2.21  Starting  /  Charging  System
JL4G15-D

2.21.1  4G15-D  Engine  Starting  /  Charging
System Overview

Compared  with  4G18-D,  4G15-D  engine  starting  /  charging
system has the same content in Specification, Description and
Operation, the System Working Principle, Component Locator,
Schematic, Removal and Installation. For specific information,
please  refer  to

2.3

 

Fuel  System  JL4G18-D

.  This  chapter

described  contents  are  different  from  4G18-D.  For  relevant
information. Refer to the following content.

Engine

Starting / Charging System JL4G15-D

2-871

2.21.1 Specifications
2.21.1.1 Starter Motor Specifications

Starter Motor Specifications

Applications

Specifications

Starter

Rated Output

12 V, 1.2 kW

Non-Load Performance

Voltage 11.0 V, Current 90 A, Speed 2,800 r/min

Load Performance

Voltage 7.7 V, Current 300 A, Torque 8 Nm, Speed 890 r /min

Solenoid

Coil Working

Voltage 12.2 V, Current 30 A

Suction Coil Working

Voltage 12.2 V, Current 5 A

2.21.1.2 Generator Specifications

Applications

Specifications

Rated Output

14 V, 90 A

Zero Current Speed

Less than 1,200 r/min

Rated Speed

6,000 r/min

Model

JFZ1906

2-872

Starting / Charging System JL4G15-D

Engine

3 Transmission / Drive Axle

3.1 Warnings and Notices.....................3-3

3.1.1 Warnings and Notices...........................................3-3

3.2 Clutch System.................................3-4

3.2.1 Specifications...........................................3-4

3.2.1.1 Fastener Tightening Specifications....................3-4
3.2.1.2 General Specifications.......................................3-4

3.2.2 Description and Operation........................3-5

3.2.2.1 Description and Operation..................................3-5

3.2.3 System Working Principle.........................3-6

3.2.3.1 System Working Principle..................................3-6

3.2.4 Disassemble View....................................3-7

3.2.4.1 Disassemble View..............................................3-7

3.2.5 Diagnostic Information and Procedures.....3-
9

3.2.5.1 Diagnosis Description.........................................3-9
3.2.5.2  Clutch  Inseparable  Malfunction  (Gearshift  Lever
Can Not Select Gear).....................................................3-9
3.2.5.3 Clutch Slipping.................................................3-10
3.2.5.4 Clutch Pedal Hard to Push...............................3-12
3.2.5.5 Clutch Pedal Does Not Return.........................3-12
3.2.5.6 Clutch Bearings Noisy When Release.............3-13

3.2.6 Removal and Installation........................3-15

3.2.6.1 Clutch Pedal Replacement...............................3-15
3.2.6.2 Clutch Master Cylinder Replacement...............3-17
3.2.6.3 Hydraulic Clutch Bleeding................................3-19
3.2.6.4 Clutch Pedal Free Travel Adjustment...............3-21
3.2.6.5 Clutch Assembly Replacement........................3-22
3.2.6.6 Clutch Pilot Bearing Replacement....................3-22
3.2.6.7 Clutch Slave Cylinder Replacement.................3-24

3.2.7 Special Tools and Equipment.................3-26

3.2.7.1 Special Tools List.............................................3-26

3.3 Manual Transmission....................3-27

3.3.1 Specifications.........................................3-27

3.3.1.1 Fastener Tightening Specifications..................3-27
3.3.1.2 Manual Transmission Specifications................3-27

3.3.2 Description and Operation......................3-30

3.3.2.1 Transmission System Operation......................3-30

3.3.3 System Working Principle.......................3-31

3.3.3.1 Shifting Working Principle................................3-31
3.3.3.2 Vehicle Speed Sensor Working Principle.........3-34
3.3.3.3 Reverse Switch Working Principle...................3-34

3.3.4 Component Locator................................3-35

3.3.4.1 Transmission Assembly Location.....................3-35
3.3.4.2 Vehicle Speed Sensor, Reverse Switch Location. . .
3-36

3.3.5 Disassemble View..................................3-37

3.3.5.1 Gear Components and Gear Box Disassemble View
.....................................................................................3-37
3.3.5.2 Control Mechanism, Fork Component Disassemble
View..............................................................................3-38

3.3.6 Schematic...............................................3-40

3.3.6.1  Reverse  Switch,  Vehicle  Speed  Sensor  Circuit
Schematic.....................................................................3-40

3.3.7 Diagnostic Information and Procedures.....3-
41

3.3.7.1 Diagnosis Description.......................................3-41
3.3.7.2 Visual Inspection..............................................3-41
3.3.7.3 Hard to Shift.....................................................3-42
3.3.7.4 Jumping Out Of Gear.......................................3-44
3.3.7.5 Hard to Disengage...........................................3-46
3.3.7.6 Abnormal Sound When Running......................3-47

3.3.8 Removal and Installation........................3-49

3.3.8.1 Transmission Fluid Level Inspection................3-49
3.3.8.2 Vehicle Speed Sensor Replacement................3-50
3.3.8.3 Transmission Assembly Replacement.............3-52
3.3.8.4 Shift Control Assembly Replacement...............3-60
3.3.8.5 Shift Control Assembly Disassemble and Assemble
.....................................................................................3-67
3.3.8.6 Shift Shaft Replacement...................................3-72
3.3.8.7 Input Shaft Disassemble and Assemble...........3-85
3.3.8.8 Main shaft Disassemble and Assemble...........3-94
3.3.8.9 Shift Lever Replacement................................3-102
3.3.8.10 Transmission Input Shaft Oil Seal Replacement...
3-111

Transmission / Drive Axle

Table of Contents

3-1

3.3.9 Special Tools and Equipment...............3-112

3.3.9.1 Special Tools List...........................................3-112

3-2

Table of Contents

Transmission / Drive Axle