VECTOR 300 Service Manual

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If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m Lock Nuts 24
3. ENGINE REMOVE AND INSTALLATION 3-1 General Information 3-3 Engine Installation 3-2 Engine Removal 3.1 General Information ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3-2 Engine Removal Before removing engine, you need to remove all of components such as seat, front and back fender, fuel tube, exhaust pipe, carburetor cable and drive chain…etc. You can then see three hanger bolts which have screwed on engine. Loosen these three hanger bolts. You have succeeded to remove this engine. There are some pictures to describe main step of removing engine. Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively. Remove the drive chain cover. Remove the drive chain retaining clip and master link, and remove the drive chain. Hanger bolt 25
Page 1 and 2: VECTOR 300 Service Manual 1
Page 3 and 4: 6. CYLINDER HEAD/VALVE 6-1 Mechanis
Page 5 and 6: 17. ELECTRICAL SYSTEM 17-1 Troubles
Page 7 and 8: 1-3 Engine Specifications Type 4 St
Page 9 and 10: 1-5 Torque Values STANDARD ● 5 mm
Page 11 and 12: For Engine 1.TACKING ACG FLY WHEEL
Page 13 and 14: 9. FABRICATING R CRANK CASE COVER 6
Page 15 and 16: 16. KNOCKING WATER PUMP OIL SEAL IM
Page 17 and 18: 2. MAINTENANCE 2-1 Maintenance Data
Page 19 and 20: 2-4 Throttle Operation Inspect for
Page 21 and 22: 2-10 Brake System Inspect the front
Page 23: 2-11 Wheels And Tires Inspect the t
Page 27 and 28: 4. LUBRICATION SYSTEM 4-1 Mechanism
Page 29 and 30: 4-4 Engine Oil Turn off engine, and
Page 31 and 32: Oil Pump Inspection Check the clear
Page 33 and 34: 4-7 Gear Oil Gear Oil Change Remove
Page 35 and 36: 5-2 Precautions In Operation Genera
Page 37 and 38: 5-4 Carburetor Remove / Install Rem
Page 39 and 40: 5-6 Throttle Valve Disassembly Remo
Page 41 and 42: Remove main jet, needle jet holder,
Page 43 and 44: 5-9 Fuel Tank Fuel unit removal Ope
Page 45 and 46: 6. CYLINDER HEAD/VALVE 6-1 Mechanis
Page 47 and 48: 6-3 Troubleshooting Engine performa
Page 49 and 50: Remove left crankcase cover, and tu
Page 51 and 52: Remove valve stem seals. Valve stem
Page 53 and 54: Valve guide Caution 5.0 mm valve gu
Page 55 and 56: 6-7 Valve Seat Inspection And Servi
Page 57 and 58: After the valve seat ground, coat v
Page 59 and 60: Install cam chain on to sprocket an
Page 61 and 62: 6-10 Valve Clearance Adjustment Loo
Page 63 and 64: To this chapter contents 7-2 Precau
Page 65 and 66: Check cylinder if warp. Service lim
Page 67 and 68: To this chapter contents 7-5 Piston
Page 69 and 70: Coat some engine oil to inside of c
Page 71 and 72: 8-2 Maintenance Description Precaut
Page 73 and 74: Left crankcase cover inspection Rem
Page 75 and 76:
Remove starter drive pulley and vol
Page 77 and 78:
Installation Caution • Pull out d
Page 79 and 80:
Inspection The weight rollers are t
Page 81 and 82:
8-7 Clutch Outer/Driven Pulley Disa
Page 83 and 84:
To this chapter contents Clutch wei
Page 85 and 86:
Installation of Clutch OUTER/Driven
Page 87 and 88:
9-2 Precautions In operation Specif
Page 89 and 90:
Remove gear box cover bolts (9 bolt
Page 91 and 92:
9-5 Inspection Of Mission Mechanism
Page 93 and 94:
9-6 Bearing Replacement Caution •
Page 95 and 96:
Special tool: Inner bearing puller
Page 97 and 98:
Align the position mark on the shif
Page 99 and 100:
10-2 Precautions In Operation Gener
Page 101 and 102:
Check the oil seal for wear or dama
Page 103 and 104:
Install starting clutch driven gear
Page 105 and 106:
Install reduction gear shaft and re
Page 107 and 108:
11. CRANKCASE / CRANK 11-1 Mechanis
Page 109 and 110:
11-4 Disassembly Of Crankcase Remov
Page 111 and 112:
11-5 Crankshaft Inspection Use a th
Page 113 and 114:
Install 2 dowel pins and new gasket
Page 115 and 116:
12. COOLING SYSTEM 12-1 Mechanism D
Page 117 and 118:
12-4 Trouble Diagnosis For Cooling
Page 119 and 120:
12-5 System Test Test on the filler
Page 121 and 122:
Loosen the radiator 4 bolts. Remove
Page 123 and 124:
Check any wear and damage of the me
Page 125 and 126:
Install the seal washer into the ro
Page 127 and 128:
13. STEERING AND SUSPENSION 13-1 Pa
Page 129 and 130:
Remove the handle bar switch on the
Page 131 and 132:
13-4 Throttle Housing DISASSEMBLY L
Page 133 and 134:
Install the steering shaft nut and
Page 135 and 136:
14-2 Troubleshooting HARD STEERING
Page 137 and 138:
Before loosening castle nut, you ha
Page 139 and 140:
14-5 Suspension Adjustment Suspensi
Page 141 and 142:
REAR BRAKE
Page 143 and 144:
Loosen two bolts to take out rear b
Page 145 and 146:
15-4 Swingarm & Rear Axle Holder Th
Page 147 and 148:
15-5 Suspension Adjustment Suspensi
Page 149 and 150:
16-2 Rear Fenders Removal There are
Page 151 and 152:
16-3 Front Fender Removal To remove
Page 153 and 154:
Bolt EXHAUST PIPE INSTALLATION Inst
Page 155 and 156:
17-2 Ignition Coil Remove the spark
Page 157 and 158:
After loosen these three screws, us
Page 159 and 160:
17-7 Instrument Pane The instrument
Page 161 and 162:
17-8 Wiring Diagram
Page 163 and 164:
18.2 Poor Performance At Low And Id
Page 165:
18-5 Poor Handling STEERING IS HEAV
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VECTOR 300 Service Manual

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