650 - 650NK - Techinical Service Manual.pdf - Mojo Motorcycles

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PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers Extension Tube Steering Stem Nut Wrench Pilot Screw Adjuster,E Oil Filter Wrench
2-14 PERIODIC MAINTENANCE Electronic Fuel Injection Air Filter Element Cleaning NOTE O In dusty areas,the element should be cleaned frequently than the recommended interval. O After rding through rain or on muddily road,element should be cleaned immediately. Screw ! WARNING If dirt or dust is allowed to pass through into the throttle assy, the throttle may become stuck, possibly causing accident. CAUTION If dirt gets through into the engine,excessive engine wear and possibly engine damage will occur. Element Comp. • Remove: Fuel tank(see Fuel Tank Removal in the Fuel System); • Remove air filter element screw; • Remove air filter element comp.. Element • Remove the holder. • Remove element NOTE O The wire screen is fastened with an adhesive for the shaded portion.Do not remove the wire screen.
Page 3 and 4: FOREWORD This manual introduces 650
Page 5: INTRODUCTION This manual is designe
Page 8 and 9: 1-2 GENERAL INFORMATION Safety Prec
Page 10 and 11: GENERAL INFORMATION 1-3 Before Serv
Page 12 and 13: 1-6 GENERAL INFORMATION Tightening
Page 14 and 15: 1-8 GENERAL INFORMATION Lubrication
Page 16 and 17: 1-10 GENERAL INFORMATION General Sp
Page 18 and 19: 1-12 GENERAL INFORMATION Items Rear
Page 20 and 21: PERIODIC MAINTENANCE 2-1 Periodic M
Page 22 and 23: PERIODIC MAINTENANCE 2-3 Periodic M
Page 24 and 25: PERIODIC MAINTENANCE 2-5 FREQUENCY
Page 26 and 27: PERIODIC MAINTENANCE 2-7 Fastener T
Page 28 and 29: PERIODIC MAINTENANCE 2-9 Fastener T
Page 30 and 31: PERIODIC MAINTENANCE 2-11 Specifica
Page 34 and 35: PERIODIC MAINTENANCE 2-15 ! WARNING
Page 36 and 37: PERIODIC MAINTENANCE 2-17 Fuel Line
Page 38 and 39: PERIODIC MAINTENANCE 2-19 Engine To
Page 40 and 41: PERIODIC MAINTENANCE 2-21 Valve Adj
Page 42 and 43: PERIODIC MAINTENANCE 2-23 Valve Cle
Page 44 and 45: PERIODIC MAINTENANCE 2-25 Clutch Cl
Page 46 and 47: PERIODIC MAINTENANCE 2-27 Wheel Bea
Page 48 and 49: PERIODIC MAINTENANCE 2-29 • Turn
Page 50 and 51: PERIODIC MAINTENANCE 2-31 Brake Sys
Page 52 and 53: PERIODIC MAINTENANCE 2-33 • Follo
Page 54 and 55: PERIODIC MAINTENANCE 2-35 Steering
Page 56 and 57: Lights and Switches Operation Inspe
Page 58 and 59: PERIODIC MAINTENANCE 2-39 • Set t
Page 60 and 61: PERIODIC MAINTENANCE 2-41 Battery (
Page 62 and 63: PERIODIC MAINTENANCE 2-43 Bolts, Nu
Page 64 and 65: PERIODIC MAINTENANCE 2-45 Coolant C
Page 66 and 67: PERIODIC MAINTENANCE 2-47 • Tempo
Page 68 and 69: PERIODIC MAINTENANCE 2-49 • Repla
Page 70 and 71: PERIODIC MAINTENANCE 2-51 Rear Mast
Page 72 and 73: PERIODIC MAINTENANCE 2-53 • Apply
Page 74 and 75: FUEL SYSTEM (EFI) Table of Contents
Page 76 and 77: a. Ignition Switch b. Engine Stop S
Page 78 and 79: FUEL SYSTEM (EFI) 3-5 a. Front Posi
Page 80 and 81: EFI Parts Location FUEL SYSTEM (EFI
Page 82 and 83:
FUEL SYSTEM (EFI) 3-9 Specification
Page 84 and 85:
FUEL SYSTEM (EFI) 3-11 Special Tool
Page 86 and 87:
FUEL SYSTEM (EFI) 3-13 EFI Servicin
Page 88 and 89:
Page 90 and 91:
Page 92 and 93:
FUEL SYSTEM (EFI) 3-19 Sample Diagn
Page 94 and 95:
FUEL SYSTEM (EFI) 3-21 NOTE ○ Thi
Page 96 and 97:
FUEL SYSTEM (EFI) 3-23 Symptoms or
Page 98 and 99:
Page 100 and 101:
Page 102 and 103:
FUEL SYSTEM (EFI) 3-29 Self-diagnos
Page 104 and 105:
FUEL SYSTEM (EFI) 3-31 How to Erase
Page 106 and 107:
FUEL SYSTEM (EFI) 3-33 Self-diagnos
Page 108 and 109:
FUEL SYSTEM (EFI) 3-35 Throttle Pos
Page 110 and 111:
FUEL SYSTEM (EFI) 3-37 Throttle Pos
Page 112 and 113:
FUEL SYSTEM (EFI) 3-39 Inlet Air Pr
Page 114 and 115:
FUEL SYSTEM (EFI) 3-41 Inlet Air Te
Page 116 and 117:
FUEL SYSTEM (EFI) 3-43 Coolant Temp
Page 118 and 119:
FUEL SYSTEM (EFI) 3-45 Speed Sensor
Page 120 and 121:
FUEL SYSTEM (EFI) 3-47 Roll-over Se
Page 122 and 123:
FUEL SYSTEM (EFI) 3-49 Roll-over Se
Page 124 and 125:
FUEL SYSTEM (EFI) 3-51 Oxygen Senso
Page 126 and 127:
FUEL SYSTEM (EFI) 3-53 Ignition Coi
Page 128 and 129:
FUEL SYSTEM (EFI) 3-55 Turn the ign
Page 130 and 131:
FUEL SYSTEM (EFI) 3-57 ECU ECU Remo
Page 132 and 133:
FUEL SYSTEM (EFI) 3-59 ECU ECU Circ
Page 134 and 135:
FUEL SYSTEM (EFI) 3-61 Fuel Line Fu
Page 136 and 137:
FUEL SYSTEM (EFI) 3-63 Fuel Pump Fu
Page 138 and 139:
Page 140 and 141:
Page 142 and 143:
FUEL SYSTEM (EFI) 3-69 Fuel Injecto
Page 144 and 145:
FUEL SYSTEM (EFI) 3-71 Fuel Injecto
Page 146 and 147:
FUEL SYSTEM (EFI) 3-73 Throttle Gri
Page 148 and 149:
FUEL SYSTEM (EFI) 3-75 Throttle Bod
Page 150 and 151:
FUEL SYSTEM (EFI) 3-77 Error Code T
Page 152 and 153:
FUEL SYSTEM (EFI) 3-79 ERROR TYPE E
Page 154 and 155:
4-2 COOLING SYSTEM Exploded View
Page 156 and 157:
4-4 COOLING SYSTEM Coolant Flow Cha
Page 158 and 159:
4-6 COOLING SYSTEM Specifications I
Page 160 and 161:
4-8 COOLING SYSTEM Coolant Coolant
Page 162 and 163:
4-10 COOLING SYSTEM Water Pump Wate
Page 164 and 165:
4-12 COOLING SYSTEM Water Pump Impe
Page 166 and 167:
4-14 COOLING SYSTEM Radiator Radiat
Page 168 and 169:
4-16 COOLING SYSTEM Thermostat Ther
Page 170 and 171:
4-18 COOLING SYSTEM Hose and Pipes
Page 172 and 173:
ENGINE TOP END 5-1 Engine Top End T
Page 174 and 175:
ENGINE TOP END 5-3 Item Fastner Tor
Page 176 and 177:
ENGINE TOP END 5-5 Item No. Fastner
Page 178 and 179:
ENGINE TOP END 5-7 Item Standard da
Page 180 and 181:
ENGINE TOP END 5-9 Compression Gaug
Page 182 and 183:
ENGINE TOP END 5-11 Cylinder Head C
Page 184 and 185:
ENGINE TOP END 5-13 Camshaft Chain
Page 186 and 187:
ENGINE TOP END 5-15 Camshaft/Timing
Page 188 and 189:
Page 190 and 191:
Page 192 and 193:
ENGINE TOP END 5-21 Cylinder head P
Page 194 and 195:
ENGINE TOP END 5-23 Cylinder head
Page 196 and 197:
ENGINE TOP END 5-25 Valves Valve Gu
Page 198 and 199:
ENGINE TOP END 5-27 Valves Valve Se
Page 200 and 201:
ENGINE TOP END 5-29 Cylinder/Piston
Page 202 and 203:
Page 204 and 205:
Page 206 and 207:
CLUTCH 6-1 Clutch Table of Contents
Page 208 and 209:
CLUTCH 6-3 Exploded View NO Fastene
Page 210 and 211:
CLUTCH 6-5 Special Tool and Sealant
Page 212 and 213:
CLUTCH 6-7 Clutch Cover Clutch Cove
Page 214 and 215:
CLUTCH 6-9 Clutch Cover Clutch Cove
Page 216 and 217:
CLUTCH 6-11 Clutch Clutch Removal
Page 218 and 219:
CLUTCH 6-13 Clutch ● Be sure that
Page 220 and 221:
CLUTCH 6-15 Clutch ● Install the
Page 222 and 223:
CLUTCH 6-17 Clutch Clutch Housing F
Page 224 and 225:
7-2 ENGINE LUBRICATION SYSTEM Explo
Page 226 and 227:
7-4 ENGINE LUBRICATION SYSTEM Engin
Page 228 and 229:
7-6 ENGINE LUBRICATION SYSTEM Speci
Page 230 and 231:
7-8 ENGINE LUBRICATION SYSTEM Engin
Page 232 and 233:
7-10 ENGINE LUBRICATION SYSTEM Oil
Page 234 and 235:
Page 236 and 237:
Page 238 and 239:
Page 240 and 241:
ENGINE REMOVAL/INSTALLATION 8-1 Eng
Page 242 and 243:
ENGINE REMOVAL/INSTALLATION 8-3 Exp
Page 244 and 245:
ENGINE REMOVAL/INSTALLATION 8-5 ●
Page 246 and 247:
ENGINE REMOVAL/INSTALLATION 8-7 Eng
Page 248 and 249:
9-2 CRANKSHAFT/TRANSMISSION Explode
Page 250 and 251:
9-4 CRANKSHAFT/TRANSMISSION Explode
Page 252 and 253:
9-6 CRANKSHAFT/TRANSMISSION Specifi
Page 254 and 255:
9-8 CRANKSHAFT/TRANSMISSION Specifi
Page 256 and 257:
9-10 CRANKSHAFT/TRANSMISSION Crankc
Page 258 and 259:
Page 260 and 261:
Page 262 and 263:
Page 264 and 265:
9-18 CRANKSHAFT/TRANSMISSION Cranks
Page 266 and 267:
Page 268 and 269:
Page 270 and 271:
Page 272 and 273:
Page 274 and 275:
9-28 CRANKSHAFT/TRANSMISSION Balanc
Page 276 and 277:
9-30 CRANKSHAFT/TRANSMISSION Transm
Page 278 and 279:
Page 280 and 281:
Page 282 and 283:
Page 284 and 285:
Page 286 and 287:
Page 288 and 289:
WHEELS/TIRES 10-2 Exploded View
Page 290 and 291:
WHEELS/TIRES 10-4 Item Standard Ser
Page 292 and 293:
WHEELS/TIRES 10-6 Wheels (Rims) Fro
Page 294 and 295:
WHEELS/TIRES 10-8 Rear Wheel Remova
Page 296 and 297:
WHEELS/TIRES 10-10 Wheel Inspection
Page 298 and 299:
WHEELS/TIRES 10-12 Balance Weight N
Page 300 and 301:
WHEELS/TIRES 10-14 ● Install a ne
Page 302 and 303:
WHEELS/TIRES 10-16 Hub Bearing Remo
Page 304 and 305:
11-2 FINAL DRIVE Exploded View
Page 306 and 307:
11-4 FINAL DRIVE Specifications Ite
Page 308 and 309:
11-6 FINAL DRIVE Drive Chain Slack
Page 310 and 311:
11-8 FINAL DRIVE ● Fit the plate
Page 312 and 313:
11-10 FINAL DRIVE Engine Sprocket R
Page 314 and 315:
11-12 FINAL DRIVE Coupling Installa
Page 316 and 317:
11-14 FINAL DRIVE Rear Sprocket War
Page 318 and 319:
12-2 BRAKES Exploded View (Front Br
Page 320 and 321:
12-4 BRAKES Exploded View (Rear Bra
Page 322 and 323:
12-6 BRAKES Specifications Item Sta
Page 324 and 325:
12-8 BRAKES Brake Lever Position Ad
Page 326 and 327:
12-10 BRAKES ● Install the right
Page 328 and 329:
12-12 BRAKES Front Caliper Disassem
Page 330 and 331:
12-14 BRAKES Front Brake Pad Remova
Page 332 and 333:
12-16 BRAKES Rear Master Cylinder R
Page 334 and 335:
12-18 BRAKES Brake Disc Removal ●
Page 336 and 337:
12-20 BRAKES ● Bleed the brake li
Page 338 and 339:
SUSPENSION 13-1 Suspension Table of
Page 340 and 341:
SUSPENSION 13-3 No Fastener Torque
Page 342 and 343:
SUSPENSION 13-5 No. Fastener Torque
Page 344 and 345:
SUSPENSION 13-7 Special Tools Insid
Page 346 and 347:
SUSPENSION 13-9 ● Compress [A] th
Page 348 and 349:
SUSPENSION 13-11 ● Remove the fol
Page 350 and 351:
SUSPENSION 13-13 Fork Spring Inspec
Page 352 and 353:
SUSPENSION 13-15 ● Remove: Upper
Page 354 and 355:
SUSPENSION 13-17 Swingarm Bearing R
Page 356 and 357:
SUSPENSION 13-19 ● Turn the beari
Page 358 and 359:
14-2 STEERING Exploded View
Page 360 and 361:
14-4 STEERING Special Tools Steerin
Page 362 and 363:
14-6 STEERING Stem, Stem Bearing Re
Page 364 and 365:
14-8 STEERING ● Settle the inner
Page 366 and 367:
14-10 STEERING Handlebar Removal
Page 368 and 369:
FRAME 15-1 FRAME Table of Contents
Page 370 and 371:
FRAME 15-3 Seats Front Seat Install
Page 372 and 373:
FRAME 15-5 Fairings Left Center Fai
Page 374 and 375:
FRAME 15-7 Side Covers Left Side Co
Page 376 and 377:
FRAME 15-9 Fenders Front Fender Rem
Page 378 and 379:
FRAME 15-11 Frame Frame Inspection
Page 380 and 381:
FRAME 15-13 Rear View Mirrors Rear
Page 382 and 383:
16-2 ELECTRICALL SYSTEM Specificati
Page 384 and 385:
16-4 ELECTRICAL SYSTEM Electrical S
Page 386 and 387:
16-6 ELECTRICAL SYSTEM Wiring Diagr
Page 388 and 389:
16-8 ELECTRICAL SYSTEM Electrical S
Page 390 and 391:
16-10 ELECTRICAL SYSTEM Battery Bat
Page 392 and 393:
16-12 ELECTRICAL SYSTEM Battery Ini
Page 394 and 395:
16-14 ELECTRICAL SYSTEM Battery Cha
Page 396 and 397:
16-16 ELECTRICAL SYSTEM Charging Sy
Page 398 and 399:
Page 400 and 401:
Page 402 and 403:
Page 404 and 405:
Page 406 and 407:
Page 408 and 409:
16-28 ELECTRICAL SYSTEM Ignition Sy
Page 410 and 411:
Page 412 and 413:
Page 414 and 415:
Page 416 and 417:
Page 418 and 419:
16-38 ELECTRICAL SYSTEM Starting Sy
Page 420 and 421:
Page 422 and 423:
16-42 ELECTRICAL SYSTEM Lighting Sy
Page 424 and 425:
Page 426 and 427:
Page 428 and 429:
Page 430 and 431:
16-50 ELECTRICAL SYSTEM Radiator Fa
Page 432 and 433:
16-52 ELECTRICAL SYSTEM Meter Unit
Page 434 and 435:
Page 436 and 437:
Page 438 and 439:
16-58 ELECTRICAL SYSTEM Switches an
Page 440 and 441:
16-60 ELECTRICAL SYSTEM Switches an
Page 442:
16-62 ELECTRICAL SYSTEM Relay and F
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650 - 650NK - Techinical Service Manual.pdf - Mojo Motorcycles

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