DAELIM vjf125
DAELIM vjf125
CONTENTS
GENERAL INFORMATION
INSPECTIONS / ADJUSTMENTS
LUBRICATION
FUEL SYSTEM
COOLING SYSTEM
ENGINE REMOVAL
CLUTCH / GEARSHIFT
10
CYLINDER / PISTON
11
CRANKCASE / TRANSMISSION /
CRANKSHAFT
12
EXTERNAL PARTS
13
14
15
HYDRAULIC BRAKE
16
17
IGNITION SYSTEM
18
ELECTRIC STARTER
19
LIGHTS/METER/SWITCHES
20
TROUBLESHOOTING
21
WIRING DIAGRAM
22
ELECTRICAL SYSTEM
FRAME
ENGINE
1. GENERAL INFORMATION
1
SERVICE INFORMATION
SERVICE RULES
CAUTION WHEN WIRING
MODEL IDENTIFICATION
SPECIFICATIONS
1-1
1-1
1-5
1-9
1-10
TORQUE VALUES
SYMBOLS / ABBREVIATIONS
TOOLS
WIRING DIAGRAM
1-12
1-14
1-15
1-16
SERVICE INFORMATION
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other workers action and always have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or
recommended parts.
1-1
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GENERAL INFORMATION
3. Store the parts of each system discriminatively to install
each part in the right place.
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.
1-2
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GENERAL INFORMATION
11. Maintenance needed to use the specialized tools must
be performed with the right tool.
12. Never reuse the ball bearing removed with the ball
applied pressure when removing press-fitted the
bearing.
OPEN TYPE
CHAMFERED EDGE
18. The brake fluid and coolant can damage the painted
plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
1-3
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GENERAL INFORMATION
19. Install the oil seal so that the manufacturer marked
surface directs outer surface.(direction not covered
with oil)
Pay attention not to bend or damage the lip.
Apply the grease to the lip.
20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.
CAVITY
MANUFACTURERS NAME
CLIP
FITTING
BOOTS
1-4
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GENERAL INFORMATION
BLACK TUBE
WHITE
TUBE
TESTER PLUG
WHITE
COUPLER.
WHITE
RED STRIPE
BLACK CORD
VALIDATION
OF CAPACITY!
REMOVE
THE
RUST!
1-5
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GENERAL INFORMATION
Turn off the main switch before connecting/disconnecting.
Release the lock to disconnect the lock of the coupler.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
1-6
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GENERAL INFORMATION
Insert the connector until the vinyl cover is fully
inserted into the terminal.
The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.
DRAINING HOLE
WIRING DRIVER
GROOVE SIDE
1-7
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GENERAL INFORMATION
In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape.
NOT TO
PULL!
Prior to using the tester, please read the manual carefully and understand the contents.
When testing the resistance of the tester, the zero
adjustment must be performed before testing.
Is this
measurement range or
configuration in accord
with the manual?
1-8
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GENERAL INFORMATION
MODEL IDENTIFICATION
TOOL BOX
REAR CUSHION
RADIATOR
HELMET HOLDER
CALIPER
BRAKE DISK
GEAR SHIFT PEDAL
MAIN STAND
ENGINE
ENGINE
ENGINE SERIAL
SERIAL
SERIAL NUMBER
NUMBER
NUMBER
SIDE STAND
FRAME
FRAME
FRAME SERIAL
SERIAL NUMBER
NUMBER
SERIAL
NUMBER
1-9
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GENERAL INFORMATION
SPECIFICATIONS
ITEM
DIMENSIONS
FRAME
SPECIFICATIONS
OVERALL LENGTH
OVERALL WIDTH
OVERALL HEIGHT
WHEEL BASE
SEAT HEIGHT
GROUND CLEARANCE
DRY WEIGHT
CURB WEIGHT
2,025mm
778mm
1,180mm
1,380mm
780mm
139mm
173kgf
292kgf
TYPE
FRONT SUSPENSION / STROKE
REAR SUSPENSION / STROKE
FRONT TIRE SIZE (TYPE)
REAR TIRE SIZE (TYPE)
TIRE PRESSURE 1 PERSON FRONT
REAR
2 PERSON FRONT
REAR
FRONT BRAKE
REAR BRAKE
FUEL CAPACITY
FUEL RESERVE CAPACITY
CASTER ANGLE
TRAIL
FRONT FORK OIL CAPACITY
Double Cradle
Telescopic / 130mm
Swingarm / 28mm
110/70-17 54P (Tubeless)
140/60-17 69P (Tubeless)
2.00kgf/cm2(200kPa)
2.00kgf/cm2(200kPa)
2.00kgf/cm2(200kPa)
2.25kgf/cm2(225kPa)
Hydraulic Disk
Hydraulic Disk
14.85
4.0
25.2
93.5mm
2652.5cc
TYPE
CYLINDER NUMBER, ARRANGEMENT
BORE AND STROKE
DISPLACEMENT
COMPRESSION RATIO
VALVE TRAIN
OIL CAPACITY
ENGINE
LUBRICATION SYSTEM
AIR FILTRATION TYPE
CYLINDER COMPRESSION
INTAKE VALVE
OPEN
CLOSED
EXHAUST VALVE
OPEN
CLOSED
VALVE CLEARANCE
INTAKE
(A COOLING-OFF PERIOD) EXHAUST
ENGINE DRY WEIGHT
1-10
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GENERAL INFORMATION
ITEM
DRIVE TRAIN
ELECTRICAL
SPECIFICATIONS
CLUTCH TYPE
TRANSMISSION TYPE
GEAR RATIO 1st
GEAR RATIO 2nd
GEAR RATIO 3rd
GEAR RATIO 4th
GEAR RATIO 5th
GEARSHIFT PATTERN
IGNITION TYPE
IGNITION TIMING F MARK
FULL ADVANCE
AC GENERATOR
BATTERY CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT (HIGH/LOW BEAM)
POSITION LAMP
TURN SIGNAL LAMP
STOP/TAIL LIGHTS
SPEEDOMETER LAMP
NEUTRAL INDICATOR LAMP
HIGH BEAM INDICATOR LAMP
WINKER INDICATOR LAMP
LICENCE PLATE LAMP
TACHOMETER LAMP
MALFUNCTION INDICATOR LAMP
Full Transisterized
18BTDC / 1,600(rpm)
30BTDC / 8,500(rpm)
12V-17A/5,000(rpm)
12V 10AH
CR9EH - 9
0.8 - 0.9mm
30A
Starter Motor
55W/55W
5W
10W4
21W/5W
3W
LED1
LED
LED
5W
LED1
LED
1-11
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GENERAL INFORMATION
TORQUE VALUES
ENGINE
ITEM
QTY
THREAD DIA
(mm)
8
4
4
1
2
1
1
1
1
3
2
3
1
2
12
1
7
1
1
10
1
1
1
1
M61.0
M101.25
M61.0
M61.0
M61.0
M61.0
M161.0
M161.0
M121.25
M81.25
M61.0
M101.25
M61.0
M61.0
M61.0
M61.0
M61.0
M141.5
M301.5
M61.0
M101.25
M61.0
M361.5
M121.25
QTY
THREAD DIA
(mm)
TORQUE
kgf.m,(N.m)
REFERENCE
1.0~1.2
3.5~4.5
0.8~1.2
0.8~1.2
1.0~1.4
0.35~0.5
6.0~7.0
6.0~7.0
5.0~6.0
3.0~3.4
1.0~1.4
1.0~1.4
1.0~1.4
1.0~1.4
1.0~1.2
1.0~1.2
1.0~1.2
0.4~0.8
1.0~2.0
1.0~1.2
1.0~1.2
1.0~1.4
1.0~2.0
1.0~2.0
FRAME
ITEM
1-12
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TORQUE
kgf.m,(N.m)
M101.25
4.5~5.5
M101.25
5.0~6.0
M101.25
4.5~5.5
M81.25
2.4~3.0
M81.25
2.4~3.0
M101.25
1.0~2.0
M101.25
4.0~5.0
M 50.8
0.35~0.5
M141.5
8.0~10.0
M101.25
5.5~6.5
M101.25
3.4~4.0
REFERENCE
HEX NUT
U- NUT
U- NUT
GENERAL INFORMATION
FRAME
ITEM
QTY
THREAD DIA
(mm)
2
2
1
6
4
4
2
1
1
2
2
2
1
2
2
4
2
5
M81.25
M61.0
M141.5
M81.25
M101.25
M81.25
M61.0
M221.0
M221.0
M81.25
M81.25
M81.25
M141.25
M101.25
6mm Tapping
M81.25
M81.25
M81.25
TORQUE
kgf.m,(N,m)
REFERENCE
2.8~3.4
1.0~1.4
5.5~6.5
4.0~4.5
3.0~4.0
2.8~3.4
1.0~1.4
6.0~9.0
0.25~0.35
2.4~3.0
3.0~4.0
2.4~3.0
8.0~10.0
3.5~4.5
0.5~0.7
4.0~4.5
1.8~2.5
4.0~4.5
U- NUT
U- NUT
*Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.
TORQUE
TYPE
TYPE
kgfm
Nm
4.0~6.0
0.45~0.6
5mm SCREW
8~12
0.8~1.2
TORQUE
kgfm
Nm
3.4~5.0
0.35~0.5
7~11
0.7~1.1
(Include SH type)
18~25
1.8~2.5
9.8~14
1.0~1.4
29~39
3.0~4.0
24~29
2.4~3.0
49~59
5.0~6.0
34~44
3.5~4.5
1-13
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GENERAL INFORMATION
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.
SYMBOL
MEANING
SYMBOL
MEANING
followed.
The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when
performing maintenance.
SYMBOL
CAUTION
Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified
Use Fork or Suspension Fluid
Use special tool
Use option tool. These tools are obtained as you order parts.
( 3-1)
Special grease, etc. that do not correspond to the above are indicated without using symbols.
1-14
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GENERAL INFORMATION
TOOLS
SPECIAL
DESCRIPTION
CLUTCH CENTER HOLDER
ACG ROTOR PULLER
VALVE GUIDE DRIVER
VALVE GUIDE REAMER
UNIVERSAL BEARING PULLER
BEARING REMOVER SET
THREAD ADAPTER
ASSEMBLY SHAFT
CRANK CASE ASSEMBLY COLOR
BALL RACE DRIVER
STEERING STEM DRIVER
FORK SEAL DRIVER
STEERING STEM SOCKET
SNAP RING PLIERS
COMMON
REF. SEC.
DESCRIPTION
8
WRENCH, 89mm
9
ADJUSTING WRENCH, B
10
LOCK NUT WRENCH, 2024mm
10
EXTENSION BAR
12
FLY WHEEL HOLDER
12
VALVE SPRING COMPRESSOR
12
DRIVER
12
ATTACHMENT
12
PILOT
14
FORK SEAL DRIVER BODY
14
BEARING REMOVER HEAD
14
BEARING REMOVER SHAFT
14
LOCK NUT(M8)
16
REF. SEC.
2
2
6
8, 14
8, 9
10
12, 14, 15
12, 14, 15
12, 14, 15
14
15
15
10
TESTER, GAUGE
DESCRIPTION
COMPRESSION GAUGE
DIGITAL MULTI TESTER
PVA TESTER
BATTERY TESTER
TESTER RECORDER
REFERENCE SECTION
REMARK
2
17, 18
17, 18
18
5
REFERENCE SECTION
REMARK
10
10
10
10
10
24.5mm IN, EX
23mm IN
20mm EX
22mm IN, EX
Use with Valve Seat
1-15
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GENERAL INFORMATION
WIRING DIAGRAM
1-16
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GENERAL INFORMATION
1-17
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GENERAL INFORMATION
1-18
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GENERAL INFORMATION
1-19
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MEMO
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1
MAINTENANCE SCHEDULE 2-3
FUEL LINE (FUEL TUBE) 2-4
2-4
THROTTLE GRIP OPERATION
AIR CLEANER 2-5
SPARK PLUG 2-5
VALVE CLEARANCE 2-6
CYLINDER COMPRESSION PRESSURE 2-7
2-8
DRIVE CHAIN
2-9
DRIVE CHAIN SLIDER
2-9
BRAKE FLUID
2-9
BRAKE PAD WEAR
SERVICE INFORMATION
The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
For information on engine oil and oil filter, refer to sections 3-3 and 3-4.
Stand the main stand prior to beginning work.
SPECIFICATIONS
THROTTLE GRIP PLAY
SPARK PLUG
SPARK PLUG GAP
IN.
EX.
VALVE CLEARANCE
CARBURETOR IDLE SPEED
CYLINDER COMPRESSION
DRIVE CHAIN SLACK
REAR BRAKE PEDAL FREE PLAY
CLUTCH LEVER FREE PLAY
2~6mm
CR9EH-9
0.8~0.9mm
0.15mm
0.20mm
1,600rpm100rpm
13.0kgf/ ( 600rpm )
10~20mm
10~20mm
10~20mm
TIRES
COLD TIRE
PRESSURE
DRIVER ONLY
DRIVER AND A
PASSENGER
TIRE SIZE
TIRE
PART MINIMUM-DEPTH
FRONT
REAR
FRONT
REAR
FRONT
REAR
FRONT
REAR
)
)
)
)
2-1
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INSPECTIONS / ADJUSTMENTS
TORQUE VALUES
SPARK PLUG
CYLINDER HEAD COVER BOLT
AC GENERATOR CAP
HOLE CAP 30mm
AIR CLEANER CASE COVER SCREW
REAR AXLE NUT
DRIVE SPROCKET BOLT
DRIVEN SPROCKET NUT
TOOLS
WRENCH, 89mm
COMPRESSION GAUGE
2-2
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1.0~1.2kgf-m
0.8~1.2kgf-m
0.4~0.8kgf-m
0.6~1.0kgf-m
0.4~0.8kgf-m
8.0~10.0kgf-m
1.0~1.4kgf-m
5.6~6.5kgf-m
INSPECTIONS / ADJUSTMENTS
MAINTENANCE SCHEDULE
Perform the Self Inspections Before Operation at each scheduled maintenance period.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
R : REPLACE L : LUBRICATE C : CLEAN A : ADJUST
FREQUENCY
ITEM
ODOMETER READING(NOTE 1)
x 1000Km
1/2
MONTH
12
12
18
FUEL LINE
FUEL FILTER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL
DRIVE CHAIN
BRAKE FLUID
BRAKE SYSTEM
HEADLIGHT AIM
SIDE STAND
SUSPENSION
NOTE (2)
CLUTCH SYSTEM
REMARK
WHEELS/TIRES
NOTE (3)
RADIATOR COOLANT
RADIATOR CORE
RADIATOR CAP
If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to
perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs.
To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers.
NOTES : (1) After the odometer reading exceeds 1,200Km, repeat maintenance service at intervals indicated in the table.
(2) Service more frequently when riding in unusually wet or dusty areas.
(3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires
mechanical skill.
2-3
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INSPECTIONS / ADJUSTMENTS
FUEL
FUEL
TUBE
FUEL TUBE
TUBE
INJECTOR
INJECTOR
INJECTOR
THROTTLE
THROTTLE
GRIP
THROTTLE GRIP
GRIP
THROTTLE
THROTTLE
CABLE
THROTTLE CABLE
CABLE
ADJUSTER
ADJUSTER
ADJUSTER
LOCK
LOCK
NUT
LOCK NUT
NUT
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
LOCK
LOCK
NUT
LOCK NUT
NUT
THROTTLE
THROTTLE
CABLE
THROTTLE CABLE
CABLE
2-4
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INSPECTIONS / ADJUSTMENTS
AIR CLEANER
SCREWS
SCREWS
SCREWS
AIR
CLEANER
AIR
AIR CLEANER
CLEANER
AIR
CLEANER
HOUSING COVER
COVER
HOUSING
COVER
HOUSING
AIR
AIR
CLEANER
AIR CLEANER
CLEANER
ELEMENT
ELEMENT
ELEMENT
SPARK PLUG
Remove the spark plug cap.
Check the plug for damage, contamination or deposits.
If the spark plug is severely contaminated or damaged,
raplace with a new one. If the plug can be reused after
removing only the carbon, use plug cleaner and wire
brush to clean the plug.
Always use a feeler gauge to check the gap.
SPARK
SPARK PLUG
PLUG WRENCH
WRENCH
SPARK
PLUG
WRENCH
CHECK GAP,
DEPOSITS
0.8~0.9mm
CHECK WASHER
FOR DAMAGE
CHECK FOR
CRACKS
2-5
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INSPECTIONS / ADJUSTMENTS
VALVE CLEARANCE
T MARK
MARK
T
T
MARK
CAM
CAM
SHAFT
CAM SHAFT
SHAFT
SHIM
SHIM
SHIM
SHIM
FEELER
GAUGE
FEELER
FEELER GAUGE
GAUGE
SHIM ADJUSTMENT
If the valve clearance is out of standard, adjust the shim
as below.
- Remove the camshaft.
- Remove the valve lifter and shim.
VALVE
VALVE
LIFTER
VALVE LIFTER
LIFTER
SHIM
SHIM
SHIM
VALVE
VALVE
LIFTER
VALVE LIFTER
LIFTER
2-6
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INSPECTIONS / ADJUSTMENTS
SHIM
SHIM
SHIM
SHIM
118800
118822
118855
118888
1.800mm
1.800mm
1.825mm
1.825mm
1.850mm
1.850mm
1.875mm
1.875mm
Tool:compression gauge.
INSPECTIONS / ADJUSTMENTS
DRIVE CHAIN
Because there is a danger which fingers get jammed
in the drive chain, never inspect or adjust it while
the engine is running.
ADJUSTER
ADJUSTER
SCALE
ADJUSTER SCALE
SCALE
WHEEL
AXLE
WHEEL
WHEEL AXLE
AXLE
WHEEL
AXLE
LOCK
NUT
LOCK
LOCK NUT
NUT
LOCK
NUT
DRIVE
SPROCKET
DRIVE
DRIVE SPROCKET
SPROCKET
DRIVE
CHAIN
DRIVE
DRIVE CHAIN
CHAIN
WEAR
NORMAL
DRIVE
SPROCKET
DRIVE
DRIVE SPROCKET
SPROCKET
2-8
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INSPECTIONS / ADJUSTMENTS
WEAR
WEAR
WEAR
WEAR
INDICATOR
INDICATOR
INDICATOR
BRAKE FLUID
BRAKE
FLUID
CHECKING
SCREEN
BRAKE
BRAKE FLUID
FLUID CHECKING
CHECKING SCREEN
SCREEN
BRAKE
FLUID
CHECKING
SCREEN
LOWER
LOWER LEVEL
LEVEL LINE
LINE
LOWER
LEVEL
LINE
FRONT BRAKE
Turn the handlebar so that the reservoir is level and
check the front brake fluid reservoir level.
If the level is near the lower level line, check the brake
pad wear.
UPPER
LOWER
REAR BRAKE
Place the motorcycle on a level surface, and support it
upright position.
Check the rear brake fluid reservoir level.
If the level is near the lower level line, check the brake
pad wear.
FRONT
FRONT
CALLIPER
FRONT CALLIPER
CALLIPER
WEAR
WEAR INDICATOR
INDICATOR
WEAR
INDICATOR
2-9
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INSPECTIONS / ADJUSTMENTS
REAR BRAKE PADS
Check the brake pads for wear.
Replace the brake pads if either pad is worn to the
bottom of wear limit groove.
Refer to page 16-7 for brake pad replacement.
WEAR
WEAR
INDICATOR
WEAR INDICATOR
INDICATOR
REAR CALLIPER
CALLIPER
REAR
REAR
CALLIPER
BRAKE SYSTEM
Check to see if there is a crack and damage in the
front and rear brake hose.
If leak, replace it with new one.
BRAKE
HOSE
BRAKE
BRAKE HOSE
HOSE
10~20mm
10~20mm
10~20mm
2-10
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INSPECTIONS / ADJUSTMENTS
BRAKE PEDAL HEIGHT ADJUSTMENT
BRAKE
BRAKE
HOSE
JOINT
BRAKE HOSE
HOSE JOINT
JOINT
Loosen the lock nut and turn the stopper bolt until
the correct pedal height is obtained.
After adjustment, tighten the lock nut securely.
ADJUST
NUT
ADJUST
ADJUST NUT
NUT
ADJUST
NUT
REAR
REAR
STOP
SWITCH
REAR STOP
STOP SWITCH
SWITCH
ADJUST
ADJUST
NUT
ADJUST NUT
NUT
HEADLIGHT AIM
CLUTCH SYSTEM
2-11
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INSPECTIONS / ADJUSTMENTS
LOCK
LOCK
NUT
LOCK NUT
NUT
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
CLUTCH
CLUTCH
CABLE
CLUTCH CABLE
CABLE
LOCK
LOCK NUT
NUT
LOCK
NUT
ADJUSTER
ADJUSTER
ADJUSTER
CLUTCH
CLUTCH
REVER
CLUTCH REVER
REVER
CLUTCH
CLUTCH
WIRE
HOLDER
CLUTCH WIRE
WIRE HOLDER
HOLDER
SIDE STAND
Erect the main stand.
SIDE
SIDE
STAND
SIDE STAND
STAND
2-12
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INSPECTIONS / ADJUSTMENTS
SUSPENSION
Do not ride motorcycle with an unsatisfactory
suspension. Loose or worn suspension parts will
lead to deterioration in the vehicle's safety and
operation efficiency.
FRONT FORK
Hold the brake lever, and compress the front fork up
and down several times to check the operating
conditions.
Check the front fork for oil leakage, parts damage
or looseness.
REAR CUSHION
Compress the rear cushion up and down several
times to check the operating conditions.
Check the rear cushion for oil leakage, parts
damage or looseness.
WHEEL INSPECTION
Erect the motorcycle with the main stand.
Check a wear of the rear fork bush by moving the
rear wheel aside. If there is a free play, replace the
rear fork bush.
Tighten all nuts and bolts of the rear suspension.
2-13
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INSPECTIONS / ADJUSTMENTS
WHEEL/TIRE
Check the tire pressure when the tires have been
cooled off. Check the tread (the part making
contact with the road surface) and side for wear,
cracks or damage. Replace damaged tires.
STANDARD PRESSURE
f/ (kpa)
ITEM
FRONT WHEEL REAR WHEEL
DRIVER ONLY
2.00(200)
2.00(200)
2.00(200)
2.25(225)
DRIVER AND A PASSENGER
STEERING STEM
Check that the cables do not interfere with
handlebar rotation.
Erect the motorcycle securely and raise the front
wheel off the ground.
Check that the handlebar moves freely from side to
side.
If the handlebar moves unevenly, binds or has
vertical movement, inspect the steering stem.
2-14
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INSPECTIONS / ADJUSTMENTS
COOLANT REPLACEMENT
Remove the radiator cap.
2-15
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MEMO
3. LUBRICATION
SERVICE INFORMATION 3-1
TROUBLESHOOTING3-2
ENGINE OIL LEVEL INSPECTION 3-3
ENGINE OIL CHANGE 3-3
SERVICE INFORMATION
GENERAL SAFETY
1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
2. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after
handling the used oil.
3. The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
1.5 (After disassembly)
OIL CAPACITY
OIL PUMP
ITEM
PUMP BODY CLEARANCE
ROTOR END CLEARANCE
-10
10
20
30
40
Unit : mm
STANDARD VALUE
0.15~0.20
0.15
SERVICE LIMIT
0.25
0.20
TORQUE VALUES
OIL DRAIN CAP
OIL FILTER COVER BOLT
1.5fm
1.1fm
3-1
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LUBRICATION
TROUBLESHOOTING
Engine oil level too low
Oil consumption naturally.
External oil leaks.
Worn piston ring or incorrect piston ring installation.
Worn valve guide or seal.
Oil contamination
Oil or filter not changed regularly.
Faulty head gasket.
Worn piston rings.
3-2
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LUBRICATION
OIL DRAIN
DRAIN CAP
CAP
OIL
OIL
DRAIN
CAP
DRAIN
DRAIN
PLUG
BOLT
DRAIN PLUG
PLUG BOLT
BOLT
TAPPET
ADJUST
HOLE
CAP
TAPPET
TAPPET ADJUST
ADJUST HOLE
HOLE CAP
CAP
TAPPET
ADJUST
HOLE
CAP
3-3
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LUBRICATION
OIL
OIL
FILTER
COVER
OIL FILTER
FILTER COVER
COVER
RH.
RH.
SIDE
COWL
RH. SIDE
SIDE COWL
COWL
OIL
OIL
FILTER
ELEMENT
OIL FILTER
FILTER ELEMENT
ELEMENT
OIL SEAL
SEAL
OIL
OIL
SEAL
OIL
PUMP
GEAR
OIL
OIL PUMP
PUMP GEAR
GEAR
OIL PUMP
REMOVAL
Drain the engine oil. (3-3)
Remove the oil filter. (3-4)
3-4
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LUBRICATION
Clean the oil pump body (inner and outer) and rotors
with fresh cleaning oil.
OUTER
OUTER ROTOR
ROTOR
OUTER
ROTOR
INNER
INNER ROTOR
ROTOR
INNER
ROTOR
INNER
INNER
ROTOR
INNER ROTOR
ROTOR
INSPECTION
Install the inner and outer rotors into the oil pump
body.
Measure the pump body clearance.
SERVICE LIMIT : 0.25mm
OUTER
OUTER
ROTOR
OUTER ROTOR
ROTOR
FEELER
FEELER
GAUGE
FEELER GAUGE
GAUGE
ASSEMBLY
Clean all parts with fresh cleaning oil.
Install the lnner and outer rotor to the pump body.
INSTALLATION
Install the oil filter cover to the RH.crank case.
Fill the recommended oil into the crankcase. (3-3)
3-5
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LUBRICATION
LUBRICATION POINTS
Use general grease
SECTION ROTATE
SLIDING PART
EDGE PART
SLIDING PART
INSIDE PART OF MASTER CYLINDER CUP
SLIDING PART
EDGE PART
SLIDING PART
EDGE PART
GEAR COUPLING
INSIDE
EDGE PART
SLIDING PART
CONCORDANT PART
SLIDING PART
CASTING AND CONTACT INSIDE PART
CASTING INSIDE PART
SLIDING PART
Apply oil or grease to the other sliding surfaces not shown here.
3-6
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DOT3 or DOT 4
ASSEMBLY OIL CCI No.20 or SUITABLENESS WIDTH
BRAKE GREASE SPECIAL
MEMO
FUEL SYSTEM
4-0
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4. FUEL SYSTEM
SERVICE INFORMATION 4-1
TROUBLESHOOTING 4-2
4-3
FUEL TANK
4-4
AIR CLEANER CASE
SERVICE INFORMATION
4
GENERAL SAFETY
Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore,
the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas.
Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly
ventilated area.
STANDARD OF MAINTENANCE
Fuel tank capacity : 14.85
Reserve fuel capacity: 4.0
Fuel pump specification : KGF38
Flow quantity : Mimnim 20/hr
Flow pressure : 380kpa
Injector specification
Injector angle : 15
Operation pressure : 380kpa
TORQUE VALUE
Air cleaner case cover screw 0.43kgfm (4.3Nm)
TOOL
Float level gauge
TROUBLESHOOTING
Engine cranks but wont start
No fule in tank
No fule to carburetor
Cylinder flooded with fuel
Clogged air cleaner
No spark at plug
4-1
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FUEL SYSTEM
FULE TANK
FUEL
FUEL
TANK
FUEL TANK
TANK
REMOVAL
FUEL
FUEL TANK
TANK SERVE
SERVE CORD
CORD
FUEL
TANK
SERVE
CORD
FUEL TUBE
TUBE
FUEL
FUEL
TUBE
CLIP
CLIP
CLIP
INSTALLATION
Install the fuel tank in the reverse order of removal.
After installation, check if there is a gasoline leak.
4-2
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FUEL TANK
FUEL SYSTEM
REMOVAL
Remove the main seat.
Remove the fuel tank.
Remove the RH. LH. side covers.
Remove the fuel tank rear stay.
FUEL
FUEL
TANK
REAR
STAY
FUEL TANK
TANK REAR
REAR STAY
STAY
INSTALLATION
Install in the reverse order of removal.
4-3
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MEMO
5-2
5-3
5-4
5-5
5-5
5-5
5-5
5-6
5-8
5-9
5-9
5-10
5-11
5-11
5-12
8. THROTTLE BODY
5-13
9. INJECTOR
5-17
10. MAPAT
5-20
5-24
5-27
5-30
5-33
5-36
5-37
5-38
5-42
5-45
- ECU INITIALIZING
5-45
5-47
5-48
5-49
5-1
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Do not touch the ECU terminal, because it may be damaged by the static.
The ignition key off before assembly and disassembly of the ECU coupler.
Do not connect adversely the polarity of battery, otherwise, it might be broken the EMS parts
5-2
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2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to
injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division
pipe and injector.
The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter.
Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of
intake system.
Injector sprays fuel into the intake system by injection signals of ECU.
3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to
control proper spark time in cylinder, high-voltage system, and so forth.
4) CONTROL SYSTEM
Various sensors to move electric signals converted by checking the current engine status
Input interface which works various processes like regulating voltage levels, removal of noise, A/D
conversion, amplifying of inputted signals from above sensors.
Micro-computer which decides output value through various calculating, arithmetic and logic
processing.
Output interface to amplify the above output signals.
Actuator being mechanically worked by receiving the amplified output signals.
5-3
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PIN NO.
FUNCTION
PIN NO.
ECU Earth
Third Gear
Communication LOW
MIL
Battery Power
ECU Earth
Neutral Gear
Communication HIGH
Ignition Signal
Injector Signal
Remarks
ECU PIN NO. 6,7,8,11,14,15,16,36 were not connected.
Terminal arrangement is based on the ECU.
5-4
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ERROR Checklist
PIN NO.
Starting
Idle RPM
Stability
Driving
ECU 24
ECU 25
ECU 26
Starting
Idle RPM
Stability
Driving
ECU 01
ECU 23
ECU 02
ECU 03
ECU 04
MIL
MIL
ECU 05
ECU 27
6, 7, 8
ECU 28
ECU 09
ECU 29
ECU 10
ECU 30
ECU 11
ECU 31
ECU 12
ECU 32
ECU 13
ECU 33
14,15,16
ECU 34
ECU 17
ECU 35
ECU 18
ECU 36
ECU 19
ECU 37
ECU 20
ECU 38
ECU 21
ECU 39
ECU 22
ECU 40
O
5-5
MIL
OFF
ON
Unable to engine start
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs
fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON
Blink
5-6
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MILoff
on/off
: :MIL
: MIL
on on
: MIL
If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.
INTAKE
INTAKE
valve of
ofintake
intaketemperature
temperatureisisfixed
fixedastoa
The value
20.25 when
thebefore
intakewhen
pressure
temperature
just
thesensor
intakeis out
of order. sensor is out of order.
pressure
! CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.
5-7
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Measure the wire harness for checking by connecting the ECU with main wire harness to check the ECU.
It has two coupler to check the terminal.
The wireharness to check the ECU arrangement
Coupler for checking : ECU PIN no. 1,2,3,4,5,9,10,12,17,18,19,20 were connected.
ECU PIN no. 6,7,8,11,13,14,15,16 is not connected.
Coupler for checking : ECU PIN no. 21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,37,39,40 were connected.
ECU PIN no. 36 is not connected.
5-8
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If the MIL on when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started.
ON
OFF
1.5 sec
3 sec
5-9
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MIL INDICATION
(The number of blinks)
Fault
code no.
Priority
order
Description
No failure
5-10
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5-11
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SEAT
SEAT
LOCK
SEAT LOCK
LOCK
! CAUTION
CENTER
COVER
CENTER
CENTER COVER
COVER
CENTER
COVER
COVER
COVER
SETTING
GROMMET
COVER SETTING
SETTING GROMMET
GROMMET
Remove
ECU
ECU
GROUND
WIRE
ECU GROUND
GROUND WIRE
WIRE
- ECU coupler
- Remove the coupler in sequence
- Remove the 4 flange bolts securing ECU
FLANGE
FLANGE
BOLTS
FLANGE BOLTS
BOLTS
Install
- Install in the reverse order of removal
! CAUTION
5-12
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8. THROTTLE BODY
Remove the seat support pipe.
Remove the fuel tank.
AIR
AIR
CLEANER
AIR CLEANER
CLEANER
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR
INJECTOR
INJECTOR
INJECTOR
INSULATOR
INSULATOR
INSULATOR
5-13
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! CAUTION
INSULATOR
INSULATOR
INSULATOR
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR
REMOVE
Loosen the throttle body 2 bolts securing the
insulator.
Disconnect the TPS (Throttle position sensor).
Disconnect the ISA(Idle speed actuator).
Disconnect the MAPAT.
! CAUTION
IDLE
SPEED
ACTUATOR
IDLE
IDLE SPEED
SPEED ACTUATOR
ACTUATOR
IDLE
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
5-14
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INJECTOR
INJECTOR
INJECTOR
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR
O-RING
O-RING
O-RING
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR
INJECTOR
INJECTOR
INJECTOR
INSULATOR
INSULATOR
INSULATOR
INSULATOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INSULATOR
INSULATOR
INSULATOR
INSULATOR
THROTTLE
THROTTLE
CABLE
THROTTLE CABLE
CABLE
ASSEMBLY
Assemble the throttle cable.
Adjust the free play of throttle grip.
ADJUST SCREW
SCREW
ADJUST
ADJUST
SCREW
ADJUST
ADJUST
SCREW
ADJUST SCREW
SCREW
5-16
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INJECTOR
INJECTOR
9.INJECTOR
Remove
Remove the fuel tank.
! CAUTION
upward.
! CAUTION
spark plug.
Remove the injector.
Assemble
Install in reverse order of removal.
5-17
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Checking Circuit
ECU
INJECTOR
40 : INJECTOR control
39 : FUEL PUMP control
5-18
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CHECKING PROCEDURE
1) Turn off the ignition key.
2) Check to see if the injector coupler has come loose or the wire is peeling off.
If there is no problem, measured the resistance of injector.
3)Disassemble the injector coupler and measure the resistance between injector terminals.
The resistance of injector : 14.50.7[ ], 20
Remarks : measuring unit for resistance : resistance R [ ]
4)If there is no problem, check the continuity between each terminal and ground.
The resistance between each terminal and ground : [ ]
If resistance value is not normal, replace injector with the new one.
5)If the resistance is normal, turns on the ignition key
- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.
6) Measure between the voltage of coupler.
Measuring terminal : BLACK/RED electric wire ~ ground
Measuring voltage : battery voltage 1.0[V]over
Remarks : Measuring unit of voltage : voltage [V]
7) If the measured voltage is normal,
Check the Blue/Yellow electric wire to see if they have been broken or have short-circuited
or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)
If there is no problem in the electric wires, ECU is broken
Replace the ECU with new one, it rechecks
8) If the measured voltage is not normal,
Check the Black/Red electric wire to see if they have been broken or have short-circuited.
Check the fuel pump relay.
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-19
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Remove
Remove the MAPAT sensor coupler.
! CAUTION
MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
SENSOR
MAPAT sensor.
Assemble
Install in reverse order of removal.
5-20
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Checking circuit
MAPAT
ECU
33: Intake
pressure sensor
: Inhalation
pressureground
26
:
5V
voltage
sensor GROUND
27
26::IMP
5V voltage
28
27::TBA
IMP 28 : TBA
CHECKING PROCEDURE
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input 5 voltage of MAPATs coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
Remarks : Measuring unit of voltage : voltage [V]
5) If voltage value is not normal,
Check to see if the ECU coupler is loose or if there is a bad contact.
Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited
Remark : refer to (5-16) if the intake pressure sensor is broken
refer to (5-16) if the intake temperature sensor is broken
After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-21
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5-22
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5-23
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Remove
Press the TPS coupler then remove it with
pulling.
! CAUTION
MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
SENSOR
SCREWS
SCREWS
SCREWS
Assemble
Install in reverse order of removal.
5-24
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Checking circuit
Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the ignition key.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPSs coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit of voltage : Voltage [V]
If voltage value is not normal,
Check to see if the ECU coupler is loose if there is bad contact.
Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been
broken or have short- circuited.
5) If the value of voltage is normal, turn off the ignition key.
5-25
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5-26
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THERMO
STAT
THERMO
THERMO STAT
STAT
Remove
After pressing the ETS coupler and pull it..
! CAUTION
ENG.
ENG.
TEMP.
ENG. TEMP.
TEMP.
SENSOR
SENSOR
SENSOR
ENG.
ENG.
TEMP.
ENG. TEMP.
TEMP.
SENSOR
SENSOR
SENSOR
Assemble
Install in reverse order of removal.
5-27
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CHECKING CIRCUIT
ETS
ECU
4 : SENSOR GROUND
20 : ETS
50V SUPPLY VOLTAGE
Checking Procedure
1) Turn off the ignition key .
2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Measure the terminal voltage of ETSs coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit for voltage : voltage [V]
If the voltage value is not normal,
Check to see if the ECU coupler is loose, or bad contact.
Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been
broken or have short- circuited.
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS :1.6[k ]~10.6[k ],20 ~80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance R [k ]
5-28
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Checking Procedure
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to 5-27)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperatures change and testers value.
Characters of ETS
Temperature
Resistance value
20
10.6[k ]~14.4[k ]
80
1.35[k ]~1.65[k ]
110
0.57[k ]~0.69[k ]
1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the Thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.
3) Install
Install in the reverse order of removal with standard torque.
5-29
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Remove
Remove the ISA coupler
! CAUTION
Assemble
Install in reverse order of removal.
5-30
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CHECKING CIRCUIT
ECU
40
39
ISA
39::ISA
FUEL
PUMP CONTROL
33
CONTROL
40
:
INJECTOR
39:FUEL PUMP CONTROL
CHECK PROCEDURE
1) Turn off ignition key .
2) Check to see if the ISA(Throttle Position Sensor) coupler is loose,
or bad.If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ],20
remarks : Measuring unit of resistance : Resistance R[ ]
4) If there is no problem, check about the level of electricity flow between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : [ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-28 )
remarks : Measuring unit for resistance : Resistance R[ ]
5-31
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5-32
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14.O2(Oxygen) SENSOR
It is located on the exhaust pipe
! CAUTION
O2
O2 SENSOR
SENSOR
O2
SENSOR
Remove
Center cowl
O2 sensor coupler
O2
SENSOR
O2
O2 SENSOR
SENSOR
O2
O2
SENSOR
COUPLER
O2 SENSOR
SENSOR COUPLER
COUPLER
O2
O2 SENSOR
SENSOR
O2
SENSOR
Assemble
Install in reverse order of removal.
5-33
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CHECKING CIRCUIT
OXYGEN SENSOR
ECU
5-34
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5-35
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CHECKING CIRCUIT
TACHOMETER
ECU
32 : ESS(ENGINE SPEED SIGNAL)
CHECK PROCEDURE
1) Turn off the ignition key .
2) Check the ESS coupler is loose, or bad.
If there is no problem, check the resistance of tachometer.
3) Check the resistance between each terminals and ground.
Measuring terminal: B electric wire ~ EARTH,
ECU NO. 32 (B/Y:BLACK/YELLOW) ~ EARTH
The resistance between each terminals and ground : [ ]
If the measured resistance value is abnormal, replace the part with new one.
Refer to ( ) for assembly and disassembly
Remark : Measuring unit of voltage : Resistance [ ]
CHECKING CIRCUIT
ECU
24 : MALFUNCTION INDICATOR LAMP OUTPUT
CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
3) Turn on the ignition key.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the Lamp.
But If the Lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : B electric wire ~
EARTH => Output Voltage: battery voltage
Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~
EARTH => Output voltage:
battery voltage
Remarks : Measuring unit of voltage : Voltage[V]
If the measured voltage is normal,
Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.
If the measured voltage is abnormal,
Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been
broken or have short- circuited.
6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
5-37
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LH.REAR
LH.REAR COVER
COVER
LH.REAR
COVER
LH.CRANK
LH.CRANK CASE
CASE COVER
COVER
LH.CRANK
CASE
COVER
AC.
GENERATOR
AC.
AC. GENERATOR
GENERATOR
AC.
GENERATOR
5-38
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SPOT
SPOT
SPOT
ASSEMBLY
Assembly is the reverse order of removal.
MEASUREMENT PVA
Disconnect the ACG (L/G) connector.
Connect the (+)cord of PVA tester to the green
terminal or ground wire.
Connect the (-)cord of PVA tester to the blue
terminal.
Crank the engine with the starter motor and
measure the peak voltage of crank position
sensor coil.
HIGHEST VOLTAGE : 1.5V Over.
TOOL : PVA Multy tester.
Assembly is the reverse order of removal.
5-39
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CHECKING CIRCUIT
GREEN
BLUE
RED
BLUE
30 : CRANK
SIGNAL-A
30 :
_ A
22 :
_ B
22 : CRANK
SIGNAL-B
22
30
CHECK PROCEDURE
1) Turn ON ignition key.
2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.
When start up the ENGINE SINK ON change OFF to ON, its okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance.
- measuring resistance : 80 ~ 150[]
5-40
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RED
BLUE
5-41
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18.FUEL PUMP
It is located inside a fuel tank
Remove the seat.
Loosen the washer bolt, 2 flange bolts
securing fuel tank.
Loosen the 4 socket bolts and remove the fuel
filler cap.
! CAUTION
Remove
Loosen the 2 special screws.
Remove the tank cover.
5-42
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18.FUEL PUMP
5-43
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Terminals resistance []
F : 192[mm]
30 5[]
1/2 : 138[mm]
300 5[]
E : 74[mm]
566 3[]
ASSEMBLY
Assembly is the reverse order of removal.
5-44
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5-45
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5-46
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5-47
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5-48
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5-49
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COOLING SYSTEM
6-0
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6. COOLING SYSTEM
STROUBLESHOOTING6-2
COOLANT6-3
WATER PUMP6-7
TERMOSENSOR6-10
RADIATOR6-4
THERMOSTATIC6-10
SERVICE INFORMATION6-1
SERVICE INFORMATION
Do not remove the radiator cap if the coolant temperature is over 100C.
It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious
scalding.
When the temperature is below, carefully remove the cap with a cloth.
Cooling system service should be done while the engine is cool.
Radiator coolant is toxic. Keep it away from skin, eyes and clothes.
- If any coolant gets on your skin or clothes, rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them with water and consults a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- Especially pay attention to reserve the coolant. Keep out of reach of children.
Do not remove the radiator cap, except to refill or drain the cooling system after servicing the cooling system.
Avoid spilling coolant on painted surfaces, if contaminated, do wash in water immediately.
After disassembling or servicing the cooling system, check for leaks with a radiator cap tester.(sale at a market)
SPECIFICATIONS
RADIATOR CAP RELIEF PRESSURE
BEGIN TO OPEN
THERMOSTAT
FULLY OPEN
TEMPERATURE
VALVE LIFT
COOLANT CAPACITY
0.90.1kg/cm2
802
C
903
C
3.5~4.5mm
Full : 1,100cc
Exchange : 1,000cc
TORQUE VALUE
WATER PUMP IMPELLER
1.0~1.4kgfm
0.8~1.2kgfm
6-1
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COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
Faulty temperature gauge or thermo sensor
Air in cooling system
Faulty thermostat stuck (Thermostat stuck closed)
Passages blocked in radiator, hoses or water jacket
Faulty fan motor switch
Faulty water pump
Coolant leaks
Faulty water pump mechanical seal
Damaged or deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated gasket
Loose hose connection or clamp
6-2
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COOLING SYSTEM
COOLANT
COOLANT INSPECTION
RADIATOR
WATER
COOLANT
Mixture
Ratio
-9C
-16C
-25C
-37C
-44.5C
20%
30%
40%
50%
60%
400
600
800
1,000
1,100
(Unit:cc)
Distilled water
1,600
1,400
1,200
1,000
900
HYDROMETER
(Sale at a market)
5
10
15
20
25
30
35
40
45
50
55
60
1.009
1.018
1.028
1.036
1.045
1.053
1.063
1.072
1.080
1.086
1.095
1.100
1.009
1.017
1.027
1.035
1.044
1.052
1.062
1.070
1.078
1.084
1.093
1.098
1.008
1.017
1.026
1.034
1.043
1.051
1.060
1.068
1.076
1.082
1.091
1.095
1.009
1.016
1.025
1.033
1.042
1.049
1.058
1.066
1.074
1.080
1.088
1.092
1.007
1.015
1.024
1.031
1.040
0.047
1.056
1.064
1.072
1.077
1.085
1.089
1.006
1.014
1.022
1.029
1.038
1.045
1.054
1.062
1.069
1.074
1.082
1.086
1.005
1.013
1.020
1.027
1.036
1.043
1.052
1.059
1.066
1.071
1.079
1.083
1.003
1.011
1.018
1.025
1.034
1.041
1.049
1.056
1.063
1.068
1.076
1.080
1.001
1.009
1.016
1.023
1.031
1.038
1.046
1.053
1.060
1.065
1.073
1.077
0.999
1.007
1.014
1.021
1.028
1.035
1.043
1.050
1.057
1.062
1.070
1.074
0.997
1.005
1.012
1.019
1.025
1.032
1.040
1.047
1.054
1.059
1.067
1.071
6-3
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COOLING SYSTEM
BOLT
BOLT
BOLT
BOLT
RADIATOR
INSPECTION
RADIATOR
RADIATOR
CAP
RADIATOR CAP
CAP
RESERVE
RESERVE
TANK
RESERVE TANK
TANK
RADIATOR
RADIATOR
RADIATOR
RADIATOR
WATER
WATER
PUMP
WATER PUMP
PUMP
REMOVAL
Remove the radiator cap.
Drain the coolant.
Disconnect the air vent tube from the radiator filler.
Remove the overflow tube clamp and disconnect
the overflow tube.
DRAIN
DRAIN
BOLT
DRAIN BOLT
BOLT
6-4
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COOLING SYSTEM
Loosen the hose band and disconnect the upper
hose and lower hose from the radiator.
Disconnect the thermostatic switch wire coupler.
Disconnect the fan motor wire coupler.
UPPER HOSE
HOSE
UPPER
UPPER
HOSE
LOWER
LOWER
HOSE
LOWER HOSE
HOSE
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
RADIATOR
RADIATOR
RADIATOR
RADIATOR
REMOVAL
Remove 3 bolts and then remove the fan/shroud from
the radiator.
FAN
FAN
SHROUD
FAN SHROUD
SHROUD
6-5
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COOLING SYSTEM
COOLING
COOLING
FAN
SWITCH
COOLING FAN
FAN SWITCH
SWITCH
FLANGE
FLANGE
BOLTS
FLANGE BOLTS
BOLTS
RADIATOR INSTALLATION
Intall the radiator on the radiator bracket with the 2
bolts and 1 nut.
FLANGE BOLTS
BOLTS
FLANGE
FLANGE
BOLTS
PASS
PASS
TUBE
PASS TUBE
TUBE
6-6
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COOLING SYSTEM
Connect the overflow tube and tighten it securely
with the tube clamp.
Fill the radiator with coolant.
Connect the vent tube to the radiator filler.
After installation, check for coolant leaks.
WATER PUMP
CHECKING
CHECKING
HOLE
CHECKING HOLE
HOLE
INLET HOSE
HOSE
INLET
INLET
HOSE
WATER
WATER
PUMP
COVER
WATER PUMP
PUMP COVER
COVER
6-7
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COOLING SYSTEM
Loosen the 3 bolts and remove the water pump
cover.
WATER
WATER
PUMP
COVER
WATER PUMP
PUMP COVER
COVER
DRAIN BOLT
BOLT
DRAIN
DRAIN
BOLT
FLANGE
BOLT
FLANGE
FLANGE BOLT
BOLT
WATER
WATER
PUMP
IMPELLER
WATER PUMP
PUMP IMPELLER
IMPELLER
WATER PUMP
PUMP BODY
BODY
WATER
WATER
PUMP
BODY
6-8
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COOLING SYSTEM
O-RING
O-RING
O-RING
CHECKING
CHECKING
HOLE
CHECKING HOLE
HOLE
6-9
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COOLING SYSTEM
ENGINE COOLANT
TEMPERATURE GAUGE
THERMOSENSOR
THERMOSENSOR
THERMOSENSOR
REMOVAL
Remove RH.side cowl.
Drain the coolant.
Disconnect the engine coolant temperature gauge
wire.
INSPECTION
Soak the engine coolant temperature gauge in the
beaker(fill the beaker with water)
Heats up the beaker.
Measure the resistance.
Temperature()
Resistance()
50
154
80
52
100
27
120
16
TEMPERATURE
INSTALLATION
Apply a sealant to the threads and install the
thermostat cover.
Connect the engine coolant temperature gauge
coupler.
6-10
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COOLING SYSTEM
THERMOSTAT
THERMOSTAT
THERMOSTAT
THERMOSTAT
REMOVAL
Disconnect the water hose from the thermostat
cover.
Remove the 2 bolts and separate the thermostat
cover.
Remove the thermostat from thermostat cover.
INSPECTION
Suspend the thermostat in a pan of water over a burner
and gradually raise the water temperature to check its
operation.
Technical data
Begins to open
Full-open
Valve lift
THERMOSTAT
THERMOMETER
802
903
3.5~4.5mm
INSTALLATION
Install in the reverse order of removal.
6-11
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ENGINE REMOVAL/INSTALLATION
7-0
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7. ENGINE REMOVAL/INSTALLATION
7-1
SERVICE INFORMATION
ENGINE REMOVAL 7-2
7-3
ENGINE INSTALLATION
SERVICE INFORMATION
GENERAL SAFETY
Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness.
Attach tape to the frame to protect it during the engine removal or installation.
The following works require engine removal for service.
- Cylinder head/valve
- Cylinder/piston
- Transmission
- Crank shaft
SPECIFICATION
ITEM
ENGINE OIL CAPACITY(AT DISASSEMBLY)
SPECIFICATIONS
1.5
TORQUE VALUES :
ENGINE HANGER BOLT (FRONT ) :
(REAR ) :
GEAR CHANGE ARM BOLT :
DRIVE SPROCKET BOLT :
LH. DOWNTUBE MOUNTING BOLT (SPECIAL BOLT) :
4.9fm
4.9fm
1.2fm
1.2fm
4.2fm
7-1
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ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil. (3-3)
Remove the muffler. (13-4)
Remove the battery ground cable and clutch cable.
Remove the throttlebody from the engine.
RADIATOR CAP
CAP
RADIATOR
RADIATOR
CAP
LH.
LH.
DOWN
TUBE
COMP.
B
LH. DOWN
DOWN TUBE
TUBE COMP.
COMP. B
B
GEAR
GEAR
CHANGE
GEAR CHANGE
CHANGE
DRIVE
DRIVE
SPROCKET
DRIVE SPROCKET
SPROCKET
7-2
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ENGINE REMOVAL/INSTALLATION
Remove the 2 rear engine hanger bolts, then
remove the LH. downtube comp. B.
FLANGE
BOLTS
FLANGE
FLANGE BOLTS
BOLTS
ENGINE INSTALLATION
Engine installation is essentially the reverse order of
removal.
4.9kgfm(49Nm)
4.9kgfm(49Nm)
1.2kgfm(12Nm)
1.2kgfm(12Nm)
CLUTCH/GEARSHIFT
8-0
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8. CLUTCH / GEARSHIFT
SERVICE INFORMATION 8-1
TROUBLESHOOTING 8-2
8-3
RH. CRANK
8-4
CLUTCH REMOVAL
8-7
GEARSHIFT SPINDLE
8-9
CLUTCH INSTALLATION
8-10
PRIMARY DRIVE GEAR
8-12
RH. CRANKCASE COVER INSTALLATION
SERVICE INFORMATION
GENERAL SAFETY
The clutch, gearshift spindle can be serviced with the engine in the frame.
If the shift fork, drum and transmission require service, remove the engine and separate the crankcase.
The quality and level of fluid affect clutch operation. If the clutch slips, check the fluid level before servicing
the clutch system.
8
SPECIFICATIONS
ITEM
CLUTCH SPRING FREE LENGTH
CLUTCH DISK THICKNESS
CLUTCH PLATE WARPAGE
CLUTCH OUTER I.D
CLUTCH OUTER GUIDE O.D.
Unit : mm
STANDARD VALUE
35.5
2.9~3.0
28.000~28.013
28-0.020~0.033
SERVICE LIMIT
34.2
2.6
0.2
28.030
28.50.1
TORQUE VALUES
CLUTCH LOCK NUT
DRUM STOPPER ARM BOLT
PRIMARY DRIVE GEAR NUT
RH. CRANKCASE COVER BOLT
GEAR SHIFT PEDAL BOLT
TOOLS
CLUTCH CENTER HOLDER
LOCK NUT WRENCH
EXTENSION BAR
FLYWHEEL HOLDER
8-1
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CLUTCH/GEARSHIFT
TROUBLESHOOTING
Clutch working problem can be solved by adjusting a cable free play.
Clutch slippage
Sticking lifter hydraulic system
Worn disks
Weak spring
Too small clutch lever free play
Gear disengages
Worn the protrusion of a gear
Bent shift fork shaft
Damaged shift drum stopper
Worn shift drum guide groove
Worn gear shift fork groove
8-2
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CLUTCH/GEARSHIFT
CABLE
CABLE
HOLDER
CABLE HOLDER
HOLDER
REMOVAL
Drain the engine oil and coolant.
Remove the clutch adjustor locknut and the
adjusting nut, then disconnect the clutch cable end
from the clutch lever.
Remove the right crankcase cover bolts and
remove the right crankcase cover.
RH.
CRANK
CASE
COVER
RH.
RH. CRANK
CRANK CASE
CASE COVER
COVER
LIFTER ROD
ROD
LIFTER
LIFTER
ROD
CLUTCH LEVER
CLUTCH
LEVER
SPRING
CLUTCH
LEVER SPRING
SPRING
CLUTCH
LEVER
CLUTCH
CLUTCH LEVER
LEVER
8-3
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CLUTCH/GEARSHIFT
HOLE
HOLE
HOLE
SPRING
SPRING
ENDS
SPRING ENDS
ENDS
BEARING
BEARING
BEARING
CLUTCH
CLUTCH
CLUTCH
PRIMARY
DRIVE
GEAR
PRIMARY
PRIMARY DRIVE
DRIVE GEAR
GEAR
CLUTCH REMOVAL
Remove the bearing.
WATER PUMP
PUMP DRIVE
DRIVE GEAR
GEAR
WATER
WATER
PUMP
DRIVE
GEAR
8-4
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CLUTCH/GEARSHIFT
Remove the lock washer.
Remove the clutch inner assy.
SPLINE
SPLINE
WASHER
SPLINE WASHER
WASHER
CLUTCH
CLUTCH
OUTER
CLUTCH OUTER
OUTER
CLUTCH
CLUTCH
OUTER
CLUTCH OUTER
OUTER
CLUTCH OUTER
CLUTCH
OUTER
GUIDE
CLUTCH
OUTER GUIDE
GUIDE
LIFTER
PLATE
LIFTER
LIFTER PLATE
PLATE
LIFTER
PLATE
BEARING
BEARING
BEARING
INSPECTION
Remove the clutch center, disk plate, clutch spring
and check the other part each.
Inspect the lifter plate bearing for damage.
(It rotates by hand, if the free play is big, replace them)
Inspect the lifter plate for damage.
If necessary, replace them.
8-5
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CLUTCH/GEARSHIFT
Measure the clutch spring free length; replace the
springs if the measurement is not within the service
limit.
SERVICE LIMIT : 34.2mm
CLUTCH
CLUTCH
DISK
CLUTCH DISK
DISK
CLUTCH
CLUTCH PLATE
PLATE
CLUTCH
PLATE
CLUTCH CENTER
FRICTION DISK
INSTALLATION
Apply the clean engine oil to the clutch friction
disk and pressure plate.
Install the 7pcs disks and 6pcs plates into the
clutch center by turns.
Install the spring, lifter plate and clutch spring
bolts to diagonal direction.
PRESSURE PLATE
8-6
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CLUTCH OUTER
CLUTCH/GEARSHIFT
REMOVAL
Loosen the hex bolt at LH. side and remove the
gear change arm.
GEAR
GEAR
SHIFT
SPINDLE
GEAR SHIFT
SHIFT SPINDLE
SPINDLE
GEAR
GEAR
SHIFT
ARM
GEAR SHIFT
SHIFT ARM
ARM
GEAR
SHIFT
SPINDLE
GEAR
GEAR SHIFT
SHIFT SPINDLE
SPINDLE
INSPECTION
Check the gear shift spindle for wear or damage.
Inspect the gear shift plate for deformation, wear,
or other damage.
Check the return spring and gear shift plate spring
for wear or damage.
8-7
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CLUTCH/GEARSHIFT
COLLAR
COLLAR
COLLAR
INSTALLATION
Install the collar, spring, drum stopper and bolt.
Tighten the bolt.
TORQUE : 1.2kgfm
SPRING
STOPPER ARM
ARM
STOPPER
STOPPER
ARM
COLLAR
STOPPER ARM
SPRING
SPRING
SPRING
GEAR
GEAR
SHIFT
CAM
GEAR SHIFT
SHIFT CAM
CAM
GEAR
GEAR
SHIFT
SPINDLE
GEAR SHIFT
SHIFT SPINDLE
SPINDLE
GEAR
CHANGE
ARM
GEAR
GEAR CHANGE
CHANGE ARM
ARM
8-8
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CLUTCH/GEARSHIFT
CLUTCH INSTALLATION
OUTER
OUTER
GUIDE
OUTER GUIDE
GUIDE
CLUTCH
CLUTCH INNER
INNER ASSY
ASSY
CLUTCH
INNER
ASSY
CLUTCH
CLUTCH
OUTER
COMP.
CLUTCH OUTER
OUTER COMP.
COMP.
CLUTCH
CLUTCH
OUTER
CLUTCH OUTER
OUTER
8-9
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CLUTCH/GEARSHIFT
Install the lock nut by pressing clutch center into
the clutch center holder.
TORQUE : 6.5kgfm
REMOVAL
Remove the LH. crankcase cover.
Loosen the locknut.
PRIMARY DRIVE
PRIMARY
DRIVE
GEAR
PRIMARY
DRIVE GEAR
GEAR
WATER
PUMP
DRIVE
GEAR
WATER
WATER PUMP
PUMP DRIVE
DRIVE GEAR
GEAR
SUB
SUB
GEAR
SUB GEAR
GEAR
8-10
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CLUTCH/GEARSHIFT
OUTER
GEAR
OUTER
OUTER GEAR
GEAR
PD
GEAR
PD
PD GEAR
GEAR
WATER
PUMP
DRIVE
GEAR
WATER
WATER PUMP
PUMP DRIVE
DRIVE GEAR
GEAR
INSTALLATION
Insert the woodruff key into the key groove of the
crankshaft.
Align the primary drive gear key groove with the
crankshaft key.
Align the sub gear and clutch outer groove and
install the gear.
8-11
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CLUTCH/GEARSHIFT
WATER
WATER
PUMP
DRIVE
GEAR
WATER PUMP
PUMP DRIVE
DRIVE GEAR
GEAR
RADIATOR
RADIATOR
HOSE
RADIATOR HOSE
HOSE
8-12
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MEMO
9-0
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9-2
A.C GENERATOR
9-6
STARTOR
SERVICE INFORMATION
GENERAL SAFETY
This section covers removal and installation of the A.C. generator.
Refer to section 17 for inspection of the A.C. generator.
The A.C. generator/starter clutch service can be done with the engine installed in the frame.
SPECIFICATIONS
Unit:mm
ITEM
STARTER DRIVEN GEAR
STARTER IDLE GEAR
STARTER IDLE GEAR SHAFT
REDUCTION GEAR
REDUCTION GEAR SHAFT
O.D.
I.D
I.D
O.D
I.D
O.D
STANDARD VALUE
39.622~39.635
22.010~22.022
10.013~10.045
9.991~10.000
10.013~10.045
9.991~10.000
SERVICE LIMIT
39.607
22.100
10.100
9.970
10.100
9.970
TORQUE VALUES
FLYWHEEL BOLT
STARTER CLUTCH SOCKET BOLT
LEFT CRANK CASE COVER BOLT
5.5kgfm(55Nm)
3.2kgfm(32Nm)
1.1kgfm(11Nm)
TOOLS
ACG ROTOR PULLER
FLYWHEEL HOLDER
9-1
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LH.
LH.
REAR
COVER
LH. REAR
REAR COVER
COVER
9-2
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LH.
LH.
CRANK
CASE
COVER
LH. CRANK
CRANK CASE
CASE COVER
COVER
FLY
FLY
WHEEL
FLY WHEEL
WHEEL
STARTER
IDLE
GEAR
STARTER
STARTER IDLE
IDLE GEAR
GEAR
STARTER
IDLE
GEAR
FLYWHEEL HOLDER
FLYWHEEL
HOLDER
FLYWHEEL
HOLDER
GEAR
GEAR
SHAFT
GEAR SHAFT
SHAFT
9-3
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ACG
ROTOR
PULLER
ACG
ACG ROTOR
ROTOR PULLER
PULLER
ACG
ROTOR
PULLER
GEAR
GEAR CHANGE
CHANGE SWITCH
SWITCH
GEAR
CHANGE
SWITCH
STARTER
STARTER
DRIVEN
GEAR
COLLAR
STARTER DRIVEN
DRIVEN GEAR
GEAR COLLAR
COLLAR
9-4
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SOCKET
BOLTS
SOCKET
SOCKET BOLTS
BOLTS
SOCKET
BOLTS
STARTER CLUTCH
DISASSEMBLY
STARTER
STARTER
DRIVEN
GEAR
STARTER DRIVEN
DRIVEN GEAR
GEAR
FLY
FLY
WHEEL
COMP
FLY WHEEL
WHEEL COMP
COMP
STARTER
STARTER
DRIVEN
GEAR
STARTER DRIVEN
DRIVEN GEAR
GEAR
STARTER
ONE-WAY
CLUTCH
ASSY
STARTER
STARTER ONE-WAY
ONE-WAY CLUTCH
CLUTCH ASSY
ASSY
STARTER
ONE-WAY
CLUTCH
ASSY
INSTALLTION
Check the one-way clutch for wear or damage.
Install the one-way clutch flange into the clutch
outer.
Apply the screw locking bond to the socket bolt
and install it.
TORQUE : 3.2kgf-m
9-5
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WIRE
GUIDE
WIRE
WIRE GUIDE
GUIDE
CRANK
CRANK POSITION
POSITION SENSOR
SENSOR
CRANK
POSITION
SENSOR
STATOR
STATOR
STATOR
INSTALLTION
STARTER
DRIVEN
GEAR
COLLAR
STARTER
STARTER DRIVEN
DRIVEN GEAR
GEAR COLLAR
COLLAR
FLY
FLY
WHEEL
FLY WHEEL
WHEEL
IDLE
IDLE
GEAR
IDLE GEAR
GEAR
ACG.
ACG.
CHANGE
SWITCH
WIRE
ACG. CHANGE
CHANGE SWITCH
SWITCH WIRE
WIRE
9-7
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LH.
LH. REAR
REAR COVER
COVER
LH.
REAR
COVER
9-8
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MEMO
10-0
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SERVICE INFORMATION
GENERAL SAFETY
The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed
from the frame to maintain the cylinder head.
The oil of camshaft is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder
head.
SPECIFICATIONS
Unit : mm
ITEM
CAMSHAFT
STANDARD VALUE
CAM HEIGHT
VALVE SPRING FREE LENGTH
VALVE STEM OUTER DIAMETER
VALVE,
VALVE GUIDE
SERVICE LIMIT
IN
32.02~32.18
31.90
EX
31.72~31.88
31.60
IN,EX
41.40
40.00
IN
4.975~4.990
4.925
EX
4.995~4.970
4.905
IN,EX
IN
EX
5.000~5.012
0.010~0.037
0.030~0.057
5.030
0.080
0.100
0.7~0.9
1.3
TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT
SPARK PLUG
CYLINDER HEADSPECIAL SOCKET BOLT
CAM CHAIN TENSIONER LIFTER BOLT
CAM CHAIN TENSIONER LIFTER SCREW
CYLINDER HEAD COVER BOLT
CRANK SHAFT HOLE CAP
A.C.GENERATOR CAP
10-1
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TROUBLESHOOTING
Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,
or by tracing noises to the top-end with a sounding rod or stethoscope.
Low comperssion
Valves
- Incorrect valve adjustment (see section 3)
- Valve springs damage
- Incorrect valve timing
- Uneven valve seating
Cylinder head
- Leaking or damage head gasket
- Warped or cracked cylinder head
Cylinder, piston (see section 10,11)
10-2
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Rough idle
Low cylinder compression
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
CAMSHAFT
SPARK
SPARK
PLUG
SPARK PLUG
PLUG
REMOVAL
Remove the side cowl.
Remove the noise suppressor cap assembly from
the spark plug.
TENSIONER
TENSIONER
TENSIONER
CYLINDER
CYLINDER
HEAD
COVER
CYLINDER HEAD
HEAD COVER
COVER
CAM
CAM SHAFT
SHAFT HOLDER
HOLDER
CAM
SHAFT
HOLDER
10-3
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CAM
CHAIN
CAM
CAM CHAIN
CHAIN
CAM
CHAIN
BEARING
BEARING
BEARING
BEARING
CYLINDER
CYLINDER
HEAD
SOCKET
NUT
(M8X
4)
CYLINDER HEAD
HEAD SOCKET
SOCKET NUT
NUT (M8X
(M8X 4)
4)
CYLINDER HEAD
REMOVAL
Remove the cylinder head cover
Remove the camshaft.
Remove the cylinder head special socket nut(M8)
Remove the throttle body insulator.
10-4
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IN
IN VALVE
VALVE
IN
VALVE
NOTE
OUT
OUT
VALVE
OUT VALVE
VALVE
INSPECTION
CYLINDER HEAD
Clean off the head gasket surface.
Inspect the spark plug assembly hole and the
crack of near valve seat. Check for the warp of
the cylinder head with a square and filler
gauge.
Service Limit : 0.1mm
10-6
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10-7
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70
20
IN : 22mm
EX : 22mm
IN : 23mm
30
45
IN : 24.5mm
EX : 24.5mm
EX : 20mm
10-8
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FOR
CYLINDER
HEAD
FOR
FOR CYLINDER
CYLINDER HEAD
HEAD
10-9
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LOCATION
LOCATION
OF
TIMING
MARK
LOCATION OF
OF TIMING
TIMING MARK
MARK
10-10
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CAM
CAM
CHAIN
GUIDE
CAM CHAIN
CHAIN GUIDE
GUIDE
CAM
SHAFT
HOLDER
CAM
CAM SHAFT
SHAFT HOLDER
HOLDER
O-RING
O-RING
O-RING
10-11
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CYLINDER / PISTON
11-0
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SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
Take care not to damage the cylinder wall and piston.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
73.005~73.015
73.10
CYLINDERICAL
0.10
ROUNDLESS
0.05
0.10
72.985~72.965
72.60
17.002~17.008
17.04
16.994~17.000
16.96
0.002~0.014
0.02
TOP
PISTON RING-TOGROOVE CLEARANCE SECOND
0.015~0.045
0.09
0.015~0.045
0.09
TOP / SECOND
0.35~0.45
0.50
0.20~0.70
1.10
0.020~0.050
0.30
17.010~17.028
17.06
0.010~0.034
0.04
INNER DIAMETER
CYLINDER
PISTON,
PISTON PIN,
PISTON RING
PISTON RING
JOINT GAP
CYLINDER-TO-PISTON CLEARANCE
TROUBLESHOOTING
Compression too low
Worn piston
Worn, damaged piston ring
Worn cylinder
Overheating
Excessive carbon build-up on top of piston
Abnormal noise
Excessive smoke
Worn cylinder, piston or piston rings
Improper installation of piston ring
Scored or scratched piston or cylinder
11-1
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CYLINDER / PISTON
CYLINDER
CYLINDER
HEAD
GASKET
CYLINDER HEAD
HEAD GASKET
GASKET
CYLINDER REMOVAL
Remove the
the cylinder
cylinder head.
head. (( 10-4
10-4 ))
Remove
10-5
Remove the
the cylinder
cylinder head
head gasket.
gasket.
Remove
Remove
Remove the
the cam
cam chain
chain guide
guide from
from the
the cylinder.
cylinder.
Remove
Remove the
the cylinder.
cylinder.
PISTON
PISTON
PISTON
PISTON
CYLINDER
CYLINDER
CYLINDER
Remove
Remove the
the gasket
gasket and
and dowel
dowel pin.
pin. Carefully
Carefully remove
remove
any
from
the
cylinder
// head
any adhering
adhering gasket
gasket material
material from
from the
thecylinder
cylindermating
head
mating
surface.
Do
not
scratch
the
surface.
mating
surface.
Do
not
scratch
the
surface.
surface.
INSPECTION
INSPECTION
INSPECTION
CYLINDER
CYLINDER
GAUGE
CYLINDER GAUGE
GAUGE
TOP
MIDDLE
BOTTOM
11-2
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CYLINDER / PISTON
WARPAGE INSPECTION
Check the torsion of contact surface in gasket cylinder.
SERVICE LIMIT : 0.100 mm
PISTON
REMOVAL
Remove the piston pin clip.
PISON
PISON
RING
PISON RING
RING
C
C
C
Y
Y
Y
LLL
III
N
N
N
D
D
D
E
E
E
R
R
R
PISTON
PISTON
PISTON
PISTON
ABNORMAL
ABNORMAL
WEAR
ABNORMAL WEAR
WEAR
11-3
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CYLINDER / PISTON
Insert the piston ring into the inside cylinder, check the
piston ring clearance.
SERVICE LIMIT TOP/SECOND: 0.5mm
OIL RING : 1.10mm.
Push the rings into the cylinder with the top of the
piston to be sure they are squarely in the cylinder.
PISTON
RING
PISTON
PISTON RING
RING
90
90
90
90
MICROMETER
MICROMETER
MICROMETER
MICROMETER
11-4
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CYLINDER / PISTON
PISTON / CYLINDER ASSEMBLY
TOP RIDNG
TOP RING
SECOND RING
SIDE RAIL
SPACER
OIL RING
SIDE RAIL
GASKET
GASKET
GASKET
PISTON
PISTON
PIN
CLIP
PISTON PIN
PIN CLIP
CLIP
11-5
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CYLINDER / PISTON
CYLINDER INSTALLATION
Install a new cylinder gasket and dowel pins.
Coat the cylinder wall with clean engine oil and
lubricate the piston rings and install the cylinder.
11-6
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MEMO
CRANKCASE/TRANSMISSION/CRANKSHAFT
12-0
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12. CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION
12-1
12-7
CRANKCASE BEARING
TROUBLESHOOTING
12-2
12-8
CRANKSHAFT INSTALLATION
12-3
CRANKCASE DISASSEMBLY
TRANSMISSION ASSEMBLY
12-4
TRANSMISSION DISASSEMBLY
12-11
CRANKCASE ASSEMBLY
12-9
CRANKSHAFT 12-6
SERVICE INFORMATION
GENERAL SAFETY
To service the transmission, crank shaft and kick starter, the crankcase should be disassembled.
Before disassembling the crankcase, the following parts must be removed.
- CLUTCH, GEAR SHIFT SPINDLE ( SECTION 8)
- A.C. GENERATOR, STARTER CLUTCH ( SECTION 9)
- CYLINDER HEAD ( SECTION 10)
- CYLINDER, PISTON ( SECTION 11)
- STARTER MOTOR ( SECTION 19)
SPECIFICATIONS
Unit: mm
ITEM
SHIFT FORK/SHAFT
FORK
SHAFT O.D.
MAIN SHAFT O.D.
COUNTER SHAFT O.D.
GEAR I.D.
TRANSMISSION
GEAR BUSHING O.D.
GEAR-TO-BUSHING I.D.
GEAR-TO-BUSHING
CLEARANCE
I.D.
CLAW THICKNESS
M3, M5
C1
C2
C4
M5
M3, C2
C4
C1
M5
M3, C2
C1
M3, C2
C1
M3, M5
C1, C2
STANDARD VALUE
SERVICE LIMIT
12.000~12.018
4.930~5.000
11.976~11.994
19.967~19.980
16.466~16.484
19.974~19.987
19.959~19.980
23.000~23.021
23.020~23.041
20.020~20.041
20.000~20.021
22.959~22.980
22.979~23.000
19.959~19.980
20.000~20.021
16.500~16.518
12.050
4.500
11.960
19.930
16.440
19.940
19.930
23.050
23.070
20.070
20.050
22.930
22.950
19.930
20.050
16.550
0.020~0.062
0.100
GEAR-TO-SHAFT
CLEARANCE
C4
0.040~0.082
0.120
BUSH-TO-SHAFT
CLEARANCE
M3
C1
C2
0.200~0.062
0.016~0.052
0.013~0.047
0.100
0.090
0.090
12-1
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CRANKCASE/TRANSMISSION/CRANKSHAFT
Unit: mm
ITEM
CRANKSHAFT
STANDARD VALUE
SERVICE LIMIT
0.050~0.300
0.600
0~0.008
0.050
CRANKSHAFT RUNOUT
RIGHT
LEFT
0.100
0.100
TORQUE VALUES
BEARING SETTING PLATE
CRANKCASE BOLT
1.2kgf m(12N m)
1.1kgf m(11N m)
TOOLS
UNIVERSAL BEARING PULLER
BEARING REMOVER SET
DRIVER
ATTACHMENT
PIROT
THREAD ADAPTER
ASSEMBLY SHAFT
CRANKCASE ASSEMBLY COLLAR
TROUBLESHOOTING
Hard to shift
Incorrect clutch system adjustment
(Free play is too big)
Shift fork bent
Shift fork shaft bent
Gear shift spindle claw bent
Shift drum guide grooves damaged
Shift fork guide spot damaged
12-2
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Engine noise
Connecting rod big end bearing worn
Connecting rod bent
Crank shaft main bearing worn or breakage
Transmission gear worn or breakage
CRANKCASE/TRANSMISSION/CRANKSHAFT
RH.
RH.
CRANK
CASE
RH. CRANK
CRANK CASE
CASE
CRANKCASE DISASSEMBLY
Drain the coolant.
The engine must be seperated from the frame.
( section 7)
Refer to the service information for removal of
necessary parts before disassembling the
crankcase.
Remove the LH. cover / Fly wheel.
Remove the RH. cover / Clutch.
Remove the Cylinder head / Cylinder / Piston.
LH.
LH.
CRANK
CASE
LH. CRANK
CRANK CASE
CASE
LH.
LH.
CRANK
CASE
LH. CRANK
CRANK CASE
CASE
BALANCE
BALANCE
GEAR
BALANCE GEAR
GEAR
MAIN
MAIN
SHAFT
MAIN SHAFT
SHAFT
GASKET
GASKET
GASKET
GASKET
COUNT
SHAFT
COUNT
COUNT SHAFT
SHAFT
COUNT
GEAR
GEAR
SHIFT
DRUM
GEAR SHIFT
SHIFT DRUM
DRUM
12-3
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CRANKCASE/TRANSMISSION/CRANKSHAFT
TRANSMISSION DISASSEMBLY
SHIFT
FORK
SHAFT
SHIFT
SHIFT FORK
FORK SHAFT
SHAFT
GEAR
GEAR
SHIFT
DRUM
GEAR SHIFT
SHIFT DRUM
DRUM
COUNTER SHAFT
COUNTER
SHAFT
COUNTER
SHAFT
MAIN SHAFT
MAIN
SHAFT
MAIN
SHAFT
CRANK
CRANK
BALANCER
GEAR
CRANK BALANCER
BALANCER GEAR
GEAR
INSPECTION
Check the shift fork for wear or damage.
Measure the shift fork inside diameter and the
shift fork claw thickness.
SERVICE LIMIT :
INSIDE DIAMETER : 12.050mm
CLAW THICKNESS : 4.500mm
CRANKCASE/TRANSMISSION/CRANKSHAFT
Check the shift drum for wear or damage.
Check the shift drum guide groove for partial wear
or damage.
GEAR
GEAR
SHIFT
DRUM
GEAR SHIFT
SHIFT DRUM
DRUM
MAIN
MAIN SHAFT
SHAFT
MAIN
SHAFT
COUNTER
SHAFT
COUNTER
COUNTER SHAFT
SHAFT
MAIN
MAIN
GEAR
MAIN GEAR
GEAR
M3
M3
M3
M5
M5
M5
M2
M2
M2
M2
COUNTER
COUNTER
GEAR
COUNTER GEAR
GEAR
M3
M3
M3
M4
M4
M4
M5
M5
M5
M5
M2
M2
M2
M2
12-5
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CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
REMOVAL
Remove the transmission.
Remove the crankshaft from the RH. crankcase
using a hydraulic press.
Remove the remaining bearings in the
RH.crankcase with a driver handle and outer
driver.
TOOLS : DRIVER
ATTACHMENT
RH.
RH.
CRANK
CASE
RH. CRANK
CRANK CASE
CASE
UNIVERSAL
UNIVERSAL
BEARING
PULLER
UNIVERSAL BEARING
BEARING PULLER
PULLER
RIGHT
RIGHT
RIGHT
LEFT
LEFT
LEFT
INSPECTION
Place the crankshaft on a stand or V-block, and
measure the crankshaft runout using dial gauge.
SERVICE LIMIT : RIGHT : 0.100 mm
LEFT : 0.100 mm
90mm
90mm
90mm
90mm
75mm
75mm
75mm
75mm
FEELER GAUGE
GAUGE
FEELER
FEELER
GAUGE
12-6
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CRANKCASE/TRANSMISSION/CRANKSHAFT
Measure the connecting rod radial clearance in both X
and Y directions.
Replace the crankshaft if the service limit is exceeded.
SERVICE LIMIT : 0.050 mm
REMOVER
REMOVER
15mm
REMOVER 15mm
15mm
CRANKCASE BEARING
MAIN
SHAFT
BEARING
MAIN
MAIN SHAFT
SHAFT BEARING
BEARING
CRANK
CRANK
BALANCE
CRANK BALANCE
BALANCE
SHAFT
SHAFT
BEARING
SHAFT BEARING
BEARING
COUNTER
COUNTER
COUNTER
SHAFT
SHAFT
SHAFT
SHAFT
BEARING
BEARING
BEARING
INSPECTION
Turn the Inner race of bearing with fingers and
inspect for smooth turning. Also inspect that the
outer race is driven into the case exactly. If the
clearance is excessive, or the driving for the case is
loose, remove and replace them.
CRANK
SHAFT
BEARING
CRANK
CRANK SHAFT
SHAFT BEARING
BEARING
REPLACEMENT
LH. Crankcase
Remove the cranke balance shaft bearing, main
shaft bearing, crank shaft bearing with the tools.
TOOL : BEARING REMOVER SET
COUNTER
COUNTER
SHAFT
OIL
SEAL
COUNTER SHAFT
SHAFT OIL
OIL SEAL
SEAL
12-7
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CRANKCASE/TRANSMISSION/CRANKSHAFT
RH. Crank Case
Remove the main shaft bearing set plate.
Remove the main shaft bearing, counter shaft
bearing and crank shaft bearing from crankcase.
Apply the new bearing with clean engine oil and
install it into crankcase.
Coat the socket bolt screw part with oil and install
the main shaft bearing set plate.
m (12N
m)
TORQUE : 1.2kgf
CRANKSHAFT INSTALLATION
Coat a new left crankshaft bearing with clean
engine oil and install new bearings into the right
crankcase.
CRANK ASSEMBLY
CRANK SHAFT
TOOLS : DRIVER
ATTACHMENT
PILOT
12-8
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CRANKCASE/TRANSMISSION/CRANKSHAFT
TRANSMISSION ASSEMBLY
C-1 GEAR
COUNTER TRANSMISSION SHAFT
C-3 GEAR
C-4 GEAR
C-5 GEAR
C-2 GEAR
DRIVE SPROCKET
MAIN SHAFT
M-3 GEAR
M-4 GEAR
M-5 GEAR
M-2 GEAR
Apply the gear and gear bush with clean engine oil
and install the main shaft and counter shaft.
COUNTER
COUNTER
SHAFT
COUNTER SHAFT
SHAFT
BALANCE
BALANCE
DRIVE
GEAR
BALANCE DRIVE
DRIVE GEAR
GEAR
BALANCE
BALANCE
DRIVEN
GEAR
BALANCE DRIVEN
DRIVEN GEAR
GEAR
12-9
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CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the main shaft and counter shaft on RH.
crank case together.
CENTER FORK
FORK
CENTER
CENTER
FORK
COUNTER SHAFT
SHAFT
COUNTER
COUNTER
SHAFT
LEFT
LEFT
FORK
LEFT FORK
FORK
DRUM
SHIFT
SHIFT
SHIFT DRUM
DRUM
MAIN
MAIN
SHAFT
MAIN SHAFT
SHAFT
SHIFT
FORK
SHAFT
SHIFT
SHIFT FORK
FORK SHAFT
SHAFT
SHIFT
FORK
SHAFT
12-10
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Install the shift fork into the shift fork shaft, then
install the shift fork shaft into the RH. crankcase
assembling hole.
CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE ASSEMBLY
Install the dowel pins and a new gasket.
RH.
RH.
CRANK
CASE
RH. CRANK
CRANK CASE
CASE
LH.
LH.
CRANK
CASE
LH. CRANK
CRANK CASE
CASE
GEAR
GEAR
CHANGE
SWITCH
GEAR CHANGE
CHANGE SWITCH
SWITCH
12-11
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CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the below parts.
- Clutch / RH. cover
- Cylinder / Cylinder head
- Flywheel / LH. cover
Install the engine on the frame. ( Section 7)
Pour the engine oil.
Pour the coolant.
12-12
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MEMO
EXTERNAL PARTS
13-0
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13-3
REAR WHEEL MUDGUARD
13-2
SEAT/SIDE COVER
13-4
MUFFLER/EXHAUST PIPE
13-2
REAR SEAT (PILLION SEAT)
13-5
FRONT FENDER
13-3
REAR COWL
13-3
REAR FENDER
SERVICE INFORMATION
GENERAL SAFETY
Beware of the muffler after driving or engine stop, as it is still hot to be burnt especially never children touch on it.
13-1
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EXTERNAL PARTS
SIDE
SIDE
COVER
SIDE COVER
COVER
SEAT REMOVAL
PILLION
PILLION SEAT
SEAT
PILLION
SEAT
MAIN
MAIN
SEAT
MAIN SEAT
SEAT
CENTER
COVER
CENTER
CENTER COVER
COVER
FRONT
FRONT
BOLT
FRONT BOLT
BOLT
13-2
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EXTERNAL PARTS
REAR COWL
REAR
REAR
COWL
REAR COWL
COWL
TAIL
TAIL
LIGHT
TAIL LIGHT
LIGHT
REAR FENDER
Remove the seat.
Remove the RH. / LH. side cover.
Remove the center cover.
Remove the pillion seat.
Remove the rear cowl.
Remove the head light relay, winker relay from the
rear fender.
Remove the tail light, winker connector.
WINKER
WINKER
RELAY
WINKER RELAY
RELAY
FUEL
PUMP
RELAY
FUSE
FUSE
BOX
FUSE BOX
BOX FUEL
FUEL PUMP
PUMP RELAY
RELAY
FUEL
PUMP
RELAY
REAR
REAR
FENDER
REAR FENDER
FENDER
REAR
REAR
WHEEL
MUDGUARD
REAR WHEEL
WHEEL MUDGUARD
MUDGUARD
13-3
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EXTERNAL PARTS
MUFFLER/EXHAUST PIPE
Do not service the exhaust system while it is hot.
REMOVAL
Remove the exhaust pipe and 4 muffler body
mounting socket bolts.
MUFFLER
MUFFLER
MUFFLER
MUFFLER
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
MUFFLER
MUFFLER
MUFFLER
FLANGE
FLANGE
GASKET
FLANGE GASKET
GASKET
CAP
NUT
CAP
CAP NUT
NUT
O2 SENSOR
SENSOR
O2
SENSOR
O2
13-4
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EXTERNAL PARTS
INSTALLATION
Install the removed parts in the reverse order of
removal.
FRONT FENDER
Remove the front fender mounting 6pcs special
screws. (RH/LH.)
Remove the front fender forward.
Install in the reverse order of removal.
13-5
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14-0
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SERVICE INFORMATION
GENERAL SAFETY
A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk
with a brake degreasing agent.
Because inhaled asbestos fibers have been found to cause respiratory disease and cancer, work so that the fibers near
the brake pad can't spread to the brake cleaner.
When removing or installing tires from the rim, use the special tire lever and rim protector so that the rim can't be
damaged.
This section covers maintenance of the front wheel, front fork and steering stem. Refer to section 15 for front brake
service.
Use a jack or a hoist under the engine to support the motorcycle.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
0.2
RADICAL
2.0
AXIAL
2.0
0.2
2452.5cc
528.0
480.0
TORQUE VALUES
STEERING HANDLE PIPE BOLT
FRONT BRAKE DISK BOLT
FRONT AXLE NUT
FORK TOP BRIDGE PINCH BOLT
FORK BOTTOM BRIDGE PINCH BOLT
FORK TUBE CAP BOLT
FORK SOCKET BOLT
CALIPER BRACKET BOLT
STEERING STEM NUT
STEERING TOP THREAD NUT
HANDLE WEIGHT SOCKET BOLT
2.6kgf
4.2kgf
5.9kgf
2.6kgf
3.4kgf
2.3kgf
2.0kgf
3.0kgf
7.4kgf
2.5kgf
0.3kgf
2.0kgf
m(26N
m(42N
m(59N
m(26N
m(34N
m(23N
m(20N
m(30N
m(74N
m(25N
m(3N
m(20N
m)
m)
m)
m)
m)
m)
m) (Apply locking agent)
m)
m)
m) (Initial torque)
m) (Last torque)
m)
14-1
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COMMON TOOLS
EXTENSION BAR
DRIVER
FORK SEAL DRIVER / BODY
LOCK NUT WRENCH
BEARING REMOVER SHAFT
REMOVER HEAD
ATTACHMENT
PILOT
TROUBLESHOOTING
Hard steering
Bearing adjustment nut too tight
Damaged, worn steering head bearing
Damaged, worn inner and outer race
Insufficient tire pressure
Worn tire
14-2
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Soft suspension
Weak springs
Oil level too low
Inferiorization of oil
Oil viscosity too low
Hard suspension
Bend fork tube
Oil level too high
Oil viscosity too high
Too much air in tire
HANDLE
WEIGHT
CAP
HANDLE
HANDLE WEIGHT
WEIGHT CAP
CAP
HANDLE BARS
REMOVAL
Loosen the socket bolt from the end of the RH. handle
grib.
MASTER
MASTER CYLINDER
CYLINDER
MASTER
CYLINDER
14-3
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SCREW
SCREW
SCREW
LEVER
BRACKET
CLUTCH LEVER
LEVER BRACKET
BRACKET
CLUTCH
CLUTCH
LEVER
BRACKET
HOLDER
HOLDER
HOLDER
HANDLE
PIPE
ASSEMBLY
HANDLE
HANDLE PIPE
PIPE ASSEMBLY
ASSEMBLY
SOCKET
BOLT
SOCKET
SOCKET BOLT
BOLT
RH.
HANDLE
PIPE
RH.
RH. HANDLE
HANDLE PIPE
PIPE
LH.
HANDLE
PIPE
LH.
LH. HANDLE
HANDLE PIPE
PIPE
LH.
HANDLE
PIPE
14-4
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RH.
RH.
HANDLE
PIPE
RH. HANDLE
HANDLE PIPE
PIPE
LH.
LH.
HANDLE
PIPE
LH. HANDLE
HANDLE PIPE
PIPE
HOLE
HOLE
HOLE
HOLE
HOLE
HOLE
HOLE
HOLE
INSTALLATION
Install the handlebars onto the front forks.
Install the handle pipe while aligning its grooves with
the fork top bridge holes.
Tighten the handle pipe pinch bolts to the specified
torque.
m
TORQUE : 2.6kgf
RH.
RH.
FRONT
FORK
RH. FRONT
FRONT FORK
FORK
RH.
RH.
FRONT
FORK
RH. FRONT
FRONT FORK
FORK
THROTTLE
THROTTLE CABLE
CABLE
THROTTLE
CABLE
14-5
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CLUTCH
CLUTCH
CASE
CLUTCH CASE
CASE
PUNCH
MARK
PUNCH
PUNCH MARK
MARK
LH.
LH.
HANDLE
PIPE
LH. HANDLE
HANDLE PIPE
PIPE
PUNCH
MARK
PUNCH
PUNCH MARK
MARK
WINKER
SWITCH
ASSY
WINKER
WINKER SWITCH
SWITCH ASSY
ASSY
14-6
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FRONT WHEEL
CLAMP
CLAMP
CLAMP
REMOVAL
Loosen the brake hose clamp bolts and remove the
clamp.
Loosen the 2 flange bolts securing the bottom case
and remove the caliper.
BRAKE
BRAKE
HOSE
BRAKE HOSE
HOSE
FRONT
FRONT
BRAKE
CALLIPER
FRONT BRAKE
BRAKE CALLIPER
CALLIPER
SPEEDOMETER
CABLE
SPEEDOMETER
SPEEDOMETER CABLE
CABLE
SPEEDOMETER
CABLE
SPEEDOMETER
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
CABLE
INSPECTION
Axle
Measure the runout of the front axle.
Install the front axle in v-block and measure the
runout with dial gauge.
SERVICE LIMIT : 2.0mm
BEARING INSPECTION
Turn the inner race of each bearing with finger.
Bearing should turn smoothly and quietly. Also check
that the bearing outer race fits tightly in the hub.
If the bearing is worn, replace the new one.
OIL
SEAL
OIL
OIL SEAL
SEAL
DISASSEMBLY
Remove and speedometer gear box, oil seal and gar
box retainer.
SPEEDOMETER
GEAR
BOX
SPEEDOMETER
SPEEDOMETER GEAR
GEAR BOX
BOX
GEAR
GEAR BOX
BOX RETAINER
RETAINER
GEAR
BOX
RETAINER
14-8
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SPEEDOMETER
GEAR
SPEEDOMETER
SPEEDOMETER GEAR
GEAR
WASHERS
WASHERS
PINION
GEAR
PINION
PINION GEAR
GEAR
14-9
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OIL SEAL
DUST SEAL
SPEEDOMETER GEAR
RADIAL BALL BEARING
FR. TIRE
LH. FR. BRAKE DISK
SPEEDOMETER GEAR BOX ASSEMBLY
GEAR
GEAR RETAINER
RETAINER
14-10
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INSTALLATION
Place the front wheel between the front forks.
Align the slot of the speedometer gear box with the
tangs of the left fork slider.
Insert the front axle into the speedometer gear box and
the wheel hub.
Install the axle nut.
m
TORQUE : 5.9 kgf
COLLAR
COLLAR
COLLAR
COLLAR
SCREW
SCREW
SCREW
14-11
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CALLIPER
CALLIPER
CALLIPER
FRONT FORK
REMOVE
Remove the front fender. ( 13-5)
Remove the RH/LH front caliper.
Remove the front wheel. ( 14-7)
STEERING
STEERING
HANDLE
PIPE
STEERING HANDLE
HANDLE PIPE
PIPE
SOCKET
BOLT
SOCKET
SOCKET BOLT
BOLT
Loosen the fork bottom pinch bolt and remove the fork
pipe from the handle pipe, fork top bridge and steering
stem.
STEERING
STEERING
STEM
BOLT
STEERING STEM
STEM BOLT
BOLT
14-12
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FRONT
FORK
BOLT
FRONT
FRONT FORK
FORK BOLT
BOLT
SEAT
SEAT
PIPE
SEAT PIPE
PIPE
DUST
DUST
SEAL
DUST SEAL
SEAL
BOTTOM CASE
CASE
BOTTOM
BOTTOM
CASE
14-13
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Pull the fork pipe out until you feel resistance from the
slider bushing.
Then move it in and out, tapping the bushing lightly
until the fork pipe separates from the bottom case.
OIL SEAL
OIL
SEAL
OIL
SEAL
BACK-UP
RING
BACK-UP
BACK-UP RING
RING
SLIDER
SLIDER
SLIDER
BUSHING
BUSHING
BUSHING
DUST SEAL
DUST
SEAL
DUST
SEAL
GUIDE
GUIDE
BUSHING
GUIDE BUSHING
BUSHING
STOPPER
RING
STOPPER
STOPPER RING
RING
INSPECTION
Place the fork spring on a level place, and measure the
free length.
If the free length deviates from the service limit,
replace the springs with new ones.
FORK
SPRING
FORK
FORK SPRING
SPRING
FORK
SPRING
REBOUND
REBOUND
SPRING
REBOUND SPRING
SPRING
14-14
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BOTTOM
CASE
BOTTOM
BOTTOM CASE
CASE
SEAT
PIPE
SEAT
SEAT PIPE
PIPE
FORK
PIPE
FORK PIPE
FORK
PIPE
FORK
PIPE
OIL LOCK
OIL
LOCK
PIECE
OIL
LOCK PIECE
PIECE
DIAL
GAUGE
DIAL
DIAL GAUGE
GAUGE
FORK
FORK
PIPE
FORK PIPE
PIPE
SLIDER BUSHING
BACK-UP RING
CHECK POINTS
14-15
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DUST SEAL
FORK PIPE
SEAT PIPE
LH. BOTTOM CASE
OIL LOCK PIECE
REBOUND SPRING
SEAT
SEAT
PIPE
SEAT PIPE
PIPE
OIL
LOCK
PIECE
OIL
OIL LOCK
LOCK PIECE
PIECE
OIL
14-16
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STOPPER
RING
STOPPER
STOPPER RING
RING
STOPPER
RING
VISE
ATTACHMENT
STOPPER
STOPPER
RING
STOPPER RING
RING
DUST SEAL
SEAL
DUST
DUST
SEAL
14-17
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FORK OIL
FORK OIL
DOWN
WARD
DOWN
DOWN WARD
WARD
DOWN
WARD
FORK
SPRING
FORK
FORK SPRING
SPRING
O-RING
O-RING
O-RING
O-RING
14-18
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FORK
FORK
TOP
BRIDGE
FORK TOP
TOP BRIDGE
BRIDGE
INSTALLATION
Install the fork pipe through the bottom bridge, fork
top bridge and handle pipe.
Position the marking line of the fork pipe with the
upper surface of the top bridge as shown.
MARKING
MARKING
LINE
MARKING LINE
LINE
FRONT
FRONT
COWL
FRONT COWL
COWL
14-19
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STEERING STEM
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
REMOVAL
Remove the following :
- Front wheel
- Kandle bars
- Front fork
Remove the 2 flange bolts and front brake hose stay.
JUNCTION
JUNCTION
VALVE
JUNCTION VALVE
VALVE
BRAKE
BRAKE
OIL
HOSE
BRAKE OIL
OIL HOSE
HOSE
STEERING
STEM
SOCKET
STEERING
STEERING STEM
STEM SOCKET
SOCKET
STEERING
STEERING STEM
STEM
STEERING
STEM
14-20
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Check the steel ball, cone race, ball race for damage or
abnormal wear and replace as necessary.
DRIVER
Install the new ball races of the frame using the driver
and attachment.
ATTACHMENT
STEERING
STEM
STEERING
STEERING STEM
STEM
TOP
TOP
CONE
RACE
TOP CONE
CONE RACE
RACE
STEERING
HEAD
STEERING
STEERING HEAD
HEAD
TOP
THREAD
TOP
TOP THREAD
THREAD
BALL
BALL
RACE
BALL RACE
RACE
STEEL
STEEL
BALL
ASSY
STEEL BALL
BALL ASSY
ASSY
STEERING
STEM
DRIVER
STEERING
STEERING STEM
STEM DRIVER
DRIVER
Install the new dust seal and washer into the steering
stem.
Install a new bottom cone race into the steering stem
using a special tool and a hydraulic press.
TOOL : STEERING STEM DRIVER
BOTTOM
CONE
RACE/DUST
SEAL
BOTTOM
BOTTOM CONE
CONE RACE/DUST
RACE/DUST SEAL
SEAL
14-21
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STEEL BALLS
STEEL BALL RACE
STEEL BALL RACE
STEEL BALLS
BOTTOM CONE RACE
DUST SEAL
WASHER
STEERING STEM
STEERING
STEERING
STEM
STEERING STEM
STEM
Move the steering stem right and left, five times to seat
the steel balls.
Retighten the steering head top thread to the specified
torque.
m (FINAL TORQUE)
TORQUE : 0.3 kgf
14-22
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14-23
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15-0
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TROUBLESHOOTING 15-2
SWINGARM 15-9
SERVICE INFORMATION
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
0.2
RADICAL
2.0
AXIAL
2.0
131
AXLE RUNOUT
REAR WHEEL RIM RUNOUT
TORQUE VALUES
REAR BRAKE DISK BLOT
REAR AXLE NUT
REAR CUSHION UPPER / DOWN BOLT
REAR CUSHION UNDER BOLT
SWINGARM PIVOT NUT
FINAL DRIVEN SPROCKET NUT
4.2fm
8.8fm
5.4fm
4.0fm
8.8fm
5.9fm
TOOLS
15
ATTACHMENT
PILOT
DRIVER
BEARING REMOVER SHAFT
BEARING REMOVER HEAD
15-1
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TROUBLESHOOTING
Wobble rear wheel
Deformed rim
Worn rear wheel bearing
Damaged tire
Axle not tightened properly
Insufficient air in tire
Worn rear fork bush
15-2
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REAR WHEEL
REMOVAL
Erect the motorcycle using a main stand.
Loosen the chain adjust nuts and lock nuts.
Remove the axle nut (U-nut).
CHAIN
CHAIN
ADJUST
CHAIN ADJUST
ADJUST
REAR
REAR
AXLE
NUT
REAR AXLE
AXLE NUT
NUT
INSPECTION
AXLE SHAFT
AXLE
SHAFT
AXLE
SHAFT
15-3
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SIDE
SIDE
COLLAR
SIDE COLLAR
COLLAR
FINAL
FINAL
DRIVEN
SPROCKET
FINAL DRIVEN
DRIVEN SPROCKET
SPROCKET
REPLACE ( X )
REAR
REAR
WHEEL
DAMPER
REAR WHEEL
WHEEL DAMPER
DAMPER
15-4
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REPLACEMENT BEARING
Install the bearing remover into the bearing.
install the bearing remover shaft at the opposite
position, and remove the wheel bearing by heating
with a hammer.
After removing the distance collar, remove the other
bearing.
TOOLS :
BEARING REMOVER SHAFT
REMOVER HEAD
ASSEMBLY
15-5
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REAR
REAR
WHEEL
SLEEVE
REAR WHEEL
WHEEL SLEEVE
SLEEVE
INSTALLATION
FT
FT
FT
AXLE
AXLE
SHAFT
AXLE SHAFT
SHAFT
REAR
REAR
WHEEL
SLEEVE
REAR WHEEL
WHEEL SLEEVE
SLEEVE
15-6
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AXLE
AXLE
SHAFT
AXLE SHAFT
SHAFT
REAR CUSHION
REMOVAL
Raise and support the motorcycle with main stand.
SIDE
COVER
SIDE
SIDE COVER
COVER
MUD GUARD
GUARD
MUD
MUD
GUARD
INSPECTION
Visually inspect the rear cushion for damage.
Check for the :
- Damper rod for bend or damage
- Damper unit for deformation or oil leaks
- Cushion rubber for wear or damage
REAR
REAR
CUSHION
ASSY
REAR CUSHION
CUSHION ASSY
ASSY
15-7
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DUST
DUST SEAL
SEAL
DUST
SEAL
DRILLING PONT
DRILL
PLASTIC BAG
INSTALLATION
Install the rear cushion into the frame and install the
rear cushion upper flange bolt to the specified torque.
TORQUE : 3.4 kgfm
15-8
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SWINGARM
REMOVAL
Remove the rear wheel. (15-3)
Remove the mudguard mounting R/L (2EA) bolts and
rear wheel mudguard.
MUD
MUD
GUARD
MUD GUARD
GUARD
SWING
SWING
ARM
SWING ARM
ARM
REAR
REAR
CUSHION
REAR CUSHION
CUSHION
BRAKE
BRAKE
HOSE
BRAKE HOSE
HOSE
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
U-NUT
U-NUT
U-NUT
U-NUT
15-9
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ASSEMBLY
RR. FORK END CAP
ADJUSTER NUT
CHAIN ADJUSTER
LOCK NUT
RR. SWING ARM
DUST SEAL CAP
BUSH
O-RING CHAIN
CHAIN SLIDER
15-10
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SLIDER
SLIDER
SLIDER
SCREWS
SCREWS
SCREWS
INSTALLATION
Apply thin coat of grease to the swingarm pivot bolt
surface.
Align the drive chain installed swingarm to drive slider
and install the frame.
Install the pivot bolt from the left side and tighten the
u-nut to the specified torque.
TORQUE : 8.8 kgfm
U-NUT
U-NUT
U-NUT
U-NUT
15-11
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HYDRAULIC BRAKE
FRONT :
REAR :
16-0
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16-9
FRONT MASTER CYLINEDR
16-2
TROUBLESHOOTING
16-13
REAR MASTER CYLINDER
16-18
FRONT BRAKE CALIPER
16-20
REAR BRAKE CALIPER
16-6
BRAKE PAD/DISK
16-23
BRAKE PEDAL
SERVICE INFORMATION
GENERAL SAFETY
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your
health.
Avoid breathing dust particles.
Never use an air hose or brush to clean brake assemblies use and OSHA-approved vacuum cleaner.
Don't put in dust or water when filling the reservoir.
Don't mix different types of fluid to prevent from changing chemically.
Don't use the removed brake fluid.
Avoid spilling brake fluid or painted plastic and rubber parts because of damaging them.
Cover the joint part of the hose to prevent the leak the brake fluid from leaked.
Clean the removed parts with brake fluid and check the airing of each part with a compressed air.
Arrange the removed parts not to be soiled with dust or dirt.
After checking if dust or dirt soils each part, install them.
Always replace the specified parts.
Brake pad can be removed without disconnecting the hose.
Bleed the air in case of removing the brake hose.
SPECIFICATIONS
ITEM
FRONT
REAR
Unti : mm
STANDARD VALUE
SERVICE LIMIT
DOT4
4.0
3.5
0.1
0.3
MASTER CYLINDER I. D.
14.000~14.043
14.055
MASTER PISTON O. D.
13.878~13.905
13.866
CALIPER CYLINDER I. D.
25.000~25.033
25.07
CALIPER PISTON O. D.
24.914~24.935
24.87
DOT4
4.0
3.0
0.1
0.3
MASTER CYLINDER I. D.
12.700~12.743
12.755
MASTER PISTON O. D.
12.657~12.684
12.645
CALIPER CYLINDER I. D.
25.000~25.033
25.070
CALIPER PISTON O. D.
24.914~24.935
24.870
16
16-1
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HYDRAULIC BRAKE
TORQUE VALUES
BRAKE CALIPER BRACKET BOLT (FRONT/REAR)
BRAKE CALIPER BLEEDER VALVE (FRONT/REAR)
BRAKE CALIPER HANGER PIN (FRONT/REAR)
BRAKE PAD PIN BOLT (FRONT/REAR)
BRAKE OIL BOLT (FRONT/REAR)
MASTER CYLINDER RESERVE CAP SCREW
BRAKE LEVER PIVOT BOLT
BRAKE LEVER PIVOT LOCK NUT
REAR MASTER CYLINDER HOLDER SOCKET BOLT
3.0fm
0.6fm
2.3fm
1.8fm
3.4fm
1.0fm
1.0fm
1.0fm
1.2fm
TOOL
SNAP RING PLIERS
TROUBLESHOOTING
Brake lever/pedal soft or spongy
Air bubbles in the hydraulic system.
Leaking hydraulic system.
Contaminated brake pad / disk .
Worn caliper piston seal.
Worn master cylinder piston seal.
Worn brake pad/disk.
Contaminated caliper.
Caliper not sliding properly.
Low brake fluid level.
Clogged fluid passage.
Warped / deformed brake disk.
Sticking / worn caliper piston.
Sticking / worn master cylinder piston.
Contaminated master cylinder.
Bent brake lever/pedal.
16-2
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Brake drags
Contaminated brake pad / disk.
Misaligned wheel.
Clogged / restricted brake hose joint.
Warped / deformed brake disk.
Caliper not sliding properly.
Clogged/restricted brake hydraulic system
Sticking/worn caliper piston
Clogged master cylinder port
HYDRAULIC BRAKE
MASTER
MASTER
CYLINDER
CAP
MASTER CYLINDER
CYLINDER CAP
CAP
DIAPHRAGM
DIAPHRAGM PLATE
PLATE
DIAPHRAGM
PLATE
16-3
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HYDRAULIC BRAKE
RESERVOIR
RESERVOIR
CAP
RESERVOIR CAP
CAP
RESERVOIR
RESERVOIR
TANK
RESERVOIR TANK
TANK
<Rear brake>
Remove the RH. side cover.
Remove the reservoir cap.
16-4
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HYDRAULIC BRAKE
FRONT
FRONT CALLIPER
CALLIPER
FRONT
CALLIPER
MASTER
MASTER
CYLINDER
MASTER CYLINDER
CYLINDER
BRAKE BLEEDING
<When the brake bleeder is not available>
Connect a clear bleeder hose to the bleeder valve.
Pump up the system pressure with the lever or pedal
until there are no air bubbles in the fluid flowing out of
the master cylinder and lever or pedal resistance is felt.
1. Squeeze the brke lever or push the brake pedal, open
the bleeder valve 1/2 turn and then close the valve.
REAR
REAR
PEDAL
REAR PEDAL
PEDAL
BRAKE OIL
OIL
BRAKE
BRAKE
OIL
Check the fluid level often, and add fluid if the fluid
level is near the lower level.
If no air leaks out of the bleeder hose, operate the
brake lever to check the presence of air.
Tighten the bleeder valve.
TORQUE : 0.6 kgfm (6Nm)
<Front brake>
Install the master cylinder cap, and tighten the screws.
<Rear brake>
Install the reservoir cap securely.
Install the RH. side cover.
Install the seat.
16-5
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HYDRAULIC BRAKE
BRAKE PAD/DISK
BRAKE
BRAKE
HOSE
CLAMP
BRAKE HOSE
HOSE CLAMP
CLAMP
FRONT
FRONT
CALIPER
FRONT CALIPER
CALIPER
BRAKE PADS
PADS
BRAKE
PIN
PIN
PLUG
PIN PLUG
PLUG
CALIPER
CALIPER
PISTON
CALIPER PISTON
PISTON
16-6
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HYDRAULIC BRAKE
Make sure the brake pad spring is in place.
Install the new brake pads.
Install the hanger pin.
PAD
PAD
SPRING
PAD SPRING
SPRING
BRAKE
BRAKE
PAD
BRAKE PAD
PAD
REAR
REAR
BRAKE
CALIPER
REAR BRAKE
BRAKE CALIPER
CALIPER
16-7
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HYDRAULIC BRAKE
Remove the hanger pins and brake pads.
BRAKE
BRAKE
PAD
BRAKE PAD
PAD
PAD
PAD
SPRING
PAD SPRING
SPRING
16-8
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HYDRAULIC BRAKE
BRAKE DISK INSPECTION
Visually inspect the brake disk for damage or crack.
Measure the brake disk thickness with a micrometer.
SERVICE LIMIT : FRONT: 3.5mm
REAR : 3.0mm
BRAKE
BRAKE
STOP
SWITCH
BRAKE STOP
STOP SWITCH
SWITCH
16-9
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HYDRAULIC BRAKE
DISASSEMBLY
Remove the handle lever bolt/nut and RH. handle lever
assembly.
STOP
STOP
SWITCH
STOP SWITCH
SWITCH
BOOT
BOOT
BOOT
16-10
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HYDRAULIC BRAKE
INSPECTION
MASTER
CYLINDER
PISTON
MASTER
MASTER CYLINDER
CYLINDER PISTON
PISTON
MASTER
CYLINDER
PISTON
ASSEMBLY
MASTER CYLINDER PISTON SET
16-11
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HYDRAULIC BRAKE
Coat all parts with clean brake fluid before assembly.
MASTER
CYLINDER
MASTER
MASTER CYLINDER
CYLINDER
SPRING
SPRING
SPRING
SPRING
PISTON
PISTON
PISTON
PISTON
BOOT
BOOT
BOOT
FRONT
BRAKE
STOP
SWITCH
FRONT
FRONT BRAKE
BRAKE STOP
STOP SWITCH
SWITCH
16-12
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HYDRAULIC BRAKE
INSTALLATION
Place the master cylinder assembly on the handlebar.
Install the master cylinder holder with the "UP" mark
facing up.
Tighten the upper bolt first, then the lower bolt.
HYDRAULIC BRAKE
Remove the two main step holder socket bolts and
main step bar assembly.
Unhook the rear brake stop switch spring from the
brake pedal spring.
JOINT
JOINT
PIN
JOINT PIN
PIN
TUBE
TUBE JOINT
JOINT PIPE
PIPE
TUBE
JOINT
PIPE
DISASSEMBLY
Remove the screw and tube joint pipe from the master
cylinder.
SCREW
SCREW
SCREW
SNAP
RING
PLIERS
SNAP
SNAP RING
RING PLIERS
PLIERS
BOOT
BOOT
BOOT
BOOT
SNAP
SNAP RING
RING
SNAP
RING
16-14
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HYDRAULIC BRAKE
MASTER
CYLINDER
MASTER
MASTER CYLINDER
CYLINDER SPRING
SPRING
SPRING
BRAKE
ROD
JOINT
BRAKE
BRAKE ROD
ROD JOINT
JOINT
REAR
PISTON
REAR
REAR PISTON
PISTON
REAR
PISTON
REAR
PISTON
REAR
REAR PISTON
PISTON
REAR
INSPECTION
Check the piston for abnormal scratches.
Check the primary cup and secondary cup for fatigue
or damage.
Measure the master rear piston O.D.
SERVICE LIMIT : 12.645mm
ASSEMBLY
16-15
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HYDRAULIC BRAKE
Coat all parts with clean brake fluid before assembly.
MASTER CYLINDER
MASTER
CYLINDER
MASTER
CYLINDER
SPRING
SPRING
SPRING
SPRING
BRAKE
ROD
JOINT
BRAKE
BRAKE ROD
ROD JOINT
JOINT
PISTON
PISTON
SNAP
RING
PLIERS
SNAP
SNAP RING
RING PLIERS
PLIERS
BOOT
BOOT
BOOT
SNAP
SNAP RING
RING
SNAP
RING
O-RING
O-RING
O-RING
TUBE
JOINT
PIPE
TUBE
TUBE JOINT
JOINT PIPE
PIPE
TUBE JOINT
TUBE
JOINT
PIPE
TUBE
JOINT PIPE
PIPE
SCREW
SCREW
SCREW
16-16
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HYDRAULIC BRAKE
INSTALLATION
JOINT
JOINT
PIN
C
JOINT PIN
PIN C
C
Install the brake hose with the oil bolt and new
washers.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4 kgfm
FRONT
FRONT
RH.
BRAKE
CALIPER
FRONT RH.
RH. BRAKE
BRAKE CALIPER
CALIPER
FRONT
LH.
BRAKE
CALIPER
FRONT
FRONT LH.
LH. BRAKE
BRAKE CALIPER
CALIPER
OIL
OIL
BOLT
OIL BOLT
BOLT
16-17
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HYDRAULIC BRAKE
DISASSEMBLY
Remove the pad spring, slide pin, caliper bracket and
boot from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
Install corrugated cardboard or soft wood sheet
between the pistons.
Apply small squirts of air pressure to the brake hose
assembly part to remove the pistons from the caliper.
PISTON SEAL
PISTON
SEAL
PISTON
SEAL
Do not use high pressure air or bring the air gun too
close.
Do not touch the inside of caliper.
Remove the piston seal and dust seal.
INSPECTION
Check the caliper friction surface for damage or
scratches.
Measure the caliper I. D.
SERVICE LIMIT : 25.07mm
16-18
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HYDRAULIC BRAKE
Check the appearance of piston for damage or
scratches.
Measure the piston O. D.
SERVICE LIMIT : 24.87mm
ASSEMBLY
Clean the piston seal and dust seal with brake fluid,
install it into caliper groove.
PISTION SEAL
PISTION
SEAL
PISTION
SEAL
CALIPER
PISTON
CALIPER
CALIPER PISTON
PISTON
DUST SEAL
DUST
SEAL
DUST
SEAL
16-19
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HYDRAULIC BRAKE
INSTALLATION
Install the front caliper to front fork.
Tighten the caliper mounting bolts to the specified
torque.
TORQUE : 3.0kgfm
Install the brake hose to the caliper body with two new
2 oil bolts washers and oil bolts.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4kgfm (34 Nm)
OIL
OIL
BOLTS
OIL BOLTS
BOLTS
DISASSEMBLY
Remove the spring, slide pin, caliper bracket and boot
from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
16-20
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HYDRAULIC BRAKE
Wrap the caliper with piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
Remove the piston from the caliper while blowing the
low piessure air in the opening of the brake hose.
DUST
SEAL
DUST
DUST SEAL
SEAL
PISTON
SEAL
PISTON
PISTON SEAL
SEAL
INSPECTION
Check the appreance of caliper for damage or
scratches..
Measure the caliper I. D.
SERVICE LIMIT : 25.070mm
ASSEMBLY
Clean the piston seal, dust seal with brake fluid install
it into caliper groove.
16-21
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HYDRAULIC BRAKE
CALIPER
CALIPER
CALIPER
CALIPER
PISTON SEAL
PISTON
SEAL
PISTON
SEAL
DUST
DUST
SEAL
DUST SEAL
SEAL
PISTON
PISTON
PISTON
BOOT
BOOT
BOOT
BOOT
PAD SPRING
PAD
SPRING
PAD
SPRING
CALIPER
BRACKET
CALIPER
CALIPER BRACKET
BRACKET
INSTALLATION
Install the rear caliper to rear caliper bracket.
Tighten the caliper mounting bolts to the specified
torque.
TORQUE : 3.0kgfm
Install the brake hose to the caliper body with two new
2 oil bolts washers and oil bolts.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4kgfm (34 Nm)
BRAKE PEDAL
REMOVAL
Remove the main step holder mounting socket bolts
and main stepbar assembly.
Unhook the stop switch spring from the brake pedal
spring.
16-22
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HYDRAULIC BRAKE
COTTER
PIN
COTTER
COTTER PIN
PIN
Strech and pull out the brake pedal joint cotter pin and
remove the joint pin C.
Remove the brake pedal spring from the brake pedal.
Remove the external cir-clip, washer and brake pedal.
INSTALLATION
Install the brake pedal to main step holder and
assemble the washer and external cir-clip.
Connect the brake pedal to the brake rod joint.
Install the joint pin C and secure it with a new cotter
pin.
REAR
REAR
BRAKE
PEDAL
REAR BRAKE
BRAKE PEDAL
PEDAL
16-23
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BATTERY/CHARGING SYSTEM
BATTERY
ECU
FUSE BOX
REGULATOR/RECTIFIER
AC GENERATOR
IGNITION COIL
Y
Y
R/W
/
MAIN
SWITCH
FUSE
(30A)
(30A)
AC GENERATOR
REGULATOR
RECTIFIER
LOAD
17-0
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FUSE
(15A)
(15A)
B (CABLE)
BATTERY
fi
ECU
B......Black
Y.......Yellow
G......Green
R......Red
W..... White
Lg.....Light green
SERVICE INFORMATION
Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.
This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
When charging the battery, remove the battery from the frame.
There is the possibility of damaging the regulator/rectifier, etc. If the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that
the battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss
in battery strength.
It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
For information on generator disassembly, refer to section 8.
17
SPECIFICATIONS
ITEM
Capacity
BATTERY
A.C.GENERATOR
REGULATOR /
RECTIFIER
STANDARD VALUES
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, BATTERY TESTER, SCANNER
17-1
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BATTERY/CHARGING SYSTEM
TROUBLESHOOTING
No power (Key turned on)
Dead battery.
- Low fluid level.
- Low specific gravity.
- Charging system failure.
Disconnected battery cable.
Main fuse burned out.
Faulty ignition switch.
Loose connection on short circuit in wire harness.
Battery undercharged.
Battery is failing.
Charging system failure.
Intermittent power
Loose battery connection.
Loose charging system connection.
Loose starting system connection.
Loose connection or short circuit in ignition system.
Loose connection or short circuit in lighting system.
Loose connection or short circuit in wire harness.
OVERCHARGED
(15V)
14 ~ 15V
ABNORMAL
INCORRECT
NORMAL
INCORRECT
CORRECT
NORMAL
Faulty battery.
17-2
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BATTERY/CHARGING SYSTEM
BATTERY
BATTERY
BATTERY
BAND
BATTERY BAND
BAND
REMOVAL/INSTALLATION
Remove the seat. (13-2)
Remove the battery band.
Disconnect the negative (-) cable and then the positive
(+) cable and remove the battery.
Install the battery in the reverse order of removal with
the proper wiring.
VOLTAGE INSPECTION
Measure the battery voltage using a multi tester.
VOLTAGE:
- Fully charged : 13.0~13.2V
- Under charged : Below 12.3V
TOOL : MULTI-TESTER
BATTERY CHARGING
Remove the battery.
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the charger negative(-) cable to the battery
negative(-) terminal.
17-3
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BATTERY/CHARGING SYSTEM
AMPERE METER
BATTERY TERMINAL
GROUND CABLE
DIGITAL TESTER
AMPERE METER
MAIN
FUSE
TERMINALS
MAIN FUSE
17-4
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BATTERY/CHARGING SYSTEM
REGULATOR RECTIFIER
REGULATOR
RECTIFIER
REGULATOR
RECTIFIER
REGULATOR/RECTIFIER
HARNESS SIDE CIRCUIT INSPECTION
Remove the seat. (13-2)
Remove the LH. side cover. (13-2)
Disconnect the regulator/rectifier coupler.
Inspect the wiring circuits at each terminal of the wire
harness side.
Inspection Items
ITEM
INSPECTION
BATTERY
WIRE(RED)
B
28~36
28~36
BATTERY/CHARGING SYSTEM
REMOVAL/INSTALLATION
Disconnect the regulator/rectifier coupler.
Remove the regulator/rectifier unit mounting bolts and
regulator/rectifier.
Install the reguator/rectifier unit in the reverse order of
removal.
17-6
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MEMO
IGNITION SYSTEM
BATTERY
ECU
FUSE BOX
REGULATOR/RECTIFIER
IGNITION COIL
18-0
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AC GENERATOR
18-3
CRANKPOSITIONSENSORINSPECTION
18-1
SERVICE INFORMATION
18-4
IGNITION COIL INSPECTION
18-2
TROUBLESHOOTING
SERVICE INFORMATION
GENERAL SAFETY
Inspect the ignition system in proper sequence based on the troubleshooting.
Dropping or giving a shock to the ECU unit causes a trouble.
There should be battery voltage with the ignition and engine stop switched ON. Turn the main switch
OFF while serving.
TRANSISTOR ignition system is used and it can not be adjusted.
Couplers are connected to other couplers which have same colour.
Coil standard resistance may not be obtained due to the different measuring circumatances.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (chapter 21-1 )
SPECIFICATIONS
Item
Primary Coil
Ignition coil
resistance
20(68)
Secondary
Coil
Standard
0.730.08, 235
Without the spark
plug cap
100RPM)
IDLE (1,6001
(15K)
80-150,20
BTDC 18
18
TOOLS
DIGITAL TESTER
PVA MULTI-TESTER
18-1
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IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug. (TOOL : PVA MUITI TESTER)
UNUSUAL CONDITION
No peak voltage.
No peak voltage.
18-2
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IGNITION SYSTEM
Inspection Items
INSPECTION
ITEM
MAIN SWITCH
CRANK POSITION SENSOR
Check the battery voltage between main switch wire (black) and ground wire when the ignition is
ON
Check the resistance of coil (between blue / yellow and green) is within the specified range.
( 80~150, 20)
IGNITION COIL (PRIMARY COIL) Check the resistance of coil (between black / yellow and green) is within the specified range.
( 0.73~0.08, 235)
GROUND WIRE
If measured data is out of standard, and there is no spark at plug, check the ignition coil by using a tester.
TOOL : DIGITAL TESTER
RESISTANCE MEASUREMENT
Remove the seat. (13-2)
Remove the LH. side cover (13-2)
Disconnect the A.C generator 4P coupler and
blue/yellow wire connector.
Measure the resistance between the green and
blue/yellow.
(20
)
STANDARD VALUE : 80-150
PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire
connector.
Connect the blue/yellow wire terminal to the PVA
tester (+) terminal.
Connect the PVA tester (-) terminal to the green wire
terminal or no painting area (ground)
Crank the engine with the starter motor and measure
the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V
TOOL : PVA MULTI TESTER
18-3
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IGNITION SYSTEM
IGNITION
IGNITION
COIL
IGNITION COIL
COIL
PULL
PULL
PULL
PUSH
PUSH
PUSH
PUSH
PRIMARY COIL
Measure the resistance between the two terminals of the
ignition primary coil.
If the resistance value is within the specified range the
coil is good.
If resistance is (infinite), replace the coil with a new one.
0.08
,
STANDARD VALUE : (Resistance) 0.73
230.5(Voltage) over 100V
SECONDARY COIL
With the spark plug cap on, measure the resistance between
the primary coil terminal and the spark plug cap.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.
K
REFERENCE VALUE : 15K
18-4
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IGNITION SYSTEM
REPLACEMENT
Remove the high-tension cord from the plug, remove
the plug cap.
Remove the primary wire from the ignition coil.
Loosen the ignition coil mounting bolt securing the
frame, remove the ignition coil.
Install in the reverse order of removal.
INSPECTION
Check the following terminals.
ITEM
SIDE STAND SWITCH
SHAFT
TERMINALS COLOR
ON
PUSH BLACK/WHITE AND
(Side stand THE
erected) SHAFT GREEN TERMINAL
PUSH THE SHAFT
STANDARD
NORMAL IF THERE
IS CONTINUITY
ELECTRIC STARTER
STARTER
SWITCH
STARTER
MAGNETIC
SWITCH
B(CABLE)
Y/R
/Y G
O
STARTER
MOTOR
FUSE
HQUaI
B/
G/W
G/Y
B/W
B/W
B/W
Lg/R
SIDE STAND
SWITCH
B(CABLE)
MAIN
SWITCH
R/W
O
R
FUSE
HSPaI
G
NEUTRAL
LAMP
19-0
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BATTERY
(12A 10AH)
Lg/R
GEAR
POSITION
SWITCH
B......Black
Y.......Yellow
G......Green
R......Red
W..... White
Lg.....Light green
STARTING DIAGRAM
19-0
19-1
SERVICE INFORMATION
TROUBLESHOOTING 19-2
SERVICE INFORMATION
GENERAL SAFETY
Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.
The starter motor can be maintained without removing the engine from the vehicle.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.
SPECIFICATION
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
10.2mm
5.0mm
TOOLS
MULTI TESTER
VERNIER CALIPER
SCANNER
19
19-1
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ELECTRIC STARTER
TROUBLESHOOTING
Starter motor will not turn.
Check for a blown out main fuse before servicing.
Make sure the battery is fully charged and in good condition.
With the ignition switchON
, check for a
CLICK sound from starter magnetic
switch. (19-6)
CLICK heard
NO VOLTAGE.
CONTINUITY.
Connect the starter magnetic switch coupler.
Measure the starter magnetic voltage at the
starter magnetic switch coupler. (19-6)
VOLTAGE MEASURED
Check the starter magnetic switch operation.
(19-6)
NORMAL
ABNORMAL
19-2
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ELECTRIC STARTER
STARTER MOTOR
REMOVAL
With the ignition switch turned to "OFF", remove the
negative cable at the battery before servicing the starter
motor.
Remove the rubber cap.
Remove the nut and starter motor cable from the starter
motor.
DISASSEMBLY
FLANGE
FLANGE
BOLTS
FLANGE BOLTS
BOLTS
INSPECTION
Check the bushing in the rear cover for wear or
damage.
Check the oil seal and bushing in the front cover for
wear or damage.
19-3
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ELECTRIC STARTER
Check the commutator bars of the armature for
discoloration.
Discoloration of the commutator bars. Replace with
a new one.
19-4
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ELECTRIC STARTER
Check for continuity between the cable terminal
and the case.
There should be no continuity.
ELECTRIC STARTER
INSTALLATION
Coat a new O-ring with oil and install it into the starter
motor groove.
Install the starter motor into the crankcase.
REMOVAL
Remove the seat. (13-2)
Remove the RH. side cover. (13-2)
Disconnect the battery wire cable from the starter
magnetic switch terminal.
Disconnect the starter motor cable from the starter
magnetic switch terrminal.
Disconnect the Yellow/Red and Green/Yellow
connector from the wire harness.
Remove the starter magnetic switch from the bracket
of the frame.
OPERATION INSPECTION
Shift the transmission into neutral.
Turn the ignition switch to "ON", and push the starter
switch button.
The coil is normal if the starter magnetic switch clicks.
If you dont hear the switch "CLICK", inspect the
magnetic switch using the procedure below.
19-6
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ELECTRIC STARTER
STARTER MAGNETIC SWITCH
VOLTAGE INSPECTION
Connect the starter magnetic switch connector.
Shift the transmission into neutral.
Measure the voltage between the Yellow/Red wire
terminal(+) and ground (-).
If the battery voltage appears only when the starter
switch is pushed with the ignition switch to "ON", it is
normal.
CONTINUITY INSPECTION
Disconnect the wire connector of the magnetic switch.
Connect the positive wire to the yellow/red wire
terminal and the negative wire to the green/yellow wire
terminal.
There should be continuity.
INSTALLATION
Install in the reverse order of removal.
19-7
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LIGHTS/METER/SWITCHES
WINKER RELAY
HEADLIGHT RELAY
ECU
FUSE BOX
HORN
SPEEDOMETER
HEADLIGHT
BATTERY
HORN
20-0
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20. LIGHTS/SWITCHES/HORN
SYSTEM LOCATION20-0
SERVICE INFORMATION20-1
TROUBLESHOOTING 20-1
HEADLIGHT 20-2
FRONT/REAR WINKER 20-3
STOP/TAIL LIGHT 20-3
COMBINATION METER 20-4
SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.
The following color codes are used throughout this section.
B = Black
Y = Yellow
L = Blue
G = Green
R = Red
W = White
Br = Brown
O = Orange
Sb = Sky Blue
Lg = Light Green P = Pink
V = Violet
Gr = Gray
TROUBLESHOOTING
Light not turned on when the main switch is ON
Faulty light bulb
Faulty switch
Faulty or disconnected wiring
Fuse cut
Battery discharged
Dim headlight
Battery discharged
Wiring and switch resistance high
20
20-1
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LIGHTS/SWITCHES/HORN
HEADLIGHT
BULB REPLACEMENT
Loosen the flange bolt secured front cowl stay.
Remove the headlight, winker, speedometer coupler.
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
HEAD
HEAD
LIGHT
DUST
COVER
HEAD LIGHT
LIGHT DUST
DUST COVER
COVER
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
HEADLIGHT
HEADLIGHT
CASE
HEADLIGHT CASE
CASE
20-2
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LIGHTS/SWITCHES/HORN
FRONT/REAR WINKER
BULB RREPLACEMENT
Remove the screw and winker lens.
FRONT
FRONT
WINKER
FRONT WINKER
WINKER
FRONT
WINKER
FRONT
FRONT WINKER
WINKER
REAR
REAR
WINKER
REAR WINKER
WINKER
STOP/TAIL LIGHT
REAR
WINKER
REAR
REAR WINKER
WINKER
INSPECTION
Turn the ignition switch to "ON", and check the tail
light operation.
Check that the stop/tail light unit light on with the front
brake lever and/or rear brake pedal applied.
When ever any one does not turn on, replace the
stop/tail light bulb.
STOP/TAIL
STOP/TAIL
LIGHT
STOP/TAIL LIGHT
LIGHT
BULB REPLACEMENT
Remove the screws and tail light lens.
Slightly press down on the bulb and turn it
counterclockwise.
Replace with a new bulb.
Install in the reverse order of removal.
20-3
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LIGHTS/SWITCHES/HORN
COMBINATION METER
REMOVAL
Remove the side RH/LH cowl.
Rempve the front cowl.
SUB PANNEL
PANNEL
SUB
SUB
PANNEL
COMBINATION
COMBINATION
METER
COMBINATION METER
METER
INNER
INNER PANNEL
PANNEL
INNER
PANNEL
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
INSTALLATION
Install in the reverse order of removal.
20-4
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LIGHTS/SWITCHES/HORN
MAIN SWITCH
REMOVAL
Remove the main seat
Remove the fuel tank
Remove the main switcs coupler
HAZARD
HAZARD
STARTER
SWITCH
COUPLER
HAZARD STARTER
STARTER SWITCH
SWITCH COUPLER
COUPLER
WINKER.
DIMMER
WINKER.
WINKER. DIMMER
DIMMER
WINKER.
DIMMER
SWITCH
SWITCH
COUPLER
SWITCH COUPLER
COUPLER
MAIN
MAIN
SWITCH
COUPLER
MAIN SWITCH
SWITCH COUPLER
COUPLER
INSPECTION
MAIN
MAIN
SWITCH
COUPLER
MAIN SWITCH
SWITCH COUPLER
COUPLER
BAT2
KEY
ON
KEY ON
OFF
KEY OFF
LOCK
KEY OFF/LOCK
COLOR
R/W
20-5
LIGHTS/SWITCHES/HORN
HAZARD
HAZARD
STARTER
SWITCH
COUPLER
HAZARD STARTER
STARTER SWITCH
SWITCH COUPLER
COUPLER
HANDLEBAR SWITCHES
Check for continuity between the wire terminals of the
handlebar switch connector.
Continuity should exist between the color coded wire
terminals as follows:
STARTER SWITCH
HEADLIGHT
HEADLIGHT
SWITCH
HEADLIGHT SWITCH
SWITCH
ST 1
BAT 2
Y/R
FREE
PUSH
COLOR
HEADLIGHT SWITCH
W
Br
Br/L
OFF
P
STARTER
STARTER
SWITCH
STARTER SWITCH
SWITCH
H
WINKER.DIMMER
WINKER.DIMMER
SWITCH
COUPLER
WINKER.DIMMER SWITCH
SWITCH COUPLER
COUPLER
COLOR
WINKER SWITCH
W
SB
R
N
L
COLOR
Gr
HORN SWITCH
WINKER
SWITCH
WINKER
WINKER SWITCH
SWITCH
WINKER
SWITCH
HO
BAT 2
LG
FREE
PUSH
COLOR
SWITCH
HORN
HORN
HORN SWITCH
SWITCH
SWITCH
20-6
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LIGHTS/SWITCHES/HORN
DIMMER SWITCH
PASSING
PASSING
SWITCH
PASSING SWITCH
SWITCH
BAT3
HI
LO
B/W
Hi
(N)
Lo
COLOR
PASSING SWITCH
DIMMER
DIMMER
SWITCH
DIMMER SWITCH
SWITCH
BAT2
HI
Hi
COLOR
ASSEMBLY
Install in the reverse order of removal.
STOP
STOP
SWITCH
STOP SWITCH
SWITCH
BRAKE LEVER
LEVER
BRAKE
BRAKE
LEVER
STOP
STOP
SWITCH
COUPLER
STOP SWITCH
SWITCH COUPLER
COUPLER
REAR
Remove the seat (13-2)
Remove the RH. side cover. (13-2)
Disconnect the rear stop switch connector and check
for continuity between the terminals.
There should be continuity with the brake pedal
applied, and there should be no continuity with the
brake pedal is released.
REAR
REAR
BRAKE
PEDAL
REAR BRAKE
BRAKE PEDAL
PEDAL
20-7
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LIGHTS/SWITCHES/HORN
HORN
Disconnect the wire connectors from the horn.
Connect the 12V battery to the horn terminal directly.
The horn is normal if it sounds when the 12V battery is
connected acress the horn terminals.
WINKER RELAY
Remove the rear seat. (13-2)
Check the following:
- Battery condition
- Burned bulbs
- Burned fuse
- Main switch and winker switch function
- Loose connectors
If the above items are all normal, check the following:
1. Short the Black and Gray terminals of the winker relay
connector with a jumper wire.
Start the engine and check the winker light by
turning the switch to ON.
Light comes on
20-8
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21. TROUBLESHOOTING
ENGINE WONT START
OR IS HARD TO START 21-1
21-2
ENGINE LACKS POWER
POOR PERFORMANCE
21-3
(AT LOW AND IDLE SPEED)
POOR PERFORMANCE
21-4
(AT HIGH SPEED)
21-4
POOR HANDLING
POOR FRONT/REAR SUSPENSION
21-5
PERFORMANCE
21-5
FUEL GAUGE
CAUSE OF TROUBLE
Fuel not supplied
to the carburetor
Weak or no
spark
Low compression
Engine starts
but stops.
Wet plug
Carburetor flooded.
Throttle valve open.
Choke closed.
Air cleaner dirty.
Rich fuel mixture.
Fuel is supplied
21
21-1
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TROUBLESHOOTING
CAUSE OF TROUBLE
Pressure low
Punctured tire.
Faulty tire valve.
Dragged brake.
Worn or damaged wheel bearings.
Lacked wheel bearings lubrication.
D
Axle nut tightened excessively.
Clutch slipping.
Worn clutch disk and plate.
Damaged clutch disk and plate.
Engine speed
doesnt increase.
Incorrect
Incorrect
Low
Clogged
Pressure normal
2. Raise wheels off ground and
rotate by hands.
Wheel rotate freely.
3. Accelerate suddenly.
Engine speed increased.
4. Accelerate lightly.
Engine speed increased.
21-2
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TROUBLESHOOTING
INSPECTION
9. Check the spark plug.
Not contaminated or not
discolored.
10. Check oil level.
CAUSE OF TROUBLE
Contaminated or
discolored
Overheated
Engine knocking
Level normal
11. Remove cylinder head
30mm hole cap, and inspect
lubrication.
Valve train lubricated properly.
12. Check for engine overheating.
Not overheated.
CAUSE OF TROUBLE
Incorrect
Leaking
Weak or intermittent
sparks
Correct
2. Check inlet pipe for leakage.
No leak
3. Check sparks.
Sparks normal.
21-3
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TROUBLESHOOTING
CAUSE OF TROUBLE
Incorrect.
Fuel flows
restricted.
Clogged.
Incorrect.
Weak.
Correct.
POOR HANDLING
INSPECTION
CAUSE OF TROUBLE
1. If steering is heavy.
21-4
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TROUBLESHOOTING
CAUSE OF TROUBLE
Sliders stuck.
Cushion stopper rubber damaged.
FUEL GAUGE
GAUGE READING INACCURATE (IGNITION SWTICH ON)
INSPECTION
1. Operate the turn signal to check the
battery circuit.
Signal operates satisfactorily.
CAUSE OF TROUBLE
Signal continuously
operates dim or does not
operate at all.
Fuse cut.
Battery weak or totally discharged.
Faulty ignition swtich.
Faulty terminal connection.
Wire harness damaged.
Needle moves.
Faulty float.
Unsatisfactory
Terminal loose.
Faulty terminal connection.
Check
21-5
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TROUBLESHOOTING
GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON)
INSPECTION
1. Operate the turn signal to check the
battery circuit.
Signal operates satisfactorily.
CAUSE OF TROUBLE
Signal continuously
operates dim or does not
operate at all.
Fuse cut.
Battery weak or totally discharged.
Ignition switch damaged or shorted.
Terminal loose of faulty connection.
Wire harness damaged.
Resistance changed
significantly.
Unsatisfactory
Needle moving.
21-6
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MEMO
MEMO
MEMO
MEMO
WIRING DIAGRAM
22
22-1
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33
1
2
1
2
1
2
1
2
01
08
09
16
17
24
25
32
34
36
38
35
37
39
40
SERVICE MANUAL
2009. 10 PRINTED
2009. 10 PUBLICATION
COPY PROHIBIT