LINDY 125 Manual de Serviços (Ingles) HJ125T-18

HJ125T-18/18A
HJ150-9A
99500H7A251E010
FOREWORD GROUP INDEX
This manual contains an introductory description on
t h e H J 1 2 5 T- 1 8 / 1 8 A a n d p r o c e d u r e s f o r i t s
inspection/ service and overhaul of its main
components. Other information considered as
generally known is not included.
GENERAL INFORMATION 1
Read the GENERAL INFORMATION section to
2
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections to
use as a guide for proper inspection and service.
PERIODIC MAINTENANCE
This manual will help you know the motorcycle better
so that you can assure your customers of fast and
3
reliable service.
ENGINE
* This manual has been prepared on the basis of the
latest specifications at the time of publication. If
4
modifications have been made since then,
differences may exist between the content of this FUEL AND LUBRICATION
* manual and actual motorcycle.
Illustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual motorcycle
* exactly in detail.
This manual is written for persons who have
CHASSIS 5
enough knowledge, skills and tools, including
6
special tools, for servicing HAOJUE motorcycles.
If you do not have the proper knowledge and tools, ELECTRICAL
ask your authorized HAOJUE motorcycle dealer to
help you.
WARNING
Inexperienced mechanics or mechanics

SERVICING INFORMATION 7
without the proper tools and equipment may
not be able to properly perform the services
described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
JIANGMEN DACHANGJIANG GROUP CO., LTD.

DEC, 2013
(The First Edition)
©COPYRIGHT JIANGMEN DACHANGJIANG GROUP CO.,LTD. 2013

HOW TO USE THIS MANUAL TO
LOCATE WHAT YOU ARE LOOKING FOR:
1.The text of this manual is divided into 8 sections.
2.The section titles are listed in the GROUP INDEX.
3.Holding the manual as shown as at the right will allow you to
find the first page of the section easily.
COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instruction and tightening torque,
lubricating points and locking points, are provided.
Example: Front wheel
1 Front axle
2 Collar
3 Oil seal
4 Roller bearing
5 Front brake disc
6 Valve
7 Front tire
8 Front rim
9 Spacer
10 Speedometer gearbox
A Brake disc bolt
B Front axle nut
ITEM N•m Kgf•m
A 18-28 1.8-2.8
B 27-43 2.7-4.3
SYMBOL
The following symbols are instructions and necessary information for maintenance.
SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.
Apply thread bond “1360"
Data beside it indicates specified
99000-32130
torque.
Apply oil. Use engine oil unless

OIL
otherwise specified Apply or use the absorber oil
Apply SUPER GREASE “A”

Apply or use brake fluid
99000-25010
Apply MOLY PASTE

Measure the voltage
99000-25140
Apply sealant “1207B”

Measure the resistance
99000-31140
Apply THREAD LOCK “1303"

Measure the continuity test
99000-32030

Use special tool
99000-32050

1322 Indication of service data
99000-32110
WIRE COLOR
B : black Gr : Gray R : Red

Bl : Blue Lb : Light blue V : Violet
Br : Brown Lg : Light green W : White
Dg : Deep green O : Orange Y : Yellow
G : Green P : Pink
B/Bl : Black with blue tracer O/B : Orange with black tracer
B/Br : Blue with brown tracer O/BI : Orange with blue tracer
B/G : Black with green tracer O/W : Orange with white tracer
B/R : Black with red tracer O/Y : Orange with yellow tracer
B/W : Black with white tracer R/B : Red with black tracer
B/Y : Black with yellow tracer R/Y : Red with yellow tracer
Bl/W : Blue with white tracer W/B : White with black tracer
W/R : White with red tracer Y/G : Yellow with green tracer
Bl/Y : Blue with yellow tracer Y/R : Yellow with red tracer
Br/Y : Brown with yellow tracer Y/W : Yellow with white tracer
G/Y : Green with yellow tracer
GENERAL INFORMATION
1
CONTENTS
WARNING/CAUTION/NOTE 1-1
GENERAL PRECAUTIONS 1-1
SERIAL NUMBER LOCATION 1-3
FUEL AND OIL RECOMMENDATION 1-3
BREAK-IN PROCEDURE 1-3
SPECIFICATIONS 1-4
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the
symbol and the words WARNING,CAUTION and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and the cautions contained in this manual cannot possibly cover
all potential hazards relating to the servicing, or lack of servicing of the motorcycle. In addition to the
WARNINGS and CAUTIONS stated, you must use good judgment and basic mechanical safety principles.
If you are unsure about how to perform a particular service operation, ask a more experienced technician
for advice.
GENERAL PRECAUTION
WARNING
Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
When 2 or more persons work together, pay attention to safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor.
When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer's instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a
while after engine operation.
After servicing fuel, oil, exhaust or brake system, check all hoses and fittings related to the
system for leaks.
1-1
GENERAL INFORMATION
If parts replacement is necessary, replace the parts with HAOJUE GENUINE PARTS or their
equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean, and also lubricated when specified.
When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified
type.
When performing service to electrical parts, if the service procedures not require used of battery
power, disconnect the positive terminal.
When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable, and
replace the terminal cover on the positive terminal.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with
smaller diameter, from inside to outside diagonally, to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, cir-clips,
and certain other parts as specified, be sure to replace them with new ones. Also, before installing
these new parts, be sure to remove any odd material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expend the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
Do not use self-locking nuts a few times over.
Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or
oil if a thread is smeared with them.
After reassembly, check parts for tightness and operation.
NOTE:
* To protect environment, do not unlawfully dispose of used motor oil and other fluids, batteries
and tires.
* To protect earth's natural resources, properly dispose of used motorcycles and parts.
1-2
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS

T he V.I.N (Vehicle Identification Number) ① is
GEAR OIL
stamped on the left chassis under the foot rest .
The engine number ② is located on the lower part The gear oil you use comes under API
of the front left crankcase . classification of GL-5 and its viscosity rating is
These numbers are required especially for SAE 80W-90.
registering the motorcycle and ordering the spare
parts. BRAKE FLUID
DOT3 OR DOT4
ABSORBER OIL
SPECIAL ABSORBER OIL
BREAK-IN PROCEDURE
FUEL AND OIL During the manufacture only the best p ossible
materials are used and all machined parts are
RECOMMENDATIONS finished to a very high standard , it is still
necessary to allow the moving part to “BREAK-IN”
FUEL before subjecting the engine to maximum
Use fuel with an octane number of 90-97 stresses . The future performance and reliability
(Research method), preferably unleaded. of the engine depend s on the care and restraint
exercised during its early life . The general rules
NOTE:
Unleaded fuel will extend spark plug life. are as follows:
The throttle must not be opened to the full

ENGINE OIL during the new motorcycle’s BREAK-IN period.
Be sure that the motorcycle engine oil you use Throttle opening should be limited to ≦ 3/4 of its
comes under API classification of SF or SG and its maximum, while violent acceleration should be
viscosity rating is SAE 10W-40. If SAE 10W-40 avoided.
engine oil is not available, select the oil viscosity Do not maintain constant engine speed for an
according to the following chart: extended time period during any portion of the
break-in. Try to vary the throttle position.
SAE
40
30
20W/50
10W/50
10W/30
20W
10W
C -20 -10 0 10 20 30 40
Temp.
F -4 14 32 50 68 86 104
1-3
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 1780 mm
Overall width 645 mm
Overall height 1085 mm
Wheelbase 1 230 mm
Ground clearance 1 25 mm
Curb weight 1 10 kg
ENGINE
Type Single cylinder, horizontal, fan-cooled, four stroke
Number of cylinders 1
Bore 52.4 mm
Stroke 57.8 mm
Piston displacement 124 m l
Compression ratio 9.4:1
Carburetor BS Type
Air cleaner Paper filter
Starter system Electric or kick starting
Lubrication system Wet sump
TRANSMISSION
Clutch Dry shoe , automatic, centrifugal type
Transmission automatic
Reduction ratio 0.782-2.672
Final reduction ratio 8.294
Drive system V-belt drive
1-4
GENERAL INFORMATION
ELECTRIC
Ignition type Electronic Ignition
Ignition timing 13° B.T.D.C/ 1700 rpm
Spark plug CR6HSA/A6RTC
Battery 12V 6Ah
Fuse 15 A
Headlight 12V,35W / 35W
Tail light / brake light 12V,5W / 21W
Turn signal light 12V,10W
Position light 12V,5W
Rear license plate light 12V,5W
CHASSIS
Front absorber Telescopic, coil spring, oil damped
Rear absorber Swing arm type, 5 level adjustable coil spring oil damped
Steering angle 47 °
Caster 25 °
Trail 72 mm
Turning diameter 3800 mm
Front brake Disc brake/hand brake
Rear brake Drum brake/hand brake/foot brake
Front tire size 90/90-10 50J
Rear tire size 100/90-10 56J
Front absorber stroke 95 mm
CAPACITIES
Fuel tank 5.8 L
Engine oil, Change 950 ml
Overhaul 1 000 ml
Final gearbox oil 90ml
Front absorbe oil(single) 85 1 ml
*These specifications are subject to change without notice.
1-4
CONTENTS
2-1
MAINTENANCE PROCEDURES
2-3 2
BATTERY/FUSE 2-3
AIR CLEANER 2-4
MUFFLER BOLTS AND NUTS 2-5
VALVE CLEARANCE 2-5
SPARK PLUG 2-6
ENGINE OIL 2-7
OIL FILTER 2-7
OIL STRAINER 2-8
GEARBOX OIL 2-8
DRIVE BELT 2-8
CLUTCH SHOE AND ROLLER 2-9
THROTTLE CABLE PLAY 2-9

CARBURETOR 2-9
FUEL HOSE AND 2ND AIR HOSE 2-10
FUEL FILTER 2-10
2ND AIR FILTER 2-10
2ND AIR VALVE 2-11
BRAKES 2-12
TIRES 2-15
STEERING 2-15
FRONT AND REAR ABSORBER 2-16
LIGHTING AND SIGNAL 2-16
CHASSIS AND ENGINE BOLTS AND NUTS 2-16
COMPRESSION PRESSURE INSPECTION 2-18
OIL PRESURE INSPECTION 2-19
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy.
CAUTION
More frequent servicing may be performed on motorcycles that are used under extreme severe conditions.
PERIODIC MAINTENANCE CHART

Interal Km Initial 1 000 Every 3 000 Every 6 000
Page
Item Month 3 6 12
Battery / Fuse Inspect Inspect 2- 3
Clean Clean
Air cleaner(filter) 2- 4
Replace every 6 000 km
Muffler bolts and nuts Inspect Inspect 2- 5
Valve clearance(when cold) Inspect Inspect 2- 5
Inspect Inspect
Spark plug 2- 6
Engine oil Replace every 500 km for initial 2 times, thereafter 2- 7
replace every 2 000 - 3 000 km.
Engine oil filter Inspect initial 1 000 km, thereafter replace every 2- 7
2 000 - 3 000 km.
Oil strainer Clean Clean 2- 7
Gearbox oil Replace 2- 8
Drive belt Inspect every 6 000 km, replace every 24 000 km 2- 8
Clutch shoe and roller Inspect 2- 9
Throttle cable play Inspect 2- 9
Carburetor Inspect Inspect 2- 9
Inspect Inspect
Fuel hose and 2nd air hose 2 - 10
Replace every 4 years
Fuel strainer Inspect Inspect Replace 2 - 10
2nd air filter Replace every 6 000 km 2 - 10
2nd air valve Inspect every 3 years or every 18 000 km 2 - 11
Brakes Inspect Inspect
Inspect Inspect
Brakes Brake hoses 2 - 12
Replace every 4 years
Brake fluid Inspect every 3 000 km, replace every 2 years.
Tires Inspect Inspect 2 - 15
Steering Inspect Inspect 2 - 15
Front and rear absorber Inspect 2 - 16
Lighting and signal Inspect Inspect 2 - 16
Chassis botls and nuts Inspect Inspect 2 - 16
2-1
LUBRICATION CHART
Interal Km Initial and Every 6 000km Every 12 000 km

Item Month 6 12
Throttle cable Engine oil
Rear brake lever screw/pivot Grease
Rear brake cable Engine oil
Rear brake camshaft Grease
Main stand and spring hook Grease
Side stand and spring hook Grease
Front brake lever screw/pin Grease
Tachometer cable Grease
Speedometer gear and Grease
gear shaft bearing
WARNING
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings,
break slippage will result.
CAUTION
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean
off any rusty spots and wipe off any grease, oil dirt or grime.
2-2
MAINTENANCE PROCEDURES
This section describes the service procedures for each section
of periodic maintenance.
BATTERY/FUSE
Inspect initial 1 000 km and every 3 000 km
BATTERY
The battery is located below the foot pedal cushion. The
battery is a sealed type battery and requires no maintenance.
The battery should be recharged if the voltage falls below 12.5
V. To remove the battery, follow the procedure below:
Confirm the ignition switch is at off position, then remove the foot
step cushion.
Remove the screw 1 and battery cover 2 .
First remove the lead, then remove the lead.
Take off the battery.
Install the battery in the reverse order of removal.
CAUTION
When installing the battery lead wires, fix the lead first
and lead last.
FUSE
Fuse is located at the battery fixation belt. If engine is shut down
suddenly during the driving or circuit is open, please check the
fuse.
WARNING
Do not use a fuse of a different specification , or it will incur

negative effect to electric, fire and power loss of engine
which is very dangerous.
Do not use aluminum, iron wire or any other substitute for
the fuse. If the fuse blows frequently, it indicates the electric
system may has problem. Always investigate the cause,
correct it and then replace the fuse.
2-3
AIR CLEANER
Clean at initial 1 000 km, thereafter every 2 000-3 000 km.
If the air cleaner is clogged with dust, intake resistance will be

increased with a resultant decrease in output and an increase
in fuel consumption.
Check and clean the cleaner in the following manner:
Remove the air cleaner screw, take off the air cleaner cover 1 .
Remove the screws, take off the paper filter 2 and sponge 3 .
Clean the filter 2 and sponge 3 .

Clean the air filter shell and air filter cover.
CAUTION
Always use air pressure on the inside of the air filter. If air
pressure is used on the outside , dirt will be forced into the
pores of the air filter thus restricting air flow through the air
filter.
Check the condition of paper filter 2 , if the air filter is

clogged with dust, intake resistance will be increased with a
resultant decrease in power output and an increase in fuel
consumption, replace the filter.
Reassemble the clean or new air cleaner components.
Make sure the air cleaner is fitted correctly and sealed
properly.
CAUTION
If driving under dusty condition, clean the air cleaner

element more frequently. The surest way to accelerate
engine wear is to use the engine without the element or to
use a ruptured element. Make sure the air cleaner is in
good condition at all times.
When performing the maintenance of the air cleaner , check

the front and rear oil deposit pipe of the air cleaner , if oil is
found in the oil deposit pipe, drain the oil in time.
2-4
MUFFLER MOUNTING BOLTS

Tighten initial 1 000 km and every 3 000 km
Tighten the muffler mounting bolt 1 to the specified torque.
Muffler mounting bolt 1 : 18~28 N•m
Tighten the muffler mounting bolt 2 .
Muffler mounting bolt 2 : 40 ~60 N•m
VALVE CLEARANCE
Excessive valve clearance results in valve noise and insuffici-

ent valve clearance results in valve damage and reduced
power. At the distances indicated above, check and adjust the
clearance to the following specification.
Remove the helmet case and front center cover. (Refer to

page 5-1)
Remove the engine breather hose 1 and ignition coil 2 .
Remove the spark plug 3 .
Remove the cylinder cover bolt and cylinder cover 4 .
To turn the cooling fan with a wrench in the normal running

direction until the “TDC” arrow on the cooling fan is aligned
with the valve timing arrow mark on the crankcase in order to
set the piston at (TDC) of the compression stroke.
Valve clearance (when cold)
Standard: IN.: 0.05-0.10 mm
EX.: 0.10-0.15 mm
2-5
CAUTION
Valve clearance is to be checked when the engine is cold.

Both the intake and exhaust valves must be checked and
adjusted when the piston is at Top-Dead-Center(TDC) of the
compression stroke.
Insert the thickness gauge to the valve stem end and the
adjusting screw on the rocker arm.
If clearance is off the specification, bring it into the specified
range by using the special tool.
TOOL 09900- 20803: Thickness gauge
11F14-019: Tappet adjust driver TOOL
Install the spark plug.

Reinstall the cylinder head cover.(Refer to page 3-15)
Install the helmet case and front center cover. (Refer to page
5-2)
SPARK PLUG
Inspect at initial 1 000 km and every 3 000 km,
replace every 10 000 km.
Remove the helmet case and front center cover.(Refer to page
5-1)
Remove the spark plug.
Remove the carbon deposits with a wire of pin and adjust
the spark plug gap to 0.6 - 0.7 mm, measuring with a thickness
gauge.
When removing carbon deposits, be sure to observe the
appearance of the plug, noting the color of the carbon deposits.
The color observed indicates whether the standard plug is
suitable or not. if the standard plug is apt to get wet, a hotter plug
should be used. If the standard plug is apt to overheat (porcelain
is whitish in appearance), replace with a coder one.
Spark plug gap: 0.7-0.8 mm
09900-20803: Thickness gauge
Type NHSP LD NGK
Hot A5RTC CR5HSA
Standard A6RTC CR6HSA
Cold A7RTC CR7HSA
CAUTION
Confirm the thread size and reach when replacing the

plug. If the reach is too short, carbon will be
0.6-0.7 mm
deposited on the screw portion of the plug hole and engine
damage may result.
2-6
ENGINE OIL AND OIL FILTER

Engine oil:
Change initial 5 00 km and 1 000 km, thereafter every 2
000 ~ 3 000 km.
Oil filter:
Replace initial 1 000 km and every 2 000 - 3 000 km
Oil should be charged while the engine is warm. Oil filter replace-
ment at the above intervals, should be done together with engine
oil change.
Support the motorcycle on the level ground with the main stand.
Drain the engine oil by removing the drain plug 1 and filler gap
/oil gauge 2 .
Remove the oil cleaner cover bolt and cleaner cover 3 .
Remove the oil cleaner filter 4 .
Install the new O-ring 5 and new oil filter element.
Apply a small quantity on the new 0-ring 6 of oil filter cover.
CAUTION
Before install the oil filter cover, check to confirm the new O-ring
( 5 and 6 ) and spring 7 is fitted correctly.
Tighten the drain plug 1. Fill with new engine oil, using a funnel.
Engine oil replacement, without changing the oil filter, uses 1000
ml of engine oil in API standard, grade SG with an oil viscosity of
SAW 10W-40.
Drain plug: 15-20 N•m
NECESSARY AMOUNT OF ENGINE OIL:
Oil change: 950 ml
Oil and filter change: 1 000 ml
Install the filler cap (filler gauge) 2 .

Filler gauge
Start up the engine and allow it to run for several minutes at
idling speed, turn off the engine and wait serval minute.
Remove the filler cap(filler gauge) and clean up. Then remove
the filler gauge, inspect the oil level, oil level should be between
the upper line and lower line.
Lower mark
Lower mark
2-7
OIL STRAINER
Clean initial 1 000 km and every 6 000 km
Remove the oil filter cover 1 ’s mounting bolt 2 .

Remove the oil filter cover bracket 3 , filter cover 1 and gasket 4 .
Take off the oil strainer 5 and clean.

Reassemble the oil strainer after cleaning, pay attention to the
strainer upper and lower setup direction.
Install the new gasket 4 , reassemble the oil filter cover 1 ,
bracket 3 and bolt 2 .
GEAR OIL
Remove the kick starter lever.

Remove the clutch cover.(Refer to page 3-20)
Remove the oil level plug 1 and drain plug 2 , drain out the oil.
Tighten the oil drain plug ② to the specified torque, add gear oil
til oil flows from the level hole.
Drain plug: 8~12 N•m
Oil viscosity and classification: SAE 80W-90, API: GL-5
Tighten the oil level plug 1 to the specified torque.
Oil level plug: 9-15 N•m
NECESSARY AMOUNT OF GEAR OIL

Oil change: 90 ml
DRIVE BELT
Inspect every 6 000 km, replace every 24 000 km
Remove the drive belt. (Refer to page 3-22)

Check the drive belt for crack, separation or excessive wear.
Measure the drive belt width.
09900 - 20101: Vernier calipers
Drive belt width: service limit: 18.4 mm
Install the drive belt. (Refer to page 3-28)
2-8
CLUTCH SHOE AND ROLLER

Inspect Every 6,000km
2mm
Remove the clutch shoe. ( Refer to page 3-22 ).
Inspect if there is any crack, uneven wear or burn in the friction
position.
Measure the thickness of friction position with a vernier caliper.
In case of defect or oversize, replaced with a new clutch.
Remove the clutch rollers. ( Refer to page 3-22 ) .
Inspect each roller and its sliding surface for uneven wear or
damage. If any defects are found, replace all the rollers.
Clutch shoe service limit 2.0 mm
THROTTLE CABLE PLAY

Use the adjuster below the throttle cable to adjust the throttle
cable free play.
Loosen the lock nut 1 .
Adjust by turning the adjusting screw 2 so that the play is
0. 5-1. 0 mm.
Tighten the lock nut 1 after adjustment is completed.
WARNING
After adjustment is completed, checked that handlebar
movement does not raise engine idle speed and that the
0.5-1.0 mm
throttle grip returns smoothly and automatically.
CARBURETOR (IDLING ADJUSTMENT)

Stable carburetor performance is the basis requirement for

engine. The carburetor is pre-set at the factory for the best
carbureting. Do not attempt to alter its setting.
Start up the engine and keep at the low speed to preheat the
engine.
After preheating the engine, close the throttle, open the saddle,
remove the plastic cover, set its speed at anywhere between
1 500 and 1 700 r/min by turning adjusting screw.
Refer to page 4-13 to get more information.
Engine idle speed: 1600±100 r/min
09900-26006: Tachometer
CAUTION
Make this adjustment when the engine is hot.
2-9
FUEL HOSE AND 2ND AIR HOSE

Inspect initial 1 000 km and every 3 000 km, replace
every 4 years.
Check the fuel hose and secondary air hose for damage or
leakage. If it is worn or damaged, replace the fuel hose with a
new one.
FUEL STRAINER
Inspect initial 1 000 km and every 3 000km, replace every
6 000 km.
If the fuel strainer is dirty with sediment, fuel will not flow
smoothly and loss in engine power may result,
Open the seat , take off the helmet case. (Refer to page 5-2)
Inspect the fuel filter 1 , if any defects are found, the fuel filter
must be replaced.
2ND AIR FILTER

Inspect every 6 000 km, replace as necessary.
Open the seat, remove the helmet case.(Refer to page 5-2)

Disconnect the 2nd air filter hose.
Remove the 2nd air filter assembly 1 .
Take off the 2nd air filter assembly.

Remove the 2nd air filter element 2 .
2-10
Fill a washing pan of a proper size with nonflammable

A B
cleaning solvent. Immerse the element in the cleaning solvent
and wash it clean.
Non - flammable
Squeeze the cleaning solvent out of the washed element by cleaning solvent
pressing it between the palms of both hands.

Immerse the element in motor oil, and squeeze the oil out of the
element leaving it slightly wet with oil.
D C
CAUTION
Do not twist or wring the element because it will tear or Engine oil
the individual cells of the element will be damaged. Inspect
the element carefully for rips, torn seams, etc. If any damage
is noted , replace the element.
2ND AIR VALVE

Inspect every 3 years or 18 000 km
Remove the tail side and right side covers.(Refer to page 5-3)
Remove the 2nd air valve mounting bolt, take off the 2nd air valve
Remove the one-way valve cover screw, take off the one-way
valve 1 .
Check the one-way valve 2 for dirt that effect the open and close
of one-way valve. Clean the one-way valve and 2nd air valve
assembly as necessary.
2-11
BRAKES
Brakes: Inspect initial 1 000 km and every 3 000 km
Brake hose and brake fluid:
Replace the brake hose every 4 years.
Replace the brake fluid every 2 years.
FRONT BRAKE
Brake fluid level
Support the motorcycle on the main stand, and place the
handlebars straight.
Check the brake fluid lever by observing the lower limit line on
the brake fluid reservoir.
When the lever is below the lower limit line, replenish with brake
fluid that meets the following specification.
HAOJUE BRAKE FLUID

CAUTION
The brake system of this motorcycle is filled with a

glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petroleum-
based fluid for refilling the system, otherwise serious
damage will be caused. Do not use any brake fluid taken
from old or used or unsealed containers. Never re-use
the brake fluid left over from the last servicing and
stored for long periods. Take care do not splash the
brake fluid on the painted and plastic surface, because it
will corrupt this surface.
WARNING
If brake fluid is swallowed, please get immediate medical
attention.
If brake fluid splashes in your eyes or on your skin,
thoroughly wash them with water and consult a doctor.
Do not wash the master cylinder with high pressure
water.
BRAKE DISC AND BRAKE PADS

Check the thickness 1 of front brake disc, replace the front
brake disc with new one if the thickness is less than 3.5mm.
The extent of brake pad wear can be checked by observing the
grooved limit line 2 on the pad. When the wear exceeds the
grooved limit line, replace the pads with new ones.
2-12
AIR BLEEDING THE BRAKE FLUID CIRCUIT Upper line
Air trapped in the fluid circuit acts like a cushion to absorb a

large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance of
the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in the
following manner:
Fill up the master cylinder reservoir to the "Upper" line. Replace
the reservoir cap to prevent entry of dirt.
Attach a lucid pipe to the caliper bleeder valve, and insert the
free end of the pipe into a receptacle.
Squeeze and release the brake lever several times in rapid
succession, and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle; this will remove
the tension of the brake lever causing it to touch the
handlebar grip. Then, close the valve, pump and squeeze
the lever, and open the valve.
Repeat this process until the fluid flowing into the receptacle no
longer contains air bubbles.
Bleeder valve: 7~10 N•m
CAUTION
Replenish the brake fluid in the reservoir as necessary while

bleeding the brake system., Make sure that there is always
some fluid visible in the reservoir.
Close the bleeder valve, and disconnect the pipe. Fill the reservoir
with brake fluid to the “Upper” end.
CAUTION
Handle the brake fluid with care: the fluid reacts chemi-
cally with paint, plastics, rubber materials ,etc.
FRONT BRAKE SWITCH

Operate the front brake lever to check the brake light switch,
inspect, adjust and replace the switch if abnormity is found.
2-13
REAR BRAKE
R ear brake free travel
Rear break lever free play 1 is the distance from the lever free
position to the brake starts to take affect by grasping the lever.
Adjust by turning the adjusting nut 2 , clockwise to turn big ,
anticlockwise to turn small, set the play to be 20-30 mm.
Rear brake lever free travel 1 : 20~30 mm
Brake lining wear limit

The motorcycle is equipped with brake lining wear limit
indicators on rear brakes. To check wear of the break lining,
follow the steps below.
First check if the brake system is properly adjusted.

While operating the brake, check to see that the extension line 3
from the index mark 4 is within the range 5 on the brake panel
as shown in the illustration at right, or else the brake shoe
assembly should be replaced to ensure safe operation.
REAR BRAKE SWITCH
Operate the front brake lever (pedal) to check the brake light
switch, inspect, adjust and replace the switch if abnormity is
found.
2-14
TIRES
There are several wear marks ① located on the tire circle. Check
around the wear marks ① (boss in the tire tread channels) to
make sure the tire tread depth is enough. A tire with its wear
marks abraded must be replaced. Inspect the tries for wear and
damage ③ ; drive a motorcycle with excessively worn tires
decreases stability and invites a host of dangerous situations. It is
highly recommended to replace a tire.
TIRE PRESSURE
SOLO RIDING DUAL RIDING

COLD INFLATION
TIRE PRESSURE kpa kg/cm
2
kpa kg/cm 2
FRONT 175 1.75 175 1.75
REAR 200 2.00 225 2.25
CAUTION
The tire pressure and tire surface is very important to

the normal functioning and safety of motorcycle. please
check the tire pressure and tire surface frequently.
STEERING
Inspect Initial 1 000 Km and every 3 000 Km
Steering stem bearings should be adjusted properly for smooth

turning of the handlebars and safe running. Check to ensure the
steering whether is smoothly movement.
Steering which is too loose will cause vibration and damage to
the steering bearing. Check to see that there is no play in the
front absorber attachment.
If the play is found, perform the steering bearing adjustment as
described in page 5-22 of this manual.
2-15
FRONT AND REAR ABSORBER

Inspect every 6 000 km
FRONT ABSORBER
Grasp the front brake, squeeze the front absorber to check it’s
motion.
Check for oil leakage or damage. Replace damaged parts and
tighten all bolts and nuts.
REAR ABSORBER
Press the rear carrier, move the rear shock absorber up and
down four or five times to check for the noise or smooth
movement.
Inspect the rear absorber spring for damage, deformation or oil
leakage.
LIGHTING AND SIGNAL

Inspect the headlight, left and right turn signal light, tail light/brake light and combination meter signal light,
replace the light with new one if there is something unusual. (Refer to page 6-14)
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

Inspect Initial 1 000 km and every 3 000 km
The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be
re-tightened, as necessary, to the specified torque with a torque wrench.
No. ITEM N•m kg•m
Front axle nut 2 7-43 2.7-4.3
Front brake caliper bolt 18-28 1 . 8-2 . 8
Front brake disc bolt 18-28 1 . 8-2 . 8
Brake fluid hose bolt 20-25 2 . 0-2 . 5
Caliper bleeder valve 7-10 0.7-1.0
Handlebar set bolt 40-60 4 . 0-6 . 0
Steering stem lock nut 25-35 2 . 5-3 . 5
Lower bracket clamping bolt 1 8-28 1.8-2.8
Rear axle nut 102-138 10 . 2-13 . 8
Rear absorber upper bolt 22-35 2 . 2-3 . 5
Rear absorber lower bolt 2 2-35 2.2-3.5
Rear brake cam lever nut 8-12 0.8-1.2
Muffler cylinder head nut 1 8-28 1.8-2.8
Muffler mounting bolt 40-60 4.0-6.0
Engine mounting bolt 7 0-100 7.0-10.0
Engine hanging bolt/nut 84-120 8.4-12.0
2-16
2-17
COMPRESSION PRESSURE
The cylinder compression is an indicator of its inner state. The necessity of repair depends on the result of
the inspection. The record of your authorized dealer should include the compression pressure readings
obtained in every maintenance.
NOTE:
* Before testing the engine for compression pressure, make
sure that the cylinder head nuts and bolts are tightened to
specified torque values and valves clearance are properly
adjusted.
* Have the engine warmed up by idling before testing.
* Ensure that the battery is fully charged.
Remove the related parts and inspect the compression pressure

in the following process:
Warm up the engine.
Remove the spark plug; (Refer to page 2-6)
Fit the pressure gauge to the spark plug hole, paying
attention to the connector tightening;
Turn the throttle to full opening;
Electrically start the motorcycle, take the maximum reading in
the recording as the cylinder compression pressure.
09915-64510: Compression gauge
Compression pressure
Standard Limit
1 000-1 400 kPa 800 kPa

2
10-14 kgf/cm 8 kgf/cm 2
A low compression pressure may indicate any of the following

malfunctions:
* Excessively worn cylinder wall.

* Worn piston or piston rings.
* Piston rings stuck in the grooves.
* Poor seating contact of the valves.
* Defective the cylinder head gasket.
2-18
OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.
OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.
Remove the oil pressure inspecting plug 1 .
Install the oil pressure gauge into the oil inspecting hole.
Warm up the engine as follows:
Summer: 10 min at 2 000 r/min 1
Winter: 20 min at 2 000 r/min
After warming up, increase the engine speed to 3 000 r/min,
(observe the tachometer), and read the oil pressure gauge.
09900-26006:Tachomenter
09915-74510:Oil pressure gauge
Install the oil pressure inspecting plug.
OIL PRESSURE SPECIFICATION

15-35kPa (0.15-0.35kgf/cm ) at 3 000 r/min ， Oil temp at 60
2
.
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE

* Clogged oil filter
* Oil leakage from the oil passage
* Damaged O-ring
* Defective oil pump
* Combination of the above items
HIGH OIL PRESSURE

* Engine oil viscosity is too high .
* Clogged oil passage
* Combination of the above items
2-19
ENGINE
CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLACE 3-1
ENGINE REMOVAL AND REMOUNTING 3-2
CYLINDER HEAD AND VALVE 3-6 3
CYLINDER, PISTON AND PISTON RING 3-18
AUTOMATIC CLUTCH ASSEMBLY 3-22
KICK STARTER 3-32
GEARBOX 3-34
GENERATOR AND STARTER CLUTCH 3-38
OIL PUMP 3-42
CRANKSHAFT AND CRANKCASE 3-44
SECONDARY AIR SYSTEM 3-46
ENGINE
REMOVING ENGINE PARTS WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer
to the page listed in each section for removal and reinstallation instructions.
ENGINE PARTS
Intake pipe 3-6

Cooling fan cover 3-6
Cylinder head cover 3-6
Cam chain tensioner 3-6
Camshaft sprocket 3-7
Cylinder head 3-7
Camshaft 3-8
Cylinder 3-18
Piston 3-18
ENGINE LEFT SIDE

Kick starter lever 3-22
Clutch outer cover 3-22
Clutch cover 3-22
Fixed drive face 3-23
Clutch shoe 3-23
Movable dirven face 3-24
Drive belt 3-24
Movable drive face 3-24
Kick starter 3-32
Gearbox cover 3-34
Transmission gear 3-34
Driven gear 3-34
ENGINE RIGHT SIDE

Cooling fan 3-38
Stator 3-38
Rotor 3-39
Staring idle gear 3-39
Starting clutch 3-39
Oil pump 3-41
3-1
ENGINE
ENGINE REMOVAL AND REASSEMBLY

ENGINE REMOVAL
Before taking the engine out of the chassis, wash the engine
with a steam cleaner. The procedure of engine removal is
sequentially explained in the following steps:
Drain the engine oil .

Remove the seat and helmet case.(Refer to page 5-1)
Remove the front center cover and left and right side frame
cover. (Refer to page 5-1)
Remove the rear rail, left and right side cover and tail cover
assembly. (Refer to page 5-1)
Remove the battery cover. (Refer to page 5-1)
Disconnect the battery negative wire .
Remove the spark plug cap 1 and cylinder head cover

breather pipe 3 .
Remove the carburetor. (Refer to page 4-11)

Disconnect the wiring harness and hose from the clamp.
Disconnect the vacuum hose 4 .
Remove the muffler mounting bolts, take off the muffler 5 .
3-2
ENGINE
Remove the generator wire coupler 6 .
Disconnect the 2nd air filter hose.

Remove the 2nd air filter 6 .
Remove the starting motor wire 7 .

Remove the engine ground wire 8 .
Loosen the intake pipe upper clamp screw, remove the

upper part of intake pipe.
Remove the rear fender 9 .
Loosen the clutch intake pipe clamp screw, remove the
clutch intake pipe 10 .
Remove the air filter 11.
3-3
ENGINE
Remove the rear brake cable 11 .
Remove the rear absorber mounting bolt .
Remove the ground wire 13 .
Remove the engine mounting nut, pull out the engine mounting
bolt 14 .
Take off the rear axle nut 15 , take off the rear wheel.
3-4
ENGINE
REASSEMBLY
Reassemble the engine in the reverse order of removal,
tighten the bolts to the specified torque.
Specified torque: A
Rear wheel nut A 102-138 N•m
Engine mounting bolt B 70-100 N•m
Rear absorber lower mounting bolt C 22-35 N•m
Muffler bolt D 11-15 N•m
Muffler bolt E 40-60 N•m
CAUTION
When installing the battery lead wires, fix the lead B
first and lead last.
After remounting the engine, route wiring harness, cables

and hoses properly by referring to the sections, for wire
routing, cable routing and hose routing.(Refer to page 7-19)
Adjust the following items to the specification.
* Throttle cable play (Refer to page 2-9)
* Idling adjustment (Refer to page 2-9)
* Rear brake cable play (Refer to page 2-13)
Pour the engine oil after reassembly and adjustment.

(Refer to page 2-7)
Inspect the engine oil level. (Refer to page 2-7)
3-5
ENGINE
CYLINDER AND VALVE

REMOVAL
INTAKE PIPE
Remove the clip, take off the rubber cover .
Remove the intake pipe nuts, take off the intake pipe .
FAN COVER
Remove the fan cover screw.
Remove the fan right cover 3 and left cover 4 .
CYLINDER HEAD COVER

Remove the cylinder head bolt , take off the cylinder head
cover 5 and gasket.
CAMSHAFT CHAIN TENSIONER ADJUSTER

Remove the camshaft chain tensioner adjuster 6 . 6
3-6
ENGINE
CAMSHAFT SPROCKET
Remove the generator inspection hole cover.
Turn the crankshaft with the wrench to bring the “TDC” line
on the rotor to the index mark on the generator stator case to
set the piston at “TDC” of the compression stroke.
”TDC” line
Remove the camshaft sprocket mounting bolt and reduction

plate 7 .
Remove the camshaft sprocket 8 .
CYLINDER HEAD ASSEMBLY

Remove the cylinder side bolts .
Remove the cylinder head nuts .
Remove the cylinder head assembly 9 .
CAUTION
Do not drop camshaft chain into the crankcase.
Remove the cylinder head gasket 10 and dowel pins.

10
3-7
ENGINE
DISASSEMBLY
Remove the camshaft block plate 1 .
Remove the cam sprocket tensioner rod 3 .
Pull out the rocker arm shaft 4 , take off the rocker arm 5 .
Remove the camshaft 6 .
Remove the valve cotters with the special tool.
TOOL 11F14-018: Valve remover
Take out the valve spring retainer, inner spring and outer
spring, valve spring , oil seal and valve .
Mark all the removed parts or place them orderly to

make sure install correctly.
3-8
ENGINE
INSPECTION
ROCKER ARM
Measure the rocker arm shaft O.D.
Rocker arm shaft standard O.D.
IN. and EX. : 9.981-9.990 mm
09900-20205: Micrometer (0-25 mm)
ROCKER ARM
Measure the rocker arm I.D., and inspect the wear of the
camshaft contacting surface.
Rocker arm standard I.D.:

IN. and EX.: 10.003-10.015 mm
09900-20605: Caliper gauge
CAMSHAFT
Worn-down cams are the cause of mistimed valve operation
resulting in reduced output power. The limit of cam wear is
specified for both intake and exhaust cams in terms of cam H
height H , which is to be measured with a micrometer.
Replace camshafts if found it worn down to the limit.
CAM HEIGHT
Camshaft height H limit:
Intake: 27.62 mm Exhaust: 27.47 mm
09900-20202 : Micrometer (25~50 mm)
CYLINDER HEAD
Decarbon the combustion chamber, and clean the gaskete
surface of cylinder head.
Chcck the spark plug hole and valve of combustion chamber
part for crack .
Check the gasketed surface of the cylinder head for
distortion with a straightedge and thickness gauge.
TOOL 09900-20803:Thickness gauge

Cylinder head distortion limit: 0.05 mm
3-9
ENGINE
VALVE SPRING
Measure valve spring free length.
Valve spring free length limit:
IN and EX: 32.9 mm
09900-20101 : Vernier calipers
Insert the valve into the valve guide, check the valve for
smooth movement of up and down.
Check the valve stem for bending or abnormal wear,
measure the valve stem O.D.
Valve stem O.D.
IN. : 4.975-4.99 mm EX. : 4.955-4.97 mm
TOOL 09900-20205: Micrometer (0-25mm)
Measure the thickness 1 , and if the thickness is found to

have been reduced to the limit, replace the valve.
Valve face thickness limit: 0.5 mm
Visually inspect each valve for wear of its seating face.

Replace any valve with an abnormally worn face.
Support the valve with “V” blocks, as shown, and check its
runout with a dial gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem runout limit: 0.05 mm
09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
09900-21304: V-block ( 100 mm)
Place the dial gauge at right angles to the valve head,

and measure the valve head radial runout. If it measures
more the limit, replace the valve .
Valve head radial runout limit: 0.03 mm

09900-20606:Dial gauge (1/100 mm)
09900-20701:Magnetic stand
09900-21304:V-block (100 mm)
3-10
ENGINE
VALVE SEAT INSPECTION AND SERVICING

Throughly clean the the carbon deposits on the valves and
valve seat.
Coat the valve seat with Prussian Blue uniformly.
Hold the valve with valve lapper, fit the valve and tap the
coated seat with the valve face in a rotating manner in order
to obtain a clear impression contact.
09916-10911: Valve lapper set

The ring-like dye impression left on the valve face must be
continuous without any break.
The contact impression can be used to check the contact
surface institute and the contact position.
In addition, the width of the dye ring, which is the visualized 15 o 30
o
seat "width", must be within the specification.

The valve seats for intake and exhaust valves are machined to
o
different angles. The seat contact surface is cut at 45º . 45 o

60
If any requirement is not met, correct the valve seat by

servicing it as follow steps.
Intake side Exhaust side

INTAKE
45 o N-122 45
o
N-122 60
O
o
30 N-126 15 o N-121 45
O
o
60 N-111
valve seat
09916-21110: Valve reamer set
CAUTION
The valve seat contact area must be inspected after EXHAUST

each cut.
Do not use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish but not a highly polished or shiny
finish. This will provide a soft surface for the final
seating of the valve which will occur during the first valve seat
few seconds of engine operation.
Check the contact surface institute.

If found any defective, service the valve seat.
Uneven contact surface Damaged contact surface
3-11
ENGINE
Using the 45 o reamer, descale and cleanup the seat with

one or two turns.
o
45
Check the contact position. If the contact surface of the

valve is too high, finish it with 30 ° reamer to reduce the
height.
30o
Contact surface is too high
If the contact surface of valve is too low, finish it with 60 °

reamer to increase the height.
Finish the valve seat surface again to standard range with
o
45 reamer.
NOTE:
The valve seat position will affect the contact surface 60
o
of valve, this is very important to the good sealing. Contact surface is too low
Check the contact width.
Valve seat width: 0.9-1.1 mm
09900-20103: Vernier calipers
Width
If the contact width is too small, cut the valve seat with a 45 o
reamer to raise.
45 o
3-12
ENGINE
If the contact width is too big, cut the valve seat out side 1/8
O
ld
o
with a 30 reamer to lower.
va
lv
e
se
at
w
id
th
o
30
Cut the bottom 1/8 with a 60 o reamer to lower.
O
ld
Check the contact width.
va
lv
If the width is out off the specication, repeat the operation
e
se
above steps.
at
w
id
th
60 o
After the desired seat position and width is achieved, apply a

layer of lapping compound and use the reamer very lightly to
service the valve seat. After servicing, clean up the remain-
ing lapping compound on the cylinder head and valve.
Check the valve seat contact surface again.
If the lapping pressure is too big, valve seat will be

possibly distorted or damaged. Change the lapping
tool angel frequently to prevent the valve seat surface
from being uneven. If the lapping compound get into
the middle of the valve and valve guide will possibly
lead to damage.
Clean and assemble the head and valve components.

Fill the intake and exhaust ports with gasoline to check for
leaks and worn seals.
If any leaks occur, check the valve seat and face for burrs or
other defects that could prevent the valve from fully seating.
Gasoline is very explosive, be sure to keep the work

area well ventilated. Keep away from fire and spark.
3-13
ENGINE
CYLINDER HEAD ASSEMBLY

Reassemble the cylinder head in the reverse order of removal,
pay attention to the following points:
Clean the cylinder head with the detergent , clean all the oil
COTTER
passages with compressed air. VALVE SEAT
Clean each valve with Moly paste.
VALVE SPRING
Insert the valves into valve guide and Install the gasket,
spring, valve spring retainer. OIL SEAL
WASHER
99000-25140 : Moly paste
When inserting each valve, take care not to damage VALVE

the lip of the stem seal.
Install the valve spring, make sure that the close-pitch end
of each spring goes in first to rest on the head.
Install the valve seat spring.
Cylinder head
Install the valve cotters with the special tool.
11F14-018: Valve remover and installer tool
3-14
ENGINE
Apply grease on the camshaft sprocket pin hole, drip the

engine oil in the camshaft bearing.
Apply engine oil on the rocker arm and rocker arm shaft
sliping surface.
Install the valve rocker arm and rocker arm shaft on the
cylinder head.
A 99000-25010: Super grease " A"
CAUTION
Install the longer rocker arm shaft in the side of intake
valve.
Install the camshaft block plate and screw.

Install the cam sprocket tensioner rod and bolt.
Turn the tensioner adjuster clockwise with thin blade screw

driver so that the tensioner rod is all the way into the end.
Install the dowel pins and gasket.
Use clean engine oil to lubricate the camshaft and cam

shaft hole.
Use gasoline to clean washer, cylinder head nut and stud
bolt, tighten the cylinder head nut to the specified torque in
2-3 steps.
Cylinder head nut: 23-27 N•m
3-15
ENGINE
Install the cylinder side nuts, and tighten the nut to the
specified torque.
Cylinder side nut: 8-12 N•m
Make sure the "TDC" line on the rotor is aligned with the
index mark on the crankcase.
CAUTION ”TDC” arrow
Turn the crankshaft clockwise only.
Install the time chain on the cam sprocket, paralleled the

marks on the cam sprocket to the surface of the cylinder
head.
Apply thread lock "1342" on the camshaft sprocket bolt, and
tighten the bolt to the specified torque.
99000-32050: Thread lock “1342"
Cam sprocket bolt: 10-12 N•m
Install the cam drive chain tensioner and tighten the bolt
to the specified torque.
Cam drive chain tensioner bolt: 8-12 N•m
Install a new seal ring on the cylinder head cover groove.

Apply the bond on the half-round block, install the cylinder
head cover on the cylinder head.
99000-31140: Bond ”1207B”
3-16
ENGINE
Tighten the cylinder head cover bolts to the specified torque.
Cylinder head cover bolts: 12-16 N•m
Install the protection cover, and tighten the screw.
Reinstall the intake pipe.
CAUTION
Only use new O-ring.
3-17
ENGINE
CYLINDER, PISTON & PISTON RING

REMOVAL
Remove the cylinder head . (Refer to page 3-6)
Remove the cam chain guide rod 1 .
Remove the cylinder .
Remove the dowel pins and gasket .

Clean the gasket material on the mating surface of the
cylinder and crankshaft.
Place a clean rag over the cylinder base to prevent the

dust or impurity from dropping into crankcase during
the cleaning of cylinder mating surface.
Place a clean rag over the cylinder base to prevent piston

pin circlip from dropping into crankcase.
Remove the piston pin circlip.
Remove the piston pin and piston with the special tool.
TOOL 09910-34510: Piston pin remover
INSPECTION
CYLINDER
Check the cylinder bore inner wall for scratches or wear.
Measure the cylinder bore diameter at six places.
Cylinder bore diameter limit: 53.635 mm
09900-20 5 08: Cylinder gauge set
Remove the remaining gasket on the cylinder surface.

Inspect the cylinder for distortion.
Cylinder distortion limit: 0.05 mm
3-18
ENGINE
PISTON
Removing the piston rings one by one by expanding the gap
symmetrically.
Do not expand the piston ring excessively since it is

apt to be broken down.
When installing the piston ring, be careful not to
damage the piston.
Decarbonize the piston.
Using a soft-metal scrapper or discarded piston ring to

decarbon the ring grooves of the piston. Do not use the
steel brush or the piston will be scratched .
Measure the piston outside diameter at the place 3 mm from

the skirt end as show in Fig.
Piston outside diameter limit:

53.345 mm at 3 mm from the skirt end
09900-20203: Micrometer(50~75 mm)
3mm
Calculate piston-cylinder clearance.
Piston-cylidner clearance limit: 0.12 mm
PISTON RING-GROOVE CLEARANCE

Temporarily fit the piston ring on the suitable position with
the marked side to the top.
Measure the piston ring-groove clearance.
Piston ring-groove clearance limit:

1st: 0.18 mm 2nd: 0.15 mm
Piston ring groove standard width :
1st: 1.01-1.03 mm 2nd: 1.03-1.03 mm
PISTON RING THICKNESS

Piston ring standard width:
1st: 0.97-0.99 mm 2nd: 0.97-0.99 mm
TOOL 09900-20205: Mircometer (0-25mm)
3-19
ENGINE
Fit the ring in the cylinder, and measure each ring end
gap using a thickness gauge at the 10 mm from the
cylinder bottom.
Piston ring end gap limit:

1st: 0.5 mm 2nd: 0.5 mm
Using a caliper gauge , measure the piston pin bore I.D..
Piston pin bore I.D. limit: 14.03 mm
Using a micrometer measure the piston pin O. D..
Piston pin O.D. limit: 13.98 mm
09900-20205: Micrometer (0-25 mm)
Measure the conrod small end I . D .
Conrod small end I.D. limit: 14.04 mm
3-20
ENGINE
REASSEMBLY
Reassemble the piston and cylinder in the reverse order of
removal, pay attention to the following points:
Clean the piston top, skirt and groove. 120

o
1st ring
o
120 120
o
2nd ring
Spacer
Fit the piston rings in the groove correctly, turn the

Side rail
piston ring in the groove to make sure it is fitted with 20mm
or more
piston circumference freely. 20mm
or more
Be sure to bring the marked side to the top when fitting the
piston rings to the piston .
1st ring
2nd ring
Take care not damage the piston ring and piston when
installing the piston ring.
Before inserting piston into cylinder, confirm that the
gaps are located as required.
The gaps of two piston rings should be staggered at 120°.
Install the piston rings in the order of oil ring, 2nd ring
and 1st ring. Do not align the gap of oil ring with
expander ring.
Piston ring should turn smoothly in the piston groove after
assembly.
Apply Moly Paste on the piston pin outer surface.
99000-25140: Moly paste
Place a clean rag over the cylinder base to prevent piston
pin circlip from dropping into crankcase, and then fit the
piston pin circlip with long-nose pliers.
Only use new circlip.

Do not align the opening of the piston circlip with the
piston pin hole.
When fitting the piston , turn mark ” ” on the piston head to

the exhaust side.
Install the new gasket and dowel pins.
Apply thread lock “1307B” on the crankcase mating

surface before installing the gasket.
99000-31140: Bond ”1207B”
3-21
ENGINE
AUTOMATIC CLUTCH ASSEMBLY

REMOVAL
Remove the intake pipe 1 .
Remove the kick starter clamp bolt and kick starter lever .
Remove the bolt , take off the clutch outer cover .
Remove the bolt, take off the clutch cover .
Remove the gasket and dowel pins.
3-22
ENGINE
Hold the fixed drive face with the special tool, remove the
fixed drive face nut.
TOOL 09930-40113: Rotor holder
Remove the kick starter nut washer 6 , kick starter driven

gear 7 .
Remove the fixed drive face 8 .
Hold the clutch house with the special tool, take off the
clutch house nut.
Remove the gasket and clutch house 9 .
3-23
ENGINE
Remove the movable driven plate 10 and drive belt 11 .
Remove the movable drive plate 12 .
DISASSEMBLY Cushion
Movable drive plate
Disassemble the movable drive plate.
Spacer
Movable
drive plate
Roller
Loosen the clutch shoe nut with the special tool.
Do not remove the clutch shoe nut at this time.

TOOL
Remove the clutch shoe nut while holding down the clutch
shoe assembly by hand.

WARNING
WARNING
Gradually back off the clutch shoe assembly pressed

down by hand to reduce the clutch spring load.
Releasing the hand suddenly may cause the parts to fly
apart.
3-24
ENGINE
Remove the clutch shoe nut , clutch shoe assembly and

spring .
CAUTION
Do not attempt to disassemble the clutch shoe assembly.
Remove the movable driven face seat with a thin brade

screwdriver.
Remove the three pins and movable driven face from

the fixed driven face 7 .
Remove the oil seals 8 and O-rings 9 .
Remove the spacer 10 .
TOOL 09900-06108: Snap ring pliers
3-25
ENGINE
Remove the bearing 11 along with the spacer with a

proper tool .
If abnormal noise does not occur, it is not necessary to

remove the bearing.
Remove the needle bearing 13 with the special tool .
TOOL 09923-73210: Bearing remover

09930-30102: Sliding shaft
TOOL
If abnormal noise does not occur, it is not necessary to

remove the bearing.
The removed bearings, 11 and 13 , should be replaced with
new ones.
INSPECTION
ROLLER
Inspect each roller for wear or damage.
SPACER
Inspect the spacer for wear or damage.
3-26
ENGINE
CLUTCH SHOE INSPECTION

Inspect the linings A for crack, uneven wear or bushing.
Measure the lining thickness with a vernier calipers.
A
If any defects are found or measurement exceeds the limit,
replace the clutch shoe assembly with a new one.
Clutch shoe thickness service limit: 2.0 mm
TOOL
09900-20101: Vernier calipers
CLUTCH HOUSING INSPECTOR

Inspect the inner surface of clutch housing for scratches or
discoloration caused by burning.
Measure the clutch housing inside diameter with an inside
calipers.
If any defects are found or measurement exceeds the limit,
replace the clutch housing with a new one.
Clutch housing I.D. Service limit: 110.5 mm
TOOL 09900-20101: Vernier calipers
DRIVE BELT INSPECTION
Inspect the drive belt for crack, separation, abnormal wear
or contamination with oil.
Measure the belt width with a vernier calipers.
If any defects are found or width is less than the service
limit, replace the drive belt with a new one.
Drive belt I.D. service limit: 18.4 mm
If drive belt is contaminated with grease or oil, clean it

with neutral detergent. TOOL
2
REASSEMBLY
Reassemble the automatic clutch in the reverse order of removal
and disassembly, pay attention to the following points:
Install the needle bearing 3 into the fixed driven face 1 with 1
the special tool.
TOOL 09943-88211: Bearing installer
Apply Super grease “A” to the needle bearing.
Install the spacer 4 .
3
Be sure to face the small bore side of the spacer 4 to

the inside.
3-27
ENGINE
Install the bearing 5 with the special tool .

TOOL
4
TOOL 09941-34513: Bearing installer 4
Install the circlip 6 with a snap ring pliers .
TOOL 09900-06108: Snap ring pilers 5
Be sure to face the sharp edge of the circlip to the outside.
Install the new oil seals ( 6 and 7 ) to both sides of the

movable driven face 8 with the special tool . TOOL
8
TOOL 09913-76010: Bearing installer
6
Apply Super grease ”A” to the lip of both oil seals ( 6 and 7 ) 6
and groove A . 7
A
A 99000-25010: Super grease “A”
Install the movable driven face to the fixed driven face.
When installing the movable driven face, insert it while

using a 0.1 mm thickness gauge as a guide to prevent the
damage of the oil seal lip.
3-28
ENGINE
Install the three pins 9 and the new O-rings 10 .

Apply Super grease ”A” to the pin groove B and O-rings 10 .
A 99000-25010: Super grease ”A”
Install the movable driven face seat 11 .
Install the spring and clutch shoe assembly .

Install the clutch shoe nut 13 while pressing down the clutch
shoe assembly,
Tighten the clutch shoe nut to the specified torque with the
special tool.
Clutch shoe nut: 50-70 N•m
Install the rollers and dampers.
CAUTION
The covered side of roller must face right as shown in the
right illustration.
3-29
ENGINE
Install the fixed drive face assembly.
CAUTION
Wipe the movable drive face with cloth contains alcohol.
Install the movable driven face and drive belt.

Install the clutch house, gasket and nut.
Hold the clutch house with the special tool, tighten the clutch
house nut to the specified torque.
Clutch house nut:65-85 N•m
Install the fixed drive face.

Hold the fixed drive face with the special tool, tighten the fix
drive face nut to the specified torque.
Fixed drive face nut: 40-60 N•m
Install the gasket and dowel pins.
CAUTION
Always use new gasket.
3-30
ENGINE
Install the clutch cover, tighten the clutch cover mounting

bolt to the specified torque.
Clutch cover mounting bolt: 8-12 N•m
CAUTION
Make sure the clamp is fitted at the right location.
Install the clutch outer cover .
Install kick starter lever, tighten the kick starter lever clamp
bolt to the specified torque.
Kick starter lever clamp bolt: 23-28 N•m
CAUTION
During the assembly, align the gap on the kick starter
with the mark line on the kick starter shaft.
3-31
ENGINE
KICK STARTER
REMOVAL
Remove the clutch cover. (Refer to page 3-2)
Remove the circlip with the special tool.
Remove the clutch cover intake guide plate .
TOOL 09900-06107: Snap ring pliers(opening type)
Remove the kick starter driven gear and kick starter shaft
assembly , spring .
Remove the kick starter shaft spacer and kick starter shaft
spring spacer .
INSPECTION
Replace the kick starter idle gear if wear or damage is found.
Inspect the following parts:

- Starter shaft wear, damage or bent.
- Gear teeth wear or damage
- Spring defect or damage
3-32
ENGINE
REASSEMBLY
Reassemble the kick starter in the reverse order of removal.
Pay attention to the following points:
Install the kick starter shaft spacer and kick starter shaft
spring spacer.
Apply Super Grease ”A” on the kick starter idle gear shaft.
99000-25010: Super Grease ”A”
Install the kick starter driven gear assembly and kick starter
shaft assembly , spring .

WARNING
Be careful do not let the spring loose and harm the hand
during the assembly of spring.
Install the clutch cover intake guide plate .
Install the circlip with the special tool .

Install the clutch cover . (Refer to page 3-29)
TOOL 09900-06107: Snap ring pliers(opening type)
3-33
ENGINE
GEARBOX
REMOVAL
Remove the automatic clutch assembly. (Refer to page 3-22)
Remove the bolt, take off the gearbox cover .
Remove the dowel pins and gasket .
Remove the rear axle and final driven gear .

Remove the idle gear shaft assembly .
Remove the circlip from the shaft, separate the rear axle
and final driven gear .
TOOL 09930-06107: Snap ring pliers (Opening type)
Remove the drive shaft from the gearbox cover 7 .
CAUTION
Do not damage the gearbox, bearing and drive shaft.
3-34
ENGINE
Remove the driveshaft oil seal 8 .

8
INSPECTION
Inspect the gearbox cover bearing for wear or damage.
Rotate the inner race by hand to inspect for an abnormal
noise and a smooth rotation. Replace the bearing if there is
some-thing unusual.
Inspect the gearbox bearing for wear or damage.

Rotate the inner race by hand to inspect for anormal noise
and a smooth rotation. Replace the bearing if there is some-
thing unusual.
Inspect the drive shaft or final driven gear for abnormal

wear, damage or burnt, replace the if there is something
unusual.
Inspect the idle gear shaft for wear, damage or corrode,

replace the idle gear shaft if there is something unusual.
3-35
ENGINE
Inspect the rear axle for wear, damage or corrode, replace

the rear axle if there is something unusual.
BEARING REPLACEMENT
Remove the idle gear shaft bearing , rear wheel shaft
bearing and drive shaft bearing with the special tool .
TOOL
09921-20210:Bearing remover
09930-30102:Slide shaft
Remove the drive shaft bearing , idel gear shaft bearing ,

oil seal and rear axle shaft bearing 7 from the gearbox with
the special tool.
TOOL 09921-20210: Bearing remover
09923-73210: Bearing remover
09930-30102: Slide shaft
CAUTION
Do not damage the gearbox and gearbox cover con-
tacting face .
Apply the engine oil on the new bearing turning part.

Install the new bearing with the special tool.
TOOL 09913-70210: Bearing installer tool
Apply super grease “A” to the new oil seal lip.

Install the new oil seal with the special tool.
99000-25010: Super grease ”A”
TOOL 09913-70210: Bearing installer set
3-36
ENGINE
REASSEMBLY
Install the driveshaft on the gearbox cover.
Apply the engine oil on the new oil seal surrounding and lip ,
fit the oil seal in the gearbox cover with the special tool.
TOOL 09925- 98221: Oil seal installer
Install the driven gear in the rear axle shaft, then install the
circlip.
TOOL 09900-06107: Snap ring pliers( Opening type)
Apply the engine oil on the gear teeth and bearing.

Fit the idle gear shaft assembly, rear axle and driven gear in
the gearbox.
Install the dowel pin and new gasket.
Install the gearbox cover and tighten the bolt to the specified
torque.
Gearbox cover bolt: 8-12 N•m
Install the automatic clutch assembly. (Refer to page 3-30)

Fill the gear oil in the gearbox. (Refer to page 2-8)
Install the rear wheel and rear brake.(Refer to page 5-31)
3-37
ENGINE
GENERATOR & STARTING CLUTCH

REMOVAL
Remove the bolt and cooling fan .
Remove the cool fan fix nut with the special tool.
TOOL 09930-40113: Sprocket holder
Remove the washer and cool fan fix plate .
Remove the crankcase right cover .
Remove the generator stator mounting bolt, trigger coil

mounting bolt and rubber plug , take off the generator
stator and trigger coil .
3-38
ENGINE
Remove the rotor nut with the special tool.

TOOL 11F14-001: Rotor holder
Remove the rotor with the special tool 7 .
TOOL 09930-30102: Slide shaft

09930-30980：Rotor remover
Remove the starting idle gear shaft 8 and idle gear 9 .

Remove the starting clutch gear 10 .
INSPECTION
Install the starting clutch gear to the starting clutch, check
to see if the staring clutch gear only turn anti-clockwise, or
replace the starting clutch assembly .
Inspect the starting idle gear for wear or damage, if any

defects are found, replace the starting idle gear for a new
one.
3-39
ENGINE
REASSEMBLY
Reassemble the generator in the reverse order of removal.
Before installing the generator stator , apply bond in the

rubber plug groove and apply thread lock on the stator
mounting bolts and tighten them to the specified torque.
99000-31140: Bond “1207B”

1342 99000-32050: Thread lock “1342"
Apply a small quantity of Moly Paste on the contacting sur-
face of starting clutch gear and crankshaft as well as the
inside of starting idle gear shaft hole.
Install the key .
Install the starting clutch gear and staring idle gear , idle
gear shaft .
Install the gasket and dowel pins.

Tighten the generator rotor nut to the specified torque while
holding the generator rotor with the special tool.
Generator rotor nut: 110-130 N•m
TOOL 11F14- 001: Rotor holder
3-40
ENGINE
Install the crankcase right cover , tighten the bolts to the

specified torque.
Crankcase bolt: 8-12 N•m
Install the cooling fan retainer 7 , apply the thread lock in the
nut, tighten the nut to the specified torque.
1342 99000-32050: Thread lock “1342"
Cooling fan nut: 25-30 N•m
TOOL 09930- 40113: Sprocket holder

7
Install the cooling fan 8 , apply the thread lock on the bolt and
tighten.
1342 99000-32050: Thread lock “1342"
3-41
ENGINE
OIL PUMP
REMOVAL
Remove the oil pump sprocket cover .
Remove the oil pump mounting bolts, take off the oil pump
2 and timing chain .
REASSEMBLY
Reassemble the oil pump in the reverse order of disassemble,
pay attention to the following points:
Apply clean engine oil on the driving chain and gear.
Install the sprocket, apply thread lock “1342" on the thread
part of nut and tighten nut to the specified torque.
1342 99000-32050: Thread lock "1342”

Sprocket nut: 7-10 N•m
Install the oil pump sprocket cover .

Install the generator and starting clutch.(Refer to page 3-40)
3-42
ENGINE
CRANKCASE AND CRANKSHAFT

REMOVAL
Remove the crankcase bolts.
Place the crankcase horizontally, remove the right crank-

case with the special tool.
TOOL
09920-13120: Crankcase separator
Remove the crankshaft from the left crankcase with the

special tool.
TOOL
09920-13120: Crankcase separator
INSPECTION
Inspect the bushing for wear or damage.
Inspect the oil seal for damage and crack, if defect is found,
replace the oil seal with a new one.
3-43
ENGINE
Inspect the play of crankcase bearing inner race by hand

while fixing it in the case.
Rotate the inner race by hand to inspect for abnormal noise
and a smooth rotation. Replace the bearing if there is some-
thing unusual.
Measure the conrod big end side clearance.
Conrod big end side clearance limit: 1.0 mm
TOOL 09900-20803: Thickness gauge
Wear on the big end of the con-rod can be estimated by

checking the movement of the small end of the rod.
This method can also check the extent of wear on the parts
of the con-rod’s big end.
Service limit: 3 mm
TOOL 09900-20606: Dial gauge

09900-21304: V-block
Support the crankshaft with V-blocks as shown , with the

two journals resting on the blocks.
Position the dial gauge, as shown, and rotate the crankshaft
slowly to read the runout.
Crankshaft runout limit: 0.05 mm

TOOL 09900-20606: Dial gauge
09900-21304: V-blocks
OIL SEAL REPLACEMENT

Remove the oil seal, install the new oil seal with the special
tool.
TOOL
09913-70210: Bearing installer
3-44
ENGINE
CRANKCASE BUSHING
Remove the crankcase bushing, install the new bushing into
the crankcase with the special tool.
TOOL
BEARING REPLACEMENT
Remove the crankshaft bearing with the special tool.
TOOL
Install the new crankshaft bearing with the special tool.
TOOL
REASSEMBLY
Reassemble the crankcase in the reverse order or removal,
pay attention to the follow points:
Install the crankshaft on the left crankcase.
TOOL
09910-32812: Crankshaft installer
Apply the bond evenly on the contacting surface of right

crankcase.
CAUTION
Make sure the bond is correct, evenly and continuous.
Install the right crankcase, and tighten the bolts to the

specified torque.
Crankcase bolts: 8-12 N•m
3-45
ENGINE
SECONDARY AIR SYSTEM

REMOVAL AND INSPECTION
Remove the tail cover and rear right frame cover. (Refer to
page 5-3)
Disconnect the 2nd air valve intake hose and 2nd air valve
hose , remove the 2nd air valve .
Inspect each wire for damage or folding, replace the wire if
damage and folding is found.
Remove the four screws, take off the valve cover .
Remove the reed valves to inspect the for damage.

Check for see the mating tightness of valve and valve seat
and the reed for distortion .
If any defect is found, replace the reed valve with a new one.
REASSEMBLY
Reassemble the 2nd air system in the reverse order of the
removal.
3-46
FUEL AND LUBRICATION
CONTENTS
FUEL SYSTEM 4-1
CARBURETOR 4-2
LUBRICATION SYSTEM 4-14
4
FUEL SYSTEM
REMOVAL
Remove the seat and helmet case. ( Refer to page 5- 2)
Remove the tail cover, and rear left and right side cover. (Refer to
page 5-3)
Remove the left and right side cover. (Refer to page 5-3)
Disconnect the fuel hose 1 , drain the fuel.

WARNING
Gasoline is extremely flammable and highly explosive

at normal temperature. Make sure that work area well
ventilated. Do not expose to heat, sparks and flame.
Disconnect the fuel gauge coupler 2 .
Remove the rear fender upper bolts.

Move the rear fender upper body 3 downward, remove the fuel
tank 4 .
Remove the bolt, disconnect the vacuum hose and fuel hose,
take off the fuel cock 5 .
Remove the fuel filter 6 .
4-1
Remove the fuel filter from the fuel tank 7 .
INSPECTION
FUEL FILTER
If the fuel filter is dirty with sediment or rust, fuel will not flow
smoothly and loss in engine power may result. Clean the fuel filter
with compressed air.
FUEL COCK
Connect the vacuum pump gauge to the vacuum port of the fuel
cock as shown in the illustration. Apply negative pressure A to
the fuel cock and blow the fuel inlet port. If air does not flow out,
replace the fuel cock with a new one.
09917-47011: Vacuum pump gauge
Use a hand operated vacuum pump. Do not apply high

negative pressure to prevent the fuel cock damage.
FUEL FILTER
Disassemble fuel filter and inspect paper filter strainer. Replace it
if it is obviously dirty.
REASSEMBLY
Reassemble the fuel system in the reverse order of removal.
4-2
FUEL GAUGE
REMOVAL
Remove the saddle and helmet case.(Refer to page 5-2)
Disconnect the fuel gauge coupler 1 .
Remove the 4 screws, take off the fuel gauge assembly 2

and gasket.

WARNING
Gasoline is extremely flammable and highly explosive

at normal temperature. Make sure that work area well
ventilated. Do not expose to heat, sparks and flame.
INSPECTION
(Refer to page 6-12)
REASSEMBLY
Reassemble the fuel gauge in the reverse order of removal.
Gasket must be replaced with a new one to prevent leakage.
4-3
CARBURETOR
CONSTRUCTION
B F E
C
D
SPECIFICATIONS
ITEM SPECIFICATION ITEM SPECIFICATION
Carburetor type BS22 Idle screw E 2,3/8 turn out
I.D. No. SVR22-2G Main needle jet F Φ 2.1 mm
Idle jet B 34.4 # Throttle cable play 0.5-1.0 mm
Bubbling pipe C Φ 2.1 mm Idle speed
Main jet D 92 #
4-4
DIAPHRAGM AND PISTON OPERATION

The carburetor is a variable-venturi type, whose venturi cross section area is increased or decreased
automatically by the piston valve 1 which moves according to the negative pressure present on the down
-stream side of the venturi A . The negative pressure is admitted into the diaphragm chamber 2 through an
orifice 3 provided in the piston valve 1 .
Rising vacuum overcomes the spring 4 force, causing the piston valve 1 to rise to increase the said area
and thus prevent the air velocity from increasing. Thus, air velocity in the venturi passage is kept relatively
constant for improved fuel atomization and for securing an optimum ratio of fuel/air in the mixture.
LOWER POSITION OF PISTON VALVE UPPER POSITION OF PISTON VALVE
A
A
1 Piston valve
2 Diaphragm chamber
Negative pressure
3 Orifice
4 Spring
A Venturi
4-5
IDLING SYSTEM
This system supplies fuel during engine operation when throttle valve is closed. The fuel from the float
chamber is metered by the idle fuel jet where it mixes with air coming in through the idle air jet .
This fixture, rich with fuel, then travels up through idle passage towards the idle air screw . A part of the
mixture is discharged into the main bore out of by-pass ports . The remainder of mixture is metered by
the idle air screw and sprayed out into the main bore through idle outlet 7 .
Air
Fuel / Air Mixture
Fuel
4-6
MAIN SYSTEM
As throttle valve 1 is opened, engine speed increases, thus increase negative pressure in the Venturi A .
Consequently the piston valve 2 moves upward.
Meanwhile, fuel in float chamber 3 is metered by main jet 4 and the metered fuel enters bubbling pipe ,
in which the fuel is mixed with air admitted through main air jet 6 to form an emulsion. The emulsified fuel
then passes through the clearance between main needle jet 7 and fuel needle 8 , and is discharged into
the Venturi A, in which main aim stream being drawn by the engine. Mixture proportioning is accomplished
in bubbling pipe , the clearance through which the emulsified fuel must flow in large or small, depending
ultimately on throttle position.
A 8
7
Throttle valve
Piston valve
Float chamber AIR (NEGATIVE PRESSURE)
Main jet
Bubbling pipe FUEL/AIR MIXTURE
Main air jet
7 Main needle jet FUEL
8 Fuel needle
A Venturi
4-7
AUTOMATIC ENRICHENER
(AUTOMATIC CHOKE) SYSTEM
The automatic enrichener (automatic choke)
device consists of the PTC heater, the thermo-wax
and plunger/needle. When the thermo-wax is cold,
the plunger/needle moves upward, fuel is drawn
into the enrichener circuit from the float chamber
. . . The enrichener jet meters this fuel, which
then flows into the plunger/needle and mixes
with the air coming from the air filter.
The proper fuel/air mixture for starting, rich in fuel
content, is produced when it is sprayed out
through outlet port into the main bore.
Air
Fuel / Air Mixture
Fuel
When engine is cold:

The automatic enrichener passage is always open
as the thermo-wax remains atomospheric temp- Thermo-wax
erature.
When the engine is started:

According to the PTC heater temperature, the PTC heater
thermo-wax gradually expands and closes enrich-
ener passage by the needle of the plunger. Thermo-wax
4-8
FLOAT SYSTEM
The float and float needle valve are integrated. When the float moves up and down, the float needle
valve also moves up and down.
When the fuel level within the float chamber increases, the float goes up so that the float needle valve
2 moves toward the valve seating. In this case, the fuel cannot flow into the float chamber ; when the fuel
level decreases, the float moves down and the float needle valve is opened so that the fuel flows into
the float chamber . The alternate opening and closing of the float needle valve can ensure constant
fuel level within the float chamber .
FUEL
4-9
REMOVAL AND DISASSEMBLY

Remove the choke coupler 1 , loosen the clamp.
Disconnect the hose 2 .
Loosen the carburetor mounting screws 3 .

Remove the throttle cable 4 .
Remove the carburetor 5 .
Remove the choke 6 .
Remove the carburetor top cap 7 .
Remove the piston valve return spring 8 and piston valve with
diaphragm 9 .
Do not blow the carburetor body with compressed air,

before removing the diaphragm. It may cause a damage to
the diaphragm.
4-10
Remove the floater chamber cover 10 by removing the screws.
Remove the float assembly 11 by removing the pin .
Remove the needle valve .
Do not use a wire for cleaning the valve seat.
Remove the main jet A .

Remove the bubbling pipe B . A
B
Remove the idle jet C .
INSPECTION
CARBURETOR JET INSPECTION
Check following items for any damage or clogging.
* Idle jet * Bubbling pipe * Gasket and O-ring
* Main jet * Float * Butterfly valve
* Main air jet * Needle valve * Diaphragm
* Idle air jet * Enrichener jet * Idle outlet and by-pass holes
4-11
NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the
needle, the gasoline will continue flowing and cause it to
overflow.
Clean the float chamber and float parts with gasoline, if the
needle is worn as shown in the illustration, replace it together
with a valve seat. Clean the fuel passage of the mixing chamber
with compressed air.
AUTOMATIC CHOKE (PTC HEATER)

INSPECTION
Connect 12V battery to the automatic choke terminal, 3
minutes later, inspect if the automatic choke is warm. If case
the automatic choke does not warm up, replace it with a new
one.(Refer to page 6-11)
REMOUNTING
Reassemble the carburetor by reversing the sequence of
disassembling steps. Pay attention to the follow points:
When installing the float chamber, make sure the O-ring is fitted
correctly.
Replace the O-ring with a new one when installing the

float chamber.
Place the tongue 1 of diaphragm to the notch 2 of carburetor

body properly.
4-12
REASSEMBLY
Remount the carburetor by reversing the sequence of removal
steps, and following adjustments and inspection are necessary
after remounting the carburetor.
THROTTLE CABLE PLAY

The adjuster of throttle cable play is located below the throttle
handlebar. Throttle cable should be adjusted as per the following 0.5~1.0mm
steps:
Loosen the lock nuts 1 .
Slide the adjuster 2 to obtain the correct play 0.5-1.0mm.
After adjusting the play, tighten the lock nut 1 .
Throttle cable play: 0.5~1.0mm
After adjustment is completed, check that handlebar move-

ment does not raise engine idle speed and that the throttle
grip returns smoothly and automatically.
IDLING ADJUSTMENT
If engine running is needed in work, be sure to keep the work

area well ventilated. Do not run engine in an closed space. In
engine exhaust gas, there is carbon monoxide that leads to
loss of consciousness or leads to death.
Engine running is allowable only at a well ventilated place or
in an enclosure with exhaust gas discharge system.
Idle air screw is factory-installed and set. Adjustment is not

necessary unless carburetor needs to be disassembled for in-
spection or screws need to be replaced. For accurate adjust-
ment, a ten-minutes engine preheating is necessary.
Screw the pilot air screw clockwise by gently turning to its home
and turning it back to its Pre-set.
Pre - set : Turn 2, 3/8

Start the engine, preheat it under idle running condition.
Adjust the idle speed by means of the idle screw.
Engine idle speed: 1 600 100 r/min

TOOL 09900-26006: Tachometer
Slowly and repeatedly adjust the idle air screw to obtain
maximum engine speed.
Adjust idle speed to specified value by means of idle screw. In
case of unstable engine running, repeat till the engine running is
easy and stable.
4-13
LUBRICATION SYSTEM
CAMSHAFT JOURNAL
BEARING (LEFT-SIDE)
ROCKER ARM ROCKER ARM

SHAFT AND SHAFT AND
ROCKER ARM ROCKER ARM
(EXHAUST-SIDE) (INTAKE-SIDE)
CAM FACES CYLINDER HEAD
CAMSHAFT JOURNAL
BEARING AND CAM CYLINDER
DRIVE CHAIN WALL PISTON PIN
(RIGHT-SIDE)
OIL PIPE
CRANK PIN BEARING

CRANKSHAFT
LEFT SIDE
BEARING AND
STARTER OIL DEFLECTOR
CLUTCH BOARD
CRANKSHAFT
RIGHT-SIDE
BEARING
OIL FILTER
BY-PASS
OIL PUMP
OIL STRAINER
OIL PAN
CHASSIS
CONTENTS
EXTERIOR PARTS REMOVAL / REMOUNTING 5-1

FRONT WHEEL 5-5
HANDLEBAR 5-10
FRONT ABSORBER 5-13
STEERING 5-19
FRONT BRAKE 5-23
REAR WHEEL / REAR BREAK 5-29 5
TIRE AND WHEEL 5-32
CHASSIS
EXTERIOR PARTS REMOVAL/

REMOUNTING
(Refer to the attachment page 1)
REMOVAL
Front handlebar’s cover
Remove the rearview mirror .
Remove the front handlebar’s cover ① .
Disconnect the front left and right turn signal light coupler ②.
METER
Remove the meter cover by unscrew the nut.
Remove the turn signal relay ①and speedometer cable ②.

Remove the meter cover assembly 3 .
Loosen the bond strip ④.
Disconnect the following wiring harness couplers:

* Rear brake switch coupler5
* Meter wiring harness coupler ⑥
* Switch coupler ⑦
5-1
CHASSIS
FRONT LEG SHIELD

Remove the front leg shield mounting screws.
Remove the front leg shield assembly 1.

Remove the headlight coupler 2 .
SEAT AND HELMET CASE

Unlock the saddle lock, open the saddle.
Remove the fuel tank cover and helmet case mounting bolt
and screw.
Remove the helmet case and saddle as a whole.
MAINTENANCE LID
Remove the maintenance lid .
5-2
CHASSIS
REAR CARRIER
Remove the tail case mounting plate.
Remove the rear carrier bolts, take off the rear carrier.
LEFT AND RIGHT SIDE COVER

Remove the rear left and right side cover,
TAIL COVER
Remove the tail cover screws, take off the tail cover.
LEFT AND RIGHT SIDE COVER AND TAIL

LIGHT ASSEMBLY
Remove the fastener.
Remove the tail light coupler 1 .
Remove the left and right side cover and tail light
assembly 2 .
5-3
CHASSIS
FRONT LEFT AND RIGHT SIDE COVER

Remove the front left and right side cover.
ASSEMBLY
Reassemble the exterior parts in the reverser order of removal.
5-4
CHASSIS
FRONT WHEEL
1 Front axle 7 Tire

ITEM N m Kgf m
2 Spacer 8 Rim
3 Oil seal 9 A 18-28 1.8-2.8
Spacer
4 Roller bearing 10 Speedometer gearbox B 27-43 2.7-4.3
5 Front brake disc A Brake disc bolt
6 Valve B Front axle nut
5-5
CHASSIS
OIL SEAL
Check the oil seal for wear or damage. Replace the oil seal
with a new one if any damage is found.
BEARING
Insect the play of wheel bearings inner race by hand while
fixing it in the wheel hub.
Rotate the inner race by hand to inspect whether abnormal
noise occurs or rotating smoothly.
Replace the bearing if there is something unusual.
REPLACEMENT
Remove the oil seal on both side with the special tool.
09913-50121: Oil seal remover
Remove the bearings on the both side, take off the spacer.
09921-20240: Bearing remover set
Apply super grease “A” to the bearings before installing.
99000-25010: Super grease " A "
5-7
CHASSIS
REMOVAL
Raise the front wheel off the ground and Support the
motorcycle with a jack or a wooden block.
Remove the front axle nut 1 , take off the front wheel 2 .
Do not operate the front brake lever when removing

the front wheel.
Remove the collar 3 .
Remove the brake disc bolts, take off the brake disc 4 .
INSPECTION
AXLE SHAFT
Using the special tools , check the axle shaft for runout
and replace it if the runout exceeds the limit.
09900-20606: dial gauge (1/100)

09900-21304: V - block
Axle shaft runout: Limit: 0.25 mm
WHEEL RIM
Inspect the wheel runout .
Excessive runout is usually due to worn or loosen wheel
bearings and can be reduced by replacing the bearings. If
bearing replacement fails to reduce the runout, replace the
wheel.
Wheel runout: Limit: 2.0 mm
5-6
CHASSIS
²First install the left wheel bearing 4 , then install the spacer
5 and right wheel bearing 6 using the special tool and removed
wheel bearings 3 .
09924-84510: Bearing installer set
The seal side of the bearing should be faced to outside.
● Remove the removed bearing 3 .
Removed wheel bearing Spacer A Left side a Clearance

Left bearing Right bearing B Right side
Lightly apply super grease “A” to the oil seal.

Install the new oil seal using the special tool.
99000-25010: Super grease " A "

09913-70210: Bearing installer set ( 10 - 75Φ)
REASSEMBLY
Reassemble the front wheel in the reverse order of removal. Pay attention
to the following point:
BRAKE DISC
Make sure that the brake disc is clean and free of any
greasy matter.
Apply Thread lock “1360" to the disc mounting bolts and tighten
them to the specified torque.
1360 99000-32130: Thread lock “1360"
Front brake disc bolt: 18-28 N•m
5-8
CHASSIS
SPEEDOMETER GEARBOX
Before installing the speedometer gearbox, apply Super
grease “A” to its dust seal lip.
Align the drive lugs 1 to the recesses 2 of the wheel hub and
attach the speedometer gearbox to the wheel hub.
A
A 99000- 25010: Super grease ”A”
Set the stopper 3 on the speedometer gearbox to the lug 4

on the front absorber as shown in the right illustration.
Rotate the wheel by hand to inspect for smooth rotation

and operation of the speedometer.
Make sure that the drive lugs the speedometer gear fit
to the recesses of the wheel hub or it may cause damage
of the speedometer gear.
Tighten the axle nut 5 to the specified torque.
Axle nut: 27-43 N•m
WARNING
After installing the front wheel , pump the brake
lever until the pistons push the pads correctly .
5-9
CHASSIS
HANDLEBAR
CONSTRUCTION
1 Rear mirror 6 Left handlebar grip

2 Handlebar 7 Throttle handlebar shell
ITEM N m kgf m
3 Throttle cable 8 Throttle grip
A 40-60 4.0-6.0
4 Rear brake cable A Handlebar nut
5 Rear break lever
REMOVAL
Remove the handlebar front cover and meter cover. (Refer to
page 5-1)
Remove the front brake switch coupler 1 .
Remove the master cylinder bolt, take off the master cylinder
2.
Remove the throttle grip shell assembly, disconnect the throttle
cable 4 .
5-10
CHASSIS
Disconnect the rear brake switch assembly 5 .

Remove the rear brake lever 6 and rear brake cable 7 .
Remove the handelbar mounting nut 8 .

Remove the hanlebar pipe 9 .
ASSEMBLY
Reassemble the handlebar in the reverse order of removal.
Install the handlebar.
Install the handlebar clamp bolt/nut 1 , and tighten the nut to
the specified torque.
Handlebar clamp bolt/nut: 40-60 N•m
Install the rear brake switch assembly 2 .

Adhesive
agent
Before installing the rear brake lever 2 , apply a small

A
quantity of Super grease “A” to the rear brake lever pivot.
A 99000-25010: Super grease " A" A
Install the rear brake cable.

Apply an adhesive agent onto the left handlebar, then install
the left handle grip 4.
Apply a small quantity of Super grease “A” to the throttle

cable end.
5-11
CHASSIS
Install the throttle cable.

Connect the throttle cable end 6 to the throttle grip and
install the throttle case 7 , then temporarily tighten the throttle
case screw.
Apply a small quantity of Super grease “A” to the throttle

cable end.
A 99000-25010: Super grease ”A”
WARNING
After tightening the throttle case screw, make sure that
the throttle grip turns smoothly.
Install the master cylinder. (Refer to page 5-12)
Be sure to face the ”up” mark on the holder ⑧ to the

up-side.
Before installing the front brake lever, apply a small
quantity of SUPER GREASE “A” to the front brake lever
pivot.
Connect the front brake light switch lead.

Install the front and rear handelbar’s covers.(Refer to page 5-4)
CHASSIS
FRONT ABSORBER
CONSTRUCTION
1 O-ring 8 Stopper ring

2 Spring 9 Oil seal
ITEM N•m kgf•m
3 Damper rod 10 Oil seal circlip
A 15-30 1.5-3.0
4 Spring 11 Bushing B 20-26 2.0-2.6
5 Oil lock piece 12 Outer tube
6 Inner tube A Front absorber cap
7 Dust seal B Damper rod bolt
5-13
CHASSIS
REMOVAL AND DISASSEMBLY

Remove the front wheel. (Refer to page 5-6)
Remove the two bolts, take off the front caliper 1 .
Loosen the lower bracket clamp bolt 2 .
CAUTION
Lightly loosen the clamping bolt ,do not remove the bolt.
Remove the front absorber 3 .
Remove the front absorber cap 4 , O-ring 5 and front absorber

spring 6 .
Invert the absorber and stroke it several times to drain out

absorber oil.
5-14
CHASSIS
Remove the dust seal 7 and stopper ring 8 .
Remove the damper rod bolt with the special tools.

Remove the inner tube from the outer tube.
TOOL 11F14-010: Front absorber tool
Remove the damper rod 9 and oil lock piece 10 from the inner
tube.
Remove the oil seal with the special tool.
09913-50121: Oil seal remover
The removed oil seal should be replaced with a new

one.
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
5-15
CHASSIS
INNER TUBE AND OUTER TUBE

Inspect the inner tube and outer tube sliding surfaces for any
scuffing or flaws.
FRONT ABSORBER SPRING

Measure the absorber spring free length. If it is shorter than
the service limit, replace it.
Front absorber spring free length:

Service limit: 227.3 mm
* Cleaning: Clean all the removed parts and blow dry.
REASSEMBLY AND REMOUNTING

Reassemble and remount the front absorber in the reverse
order of removal and disassembly. Pay attention to the following
points:
Wash each metal part with cleaning solvent before

reassembly.
Never re-use absorber oil left over from the last servicing.
Replace the oil seal and dust seal with new ones when
reassembly.
DAMPER ROD BOLT

Apply thread lock to the damper rod bolt and tighten it to the
specified torque with the special tools .
99000-32040: THREAD LOCK “1303"

Thread Lock Cement Gasket
11F14-010: Front absorber tool
Damper rod: 20~26 N•m
The removed oil seal should be replaced with a new one.
5-16
CHASSIS
OIL SEAL
Install the oil seal 1 to the outer tube by using the special tool
as shown.
Before installing the oil seal 1 , apply a small quantity of

SUPER GREASE “A” to the lip of oil seal.
A 99000-25010: SUPER GREASE “A”

TOOL 09940-50113: Front absorber oil seal installer set
Install the stopper ring 2 and dust seal 3 .
Make sure that the stopper ring 2 fitted securely.
FRONT ABSORBER OIL

Pour specified absorber oil into the inner tube.
Capacity (each leg): 85 ml

Absorber oil type: MX46
Hold the front absorber vertical and adjust the absorber oil
level with the special tool.
When adjusting oil level , remove the absorber spring

and compress the inner tube fully.
09943-74111: Absorber oil level gauge

Oil level: 72.5 mm
ABSORBER SPRING Up side
When installing the front absorber spring, the close pitch

end should position upside.
Down side
5-17
CHASSIS
REASSEMBLY
Reassembly and install the front abosrber in the reverse order of
removal and disassembly. Pay attention to the following points:
Apply a small quantity of absorber oil on the O-ring 1 of front

absorber cap.
Absorber oil type: MX46
Tighten the front absorber cap 2 to the specified torque.
Front absorber cap: 135-30 N•m
Install the front absorber to the lower bracket, tighten the

front absorber lower bracket clamping bolt 3 to the specified
torque.
Lower bracket clamping bolt: 18-28 N•m
Install the front brake caliper, and tighten the mounting bolt 4
to the specified torque.
Brake caliper mounting bolt: 18-28 N•m
Install the front wheel. (Refer to page 5-8)
5-18
CHASSIS
STEERING STEM
CONSTRUCTION
1 Lower bracket assembly 8 Inner upper race

2 Dust cover 9 Inner lower race ITEM N•m kgf•m
3 Steering stem nut 10 Ball A 25-35 2 . 5-3.5
4 Washer 11 Outer lower race B 18-28 1.8-2.8
5 Dust seal 12 Steering stem lower seal ring
6 Outer upper race A Steering stem lock nut
7 Ball B Lower bracket clamp bolt
5-19
CHASSIS
REMOVAL
Remove the front wheel.( Refer to page 5- 6)
Remove the handlebar. (Refer to page 5-10)
Remove the front absorber. (Refer to page 5-14)
Remove the sponge cover 1 .
Remove the steering stem lock nut using special tool 2 .
TOOL 09910-60611: Universal clamp wrench
Remove the steering stem nut 3 .

Remove the steering stem nut 4 with the special tool.
TOOL 09910-60611: Universal clamp wrench
Hold the steering stem by hand to prevent from falling.
Remove the steering stem dust seal 5 .
Remove the Outer upper race 6 .
5-20
CHASSIS
Remove the lower bracket assembly 7 and upper and lower

steel balls.
Number of balls : 22 pcs ( Upper)

18 pcs (Lower)
Remove the outer lower race with a thin chisel.
The outer lower race is pressed to the steering stem. If

the lower race is removed, replace it with a new one. It is
not necessary to remove the outer lower race if corrosion,
dents or damage on the race have not occurred.
Draw out the steering stem races, upper 7 and lower,

with a suitable bar 8 .
INSPECTION
Inspect and check the removal parts for the following
abnormalities.
Race wear and brineling.
Worn or damaged steel balls.
Distortion of steering stem.
REASSEMBLY
Reassemble and remount the steering stem in the reverse
order of disassembly and removal, and also carry out the TOOL
following steps:
INNER RACES
Press in the upper and lower inner races using the
special tool.
09941-34513 : Steering race installer

5-21
CHASSIS
OUTER RACE
Apply grease to the new lower oil seal.
Press in the new lower outer race by using the special tool.
99000-25010 : Super grease “A”
09941-74910 ：Steering bearing installer
REMOUNTING
Reassemble the steering in the reverse order of the
removal.
STEEL BALL
Apply grease to the upper and lower inner races when
installing the steel balls.
99000-25010: Super grease " A "
STEERING STEM NUT

Tighten the steering stem nut with the special tool.
Turn the steering stem right and left, lock-to-lock, five or six
times to “seat” the steel ball bearings.
09910-60611 : Universal clamp wrench
Check to be sure that the steering stem moves freely from

left to right with its own weight. If play or stiffness is
noticeable, re-adjust the steering stem nut.
The adjustment will vary from motorcycle to another

one.
Tighten the steering stem head bolt to the specified torque.
09910-60611 : Universal clamp wrench
Steering stem lock nut: 25~35 N•m
Install the front absorber . (Refer to page 5-18)

Install the handlebar assembly. (Refer to page 5-11)
Install the front wheel. (Refer to page 5-8)
5-22
CHASSIS
FRONT BRAKE
CONSTRUCTION
A
B
1 Brake lever 5 Brake pad ITEM N•m kgf • m

2 Brake caliper piston A Master cylinder mounting bolt A 8-12 0.8-1.2
3 Brake light switch B Brake hose union bolt B 20-25 2.0-2.5
C 18-28 1.8-2.8
4 Brake hose C Brake caliper mounting bolt
5-23
CHASSIS
WARNING
The brake system of this motorcycle is filled with a Haojue brake fluid. Do not use or mix
different types of fluid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will be caused.
Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the
brake fluid left over from the last servicing and stored for long periods.
When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
Immediately and completely wipe off any brake fluid contacting any part of the motorcycle.
The brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage
them severely.
Brake Pad Replacement

Loosen brake caliper mounting bolts 1 .
Remove the brake pads 2 .
Replace the brake pads as a set, otherwise braking

performance will be adversely affected.
Reassemble the new brake pads and brake caliper in the

reverse order of removal.
Tighten the brake caliper mounting bolt to the specified torque.
Brake caliper mounting bolt: 18~28 N•m
Push the pistons all the way into brake caliper.
5-24
CHASSIS
CALIPER REMOVAL AND DISASSEMBLY

Disconnect the brake hose 1 from the caliper and catch the
brake fluid in a suitable receptacle.
Remove the brake caliper mounting bolts 2 , take off the
brake caliper.
N ever re-use the brake fluid left over from the last
servicing and stored for long periods. Do not operate
the brake lever while dismounting the brake pad.
Remove the brake caliper pads .

Remove the brake caliper spring washer 3 .
Remove the brake caliper bracket 4 .
Place a clean rag over the pistons to prevent it from popping

out and then force out the pistons using compressed air.
Do not use high pressure air to prevent piston damage.
Remove the piston , piston boot and piston seal .
Do not reuse the removed piston seal to prevent leaking.
INSPECTION
CALIPER CYLINDER
Inspect the cylinder bore wall for nick, scratch or other damage.
5-25
CHASSIS
PISTON
Inspect the piston surface for scratches or other damage.
RUBBER PARTS
Inspect the rubber parts for cracks and damage. If any defects
are found, replace the affected parts.
BRAKE DISC
Visually inspect brake disc for cracks or damage, and measure
brake disc thickness with a micrometer.
09900-20205: Micrometer ( 0-25 mm)

Brake disc thickness:
Service limit: 3.5 mm
Measure runout of the brake disc with a dial gauge.
09900-20606: Dial gauge（1/100 mm)

Brake disc runout:

Service limit : 0.3 mm
R E A S S E M B LY
Reassemble and remount the brake caliper in the reverse orders of
disassembly and removal, and also carry out the following steps.
Wash the master cylinder components with fresh brake fluid

before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all internal parts
before inserting into the bore.
5-26
CHASSIS
Tighten the brake caliper mounting bolt 1 and brake hose

union bolt 2 to the specific torque.
Brake hose union bolt: 20~25 N•m

Brake caliper mounting bolt:18~28 N•m
Bleed air from the brake fluid circuit after reassembling
mater cylinder. (Refer to page 2- 12)
Brake fluid, if it leaks, will interfere with safe running and

immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joint for
leakage before riding.
MASTER CYLINDER REMOVAL

Remove the front handlebar’s cover and meter cover.
(Refer to page 5-1)
Remove the front brake switch coupler ① .
Drain the brake fluid, remove the brake hose union bolt ② .
Remove Brake caliper mounting bolt ③ .
The fluid reacts chemically with paint, plastics and

rubber materials, etc. and will damage them severely.
Remove the brake lever 4 .
Remove the reservoir cap 5 and diaphragm 6 .
Remove the dust seal 7.

Remove the circlip 8 by using the special tool.
TOOL 09900-06108: Snap ring pliers
Remove the piston/cup 9 and return spring 10 .
5-27
CHASSIS
INSPECTION
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scratches or other
damage.
Inspect the piston surface for any scratches or other damage.
Inspect the piston cup and dust seal for wear or damage.
BF
MASTER CYLINDER REASSEMBLY

AND REMOUNTING
Reassemble and remount the master cylinder in the reverse
orders of disassembly and removal, and also carry out the
following steps:
● Wash the master cylinder components with fresh brake
fluid before reassembly.
Brake fluid specification: Haojue brake fluid
When washing the components, use the specified A

B Upper side
brake fluid. Never use different types of fluid or Upper
cleaning solvents such as gasoline, kerosine, etc. clamp
Do not wipe the brake fluid off after washing the bolt Handlebar
components.
" UP"
Apply brake fluid to the cylinder bore and all internal mark
Master
parts before inserting into the bore. cylinder
Clearance
When remounting the master cylinder on the handlebar,
align the master cylinder holder’s mating surface A with B
punched mark on the handlebar and tighten the upper clamp
bolt first as shown.
Tightening torque: 8~12 N•m
Be sure to face the "UP" mark on the holder to the up-side.
Connect the brake hose, tighten the union bolt to the

specified torque
Brake hose union bolt: 20~25 N•m
Bleed air from brake system after installing the master

cylinder. (Refer to page 2-12)
5-28
CHASSIS
REAR WHEEL AND REAR BRAKE

CONSTRUCTION
1 Rear rim 5 Rear brake cam rocker arm

2 Brake shoe 6 Rear wheel tubeless tire ITEM N m kgf m
3 Break cam A Rear w heel nut A 102-138 10.2-13.8
4 Rear brake indicator B Brake cam rocker nut B 8-12 0. 8-1.2
REMOVAL
Support the motorcycle with the main stand.
Remove the rear brake adjust nut ①.
Remove the rear brake cable pin ② and r ear break cable
adjust spring ③.
5-29
CHASSIS
Remove the rear axle nut 4 , deflate the tire.

Remove the rear wheel.
If it is difficult to remove the rear wheel, remove the

muffler mounting bolt 5 .
Remove the brake shoe 6 .
INSPECTION
REAR WHEEL
(Refer to page 5-3)
WHEEL HUB
Measure wheel hub I. D and ascertain its wear extent. In
case wear exceeds wear limit, replace the wheel hub.
Wheel hub I.D.: Service limit: 111 mm

BRAKE SHOE
Check the brake shoe and decide whether it should be
replaced or not from the thickness of the brake shoe lining.
Brake shoe thickness: service limit: 1.5 mm
Replace the brake shoe as a set, otherwise braking

performance will be adversely affected.
5-30
CHASSIS
REASSEMBLY
Reassemble and remount the rear wheel and brake in the
reverse order of removal and disassembly. Pay attention to the
following points.
Turn the punched mark 1 on the camshaft to the rear axle

shaft side.
1
Install the protrusion 2 of indicator plate to the groove 3 of

camshaft.
When installing the brake cam lever, align the groove 4 of

camshaft with slit 5 on cam lever.
Brake cam lever nut: 8~12 N•m
Apply grease to the camshaft rocker arm and pin before

installing the brake shoes.
A 99000-25010: SUPER GREASE ”A”
Be careful not to apply too much grease to the camshaft

and pin. If grease gets on the lining, brake effectiveness
will be lost.
Install the brake shoe.

Tighten the rear axle nut 6 and muffler mounting bolt 7 .
Adjust the rear brake cable free play. (Refer to page 2-13)
Rear axle nut:102~138 N•m

Muffler mounting bolt: 40~60 N•m
5-31
CHASSIS
TIRE AND WHEEL

TIRE REMOVAL
Remove the valve core from the valve stem, and deflate
the tire completely.
Mark the tire with chalk to note the position 1 of the

tire on the rim and rotational direction 2 of the tire.
Remove the tire with the tire changer.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following point:
Distortion and crack
Any flaws and scratches at the bead seating area.
Wheel runout
TIRE
There are serial marks (tire wear indicator) 3 in the edge of
the tire. Check the block of T.W.I. in the tread near the mark.
If the tire wears off to reach the boss 4 , the tire should be
replaced.
Check the damage 5 (punctures or fractures) on the tire
surface visually. As surface damage may impede driving
stability, such tires should be replaced.
Nick and rupture on side wall
Tire tread depth
Abnormal, uneven wear on tread
Surface damage on bead
Localized tread wear due to skidding(Flat spot)
Abnormal condition of inner liner
When repairing a flat tire, follow the repair instructions

and use only recommended repairing materials.
VALVE INSPECTION
Inspect the valve after the tire is removed from the rim. Replace Valve
the valve with a new one if the seal rubber is peeling or has
damage.
5-32
CHASSIS
If the seal has abnormal deformation, replace the valve with a

new one.
Seal
VALVE INSTALLATION
Any dust or rust around the valve hole must be cleaned off,
then install the new valve in the rim.
Valve hole
To properly install the valve into the valve hole, apply a

special tire lubricant or neutral soapy liquid to the valve.
Wheel
Be careful not to damage the lip of valve.
Valve lip Valve
TIRE INSTALLATION
Apply tire lubricant or neutral soapy to the tire bead.
Never use oil, grease or gasoline.
When installing the tire, the arrow on the side wall should point
to the direction of wheel rotation.
Valve
5-33
CHASSIS
Install the tire.
CAUTION
Align the chalk mark put on the tire at the time of removal
with the valve position.
Inflate the tire.
WARNING

Do not inflate the tire to more than 400 kpa (4.0 kgf/cm ,
57 psi). The tire should burst with sufficient force to
cause severe injury. Never stand directly over the tire
while inflating it.
In this condition, check the “rim line” cast on the tire side
walls. The line must be equidistant from the wheel rim all
Rim line
around. If the distance between the rim line and wheel rim
varies, this indicates that the bead is not properly seated.
If this Is the case, deflate the tire completely and unseat
the bead for both sides. Coat the bead with lubricant and
fit the tire again.
After tire is properly seated to the wheel rim, adjust the air-
pressure to the recommended pressure.
Do not run with a repaired tire more than 50 km/h within

24hours after tire repairing. since the patch may not be
completely cured.
TIRE PRESSURE
Solo riding Dual riding
kPa Kg/cm2 kPa Kg/cm 2
Front wheel 125 1.25 125 1.25
Rear wheel 200 2.00 250 2.50
5-34
ELECTRICAL
CONTENTS
CAUTIONS IN SERVICING 6-1
CHARGING SYSTEM 6-3
STARTING SYSTEM 6-6
IGNITION SYSTEM 6-10
FUEL LEVEL GAUGE 6-12
DASHBOARD 6-13
LIGHTS 6-14
SWITCHES 6-15
BATTERY 6-16
6
ELECTRICAL
CAUTIONS IN SERVICING
CONNECTOR
“Click”
When connecting a connector, be sure to push it in until a click
is felt.
Inspect the connector for corrosion, contamination and break-
age in its cover.
COUPLER
With a lock type coupler, be sure to release the lock when
disconnecting, and push in fully to engage the lock when “Click”
connecting.
When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
Inspect each terminal on the coupler for being loose or bent.
Push in the coupler straightly. An angled or skewed insertion
may cause the terminal to be deformed, possibly resulting in
poor electrical contact.
Inspect each terminal for corrosion and contamination. The
terminals must be clean and free of any foreign material which
could impede proper terminal contact.
Correct Incorrect
CLAMP
Clamp the wire harness at such positions as indicated in “
WIRING HARNESS ROUTING”.
Bend the clamp properly so that the wire harness is clamped
securely.
In clamping the wire harness, use care not to allow it to hang
down.
Do not use wire or any other substitute for the band type
clamp.
FUSE
When a fuse blows, always investigate the cause to correct it
and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use wire or any other substitute for the fuse.
SEMI-CONDUCTOR EQUIPPED PART

Incorrect
Be careful not to drop the part with a semi-conductor built in
such as a CDI unit and regulator/rectifier.
When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.
6-1
ELECTRICAL
BATTERY
The MF battery used in this motorcycle does not require
maintenance (e.g., electrolyte level inspection, distilled water
replenishment).
During normal charging, no hydrogen gas is produced.
However, if the battery is overcharged, hydrogen gas may be
produced. Therefore, be sure there are no fire or spark sources
(e.g., Shorted circuit) nearby when charging the battery. Be
sure to recharge the battery in a well-ventilated and open area.
Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.
CONNECTING THE BATTERY

When disconnecting terminals from the battery for disassembly
or servicing, be sure to disconnect the battery lead wire
first.
When connecting the battery lead wires, be sure to connect the
battery lead wire first.
If the terminal is corroded, remove the battery, pour warm water
over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the
battery terminal.
Install the cover over the battery terminal.
USING THE POCKET TESTER

Properly use the pocket tester and probes. Improper use
can cause damage to the motorcycle and tester.
If the voltage and current values are not known, begin
measuring in the highest range.
When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
After using the tester, be sure to turn the switch OFF.
6-2
ELECTRICAL
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in the figure, which is composed of an AC generator,
regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current, then is
charges the battery.
TROUBLESHOOTING
Battery runs down quickly
Check accessories which mounted Remove accessories

excessively waste electric power.
Not installed
Inspect battery leak current leakage Shorted circuit of wire

Loose or disconnected wires
No leak Faulty battery
Inspect charging voltage correct Faulty battery

between battery terminals.
Abnormal driving condition
Incorrect
Faulty generator coils or discon- not conductive Faulty generator coils or

nected lead wires disconnected lead wire.
Correct
incorrect Faulty generator rotor

Inspect generator no-load voltage
Correct
Inspect regulator/rectifier incorrect Faulty regulator/rectifier
Correct
Inspect wirings incorrect Shorted circuit of wire.

Poor contact of couplers.
Correct
Faulty battery
Others
Faulty regulator/rectifier
Battery overcharge
Faulty battery
Poor contact of generator
lead wire coupler
6-4
ELECTRICAL
INSPECTION
BATTERY LEAK CURRENT INSPECTION
Remove the battery maintenance lid 1 .
Turn the ignition switch to the OFF position.
Disconnect the battery lead wire.
Measure voltage between the battery terminal and the
ground cable terminal. If the reading exceeds the specified
value, then leakage is present.
09900-25008: Pocket tester

Battery leakage : Less than 3mA mA
Test scale: Current ( --- , 20mA)
CAUTION
Because the leak current might be large, turn the

tester to high range first when connecting an ammeter.
Do not turn the ignition switch to the ON position when
measuring current.
CHARGING OUTPUT INSPECTION

Remove the battery box cover.
Start the engine, keep it running at 5 000 r/min, with lighting
switch turned ON and dimmer switch turned HI position.
Measure the DC voltage between the battery terminal and with
a pocket tester. If the tester reads under the specified value,
inspect the generator coil and regulator/rectifier.
CAUTION
When making this test, be sure that the battery is fully-

Battery
chaged condition.
Teat scale: Voltage
(DC)
Charging output Pocket tester
Standard: 14.0-15.0V at 5 000 r/min
GENERATOR COIL INSPECTION

Open the saddle, remove the helmet box. (Refer to page 5-1)
Disconnect generator coupler .
Measure the resistence 1 between the lead wires, if the
resistence is incorrect, replace the generator coil. 1

Teat scale: Resistance
Generator coil resistance: 0.75 Ω (B-B)
6-4
ELECTRICAL
GENERATOR NO-LOAD PERFORMANCE INSPECTION

Disconnect the generator coupler. (Refer to page 6-4)
Start engine and keep it running at 5,000 rpm.
Measure voltage between generator terminal and ground by
using the pocket tester. If the reading is below standard values,
replace with a new generator coil.(Refer to page 3-36)
CAUTION
It is not necessary to remove the engine from the

chassis during the removal the generator coil.

Teat scale: Voltage
Generator no-load performance:

More than 70V/5000 r/min
(When engine is cold)
REGULATOR/RECTIFIER INSPECTION
If the resistance checked is incorrect, replace the regulator
/rectifier with a ne w one.
6-5
ELECTRICAL
STARTING SYSTEM
DESCRIPTION
The starting system is shown in the diagram below : namely , the starting motor , starting relay , front
brake light switch, rear brake light switch, starting switch, Ignition switch and battery.
Depressing the starter switch energizes the relay, causing the contact points to close which connects the
starting motor to the battery. The motor draws about 70 amperes to start the engine.
TROUBLESHOOTING
* Check: One of the front and rear brake light
switches is ON position.
Ignition switch is ON position.
Fuse is not blown before check.
Starting motor will not run
Check whether to run the starting

motor when connect the starting
Check whether to hear the click noise
Clicks motor terminal to the battery
from the starting relay when the
terminal directly. (Do not use thin
starting button is pushed.
wire, because a large amount
of current flows.)
Not run
Run
No click
Faulty starting motor
Faulty starting relay

Loose or disconnected starting
motor lead wire
Measure the starting relay voltage at
Not voltage Faulty ignition switch
the starting relay connector (between
Y/G and W/B ) when the starting Faulty front brake light switch
button is pushed. Faulty rear brake light switch
Faulty starting button
Poor contact of connector
Opened circuit in wiring harness
Voltage measured
Check the starting relay

Incorrect Faulty starting relay
(Refer to page 6-9)
Starting motor runs, Opened circuit in wiring harness

but does not start engine. Poor contact of connector
Faulty CDI
Faulty ignition coil
Faulty generator
Faulty starting clutch
6-6
ELECTRICAL
STARTING MOTOR DISASSEMBLY

Disconnect the starting motor wire 1 .
Remove the starting motor mounting bolt 2 , take off the
starting motor 3 .
STARTING MOTOR DISASSEMBLY

Dissemble the starting motor as shown in the illustration.
1 Housing end(inside) 4 Amature shaft 7 Housing end(outside)

2 O-ring 5 Washer 8 O-ring
3 Motor body 6 Washer
STARTING MOTOR INSPECTION

CARBON BRUSHES
When the brushes are worn, the motor will be unable to produce
sufficient torque, and the engine will be difficult to turn over. To
prevent this, periodically, inspect the length of the brushes,
replacing them when they are too short or chipping.
6-7
ELECTRICAL
COMMUTATOR
segment
Inspect the commutator for discoloration, abnormal wear or
undercut A . If the commutator shows abnormal wear, replace it A
with a new one. If the surface is discolored, polish it with #400
sand paper and wiped with a clean dry cloth.
If there is no undercut, scrape out insulator 1 with a saw blade.
1
ARMATURE COIL
Check for continuity between each segment.
Check for continuity between each segment and the armature
shaft. If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
armature with a new one.
Test scale: Continuity
OIL SEAL INSPECTION

Check the seal lip for damage or leakage.
If any damage is found, replace the bracket.
STARTING MOTOR REASSEMBLY

Reassemble the starting motor in the reverse order of
disassembly. Pay attention to the following points:
CAUTION
Replace the O-rings with new ones to prevent oil

leakage and moisture.
Apply SUPER GREASE " A" to the lip of the oil seal.
A 99000-25010: SUPER GREASE " A"
Apply a small quantity of Moly paste to the armature shaft.
99000-25140: Moly paste
6-8
ELECTRICAL
When fixing brush holder to starting motor case, align the

protrusion ① of the starting motor case with the notch ② of the
brush holder.
When installing housing end, fix the protrusion ③ of the
starting motor case to the notch ④ on the housing end.
Apply a small quantity of THREAD LOCK “1342" to the starting

motor housing screws.
99000 - 32050: THREAD LOCK ”1342”
STARTING RELAY INSPECTION

Remove the battery cover. (Refer to page 5-1)
Remove the starting relay.
Apply 12 volts 1 to 2 and terminals, inspect the continuity

between the terminals, positive and negative.
If the starting relay is in sound condition, continuity is found.
Test scale: continuity
CAUTION
Do not apply a battery voltage more than 5 seconds

to the starter relay as It may overheat and cause
damage to the relay coil.
Check the coil for ”opened”, “grounded” and ohmic resist-

ance. The coil is in good condition if the resistance is as
follows.

Test range: Resistence
Starter relay resistence : 3 - 6 Ω
6-9
CHOKE
Remove the saddle and helmet case.( Refer to page 5- 2)
Disconnect the choke 1 .
ELECTRICAL
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug *Check the ignition switch is “ ” position.

Inspect that the fuse is not blown before check.
Inspect the battery voltage Less than 12V Recharge the battery or
replace the battery
12V
Check the CDI unit couplers for Looseness Poor contact of couplers
poor contact
Correct
Incorrect Faulty ignition switch

Broken wire harness or poor
contact of related circuit
connectors
Correct
Inspect the resistance of trigger coil Incorrect Faulty trigger coil

(Brown and white)
Correct
Faulty CDI unit

Faulty ignition coil
6-10
ELECTRICAL
IGNITION COIL
Remove the helmet case and front center cover. (Refer to
page 5-2)
Remove the spark plug cap 1 .
Measure the ignition coil resistence with the pocket tester. Tap

Test range: resistence Ω
κΩ
Primary: 3.1~4.3 Ω (tap-tap)
Secondary: 28.5~38.5 K Ω (tap- Plug cap)
Tap
TRIGGER COIL
Using the pocket tester, measure the coil resistance between
the lead wires.
Test range: Resistence
Trigger coil resistance: 190 Ω

(Blue/Green-Ground)
SPARK PLUG
(Refer to page 2-6)
IGNITOR UNIT
If the ignition system is defective and no problem is found in the
inspection above, replace the ignitor.
6-11
ELECTRICAL
FUEL METER
FUEL METER CIRCUIT
O B/W Fuel lever gauge
Y/ B
FUEL TANK
INSPECTION
FUEL LEVER GAUGE A
Remove the fuel lever gauge. (Refer to page 4-4)
B
Check the resistance of each float position with a pocket tester.
If the resistance measured is incorrect, replace the fuel gauge
assembly with a new one.
The relation between the position of the fuel gauge float and
resistance is shown in the following table.
Float position Resistance

A Full 4-10 Ω
B Empty 90-100 Ω
TOOL 09900- 25008: Pocket tester
Ω
Tester knob indication: x 1 Ω
CAUTION
When inspecting the gauge resistance, be sure to
disconnect the battery lead wire, or a pocket tester may
6-12
ELECTRICAL
DASHBOARD
Remove the dashboard. (Refer to page 5-1)
Disassemble the dashboard as follows.
Top cover Bottom cover

Meter cover Bulb
Meter panel Wiring harness
INSPECTION
Using the pocket tester, check the continuity between lead DASHBOARD
wires.
If the continuity measured is incorrect, replace the respective
parts. Fuel
gauge

Lg
Y/B
B/W
Gr
Test scale: continuity
CAUTION
When making this test, it is not ne ed to remove the
dashboard.
6-13
ELECTRICAL
LAMPS TAIL LIGHT/BRAKE LIGHT/

REAR TURN SIGNAL LIGHT/
HEADLIGHT
LICENSE LIGHT
FRONT TURN SIGNAL LIGHT
REMOVAL
Remove the front leg shield. (Refer to attachment page 5-2)
Remove the headlight bulb and position light bulb.
Remove the front handlebar’s cover. (Refer to page 5-1)

Remove the front turn signal light bulb.
6-14
ELECTRICAL
Remove the tail cover, and left and right side cover. (Refer to
page 5-4)
Remove the tail light/brake light bulb and rear turn signal light
bulb.
SWITCHES
Inspect each switch for continuity with the pocket tester.
If any abnormality is found, replace the respective switch
assemblies with new ones.

Test scale: Continuity
IGNITION SWITCH DIMMER SWITCH

O/Y Br R O Y/W W Y O
OFF ○ ○
ON ○ ○ ○ ○ ○
○ ○ PASSING ○ ○ ○ ○
TURN SIGNAL LIGHT SWITCH

LIGHTING SWITCH B Lb Lg
○ ○
Gr O/W O/W Y/W
○ ○ ○
○ ○ ○ ○ ○
○ ○ ○ ○
HORN SWITCH
STARTING BUTTON
O G
B/W Y/G
OFF
○ ○
○ ○
FRONT BRAKE LIGHT SWITCH

O W/B REAR BREAK LIGHT SWITCH
OFF O W/B
ON ○ ○ OFF
ON ○ ○
6-15
ELECTRICAL
BATTERY
SPECIFICATIONS
TYPE YTX7A- BS
Capacity 12V(6Ah)
Standard electrolyte S.G. 1.320 at 20 C
O
INITIAL CHARGING
Remove the aluminum tape 1 sealing the battery electrolyte
filler holes.
Filler holes
Remove the caps 2 .
CAUTION
After filling the electrolyte completely, use the removed
cap as the sealed caps of battery-filler holes.
Insert the nozzles of the electrolyte container into the

battery’s electrolyte filler holes, holding the container firmly so
Electroyte
that it does not fall. containers
WARNING
Take precaution not to allow any of the fluid to spill. Insert in

filler holes
Make sure air bubbles are coming up each electrolyte

container, and leave in this position for about more than 20
minutes.
Air
bubbles
6-16
ELECTRICAL
CAUTION
If no air bubbles are coming up from a filler port, tap the

bottom of the two or three times. Never remove the
container from the battery.
After confirming that the electrolyte has entered that battery

completely, remove the electrolyte containers from the battery.
Wait for around 20 minutes.
Insert the caps into the filler holes, pressing in firmly so that the
top of the caps do not protrude above the upper surface of the
battery’s top cover.
CAUTION
Insert the caps firmly
Once install the caps to the battery; do not remove
the caps.
Using the pocket tester, measure the battery voltage. The

tester should indicate more than 12. 5-12. 6V (DC) as shown in
the Fig. If the battery voltage is lower than the specification,
charge the battery with a battery charger. (Refer to the
recharging operation.)
CAUTION
Initial charging for a new battery is recommended if two years have elapsed since the date of
manufacture.
SERVICING
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the
sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be
coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.
RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V(DC),recharge
the battery with a battery charger.
CAUTION
When recharging the battery, remove the battery from the motorcycle.
Recharging time: 3A for 1 hour or 0.7A for 5 hours

CAUTION
Be careful not to permit the charging current to exceed 3A at any time.
After recharging, wait for more than 30 minutes and check the battery voltage with a pocket tester.
If the battery voltage is less than the 12.5V, recharge the battery again.
If the battery voltage is still less than 12.5V, after recharging, replace the battery with a new one.
When the motorcycle is not used for a long period, check the battery every 1 month to prevent the battery
discharge.
6-17
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 7-1
SPECIAL TOOLS 7-7
TIGHTENING TORQUE 7-9
SERVICE DATA 7-11
WIRE AND CABLE ROUTING 7-16
7
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low
or is hard to start. 1. Valve clearance out of limit. Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3. Valves mistiming. Adjust.
4. Piston rings excessively worn. Replace.
5. Worn-down cylinder bore. Replace or rebore.
6. Poor seating of spark plug. Retighten.
7. Starting motor cranks but too slowly. Consult "electrical complaints"
Plug not sparking
1. Fouled spark plug. Clean or replace.
2. Wet spark plug. Clean and dry.
3. Defective trigger coil. Replace.
4. Defective ignitor unit. Replace.
5. Defective ignition coil. Replace.
No fuel reaching the carburetor
1. Clogged hole in the fuel tank cap. Clean.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float needle valve. Replace.
4. Clogged fuel pipe. Clean or replace.
5. Clogged fuel filter. Clean or replace.
1. Fouled spark plug. Clean.

Engine stalls easily
2. Defective trigger coil. Replace.
3. Defective ignitor unit. Replace.
4. Clogged fuel pipe. Clean.
5. Clogged jets in carburetor. Clean.
6. Valve clearance out of limit. Adjust.
7. Clogged fuel filter. Clean or replace.
Noisy engine Excessive valve chatter

1. Valve clearance too large. Adjust.
2. Weakened of broken valve springs. Replace.
3. Worn down rocker arm or rocker arm shaft. Replace.
Noise appears to come from piston
1. Piston or cylinder worn down. Replace.
2. Combustion chamber fouled with carbon. Clean.
3. Piston pin or piston pin bore worn. Replace.
4. Piston rings or ring groove worn. Replace.
Noise seems to come from clutch
1. Worn or slipping drive belt. Replace.
2. Worn rollers in the movable drive face. Replace.
3. Worn or slipping clutch shoes. Replace.
Noise seems to come from crankshaft
1. Worn of burnt bearings. Replace.
2. Worn and burnt camshaft journal contact surface. Replace.
3. Too big thrust clearance. Replace or readjust.
Noise seems to come from transmission
1. Worn or rubbing gears. Replace.
2. Badly worn splines. Replace.
3. Badly worn bearings. Replace.
7-1

Slipping clutch 1.Clutch centrifugal shoe block worn or damaged. Replace
2.Clutch spring elasticity reduced. Replace
3.Clutch outer disc worn. Replace
4.Drive belt worn or slipped. Replace
Engine idles poorly. 1.Valve clearance out of limit. Adjust.

2.Poor seating of valves. Replace.
3.Defective valve guides. Replace.
4.Worn rocker arm or arm shaft. Replace
5.Defective trigger coil. Replace.
6.Defective ignitor unit. Replace.
7.Defective ignition coil resulting in weak sparking. Replace.
8.Spark plug gap too wide. Adjust or replace.
9.Clogged jets. Clean.
Engine runs poorly 1.Valve springs weakened. Replace.

in high speed range. 2.Valve timing out of limit. Adjust.
3.Worn cams or rocker arms. Replace.
4.Spark plug gap too narrow. Repair.
5.Defective ignition coil. Replace.
6.Clogged air cleaner element. Clean.
7.Clogged fuel hose, resulting in inadequate fuel Clean and prime.
supply to carburetor,
8.Defective trigger coil or ignitor unit. Replace.
Dirty or heavy 1.Too much engine oil in the engine. Check oil level.
exhaust smoke. 2.Worn piston rings or cylinder. Replace.
3.Worn valve guides. Replace.
4.Cylinder wall scored or scuffed. Replace.
5.Worn valves stems. Replace.
6.Defective stem seals. Replace.
7.Worn oil rings. Replace.
Engine lacks power. 1. Valve clearance out of limit. Adjust.

2. Valve springs weakened. Replace.
3. Valve timing out of limit. Adjust.
4. Worn piston ring or cylinder. Replace.
5. Poor seating of valves. Repair.
6. Worn rocker arms or its shafts. Replace.
7. Fouled spark plug. Clean or replace.
8. Spark plug gap incorrect. Adjust or replace.
9. Clogged jets in carburetor. Clean.
10. Clogged air cleaner element. Clean.
11. Too much engine oil. Drain out excess oil.
12. Suck air intake pipe. Retighten or replace.
13.Drive belt slipped or worn. Clean or replace.
14.Clutch shoe slipped or worn Clean or replace.
Engine overheats. 1. Heavy carbon deposit on piston crown. Clean.

2. Not enough oil in the engine. Pour oil.
3. Defective oil pump or clogged oil circuit. Repair or clean.
4. Air leak from intake pipe. Retighten or replace.
5. Use of incorrect engine oil. Change.
6. Air filter clogged by dust. Clean or replace.
7-2
CARBURETOR
Trouble with 1.Starting jet is clogged. Clean.
starting. 2.Starting pipe is clogged. Clean.
3. Air leakage from a joint between choke and carburetor. Check and retighten.
4. A ir leakage at carburetor joint or vacuum tube joint. Check and retighten.
5 .Starting plunger is not operated properly. Check and adjust.
Idle or low speed 1. Idle jet, idle air jet are clogged or loose. Check and clean.
trouble. 2. Air leakage at carburetor joint, vacuum tube joint or Check and retighten.
choke.
3. Idle outlet or by-pass is clogged. Check and clean.
4. Starting plunger is not fully closed. Check and adjust.
5. Aging or torn diaphragm. Replace.
Medium or high- 1. Main jet or main air jet is clogged. Check and clean.
speed trouble. 2. Bubbling pipe is clogged. Check and clean.
3. Throttle valve is not operated properly. Check and adjust.
4. Air filter is clogged. Check and clean.
5. Aging or tor n diaphragm. Replace.
Overflow and fuel 1. Needle valve is worn or damaged. Replace.

level fluctuations. 2. Needle valve spring is broken. Replace.
3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.
BRAKES
Poor braking. 1. Not enough brake fluid in the reservoir. Check and refill to level mark.
2. Air trapped in brae fluid circuit. Bleed air out.
3. Pads worn down. Replace.
4. Linings worn down. Replace.
5. Brake disc worn down. Replace.
6. Wheel hub worn down. Replace.
7. Oil adhesion on engaging surface of pads or linings. Clean.
8. Too much play on brake lever. Adjust.
Brake squeaking. 1.Carbon adhesion on pad surface. Repair surface with sandpaper.
2.Tilted pad. Modify pad fitting.
3.Damaged wheel bearing. Replace.
4.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5.Pads or linings worn down. Replace.
6.Foreign material in brake fluid. Replace brake fluid.
7.Clogged return port of master cylinder Disassemble and clean master
cylinder.
Excessive brake 1.Air in hydraulic system. Bleed air out.

lever free stroke. 2.Brake lever cam worn down. Replace brake lever.
3.Insufficient brake fluid. Replenish .
4.Improper quality of brake fluid. Replace with correct fluid.
5.Brake linings or wheel hub worn down. Replace.
Leakage of brake 1.Insufficlent tightening of connection joints. Tighten to specified torque.

fluid. 2.Cracked hose. Replace.
3.Worn piston and/or seal ring. Replace piston and/or cup.
7-3
CHASSIS
Steering feels too 1. Steering stem nut over-tightened. Adjust.

heavy or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Steering oscillation. 1. Loss of balance between right and left front absorbers. Replace.
2. Distorted front absorbers. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobby front wheel. 1.Distorted wheel rim. Replace.

2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.
Front absorbers too 1. Weakened springs. Replace.

soft. 2. Not enough absorber oil. Refill.
Front absorbers too 1. Absorber oil too viscous. Replace.

stiff 2. Too much absorber oil. Remove excess oil.
Noisy front absorbers. 1. Not enough absorbers oil. Refill.

2. Loose nuts on absorbers . Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Remedy

2. Worn-down rear wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushings. Replace.
6. Loosen nuts on the rear absorbers. Retighten.
Rear absorbers too 1. Weakened springs. Replace.

soft. 2. Rear absorbers adjuster improperly set. Adjust.
Rear absorbers too 1. Rear suspension adjuster improperly set. Adjust.

stiff. 2. Warn swing arm bushings. Replace.
Noisy rear absorbers. 1. Loose nuts on the rear absorbers . Retighten.

2. Worn swing arm bushings. Replace.
7-4
ELECTRICAL
No spark or 1. Defective ignition coil. Replace.

poor spark. 2. Defective spark plug. Replace.
3. Defective trigger coil or ignitor unit. Replace.
Spark plug soon 1. Mixture too rich. Adjust carburetor.

become fouled 2. Too high idle speed. Adjust carburetor.
with carbon. 3. Incorrect fuel. Change.
4. Dirty element in air cleaner. Clean.
5. Spark plug too cold. Replace by hot type plug.
Spark plug 1.Worn piston rings. Replace.

become fouled 2.Pistons or cylinder worn. Replace.
too soon. 3.Excessive clearance of valve stems in valve guides. Replace.
4.Worn stem oil seals. Replace.
Spark plug 1.Spark plug too hot. Replace by cold type plug.
electrodes 2.The engine overheats. Adjust.
overheat or burn. 3.Defective trigger coil or ignitor unit. Replace.
4.Spark plug loose. Tighten.
5.Mixture too poor. Adjust carburetor.
Generator does 1.Opened or shorted in lead wires, or loose lead Repair or replace or
not charge. connections. re-tighten.
2.Shorted, grounded or opened generator coils. Replace.
3.Shorted or destroyed regulator/rectifier. Replace.
Generator charge, 1.Lead wires tend to get shorted or opened circuit or Repair or tighten.
but charging rate loosely connected at terminals.
is below the 2.Grounded or opened circuit generator stator. Replace.
specification. 3.Defective regulator/rectifier. Replace.
4.Defective cell plates in the battery. Replace the battery.
Generator 1.Internal shorted circuit in the battery. Replace the battery.

overcharges. 2.Resistor element in the regulator/rectifier damaged Replace.
or defective. Clean and tighten ground
3.Regulator/rectifier poorly grounded. connection.
Unstable 1.Lead wire insulation frayed due to vibration, resulting Repair or replace.
charging. in intermittent shorted circle.
2.Generator internally shorted circle. Replace.
3.Defective regulator/rectifier. Replace.
Starting button 1.Battery run down. Recharge or replace.
is not effective. 2.Defective switch contacts. Replace.
3.Brusnes not seated properly on commutator in Repair or replace.
starting motor.
4.Defective starting relay. Replace.
7-5
BATTERY
Battery “sulfation”. 1. Battery case is cracked. Replace.
2 .Charging rate is too low or too high. Replace.
3 .Battery has been left in a run-down condition for a long Replace.
time.
Battery runs down 1.Incorrect charging system. Check generator, regulator/

quickly. rectifier and electric terminals,
adjust to obtain specified
charging operation.
2.Battery cell plates have lost much of their active Replace battery and regulator/
material as a result of overcharging. rectifier charging system
3.A shorted circuit within battery Replace.
4.Battery voltage is too low Recharge.
5.Too old battery Replace.
Battery discharges
Dirty battery top and flanks Clean
too rapidly.
7-6
SPECIAL TOOLS
09900-06107 09900-20101 09900-20203 09900-20205 09900-20508

Snap ring pliers Vernier calipers Micrometer Micrometer Cylinder bore gauge kit
(opening type) (1/50mm,150mm) (1/100mm,50~75mm) (1/100mm,0~25mm) (1/100mm,40~80mm)
09900-20605 09900-20606
Dial calipers Dial meter 09900-20701 09900-20803 09900-21304
(1/100mm,10~34mm) (1/100mm,10mm) Magnetic bracket Thickness gauge V-block (set) (100mm)
09900-25008 09900-26006 09910- 32812 09910-34510 09910-60611

Pocket tester Tachometer Crankshaft installer Piston pin puller Universal wrench
09913-50121 09913-70210 09913-76010 09916-10911 09916-21110

Oil seal remover Bearing installer Bearing installer Valve lapper set Valve seat reamer set
09920-13120 09921-20240 099230-73210 09924-84520 09925-98221

Crankcase separator Bearing remover Bearing puller (15-17 mm) Bearing installer set Bearing installer
09940- 50113
09930-30104 Front absorber oil seal 09941-34513 09941-74910 09925-88221
Slide shaft installer Steering race installer Steering race installer Bearing installer
7-7
11F14-001 11F14-003 11F14-006 11F14-007 11F14-008

Rotor holder M16 bolt Rotor remover M33 Gear remover Rotor & sprocket holder
11F14-039
11F14-010 11F14-018 11F14- 019 11F14-023 Steering stem nut
Front absorber tools Valve tools “T” type valve adjuster Pressure gauge socket wrench
Note:
When ordering the special tools, please confirm whether it is available or not.
7-8
TIGHTENING TORQUE
ENGINE
ITEM N•m Kg • m
Left crankcase bolts 9-15 0.9-1.5

Rear brake rocker arm bolt 8-12 0.8-1.2
Oil filter cover bolt 8-12 0.8-1.2
Crankcase bolt 10-15 1.0-1.5
Drain plug 15-20 1.5-2.0
Cylinder head nut 23-27 2.3-2.7
Camshaft sprocket bolt 10-12 1.0-1.2
Gearbox cover bolt 8-12 0.8-1.2
Gearbox oil level plug 9-15 0.9-1.5
Oil filter cover bolt 8-12 0.8-1.2
Oil pump screw 7-10 0.7-1.0
Generator rotor mounting nut 110-130 11.0-13.0
Crankcase right cover bolt 8-12 0.8-1.2
Cool fan mounting nut 30-35 3.0-3.5
Cooling fan bolt 8-12 0.8-1.2
Cylinder head side nut 8-12 0.8-1.2
Cylinder head cover bolt 12-16 1.2-1.6
Spark plug 10-12 1.0-1.2
Clutch cover intake plate bolt 8-12 0.8-1.2
Fixed drive face nut 40-60 4.0-6.0
Cylinder ventilative screw 7-10 0.7-1.0
Clutch housing nut 65-85 6.5-8.5
Clutch cover bolt 8-12 0.8-1.2
Kick starter lever bolt 23-28 2.3-2.8
7-9
CHASSIS
ITEM N•m Kg • m
Handlebar clamping nut or bolt 40 - 60 4.0-6.0

Lower bracket clamp bolt 18-28 1.8-2.8
Front absorber cap 15-30 1.5-3.0
Steering stem nut 25-35 2.5-3.5
Front axle nut 27-43 2.7-4.3
Front brake disc bolt 18-28 1.8-2.8
Bleed valve 7-10 0.7-1.0
Brake caliper mounting bolt 18-28 1.8-2.8
Brake oil hose mounting bolt 20-25 2.0-2.5
Master cylinder mounting bolt 8-12 0.8-1.2
Swing arm bolt/nut ( Front/rear) 84-120 8.4-12.0
Rear absorber upper mounting bolt 22-35 2.2-3.5
Rear absorber lower mounting bolt 22-35 2.2-3.5
Rear axle nut 102-138 10.2-13.8
Engine mounting bolt 70-100 7.0-10.0
Muffler cylinder nut 18-28 1.8-2.8
Muffler cylinder nut 40-60 4.0-6.0
TIGHTENING TORQUE CHART

For other bolts and nuts who’s torque is not listed, refer to this chart:
Bolt Diameter Conventional or "4" marked bolt "7" marked bolt

A (mm) N•m Kg • m N•m Kg • m
4 1.5 0.15 2 0.2
5 3 0.3 5 0.5
6 6 0.6 10 1.0
8 13 1.3 23 2.3
10 29 2.9 50 5.0
12 45 4.5 85 8.5
14 65 6.5 135 13.5
16 105 10.5 210 21.0
18 160 16.0 240 24.0
Conventional bolt ”4” marked bolt ”7” marked bolt
7-10
SERVICE DATA
VALVE + GUIDE Unit: mm
ITEM STANDARD LIMIT

Valve diam. IN. 25
EX. 22
Valve clearance(when cold) IN. 0.05-0.10
EX. 0.10-0.15
Valve stem O . D IN. 4.975-4.990
EX. 4.955-4.970
Valve stem deflection IN . & EX . 0.35
Valve stem runout IN . & EX . 0.05
Valve head thickness IN . & EX . 0.5
Valve seat width IN . & EX . 0.9-1.1
Valve head radial runout IN . & EX . 0.03
INNER 32.9
Valve spring free length
(IN. & EX.) 32.9
OUTER
CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMIT
Cam height IN. 27.92-28.02 27.62
EX. 27.77-27.87 27.47
Camshaft runout 0.10
Rocker arm I . D . IN. & EX. 10.003-12.018
Rocker arm shaft O . D . IN. & EX. 9.981-9.990
Cylidner head distortion 0.05
Cylinder head cover distortion 0.05
7-11
CYLINDER PISTON PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400 kPa 800 kPa
Piston to cylinder clearance 0.03-0.05 0.12
Cylinder bore 53.500-53.515 53.635
Piston diam. 53.465-53.470 Measure at 3 mm from skirt end 53.345
Cylinder distortion 0.05
Piston ring free end gap 1st 0.10-0.25 0.7
2nd 0.10-0.25 0.7
Piston ring to groove clearance 1st 0.18
2nd 0.15
Piston ring groove width 1st 1.01-1.03
2nd 1.01-1.03
Oil ring 2.01-2.03
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 14.002-14.008 14.03
Piston pin O . D . 13.996-14.0 13.98
CONROD CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 14.006-14.024 14.04
Conrod big end side clearance 0.15-0.45 1.0
Conrod big end width 16.95-17.00
Crankshaft runout 0.05
Crankshaft web to web width 48.9-49.1
OIL PUMP
ITEM STANDARD LIMIT
o o
Oil pressure ( at 60C , 140 F ) 10-30 kPa at 3 000 r/min
7-12
CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch wheel I.D. 110.0-110.15 110.5
Clutch shoe thickness 2
TRANSMISSION Unit: mm
ITEM STANDARD LIMIT
Reduction ratio 0.782-2.672
Final reduction ratio 8.294
Drive belt width 18.4
CARBURETOR
Carburetor type BS22 Main needle jet Φ 2.1 mm
I.D. No. SVB22-2G Idle screw 2,3/8 turn out
Idle jet 34.4 # Throttle cable play 0.5-1.0 mm

Bubbling pipe Φ 2.1 mm Idle speed
Main jet 92 #
7-13
ELECTRICAL
ITEM SPECIFICATION NOTE
o
BDTC 10 /1 500 r/min
Ignition timing o
BDTC 25 /4 000 r/min
Type NGK CR7HSA

Spark plug
Gap 0.6 mm-0.7 mm
Primary 3.1 Ω -4.3 Ω W- P
Ignition coil resistance
Secondary 28.5 K Ω -38.5 K Ω Plug cap- P
Trigger 190 Ω Bl/Y-Ground
Ignition coil resistance
Charging 0.75 Ω Y-Y
Generator no-load voltage More than 70 V at 5 000 r/min.
Regulated voltage 14.0 -15.0 V at 5 000 r/min
Type designation GTX7A-BS
Battery Capacity 6 Ah
Standard 1.28
o
0.01 (20 C)
electrolyte S . G .
Fuse 15 A
LIGHTS
Hi 35 W Position light 5W
Headlight
LO 35 W License light 2W
Tail light/Brake light 5/21 W High beam indicator light 2W
Turn signal light 10 W Turn signal indicator light 2W
TIRE PRESSURE
ITEM SPECIFICATION LIMIT
Cold Inflation Front 175 kPa(1.75 kgf/cm²)
Tire Pressure(Solo) Rear 225 kPa(2.00 kgf/cm²)
Cold Inflation Front 175 kPa(1.75 kgf/cm²)

Tire Pressure(Dual) Rear 225 kPa(2.25 kgf/cm²)
Front 90/90-10 50J
Tire type
Rear 100/90-10 56J
7-14
BRAKE + WHEEL Unit: mm

Rear brake lever free travel Hand brake 20-30
Foot brake 10-20
Brake disc thickness Front 3.8-4.2 3.5
Brake disc runout 0.3
Brake fluid type Haojue motorcycle brake fluid
Brake drum I . D . 120.7
Brake shoe thickness 1.5
Wheel rim runout Front 2.0
Rear 2.0
Wheel axle runout Front 0.25
Rear 0.25
SUSPENSION Unit: mm
Front fork stroke 80
Front fork spring free length 231.9 227.3
Front fork oil level 85
Front fork oil type MX46
Front fork oil capacity
(each leg) 85
Swing arm pivot shaft runout 0.6
FUEL +OIL
ITEM STD/SPEC. NOTE
Fuel type Use only unleaded gasoline of at least 90# octane
Fuel tank capacity 5.8 L
Engine oil type and grade SAE 10W/40, API SF or SG
Change 950 ml
Engine oil capacity
Filter change 1 000 ml
Gearbox oil type SAE90 or SAE 85W/90, API: GL-5
Change 90 ml
Gearbox oil capacity
Overhaul 100 ml
7-15
Carburetor heater switch
Fit the wire harness Clamp coupler(reserved)
License light coupler Keep excessive wire of
in the clamp Clamp Fuse box carburetor heater switch
Rear brake switch branch Carburetor heater
Install vertically in this area.
switch (Optional)
Chassis bracket
Clamp Carburetor heater
Battery
negative lead switch(Optional)
( Heat melt point ) Fuse box negative
wire (Two)
0-10
Carburetor heater switch
Rear brake switch Left handlebar branch
wiring harness Turning relay Headlight coupler wiring harness
Taillight wiring harness Rear brake switch routing (Rear brake switch
Carburetor heater wire (Optional) wiring harness)
Clamp PVC jacket

Set the initial part of clamp Ignition coil lead Meter coupler
as close to the inside of connection map
chassis as possible.
WIRE HARNESS ROUTING
Clamp
Wiring harness Wiring harness
Avoid clamped
View B Ignition switch
Clamp
wiring harness
Wiring harness
Carburetor to heater wire ( White mark )
PVC Jacket (Cut the Alarm branch
PTC redundant part)
Clamp
Wiring harness
7-17
10 +100 (Assembly mark) Wiring harness
Clamp
Heater connector
Bracket Weld clamp
Clamp Ignition coil branch Ignition branch
Clamp Wiring harness Rectifier branch
Wiring harness
Starting motor Weld clamp

wiring harness PVC jacket PVC jacket Wiring harness Fuel level gauge coupler Rectifier branch
Engine ground wire near inside Tail light Press down generator wire Generator coupler (on the bracket)
Weld clamp Wiring harness after assembly coupler after assembly to avoid contact
Fuel lever gauge coupler Generator wiring with the fuel pipe. Fit the wire inside
Generator coupler the clamp
Chassis Alarm tie
PVC jacket
PVC jacket(Starting ground wire
Fuel level gauge coupler motor signal wire) Close to
Generator coupler the chassis
Place jacket between the 90
side Engineground
WIRE HARNESS, CABLE AND HOSE ROUTING
wire and side cover.

wire
Cushion close to bracket 30 10
Chassis
Flatten Generator wire below Clamp

Bubbles not the wiring harness.
Alarm wire routing
allowed inside
10
Weld clamp Wiring harness

Fuel level gauge Adhere on
wiring harness 10
the chassis pipe
G-G
A
Wiring
Rear brake cable
Rear brake cable

Rear brake cable
Throttle cable
Speedometer cable
Throttle cable
Front brake hose
Rear brake cable
Saddle lock cable Brake hose guide clamp
Guide ring
Throttle cable Throttle cable
CABLE ROUTING
Front brake hose Rear brake cable

Throttle cable Rear brake cable Throttle cable
Speedometer cable Front brake hose Wiring harness
Saddle lock cable
Saddle lock cable
Brake hose guide clamp
Throttle cable
Front brake hose Hexagon bolt
Rear brake cable
Saddle lock cable Brake hose guide clamp
Cross screw Throttle cable
Front brake hose
Rear brake cable
Saddle lock cable C
Hexagon face bolt
B Saddlet lock cable Throttle cable Rear brake cable Throttle cable
A
B
7-17
Rear brake cable guide ring
Rear brake cable
Throttle cable
Saddle lock cable
Rear brake guide ring
Clamp Rear brake cable D

Rear brake cable
D E
Detail E Rear view
Make sure the clearance

Rear brake cable Rear brake cable block plate
between the throttle
cable and air filter is Rear brake cable
C over 8mm.
Rear brake cable
Tighten the screw
after contact with
crankcase block
Cross screw Crankcase

Hexagon face bolt
F
Overflow pipe
Guide ring
Throttle cable
Overflow pipe
Saddle lock cable
Throttle cable
Guide ring
Throttle cable
Throttle cable Saddle lock cable
FUEL HOSE ROUTING

White mark Yellow mark
The clamp faces

inside during the
White mark assembly
The clearance required

The clamp faces rearward
over 3mm
during the assembly
Place the white mark The clamp faces

of breathe pipe in the forward during the assembly
cylinder ventilate
cover slot.
Fuel tank Hexagon bolt

Clamp Fuel cock a ssembly
Fuel inlet pipe I Fuel outlet pipe
Clamp Vacuum pipe
Hexagon bolt Clamp
Fuel filter clamp I Hexagon bolt
Fuel fliter clamp II Guide ring
Fuel filter Clamp
Fuel inlet pipe II 2nd air filter bracket
Fuel cock cover 2nd air filter
7-18
AIR FILTER INTAKE HOSE ROUTING
Position point should

face center
Detail A
Mark H7A0's direction as shown

during the assembly of Item 1,2,3,4.
EXPLOSIVE VIEW B
Air filter assembly Air filter intake pipe

Intake hose Clamp
Clamp Chassis
7-19
Throttle cable Speedometer cable
Gasket
Front brake hose
Rear brake cable
Front brake master

Cylinder assembly
Rear brake cable
Brake hose bolt
Throttle cable Guide ring

Wiring harness Brake hose guide
Speedometer cable
Brake hose guide ring

Front brake hose
Bolt Throttle cable Fit the brake hose jacket

in the pipe clamp correctly
Front brake hose
Rear brake cable

Front movable fender
Screw
FRONT BRAKE HOSE ROUTING
Bolt Brake hose clamp

Front brake hose bracket
Hexagon face bolt
7-20
Brake hose bolt
Gasket
Front brake caliper Tighten the brake hose guide

front end against the block.
Detail Z
Section A-A
Tighten the brake hose Tighten the brake hose

lower connector against upper connector against
the caliper block. the caliper block
Handlebar’s front Meter cover
decoration cover
Handlebar front cover

Front leg shield
nd
Ha
ba r le
Helmet case
Helmet case mounting bolt
Horn cover
Handle
bar
Rear cover plate

Chassis
Front case
upper part
Chassis
Right side
Chassis cover
Chassis
Rear right frame cover
Front center cover
2nd air valve bracket
Engine
Front case
lower part Stud bolt Air filter assembly
7-21
Rear fender lower part
Frotn right frame cover
Front lower Chassis
cover
Chassis Tail cover
Rear fender
Upper part
Front leg shield
bracket assembly
Front leg shield
bracket assembly
Chassis
EXTERIOR PARTS REMOVAL/REMOUNTING
Battery box cover

Front leg shield
bracket assembly
Foot pedal
Front fender Tail frame cover

Chassis
Chassis
Chassis
Chassis
Left side cover

Rear left frame cover
Chassis
Chassis
Chassis
Bottom cover Front left frame cover

Dashboard
Turning Horn Carburetor Ignitor
Rear brake Dimmer switch light switch button Heater
switch Light switch Front brake switchTurn signal relay Regulator/Rectifier choke Ignition coil Heater
switch
ON ON ON
OFF OFF OFF
Y
Y
Starter button
B
B
Y
B
Lb
B/W
W
O
G
Lg
O
Y/W
W/B
o
O
Y
Lg
Y
R
W/B
Y/W
O/W
O/W
Gr
B/W
Gr
B
Lg
Y/B
B/W
O
O
B/W
W/B
WIRING DIAGRAM
Fuel gauge
B
B/Y
B
B/W
W
O
W
B/Y
O/G
Bl
O/G
O
B/W
O
O/Y
O
R/W
W/B
Y/G
Y/B
B/W
Y
B
Lg
Lb
Y/G
G
Gr
B/W
O
W/B
Y/B
O/W
Lg
Lb
B
Y
O
Y/B
W
Y/B
Gr
B/W
G
Y/G
B/W
W/B
O/W
Lg Rear right turn
B/W signal light
Lg
B/W W/B
B/W B/W Tail light
Gr Gr
7-22
Front right turn B/W B/W B
signal light Lg Lg Rear left turn
B/W
B signal light
Y Y Gr
B/W License light
Headlight B/W B/W
W W
Gr
B/W
Position light Gr
Front left turn B/W B/W

signal light B B
B
B/W
B
B
B/W
B
R
R
R
Y
R
Y
R
W/B
R/B
B/W
Bl
Y/G
R
O
O/Y
O
G
Starting relay
B
B
R/B
G
Bl
Lg
R
B/W
B
Br
O
R
O
Bl
O/Y
Horn Fuse Battery

ON
OFF
Lock
Engine ground
Alarm socket
Chassis ground
Starting motor
Ignition switch Generator
JIANGMEN DACHANGJIANG GROUP CO., LTD.
Address: No.5, Jiandabei Road, Jiangmen City, Guangdong Province, P.R.C
Telephone: 86-750-3288999 Fax: 86-750-3288333 Postcode: 529030

LINDY 125 Manual de Serviços (Ingles) HJ125T-18

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LINDY 125 Manual de Serviços (Ingles) HJ125T-18

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HJ125T-18/18A

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©COPYRIGHT JIANGMEN DACHANGJIANG GROUP CO.,LTD. 2013

COMPONENT PARTS AND WORK TO BE DONE

ITEM N•m Kgf•m

SYMBOL DEFINITION SYMBOL DEFINITION

Apply oil. Use engine oil unless

otherwise specified Apply or use the absorber oil

Apply SUPER GREASE “A”

Apply MOLY PASTE

Apply sealant “1207B”

Apply THREAD LOCK “1303"

Apply THREAD LOCK “1342"

Apply THREAD LOCK “1322"

B : black Gr : Gray R : Red

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.

SERIAL NUMBER LOCATIONS

The throttle must not be opened to the full

*These specifications are subject to change without notice.

AIR CLEANER 2-4

MUFFLER BOLTS AND NUTS 2-5

VALVE CLEARANCE 2-5

SPARK PLUG 2-6

ENGINE OIL 2-7

OIL FILTER 2-7

OIL STRAINER 2-8

GEARBOX OIL 2-8

DRIVE BELT 2-8

CLUTCH SHOE AND ROLLER 2-9

THROTTLE CABLE PLAY 2-9

PERIODIC MAINTENANCE CHART

Interal Km Initial and Every 6 000km Every 12 000 km

Install the battery in the reverse order of removal.

Do not use a fuse of a different specification , or it will incur

If the air cleaner is clogged with dust, intake resistance will be

Clean the filter 2 and sponge 3 .

Check the condition of paper filter 2 , if the air filter is

If driving under dusty condition, clean the air cleaner

When performing the maintenance of the air cleaner , check

MUFFLER MOUNTING BOLTS

Tighten the muffler mounting bolt 1 to the specified torque.

Muffler mounting bolt 1 : 18~28 N•m

Tighten the muffler mounting bolt 2 .

Muffler mounting bolt 2 : 40 ~60 N•m

Excessive valve clearance results in valve noise and insuffici-

Remove the helmet case and front center cover. (Refer to

To turn the cooling fan with a wrench in the normal running

Valve clearance is to be checked when the engine is cold.

Install the spark plug.

Type NHSP LD NGK

Hot A5RTC CR5HSA

Standard A6RTC CR6HSA

Cold A7RTC CR7HSA

Confirm the thread size and reach when replacing the

ENGINE OIL AND OIL FILTER

Install the filler cap (filler gauge) 2 .

Remove the oil filter cover 1 ’s mounting bolt 2 .

Take off the oil strainer 5 and clean.