The scooter

Honda Dio
Manual device on operation
preventive 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 012,3M4
,.* 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.% <il pump
5.2 <il tank
5.( 7hoke
5.* 7aruretor
5., 9etalous valve
5.5 =uel tank
5.6 =uel pump
5.8 Air )ilter
5.: &emoval and installation o) motor
5.%3 Dismantlin+ and assemlin+ en+ine
5.%% 7ylinder head. cylinder and piston
5.%2 >ackets o) po;er unit
5.%( 2ick? starter
5.%* @ariator
5.%, Main drive
5.%5 7arter en+ine
6. 7heckin+ and the repair o) po;er unit
8. Andercarria+e
8.% =ront suspension and )ront rake 012,3M4
8.2 7heckin+ o) the knot o) )ront rake
8.( Torr system ;ith disk )ront rake 012,3M4
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
%. Bith 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
D$ and 1uperDio D$ ;ith the au+mented
en+ine. the disk rakes and the sport
suspension. and also di))erent poluseriynye Dio
D$ ? 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 D$. 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. Bith %::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.
*.% &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 0dependin+ 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. Bith 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.
<ther;ise. ;ith the sharp decrease o) the )re/uency o) rotation centri)u+al cohesion does not mana+e to
disconnect en+ine )rom the transmission and occurs intensive rakin+ y en+ine.
6. al;ays include lo;er eam ;ith the ride on the scooter.
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................12,3M
Honda Tact...................1D,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) 3.8 l
the transmission oil......... o).3.3: l
Honda Tact The )uel tank... o) ,.3 l 01T4H*., l 0A14 motor
oil........................ o) %.2 l
the transmission oil......... o).3.3: l
=i+. (. recommended viscosity o) motor oil
$arburetor
7aruretor............... 9B83 0Dio4 or 9B83B 0Tact4: the diameter o) the choke.................. o) %* mm
=re/uency o) the rotation o) idlin+........................ y %633?%:33 rHmin
Main -et......... o).I88 0Dio4 or 68 0Tact4
!dle -et............ o).I(,
9ressure in the tires: the )ront ;heel............... o) %.2, k+Hcm
the rear ;heel.................. o).2.33 k+Hcm.
%lectrical e&uipment#
1tora+e attery. ............... %2@H (Ah
the lead an+le o) i+nition............... %6 @MT o) sparkplu+:
Dio: "'2....................B9&,H1. B9&5H1. B9&6H1. B9&8H&
Denso.................. B%5=9&. B23=9&. B22=9&. B2*=9&
Tact: "'2....................B&*H1A. B&8H1A
Denso.................. B%*=&?L. B2*=&?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+ column ? checkin+ and the ad-ustment o) the ropes o) the rakes ? checkin+ the
rake linin+s ? checkin+ the stora+e attery ? checkin+ the ;ear o) the tires ? checkin+ the )astenin+ ? the
luricant o) ropes
)''' (m ? the replacement 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 012,3M4.
% ? 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 012,3M4
. % ? 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 012,3M4.
% ? 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 012,3M4.
% ? 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 012,3M4.
% ? 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 plaits o) installation 012,3M4.
% ? the rope o) speedometer. 2 ? the installation o) the lock o) i+nition. ( ? rope o) +as. * ? hose o) )ront
rake. , ? rope o) speedometer. 5 ? rope o) rear rake. 6 ? yokes o) ;ires. 8 ? 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 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. * ? 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+. Bith 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
Bash 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. Bipe ;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 rHmin4. the nominal pressure......... o) %3 k+Hs/ 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 o) indicator. !) indicator eCceeds the limits o) the Eone. sho;n in the )orm o)
marker. then should e replaced the rake linin+s.
). -o.er 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. % ? 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. 012,3M4.
% ? 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 ?
<?rin+ seal. 6 ? paddin+. 8 ? <?rin+ seal. : ? caruretor.
=i+. *2. 7aruretor. Dismantlin+ and assemlin+.
% ? cover o) startin+ enricher. 2 ? scre;s o) )astenin+. ( ? aout rate. * ? startin+ enricher. , ? <?rin+ seal. 5
? scre;s o) )astenin+. 6 ? )loat chamer. 8 ? <?rin+ seal. : ? aCis o) )loat. %3 ? )loat. %% ? needle valve. %2 ?
scre; o) /uality. %( ? idle -et. %* ? main -et. %, ? emulsion tue.
=i+. *(. petalous valve. Dismantlin+ and assemlin+.
% ? clamp olt. 2 ? clamp olt. ( ? protective housin+. * ? clamp olts. , ? inlet pipe. 5 ? paddin+. 6 ?
petalous valve. 8 ? paddin+.
=i+. **. )uel tank. &emoval and 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 012,3M4.
% ? )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 012,3M4.
% ? 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 012,3M4.
% ? 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.
% ? 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+. %( ? lo;er rin+.
=i+. ,2. >ackets o) po;er unit. &emoval and installation.
%? clamp olts. rear -acket is 2nd. (? paddin+. *? clamp olts. )ront -acket is ,th. 5? paddin+. 6? the
do;el pin.
=i+. ,(. 2ick? starter. &emoval and installation.
%? drive +ear. it is 2nd ;asher. (? clamp olt. *? pedal o) kick? starter. it is ,th check rin+. 5? ;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) 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 o) the aCes o) +ear /uadrant and drive +ear.
=i+. ,5. %? splined ushin+. it is 2? return sprin+. (? ushin+.
=i+. ,8. @ariator. &emoval and installation.
%? +ear o) electric starter. it is 2nd the nut o) )astenin+. (? 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+.
%? clamp olts. it is 2nd the cover o) the clutch o) variator. (? the +uidin+ plate. *? +uidin+. it is ,th
<?rin+ seal. 5? small ;ei+hts. 6? moile cheek.
=i+. 53. Anit o) cohesion. Dismantlin+ and assemlin+.
%? nut o) )astenin+. it is 2nd check rin+. (? ;asher. *? oot?tree o) cohesion. it is ,th the sprin+ o) the
oot?trees o) cohesion. 5? damper. 6? supportin+ disk. it is ei+hth the thrust ushin+ o) sprin+. :
sprin+ o) )ollo;er pulley. %3 ushin+. %%? +uide pin. %2? moile cheek o) )ollo;er pulley. %(? <?
rin+ seal. %*? stu))in+ oC. %,? earin+. %5? check rin+. %6? earin+. %8? the )iCed cheek
=i+. 5%. Main drive. Dismantlin+ and assemlin+.
%? clamp olt. it is 2nd the cover o) reducer. (? paddin+. *? the do;el pin. it is ,th ;asher. 5? output
sha)t. 6? ;asher. it is ei+hth idlers. : ;asher. %3 input sha)t.
=i+. 52. &emoval o) crankcase !nstallation o) crankcase
%. Turn a;ay clamp olts. %. Kou ;ill install ri+ht earin+.
2. &emove the cover o) crankcase. 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. it is 2nd the cover o) crankcase (? paddin+. *? the do;el pin. cranksha)t is ,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 po.er unit
%. Kou ;ill clean cylinder head.
A4 Kou ;ill clean remainders o) paddin+ and caron deposit )rom in-ector )ace. "ote: you e
care)ul. in order not to in-ure the in-ector )ace o) cylinder. 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 cylinder
The maCimum permissile non planarity o) ..................... 3.32 mm
i) the value o) non planarity eCceeds maCimum permissile. you ;ill replace cylinder head or +rind
it.
(. Kou ;ill clean caron deposit )rom internal sur)ace o) eChaust o) cylinder.
*. @eri)y cylinder.
A4 By precision rule and y )lat proe. as sho;n in )i+ure. veri)y the non planarity o) the sur)ace o)
cylinder.
The maCimum permissile non planarity o) .................... 3.32 mm
i) the value o) non planarity eCceeds maCimum permissile. you ;ill replace cylinder or +rind it.
54 measure the diameter 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:
12,3M
nominal .......... (:.333?(:.323 mm
maCimum .................... (:.3,3 mm
1D,39
marker LAM
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) ...... 3.3, 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 ;ith the piece o) the roken rin+.
c4 By solvent and y so)t hair rush you ;ill )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:
12,3M
nominal ......... (8.:,,?(8.:63 mm
minimum ..................... (8.:33 mm
1D,39 ;ithout the marker
nominal ......... (8.:53?(8.:5, mm
minimum ..................... (8.:33 mm
marker LAM
nominal ......... (8.:,,?(8.:53 mm
minimum ..................... (8.:33 mm
marker LintoM
nominal ......... (8.:5,?(8.:63 mm
minimum ..................... (8.:33 mm
6. Kou ;ill determine clearance et;een the cylinder and the
piston. a)ter )indin+ a di))erence in the results o) the measurements
o) the diameter o) piston and diameter o) cylinder. The nominal
clearance o) ...... 3.3(,?3.3,3 mm
i) clearance is more than nominal. you ;ill replace piston and
cylinder.
8. @eri)y clearance in the piston?rin+ lock.
A4 put piston rin+ into the cylinder up to the distance o) %3 mm )rom the
partin+ plane.
4 y )lat proe measure the clearance in the lock
=i+. 6%
"ominal clearance o) .......... 3.%3?3.2, 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 Lcompression rin+ ? piston +rooveM. a)ter measurin+ y its )lat proe. as
sho;n in =i+. 6(.
"ominal clearance o) .......... 3.3(?3.3, 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 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) .................... %2.332?%2.338 mm
the maCimum diameter o) ...... %2.3(3 mm
c4 usin+ a micrometer. measure the diameter o) ;rist pin. "ominal
diameter o) .......... %%.::*?%2.333 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) ........................ %36.3?%36.2 mm
the maCimum diameter o) ........ %36., mm
4 measure the thickness
o) the )riction linin+.


=i+. 6, =i+. 65
"ominal thickness o) ........ *.3?*.% mm
the minimum thickness o) ............. 2.3 mm
%2. @eri)y the clutch o) variator.
a4 @eri)y the sur)aces o) moile and stationary cheeks.
4 Measure the diameter o) ushin+. The
nominal
thickness o) .................. 23.3(,?23.38, mm
the minimum thickness o) ....... 23.533 mm
c4 @eri)y the diameter o) roller.
"ominal diameterP.%,.:2?%5.38 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 =i+. 66
Minimum ;idth o) ............... %*., mm
%*. @eri)y )ollo;er pulley. 0=i+. 684
a4 @eri)y sur)ace condition moile and )iCed o) pulleys.
4 @eri)y and you ;ill i) necessary replace stu))in+ oC.
c4 @eri)y the smoothness o) the rotation o) pulley.
+4 veri)y the len+th o) unloaded sprin+.
"ominal len+th o) .................. :8.% mm
The minimum len+th o) .................. :2.8 mm
=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) .............. 3.3* 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 012,3M4

%? 1cre; o) )astenin+. the rope o) speedometer is 2nd. (? the nut o) )ront rake. *? NvtupkaO o) rake
eams. the rope o) )ront rake is ,th. 5? nut o) aCis. 6? aCle o) )ront ;heel. it is ei+hth 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
%. Measure the )ree motion o) rake
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) .............. (.3
mm
the minimum thickness o) ..............
2.3 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 012,3M4.
%? rake shoes ;ith the sprin+s. clamp olt is 2nd. (? lever. *? indicator o) the ;ear o) cover 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 012,3M4.
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 012,3M4.
Dismantlin+ and assemlin+. %? cover o) the )eather o) )ront )ork. anther is 2nd. (? check rin+. *?
ushin+. it is ,th the sprin+ o) the motion o) return. 5? )iCed 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 012,3M4
=i+. 8*. =ront ;heel. &emoval and installation.
%? scre; o) )astenin+ the rope o) speedometer. the rope o) 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+. the link olt o) the lever o) )ront rake is 2nd. (? the lever o) )ront 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.
%? clamp olt. it is 2nd +uide )in+ers. (? the rake linin+s. *? plate.
=i+. 86. Master rake cylinder 012,3M4. Dismantlin+ and 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?%3.:8* 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 o) the piston o) )ront. rake.
"ominal diameter o) .................... (3.%*8?(3.%:8 mm
the minimum diameter o) ........ (3.2:3 mm
,. Measure the diameter o) the cylinder o) )ront rake.
"ominal diameter o) .................... (3.2(3?(3.283 mm
the maCimum diameter o) ........ %%.3, mm
5. Measure the thickness o) retardin+ disc.
"ominal thickness o) .............. (.3 mm
the minimum thickness o) .............. 2., mm
=i+. 88. 1upport o) )ront rake 012,3M4. Dismantlin+ and assemlin+.
%? ypass olt and ;asher. it is 2nd the cover o) +uide o) )in+er. (? the clamp olts o) 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. %*? 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 olt. upper clamp olt is 2nd. (? rear shock asorer.
=i+. :%. Dismantlin+ and assemlin+ shock asorer.
%? ushin+. it is 2nd the +rommet. (? the lo;er openin+ o) )astenin+. *? sprin+. it is ,th the lock nut.
5? ruer damper. 6 ? QRSTU VWXYZ[\. shock asorer is ei+hth.
%. &emove ushin+.
2. &emove the +rommet.
(. &emove the lo;er openin+ o) )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. 2r ? red. N2chO ? ro;n. Dh is yello;. Bith dark?lue. (? +reen. N&EO ? pink. 1r ? +ray. Aout
the oran+e. TD ? dark +reen. NT2chO ? 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 is 2nd. (? o) the relay o) starter. *? stora+e attery. electric starter is ,th. 5? 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 1attery
=i+. :,.
%? scre;s o) )astenin+ the cover o) stora+e attery. it is 2nd cover. (? ne+ative terminal. *? positive
terminal. it is ,th stora+e attery.
=!'. :6 =!'. :5
$hec(ing storage battery
%. @eri)y stress on the outputs o) stora+e attery. i) it lo;er than nominal. you ;ill load stora+e
attery. 0=i+. :54
nominal stress. %(.3?%(.2 NvO
minimum stress ......... %2.( NvO
2. @eri)y ;ith the aid o) the ammeter the asence o) closin+ to the mass o) electrical e/uipment.
MaCimum current o) ........................ % mA 0=i+. :64
,.2 Regulator of "oltage 2rectifier3
veri)y resistance et;een the outputs o) the recti)ier
=!'. :8
,.3 Generator
7heckin+ on the en+ine
@eri)y stress. issued y +enerator.
a4 Kou ;ill ne+lect en+ine.
4 Kou ;ill include illumination. the s;itch o) the li+ht o) headli+hts ? to the position LH!M.
c4 Measure the stress.
"ominal stress
0;ith ,333 aoutmin4 ................ %2.5?%(.5 NvO
=!'. ::
=i+. %33. Dismantlin+ and assemlin+ +enerator.
%? clamp olt. )an housin+ is 2nd. (? clamp olt. *? coolin+?system )an. it is ,th )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.
"ominal resistance:
The ;indin+ o) char+in+ .............. 3.2?%.3 <hm is
the ;indin+s o) illumination ......... 3.%?3.8 <hm
2. Measure the resistance o) resistor.
"ominal resistance:
5.6 3NmO. ,N@tO o) ...................... *.6?,.(N<mO
,.: <hm. (3 B .................... ,.5?5.2 <hm

=i+. %3%
,.4 interrupter 2bloc( $DI3
Measure the resistance et;een the conclusions o) the -oint o) the interrupter:
Bire &esistance. <hm are
#Ccitation ;indin+ lack? red+reen ,33?:33
9ulse +enerator dark?lue? yello;+reen ,3?233
!+nition coils lack? yello;+reen 3.2?3.(
,.5 Ignition coil
Measure the resistance
o) the primary ;indin+ o) i+nition coil.
"ominal resistance:
Dio ...................................... 3.2?3.( <hm
Tact .................................... 3.%?3.* <hm
Measure the resistance
the secondary ;indin+ o) i+nition coil.
"ominal resistance:
;ith the tip o) the spark plu+:
Dio .................................... 8.2?:.( kilohms
<) tact o) ................................. 5.(,?:.6 kilohms
;ithout the tip o) spark plu+P 2.6?(.* kilohms =i+. %32
=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](^Ndo@MTO
=i+. %3,
,.* /he !tarter
=i+. %35. &emoval and the installation o) starter.
%? clamp olt. the racket o) control cale o) oil pump is 2nd. (? the clamp olt o) starter. *? starter.
it is ,th <?rin+ seal. 5? -oint o) starter.
=i+. %36. Dismantlin+ and assemlin+ starter.
%? clamp olt. stator is 2nd. (? anchor. *? rush holder. it is ,th sprin+. 5? <?rin+ seal. 6? )ront cover
o) starter.
,.+ !ensor of 4uel 5e"el
Measure the resistance et;een the outputs
o) the sensor o) )uel level ;ith di))erent
position o) )loat.
=!'. %38
7onclusions 9osition o) the )loat
upper lo;er
+reen? yello;;hite 2,?*% <hm *,3?6,3 <hm
+reen? are dark?lue;hite *(3?633 <hm 2,?*% <hm
are yello;;hite? dark?lue;hite *,3?6,3 <hm *,3?6,3 <hm
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 Fig. 11#. $llumination of the combination of the
instruments
F$% 11& 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 y0hcha, # - loc! of ignition, & - relay of generator, - -
generator, 1 - magnetic valve, . - bu))er, , - switch of drive, 9 - servodrive, 10 - relay of the
system of drive.
2is.1"1. 0chematic of electrical e3uipment (4io 05-06+.
1 - the switch of stop signals, " - the switch of starter, # - light switch, & - loc! of ignition, - -
relay of starter, 1 - 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, 11 -
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, "1 - 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 9:, ## - ignition
coil