Topic 3
TUNE-UP AND SERVICING
TUNE-UP AND SERVICING
Objectives;
• Identify the different parts of motorcycle that need tune-ups.
• Know the procedure of tune-ups in different parts of motorcycle.
• Apply how to perform tune-up in motorcycle.
Motorcycle tune-up is an extensive maintenance/service session. It’s a thorough check done on a bike to see if any parts or fluids need cleaning or replacement, done about every 5,000km or so, or once every six months.
Here are the parts of mororcycle that need tune-ups;
Removing and Installing Body Components
Removal
Make sure the ignition switch is in the (Off) position.
1. Remove the battery lid from step floor by removing the screw.
2. Remove the service coupler from the battery cover guide.
3. Remove the battery cover from step floor.
4. Disconnect the negative - terminal from the battery.
5. Disconnect the positive + terminal from the battery.
6. Remove the battery taking care not to drop the terminal nuts.
Installation
Install the parts in the reverse order of removal. Always connect the positive + terminal first. Make sure that bolts and nuts are tight. Make sure the clock information is correct after the battery is reconnected. The anti-theft alarm system will be deactivated if the battery is disconnected. The system will remain off when the battery is reconnected.
Spark Plug
Use only the recommended type of spark plug in the recommended heat range.
1. Place your scooter on the centre stand on a level surface.
2. Disconnect the spark plug cap from the spark plug.
3. Clean any dirt from around the spark plug base.
4. Remove the spark plug using provided spark plug wrench.
5. Inspect the electrodes and centre porcelain for deposits, erosion or carbon fouling. If the erosion or deposit is heavy, replace the plug. Clean a carbon or wet-fouled plug with a plug cleaner, otherwise use a wire brush.
6. Check the spark plug gap using a wire type feeler gauge. If adjustment is necessary, bend the side electrode carefully.
7. Make sure the plug washer is in good condition.
8. Install the spark plug. With the plug washer attached, thread the spark plug in by hand to prevent cross-threading.
9. Tighten the spark plug:
● If the old plug is good: 1/8 turn after it seats. ● If installing a new plug tighten it twice to prevent loosening
a) First, tighten the plug: NGK: 1/2 turn after it seats. DENSO: 3/4 turn after it seats.
b) Then loosen the plug.
c) Next, tighten the plug again: 1/8 turn after it seats.
10. Install the parts in the reverse order of removal. When reinstalling the spark plug cap, take care to avoid pinching any cables or wires.
Engine Oil
Check the engine oil with the Idling Stop switch at IDLING.
1. If the engine is cold, idle the engine for 3 to 5 minutes.
2. Turn the ignition switch to the (Off) position and wait for 2 to 3 minutes.
3. Place your scooter on its centre stand on a firm, level surface.
4. Remove the oil fill cap/dipstick and wipe it clean.
5. Insert the oil fill cap/dipstick until it seats, but don’t screw it in.
6. Check that the oil level is between the upper level and lower level marks on the oil fill cap/dipstick.
7. Securely install the oil fill cap/dipstick.
Adding Engine Oil
If the engine oil is below or near the lower level mark, add the recommended engine oil.
1. Remove the oil fill cap/dipstick. Add the recommended oil until it reaches the upper level mark. Place your scooter on its centre stand on a firm, level surface when checking the oil level.
Do not overfill above the upper level mark. Make sure no foreign objects enter the oil filler opening. Wipe up any spills immediately.
2. Securely reinstall the oil fill cap/dipstick.
If the fuel pump filter is clogged, unstable engine operation will occur intermittently while riding. Even if this symptom occurs, you can continue to ride your scooter.
If unstable engine operation occurs even if sufficient fuel is available, have your scooter inspected by your dealer as soon as possible.
Coolant
Check that the coolant level in the reserve tank while the engine is cold.
1. Place your scooter on a firm, level surface.
2. Hold your scooter in an upright position.
3. Check that the coolant level is between the UPPER level and LOWER level marks on the reserve tank. If the coolant level is dropping noticeably or the reserve tank is empty, you likely have a serious leak. Have your scooter inspected by your dealer.
Adding Coolant
If the coolant level is below the LOWER level mark, add the recommended coolant until the level reaches the UPPER level mark.
Add fluid only from the reserve tank cap and do not remove the radiator cap.
1. Remove the reserve tank cover by removing the screw.
2. Remove the reserve tank cap and add fluid while monitoring the coolant level. Do not overfill above the UPPER level mark. Make sure no foreign objects enter the reserve tank opening.
3. Securely reinstall the reserve tank cap.
4. Install the removed parts in the reverse order of removal.
Changing Coolant
Have your dealer change the coolant unless you have the proper tools and are mechanically qualified.
Brakes
1. Place your scooter in an upright position on a firm, level surface.
2. Check that the brake fluid reservoir is horizontal and that the fluid level is above the LWR mark.
If the brake fluid level in the reservoir is below the LWR mark or the brake lever freeplay becomes excessive, inspect the brake pads for wear. If the brake pads are not worn, you most likely have a leak. Have your scooter inspected by your dealer.
Check the condition of the brake pad wear indicators. The pads need to be replaced if a brake pad is worn to the indicator.
Inspect the brake pads from below the brake caliper. If necessary have the pads replaced by your dealer. Always replace both left and right brake pads at the same time.
1. Place the scooter on its centre stand.
2. Measure the distance the rear brake lever moves before the brake takes hold.
Check the brake cable for kinks or signs of wear. If necessary have it replaced by your dealer.
Lubricate the brake cable with a commercially available cable lubricant to prevent premature wear and corrosion. Make sure the brake arm, spring and fastener are in good condition.
Adjust the freeplay of the brake lever with the front wheel pointed straight ahead. Make sure the cut-out on the adjusting nut is seated on the brake arm pin when adjusting the freeplay.
If proper adjustment cannot be obtained by this method, see your dealer.
1. Adjust by turning the rear brake adjusting nut a half-turn at a time.
2. Apply the brake several times and check for free wheel rotation after the brake lever is released.
3. Push the brake arm to confirm that there is a gap between the rear brake adjusting nut and brake arm pin. After adjustment, confirm the freeplay of the brake lever.
When the brake is applied, an arrow attached to the brake arm moves toward a reference mark on the brake panel. If the arrow aligns with the reference mark on full application of the brake, the brake shoes must be replaced.
Side Stand
1. Place your scooter on its centre stand on a firm, level surface.
2. Check that the side stand operates smoothly. If the side stand is stiff or squeaky, clean the pivot area and lubricate the pivot bolt with clean grease.
3. Check the spring for damage or loss of tension.
4. Sit on the scooter and raise the side stand.
5. Start the engine.
6. Lower the side stand all the way. The engine should stop as you lower the side stand. If the engine doesn’t stop, have your scooter inspected by your dealer.
Throttle
With the engine off, check that the throttle rotates smoothly from fully closed to fully open in all steering positions and throttle freeplay is correct. If the throttle does not move smoothly, close automatically, or if the cable is damaged, have the scooter inspected by your dealer.
Crankcase Breather
1. Place a suitable container under the crankcase breather tube.
2. Remove the crankcase breather tube and drain deposits.
3. Reinstall the crankcase breather tube.
Other Adjustments
The right and left headlight aim can be adjusted in the same way. You can adjust vertical aim of the headlights for proper alignment. Turn the pinion in or out as necessary using provided Phillips screwdriver. Obey local laws and regulations.
Other Replacement
When the remote transmitter battery begins to get weak, it may take several pushes on the button to operate the anti-theft alarm system or answer back system, and the LED will get dim.
Replace the battery as soon as possible. We recommend to see your dealer for this service.
1. Remove the upper case by carefully prying on the edge with a coin or a screw driver. Wrap a coin or a screwdriver with a protective cloth to prevent scratching the remote transmitter. Do not touch the circuit or terminal. This may cause problems. Be careful to avoid scratching the waterproof covering or allowing dust to enter. Do not forcibly dismantle the remote transmitter body.
2. Replace the old battery with a new battery with the negative - side facing up.
3. Snap the two halves of the remote transmitter back together. uMake sure that upper and lower cases are set in the right position.
Troubleshooting
Engine will not start
Starter Motor Operates But Engine Does Not Start
Check the following items:
● Check the correct engine starting sequence.
● Check that there is petrol in the fuel tank.
● Check if the PGM-FI malfunction indicator lamp (MIL) is on.
uIf the indicator lamp is on, contact your dealer as soon as possible.
Starter Motor Does Not Operate
Check the following items:
● Check the correct engine starting sequence.
● Check for a blown fuse.
● Check for a loose battery connection or battery terminal corrosion
● Check the condition of the battery.
If the problem continues, have your scooter inspected by your dealer.
Overheating (High coolant temperature indicator is on)
The engine is overheating when the following
occurs:
● High coolant temperature indicator comes on.
● Acceleration becomes sluggish. If this occurs, pull safely to the side of the road and perform the following procedure.
Extended fast idling may cause the high coolant temperature indicator to come on.
1. Stop the engine using the ignition switch.
2. Allow the engine to cool with the ignition switch in the (Off) position.
3. After the engine has cooled, inspect the radiator hose and check if there is a leak. Do not start the engine. Transport your scooter to your dealer.
4. Check the coolant level in the reserve tank. Add coolant as necessary.
5. If 1-4 check normal, you may continue riding, but closely monitor the high coolant temperature indicator.
Warning Indicators On or Flashing
PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL)
If the indicator comes on while riding, you may have a serious problem with the PGM-FI system. Reduce speed and have your scooter inspected by your dealer as soon as possible.
Battery Charging Condition Indicator
If the indicator comes on while riding, you may have a condition of low battery voltage or battery performance degradation. Have your scooter inspected by your dealer. If the battery does not have enough voltage to drive the indicator system, the indicator may not come on.
Other Warning Indications
If the fuel system has an error, the fuel gauge indicators will be displayed as shown in the illustration. If these occur, see your dealer as soon as possible.
When the Idling Stop System Does Not Operate Properly
Iling Stop Indicator Does Not Come On
When the Idling Stop indicator does not come on, perform the followings.
If the Idling Stop switch is at IDLING:
Press the Idling Stop switch to IDLING STOP.
If the engine is cold:
Warm up the engine. The Idling Stop system does not operate when the engine is cold.
If you did not ride the scooter after engine starts:
Ride the scooter at speeds of over 10 km/h (6 mph). The Idling Stop system does not operate until you ride once.
If PGM-FI malfunction indicator lamp (MIL) lights:
When the PGM-FI malfunction indicator lamp (MIL) lights, the Idling Stop system does not operate for protection of the engine. See your dealer.
If the battery voltage is slow:
Ride the scooter awhile, then stop the engine and then restart the engine with the start button, referring to the starting procedure for standard engine starting. The Idling Stop system may not operate if the battery voltage is low. If this occurs frequently, contact your dealer.
Tyre Puncture
Repairing a puncture or removing a wheel requires special tools and technical expertise. We recommend you have this type of service performed by your dealer. After an emergency repair, always have the tyre inspected/replaced by your dealer.
Emergency Repair Using a Tyre Repair Kit
If your tyre has a minor puncture, you can make an emergency repair using a tubeless tyre repair kit. Follow the instructions provided with the emergency tyre repair kit. Riding your scooter with a temporary tyre repair is very risky. Do not exceed 50 km/h (30 mph). Have the tyre replaced by your dealer as soon as possible.
Electrical Trouble
Battery Goes Dead
Charge the battery using a motorcycle battery charger. Remove the battery from the scooter before charging. Do not use an automobile-type battery charger, as these can overheat a scooter battery and cause permanent damage. If the battery does not recover after recharging, contact your dealer.
Burned-out Light Bulb
All light bulbs on the scooter's are LEDs. If there is an LED which is not turned on, see your dealer for servicing.
The headlight/front turn signal light/position light use several LEDs. If there is an LED which is not turned on, see your dealer for this servicing.
The brakelight/taillight/rear turn signal light/license plate light use several LEDs. If there is an LED which is not turned on, see your dealer for this servicing.
Blown Fuse
1. Remove the battery lid and the battery cover from the step floor. 2 P. 71
2. Pull out the fuses one by one to check for a blown fuse. Always replace a blown fuse with a spare of the same rating. Spare fuses are provided on the reverse side of the battery cover.
3. Install the battery lid and the battery cover.
Unstable Engine Operation Occurs Intermittently
If the fuel pump filter is clogged, unstable engine operation will occur intermittently while riding. Even if this symptom occurs, you can continue to ride your scooter. If unstable engine operation occurs even if sufficient fuel is available, have your scooter inspected by your dealer as soon as possible.