User manual ETON YUKON ST SERVICE MANUAL

[. . . ] REAR WHEEL SYSTEM FENDERS AND EXHAUST PIPE ELECTRICAL SYSTEM TROUBLE SHOOTING 1. INFORMATION 1. 1 1. 2 1. 3 SAFTY NOTES SPECIFICATION 1. 4 1. 5 SERIAL NUMBER TORQUE VALUE 1. 1 SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid. [. . . ] Measure open width of shift spring as fig-2. fig-2 If open width greater than 5mm, it must be replaced. SERVICE LIMITS: 5 mm Shift Spring Shift Gear Shift Motor Check shift motor whether it's action is normal as follow data: Disassembly mission side cover, parts of shift mechanism and mission cover. Replace it if necessary. Brush Seal Bearing 7. 4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable transmission, which can change the transmission ratio automatically. When engine speed increase, the drive pulley will be push to belt by the centrifugal force from six rollers. The belt at driven pulley is forced to move to the center of shaft, then the radius of pitch circle is decreased. The transmission ratio is therefore altered by the alteration of pitch circle's radius. (In the drawing, "H" means high speed, "L" means low speed) 7. 5 CONTINUOUS VARIABLE TRANSMISSION V-Belt Made of rubber fiber, resistant to head, pressure and abrasion. The inner side of the Belt is toothed. Drive Pulley Due to the increasing engine speed, the rollers push the movable drive face by centrifugal force. It can reduce the belt temperature. Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. When the outside load is higher than the engine's output, the pulley of fixed shaft and belt slip to make the Movable Drive Face move along the inner side of Cam and compensate to increase to high torque (toward to low speed) and make the engine maintain smooth running with original revolution. 7. 6 GEAR BOX Reverse Shaft Comp Sensor Drive Shaft Comp Drum Gear Shift Fork Fork Counter Shaft Comp Shaft Remove mission side cover, parts of shift mechanism and mission cover. The gear ratio of front gear composition is about 47 x 31 15 11 49 49 31 × × 15 16 11 The gear ratio of reverse gear composition is about 7. 7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can act only when the left hand brake is applied. ELECTRIC SELF-STARTER MECHANISM KICK STARTER 7. 8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the gear of start shaft will drive the kick-starter to revolve the crankshaft to start the engine. After the engine is started, the kick-started will stop transfer the power to the kick-starter driven gear. When the kick-starter lever is released, the kick-starter gear will go back to its original position. 7. 9 DISASSEMBLY AND CHECK OF C. V. T. STEERING SYSTEM 8. 1 THE PARTS DRAWING OF STEERING SYSTEM 8. 2 TROUBLESHOOTING 8. 3 HANDLEBAR 8. 4 STEERING SYSTEM 8. 1 THE PARTS DRAWING OF STEERING SYSTEM 8. 2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment FRONT WHEEL WOBBLING STEERS TO ONE SIDE FRONT SUSPENSION NOISE ¡¹ ¡¹ HARD SUSPENSION ¡¹ ¡¹ ¡¹ SOFT SUSPENSION ¡¹ Loose front suspension fasteners Binding suspension link Faulty front swing arm bushings Improperly installed front swing arms Bent front shock absorber swing rod Weak front shock absorber springs Worn or damage front swing arm bushings ¡¹ 8. 3 HANDLEBAR REMOVAL Remove the right side handlebar cover by unscrew two fix screws. Remove the throttle lever housing on the right side handle bar. Remove brake lever bracket assemb Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Remove the bolts attaching the handlebar upper holder. Remove the handlebar. I INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark match with the top end of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. Install the handlebar upper holder's cover. Install the switch housing, aligning the boss with the hole. [. . . ] Remove the exhaust pipe carefully. For E-MARK EXHAUST PIPE INSTALLATION Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30 N. m (22 lbf. ft) After installation, make sure that there are no exhaust leaks. 12. ELECTRICAL SYSTEM 12. 1 TROUBLESHOOTING 12. 2 IGNITION COIL 12. 3 BATTERY CAUTION 12. 4 BATTERY INSPECTION 12. 5 CHARGING 12. 6 ELECTRIC STARTER 12. 7 WIRING DIAGRAMS 12. 8 SPEEDOMETER AND FUEL METER 12. 9 WIRING DIAGRAM 12. 1 TROUBLESHOOTING ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG ENGINE STOP SWITCH AT " OFF " FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POOLY CONNECTED: Between CDI and ignition coil Between alternator and CDI unit Between CDI and engine stop switch Between ignition coil and spark plug Between generator and CDI unit IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit NO SPARK AT PLUG ENGINE STARTS BUT RUNS POORLY CHARGING SYSTEM FAILURE LOOSE, BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE FAULTY IGNITION SYSTEM ENGINE PROBLEMS FAULTY ENGINE STOP SWITCH FAULTY REMOTE CONTROLLER SCANTY CONTROLLER BATTERY ELECTRIC ENGINE INTERMITTENT POWER STARTER MOTOR WILL NOT TURN STARTER MOTOR AND ENGINE TURN, BUT ENGINE DOES NOT START REMOTE CONTROLLER INCAPABLE ACTION TO MAKE ENGINE UNABLE RUNNING 12. 2 IGNITION COIL Remove the spark plug cap from the spark plug Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0. 1 - 0. 3(20) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7. 4 ­ 12 k(20) IGNITION TIMING The ignition advance is 15°± 3°/4000rpm The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment. ALTERNATOR EXCITER COIL Remove the seat / rear fender and front fender. Measure the resistance between the yellow / red wire and ground. STANDER : 460-700 (AT 20, 68) 12. 3 BATTERY CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. [. . . ]