dink 01 general information

8/8/2019 Dink 01 General Information

http://slidepdf.com/reader/full/dink-01-general-information 1/40

1. GENERAL INFORMATION1ENGINE SERIAL NUMBER ----1-0 TOOLS----------------------------1-11SPECIFICATION -----------------1-1 LUBRICATION POINTS -------1-12SERVICE PRECAUTIONS ------1-2 WIRING DIAGRAM-------------1-

14TORQUE VALUES---------------1-9 CABLE & HARNESS ROUTING1-19TROUBLESHOOTING----------1-20

ENGINE SERIAL NUMBER

Location of Engine Serial Number

1-0



1. GENERAL INFORMATIONSPECIFICATIONS

Name & Model No. SF30AAMotorcycle Name & Type

Overall length 1940mmOverall width 745mmOverall height 1140mmWheel base 1350mmEngine type Water cooled 4-stroke,OHC engineDisplacement 149.4ccFuel Used 92# nonleaded gasolineNet weight (kg)Front wheel 45Rear wheel 68Total 113

Gross weight(kg)Front wheel 49Rear wheel 75Total 124Tires Front wheel 100/90-10Rear wheel 120/70-10Ground clearance 130mmPerform-anceBraking distance (m) 7.9m /40km/HVMin. turning radius 2030mmEngine

Starting systemStarting motor &kick starterType Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) 57.4 x 57.8Compression ratio 10.6:1Compression pressure(kg/cm_-rpm) 16.400Max. output (ps/rpm) 12.0/7500Max. torque (kg m/rpm) 1.2/6000PorttimingIntake(1mm)Open BTDC 12°Close ATDC 35°Exhaust(1mm)Open BDDC 28°Close 0°Valve

clearance (cold)Intake 0.1Exhaust 0.1



Idle speed (rpm) 1500rpmSystemLubrication type Forced pressure &wet sumpOil pump type Inner/outer rotortype

Oil filter type Full-flow filtration

Oil capacity 1.1 litersCooling Type Water cooling

Fuel SystemAir cleaner type & No Paper element, wetFuel capacity 10.5 litersCarburetorType cvPiston dia. 26Venturi dia. 26 equivalentThrottle type Butterfly typeElectricalIgnition SystemType CDIIgnition timing BTDC 10°±3°

Contact breaker Non-contact pointtypeSpark plug NGKDP7EA-9Spark plug gap 0.8_ 1.0mmBattery Capacity 12V9AHPower Drive SystemClutch Type Dry multi-disc clutchTransmissionGearType Non-stage transmissionOperation Automaticcentrifugaltype ReductionGearType Two-stage reduction

Reductionratio1st2ndMoving DeviceFrontAxleCaster angleConnecting rodTire pressure(kg/cm_)Front 1.75Rear 2.25TurningangleLeft 43°Right 43°Brake systemtypeFront Disk brakeRear Disk brakeDampingDeviceSuspensiontypeFront TelescopeRear Double swing

Shock absorbertypeFront Telescope



Rear Double swingFrame type Under bone



1. GENERAL INFORMATIONSERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally. Use genuine parts and lubricants. When servicing the motorcycle, be sure to

use special tools for removal andinstallation. After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.1-2



1. GENERAL INFORMATION When connecting the battery, the positive(+) terminal must be connected first. After connection, apply grease to the

battery terminals. Terminal caps shall be installed securely. Apply or add designated greases andlubricants to the specified lubricationpoints. After reassembly, check all parts forproper tightening and operation. When two persons work together, pay

attention to the mutual working safety. Disconnect the battery negative (-) terminalbefore operation. When using a spanner or other tools, makesure not to damage the motorcycle surface. After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.



1. GENERAL INFORMATION If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

After operation, terminal caps shall beinstalled securely. When taking out the connector, the lock onthe connector shall be released beforeoperation. Hold the connector body when connectingor disconnecting it. Do not pull the connector wire.

Check if any connector terminal is bending,protruding or loose.ConfirmCapacity



1. GENERAL INFORMATIONinsulated surfaces contact the wireharnesses.

The connector shall be inserted

completely. If the double connector has a lock, lockit at the correct position. Snapping! Check if there is any loose wire. Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal. Check the double connector cover for

proper coverage and installation. Insert the terminal completely. Check the terminal cover for propercoverage. Do not make the terminal cover openingface up. Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.

Tighten the bands so that only the



1. GENERAL INFORMATION After clamping, check each wire to makesure it is secure. Do not squeeze wires against the weld or

its clamp. After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts. When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat. Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends of

bolts and screws. Route wire harnesses passing through theside of bolts and screws. Avoid theprojected ends of bolts and screws.No Contact !



1. GENERAL INFORMATION Route harnesses so they are neitherpulled tight nor have excessive slack. Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge orcorner. When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely. Do not break the sheath of wire. If a wire or harness is with a broken sheath,repair by wrapping it with protective tapeor replace it. When installing other parts, do not press orsqueeze the wires.Do notpull tooDo not press orsqueeze the wire.



1. GENERAL INFORMATIONDamaged control cables will not operatesmoothly and may stick or bind.

After routing, check that the wire harnesses

are not twisted or kinked. Wire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions. When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

Be careful not to drop any parts. When rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting. Do not bend or twist control cables.Do you understandthe instrument? Isthe instrument setcorrectly?Remove Rust!



1. GENERAL INFORMATION Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

Engine Oil: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

GreaseGear Oil

: Use special tool.Special

*: Caution: Warning

1-9



1. GENERAL INFORMATIONTORQUE VALUESSTANDARD TORQUE VALUES

Item Torque (kg-m) Item Torque (kg-m)5mm bolt, nut

6mm bolt, nut8mm bolt, nut10mm bolt, nut12mm bolt, nut0.51.02.23.55.55mm screw6mm screw, SH bolt6mm flange bolt, nut

8mm flange bolt, nut10mm flange bolt, nut0.40.91.22.74.0

Torque specifications listed below are for important fasteners.

ENGINE

Item Qty Thread dia.(mm) Torque (kg-m) Remarks

Cylinder head bolt A 2 8 2.2 Double end boltCylinder head bolt B 2 8 2.2 Double end boltOil filter screen cap 1 30 1.5 Apply oil toExhaust muffler joint lock nut 2 8 0.9 threadsCylinder head cap nut 4 8 2.2Valve adjusting lock nut 2 5 0.9Cam chain tensioner slipper bolt 1 6 0.9Oil bolt 1 12 1.3Clutch outer nut 1 12 5.5Clutch drive plate nut 1 12 5.5Flywheel nut 1 14 5.5Oil pump bolt 2 5 0.4Cylinder head cover bolt 4 6 1.2Spark plug 1 10 1.2Cam chain tensioner bolt 1 6 0.9Water pump impeller 1 8 1.4 Left hand threads

FRAME

Item Qty Thread dia.(mm) Torque (kg-m) Remarks

1-10



1. GENERAL INFORMATIONSteering stem lock nut 1 10 4.5 U-nutFront axle nut 1 12 6.0 U-nutRear axle nut 1 14 9.0 U-nutRear shock absorber upper bolt 2 10 3.0Rear shock absorber lower bolt 2 8 3.0

Front shock absorber lock bolt 4 10 2.5Engine hanger bolt 1 12 5.5

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. PageValve guide driver Valve guide removal/installationValve guide reamer Valve guide grindingValve spring compressor Valve removalLock nut wrench, 39mm Clutch disassemblyBearing driver Bearing removal

Bearing remover, 12mm Bearing removalRemover shaft Bearing removalRemover weight Bearing removalBearing remover, 15mm Bearing removalBearing driver Bearing removalClutch spring compressor Clutch disassemblyBall race remover extension Ball race removalBall race remover Ball race removalSpring compressor Spring removalMechanical seal driver Water pump mechanical sealremoval/installationKick starter spring remover Kick starter spring removalGear remover Starter gear removal

Valve adjuster Tapper adjustmentFloat level gauge Carburetor fuel level checkValve seat cutter 45°Valve seat refacingValve seat cutter 32°Valve seat refacingValve seat cutter 60°Valve seat refacingCutter clip, 5mmUniversal holder Holding clutch for removalBearing driver (32x35mm) Bearing installationPilot, 12mm Bearing installationPilot, 15mm Bearing installationPilot, 17mm Bearing installationFlywheel puller A.C. generator flywheel removalRear shock absorber compressor Rear shock absorber disassemblySteering head bearing remover Steering head bearing removal

1-11



1. GENERAL INFORMATIONKick starter spring remover Kick starter spring installationFlywheel holder A.C. generator flywheel holdingReamer clipFuel unit wrench Fuel unit removal

LUBRICATION POINTSENGINE

Lubrication Points LubricantValve guide/valve stem movable partCamshaft protruding surfaceValve rocker arm friction surfaceCamshaft drive chainCylinder lock bolt and nutPiston surroundings and piston ring groovesPiston pin surroundingsCylinder inside wall

Connecting rod/piston pin holeConnecting rod big endCrankshaftCranksahft one-way clutch movable partOil pump drive chainStarter reduction gear engaging partCountershaft gear engaging partFinal gear engaging partBearing movable partO-ring faceOil seal lipGenuine KYMCO Engine Oil (SAE10W-30)API SE, SF or SG Egnine Oil

Starter idle gearFriction springmovable part/shaft movable partShaft movable grooved partStarter spindle movable partHigh-temperature resistant greaseStarter one-way clutch threads Thread locking agentA.C. generator connectorTransmission case breather tubeeAdhesive

1-12



1. GENERAL INFORMATIONFRAME

The following is the lubrication points for the frame.Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified. This

will avoidabnormal noise and rise the durability of the motorcycle.

Seat LockRear Wheel BearingGreaseSpeedometer CableThrottle CableMain Stand PivotSide Stand PivotSpeedometer Gear/

Front Wheel BearingEngine OilGreaseGreaseGreaseGreaseFront Brake Lever Pivot1-13



1. GENERAL INFORMATIONCABLE & HARNESS ROUTING

Front Brake Fluid Tube

1-14

Front Stop SwitchRear Stop SwitchThrottle CableFuel VaporRecovery TubeRegulator/RectifierWire ConnectorsRadiatorRear Brake Fluid TubeSpeedometer CableHornFuel Tank

Breather TubeWater HoseFuel VaporRecovery TubePressureTypeCharging Indicator



1. GENERAL INFORMATIONFuel VaporRecovery TubeIgnition SwitchFuel FillerFuel Tank

Inlet TubeWinkerFuse BoxThermostaticSwitchRear Brake Fluid TubeWater HoseFuel TankBreather TubeFront Brake Fluid Tube1-15

Radiator Air Vent Tube



1. GENERAL INFORMATIONWater Hoses

ThrottleCableSpeedometer Cable

Fuel VaporRecovery TubePressureTypeRadiator AirVent TubeRear Brake FluidTubeFuel Tank InletTubeWater HoseFuel Filler

Fuel TankBreather TubeThrottleCableWire HarnessFuel UnitFront StopSwitch

1-16



1. GENERAL INFORMATIONStarter RelayFuel VaporRecovery TubePositive CrankcaseVentilation (PCV)

FuelTubeBattery (+) Cable Battery (-) CableIgnition CoilCDI UnitAuto Bystarter WireCarburetorOverflow TubeAir Cut-offValve (A.C.V.)1-17



1. GENERAL INFORMATIONThermostat

Spark Plug Cap Fuel Pump Vacuum Tube

Starter Relay

FuelTubeIgnition CoilThermostatAir Cut-offValve (A.C.V.)Fuel VaporRecovery TubeAuto BystarterStarter MotorPurge Control ValveVacuum Tube

Fuel Unit WireThrottleCableVacuum TeeGround WireFuel VaporRecovery Tube

1-18

BatteryFuelCDI Unit

FuelPump Wire HarnessPositive CrankcaseVentilation (PCV)Purge Control ValveVacuum TubeFuel Pump Vacuum TubeFuel FilterCharcoal CanisterAir InjectionAir CleanerAir Injection Cut-offValve (A.I.C.V.)Ignition Coil



1. GENERAL INFORMATIONFuelVacuum TeeSpark Plug CapFuel Unit Wire

Reed Valve

WIRING DIAGRAM

R Red O OrangeB Black P PinkW White Br BrownG Green LG Light greenV Violet SB Light blueL Blue GR Gray1-19



1. GENERAL INFORMATIONTROUBLESHOOTINGENGINE WILL NOT START OR IS HARD TO START

.Empty fuel tank

.Clogged carburetor fuel inlettube, vacuum tube or fuel tube

.Clogged auto fuel valve

.Clogged float oil passage

.Clogged fuel tank capbreather hole.Clogged fuel strainer.Clogged fuel filter.Faulty fuel pump.Faulty spark plug.Fouled spark plug.Faulty CDI unit.Faulty A.C. generator.Broken or shorted ignition coil

.Broken or shorted excitercoil

.Faulty ignition switch

.Starter motor idles butcrankshaft does not rotate.Valve clearance too small.Improper valve and seatcontact.Worn cylinder and piston rings.Blown cylinder head gasket.Flaws in cylinder head.Seized valve.Improper valve timing

.Faulty auto bystarter

.Air leaking through intakepipe

.Incorrect ignition timing

.Incorrectly adjusted pilotCheck if fuel reachescarburetor byloosening drain screwRemove spark plugand install it intospark plug cap to testspark by connecting itto engine groundInspection/Adjustment Probable CauseSpark jumpsNormalcompressionEngine does notfireWeak or no sparkLow or nocompressionEngine fires butdoes not startTest cylindercompressionStart engine by follow-ing normal startingprocedureSymptomFuel reachescarburetorFuel does not

reach carburetor1-20



1. GENERAL INFORMATIONscrew

Wet spark plug Dry spark plugRemove spark plug andinspect again

.Flooded carburetor


.Throttle valve excessivelyopenENGINE LACKS POWER

SymptomInspection/Adjustment

Probable Cause

Start engine and acceleratelightly for observation

1-21.Clogged oil pipe.Faulty oil pumpEngine speedincreasesCorrect timingEngine speed doesnot increasesufficiently

Incorrect timingCheck ignition timing(using a timing light)Test cylinder compressionCheck carburetor forcloggingRemove spark plug andinspectCheck valve clearanceCorrect IncorrectNormalcompressionAbnormalcompressionNot Clogged CloggedPlug not fouled ordiscoloredPlug fouled ordiscoloredCorrect and notcontaminatedIncorrect orcontaminatedValve train lubricatedproperly

Valve train notlubricated properly.Clogged air cleaner



.Restricted fuel flow

.Clogged fuel line between fueltank and carburetor

.Clogged exhaust muffler


.Split carburetor vacuum pistondiaphragm

.Faulty CDI unit

.Faulty A.C. generator

.Improper valve clearanceadjustment

.Worn valve seat (valve stem tooprotruding

.Improper valve and seat contact

.Worn cylinder and piston rings

.Blown cylinder head gasket

.Flaws in cylinder head

.Improper valve timing

.Clogged carburetor jets

.Fouled spark plug

.Incorrect heat range plug

.Oil level too high

.Oil level too low

.Oil not changedRemove oil dipstick andcheck oil level and condition

Remove cylinder head oilpipe bolt and inspect



1. GENERAL INFORMATIONRapidly accelerate or runat high speedCheck if engine overheatsEngine overheatsEngine does notoverheats

Engine does not knock Engine knocks.Insufficient coolant.Faulty thermostat.Worn cylinder and piston rings.Mixture too lean.Poor quality fuel.Excessive carbon buildup incombustion chamber.Ignition timing too early.Air in cooling system.Excessive carbon build-up incombustion chamber.Poor quality fuel.Clutch slipping

.Mixture too lean Ignition timing too earlyPOOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

1-22.Faulty CDI unit.Faulty A.C. generator.Mixture too rich (turn screwout).Mixture too lean (turn screwin).Damaged insulator rubber

.Carburetor not securelytightened

.Faulty intake manifoldgasket

.Deformed carburetor O-ring

.Faulty or fouled spark plug

.Faulty CDI unit


.Faulty ignition coil

.Broken or shorted hightension wire.Faulty ignition switchRemove spark plugand install it intospark plug cap to testspark by connecting itto engine groundInspection/Adjustment Symptom Probable CauseCheck ignition timingCheck carburetor aircut-off valveCheck carburetorgasket for air leaksCheck carburetor pilotscrew adjustmentCorrect timing Incorrect timingCorrectly adjustedNo air leak Air leaksGood spark Weak or inter-

mittent sparkIncorrectly adjusted



1. GENERAL INFORMATION.Damaged air cut-off valvediaphragm.Damaged air cut-off valvespringGood FaultyPOOR PERFORMANCE (AT HIGH SPEED)

.Faulty CDI unit


.Improperly adjusted valveclearance

.Worn valve seat

.Empty fuel tank

.Clogged fuel tube or filter

.Faulty fuel pump

.Cracked fuel pump vacuumtube.Clean and unclog

.Cam timing gear aligningInspection/Adjustment Symptom Probable CauseCheck ignition timingCheck carburetor jetsfor cloggingCheck fuel pump forfuel supplyCorrect timing Incorrect timingCheck valve clearanceFuel flows freely Fuel flow restrictedCorrect IncorrectNot clogged CloggedCorrectly adjusted Incorrectly adjustedCheck valve timing

1-23



1-24marks not aligned.Faulty springENGINE NOISE.Valve clearance too large.Worn camshaft lobe

.Worn piston rings

.Worn piston pin and connecting rodsmall end.Excessive carbon build-up in combustionchamber.Damaged cam chain tensioner.Worn cam gear teeth.Worn or damaged cam chain.Extended cam chain.Faulty crankshaft bearing.Worn crank pin bearing.Worn or damaged final reduction gears

Valve noiseSymptom Probable CauseCheck valve springtensionCrankshaft noiseGear noisePiston noiseCam chain noiseNot weakened Weak springmarks not aligned.Faulty springENGINE NOISE.Valve clearance too large

.Worn camshaft lobe

.Worn piston rings

.Worn piston pin and connecting rodsmall end.Excessive carbon build-up in combustionchamber.Damaged cam chain tensioner.Worn cam gear teeth.Worn or damaged cam chain.Extended cam chain.Faulty crankshaft bearing.Worn crank pin bearing.Worn or damaged final reduction gearsValve noiseSymptom Probable CauseCheck valve springtensionCrankshaft noiseGear noisePiston noiseCam chain noiseNot weakened Weak spring



1. GENERAL INFORMATION.Worn final reduction gear shaft splinesCLUTCH, DRIVE AND DRIVEN PULLEYS

1-25

.Worn or slipping drive belt

.Broken ramp plate

.Broken drive face spring

.Separated clutch lining

.Damaged driven pulley shaft splines

.Damaged final gear

.Seized final gear

.Broken shoe spring

.Clutch outer and clutch weight stuck

.Seized pivot


.Worn weight rollers

.Seized drive pulley bearings.Weak driven face spring

.Worn or seized driven pulley bearings


.Worn weight rollers

.Worn or seized driven pulley bearingsEngine starts butmotor-cycle does notEngine lacks power atstart of a grade(poorslope performance)Symptom Probable CauseEngine lacks power at

high speedMotorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)



1. GENERAL INFORMATIONThere is abnormalnoise.Oil or grease fouled drive belt.Worn drive belt.Weak driven face spring

.Worn or seized driven pulley bearingsSTARTER MOTOR

1. Starter motor wont turn.Burned out fuse.Weak or dead battery.Faulty stop switch.Loose or disconnectedconnectors.Broken or shorted ignitionswitch wire.Faulty or weak battery.Poor starter button

connection.Open or shorted starter relay.Loose or disconnectedconnectors.Worn brushes.Open or shorted wires orrotor.Open starter motor cable.Loose connectors.Open wire harness2. Starter motor turns slowly or idles.Weak or dead battery.Loose connector or terminal

.Poor contact in starter relay

.Faulty starter clutchInspection/AdjustmenInspection/AdjustmenSymptomSymptomCheck operation ofstop switch byapplying brakeStoplight does notcome onStoplight comesCheck batterycircuit by operatingturn signalsCheck batterycircuit by operatingturn signalsProbable CauseProbable CauseSignals operateproperlySignals dim, remainon or dont Check operation ofstarter relay bydepressing starterbuttonConnect startermotor directly tobatteryConnect startermotor directly to

batteryStarter motorturns slowly



Starter motorturns normallySignals operateproperlySignals dim, remainon or dont operateRotate crankshaftStarter motor Starter does not

tRelay operatesproperlyRelay does notoperateTurns easily Hard to turn1-26



1. GENERAL INFORMATION.Seized cylinder3. Starter motor does not stop turning.Broken or shorted startermotor cableInspection/Adjustmen Symptom Probable Cause

NO SPARK AT SPARK PLUGReplace with a newspark plug and inspectagainCheck CDI unitcoupler for loosenessInspection/Adjustment SymptomTurn ignitionswitchMeasure resistancebetween terminals ofCDI unit coupler

Weak or no sparkNot looseGood sparkLooseGood GoodNot stopped StoppedCheck spark plug capand high-tension wirefor looseness.Faulty starter pinion.Starter relay shorted or stuckclosedProbable Cause

.Faulty spark plug

.Faulty spark plug

.Poorly connected coupler1-27.Faulty ignition switch.Faulty exciter coil.Faulty pulser coil.Faulty ignition coilNormalNormal AbnormalAbnormalCheck related parts



1. GENERAL INFORMATIONPOOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)UnderchargingNormalAbnormalAbnormal

Start engine and testlimit voltage ofbattery terminalsTest output voltage ofregulator/rectifiercoupler red wireInspection/Adjustment SymptomNormal voltageCheck ignition coilwith a CDI unit testerNormalVoltage does notincreaseResistance tooMeasure resistancebetween AC generatorcoil terminals

Check CDI unit with aCDI unit tester.Broken wire harness.Poorly connected coupler.Faulty CDI unit.Faulty ignition coilProbable Cause

.Faulty AC generator

.Faulty regulator/rectifier

.Faulty battery

.Shorted AC generator coil

.Open circuit between ACgenerator 3 yellow wires

.Faulty regulator/rectifier

.Faulty AC generator

.Loose regulator/rectifiercoupler

.Limit voltage too highNormal voltage No voltageOvercharging

Inspection/Adjustment

Symptom

Probable Cause

1-28Measure battery limitvoltage with anelectric tester



1. GENERAL INFORMATION.Faulty battery.Faulty regulator/rectifier.Broken or poorlyconnectedregulator/rectifier black wire

1. Pointer does not register correctly (Ignition switch ON).Burned out fuse.Weak or dead battery.Faulty ignition switch.Loose or disconnectedconnectors.Broken wire harness.Faulty float.Broken or shorted fuelunit wire.Disconnected connector.Incorrectly connected

connector.Broken or shorted wire infuel gauge2. Pointer fluctuates or swings (Ignition switch ON)SymptomSymptomSignals operateproperlySignals dim, remainon or dontNormal AbnormalSignals operateproperly

Signals dim,remaindontProbable CauseProbable CausePointer does notmove Pointer movesPointer moves Pointer does notmoveGood FaultyAbnormalCheck resistancebetween regulator/rectifier terminals

Normal

.Limit voltage too highFUEL GAUGE


Check battery circuitby operating turn

signals

Remove fuel unit and



check operation ofpointer by movingfloat up and down

Float up: FullFloat down: Empty

Check operation ofpointer by opening andshorting fuel unitterminal on wire

harness side

Check connectors forproper connection


Check battery circuitby operating turnsignals and horn

.Burned out fuse

.Weak or dead battery

.Faulty ignition switch.Loose or disconnectedRemove fuel unit and

connector

check operation of

.Broken wire harnesspointer by movingfloat up and down

1-29



1. GENERAL INFORMATION.Poor contact in fuel unit.Insufficient damping oil infuel gauge.Loose or disconnectedconnector.Broken or shorted wire in

fuel gauge(Front and rear tire pressures are normal)

.Steering stem nut too tight

.Broken steering steel balls

.Excessive wheel bearing play

.Bent rim

.Loose axle nut

.Misaligned front and rear wheels

.Bent front forkSTEERING HANDLEBAR DOES NOT TRACK STRAIGHTPOOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal).Weak shock spring.Excessive load.Shock damper oil leaking.Bent fork tube or shock rod.Fork tube and slider binding.Fork spring and slider binding.Damaged shock stopper rubber.Loose steering stem nutSteering is heavySuspension is too softFront or rear wheel iswobbling

SymptomSymptomProbable CauseSteering handlebar pullsto one sideMove float up anddown rapidly (1 round/sec.) to check theoperation of pointerPointer does notmoveSuspension is too hardPointer movesSuspension is noisyPointer does not Pointer moves inmove in accord-ance with float floataccordance withCheck connectors forproper connection.Good FaultyProbable Cause

1-30POOR BRAKE PERFORMANCE.Worn brake linings

.Foreign matter on brake linings

.Rough brake drum contacting areaSoft brake lever



Symptom Probable Cause



1. GENERAL INFORMATION.Worn brake linings.Foreign matter on brake linings.Rough brake drum contacting areaHard brake leverPoor brake

performanceBrake squeaksHard to brake.Worn brake linings.Worn brake cam contacting area on.Worn brake linings.Foreign matter on brake linings.Sluggish or elongated brake cables.Brake shoes improperly contact.Water and mud in brake system.Oil or grease on brake linings1-31

dink 01 general information

Documents