
	6.	Notenoughbrakefluidinthereservoir.		Replenish.
Brakesqueaking.	1.	Carbonadhesiononpadsurface.		Repairsurfacewith
				sandpaper.
	2.	Tiltedpad.		Modifypadfittingor
	3.	Damagedwheelbearing.		replace.Replace.
	4.	Loosenfront-wheelaxleorrear-wheelaxle.		Tightentospecified
				torque.
	5.	Wornpads.		Replace.
	6.	Foreignmaterialinbrakefluid.		Replacebrakefluid.
	_7.	_C_l_og_g_ed_r_e_t_urnpo_rt_ofm_a_stercylin_d_er.		_Disass_emb_lean_d
				cleanmastercylinder.
Excessivebrake	1.	Airinhydraulicsystem.		Bleedair.
leverstroke.	2.	Insufficientbrakefluid.		Replenishfluidtospe-
	3.	Improperqualityofbrakefluid.		citiedlevel;bleedair.Replacewithcorrect
				fluid.
Leakageofbrake	1.	Insufficienttighteningofconnection	joints.	Tightentospecified
fluid				torque.
	2.Crackedhose. 3.Wornpistonand/orcup.			Replace. Replacepistonand/or
				cup.
Brakedrags.	1.Rustypart.			Cleanandlubricate.
	2.Insufficientbrakeleverorbrakepedal			Lubricate.

pivotlubrication.

ELECTRICAL

^Co^m^pl^aⁱ^nt^Sy^m^p^t^o^m^and^p^ossⁱ^b^l^e^c^ause^sRemedy

^No^spar^kⁱⁿ^go^rp^oo^r¹^.^D^e^f^ec^tiv^e^ignⁱ^tⁱ^on^c^oil/^p^lu^gcapo^r^c^amshaft^Replace.sparking.positionsensor.

²^.^D^e^fec^t^ives^p^a^r^k^plu^gs.^Rep^l^ace^.

3.Defectivecrankshaftpositionsensor.Replace.

4.^De^f^ectⁱ^v^e^E^CM^.^Rep^l^ace.

5.Defectivetipoversensor.Replace.

6.^Open^-^cⁱ^r^c^uⁱ^t^e^d^wi^rⁱ^ng^connec^ti^ons.Checkandrepair.

Sparkplugsoon1.^Mⁱ^xtu^r^etoo^rⁱ^ch^.^ConsultFlsystem.becomefouledwith2.Idlingspeedsettoohigh.Adjustfastidleorcarbon.throttlestopscrew.

3.^Iⁿ^correct^gaso^lⁱⁿ^e.^Change.

4.Dirtyelementinaircleaner.Cleanorreplace.

5.^T^oo^co^l^dspa^r^k^p^l^ugs^.^Replacewithhottypeplugs.

^Sp^ark^p^lu^gs^b^eco^me¹.^Worn^pⁱ^s^t^oⁿ^rin^g^s.^Replace.fouledtoosoon.2.Wornpistonorcylinders.Replace.

³^.^E^xcessⁱ^{veclearanceof}^va^l^ves^t^e^m^sin^va^l^veReplace.

guides.

^4.^Wornste^m^oil^sea^l.^Replace.

^Sparkpl^u^ge^l^ectrod^-¹.^Toohotspa^r^kplugs.^Replacewithcoldesoverheatorburn.typeplugs.

2.^O^v^e^r^heatedthe^engⁱ^ne.^Tuneup.

3.Loosesparkplugs.Retighten.

4.Tooleanmixture.ConsultFlsystem.^G^ene^r^ator^d^oesⁿ^ot¹.Openorshortleadwires,orlooseleadRepairorreplaceor^c^ha^rge^.^connectⁱ^ons^.^retighten.

2.Shorted,groundedoropengeneratorcoils.Replace.

³^.^Shorte^d^or^panctu^r^ed^r^egu^l^a^t^or^/^rectⁱ^f^ie^r^s^.^Replace.

^Geⁿ^erator^does¹^.^Leadwirestendtogetshortedoropen-circuitedRepairorretighten.charge,butchargingorlooselyconnectedatterminals.

^rateⁱ^s^belowt^h^e²^.^Groundedor^o^peⁿ^-^circuⁱ^tedstator^coⁱ^l^s^or^Replace.specification.generator.

³^.^De^f^ective^r^egulato^r^/^r^ecti^fi^e^r.^Replace.

4.^D^e^f^ectⁱ^vecell^p^l^atesⁱⁿ^the^batte^r^y^.^Replacethebattery.^Generator¹.^I^nterna^l^sho^r^t^-^ci^r^cuⁱ^tⁱⁿ^t^h^e^battery^.^Replacethebattery.^ove^r^c^h^arg^e^s.².Damagedordefectiveregulator/rectifier.Replace.

³^.^P^oo^r^l^y^g^ro^unded^r^egu^l^a^t^o^r/r^ec^ti^fier^.^R^epaⁱ^r^,^r^e^pl^a^c^e^.^or

connectproperly.^U^{nstablechargi}ⁿ^g.^1.^Le^a^d^wⁱ^r^eⁱ^nsu^l^at^ionfrayed^d^ue^t^o^vⁱ^b^ration^,^Repairorreplace.

^resu^l^tⁱ^ngⁱⁿⁱⁿ^termi^tt^en^t^sho^rt^ing^.

^2.^I^nterna^l^l^y^s^horted^g^ener^ato^r^.^Replace.

³^.^D^e^f^ectⁱ^ve^regu^l^ato^r/r^ectⁱ^fi^er.^Replace.

^{Starterbuttonis}ⁿ^ot¹^.^Run^dowⁿ^b^attery^.^Repairorreplace.^effectiv^e^.^2.^D^efec^tⁱ^ve^swⁱ^tch^c^ontacts^.^Replace.

³^.^Not^seatⁱ^ng^prope^r^l^y^brushesonco^m^mutato^rⁱⁿ^Repaⁱ^r^or^r^eplace.

startermotor.

⁴^.^Defectives^t^a^rt^er^re^l^a^y^/^s^t^a^r^te^rⁱ^nte^r^l^oc^k^swⁱ^tch^.^Replace.

⁵^.^Defectⁱ^ve^maⁱⁿ^fuse.^Replace.

_BATTERY

Complaint		Symptomandpossiblecauses		Remedy
"Sulfation",acidic	1.	Crackedbatterycase.		Replacethebattery.
whitepowderysub-	2.	Batteryhasbeenleftinarun-downcondition	for	Replacethebattery.
stanceorspotson		alongtime.
surfaceofcellplates.

....

Batteryrunsdown¹^.^Notcorrect^t^hechargⁱ^ng^s^ys^t^em^.^C^h^eckthe^generator^,^quickly.^regu^l^ato^r^/^rec^tⁱ^fi^e^r^and

circuitconnectionsandmakenecessaryadjustmentstoobtainspecifiedchargingoperation.

2.^Ce^l^l^p^l^ateshave^l^ostmuch^o^f^theⁱ^r^ac^t^ive^Replacethebattery,

^mate^ri^{alasaresultof}^ov^e^r^ch^ar^ging^.^andcorrectthecharg-ingsystem.

3.Ashort-circuitconditionexistswithinthebattery.Replacethebattery.

4.^To^o^l^o^w^b^att^ery^vo^l^tage^.^R^echarge^t^h^e^batte^r^y^fully.

Battery"sulfation".	1.	Incorrectchargingrate.	Replacethebattery.
		(Whennotinusebatteriesshouldbecheckedat
		leastonceamonthtoavoidsulfation.)
	2.	Thebatterywasleftunusedinacoldclimatefortoolong.	Replacethebatteryifbadlysulfated.
Batterydischargestoorapidly.	1.	Dirtycontainertopandsides.	Clean.

5.^Too^o^l^dbattery.^R^ep^l^ace^t^he^battery^.

WIRINGHARNESS,CABLEANDHOSEROUTING

WIRINGHARNESSROUTING

Setthewiringharnesstotherightsideofheadlight,andpushittothegrooveoftheheadlighthousing.

Wiringharness

Clamp

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