4-30 FUEL SYSTEM & EMS Diagnosis & 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
4-31 FUEL SYSTEM & EMS Diagnosis & 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 Malfunction Indicator Lamp (MIL) Control Circuit Short Circuit to Ground. 26 P0650 Malfunction 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.
4-32 FUEL SYSTEM & EMS Diagnosis & 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
4-33 FUEL SYSTEM & EMS Diagnosis & 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.
4-34 FUEL SYSTEM & EMS Diagnosis & 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.
Chapter 5 Engine & Transmission Table of Contents Exploded View ................................................... 5-2 Tightening Torques Engine ……........................ 5-10 Service Limits Engine ........................................ 5-13 Important Bolts Tightening Sequence .……....... 5-16 Engine Dismantling …........................................ 5-17 Engine Oil Flow Path ……................................... 5-40 51
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 1.0 ~ 1.2Kgf-m 1.0 ~ 1.2Kgf-m 1.0 ~ 1.2 Kgf-m 1.8 ~ 2.0 Kgf-m 1.0 ~ 1.2 Kgf-m 1.0 ~ 1.2Kgf-m 1.2 ~ 1.4 Kgf-m 1.0 ~ 1.2 Kgf-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 Cylinder Head Cover Bolts Spark Plug Oil Strainer Cap (18 mm A / F) Coolant Temperature Sensor Stator Mounting Bolts Silencer Bracket Bolts Oil Pump Mounting Bolts Clutch Cover Bolts Cap Oil Filter Bolts Chain Tensioner Mounting Bolts Output Sprocket Bolts Magneto Cover Bolts
5-11 ENGINE & TRANSMISSION Tightening Torques Engine 10 ~ 10.5 Kgf-m 1.0 ~ 1.2 Kgf-m 1.1 ~ 1.2 Kgf-m 3.9 ~ 4.1 Kgf-m 1.0 ~ 1.2 Kgf-m 6.0 ~ 6.5 Kgf-m 1.1 ~ 1.2 Kgf-m 1.1 ~ 1.2 Kgf-m 14.5 ~ 15 Kgf-m 0.8Kgf-m Magneto Rotor Mounting Bolt Stator Motor Mounting Bolt Inhibitor Allen Bolt Cylinder Head Small Allen Bolts Guide Gear Allen Bolt Clutch Holder Bolts / Spring Clutch Bal. Driver Nut Gear Mounting Bal. Driven Gear Mounting(Allen) Cylinder Head Allen Bolts Cam Holder Bolts 14.5 ~ 15 Kgf-m 4.1 ~ 4.3Kgf-m Primary Gear Nut Cam Shaft Sprocket Allen Bolt
5-12 ENGINE & TRANSMISSION Tightening Torques Engine 1.0 ~ 1.2 Kgf-m 0.7 ~ 0.9 Kgf-m 1.1 ~ 1.2 Kgf-m 14.5 ~15.0 Kgf-m 12.0 ~ 12.2 Kgf-m Manifold Mounting Nuts Nut Securing Primary Gear Crankcase Joining Bolts Drum / Cam Allen Bolt Nut Securing Clutch Assembly
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 7.5mm Serv.Limit 7.47mm Std. Limit 63.95 mm Od & 70.48 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 47.7 mm Serv.Limit 46.7 mm Valve TappetClearance Clutch Spring FreeLength Crankshaft Runout Std. Limit 1.92 ~ 2.08 mm Serv.Limit 1.87 mm Std. Limit 2.92 ~ 3.08 mm Serv.Limit 2.72 mm Steel Plate Thickness Friction PlateThickness Friction PlateWarp Std. Limit N/A Serv.Limit N/A Steel PlateWarp Std. Limit 0.1 mm Serv.Limit 0.2 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 EndGap Cam Lobe Height Std. Limit 40.28mm Serv.Limit 39.28mm Std. Limit 127 – 127.15mm Serv.Limit 127.66mm Camshaft ChainLength Valve Spring free Length Intake Exhaust Std. Limit 34.40mm 34.26mm Serv.Limit 34.35mm 34.21mm Intake Exhaust Std. Limit 5 - 0.01 / - 0.025mm 5 - 0.03 / - 0.045mm Serv.Limit 4.957mm 4.95mm 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 0.03 mm Serv.Limit N/A Std. Limit 72.006 ~ 72.013 mm Serv.Limit N/A Std. Limit 0.02 ~ 0.05 mm Serv.Limit 0.1 mm CylinderHead Warp Cylinder PistonClearance Piston Diameter At Height 8mm From Bottom Std. Limit 71.963 ~ 71.977 mm Serv. Limit N/A Piston Ring GrooveClearance Top Second ORing Std. Limit 0.1~ 0.25 0.35 ~ 0.5 0.20 ~0.7 Serv. Limit 0.50 mm 0.75 mm 1.0 mm Top Second O Ring Std. Limit 0.020~0.060 0.020~0.060 0.040~0.110 Serv. Limit 0.15 mm 0.15 mm 0.16 mm Cyl. InsideDiameter At ht 40mm From Cyl. Head SeatingFace
5-15 ENGINE & TRANSMISSION Service Limits Engine Gear Shift Fork Guide Pin Diameter Shaft Fork Shift OutsideDiameter Std. Limit 5.05 ~ 5.15 mm Serv.Limit 5.2 mm Std. Limit 10 ~ 10.02 mm Serv.Limit 10.04 mm Std. Limit 9.96 ~ 9.98 mm Serv.Limit 9.95 mm Fork Shift Inside Diameter 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 0.2 ~ 0.35 mm Serv.Limit 0.6 mm Connecting Rod Side(Axial) Clearance
5-16 ENGINE & TRANSMISSION Important Bolts Tightening Sequence Tightening Torque: 1.0 - 1.2Kgf-m (9.8 - 11.8Nm) TighteningTorque: Big Bolts: 6.0 - 6.5 Kgf-m (58.9 - 63.8Nm) Small Bolts: 1.0 - 1.2 Kgf-m (9.8 - 11.8Nm) Tightening Torque : 1.0 - 1.2 Kgf-m (9.8 - 11.8Nm) Cylinder Head Mounting Allen Bolts Crankcase JoiningBolts Clutch Cover MountingBolts Magneto Cover MountingBolts Step 1) All bolts should be prefit first (1 to 5) Step 2) Bolts of frame should be tightened first (1,2) 1) 4.5Kgf-m (44.1Nm) 2) 4.5Kgf-m (44.1Nm) Step 3) Bolts on engine stay (3,4,5) 3) 4.5Kgf-m (44.1Nm) 4) 2.6Kgf-m (25.5Nm) 5) 2.6Kgf-m (25.5Nm) 4 5 3 2 1 Engine Mounting Bolts Bolt tightening steps to be followed :
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 criss-cross pattern and take out cylinder head cover.
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 & lock it [B]. • Remove Chain tensioner mounting bolts (2 nos.) using 8 mm spanner. • Remove 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 holder mounting bolts (6 nos.) using 8 mm spanner [B]. • Take out Cam sprocket & Cam Chain sprocket. • Remove the cam chain. A A B B B B B B
5-19 ENGINE & TRANSMISSION Engine Dismantling Cylinder Head Assembly Dismantling • Remove • Cylinder head mounting allen bolts 5 mm [A] - 2 nos. & 8 mm [B] - 4 nos. using 5 mm & 8 mm allen key. • Take out cylinder head. • Remove • Intake & exhaust rocker arm allen bolts (2 nos.) using 5 mm allen key. • Remove • Intake & exhaust rocker arm shaft with using rocker arm shafts removing special tool, Rocker Shaft Removal Tool (37 10DH 35). (Please refer page Chapter 1-12) A B B B B
5-20 ENGINE & TRANSMISSION Engine Dismantling • Take out intake & exhaust rocker arms . • Take out camshaft assembly. • Using valve spring compressor & adapter, take out valve collect & remove valve. • Remove intake pipe screws (3 nos.) with Philips head screw driver & take out intake pipe. • Ensure that pipe intake ‘O’ ring is in good condition.
5-21 ENGINE & TRANSMISSION Engine Dismantling • Remove spark plug LH by using spark plug removing special tool (37 2540 34), Please refer page Chapter 1-12) • 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].
5-22 ENGINE & TRANSMISSION Engine Dismantling • Remove cylinder block, cylinder block gasket & dowels (2 nos.) [A]. • Cover crankcase bore with clean cotton cloth and remove piston pin circlip. • Remove piston & piston pin using piston pin removal special tool (P/N : 37 104341)(Please refer page Chapter 1-11).
5-23 ENGINE & TRANSMISSION Engine Dismantling Clutch Cover Dismantling • Remove oil filter cover mounting bolts (2 nos.) with 8 mm spanner & take out oil filter cover. Clutch Side Dismantling • Ensure that oil filter cover ‘O’ ring is good condition & take out engine oil filter . • Remove clutch release shaft along with washer & torsion spring. • Remove clutch cover gasket & dowels pin (2 nos.). • Take out timing chain .
5-24 ENGINE & TRANSMISSION Engine Dismantling • Remove chain guide mounting allen bolt with 5 mm allen key & take out chain guide. • Remove Primary gear nut with 24 mm spanner. • Take out primary gear nut, belleville washer, plain washer & 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.) & wheel clutch. • Take out pull rod. • Take out belleville washer & plain washer. • Take out clutch discs & spacers
5-26 ENGINE & TRANSMISSION Engine Dismantling • Remove clutch nut clockwise using 24 mm spanner & using clutch centre holding tool (P/N : 37 104338), please refer page Chapter 1-13). • Take out belleville washer & plain washer. • Take out clutch centre along with thick washer. • Take out clutch housing & clutch spacer.
5-27 ENGINE & TRANSMISSION Engine Dismantling • Take out primary gear & key. • Remove oil pump drive gear circlip & washer. • Remove oil pump drive gear. • Remove oil pump drive gear lock pin & washer.
5-28 ENGINE & TRANSMISSION Engine Dismantling • Remove oil pump mounting bolt (3 nos.) & take out oil pump assembly. • Remove oil pump driven gear pin & dowels (2 nos.) & take out lever complete gear shift. • Remove inhibitor mounting allen bolt with 5 mm allen key & take out inhibitor, washer (2 nos.) & spring. • Remove guide gear shift mounting allen bolt with 5 mm allen key & 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.) & take out magneto cover. • Remove stator plate wiring branch guide plates mounting bolts (3 nos.) & take out wiring guides plates. • Remove stator allen bolts (3 nos.) & take out stator.
5-30 ENGINE & TRANSMISSION Engine Dismantling • Remove grommet from magneto cover. • Remove magneto cover gasket and 2 dowels. • Remove gear starter clutch lock plate mounting bolt & take out lock plate. • Remove rotor mounting bolt.
5-31 ENGINE & TRANSMISSION Engine Dismantling • Remove magneto rotor using magneto rotor puller (Part No. 37 004276, Please refer page Chapter 1-12) • Remove balancer driving gear nut using balancer driving gear nut removing tool. (Part No. 37 004176, Please refer page Chapter 1-12). • Take out belleville washer & plain washer. • Remove balancer driving gear allen bolt & washer
5-32 ENGINE & TRANSMISSION Engine Dismantling • Take out balancer drive gear. • Remove neutral switch mounting bolt (2 nos.) & take out neutral Switch. • Take out balancer drive gear using balancer driver gear extractor (Part No. 37 104343) & key. (Please refer page Chapter 1 – 11) • Remove stater counter gear assembly. • Remove crank angle sensor mounting bolts (2 nos.).
5-33 ENGINE & TRANSMISSION Engine Dismantling • Remove neutral switch wiring branch guide plates mounting bolts ( 3 nos). • Remove grommet from crankcase & take out crank angle sensor & neutral switch. • Remove evacuation pump mounting bolts (3 nos.) & take out cover evacuation pump. • Remove lock pin & shaft evacuation pump.
5-34 ENGINE & TRANSMISSION Engine Dismantling • Remove ‘T’ pipe mounting bolts (2 nos.) & take out ‘T’ pipe along with ‘O’ ring. Crankcase Splitting • Ensure that ‘T’ pipe ‘O’ ring is in good condition. • Remove water pump cover mounting bolts (5 nos.) & take out water pump cover along with ‘O’ ring. Ensure that water pump ‘O’ ring is in good condition. • Remove dowel pins (2 nos.). • Remove water pump mounting nut with 10 mm spanner counter clock wise & take out water pump rotor.
5-35 ENGINE & TRANSMISSION Engine Dismantling • Remove chain guard mounting screws (3 nos.) & take out chain guard. • Remove starter motor mounting bolt ( 2 nos ) & take out starter motor.
5-36 ENGINE & TRANSMISSION Engine Dismantling • Remove RH side crankcase mounting bolt (1 nos.). • Note : Open this bolt before splitting crankcase. • Remove LH side crankcase assembly & take out crankshaft assembly. • Take out dowels (2 nos.). • Remove LH side crankcase mounting bolts (16 nos.). • Note : Bolt shown by arrow in photograph is long in length than others. • Remove balancer bearing lock plate mounting bolt.
5-37 ENGINE & TRANSMISSION Engine Dismantling • Remove input shaft & take out 1 nos input fork gear shift. • Remove gear change drum. • Remove input & output shaft assembly. • Remove shaft along with spring & 2 nos output fork gear shift. • Remove oil rail.
5-38 ENGINE & TRANSMISSION Engine Dismantling • Remove output shaft oil seal lock. • Remove output shaft bearing & lever complete gear shift of seal. Using oil seal fitment tool (Part No. 37 104256) for oil seal fitment. (Please refer page Chapter 1-12) Crankcase LH Dismantling • Remove input shaft bearing & output shaft bush using bearing extractor (Part No. 37 10DJ76, please refer page Chapter 1-13).
5-39 ENGINE & TRANSMISSION Engine Dismantling • Remove gear change drum bearing lock plate bolt & take out gear change drum bearing lock plate. • Using bearing driver set remove input shaft bearing & output shaft bearing. • Using bearing driver set remove gear change drum bearing. • Remove complete gear shift stopper using 12 mm spanner. Crankcase RH Dismantling • Remove water pump oil seal (2 nos.). • Note : Using water pump oil seal fitment tool (Part No. 37 004156) for oil seal fitment. (Please refer page Chapter 1-12) • Remove input shaft bearing lock plate bolt & take out input shaft bearing lock plate.
5-40 ENGINE & TRANSMISSION Reliefvalve A Engine Oil Flow Path A Oil pumpinlet Oilstrainer Engine oilfilter Oil pumpoutlet End Engine oil filter chamber RHcrankcase RH crankcase oilgallery RH Crankcase hole for entry in clutchcover LH Crankcase oil gallery RH crankshaft journal bearinglubrication
5-41 ENGINE & TRANSMISSION Engine Oil Flow Path Clutchcover Towards crankshaft 2 nos. oil jet for clutch lubrication Clutch cover topside Connecting rod lubrication End End A RH crankcasehole Top side holein RHcrankcase B
5-42 ENGINE & TRANSMISSION C Cylinder block In & out Engine Oil Flow Path CONTINUEFROM Cylinder head In &out CONTINUE FROM A C Tooil jet Tonozzle End LH crankshaft journal bearing lubrication B
5-43 ENGINE & TRANSMISSION Engine Oil Flow Path CONTINUE FROM To oil jet Input & output shaft bearing lubrication Oil jet for stator lubrication Hole on magneto cover Oil rail for gearlubrication Oilrail fitment hole on LH crankcase Hole on LH crankcasefor entry in magneto cover LH Crankcase Oil Gallery C
5-44 ENGINE & TRANSMISSION Engine Oil Flow Path Crankshaft chamber Evacuation strainer Evacuation pump inlet Evacuation pump outlet Release engine oil in gear box chamber through evacuation pipe Evacuation passage
1 Chapter 6 Frame & Suspension Table of Contents Exploded View .................................................. 6-2 Tightening Torques Frame …............................ 6-5 Evaporative Emission System .......................... 6-8 Important SOP.................................................... 6-10 Special Tools ……………………………………. 6-14 Front Fork Oil Leakage Confirmation …………. 6-15 Dust Seal & Oil Seal Replacement ……………. 6-19 Oil Seal & Dust Seal Fitment .............................6-24 Fork Inner Pipe Replacement ............................6-29 Twin Channel Antilock Brake System ................6-34 ABS Failure Code ……………………………….. 6-36 6