4-17 FUEL SYSTEM & EMS Working Of Systems Function To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. Further movement of throttle position : Wide Open Throttle Resistance Coil Closed Throttle Wiper Pivot Blade Output Voltage to ECU 5 Volts from ECU Throttle Position Sensor Construction The throttle body has a throttle valve mounted on the intake manifold. The throttle valve is connected by accelerator cable and its opening and closing is controlled by accelerator twist grip mounted on RH side of handle bar. The throttle position sensor mounted on the throttle valve continuously reports the throttle position to the ECU. This is rotary throttle position sensor having a variable resistor also called as a potentiometer. Internally it has a coil resistance wire in the form of a half circle. One end connects to the ground and other end is connected to a 5 volt source from ECU. The wiper blade has a contact that rides on the coil and connects to the throttle valve shaft. Also the position of the throttle valve is important in controlling the idling rpm. Working Upon acceleration the throttle valve position changes. The wiper type blade moves over the coil winding as it is pivoted directly on the throttle valve shaft. Throttle position at zero (closed) position : When the throttle valve is closed, the blade is at the grounded end of the coil. A small voltage signal is send to ECU at this position which senses that the throttle position is at zero.
4-18 FUEL SYSTEM & EMS Working Of Systems Engine Temperature Sensor (ETS) Function To measure the engine / engine oil temperature up to 2000 C. Construction The principal methods of temperature measurement is done by the thermistor. The thermistor is made from semi conductor material such as cobalt or nickel oxides and is encapsulated in a brass sleeve for mechanical protection. Working The thermistors are semi conductor resistors which change their resistance valve with temperature. The resistance decreases with an increase in engine temperature as it has a negative temperature coefficient (NTC) and vice versa. The characteristic of engine temperature is represented graphically (The values do not match exactly, it is just a representation for understanding). This NTC type thermistor is used to measure the engine temperature in engine management system. 200 180 160 140 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 NTC Thermistor Characteristic Temp. 0 C Thermistor Resistance (Ohm) NTC Thermistor
4-19 FUEL SYSTEM & EMS Working Of Systems Roll Over Sensor Main Switch Sensor Magnet Function To send the ignition cut off signal to ECU for shutting down the engine if the bike exceeds the inclination angle beyond 60° on either of the side. Construction The roll over sensor is a sealed sensor unit and that contains moving weight which is suspended freely on a shaft. This is mounted below the air filter box on to the chassis. Please note, even if over sensor is not connected (coupler open) the vehicle does not start (to ensure safety) and the malfunction will be shown on speedometer. Working The moving weights are suspended freely. When the vehicle leans down on either of the LH and RH side of the position of this weights changes. The change of position of the weights is sensed by the sensor. If the inclination angle exceeds beyond 60º to the vertical the sensor will give signal to ECU to cut off the ignition system. This is a useful safety feature because inclination angle exceeding 60º indicates that the rider has dropped the bike or is involved in an accident. Thus, safety of the bike and rider is ensured. y x 0
4-20 FUEL SYSTEM & EMS Working Of Systems Function To communicate the ECU how fast the crankshaft is rotating per minute and help ECU in delivering precise fuel metering and ignition spark advance. Crank Angle Sensor Construction A magnetic sensor located in magneto cover facing towards square notched I square block on the rotor periphery. Working As the rotor rotates the notched square blocks on the rotor periphery causes voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts the number of pulses per second and understands at what RPM the engine is operating and accordingly precise fuel metering and ignition spark advance is controlled. These are 23 square notches I square blocks on the rotor outer periphery and are placed equidistance. At a particular location these is wide gap seen between 2 square notches I square blocks. This can also be determined as square notch missing. The missing square notch area represents the BTDC position. At this BDTC position voltage pulse is sensed by crank angle sensor and communicated to ECU. ECU use this information to control ignition spark plug advance.
4-21 FUEL SYSTEM & EMS Working Of Systems Crank Angle Sensor Working When certain troubles develop on the electronic control system, the ECU stores in its memory or number or trouble code for each fault. This turns a Malfunction Red Indicator Light on the primary speedometer (next to Neutral Gear Indicator). This alert the driver that there is some problem and repair / service in needed. If a single sensor or its harness part falls the ECU may subtitle a value for failed sensor. This allows the engine to appear to run normal. A fault that turns on the malfunction indicator light may also put the engine into its limp-in mode. This means that limited operation strategy (LOS) chip in the ECU has taken over. It provides basic instructions to the microprocessor if a part of the electronic system fails. The engine runs but with fixed ignition timing and air fuel ratio. The injector pulse width does not change. This allows the vehicle to be driven but with greatly reduced performance. The benefit of this is vehicle can be limp-in for service instead of being towed or transported into cargo. The technician can retrieve the stored trouble code from ECU memory using the diagnostic tool. To use the code the technician can refer the Diagnostic Chart or the Flash Code. This chart explains where lies the problem and its probable cause.
4-22 FUEL SYSTEM & EMS Working Of Systems Advantages of Fuel Injection • Increased power output per unit of displacement. • Higher torque at low engine rpm. • Improved cold start, warm up and sudden acceleration (No chance of wetting intake manifold). • Lower fuel consumption. • Overall superb drive-ability. • Lower maintenance cost • Communicates malfunctioning of fuel injection system, if any. • Low emission level. Limitations of Carburetor • Restricted air flow due to venture design causes power loss (volumetric effeciency is limited). • As intake manifold contains combustible mixture, danger of back fire from the cylinder into the manifold is always there. • At high altitude or in warm weather, possibility of vapors lock. • After burning noise in silencer on sudden deceleration. • Does not support sudden acceleration. • Difficult cold starting and required choke for starting. In cold conditions, fuel wets the wall of the induction manifold causing running difficulties. • Maintenance cost is reasonably more. • High emission level. • Inconsistence in fuel efficiency. FUEL INJECTION - ADVANTAGES OVER CARBURATOR
4-23 FUEL SYSTEM & EMS Fuel Injection System Measure the Coolant Temperature and assist ECU to adjust the fuel injection volume. It detects the side stand position and gives signal to ECU. Detect the tilt angle of motorcycle and if it is more than 60 degree ECU disable the ignition and fuel supply. Measure the oxygen proportioning exhaust and assist ECU to adjust the amount of fuel to be injected. Measure the rotational speed of crankshaft and assist ECU to determine injection and ignition timing. Measures the intake air temperature and pressure and assist the ECU to adjust the fuel injection volume. Detect the throttle position COOLANT TEMP SENSOR SIDE STAND SWITCH TEMPERATURE / MANIFOLD PRESSURE SENSOR CRANK ANGLE SENSOR THROTTLE POSITION SENSOR ROLLOVER SENSOR OXYGEN SENSOR Input toECU Output fromECU ECU calculates and determines the volume of fuel to be injected and the injection and ignition timing. For connecting the diagnostic tool. Start when coolant temp reach 98 degree and stop at 88 degree RADIATOR FAN DIAGNOSTIC TOOL COUPLER Blinks if there is any malfunctioning in FI system. MALFUNCTION INDICATOR H.T COIL Adjust the idle speed of engine base on input from ECU. Supply pressurized to injector. Injects the precise amount of fuel based on the ECU data. Injects appropriately based on the ECU data. STEPPER MOTOR FUEL INJECTOR FUEL PUMP
4-24 FUEL SYSTEM & EMS EMS Sensors And Actuators Purpose • To control precisely air fuel mixture as per the engine RPM and to get optimum engine performance. Advantages over Carburetor System • Increased power output per unit of displacement. • Higher torque at low engine rpm. • Improved cold start ability, roll over and sudden acceleration. • Lower fuel consumption - better mileage. • Overall superb drive-ability. • Low maintenance cost. • Communicates malfunctioning of fuel injection system, if any. • Low emission level. Sensors And Actuators
4-25 FUEL SYSTEM & EMS EMS Sensors And Actuators 1 - MPRD (Relay) 2 - Steeper Motor 3 - Injector 5 - TPS 7 - H. T. Coils (LH And RH) 8 - H. T. Coils (CENTRE) 9 - Engine Malfunction Indicator (MIL) 11 - Radiator Fan 10 - Diagnostic Coupler 6 - Fuel Pump 4 - T MAP Sensor P4 P3P2 P1 3 1 Sensors And Actuators 10 5 11 1 6 7 8 9 4 3 2
4-26 FUEL SYSTEM & EMS EMS Sensors And Actuators Fuel Injection System Sensors - Working And Malfunction Effect S.N. Input to ECU Input Details How ECU Uses Input Effect incase of abnormability 1 Coolant Temperature Sensor Temperature of coolant. Radiator fan relay gets ON. Adjusts temperature based Ignition timing. 1. Radiator fan will not work and coolant temperature may shoot up affecting engine performance 2. High coolant temperature icon may not blink. 3. Start ability, fuel consumption and power- pickup will be affected. 2 Engine Oil Pressure Sensor Engine oil pressure. Glowing of Engine oil pressure icon. Running of engine on low oil level may result in early wear of engine parts. 3 Roll Over Sensor Voltage of 2 VDC in vehicle tilted condition. ECU cuts off main relay and ignition is cut off. Engine will keep running in case of accident or vehicle slips and may result in serious injury to rider and damage to vehicle. 4 Side Stand Switch Voltage of 5 VDC in case when vehicle is parked on side stand. ECU will switch ON side stand indication in speedo console and will cut off ignition system. No indication of side stand ON in speedo console. Vehicle will not run in gear. 5 Oxygen Sensor Voltage signal depending on amount of oxygen in exhaust. ECU determines air fuel mixture and adjusts accordingly. Malfunctioning of Oxygen sensor will result in either rich mixture causing black smoke or lean mixture resulting in vehicle drive ability. 6 Crank Angle Sensor It senses rotation of crank shaft and gives pulse input to ECU. ECU calculates no. of pulses revolution and indicates engine RPM on Tachometer dial. Gives input to ECU for ignition circuit. Wrong indication of Engine RPM in speedo. Malfunction Ignition system. No start situation in case of open circuit. 7 Throttle Position Sensor Monitors position of throttle and gives voltage input to ECU in POT to WOT modes ECU increases or reduces fuel rate to Engine suitably. Fuel consumption and power - pickup will be affected. 8 TMAP Sensor Monitors temperature and pressure of air entering manifold and gives SVDC signal to ECU. ECU increases or reduces. Air supply rate to Engine suitably. Start ability, Fuel consumption and power - pickupwill be affected.
4-27 FUEL SYSTEM & EMS EMS Sensors And Actuators Fuel Injection System - Actuators S.N. Output from ECU Input Details Effect incase of abnormability 1 Fuel Pump Fuel pump relay gets ON through ECU Malfunctioning of fuel pump will result in intermittent fuel supply causing hesitation / misfiring, no start. 2 Fuel Injector Earthing signal from ECU Malfunctioning of fuel injector will result in either rich or lean mixture causing Smokey exhaust / misfiring problems. Knocking / Combustion noise. 3 HT Coils Earthing signal from ECU 4 Radiator Fan Radiator fan motor relay gets ON Radiator fan will not work and coolant temperature may increase excessively affecting engine components. Icon glows in speedometer at 115 degree Centigrade and vehicle can not be accelerated above 4000 rpm. At 120 Degree Centigrade engine will getOFF. 5 Malfunction Indicator Malfunction in FI system signal from ECU Malfunctioning in F1 system will go unnoticed. 6 Stepper Motor Signal from ECU Unstable idling RPM. Start ability will be affected. 7 Diagnostic tool port CAN high / Low input from ECU No communication with BOSCH Diagnostic tool - show link error. Important : Do not disturb the position of throttle adjuster screw. If done it will affect the vehicle performance and claim will not be accepted under warranty. Misfiring or hesitation problems. No spark resulting in on start.
4-28 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes No. P-Code DTC meaning DTC cause Symptoms To Check 1 P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit High Short circuit to battery voltage, short to sensor supply +5V - Idle control is affected. - No overrun fuel cut-off happens. - Drivability is affected. -Load on engine(In tool, group1,entry5 is engine load which is equivalent to volumetric efficiency) is calculated based on Manifold. Air Pressure sensor. Throttle Position Sensor connections, wiring harness. Replace Throttle body and check. 2 P0122 Throttle/Pedal Position Sensor/Switch “A” Circuit Low Short circuit to Ground ; Open Circuit - Idle control is affected. - No overrun fuel cut-off happens. - Drivability is affected. -Load on engine(In tool, group1,entry5 is engine load which is equivalent to volumetric efficiency) is calculated based on Manifold Air Pressure sensor. Throttle Position Sensor connections, wiring harness. Replace Throttle body and check. 3 P0507 Idle Air Control System RPM Higher Than Expected Intake manifold leakage Limited engine speed Check for intake manifold leakage. 4 P0506 Idle Air Control System RPM Lower Than Expected Torque loss of engine is too high Check for any damage to engine (Damage inside engine - valve, piston, crank shaft etc). 5 P0108 Manifold Absolute Pressure/ Barometric Pressure Circuit High Short Circuit to battery voltage; Short Circuit to sensor Supply ; Open Circuit Deactivation of manifold pressure diagnosis -Cold Start and after start is affected. - Altitude adaptation doesn’t happen. - Secondary Load sensor i.e. Throttle Position Sensor is used for sensing load. - Drivability is affected - Vehicle running in group injection mode (In ok case 1 injection happens in one cycle, but in case of this error 2 injections happen in one cycle and that is called group injection). Temperature Manifold Air Pressure connections, wiring harness. Replace Throttle body and check. 6 P0107 Manifold Absolute Pressure/ Barometric Pressure Circuit Low Short Circuit to Ground
4-29 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes No. PCode DTC meaning DTC cause Symptoms To Check 7 P0629 Fuel Pump “A” Control Circuit High Short Circuit to battery voltage Deactivation of power stage (power will not be given to fuel pump). Fuel Pump will not function. Check fuel pump connections, wiring harness. Replace fuel 8 P0628 pump and check. Fuel Pump “A” Control Circuit Low Short Circuit to Ground 9 P0627 Fuel Pump “A” Control Circuit/Open Open Circuit 10 P0336 Cranksh aft Position Sensor “A” Circuit Range / Performance Loose connection, electrical disturbance, defective tooth wheel of Rotor (broken / damaged teeth) - Resynchronization of crank wheel happens Engine may not start / it stops. - Engine may run irregula.r Check for loose connections in pick up coil connection. Replace pick up coil and check. 11 P0262 Cylinder 1 Injector Circuit High Short Circuit to battery voltage - Engine doesn’t start / stalls. -With intermittent error engine running irregular. Check for Injector connections. Replace injector and check. 12 P0261 Cylinder 1 Injector Circuit Low Short Circuit to Ground 13 P0201 Injector Circuit/Ope n–Cylinder 1 Open Circuit 14 P0032 HO2S Heater Control Circuit High Bank 1 Sensor 1 Short Circuit to battery voltage -Lambda control activation is delayed. - Lambda sensor signal diagnosis is switched off. - Drivability may get affected. - Exhaust emissions are affected. Check for lambda sensor connections, replace lambda sensor and check. 15 P0031 HO2S Heater Control Circuit Low Bank 1 Sensor 1 Short Circuit to Ground 16 P0030 HO2S Heater Control Circuit Bank 1 Sensor 1 Open Circuit 17 P0692 Radiator Fan Control Circuit High Short Circuit to battery voltage - Fan is not running. - Engine will heat up and seize and may cause damage to components. Check for fan connections. 18 P0691 Replace fan and check. Radiator Fan Control Circuit Low Short Circuit to Ground 19 P0480 Radiator Fan Relay Control Circuit fault Open Circuit
4-30 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes No. P-Code DTC meaning DTC cause Symptoms To Check 20 P0132 O2 Sensor Circuit Bank 1 Sensor 1 Short Circuit to battery voltage - Lambda control is deactivated. - Drivability could be affected. - Exhaust emissions are affected. Check for lambda sensor connections, replace lambda sensor and check. 21 P0131 O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 Short Circuit to Ground 22 P0130 O2 Sensor Circuit Bank 1 Sensor 1 Heater encoupling to sensor signal (In lambda (O2) sensor cable there are 4 wires.2 for sensor and 2 for heater. If heater cable gets shorted to sensor cable, then this error pops up). 23 P0134 O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1 Open Circuit signal or open Circuit Ground. 24 P1605 Malfunction Indicator Lamp (MIL) Control Circuit Short Circuit to battery voltage. - Check for MIL connections. Replace Speedometer console and check. 25 P1604 Malfunctio n Indicator Lamp (MIL) Control Circuit Short Circuit to Ground. 26 P0650 Malfunctio n Indicator Lamp (MIL) Control Circuit Open Circuit. 27 P1504 Side stand sensor Short Circuit to battery Short Circuit to battery voltage. - No fuel pump safety shut-off, ignition cut-off or injection cutoff can happen in case of vehicle tilted / fall down. Check for side stand sensor & roll over sensor connections. Replace side stand sensor or roll over sensor and check. 28 P1503 Side stand sensor Short Circuit to Ground Short Circuit to Ground. 29 P1501 Side stand sensor Circuit signal nonplausible No valid sensor signal is present. 30 P1502 Side stand sensor Open Circuit Open Circuit.
4-31 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes 31 P1508 Side Stand sensor Short Circuit to battery Short Circuit to battery voltage Safety fuel cut-off is active when vehicle is not in neutral gear. Check for side stand sensor connections. Replace side stand sensor and check. 32 P1507 Side Stand sensor Short Circuit to Ground Short Circuit to Ground 33 P1505 Side Stand sensor Circuit signal nonplausible No valid sensor signal is present 34 P1506 Side Stand sensor Circuit open Open Circuit 35 P0509 Idle Air Control System Circuit High Short Circuit to battery voltage - Engine Start is affected. - Idle is not stable. - Vehicle crawling in low gear is affected. Check for IACV connections. Replace IACV and check. 36 P0508 Idle Air Control System Circuit Low Short Circuit to Ground 37 P0511 Idle Air Control Circuit Open Circuit 38 P0689 ECM / PCM Power Relay Sense Circuit Low Main relay is "sticky" and does not open properly - ECU life may reduce. Check main relay connection. Replace main relay and check. 39 P0112 Intake Air Temperature Sensor 1 Circuit Low Short Circuit to Ground (note that the temperature and voltage are vice versa) Intake air temperature value in deg C. is switched to a fixed value - Engine start and hot start is affected. - Drivability is affected. Check for TMAP connections. Replace throttle body and check. 40 P0113 Intake Air Temperature Sensor 1 Circuit High Short Circuit to battery voltage (note that the temperature and voltage are vice versa) 41 P0117 Engine Coolant Temperature Sensor 1 Short Circuit to Ground (note that the temperature and voltage are vice versa) Coolant temperature is predicted by ECU based on internal logic. - Engine Start affected depending upon ambient temperature. - Radiator Fa.n runs continuously - Fuel consumption may get affected. Check for CTS connections. Replace CTS and check. 42 P0118 Engine Coolant Temperature Sensor 1 Circuit High Short Circuit to battery voltage (note that the temperature and voltage are vice versa) 43 P1608 Engine Speed Signal Circuit High Short Short Circuit to battery voltage - Check connections of engine speed signal to speedometer console. 44 P1607 Engine Speed Signal Circuit Low Short Circuit to Ground 45 P1606 Engine Speed Signal Circuit open Open Circuit
4-32 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes No. P-Code DTC meaning DTC cause Symptoms To Check 46 P0563 System Voltage High Short Circuit to battery voltage. - No effect on drivability. - May affect Idle as IACV is closed. - May damage ECU and other components if voltage is too high and Voltage remaining high for longer time. Check RR unit connections. Replace RR unit and check. 47 P0562 System Voltage Low Short Circuit to Ground. - No effect on drivability but engine may hunt / stop if battery is fully discharged as ECU will stop functioning. 48 P1510 System Voltage sensing failure in ECU Battery voltage is measured incorrectly. Battery voltage switched to fix value. Replace ECU and check. 49 P0501 Vehicle Speed Sensor “A” Range / Performance Open Circuit. Vehicle speed not displayed. Check for vehicle speed sensor connections. Replace vehicle speed sensor and check. 50 P0641 Sensor Reference Voltage “A” Circuit error Short Circuit to battery voltage. - This is related to pin 3 of ECU which give power to Coolant Temperature Sensor, Manifold Air Pressure and Manifold Air Temperature. Replace ECU and check. Check connections and replace Coolant Temperature Sensor, Throttle body and check. 51 P0651 Sensor Reference Voltage “B” Circuit error Short Circuit to Ground. - This is related to pin 27 of ECU which give power to Throttle Position Sensor, roll over sensor, side stand. Replace ECU and check. Check connections and replace Throttle body, roll over sensor, side stand sensor and check. 52 P0217 Engine Speed limited (limp home mode) due to engine coolant temp overheating Engine coolant temp overheating. Engine speed limited to lower RPM. If temp reaches 120°C then engine is shut down ; If temp reduces to 110°C then there is no error anymore and P code is not active. Check coolant level, check oil level, check functioning of fan. 53 P0459 EVAP System Purge control valve circuit high Short Circuit to battery voltage. 54 P0458 EVAP System Purge control valve circuit low Short Circuit to Ground. Purging will not happen Check for purge valve connections. Replace purge valve and check. 55 P0444 EVAP System Purge control valve circuit open Open Circuit.
4-33 FUEL SYSTEM & EMS Diagnosis And Trouble Shooting of Error Codes D&T Codes No. P-Code DTC meaning DTC cause Symptoms To Check 56 P0351 Ignition Coil "A" Primary Control Circuit / Open Open Circuit ; Short to ground. Ignition and Injection is cut off. Engine does not start. Check primary ignition coil connections. Replace ignition coil and check. 57 P0352 Ignition Coil “B" Primary Control Circuit / Open Open Circuit ; Short to ground. Check secondary ignition coil connections. Replace ignition coil and check. 58 P0655 Temperature Warning Lamp circuit high Short Circuit to battery voltage. Overheat indication on speedometer console will not function if engine overheats. Check for connections to temperature warning lamp. Replace speedometer console and check. 59 P0656 Temperature Warning Lamp circuit low Short Circuit to Ground. 60 P0657 Temperature Warning Lamp circuit open Open Circuit.
1 5 Chapter 5 Engine And Transmission Table Of Contents Exploded View ................................................... 5-2 Tightening Torques Engine ................................ 5-10 Service Limits Engine ........................................ 5-13 Important Bolt Tightening Sequence .................. 5-16 Engine Dismantling ............................................ 5-17 Engine Oil Flow Path ......................................... 5-40
5-2 ENGINE & TRANSMISSION Exploded View Cover Cylinder Head Cylinder Head
5-3 ENGINE & TRANSMISSION Exploded View Valve Camshaft / Tensioner
5-4 ENGINE & TRANSMISSION Exploded View Cylinder and Piston Crankshaft
5-5 ENGINE & TRANSMISSION Exploded View Transmission Change Drum / Shift Fork
5-6 ENGINE & TRANSMISSION Exploded View Gear Change Mechanism Engine Assembly / Crankcase RH
5-7 ENGINE & TRANSMISSION Exploded View Balancer Idler Gear / Water Pump Crankcase LH
5-8 ENGINE & TRANSMISSION Exploded View Oil Pump Cover Clutch
5-9 ENGINE & TRANSMISSION Exploded View Radiator Cover Magneto
5-10 ENGINE & TRANSMISSION Tightening Torques Engine Cylinder Head Cover Bolts Spark Plug Oil Strainer Cap (18 mm A/F) Primary GearNut Cam Shaft Sprocket Allen Bolt Nut Securing ClutchAssly. Magneto CoverBolts CoolantTemperature Sensor Clutch Cover Bolts Stator Plate Mtg. Bolts Silencer BracketBolts Oil Pump MountingBolts Chain Tensioner Mounting Bolts Output Sprocket Bolts 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2 Kgf-m 1.8 ~ 2.0 Kgf-m 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2 Kgf-m 1.2 ~ 1.4 Kgf-m 1.0 ~ 1.2 Kgf-m 14.5 ~ 15 Kgf-m 4.1 ~ 4.3 Kgf-m 12.0 ~ 12.2Kgf-m 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2 Kgf-m 1.9 ~ 2.1 Kgf-m 1.0 ~ 1.2 Kgf-m Cap Oil Filter Cover Bolts
5-11 ENGINE & TRANSMISSION Tightening Torques Engine 10 ~ 10.5 Kgf-m 1.1 ~ 1.2 Kgf-m Magneto Rotor Mounting Nut Inhibitor Nut 1.0 ~ 1.2 Kgf-m Stator Motor Mounting Nut 3.9 ~ 4.1 Kgf-m 6.0 ~ 6.5 Kgf-m Bal. Driven GearMounting(Allen) Cylinder Head Big Bolts 1.0 ~ 1.2 Kgf-m Cylinder Head Small Bolts 1.1 ~ 1.2 Kgf-m 14.5 ~ 15 Kgf-m Guide Gear Allen Bolt Bal. Driver Gear Mounting 1.1 ~ 1.2 Kgf-m Cam Holder Bolts 0.8Kgf-m Clutch Holder Bolts / Spring Clutch
5-12 ENGINE & TRANSMISSION Tightening Torques Engine 1.1 ~ 1.2 Kgf-m Drum / Cam Allen Bolt 0.7 ~ 0.9 Kgf-m Manifold MountingBolts 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2 Kgf-m Oil Strainer Cap (18mmA/F) Crankcase Joining Bolts 14.5 ~15.0 Kgf-m Net Securing Primary Gear
5-13 ENGINE & TRANSMISSION Service Limits Engine Clutch HubHeight Std. Limit 27.3 ~ 27.7 mm Serv.Limit 27.9 mm Std. Limit 32.936 ~ 33.34 mm Serv.Limit 30.6 mm Std. Limit 0.02 mm Serv.Limit 0.05 mm Clutch Stack Up Height Std. Limit 7.50mm Serv.Limit 7.47mm Std. Limit 70.84 mm Od & 72.76 mm PCD Serv.Limit N/A Rocker Arm Shaft Cam SprocketDiameter Std. Limit 8 ~ 12 bar / 800 ~ 1200 kPa Serv.Limit N/A Intake Exhaust Std. Limit 0.08mm~ 0.12mm 0.13mm~ 0.17mm Serv.Limit N/A N/A CompressionPressure Std. Limit 52.1 mm Serv.Limit 51 mm Valve TappetClearance Clutch Spring FreeLength Crankshaft Runout Std. Limit 1.6 mm Serv.Limit 1.5 mm Std. Limit 2.92 ~ 3.08 mm Serv.Limit 2.72 mm Steel Plate Thickness Friction PlateThickness Friction PlateWarp Std. Limit 0.1 mm Serv.Limit 0.2 mm Steel PlateWarp Std. Limit 0.1 mm Serv.Limit 0.15 mm
5-14 ENGINE & TRANSMISSION Service Limits Engine Valve Stem Diameter Std. Limit Total Indicator Reading(TIR) 0.01 mm Serv.Limit Total Indicator Reading(TIR) 0.015 mm Valve Stem Bend Piston Ring End Gap Cam Lobe Height Std. Limit 40.28 mm Serv.Limit 39.28 mm Std. Limit 133.35mm Serv.Limit 132.9 mm Camshaft ChainLength Valve Spring free Length Intake Exhaust Std. Limit 34.30mm 34.16mm Serv.Limit 34.25mm 34.11mm Intake Exhaust Std. Limit 5-0.01/ -0.025mm 5-0.03/ -0.045mm Serv.Limit 4.957mm 4.95 mm Inlet in mm Exhaust in mm Std. Limit 0.037 ~ 0.052 0.03 ~ 0.057 Serv.Limit 0.062 0.067 Valve Stem to Guide Clearance Std. Limit 0.05 mm Serv.Limit N/A Std. Limit 89.01 ~ 89.024 mm Serv.Limit N/A Std. Limit 0.060 ~ 0.075 mm Serv.Limit 0.1 mm CylinderHead Warp Cylinder Piston Clearance Piston Diameter At Height 8mm From Bottom Std. Limit 88.94 ~ 88.95mm Serv. Limit 88.97 Piston Ring GrooveClearance Top Second O Ring Std. Limit 0.20~0.35 0.40~0.55 0.30~0.70 Serv. Limit 0.55 mm 0.75 mm 1.0 mm Top Second O Ring Std. Limit 0.050~0.070 0.030~0.070 0.060~0.140 Serv. Limit 0.15 mm 0.15 mm 0.16 mm Cyl. Inside Diameter At ht 40mm From Cyl. Head SeatingFace
5-15 ENGINE & TRANSMISSION Service Limits Engine Gear Shift Fork Guide Pin Diameter Shaft Fork Shift O.D Std. Limit 5.05 ~ 5.15 mm Serv.Limit 5.2 mm Std. Limit 10 ~ 10.02 mm Serv.Limit 10.06 mm Std. Limit 9.96 ~ 9.98 mm Serv.Limit 9.95 mm Fork Shift I.D Gear Shift Drum Groove Width Std. Limit 4.96 ~ 4.99 mm Serv.Limit 4.91 mm Cam LobeWidth Intake Exhaust Std. Limit 9.4 - 9.6mm 9.4 - 9.6mm & 8.4 - 8.6mm Serv.Limit N/A N/A Std. Limit - Serv.Limit 0.4 mm Connecting Rod Side(Axial) Clearance
5-16 ENGINE & TRANSMISSION Important Bolts Tightening Sequence Tightening Torque : 1.0 - 1.2 Kgf-m (9.8 - 11.8Nm) Cylinder Head MountingBolts Engine Mounting Bolts 1 2 3 5 6 4 5 3 1 2 4 Clutch Cover MountingBolts Crankcase JoiningBolts Magneto Cover MountingBolts Tightening Torque : Small Bolts No 1 to No 2 : 1.0 - 1.2 Kgf-m (9.8 - 11.8 Nm) Big Bolts No 3 to No 6 : 6.0 - 6.5 Kgf-m (58.9 - 63.8 Nm) Tightening Torque : 1.0 - 1.2 Kgf-m (9.8 - 11.8 Nm) Bolt tightening steps to be followed : Step 1 - All bolts (No 1 to No 5) should be prefit first. Step 2 - Bolts of frame should be tightened first (No 1, No 2), Tightening Torque : No 1 and No 2 : 4.5Kgf-m (44.1 Nm). Step 3 - Bolts on engine stay should be tightening (No 3, No 4, No 5), Tightening Torque : No 3 : 4.5 Kgf-m(44.1 Nm) No 4 and No 5 : 2.6 Kgf-m (25.5 Nm)
5-17 ENGINE & TRANSMISSION Engine Dismantling • Follow the sequence to remove clutch cover mounting bolts (12 nos.) take out clutch cover. • Ensure the piston is at TDC by aligning primary gear mark with crankcase. • Ensure ' T ‘ mark on cam sprocket should be upwards by aligning it with the mark on cam holder [A] and the ( - ) mark on cam sprocket will be horizontally follows the cylinder head upper surface [B]. • Remove dummy and bolt lock crankshaft using crankshaft locking tool. Top Side Dismantling • Remove cylinder head cover mounting bolts (4 nos.) in crisscross pattern and take out cylinder head cover. T A T B
5-18 ENGINE & TRANSMISSION Engine Dismantling • Remove chain tensioner dummy bolt using 10 mm spanner [A]. • Using small screw driver, rotate chain tension screw to take plunger backward and lock it [B]. • Remove Chain tensioner mounting bolts (2 nos.) using 8 mm spanner. • Take out chain tensioner along with gasket. • Remove cam sprocket mounting bolt. • Remove central spark plug. • Remove spark plug sleeve using spark plug removal tool. • Remove cam sprocket allen bolts (2 nos.) using 8 mm allen key. • Remove guide chain top mounting bolts (2 nos.) using 8 mm spanner [A]. • Remove cam sprocket mounting bolts (6 nos.) using 8 mm spanner [B]. • Take out cam sprocket and cam chain sprocket. • Tie the cam chain. A A B B B B B B A B
5-19 ENGINE & TRANSMISSION Engine Dismantling Cylinder Head Assembly Dismantling • Remove cylinder head mounting bolts 5 mm [A] - 2 nos. and 8 mm [B] - 4 nos. using 5 mm & 8 mm Allen key. • Take out cylinder head. • Remove intake and exhaust rocker arm Allen bolts (2 nos.) using 5 mm Allen key. • Remove intake and exhaust rocker arm shaft with using rocker arm shafts removing special tool, Rocker Shaft Removal Tool (37 10DH 35). (Please refer page Chapter 1-13). • Remove Grub Allen nut sleeve with 2.5 mm Allen key. • Remove spark plug sleeve with using spark plug sleeve removing special tool, Spark Plug Sleeve Removal Tool (37 1043 09). A B B B B
5-20 ENGINE & TRANSMISSION Engine Dismantling • Take out Intake and Exhaust rocker arms. • Remove Belleville washer (1 nos.) and plain washer (2 nos.) • Take out camshaft assembly. • Using valve spring compressor and adapter, take out valve and valve repair kit. • Remove intake pipe screws (3 nos.) with Philips head screw driver and take out intake pipe. • Ensure that intake pipe ‘O’ ring is in good condition.
5-21 ENGINE & TRANSMISSION Engine Dismantling • Remove spark plug LH and RH by using spark plug removing special tool (37 2540 34). (Please refer page Chapter 1-11) • Remove oil pressure sensor using oil pressure sensor removing with spanner 21 mm spanner. • Ensure that oil pressure sensor ‘O’ ring is in good condition. • Remove coolant temperature sensor using 18 mm spanner. • Remove cylinder head gasket & dowels (2 nos.) [A]. LH RH A
5-22 ENGINE & TRANSMISSION Engine Dismantling • Remove cylinder block gasket and dowels (2 nos.) [A] and cylinder block. • Cover crankcase bore with clean cotton cloth and remove piston pin circlip. • Using piston pin removal special tool (P/N : 37 1043 41), remove piston pin and piston (Please refer page Chapter 1 - 12). A
5-23 ENGINE & TRANSMISSION Engine Dismantling Clutch Cover Dismantling • Remove oil filter cover mounting bolts (2 nos.) with 8 mm spanner and take out oil filter cover. Clutch Side Dismantling • Ensure that oil filter cover ‘O’ ring is good condition and take out engine oil filter. • Remove clutch release shaft along with washer and torsion spring. • Remove clutch cover gasket and dowels (2 nos.) and take out timing chain.
5-24 ENGINE & TRANSMISSION Engine Dismantling • Remove chain guide mounting bolt with 5 mm Allen key and take out chain guide. • Remove primary gear nut with 24 mm spanner. • Take out primary gear nut, Belleville washer, plain washer and crankshaft sprocket. • Remove plate stopper mounting bolt (3 nos.).
5-25 ENGINE & TRANSMISSION Engine Dismantling • Take out plate stopper. • Take out clutch springs (3 nos.) and wheel clutch. • Take out pull rod, friction and pressure plates. • Take out Belleville washer and plain washer.
5-26 ENGINE & TRANSMISSION Engine Dismantling • Using clutch centre holding tool (P/N : 37104338), remove clutch nut clockwise using 24 mm spanner. (Please refer page Chapter 1-13) • Take out Belleville washer and plain washer. • Take out clutch centre along with thick washer. • Take out clutch housing and clutch pacer.
5-27 ENGINE & TRANSMISSION Engine Dismantling • Take out primary gear and key. • Remove oil pump drive gear circlip and washer. • Remove oil pump drive gear. • Remove oil pump drive gear lock pin and washer.
5-28 ENGINE & TRANSMISSION Engine Dismantling • Remove oil pump mounting bolt (3 nos.) and take out oil pump assembly. • Remove oil pump driven gear pin and dowels (2 nos.) and take out lever complete gear shift. • Remove inhibitor mounting bolt with 5 mm Allen key and take out inhibitor, washer (2 nos.) and spring. • Remove guide gear shift mounting bolt with 5 mm Allen key and take out guide gear shift along with bush. • Remove parallel pin from gear change drum using flexible magnetic wire.
5-29 ENGINE & TRANSMISSION Engine Dismantling Magneto Side Dismantling Magnetor Cover Dismantling • Remove magneto cover mounting bolts (15 nos.) and take out magneto cover. • Remove stator plate wiring branch guide plates mounting bolts (3 nos.) and take out guides plates. • Remove guide gear shift mounting bolt with 5 mm Allen key and take out guides gear shift along with bush.
5-30 ENGINE & TRANSMISSION Engine Dismantling • Remove grommet from magneto cover and take out stator plate. • Remove magneto cover gasket and 2 dowels. • Remove gear starter clutch lock plate mounting bolt and take out lock plate. • Remove rotor mounting bolt.
5-31 ENGINE & TRANSMISSION Engine Dismantling • Remove magneto rotor using magneto rotor puller (Part No. 37 0042 76, refer page Chapter 1-13). • Remove balancer driving gear nut using balancer driving gear nut removing tool. • Take out Belleville washer and plain washer. • Remove balancer driving gear bolt and washer.
5-32 ENGINE & TRANSMISSION Engine Dismantling • Take out balancer drive gear. • Remove neutral switch mounting bolt (2 nos.) and take out neutral switch. • Take out balancer drive gear using balancer driver gear extractor (Part No. 37104343, refer page Chapter 1-10), remove key. • Remove starter counter gear assembly and crank angle sensor mounting bolts.
5-33 ENGINE & TRANSMISSION Engine Dismantling • Remove crank angle sensor cum neutral switch wiring branch guide plates mounting bolts. • Remove grommet from crankcase and take out crank angle sensor cum neutral switch. • Remove evacuation pump mounting bolts (3 nos.) and take out evacuation pump mounting bolts (3 nos.). • Remove lock pin and take out shaft.