The scooter
Honda Dio Manual device on operation preventive maintenance maintenance and repair
By Andrey Levkovich Aka Dusha Mail To: dusha_.ko2@tut.y
!"D#$ %. &eduction and aritrary symols 2. 'eneral instructions on repair (. !denti)ication *. Description and the recommendation o) *.% &ecommendations re+ardin+ maintenance y *.2 &ecommendations re+ardin+ control o) scooter ,. Maintenance and the +eneral audit procedures and ad-ustment ,.% Maintenance rate ,.2 Arran+ement o) the elements o) the systems o) control nourishment electrical e/uipment ,.( Body elements 01,3M4 ,.* Ad-ustment o) headli+ht ,., Ad-ustment o) oil pump ,.5 Testin+ )uel pump ,.6 7leanin+ air )ilter ,.8 9ressure testin+ o) the end o) the compression stroke ,. 7heckin+ rake linin+s 5. 9o;er unit 5.% ackets o) po;er unit 5.%( ick? starter 5.%* ariator 5.%, Main drive 5.%5 7arter en+ine 6. 7heckin+ and the repair o) po;er unit 8. ndercarria+e 8.% =ront suspension and )ront rake 01,3M4 8.2 7heckin+ o) the knot o) )ront rake 8.( Torr system ;ith disk )ront rake 01,3M4 8.* Handle o) +as 8., &ear suspension and rear rake 8.5 1hock asorer . #lectrical e/uipment .% 1tora+e attery .2 &e+ulator o) volta+e 0recti)ier4 .( 'enerator
.* !nterrupter 0lock 7D!4 ., !+nition coil .5 7heckin+ the lead an+le o) i+nition .6 1tarter .8 1ensor o) )uel level . 1ensor o) oil level .%3 Lock o) i+nition .%% 1;itch o) the turn indicators o) .%2 Lamps .%( 1teerin+ s;itches o) .%* 1chematics o) the electrical e/uipment
1. Reduction and arbitrary symols o) reduction <==.................................... is s;itched o)) <".........................................vklyucheno
The aritrary symols
2. General instructions on repair %. ith the dismantlin+ plot details in the appropriate order in order to )acilitate the suse/uent assemlin+. 2. Be)ore the )ul)illment o) ;orks ;ith the electrical e/uipment you ;ill disconnect ;ire )rom the ne+ative terminal o) stora+e attery. (. 7ompulsorily sustitute split cotter pins sealin+ +askets )errules stu))in+ oCes and so )orth y the ne;. *. !) necessary it is necessary to rin+ the sealin+ composition )or avertin+ the leaka+es to the sealin+ +askets. ,. Thorou+hly solyudayte all technical speci)ications ;ith respect to the values o) the moment o) the delay o) threaded connections. 7ompulsorily use a tor/ue ;rench. 5. Dependin+ on the nature o) the repair produced can e re/uired the application o) special materials and special tool )or the maintenance and the repair. 6. Durin+ the replacement o) the urnt out sa)ety devices it is necessary to trace so that the ne; sa)ety )use ;ould e calculated )or the appropriate current stren+th.
3. Identification 1eries numers are sustituted in the indicated in the )i+ure places: The scooters o) )irm Honda are di))ered )rom other stamps in terms o) more durale 0and heavier4 construction and su))iciently lon+? lived motors ;hich are ;orse yielded to oostin+. Are most common the scooters o) )amily Dio 0Dio Dio 1& Dio 7ity Movement and others4. Are in series produced models Dio $ and 1uperDio $ ;ith the au+mented en+ine the disk rakes and the sport suspension and also di))erent poluseriynye Dio $ ? special modi)ications ;ith the sport s;itchoards and the caruretors even y the more )orced motors ;ith the disposed release intensi)ied y )rame and suspensions. The ;eak place o) the usual Dio are the anthers o) )ront )ork. Burstin+ they pass mud inside the )ork ? as a result o) ushin+ and )eathers rapidly they are ;orn out and +o out o) order. =urthermore usual Dio have a some;hat unsuccess)ul tunin+ o) variator 0;ith )ailure and pickup4 ;hich hampers calm ride. These de)iciencies are corrected on the more
eCpensive models Dio $. The scooters o) )amily Tact are intended )or the e+innin+ drivers. The merits o) scooters Honda include the vertical en+ine ;hich ensures lar+er than in analo+s road clearance and in comination ;ith the more ru++ed construction it makes it possile to use a machine not only around the city ut also under the poor road conditions. ith %5?6 the annual production o) scooters Honda trans)erred into the !ndian ranches o) )irm ;hich ;as re)lected in the /uality o) those completin+ and assemlin+ o) machines.
4. Description and recommendation. recommendation. *.% &ecommendations re+ardin+ the maintenance on the scooters should e used +asoline ;ith the octane numer not lo;er than 2. !n the system o) separate luricant is compulsory the use o) special motor oil )or the t;o?stroke en+ines. The tentative consumption o) oil ? aout % l on %333 km ;ith a decrease in the oil level to the emer+ency reserve li+hts up pilot lamp on the comination o) instruments. 1parkplu+s should e checked every %?2 thousand. km o) path. A)ter path in *?8 thousand km 0 dependin+ on operatin+ conditions4 one should sustitute sparkplu+. The periodicity o) servicin+ air )ilter is ,33 km ;ith the ride alon+ the dusty roads. Transmission oil in the reducer o) rear ;heel should e sustituted yearly. *.2 some recommendations re+ardin+ control o) scooter are eCamined elo; some distinctive special )eatures o) the scooters o) )orei+n production. %. ;ith the Eero?len+th launch and the acceleration )rom the lo; speed do not t;ist out to the re)usal the kno o) +as to avoid the li)t o) scooter to the rear ;heel and the tiltin+. #specially this is dan+erous durin+ the contact into the hill or ;ith the si+ni)icant load on the a++a+e carrier. 2. ecause o) the ?elt variator acceleration occurs ;ith a constant )re/uency o) the rotation o) en+ine 0close to the revolutions maCimum po;er4F there)ore the speed o) scooter compulsorily should e checked on the speedometer. (. ;ith the rakin+ should e used a )ront and rear rake. ith the use only o) rear rake is possile the heapin+ up o) scooter side;ays only )ront ? the un+uided dri)t or revolution throu+h the control. *. small siEe o) ;heels and short ase make scooter sensitive to the unevennesses o) road and they re/uire the speci)ic strictness in control. ,. should e )ollo;ed the hei+ht o) the protector o) tires and as needed sustituted they. &ide on the scooter ;ith the ;orn protector o) ;heels is eCtremely unsa)e. 5. ;ith the passa+e o) turnin+s one ou+ht not to discard +as in the turnin+ in order to avoid o) eCtension )rom the road. Turnin+ should e passed Gvnatya+G checkin+ +as or to in advance discard it.
5. Maintenance and the general audit procedures and adustment Attention: in this mana+ement are used the )ollo;in+ aritrary symols o) the modi)ications o) scooters Honda: Honda Dio................1,3M Honda Tact...................1,39 1T.............1tandart 0ase model4 As...... o)..Auto1tand 0;ith the servodrive o) support4 DB............... o)..Disch Brake 0;ith the disk rake4 the attention: removal and dismantlin+ it is main and a++re+ates it is achieved y ;ay o) the numers indicated in the )i+ures. Assemlin+ and installation are accomplished in the order reverse to dismantlin+ and to removal.
!er"icing capacities# Honda Dio The )uel tank........................... o).*3 l motor oil........................ o) 38 l the transmission oil......... o).33 l Honda Tact The )uel tank... o) ,3 l 01T4*, l 0A14 motor oil........................ o) %2 l the transmission oil......... o).33 l
=i+. (. recommended viscosity o) motor oil
$arburetor 7aruretor............... 9B83 0Dio4 or 9B83 0Tact4: the diameter o) the choke.................. o) %* mm =re/uency o) the rotation o) idlin+...................... .. y %633?%33 rmin Main -et......... o).I88 0Dio4 or 68 0Tact4 !dle -et............ o).I(, 9ressure in the tires: the )ront ;heel............... o) %2, k+cm the rear ;heel.................. o).233 k+cm.
%lectrical e&uipment# 1tora+e attery. ............... %2 (Ah the lead an+le o) i+nition............... %6 MT o) sparkplu+: Dio: "'....................B9&,H1 B9&5H1 B9&6H1 B9&8H& Denso.................. %5=9& 23=9& 22=9& 2*=9& Tact: "'....................B&*H1A B&8H1A Denso.................. %*=&?L 2*=&?L Maintenance rate# 1''' (m ? checkin+ and cleanin+ the air )ilter ? checkin+ and the ad-ustment o) the rope o) the +as ? checkin+ the rakes ? pressure testin+ in the tires ? checkin+ the li+ht instruments ? checkin+ sparkplu+s throu+h 3''' (m ? decaroniEin+ )rom the en+ine ? checkin+ the level o) the transmission oil ? checkin+ the earin+s o) the steerin+ steerin+ column ? checkin+ and the the ad-ustment o) the ropes o) o) the rakes ? checkin+ the rake linin+s ? checkin+ checkin+ the stora+e attery ? checkin+ the ;ear o) the tires tires ? checkin+ the )astenin+ )astenin+ ? the luricant o) ropes )''' (m ? the replacement r eplacement o) sparkplu+s ? the replacement o) the transmission oil ? checkin+ the )ront )ork ? checkin+ the shock asorers ? cleanin+ the caruretor
=i+. *. Arran+ement <) the elements <) electrical e/uipment 01,3M4. % ? recti)ier 2 ? the sensor o) oil level ( ? hi+h?volta+e ;ire * ? main plait o) installation
, ? i+nition coil.
=i+. ,. arran+ement o) ropes and plaits o) installation 01,3M4 . % ? rope o) )ront rake 2 ? rope o) rear rake ( ? resistor * ? installation o) the lock o) i+nition , ? rope o) +as 5 ? li+ht s;itch 6 ? ri+ht plait o) steerin+ s;itches 8 ? le)t plait o) steerin+ s;itches ? s;itch o) the li+ht o) headli+hts %3 ? s;itch o) turn indicators %% ? s;itch o) sound si+nal %2 ? ;ire o) stop si+nal
0)rom the lever o) rear rake4 %( ? ;ire o) le)t turn indicator %* ? ;ire o) )ront headli+ht %, ? ;ire o) ri+ht turn indicator %5 ? ;ire o) stop si+nal 0)rom the lever o) )ront rake4.
=i+. 5. arran+ement o) ropes and plaits o) installation 01,3M4. % ? the rope o) speedometer 2 ? the asic plait o) installation ( ? rope o) rear rake * ? rope o) +as , ? hose o) )ront rake.
=i+. 6. arran+ement o) the elements o) the system o) control 01,3M4.
% ? the rope o) +as 2 ? the rope o) rear rake ( ? rope o) speedometer * ? rope o) )ront rake , ? main plait o) installation.
=i+. . arran+ement o) the elements o) the system o) control and nourishment 01,3M4. % ? plait o) the installation o) +enerator and starter 2 ? the rope o) +as ( ? the unit o) sa)ety devices * ? interrupter , ? relay o) starter 5 ? ;ire o) electric starter 6 ? le)t tue o) the ventilation o) crankcase 8 ? tue o) the oil supply ? rope o) rear rake %3 ? control cale o) oil pump %% ? oil tue %2 ? ;ire o) the sensor o) )uel level.
=i+. %3. arran+ement o) ropes and a nd plaits o) installation 01,3M4. % ? the rope o) speedometer 2 ? the installation o) the lock o) i+nition ( ? rope o) +as * ? hose o) )ront rake , ? rope o) speedometer speedometer 5 ? rope o) rear rake 6 ? yokes o) ;ires 8 ? resistor resistor ? s;itch o) starter
%3 ? li+ht s;itch %%%2 ? installation o) steerin+ s;itches %( ? s;itch o) the li+ht o) headli+ht %* ? s;itch o) turn indicators %, ? ;ire o) stop si+nal %5 ? ;ire o) le)t turn indicator %6 ? ;ire o) )ront headli+ht %8 ? ;ire o) ri+ht turn indicator.
=i+. %,. lateral revetment. % ? catch 2 ? lateral revetment ( ? scre;s o) the )astenin+
=i+. %5. )ront )airin+. % ? the scre;s o) )astenin+ 2 ? )ront )airin+ ( ? )ront cover * ? scre;s o) )astenin+ , ? catch .
=i+. %6. lateral )airin+. % ? )lan+ed nut 2 ? )lan+ed olt ( ? rear a++a+e carrier * ? catch , ? lateral )airin+ 5 ? scre;s o) )astenin+.
=i+. %8. outdoor revetment. % ? catchs 2 ? the revetment o) steps ( ? clamp olts.
=i+. %. )ront cover. % ? clamp olt 2 ? )ront cover ( ? catchs * ? scre;s o) )astenin+.
=i+. 23. a++a+e hold.
% ? )lan+ed olts 2 ? paddin+ ( ? cover o) oil tank * ? rear a++a+e carrier , ? )lan+ed olt 5 ? )lan+ed nut 6 ? a++a+e hold.
=i+. 2%. steerin+ )airin+. % ? mirror o) rear )orm 2 ? -oints o) the installation o) )ront headli+ht headli+ht and turn indicators ( ? the scre;s o) )astenin+ * ? steerin+ )airin+ , ? clamp olt 5 ? catchs.
=i+. 22. rear ;in+. % ? catch 2 ? the ;ire o) rear turn indicator ( ? rear ;in+ * ? clamp olts.
=i+. 2(. LAT#&AL &##TM#"T.
=i+. 2*. steerin+ )airin+. % ? the rope o) speedometer 2 ? the tail end o) the steerin+ )airin+ ( ? olt * ? installation o) steerin+ s;itches , ? scre;s o) )astenin+.
=i+. 2,. Body #lements. % ? lateral revetment 2 ? a++a+e hold ( ? lateral )airin+ * ? outdoor revetment , ? rear ;in+ 5 ? )ront )airin+ 6 ? )ront cover 8 ? steerin+ )airin+ ? the tail end o) the steerin+ )airin+
=i+. 25. a++a+e hold. % ? clamp olt 2 ? the cover o) tank ( ? the packin+ ;asher * ? the a++a+e hold
=i+. 26. outdoor revetment. % ? catch 2 ? clamp olt ( ? outdoor revetment * ? catch ;in+ ( ? scre;s o) )astenin+.
=i+. 28. )ront ;in+ % ? the scre;s o) )astenin+ 2 ? )ront
=i+. 2. )ront cover. % ? the scre;s o) )astenin+ 2 ? clamp ( ? clamp olt * ? )ront cover , ? catch.
=i+. (3. lateral )airin+. % ? catch 2 ? )airin+ ( ? rear a++a+e carrier * ? clamp olt , ? rope 5 ? -oints o) ;irin+ 6 ? scre;s o) the )astenin+
=i+. (%. rear ;in+. % ? clamp olt o) oil tank 2 ? relay ( ? racket * ? clamp olt , ? interrupter 0knot 7D!4 5 ? clamp 6 ? rear ;in+.
=i+. (2. ad-ustment o) headli+ht 9roverJte the direction o) the li+ht eam o) )ront headli+ht and i) necessary ad-ust it ;ith the aid o) the ad-ustin+ scre;
=i+. ((. steerin+ )airin+. % ? the scre;s o) )astenin+ 2 ? the scre; o) )astenin+ ( ? paddin+ o) master rake cylinder * ? steerin+ )airin+ , ? mirror o) rear )orm.
=i+. (*. the tail end o) the steerin+ )airin+. % ? -oint o) the s;itch o) stop si+nal 2 ? -oint o) the s;itch o) stop si+nal ( ? -oint o) the installation o) the comination o) instruments instruments * ? rope o) speedometer , ? scre;s o) )astenin+ 5 ? -oint o) the s;itch o) stop si+nal 01T A14.
=i+. (,. ad-ustment o) )uel pump. % ? controllin+ lever 2 ? the housin+ o) oil pump ( ? marker * ? ad-ustin+ nut. Kou ;ill completely unscre; the handle o) +as 0open the throttle4 and proverJte that the markers on the housin+ o) oil pump and the controllin+ lever coincide. !) necessary ad-ust ;ith the aid o) the ad-ustin+ nut.
=i+. (5. testin+ )uel pump. % ? caruretor 2 ? )uel tue ( ? )astenin+. ith the ;ork o) en+ine at the idlin+ measure a /uantity o) )uel supplied ;ith pump )or %3 s. "ominal volume.................. o) 23 cc
5.* cleaning of air filter ash the )ilterin+ element in ;ashin+ oil a)ter ;hich sli+htly )inish harvestin+ and +ive completely to +et dry. Kou ;ill look around eCterior vie; and state o) porolon. !) porolon has cracks and scalin+s it should e replaced y the ne; )ilterin+ element. ipe ;ith the clean ra+s moistened in the +asoline the internal part o) the cover o) )ilter and the internal cavity o) housin+. Kou ;ill look around the air duct o) )ilter to the caruretor. The casin+ o) )ilter and air duct must not have cracks. !mpre+nate the dry and clean )ilterin+ element e)ore the installation in oil. =or this use special oil )or the impre+nation or another oil ;ith a su))icient viscosity. Kou ;ill distriute oil evenly alon+ the )ilter ut do not t;ist out the )ilterin+ element. =ilter is ready to installation i) it aundantly it is impre+nated ;ith oil on the entire sur)ace and the thickness.
5.+ pressure testing of the end of the compression stro(e %. Turn inside out sparkplu+. 2. Kou ;ill estalish compressometer. (. Kou ;ill completely unscre; the handle o) +as. *. Measure the value o) compression ;ith crankin+ o) cranksha)t y the electric starter 0)re/uency o) rotation not less than 533 rmin4 the nominal pressure......... o) %3 k+s/ cm the reason )or insu))icient compression they can e: a4 The dama+e o) the paddin+ o) the cylinder head 4 The ;ear o) piston rin+s the dama+e o) piston c4 The ;ear o) cylinder.
5., $hec(ing of the bra(e linings 9roverJte the state o) the rake linin+s. a4 press on the rake eams. 4 proverJte the position position o) indicator. !) indicator indicator eCceeds the limits limits o) the Eone sho;n in the the )orm o) marker then should e replaced the rake linin+s.
). -oer unit Attention: removal and dismantlin+ it is main and a++re+ates it is achieved y ;ay o) the numers indicated in the )i+ures. Assemlin+ and installation are accomplished in the order reverse to dismantlin+ and to removal.
=i+. (6. oil pump. &emoval and installation. installation. % ? oil tue 2 ? the tue o) oil )eed ( ? clamp olts o) the racket o) control cale * ? control cale ;ith the racket , ? oil pump.
=i+. (8. oil tank. &emoval and installation. installation. 01,3M4. % ? oil tue 2 ? the -oint o) installation ( ? nut o) )astenin+ * ? clamp olt , ? rear ;in+ 5 ? clamp olt 6 ? oil tank.
=i+. *3. choke. Dismantlin+ and assemlin+. % ? choke 2 ? the rope o) +as ( ? sprin+ o) choke * ? paddin+ , ? cover o) caruretor 5 ? shieldin+ cap 6 ? catch 8 ? lockin+ needle ? clamp .
=i+. *%. 7aruretor. &emoval and installation. % ? choke 2 ? )uel tue ( ? tue o) oil )eed * ? ;ire o) startin+ enricher , ? clamp olts o) caruretor 5 ?
=i+. *2. 7aruretor. Dismantlin+ and assemlin+. % ? cover o) startin+ enricher 2 ? scre;s o) )astenin+ ( ? aout rate * ? startin+ enricher , ?
=i+. *(. petalous valve. Dismantlin+ and assemlin+. % ? clamp olt 2 ? clamp olt ( ? protective housin+ * ? clamp olts , ? inlet pipe 5 ? paddin+ 6 ? petalous valve 8 ? paddin+. paddin+.
=i+. **. )uel tank. &emoval and installation. installation. % ? the -oint o) installation 2 ? holder ( ? sensor o) )uel level * ? packin+ , ? )uel tue 5 ? clamp olt 6 ? cover plate 8 ? )uel tank.
=i+. *,. )uel pump. &emoval and installation 01,3M4. % ? )uel )ilter 2 ? )uel tue ( ? )uel tue * ? vacuum hose , ? clamp olt 5 ? )uel pump 6 ? nut o) )astenin+ 8 ? )uel pump racket
=i+. *6. air )ilter. &emoval and installation 01,3M4. % ? the scre;s o) )astenin+ 2 ? the cover o) air )ilter ( ? )ilterin+ element * ? scre; o) yoke , ? clamp olts 5 ? casin+ o) air o) )ilter 6 ? vent pipe.
=i+. *. remo"al and installation o) motor 01,3M4. % ? installation o) +enerator and electric starter 2 ? ;ire o) startin+ enricher ( ? oil tue * ? )uel tue , ? vacuum hose 5 ? cover o) sparkplu+ 6 ? clamp olt o) rear shock asorer 8 ? control cale o) oil pump ? rope o) rear rake %3 ? nut o) )astenin+ %% ? clamp olt %2 ? en+ine %( ? olt o) the mountin+ racket o) en+ine %* ? mountin+ racket o) the en+ine
=i+. ,%. cylinder head cylinder and piston. &emoval and installation. installation. % ? clamp olts o) cylinder head 2 ? cylinder head ( ? paddin+ o) cylinder head * ? cylinder , ? paddin+ o) cylinder 5 ? check rin+s 6 ? ;rist pin 8 ? piston ? piston rin+s %3 ? dilator o) rin+s %% ? needle earin+ %2 ? upper rin+ rin+ %( ? lo;er rin+.
=i+. ,2. >ackets o) po;er unit. &emoval and installation. %? clamp olts olts rear -acket is 2nd (? (? paddin+ *? clamp olts olts )ront -acket is ,th 5? paddin+ paddin+ 6? the do;el pin.
=i+. ,(. ick? starter. &emoval and installation. %? drive drive +ear it is 2nd 2nd ;asher ;asher (? clamp clamp olt *? pedal pedal o) kick? kick? starter starter it is ,th check check rin+ 5? ;asher ;asher 6? the +ear /uadrant o) kick? starter it is ei+hth return sprin+ ushin+.
).13 chec(ing is the (ic(s of starter %. eri)y kick? starter. A4 eri)y splined ushin+. 4 eri)y the +ear /uadrant o) o) kick? starter. c4 eri)y the +ear the drive o) kick? starter.
=i+. ,*. %? drive +ear it is 2nd retainin+ sprin+ (? the do;el pin .
=i+. ,, %. eri)y the eds eds o) the the aCes aCes o) +ear +ear /uadrant /uadrant and drive drive +ear. +ear.
=i+. ,5.
%? splined splined ushin+ it is 2? return return sprin+ sprin+ (? ushin+.
=i+. ,8. ariator. &emoval and installation. %? +ear o) electric electric starter it it is 2nd 2nd the nut nut o) )astenin+ )astenin+ (? ushin+ ushin+ *? )iCed cheek o) +uide pulley ?elt is ,th 5? nut o) )astenin+ the drum o) cohesion 6? drum o) cohesion the unit o) cohesion and )ollo;er pulley is ei+hth mu)) o) variator %3 clutch o) the variator
=i+. ,. 7lutch o) variator. Dismantlin+ and assemlin+. assemlin+. %? clamp olts olts it is 2nd the cover o) the the clutch o) variator (? the +uidin+ +uidin+ plate plate *? +uidin+ +uidin+ it is is ,th
=i+. 53. nit o) cohesion. Dismantlin+ and assemlin+. %? nut o) )astenin )astenin+ + it is 2nd check check rin+ rin+ (? ;asher ;asher *? oot?tre oot?treee o) cohesion cohesion it is ,th ,th the sprin+ sprin+ o) the oot?trees o) cohesion cohesion 5? damper 6? supportin+ disk disk it is ei+hth the the thrust ushin+ o) sprin+ sprin+ sprin+ o) )ollo;er pulley %3 ushin+ %%? +uide pin %2? moile cheek o) )ollo;er pulley %(?
=i+. 5%. Main drive. Dismantlin+ and assemlin+. %? clamp olt it is 2nd the cover o) reducer reducer (? paddin+ paddin+ *? the the do;el pin it is ,th ;asher 5? output output sha)t 6? ;asher it is ei+hth idlers ;asher %3 input sha)t.
=i+. 52. &emoval o) crankcase %. Turn a;ay clamp olts. 2. 2. &emove the cover o) crankcase.
!nstallation o) crankcase %. Kou ;ill install ri+ht earin+. 2. Kou ;ill install le)t earin+. (. Kou ;ill estalish cranksha)t. *. Kou ;ill estalish the le)t stu))in+ oC
=i+. 5*. 7rankcase. &emoval and installation. %? clamp olts olts it is 2nd the cover o) crankcase crankcase (? paddin+ *? the do;el pin cranksha)t cranksha)t is ,th ,th 5? ri+ht stu))in+ oC 6? le)t stu))in+ oC ri+ht earin+ is ei+hth le)t earin+.
*. $hec(ing and the repair of poer unit %. Kou ;ill clean cylinder head. A4 Kou Kou ;ill ;ill clean remainders remainders o) paddin+ paddin+ and caron caron deposit )rom in-ector in-ector )ace. "ote: "ote: you e care)ul in order not to in-ure the in-ector )ace o) cylinder c ylinder mated ;ith the paddin+. 2. eri)y cylinder head. By precision rule and y )lat proe as sho;n in )i+ure veri)y the nonplanarity o) the ;orkin+ in-ector )ace o) the c ylinder
The maCimum permissile non planarity o) ..................... 332 mm i) the value o) non planarity eCceeds maCimum permissile you ;ill replace cylinder head or +rind it. (. Kou ;ill clean caron caron deposit )rom internal sur)ace sur)ace o) eChaust o) cylinder. cylinder. *. eri)y cylinder. A4 By precision rule and y )lat proe as sho;n in )i+ure ) i+ure veri)y the non planarity o) the sur)ace o) cylinder. The maCimum permissile non planarity o) .................... 332 mm i) the value o) non planarity eCceeds maCimum permissile you ;ill replace cylinder or +rind it.
54 measure the the diameter o) o) cylinder. =i+. 56 y !ndicator? inside calipers measure the diameter o) cylinder at three levels in transverse 0a4 and lon+itudinal 04 directions as sho;n in )i+ure. !) the diameter more than maCimum permissile you ;ill replace it. Diameter o) the cylinder: 1,3M nominal .......... (333?(323 mm maCimum .................... (3,3 mm 1,39 marker A nominal .......... (333?(33, mm maCimum o) .................... (3,3 mi ;ithout the marker nominal .......... (33,?(3%3 mm maCimum .................... (3,3 mm the maCimum conicity o) ...... 33, mm ,. Kou ;ill clean piston. A4 By scraper remove caron deposit and others caronic the deposit NsO piston head. 4 Kou ;ill clean deposits )rom +rooves o) piston piston ;ith the piece o) the roken rin+. rin+. c4 By solvent and y so)t hair hair rush you ;ill ;ill )inally )inally clean piston. "ote: do not use ;ire rush. 5. eri)y piston. A4 y micrometer measure the diameter o) piston skirt o) at a distance * mm rel.un. o) ed+e also in the direction perpendicular to the aCis o) ;rist pin as sho;n in =i+. 63. Diameter o) the piston: 1,3M nominal ......... (8,,?(863 mm minimum ..................... (833 mm 1,39 ;ithout the marker nominal ......... (853?(85, mm
minimum ..................... (833 mm marker A nominal ......... (8,,?(853 mm minimum ..................... (833 mm marker into nominal ......... (85,?(863 mm minimum ..................... (833 mm 6. Kou ;ill ;ill determine determine clearance et;een the cylinder cylinder and the piston a)ter )indin+ a di))erence di))erence in the results o) o) the measurements o) the diameter o) piston and diameter o) cylinder. The nominal clearance o) ...... 33(,?33,3 mm i) clearance is more than nominal you ;ill replace piston and cylinder. 8. eri)y clearance in the piston?rin+ piston?rin+ lock. A4 put piston rin+ into into the cylinder up to the distance distance o) %3 mm )rom the partin+ plane. 4 y )lat proe measure the clearance clearance in the lock =i+. 6% "ominal clearance o) .......... 3%3?32, mm The maCimum clearance o) ................ 3*3 mm i) clearance in the lock is more than maCimum you ;ill replace piston rin+. !) clearance in the lock is more than maCimum even ;ith the ne; piston rin+ you ;ill replace cylinder and piston. . eri)y end clearance compression rin+ ? piston +roove a)ter measurin+ y its )lat proe as sho;n in =i+. 6(. "ominal clearance o) .......... 33(?33, mm =i+. 62 maCimum clearance o) ................ 3%3 mm i) the clearance it is more permitted you ;ill replace piston. %3. eri)y ;rist pin. 0=i+. 6*4 a4 9ut piston the )in+er you ;ill e convinced ;ith the earin+ into the connectin+?rod connectin+?rod end that the )in+er it pivots ;ithout the perceptile +ap. 4 By inside calipers measure the inside ore diameter under the )in+er in the piston. "ominal =i+. 6( diameter o) ................. ... %2332?%2338 mm the maCimum diameter o) ...... %23(3 mm c4 usin+ a micrometer micrometer measure the diameter o) ;rist pin. pin. "ominal diameter o) .......... %%*?%2333 mm the minimum diameter o) ....... %%83 mm i) it is necessary you ;ill replace piston and ;rist pin in the collection. %%. eri)y cohesion. =i+. 6* a4 Measure internal the diameter o) the drum o) cohesion. The nominal diameter o) ........................ %363?%362 mm the maCimum diameter o) ........ %36, mm 4 measure the thickness o) the )riction linin+.
=i+. 6, "ominal thickness o) o) ........ *3?*% mm the minimum thickness o) ............. 23 mm %2. eri)y the clutch o) variator. a4 eri)y the sur)aces o) moile moile and stationary cheeks. 4 Measure Measure the diameter o) o) ushin+. ushin+. The nominal thickness o) .................. 233(,?2338, mm the minimum thickness o) ....... 23533 mm c4 eri)y the diameter o) roller. "ominal diameterP.%,2?%538 diameterP.%,2?%538 mm the minimum diameter o) ......... %,*3 mm %(. eri)y ?elt. 0=i+. 664 a4 eri)y the sur)ace condition o) elt 0%4. 4 Measure the ;idth o) elt 024. "ominal ;idth o) ............... %,, mm Minimum ;idth o) ............... %*, mm %*. eri)y )ollo;er pulley. 0=i+. 684 a4 eri)y sur)ace condition moile and )iCed o) 4 eri)y and you ;ill i) necessary replace stu))in+ c4 eri)y the smoothness o) the the rotation rotation o) pulley. pulley. +4 veri)y the len+th o) unloaded sprin+. "ominal len+th o) .................. 8% 8% mm The minimum minimum len+th o) .................. 28 mm
=i+. 65
=i+. 66
pulleys. oC.
=i+. 68 %,. eri)y electric starter. a4 eri)y the state o) )ly;heel and idlers. %5. 7heckin+ main drive. a4 eri)y the state the driven +ear o) main drive sha)t idlers slave +ear. 4 eri)y the state the radial earin+s o) driven +ears. %6. eri)y cranksha)t.
a4 eri)y the end o) cranksha)t. MaCimum end o) .............. 33* mm
+. /he undercarriage Attention: removal and the dismantlin+ o) units and a++re+ates is achieved y ;ay o) numers indicated in the )i+ure. Assemlin+ and installation is accomplished in the order reverse to dismantlin+ and to removal.
=i+. 6. &emoval and the installation o) )ront ;heel 01,3M4
%? 1cre; o) o) )astenin+ )astenin+ the rope rope o) speedom speedometer eter is 2nd 2nd (? the the nut o) )ront )ront rake rake *? Nvtup NvtupkaO kaO o) rake rake eams the rope o) )ront rake is is ,th 5? nut o) aCis 6? aCle o) )ront )ront ;heel it is ei+hth ushin+ ushin+ )ront ;heel %3 )ront ;in+ %%? unit o) )ront rake %2? anther %(? le)t earin+ %*? the spacin+ collar %,? ri+ht earin+.
+.2 chec(ing of the unit of front bra(e %. Measur Measuree the )ree )ree moti motion on o) rak rakee eams and ;ith the need ad-ust it. "ominal motion y .................... %3? 23 mm 2. Measure the diameter o) the internal sur)ace o) rake drum. "ominal diameter o) ............ ,3 mm the maCimum diameter o) .......... ,, mm (. Measure the thickness o) the rake linin+s. "ominal thickness o) o) .............. (3 mm the minimum thickness o) .............. 23 mm =i+. 83. %? anther le)t earin+ is 2nd (? the spacin+ collar *? ri+ht earin+.
=i+. 8%. Dismantlin+ and the assemly o) the unit o) )ront rake 01,3M4. %? rake shoes ;ith the sprin+s clamp clamp olt is is 2nd (? lever *? indicator indicator o) the ;ear o) o) cover plates plates it is ,th return sprin+ 5? unclaspin+ )ist 6? stu))in+ oC o) unclaspin+ )ist anther is ei+hth +ear o) speedometer %3 housin+ o) the unit o) the )ront rake
=i+. 82. The steerin+ column 01,3M4. Dismantlin+ and assemlin+. %? nut o) )astenin+ the steerin+ column it is 2nd upper lid (? the steerin+ column *? lo;er cover it is ,th earin+s 5? earin+ cap 6? clamp olts it is ei+hth )astenin+ )ront ;in+ clamp olt %3 )ront )ork.
=i+. 8(. =ront )ork 01,3M4. Dismantlin+ and assemlin+. %? cover o) the )eather o) )ront )ork anther is 2nd (? check rin+ *? ushin+ it is ,th ,th the sprin+ o) the motion motion o) return 5? )iCed pipe pipe o) the )eather o) )ront )ork 6? sprin+ o) the )eather o) )ront )ork ruer damper is ei+hth moile tip.
8.( Torr system ;ith the disk )ront rake 01,3M4
=i+. 8*. =ront ;heel. &emoval and installation. installation.
%? scre; o) )astenin+ )astenin+ the rope o) speedometer speedometer the rope o) speedometer speedometer is 2nd (? the nut o) aCis *? *? ;heel aCle it is ,th )ront ;heel 5? ushin+ 6? drive o) the speedometer
Handle o) +as. &emoval and installation. %? nut o) )astenin )astenin+ + the link link olt o) the the lever o) )ront )ront rake rake is 2nd (? the the lever o) )ront )ront rake rake *? rope o) )ront rake clamp olt is ,th 5? the upper lid o) the handle o) +as 6? racket o) the lever o) )ront rake the rope o) +as is ei+hth handle o) +as.
=i+. 8,. &etardin+ disc. &emoval and installation.
%? anther ri+ht earin+ is 2nd (? the spacin+ collar *? le)t earin+ it is ,th the clamp olts o) retardin+ disc 5? retardin+ disc.
=i+. 85. Brake support. &emoval and installation. installation. %? clamp olt olt it it is 2nd +uide +uide )in+er )in+ers s (? the rake rake linin+s linin+s *? plate. plate.
=i+. 86. Master rake cylinder c ylinder 01,3M4. Dismantlin+ and assemlin+. assemlin+. %? scre;s o) )astenin+ cylinder cover it is 2nd cylinder cover (? the memrane *? ypass olt and ;asher rake hose is ,th 5? the link olt o) rake eams 6? rake eams it is ei+hth the clamp olts o) holder holder o) cylinder %3 rake cylinder in the collection %%? scre;s o) )astenin+ the s;itch o) stop si+nal %2? s;itch o) stop si+nal %(? ushin+ %*? check rin+ %,? valve %5? sprin+. 7heckin+ )ront disk rake %. Measure the )ree motion o) rake eams and i) necessary ad-ust it. "ominal motion y ................... %3?23 mm 2. Measure the diameter o) the piston o) master rake cylinder. "ominal diameter o) ............ %3,6?%38* %3,6?%38* mm the minimum diameter o) ....... %3%3 mm (. Measure the diameter o) master rake cylinder. "ominal diameter o) .................... %%333?%%3*( mm the maCimum diameter o) ........ %%3, mm *. Measure the diameter diameter o) the piston piston o) )ront rake. rake. "ominal diameter o) .................... (3%*8?(3%8 mm the minimum diameter o) ........ (323 mm ,. Measure the diameter o) o) the cylinder o) o) )ront rake. "ominal diameter o) .................... (32(3?(3283 mm the maCimum diameter o) ........ %%3, mm 5. Measure the thickness o) retardin+ disc. "ominal thickness thickness o) .............. (3 mm the minimum thickness o) .............. 2, mm
=i+. 88. 1upport o) )ront rake 01,3M4. Dismantlin+ and assemlin+. %? ypass ypass olt and and ;asher ;asher it is 2nd the the cover o) +uide +uide o) )in+er )in+er (? the clamp clamp olts olts o) support support *? Torr support it is ,th the +uide )in+ers o) oot?trees 5? rake shoes 6? ad-ustin+ plate it is ei+hth unclaspin+ sprin+ +uide )in+er %3 racket o) support %%? cover o) +uide o) )in+er %2? ushin+ %(? piston piston %*? case %,? collar.
8.* &ear suspension and the rear rake
=i+. 8. Dismantlin+ and assemlin+ rear rake. %?ad-ustin+ nut it is 2nd the ushin+ o) lever (? the rope o) rear rake *? rake shoes ;ith the sprin+s the clamp olt o) lever is ,th 5? lever o) rear rake 6? return sprin+ the indicator o) the ;ear o) the rake linin+s is ei+hth stu))in+ oC %3 unclaspin+ )ist %%? travel limiter o) oot?tree.
=i+. 3. &emoval and the installation o) shock asorer. %? lo;er clamp clamp olt olt upper upper clamp clamp olt is 2nd 2nd (? rear rear shock shock asorer. asorer.
=i+. %. Dismantlin+ and assemlin+ shock asorer. %? ushin+ it is 2nd the the +rommet +rommet (? the lo;er lo;er openin+ o) )astenin+ )astenin+ *? sprin+ sprin+ it is ,th the lock nut 5? ruer damper 6 ? QRSU VWXYZ[\ shock asorer is ei+hth.
%. &emove ushin+. 2. &emove the +rommet. (. &emove the lo;er lo;er openin+ o) )astenin+. )astenin+. *. &emove sprin+.
,. Turn a;ay the lock nut. 5. &emove ruer damper. 6. &emove the saddle o) sprin+. 8. &emove shock asorer. Assemlin+ shock asorer is produced in the order reverse to its dismantlin+.
=!'. (
,. %lectrical e&uipment is 0ote. =or the desi+nation o) the colors o) ;ires the )ollo;in+ reductions are used: B is ;hite 7h is lack r ? red NchO ? ro;n h is yello; yello; ith dark?lue (? +reen +reen N&EO ? pink 1r ? +ray Aout the oran+e T ? dark +reen NTchO ? dark ro;n. !n this case the )irst part o) the desi+nation indicates the primary color o) ;ire the second 0i) there is4 ? the color o) strips.
=i+. *. Arran+ement o) the elements o) electrical e/uipment. %? interrupter recti)ier recti)ier is 2nd 2nd (? o) the relay o) starter *? *? stora+e attery attery electric starter is ,th 5? it it soaked i+nitions 6? s;itch o) sound si+nal the s;itch o) turn indicators is ei+hth s;itch o) the li+ht o) headli+ht %3 li+ht s;itch %%? s;itch o) starter %2? resistor %(? ;indin+ o) i+nition %*? alternator %,? i+nition coil %5? i+nition coil.
,.1 /he storage attery
=i+. ,. %? scre;s o) )astenin+ the cover o) stora+e stora+e attery attery it is 2nd 2nd cover (? (? ne+ative terminal *? positive terminal it is ,th stora+e attery.
=!'. 6
=!'. 5
$hec(ing storage battery %. eri)y stress stress on the outpu outputs ts o) o) stora+e stora+e attery attery i) it lo;er lo;er than nominal nominal you ;ill load stora+e stora+e attery. 0=i+. 54 nominal stress. %(3?%(2 NvO minimum stress ......... %2( NvO 2. eri)y ;ith the the aid o) the ammeter the asence o) closin+ to to the mass o) electrical e/uipment. e/uipment. MaCimum current o) ........................ % mA 0=i+. 64
,.2 Regulator of "oltage rectifier veri)y resistance et;een the outputs o) the r ecti)ier
=!'. 8
,.3 Generator 7heckin+ on the en+ine eri)y eri)y stress issued y +enerator. a4 Kou ;ill ne+lect en+ine. 4 Kou ;ill ;ill include illumination the s;itch o) the li+ht li+ht o) headli+hts ? to the position H!. H!. c4 Measure the stress. "ominal stress 0;ith ,333 aoutmin4 ................ %25?%(5 NvO
=!'.
=i+. %33. Dismantlin+ and assemlin+ +enerator. %? clamp olt )an housin+ housin+ is 2nd 2nd (? clamp olt *? coolin+?system )an it is is ,th )lan+ed )lan+ed nut 5? rotor 0)ly;heel4 6? key the ;ire o) +enerator is ei+hth -oint o) starter %3 clamp olt %%? clamp olt o) pulse +enerator %2? pulse +enerator %(? clamp olt o) stator %*? stator %,? the protective ushin+
$hec(ing Generator %. eri)y ;indin+ impedance o) +enerator. +enerator. "ominal resistance: The ;indin+ o) char+in+ .............. 32?%3
,.4 interrupter bloc( $DI Measure the resistance et;een the conclusions o) the -oint o) the interrupter: ire &esistance
,.5 Ignition coil Measure the resistance o) the primary ;indin+ o) i+nition coil. "ominal resistance: Dio .......................... ............ 32?3(
=i+. %3( =i+. %3*
,.) $hec(ing the angle ignition ad"ance eri)y the lead an+le o) i+nition ;ith the )re/uency o) rotation %833 aoutmin. "ominal lead an+le o) the i+nition o) ........ %6](^NdoMTO
=i+. %3,
=i+. %32
,.* /he !tarter
=i+. %35. &emoval and the installation o) starter. %? clamp olt the racket o) control cale o) oil oil pump is is 2nd (? (? the clamp clamp olt o) o) starter *? starter it is ,th
=i+. %36. Dismantlin+ and assemlin+ starter. %? clamp olt stator is 2nd (? anchor anchor *? rush rush holder it is ,th sprin+ sprin+ 5?
,.+ !ensor of uel e"el Measure the resistance et;een the outputs o) the sensor o) )uel level ;ith di))erent position o) )loat.
=!'. %38 7onclusions +reen? yello;;hite +reen? are dark?lue;hite ar are yello;;hite? dark?lue;hite
9osition o) the )loat upper lo;er 2,?*%
9.9 sensor of oil level You will connect ohmmeter and will ascertain that with the upper position of float there is no conductivity, and with the lower position there is conductivity between the outputs of sensor. Fig. 109
9.10 lock of ignition Proverte conductivity between the outputs of the loc! of ignition with its different positions, as shown in diagram
=!'. %%3
9.11 Switch of turn indicators Proverte conductivity between the outputs of the switch of turn indicators with its different positions, as shown in diagram.
=!'. %%%
9.12 lamps
Fig. 11". front headlight
F$% 11&
Fig. 11#. $llumination of the combination of the instruments
1 - bolt, " - the loc! of ignition, # - 'oint of the loc! of ignition.
9.13 The steering switches Proverte conductivity between the outputs of light switch with its different positions, as shown in diagram.
=!' %%,
Proverte conductivity between the outputs ()heltyy*!rasnyy and green+ of the switch of starter with its switch oned position.
=!'. %%5 Proverte conductivity between the outputs of the switch of sound signal with its switch oned position. Proverte conductivity between the outputs of the switch of the light of headlights with its different positions, as shown in diagram.
=!'. %%6
Fig. 11. bac!ing lamp. 1 - lamp of rear turn indicators, " - lamp of stop signal, # - glass- stop signal, & - screws of fastening, - glass- turn indicator.
Fig. 119. arrangement of the elements of the system of the drive of support. 1 - the relay of generator, " - the relay of the system of drive, # - 'oint of magnetic valve, & magnetic valve, - loc! of ignition, b - bu))er, / servo drive, - !not of the support
Fig. 1"0. schematic of the system of drive. 1 - storage battery, " - the safety device of yhcha, # - loc! of ignition, & - relay of generator, generator, - magnetic valve, - bu))er, - switch of drive, 9 - servodrive, 10 - relay of the system of drive.
2is.1"1. chematic of electrical e3uipment (4io 506+. 1 - the switch of stop signals, " - the switch of starter, # - light switch, & - loc! of ignition, relay of starter, - storage battery, - regulator of voltage (rectifier+, - sensor of fuel level, 9 sensor of oil level, 10 - right rear turn indicator, 11 - stop signal and rear dimensional fire, 1" left rear turn indicator, 1# - spar!plug, 1& - interrupter (!not 74$+, 1 - starting enricher, 1 generator, 1 - electric starter, 1 - resistor, 19 - sound signal, "0 - switch of the light of headlight, "1 - switch of turn indicators, "" - sound signal, "# - relay of turn indicators, "& - left front turn indicator, " - front headlight, " - right front turn indicator, " - combination of instruments, " - lamp of illumination, "9 - level indicator of fuel, #0 - the pilot lamp of the oil level, #1 - the pilot lamp of e8ceeding allowable speed, #" - the safety device of :, ## - ignition coil
