Informações Técnicas - Burgman
Informações Técnicas - Burgman
CONTENTS
                                                                                    7
                                        SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
      COMPLAINT               SYMPTOM AND POSSIBLE CAUSE                              REMEDY
 ENGINE ABNORMAL
                        EXCESSIVE VALVE VIBRATION
 NOISE
                        1.excessive throttle play                             Adjust
                        2.reduced elasticity or damage of valve spring        Replace
                        3. swing arm wear or cam surface wear                 Replace
                        4 camshaft neck wear or damage                        Replace
                        ABNORMAL NOISE IN CYLINDER
                        1.piston wear or cylinder wear                        Replace
                        2.serious carbon deposit in combustion chamber        Clean
                        3.piston pin wear or piston pin hole wear             Replace
                        4.piston ring wear or ring groove wear                Replace
                        ABNORMAL NOISE OF CAMSHAFT DRIVE CHAIN
                        1.stretched drive chain                               Replace
                        2.worn sprocket gear teeth                            Replace
                        3.tension adjuster failure                            Repair or replace
                        ABNORMAL NOISE OF CLUTCH
                        1.wear or slippage of drive belt                      Replace
                        2.wear of driving pulley roller                       Replace
                        ABNORMAL NOISE OF CRANK LEVER
                        1.crank rod bearing wear or burn                      Replace
                        2.crank rod big end bearing wear or burn              Replace
                        3.crank bearing wear or burn                          Replace
                        4.excessive thrust play                               Replace or adjust thrust pad
                                                       7-1
                                    SERVICING INFORMATION
                                                  7-2
                                       SERVICING INFORMATION
CARBURETOR
      COMPLAINT              SYMPTOM AND POSSIBLE CAUSE                                          REMEDY
 DIFFICULT STARTING    1.primer nozzle clogging                                         Clean
                       2.fuel pipe clogging                                             Clean
                       3.primer air strainer clogging                                   Clean or replace
                       4.air leakage at carburetor joint or vacumm tube joint           Inspect and adjust
                       5.poor priming plunger performance                               Inspect, adjust or replace
 UNSTABLE IDLE SPEED   1.clogging or looseness of starting nozzle or idle air nozzle    Inspect and clean
 OR LOW SPEED          2.air leakage at carburetor joint, vacuum tube joint or primer   Inspect and adjust
                       3.clogging of idle outlet                                        Inspect and clean
                       4.incomplete closing of priming plunger                          Inspect and adjust
 UNSTABLE MEDIUM       1.clogging of main jet or primary air jet                        Inspect or clean
 SPEED OR HIGH         2.clogging of main jet nozzle                                    Inspect or clean
 SPEED                 3.poor throttle valve operation                                  Inspect throttle valve operation
                       4.clogging of fuel filter                                        Inspect and clean
                       5.poor accelerator pump piston                                   replace
                                                     7-3
                                        SERVICING INFORMATION
ELECTRICAL
      COMPLAINT               SYMPTOM AND POSSIBLE CAUSE                                         REMEDY
 SPARK PLUG WITH NO     1.poor ignition coil or poor CDI                                  Replace
 SPARK OR WITH WEAK     2.poor spark plug                                                 Replace
 SPARK                  3.poor trigger coil                                               Replace
                        4 .loose wire connection                                          Tighten
 GENERATOR CHARGE       1.short circuit, open circuit or loose connection                 Repair or retighten
 BELOW SPECIFICATION    2.earthing of generator stator coil or open circuit               Replace
                        3.poor stabilized rectifier                                       Replace
                        4.poor battery plate in storage battery                           Replace storage battery
                                                      7-4
                                        SERVICING INFORMATION
BATTERY
      COMPLAINT                SYMPTOM AND POSSIBLE CAUSE                                             REMEDY
 STORAGE BATTERY
 PLATE SURFACE WITH     1.storage battery case with fissure                                 Replace storage battery
 WHITE ACIDIC POWDERY   2.long period of battery storage                                    Replace storage battery
 SUBSTANCE OR STAINS
 STORAGE BATTERY        1.incorrct charging system                                          Inspect generator, stabilized
 CONSUMPTION TOO                                                                            rectifier and electric terminals,
 FAST                                                                                       effect necessary adjustment
                                                                                            to ensure specified charging
                        2.battery plate with no active substance due to overcharging        Replace storage battery and
                                                                                            rectify charging system
                        3.short circuit in storage battery                                  Replace storage battery
                        4.storage battery voltage too low                                   Recharge storage battery
                        5.stale storage battery                                             Replace storage battery
 STORAGE BATTERY        1.overcharging or undercharging (When storage is not in use,        Replace battery
 SULPHATION               inspect it at least once a month to prevent it from sulphation)
                        2.storage battery not in use for a long time in cold weather        In case of serious sulphation,
                                                                                            replace storage battery
 STORAGE BATTERY
                        dirty battery top and flanks                                        clean
 DISCHARGE TOO QUICK
                                                       7-5
                                     SERVICING INFORMATION
CHASSIS
 HANDLEBAR SWING     1.imbalance between right front fork and left front fork   Replace
                     2.bent front fork                                          Repair or replace
                     3.bent front wheel axle or tilted tire                     Replace
 REAR SHOCK
                     1.wear of crankcase bush                                   Replace
 ABSORBER TOO SOFT
                                                      7-6
                                     SERVICING INFORMATION
BRAKE
      COMPLAINT            SYMPTOM AND POSSIBLE CAUSE                             REMEDY
 POOR BRAKING       1.brake fluid leakage                                 Repair or replace
 (FRONT, REAR)      2.wear of brake caliper lining                        Replace
                    3.sticky oily friction lining surface                 Clean brake disc and
                                                                          friction lining
                    4.wear of brake disc                                  Replace
                    5.air in hydraulic system                             Exhaust air
                    6.wear of brake shoe lining                           Replace
                    7.oily brake shoe lining                              Replace
                    8.excessive wear of wheel hub                         Replace
                    9.brake rod play too large                            Adjust
 SHRILL BRAKING     1.friction lining with hard matter                   Rub surface with sandpaper
 NOISE              2.brake caliper friction lining tilted               Adjust or replace friction lining
                    3.damage of wheel bearing                            Replace
                    4.loose front axle or rear axle                      Tighten to specified torque
                    5.wear of friction lining                            Replace
                    6.foreign matter in brake fluid                      Replace brake fluid
                    7.clogging of main oil cylinder return port          Disassemble and clean
                                                                         main oil cylinder
                    8.smoothening of brake shoe                          Rub surface with sandpaper
                    9.wear of brake shoe                                 Replace
 EXCESSIVE TRAVEL   1.air in hydraulic system                            Exhaust air
                    2.inadequate brake fluid                             Add brake oil to specified
 OF BRAKE LEVER
                    3.unqualified brake fluid                            oil level; exhaust air and
                                                                         replace brake fluid with
                                                                         qualified brake fluid
                    4.wear of brake lever cam                            Replace
                    5.excessive wear of brake shoe lining or wheel hub   Replace
 BRAKE FLUID        1.inadequate fastening of joint                      Tighten to specified torque
                    2.fissure in hose                                    Replace
 LEAKAGE
                    3.wear of piston or wear of piston seal ring         Replace piston or piston
                                                                         seal ring
                                                    7-7
                                       SERVICING INFORMATION
TIGHTENING TORQUE
ENGINE
                       ITEM                                    N·m      kg·m
         Oil filter cap bol ts                                 8~12     0.8~1.2
         Crankcase bol t                                       8~12     0.8~1.2
         Tensi oner sdj ust er mount ing bol t                 8~12     0.8~1.2
         Oil st rai ner cap bol ts                             8~12     0.8~1.2
         Star ter bol t                                        8~12     0.8~1.2
         Fan bol ts                                            8~12     0.8~1.2
         Clut ch cover bol t                                   8~12     0.8~1.2
         Oil dr ai n bol t                                     15~20    1.5~2.0
         Cyl inder head nut                                    23~27    2.3~2.7
         Cam chai n tensi oner bol t                           10~12    1.0~1.2
         Oil level pl ug                                       9~15     0.9~1.5
         Gear box cover bol t                                  8~12     0.8~1.2
         Magnet o rot or nut                               110~130     11.0~13.0
         Cyl inder head si de bol t                            8~12     0.8~1.2
         Cyl inder head cover bol t                            12~16    1.2~1.6
         Drive di sc nut                                       40~60    4.0~6.0
         Clut ch out di sc nut                                 65~85    6.5~8.5
         Kick st ar ter bol t                                  23~28    2.3~2.8
         Gear box oi l dr ai n bol t                           8~12     0.8~1.2
         Oil st rai ner cover check bol t                      9~15     0.9~1.5
                                                 7-8
                                                  SERVICING INFORMATION
CHASSIS
                                   ITEM                                     N·m                     kg·m
             Eng ine mou nt ing bo lt                                      70-100                  7.0-10.0
             Eng ine br acke t mou nting bo lt                             80-100                  8.0-10.0
             Stee ring stem lock nu t                                       25-35                   2.5-3.5
             Fron t axl e nu t                                              32-52                   3.2-5.2
             Rea r axl e nu t                                              102-138                 10.2-13.8
             Fron t sho ck ab sor be r low er cl am p bo lt                 18-28                   1.8-2.8
             Rea r sho ck ab sor be r up pe r cl am p bo lt                 22-35                   2.2-3.5
             Rea r sho ck ab sor be r low er cl am p bo lt                  22-35                   2.2-3.5
             Fron t br ake cal ipe r bo lt                                  20-31                   2.0-3.1
             Fron t br ake di sc bo lt                                      18-28                   1.8-2.8
             Fron t br ake flui d pi pe bo lt                               20-25                   2.0-2.5
             Fron t br ake flui d dr ai n bo lt                             7-10                    0.7-1.0
             Han dl eb ar cl am p nu t                                      40-50                   4.0-5.0
             Han dl eb ar po si tion ing bo lt                              22-28                   2.2-2.8
             Exha ust pi pe mou nting nu t                                  24-28                   2.4-2.8
             Muff ler cl am p bo lt                                         11-15                   1.1-1.5
                                                               7-9
                                        SERVICING INFORMATION
SERVICE DATA
VALVE + GUIDE                                                                 Unit: mm
               ITEM                                  STANDARD              LIMIT
                                        IN.                  24.9-25.1
 Valve diam
                                        EX.                  21.9-22.1
 Valve guide to valvestem clearance   IN. or EX.            0.010-0.037
                                         IN.                 0.05-0.08
 Valve clearance(when cold)
                                        EX.                  0.10-0.13
 Valve stem deflection                IN. or EX.                            0.35
 valve guide I.D.                     IN. or EX.            5.000-5.012
                                         IN.                4.975-4.990
 Valve stem O.D.
                                        EX.                 4.955-4.970
 Valve stem runout                    IN. or EX.                            0.05
 Valve head thickness                 IN. or EX.                            0.5
 Valve stem end length                IN. or EX.                            2.8
 Valve seat width                     IN. or EX.               0.9-1.1
 Valve head radial runout             IN. or EX.                            0.03
                                         IN.                               32.83
 Valve spring free length
                                        EX.                                32.83
                                                   7-10
                                        SERVICING INFORMATION
CLUTCH                                                                                                     Unit: mm
                 ITEM                                   STANDARD                                        LIMIT
  Clutch wheel I.D.                                     110.00-110.15                                  110.50
  Clutch shoe thickness                                       3.0                                        2.0
CARBURETOR
             ITEM                  STD/SPEC.                           ITEM                        STD/SPEC.
  Carburetor type                   SVR22                Jet needle               (J.N.)   4U24
  Bore size                                              Needle jet               (N.J.)   φ1.0
  I.D.number                       33GB 8L01             Throttle valve        (Th.V.)     12O
  Idle rpm                       1600±100 r/min          Pilot jet             (P.J.)      φ0.32
  Float height                    25±0.5 mm              Starter jet           (G.S.)      φ0.42
  Main jet           (M.J.)          φ1.0                Pilot screw            (P.S.)     PRE-SET(2,1/2)turn back
  Main air jet      (M.A.J.)         φ 0.8               Throttle cable play               0.5-1.0mm
                                                      7-11
                                             SERVICING INFORMATION
ELECTRICAL
              ITEM                                           STD/SPEC.                            NOTE
 Timing                                              at 1600rpm 10°B.T.D.C.
                                            Type             NGK CR6HSA
 Spark plug
                                            Gap                0.6-0.7 mm
 Spark performance                           Over 8mm at 1 atmospheric pressure unit
                                                                                           electroprobe
                                          Primary                  0.09-0.13 Ω             electroprobe
 Ignition coil resistance                                                                  spark plug cap
                                         Secondary                 4.96-7.44kΩ             electroprobe
 Generator no-load voltage                              Over 70V/5000rpm         (AC)      In cold engine state
 Regulated voltage                                           14.5±0.5V
                      Type                                  MTX7A-BS
 Battery             Capacity                                   12V(6Ah)
              Standard eletrolyte S.G.                  1.320±0.01(20°C)
 Fuse size                                                        15 A
                                            Full                           10 Ω
 Fuel level gauge resistance
                                           Empty                           90 Ω
WATTAGE                                                                                                Unit :W
           ITEM                          STD/SPEC.                        ITEM             STD/SPEC.
                      high                  35               Odometer light                      2
 Headlight
                      low                   35               Turn signal indicator light         2
 Position light                             5                High beam indicator light           2
 Tail/brake light                          5/21
 Turn signal light                          10
                                                         7-12
                                        SERVICING INFORMATION
SUSPENSION                                                                                                Unit: mm
          ITEM                   STANDARD                                LIMIT                     NOTE
Front fork stroke                      80
Front fork spring free length                                            244.0
Rear wheel travel                      85
Front fork oil level                   81
TIRE PRESSURE
        Cold state                      Single rider                                      Two riders
                                 KPa                    kg/cm                       KPa                kg/cm
                                                                2                                             2
       Tire pressure
         Front tire              125                     1.25                       125                1.25
         Rear tire               225                     2.25                       225                2.25
FUEL + OIL
              Item                                            Standard                                 Note
                                  Gasoline used should be graded 90 octane or higher.
  Fuel type
                                  An nonleaded gasoline type is recommended.
  Fuel tank capacity                                                6L
  Engine oil and gear oil type           SAE10W-40, API SF or SG with JASO MA
                                         Change                            900ml
  Engine oil capacity
                                       Filter change                      1 000ml
                                         Change                             90ml
  Gear oil capcity
                                         Overhaul                           110ml
 Front shock absorber oil type                                 Mx46#
 Front shock absorber oil
                                                              85±2ml
 capacity (each leg)
 Brake fluid type                                       DOT3 or DOT4
                                                       7-13
                                                 SERVICING INFORMATION
SPECIAL TOOLS
The tools listed in the table are incomplete and are for reference purposes only; for specific uses,
please refer to the tools listed in the above maintenance section.
09900-21304                                          09900-22401
V-block (set)             09900-22302                small bore gauge    09900-25002               09910-20116
(100mm)                   plasti-gauge               (10~18mm)           circuit tester            connecting rod bracket
                                                                         09915-64510
                                                                         pressure gage
09913-75830               09913-76010                09914-24510         09915-63310
bearing mounting device   bearing mounting device    T-bar               (adapter)
                                                              7-14
SERVICING INFORMATION
                   09916-21110
                   valve seat cutter kit
                   09916-34580
                   throttle bush reamer
                   (10.8mm)
                   09921-20210
                   bearing remover
                   09925-98221
                   bearing mounting device
                   09930-30190
                   rotor remover toolt
                   09940-50113                    09941-34513
                   front fork oil seal mounting   steering race mounting
                   tool                           tool
        7-15
                                     SERVICING INFORMATION
                  09941-74910
09941-50111       steering bearing     09943-74111                  09943-88211             09951-76010
bearing remover   mounting tool        front fork oil level gauge   bearing mounting tool   bearing mounting tool
7-16