E-FIVE & S-Five Service Manual

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This is for E-five, can be used also for S-Five.

Text of E-FIVE & S-Five Service Manual

CONTENTS1. SERIAL NUMBER LOCATION 12. CHANGED ITEMS COMPARED WITH S-FIVE 23. SPECIFICATIONS 64. CABLE & HARNESS ROUTING 75. INSPECTION / MAINTENANCE 101) FUEL UNIT 102) HANDLE SWITCH INSPECTION 123) SPEEDOMETER REPLACEMENT 134) PILOT BOX SET BULB REPLACEMENT 145) FRONT MINI COVER REMOVAL 146) LUGGAGE CARRIER REMOVAL 157) HANDLE LEVER PROTECTOR REMOVAL 156. WIRING DIAGRAM 16ThisE-FIVEservicemanualcontainsonlyitems,whichischanged due to the design change from S-FIVE.Foritemsnotexplainedinthismanual,refertoS-FIVEservice manual.1. SERIAL NUMBER LOCATIONENGINE SERIAL NUMBER FRAME SERIAL NUMBER(1) The engine serial number is stamped on the rearface of the left crankcase.(2) The frame serial number is stamped on the frontcentral part of the frame.122. CHANGED ITEMS COMPARED WITH S-FIVESTEERINGHANDLEHandle cover is installed. Handle cover is removed.Wind screen is added newly.FRONTFENDERFront fender is installed. ON-ROAD TypeFront fender is removed.Front guard, front mini cover is installed. OFF-ROAD TypeSPEEDOMETERSpeedometer is installed on the interior of thehandle cover.Fuel meter is installed.Removable and compact Type.Fuel meter is replaced by fuel warning indicator.FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVER FRONT MINI COVERFRONT MINI COVERFRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARD FRONT MINI GUARDFRONT MINI GUARDCHANGED ITEMS COMPARED WITH S-FIVEHANDLELEVELPROTECTORHandle lever protector is not installed. Handle lever protector is installed. Improved safetyREARCARRIERSpoiler Type Rod Type (easy to load freight)LIGHTINGSWITCHSlide Type (right and left) Slide Type (up and down)3HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTOR HANDLE LEVER PROTECTORHANDLE LEVER PROTECTORLIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCHLIGHTING SWITCHLIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCHLIGHTING SWITCH4CHANGED ITEMS COMPARED WITH S-FIVEHAZARDSWITCHHazard switch is installed. Hazard switch is not installed.FUEL UNITFloat is installed. Thermistor is installed. Fuel warning light turns on due to thethermistors self radiation of heat.BACK MIRRORCurve Type Rectangle Type Unpolished Off-road imageHAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH HAZARD SWITCHHAZARD SWITCHFLOATTHERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTORTHERMISTOR5CHANGED ITEMS COMPARED WITH S-FIVEWHEELS12Silver painted10Black paintedTIRESFRONT : 120/70-12 58LREAR : 130/70-12 62LTIRE PATTERN : ON-ROAD USE (SEMI-BLOCK)FRONT : 130/90-10 61JREAR : 130/90-10 61JTIRE PATTERN : ON/OFF-ROAD USE (BLOCK)MUFFLERHot Tube Type Honey Comb. Type Noise reduction effect 63. SPECIFICATIONSITEMTYPE OF VEHICLEOVERALL LENGTHOVERALL WIDTHOVERALL HEIGHTWHEEL BASEMOTOR TYPEDISPLACEMENTFUEL TYPEMIN. REVOLUTION RADIUSCOOLING TYPESTARTINGMOTOR TYPENO. OF CYLINDER/MOUNTINGVALVE APPARATUSBORE X STROKECOMPRESSION RATIOMAX. OUTPUTMAX. TORQUEPRIMARY SPEEDREDUCTION RATIOSECONDARY SPEEDREDUCTION RATIOTRANSMISSION TYPEFRAME SERIALNUMBERENGINE SERIALNUMBERTIRE SIZE130/90-10 61J130/90-10 61JTELESCOPICHYDRAULIC DISKDRUM BRAKESUSPENSIONBRAKETIRE TYPE TUBELESSFR.RR.FR.RR.FR.RR.TRANSMISSION RATIO1st GEARE-FIVE (MAJOR ATS)1,790mm685mm1,130mm1,260mmSJ50E49.5ccGASOLINE34.5kg51.5kg86kg2 (65kg)C.D.I12V3AH(MF TYPE)6.0(RESERVIOR 1.1)1.2BP7HS7A131mm2680.5mmUNDER BONE9.5m(36km/h)1.8mmAIR-COOLEDSTARTER MOTOR/KICK2-CYCLE39.0 x 41.4mm6.8 : 15.1PS/7,000rpm0.55kgf.m/7,000rpm4.0833.6152.41~0.76KMYSEIB4N2C000001~SJ50E4000001~PASSENGERSIGNITION SYSTEMBATTERY CAPACITYFUEL TANK CAPACITYOIL TANK CAPACITYSPARK PLUGFUSEGROUND CLEARANCECASTERTRAILFRAME TYPEBRAKING DISTANCEFRONT AXLEREAR AXLETOTALDRYWEIGHTITEM SPECIFICATIONS SPECIFICATIONS1CYCLINDER /TRANSVERSEREED VALVE, PISTONVALVE COMBINATIONV-MATIC GEARLESSTRANSMISSIONUNIT SWING ARMOIL DAMPER74. CABLE & HARNESS ROUTING1HPO11|[ AE|[PP EPAK[ AE|[P|O1 EOX OP[WNK[P SlW OP[PP EPAK[ SlW OP[WNK[P SlW OP[PP EPAK[ SlW OP[SP[[[OM[1[P OP[SP[[[OM[1[P AE|[P|O1 EOX OP[HOPN OMPFPAM[ [AP1H1H1 A1 1H[ SAM[ 1M[ W1H 1H[ HOPNP[SS1OP30W 59PP[SS 1O A11AH 1H[S[| S[1ON 1O 1H[ PP[FP EPAK[ HOS[SP[[[OM[1[P AE|[|H1N SlW OP[FP EPAK[ SlW OP[SP[[[OM[1[P OP[|H1N SlW OP[SP[[[OM[1[P ASS'YFP EPAK[ HOS[1HPO11|[ AE|[APP|Y A P[AS[N 1HS S[1ONS[A1 |OK AE|[OME |OK SlWPP EPAK[ AE|[WNK[P SlW OP[FU[| UN1 ONN[1N OUP|[PPl| 1A| S1OP PP WNK[P ONN[1N OUP|[PAU1O EYS1AP1[P5W 67,O| 1ANKFU[| 1ANKWP[ HAPN[SSA[N[PA1OP1HS S[1ON SHOU|[ NO1E[ PPOJ[1[[ 1HAN 1H[ FPON1OF 1H[ FPAM[ AN[ NO1 HAv[ ANY |OOS[N[SSEA11[PY ASS'YPO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|Yl O|PO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|YS[A1 |OK AE|[OME |OK SlWONN[1N OUP|[POME |OK SlWP[U|A1[ P[1F[PH[A[|H1 1[[OWN OUP|[PPO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|YP[SS1OP ONN[1N OUP|[PHOPN OMP1H1 A1 1H[ SAM[ 1M[ W1H 1H[ HOPNFPAM[ [AP1H[ UN1 ASS'YS1AP1[P P[A|Y ASS' Y8CABLE & HARNESS ROUTINGFPAM[ [AP1H 1[PMNA|H[A[|H1 (1[[OWN OUP|[P)1[[OWN OUP|[P 1[[OWN OUP|[P P[SS1OP ONN[1NONN[1OP 30W 59 AP WNK[P P[|AYWNK[P P[|AY1[[OWN OUP|[PHOPN OMPONN[1N ONN[1OPP[SS1OP ONN[1N ONN[1OPAU1O EYS1AP1[P 5W 67,P[U|A1[ P[1F[POME |OK SlWWP[ HAPN[SSSP[[[OM[1[P OP[PO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|YO| PUMP AE|[1HPO11|[ AE|[AU1O EYS1AP1[P OP[1HPO11|[ AE|[EA11[PY ASS'Y 1HS S[1ON SHOU|[ NO1E[ PPOJ[1[[ 1HAN 1H[ FPON1OF 1H[ FPAM[ AN[ NO1 HAv[ ANY |OOS[N[SSAU1O EYS1AP1[P 5W 67,FP EPAK[ HOS[P[SS1OPPP EPAK[ AE|[PO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|YS[A1 |OK AE|[1HPO11|[ AE|[PP EPAK[ AE|[O| PASS 1UE[S[A1 |OK AE|[O| 1UE[FU[| v[N1 1UE[FU[| S1PAN[PFU[| AU1O OK ASS'YN[A1v[ PP[SSUP[ 1UE[FU[| 1UE[P[SS1OPv30W 59,S[[ S1AN[ SW1HCABLE & HARNESS ROUTING9PP EPAK[ AE|[1HPO11|[ AE|[S[A1 |OK AE|[HH 1[NSON OP[S[[ S1AN[ SlWS1AP1[P MO1OPO| PUMP AE|[1HPO11|[ AE|[O| PASS 1UE[O| 1UE[AU1O EYS1AP1[P OP[FU[| 1UE[N[A1v[ PP[SSUP[ 1UE[FU[| AU1O OK ASS'YFU[| S1PAN[PFU[| 1ANKFU[| v[N1 1UE[S[A1 |OK AE|[|H PP WNK[P |H1PH PP WNK[P |H11A| |H1 ASS'YFU[| UN11A| |H1 ONN[1N ONN[1OP[ UN1 ASS'YO| |[v[| SlWAU1O EYS1AP1[P ONN[1N OUP|[PA ONN[1N OUP|[P A OP[ |AMPPO|| 1H[ WH1[ 1AP[ AP[A OF A OP[ |AMP N 1H[ POS1ON OF 1H[ |AMP FPM|Yl O|l O|EA11[PY ASS'YWP[ HAPN[SSS1AP1[P P[A|Y ASS'Y[NN[ [AP1H 1H1 A1 1H[ SAM[ 1M[ W1H 1H[ S1AP1N MO1OPPP[SS 1O A11AH 1H[ S[| S[1ON 1O 1H[ PP[PO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|YPO|| 1H[ H[S |AMPW1H 1H[ OP[ S[UP[|Y5. INSPECTION /MAINTENANCE1) FUEL UNITREMOVALRemove the luggage box.Remove the fuel unit wire from the wire harness.Turnthefuelunitsetcapcompletetotheleft,andremove it.INSTALLATIONInstall the base packing to the fuel tank.Install the fuel unit.Remove the base packing.NOTENOTE10Becarefulofpreventionthefuelunitwirefromdamaging.Whendisassembling,becarefulofpreventionthethermistor from damaging.Check the base packing for damage.NOTEInstallitaligningthe partofthefuelunitwiththeloop part of fuel tank.Check the fuel leakage.FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNITFUEL UNITFUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNITFUEL UNITFUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNITFUEL UNITTHERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTOR THERMISTORTHERMISTORBASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKING BASE PACKINGBASE PACKINGINSPECTION/MAINTENANCEBLACKFUSEGREEN YELLOW/WHITEFUEL WARNING INDICATORLEVEL SENSOR(THERMISTOR)RED GREENMAIN SWITCH11FUEL UNIT INSPECTIONINFORMATIONRemove the fuel unit and check for proper operation inthe air and gasoline.- Connectadditionalbulbbetweenterminalsofthefuelunitandbatterysidesandcheckthatthebulbisilluminating.(ADDITIONAL BULB CAPACITY : 14V 3W)Check for battery voltage between the fuel level sensorconnector terminals.The bulb must be illuminated within 3minutes after thethermistor of the fuel unit is exposed in the air.Thebulbmustnotbeilluminatedwithi