s2250 Service Manual

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HOW TO USE THIS MANUAL CONTENTS
This manual describes effective maintenance procedure for
the S2-250 manufactured by DAELIM Motor Co., Ltd.
To ensure safety and optimal operating conditions of the
vehicle, carry out regular inspections according to the SERVICE INFORMATION 1
GENERAL
maintenance schedule (Section 2).
Sections 1 through 2 provide information on overall
vehicle; section 3, assembly and disassembly procedures
for external components, and section 4 describes
INSPECTIONS/ADJUSTMENTS 2
maintenance procedure for the engine, frame and electrical
systems. EXTERNAL PARTS 3
To facilitate use of this manual, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide. If you cannot find the cause of LUBRICATION SYSTEM 4
trouble, refer to Section 18: Troubleshooting.
FUEL SYSTEM 5
Contents of this manual and specifications are COOLING SYSTEM 6

subject to change without prior notice for
improvement of vehicle quality.
No part of this publication may be reproduced ENGINE REMOVAL/INSTALLATION 7
without written permission of DAELIM Motor Co., ENGINE
Ltd.,
LH.CRANK CASE COVER/TRANSMISSION 8
A.C. GENERATOR/STARTING CLUTCH 9
CYLINDER HEAD/VALVE 10
CYLINDER/PISTON 11
CRANK SHAFT/CRANK CASE 12
FINAL REDUCTION 13
FRONT WHEEL / FRONT FORK
ELECTRICAL SYSTEM FRAME
/ STEERING / BRAKE 14
REAR WHEEL / BRAKE 15
/ SUSPENSION / REAR SWING ARM
CHARGING SYSTEM 16
IGNITION SYSTEM 17
STARTING SYSTEM 18
LIGHTS / SWITCHES / HORN 19
WIRING DIAGRAM 20
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1. SERVICE INFORMATION
GENERAL SAFETY 1-1 TORQUE VALUES 1-12

SERVICE RULES 1-1 STANDARD TORQUE VALUES 1-13
1
CAUTION WHEN WIRING 1-5 SYMBOLS 1-13
SERIAL NUMBER LOCATION 1-9 LUBRICATION OIL 1-14
SPECIFICATIONS 1-10 WIRING DIAGRAM 1-15
GENERAL SAFETY
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the
recommended parts. chassis.
1-1
SERVICE INFORMATION
3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter
each part in the right place. pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data
remove the cleaning oil with compressed air. Apply oil during installation. When installing, return to the state
to seal face during installation. before removing.
7. Align the bolts to uniform the tightening points before 8. Bolts, nuts and pieces must be tightened from the bigger
tightening them when you don’t know the bolt length. diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
9. Check to see if the rubber part is worn out when 10. Recommended grease must be applied to or filled in
removing it and replace it if necessary. Some rubber part the specified place.
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
1-2
SERVICE INFORMATION
11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
be performed with the right tool. applied pressure when removing press-fitted the
bearing.
13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the
ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open-
• Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way
longitudinal hanging. that the face marked with manufacturer and size
•Wipe the ball bearing likely to have hanging with should direct to the outer axle.
cleaning oil.(except double-sided sealed type ball
bearing)
• Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
’
15. When blowing the ball bearing with compressed air 16. Install the snap ring so that chamfered side directs to
after cleaning, keep the race from rotating. High speed the load-applied side. After installation, check the
rotation of the race may damage the bearing. Prior to proper installation by rotating the snap ring.
installation, apply oil or grease to the bearing.
17. Check each part for proper tightening and operation 18. The brake fluid and coolant can damage the painted
after installation. plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
1-3
SERVICE INFORMATION
19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
• Pay attention not to bend or damage the lip.
• Apply the grease to the lip.
21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of
interior from the infiltration of dust. each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively. 24. Install the boots with the installing groove by inserting
Transformed or damaged cable may cause malfunction the boots into the groove.
or damage.
1-4
SERVICE INFORMATION
CAUTION WHEN WIRING

•Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord
When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of
around the connector. Connect the coupler to the the coupler. Pay attention not to open the cord terminal
connector with same color and same pin number. and contact the tester plug from the front of the coupler
•Identify the two-colored cord by main color first and in case of water-proof coupler.
then spriped color .
•Recheck the condition of contact, securing and

continuity of each part after maintenance.
•When connecting the battery, the plus terminal must be
connected first.
•After connecting the terminal, apply the grease to the
terminal.
•When disconnecting the battery, the minus terminal •Connect covers to the terminal after maintenance.
must be disconnected first.
•Make sure that the tool such as spanner do not contact
with the frame.
•If the fuse is short-circuited, find out the cause and •If there is rust in the terminal, remove the rust with sand
repair. Replace with the fuse having the specified paper prior to connecting.
capacity.
VALIDATION REMOVE
OF CAPACITY! THE
RUST!
1-5
SERVICE INFORMATION
•Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while
connecting. holding the coupler body. Pull while holding the wire
•Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
•The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
•Insert the lock of the coupler until the lock is fully

secured.
•Release the lock by inserting the coupler slightly and •Pay attention not to damage the vinyl cover of the
then narrowing connection to remove the coupler. coupler.
•Check to see if there is bended terminal and secure it to •If the wire harness coating is damaged, repair by
avoid disconnecting. winding vinyl tape or replace it.
•Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.
1-6
SERVICE INFORMATION
•Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start
inserted into the terminal. using the wiring driver and release the torque.
•The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then
direction but in case of the plain connector, the draining insert until the groove is locked.
opening must face at the sky direction. •When removing T-start from the frame, replace it with
the new one.
•Wire band must be secured firmly in the specified •Secure the wire harness firmly using the clamp.
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.
•In case of the weld clamp, do not clamp in the welded •When clamping the wire harness, make sure that the
part. harness is not contacted with the shaft or rotating part.
•When clamping the wire, pay attention not to contact •The wire harness must be routed without contacting
with hot part. with the end of the lamp or any sharp edge.
•The wire harness must be routed without contacting
with the end of the bolt or the piece.
1-7
SERVICE INFORMATION
•In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively.
the sharp edge, protect both parts with tube or tape.
NOT TO
PULL!
•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness
is not pressed by the parts.
•Do not twist the wire harness. •Wire the wire harness not to be pulled or expended
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
•Prior to using the tester, please read the manual care- •Do not drop or throw the parts especially
fully and understand the contents. semiconductor contained parts because these parts may
•When testing the resistance of the tester, the zero be damaged by the impact of the drop.
adjustment must be performed before testing.
Is this
measurement range or
configuration in accord
with the manual?
1-8
SERVICE INFORMATION
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION
1-9
SERVICE INFORMATION
SPECIFICATIONS
ITEM SPECIFICATIONS
OVERALL LENGTH 2,110 mm

OVERALL WIDTH 745 mm
OVERALL HEIGHT 1,356 mm
WHEEL BASE 1,481 mm
DIMENSIONS SEAT HEIGHT 760 mm
GROUND CLEARANCE 121 mm
DRY WEIGHT 164 kg
GROSS WEIGHT 294 kg
TYPE Underbone
FRONT SUSPENSION / STROKE Telescopic
REAR SUSPENSION / STROKE Swing arm
FRONT TIRE SIZE / TYPE 120 / 70 - 12 / Tubeless
REAR TIRE SIZE / TYPE 140 / 60 - 13 / Tubeless
TIRE PRESSURE 1 PERSON FRONT 2.00 Kgf / ㎠
REAR 2.00 Kgf / ㎠
2 PERSON FRONT 2.00 Kgf / ㎠
FRAME REAR 2.25 Kgf / ㎠
FRONT BRAKE Hydraulic disk
REAR BRAKE Hydraulic disk
FUEL TANK CAPACITY FULL CAPACITY 11ℓ
RESERVE CAPACITY 2.8ℓ
CASTER ANGLE 27。
TRAIL 87.1 mm
FRONT FORK /REAR FORK OIL CAPACITY 100/65 ㎠
TYPE Water cooled 4 cycle SOHC engine

CYLINDERS / ARRANGEMENT 1(Single cylinder), front angle 80。
BORE AND STROKE 72.7×60 mm
DISPLACEMENT 249 ㏄
COMPRESSION RATIO 10.3 : 1
VALVE TRAIN SOHC chain drive
OIL CAPACITY 1.1ℓAfter disassembly
0.95ℓAfter Oil filter change
ENGINE 0.9ℓAfter Oil change
LUBRICATION SYSTEM Forced pressure splash type
AIR CLEANER TYPE Paper Filter
CYLINDER COMPRESSION 15 kgf / ㎠ (600 rpm)
INTAKE VALVE OPEN 8。 BTDC
CLOSED 42。 ABDC
EXHAUST VALVE OPEN 33。 BBDC
CLOSED 1。 ATDC
VALVE CLEARANCE (COOLING-OFF PERIOD)
INTAKE 0.1 mm
EXHAUST 0.1 mm
1-10
SERVICE INFORMATION
ITEM SPECIFICATIONS
TYPE / VENTURI BORE CVK type/30 mm

CHOKE TYPE Butterfly
MAIN JET # 102
CARBURETOR PILOT SCREW INITIAL SETTING 2½
FLOAT LEVEL 18.5 mm
IDLE SPEED 1,700±100 rpm
CLUTCH TYPE Automatic Transmission

PRIMARY REDUCTION 2.8 (42/15)
DRIVE TRAIN
SECONDARY REDUCTION 2.79 (39/14)
IGNITION SYSTEM Full-Transistor

IGNITION TIMING F MARK BTDC 5。/ 1,700 ( rpm )
BATTERY TYPE / CAPACITY 12V 10AH (MF type)
SPARK PLUG NGK DPR 7EA-9
SPARK PLUG GAP 0.9 mm
STARTING SYSTEM Starter motor
HEADLIGHT ( HIGH / LOW ) 55/ 55W
POSITION LIGHT 5W
ELECTRICAL
WINKER LIGHTS ( FR / RR ) 10W×2/10W×2
SYSTEM
TAIL / STOP LIGHT 5/21W
HIGH-BEAM PILOT 3W
SPEEDOMETER LAMP 1.7W×2
WINKER PILOT 3W×2
TRUNK LAMP 1.4W×1
LICENSE LAMP 5W×1
COOLANT/MIXTURE RATIO LG-Caltex Oil CX AF EQUIV/40%

COOLANT CAPACITY RADIATOR AND ENGINE/AT REPLACING 1.4ℓ/ 1.0ℓ
COOLING THERMOSTAT VALVE OPEN 80 2 C
SYSTEM
RADIATOR CAP VALVE OPEN PRESSURE 0.9 0.15kgf/cm2
COOLING FAN DRIVING METHOD/OPERATING TEMPERATURE Motor / 90 3 C
FUEL CONSUMPTION RATIO 43km/ (50km/h)

ENGINE MAXIMUM POWER 22PS/7000rpm
THE ENGINE MAXIMUM TORQUE 2.2kgf m
OTHERS ENGINE OIL SAE:15W 40# or 10W 30, API:SJ
GENERATOR TYPE Triple phase wave
HORN 100 5dB
1-11
SERVICE INFORMATION
TORQUE VALUES
ENGINE
ITEM Q’TY THREAD DIA TORQUE VALUE REFERENCE

(mm)
CYLINDER HEAD BOLT A 2 8 3.0 kgf·m
CYLINDER HEAD BOLT B 2 8 3.0 kgf·m
OIL FILTER SCREEN CAP 1 30 1.47 kgf·m
EXHAUST MUFFLER JOINT LOCK NUT 2 8 2.2 kgf·m
CYLINDER HEAD CAP NUT 4 8 2.45 kgf·m
VALVE ADJUST LOCK NUT 2 5 1.1 kgf·m
CAM CHAIN TENSIONER SLIPER BOLT 1 6 1.0 kgf·m
OIL BOLT 1 12 1.27 kgf·m
CLUTCH OUTER NUT 1 12 5.5 kgf·m
CLUTCH DRIVE PLATE NUT 1 12 5.5 kgf·m
FLYWHEEL NUT 1 14 5.88 kgf·m
OIL PUMP BOLT 2 5 0.5 kgf·m
CYLINDER HEAD COVER BOLT 4 6 1.18 kgf·m
SPARK PLUG 1 10 1.72 kgf·m
WATER PUMP IMPELLER 1 6 1.18 kgf·m
CAM CHAIN TENSIONER BOLT 1 8 1.18 kgf·m
MUFFLER TORQUE BOLT 2 8 2.8 kgf·m
1 10 4.0 kgf·m
FRAME
ITEM Q’TY THREAD DIA TORQUE VALUE REFERENCE

(mm)
STEERING STEM NUT 1 26 7.0 kgf·m
STEERING TOP THREAD NUT 1 26 0.25 kgf·m
FORK PIPE BOTTOM BRIDGE 1 10 7.5 kgf·m Initial torque
HANDLE POST 2 10 6.0 kgf·m
FRONT AXLE NUT 1 12 6.0 kgf·m
FRONT CALIPER BRACKET BOLT 2 8 3.1 kgf·m
FRONT MASTER CYLINDER HOLDER BOLT 2 6 1.2 kgf·m
FRIBT DISK PLATE BOLT 3 8 4.25 kgf·m
REAR AXLE NUT 1 16 12.5 kgf·m
REAR CALIPER BRACKET BOLT 2 8 3.1 kgf·m
REAR MASTER CYLINDER HOLDER BOLT 2 6 1.2 kgf·m
REAR DISK PLATE BOLT 3 8 4.25 kgf·m
SPEEDOMETER GEARBOX SCREW 1 5 0.43 kgf·m
FRONT FORK BOLT 2 22 2.25 kgf·m
REAR CUSHION UPPER BOLT 2 10 4.0 kgf·m
REAR CUSHION UNDER BOLT 2 10 4.0 kgf·m
REAR CUSHION LOCK NUT 2 10 3.5 kgf·m
ENGINE HANGER UPPER BOLT 2 12 5.25 kgf·m
ENGINE HANGER LOWER BOLT 1 10 4.5 kgf·m
MAINSTAND BOLT 2 10 4.0 kgf·m
SIDESTAND PIVET SEREW 1 10 1.5 kgf·m
SIDESTAND PIVET NUT 1 10 4.5 kgf·m
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.
1-12
SERVICE INFORMATION
STANDARD TORQUE VALUES
ITEM TORQUE VALUE ITEM TORQUE VALUE
5mm BOLT, NUT 0.5 kgf·m 5mm SCREW 0.4 kgf·m

6mm BOLT, NUT 1.0 kgf·m 6mm SCREW 0.9 kgf·m
8mm BOLT, NUT 2.2 kgf·m 6mm FLANGE BOLT, NUT 1.2 kgf·m
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.
SYMBOL MEANING SYMBOL MEANING

Indicates important work. Minor injury or
Indicates dangerous area. Serious vehicle part damage may result if instruction
accident may result if instructions are not are not followed.
followed. Indicates general safety matters. Provides
safety and appropriate handling procedures.
The following symbols indicate oil adding, oil change, or parts.
SYMBOL MEANING
OIL Add oil. If there is no specific oil indicated, use the designated or recommended engine oil.
GREASE Apply grease
(⇨3-1) Indicates reference page. (example : Refer to page 3-1)
The following abbreviations are used in this manual.
ASS’Y ASSEMBLY
LH. Left
RH. Right
1-13
SERVICE INFORMATION
LUBRICATION OIL
ENGINE
LUBRICATION POINTS REFERENCE

VALVE GUIDE/VALVE STEM OPERATING PARTS SAE15W-40 or SAE10W 30#
CAM SHAFT CONTACT AREA API SE, SF or SG
CAM SHAFT DRIVE CHAIN
CYLINDER LOCK BOLT AND NUT
PISTON AROUND AND PISTON RING GROOVE
PISTON PIN AROUND
CONNECTING ROD, PISTON PIN HOLE
CONNECTING ROD BIG END
CRANK SHAFT
CRANK SHAFT ONE-WAY CLUTCH OPERATING PARTS
OIL PUMP DRIVE CHAIN
STARTER REDUCTION GEAR PARTS
COUNTER SHAFT GEAR PARTS
FINAL GEAR PARTS
BEARING OPERATING PARTS
O-RING SURFACE
OIL SEAL RIP
STARTER IDLE GEAR

FRICTION SPRING OPERATING PARTS/SHAFT OPERATING PARTS HEAT-RESISTANT GREASE
SHAFT OPERATING PARTS
STARTER SPINDLE OPERATING PARTS
STARTER ONE-WAY CLUTCH THREAD LOCTITE APPLIES
A.C. GENERATOR CONNECTOR

GLUE
TRANSMISSION CASE BLEEDER TUBE
1-14
SERVICE INFORMATION
WIRING DIAGRAM
WATER PASS TUBE A

HOSE CLIP
WATER PASS TUBE C
E.M.I. UNIT COMP.
RADIATOR HOSE A BATTERY (12V 10AH)
RESISTER COMP.
HORN
HEATER CONTROLLER
FUEL NECK EARTH WIRE IGNITION UNIT COMP.
WATER PASS TUBE A
L. SEAT LOCK CABLE
E.M.I. CORD (WIRE) I.G COIL
E.M.I. CORD (FAN MOTOR) AUTO CHOCK COUPLER
SIDE STAND SWITCH COUPLER
WATER PASS TUBE B
THROTTLE POSITION
FUEL BREATHER TUBE SENSER COUPLER
TRANK LAMP WIRE
FUEL UNIT COUPLER DRAIN TUBE

AIR CLEANER TUBE(AIR CLEANER)
THEROMO SWITCH WIRE

WATER PASS TUBE A
REGULATOR RECTIFIER RADIATOR CAP HOSE

HEADLIGHT CONTROL UNIT
STARTER MAGNETIC SWITCH
FUEL TUBE (CARBURETOR)

FUEL TUBE (FUEL TANK)
FUEL TUBE (INSULATOR)
LICENSE LAMP WIRE
RADIATOR HOSE A SPEEDOMETER CABLE
RADIATOR HOSE B
FR. BRAKE HOSE
A.C.G. COUPLER FUEL STRAINER
STARTER MAGNETIC
SWITCH WIRE
EARTH CABLE
RR. STAY
WATER PIPE A
RR. BRAKE HOSE WATER PIPE B
WATER HOSE A
STARTER MOTOR CABLE WATER HOSE B
WATER HOSE C
A.C.G CORD
1-15
SERVICE INFORMATION
E.M.I. UNIT COMP.

HORN WIRE
WATER PASS TUBE B
E.M.I. CORD(WIRE HARNESS)
THROTTLE CABLE
WATER PASS TUBE A WATER PASS TUBE A
E.M.I. CORD(FAN MOTOR)
RADIATOR CAP HOSE

RADIATOR HOSE A
THERMO SWITCH WIRE

SEAT LOCK CABLE
SEAT LOCK CABLE
COMB METER COUPLER
THERMO SWITCH WIRE
RADIATOR HOSE B
RADIATOR HOSE A
WATER PASS TUBE B
WATER PIPE A
WATER PIPE B
WATER PASS TUBE B

RR. BRAKE HOSE PIPE
LH. SEAT LOCK CABLE
RH. SEAT LOCK CABLE
FUEL TUBE
FUEL STRAINER COMP.
FUEL WATER PASS TUBE B
TUBE CLIP
WATER HOSE B RR. STAY
WATER HOSE A WATER PIPE A
WATER HOSE CLAMP WATER PIPE B
RR. BRAKE HOSE PIPE

WATER PASS TUBE B
1-16
SERVICE INFORMATION
HEAD LIGHT RELAY
THERMO SWITCH RELAY
WINKER RELAY
EARTH CABLE
BATTERY BOX
COUPLER
*NOTE
- WHITE COLOR : EXPORT USE ONLY
- BLACK COLOR : DOMESTIC USE ONLY
HEAD LIGHT CONTROLLER
REGULATOR RECTIFIER
START MAGNETIC
SWITCH
REGULATOR
COUPLER 2EA
BATTERY EARTH CABLE
HEADLIGHT CONTROLLER CODE
1-17
SERVICE INFORMATION
WINKER RELAY
THERMO SWITCH RELAY
HEADLIGHT RELAY
FUSE BOX ASS'Y
BATTERY BOX
HEADLIGHT RELAY
BATTERY EARTH CABLE
RESERVE FUSE
BATTERY BOX
FUSE BOX
1-18
SERVICE INFORMATION
FUEL TUBE (CARBURETOR)
TRUNK LAMP WIRE

RR. BRAKE HOSE
WATER HOSE B
THERMO SENSOR WIRE
WATER HOSE A
NOISE SUPPRESSOR CAP
AIR CLEANER BREATHER TUBE

(AIR CLEANER)
AUTO CHOCK CORD CARBURETOR DRAIN TUBE
I.G. COIL CARBURETOR BREATHER TUBE

SIDE STAND SWITCH COUPLER
THROTTLE POSITION COUPLER

CARBURETOR HEATER CORD
START MAGNETIC SWITCH
START MOTOR CABLE
FUEL PUMP
1-19
MEMO

2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION ··· 2-1 DRIVE BELT· ·········· 2-7

MAINTENANCE SCHEDULE· ·· 2-3 COOLING LEVEL INSPECTION · 2-8
FUEL LINE· ········· 2-4 COOLANT REPLACEMENT· ··2-8
2
THROTTLE GRIP OPERATION· ··2-4 BRAKE FLUID· ········· 2-9
AIR CLEANER ······· 2-5 BRAKE PAD· ·········· 2-9
SPARK PLUG· ··········2-5 BRAKE SYSTEM ········ 2-9
VALVE CLEARANCE· ······2-5 SIDE STAND· ·········· 2-9
CYLINDER COMPRESSION PRESSURE ·2-6 SUSPENSION· ········· 2-10
CARBURETOR IDLING ···· 2-6 ·· 2-10
BOLTS, NUTS, FASTENERS·
FINAL REDUCTION GEAR OIL· ··2-6 WHEELS / TIRES········· 2-11
GEAR OIL REPLACEMENT· ···2-7 STEERING HEAD BEARING··· 2-11
SERVICE INFORMATION
•The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
•Refer to 2~3, 2~4 with respect to Engine oil and oil filter.
•Stand the main stand prior to beginning work.
SPECIFICATIONS
THROTTLE GRIP PLAY 2- 6mm
SPARK PLUG DPR7EA-9
SPARK PLUG GAP 0.9mm
IN 0.1mm
VALVE CLEARANCE
EX 0.1mm
CARBURETOR IDLE SPEED 1,700±100rpm
CYLINDER COMPRESSION PRESSURE ㎠
15±2kgf/㎠
DISASSEMBLY 1.1
ENGINE OIL
REPLACE 0.9
DISASSEMBLY 0.2
GEAR OIL
REPLACE 0.18
RADIATOR CAPACITY 1,000 20cc
COOLANT CAPACITY 1,400 20cc
RESERVE TANK CAPACITY 400 20cc
2-1
INSPECTIONS / ADJUSTMENTS
TIRES
FRONT TIRE ㎠
2.00kgf/㎠
DRIVER ONLY
COLD TIRE REAR TIRE ㎠
2.00kgf/㎠
PRESSURE DRIVER AND A FRONT TIRE ㎠
2.00kgf/㎠
PASSENGER REAR TIRE ㎠
2.25kgf/㎠
FRONT TIRE 120/70 - 12 (Tubeless)
TIRE SIZE
REAR TIRE 140/60 - 13 (Tubeless)
2-2
MAINTENANCE SCHEDULE
● Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s
manual.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
R : REPLACE L : LUBRICATE C : CLEAN
ODOMETER READING(NOTE 1)
FREQUENCY
1,000Km 4,000Km 8,000Km 12,000Km 16,000Km REMARK
ITEM
1MONTH 6MONTH 12MONTH 18MONTH 24MONTH
ENGINE OIL R(Brand new) R R R R
300Km
ENGINE OIL FILTER SCREEN I I I I
＊ FUEL FILTER R R R R R
GEAR OIL R(Brand new) R R
300Km
＊ VALVE CLEARANCE I I I I
＊ CARB. IDLE I I I I
AIR CLEARER I I I I I
SPARK PLUG I I I I I
BRAKE SYSTEM I I I I I
＊ DRIVE BELT I I I I
＊ SUSPENSION I I I I
＊ NUTS, BOLTS, FASTENERS I I I I I
TIRE I I I
STEERING HEAD BEARING I I I I I
BRAKE FLUID Daily check priorto driving
RADIATOR COOLANT I I R I R
RADIATOR CORE I I I I I
RADIATOR CAP I I I I
BRAKE LEVER I I I I
BRAKE PAD WEAR I I I I I
I I I I
＊ If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology
contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections.
To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops,
dealers or other designated repair shops.
NOTE
1. After the odometer reading exceeds 12,000km, repeat maintenance service at intervals indicated in the table.
2. After riding in areas with high humidity or pollution, carry out maintenance service more frequently.
3. Replace every 2 years. Proper technology is required for this job.
2-3
FUEL LINE(FUEL TUBE)

● Remove the luggage box.
● Check the fuel tube of the fuel auto cock connected to
the fuel tank and carburetor. If the fuel tube is cranked,
damaged or leaks, replace it.
THROTTLE GRIP OPERATION

● Check if the throttle grip operates smoothly in any
steering position.
● If the throttle grip does not operate properly, lubricate
the throttle cable.
● If the throttle grip does not operate properly, check the
throttle cable for aging, damage or kinking.
● Check the throttle grip free play.
FREE PLAY : 2~6mm
● For main adjustment, loosen the lock nut and turn

adjuster.
● After adjusting, tighten lock nut. After adjustment is
completed, recheck the throttle grip free play.
ADJUSTRING
ADJUSTRING NUTS
ADJUSTRING NUTS
NUTS
LOCK
LOCK NUTS
LOCK NUTS
NUTS
● For simple adjustment, use the adjuster under the

throttle grip. RH.
● Remove the Rubber.
● Loosen the lock nut and turn the adjuster.
2-4
AIR CLEANER
● Loosen the 6 screws securing the air cleaner case cover,
remove it.
● Loosen the 2 screws securing the air cleaner element
holder, remove it.
● Remove the air cleaner element.

● Wash away any accumulated dust or dirt, by gently
squeezing it in non flammable or high flash point
solvent.
•Using gasoline or low flash point solvents for

cleaning parts may result in a fire or explosion.
CHECK GAP, SPARK PLUG

DEPOSITS 0.6 ~ 0.7mm ● Remove the plug maintenance cover.
● Remove the spark plug cap and disassemble the plug.
● Check the plug for damage, contamination or deposits.
● If the spark plug is severely contaminated or damaged,
raplace with a new one. If the plug can be reused after
removing only the carbon, use plug cleaner and wire
CHECK WASHER
FOR DAMAGE
brush to clean the plug.
● Always use a feeler gauge to check the gap.
CHECK FOR
GENUINE PLUG : DPR7EA9
CRACKS
SPARK PLUG : 0.9~1.0mm
TORQUE VALUE : 1.47~1.96kgf·m
•Make sure there is no dirt or debris on the seat of the

spark plug hole before inserting the spark plug.
•To prevent damage to the cylinder head, hand-
tighten the spark plug before using a wrench to
tighten to the specified torque.
•Do not overtighten the spark plug.
VALVE CLEARANCE
● Remove the cylinder head cover.
2-5
•Inspect and adjust the valve clearance when the

engine is cool. (under 35 °
C / 95 °F)
•Remove the cylinder head cover.
•Turn the flywheel counterclockwise, and align the
“T” mark on the flywheel with the index mark on
the RH. crank case cover.
•The piston at this time must be at the top dead center
of the compression stroke.
● Measure valve clearance with a feeler gauge.

VALVE CLEARANCE : Intake : 0.1mm
Exhaust : 0.1mm
● Loosen the lock nut with a valve wrench, and set valve
clearance to a prescribed level by turning the adjusting
screw with a valve adjusting wrench.
● After setting clearance to the prescribed level, hold the
adjuster screw with a valve adjusting wrench, and
tighten the lock nut.
TORQUE VALUES : 1.1kgf·m
TOOLS : WRENCH 8X9mm
ADJUSTING WRENCH B
FEELER GAUGE
● Measure the valve clearance again.

● Install the cylinder head cover and tighten the bolts.
TORQUE VALUES : 1.0 kgf·m
CYLINDER COMPRESSION PRESSURE

● Start and warm up the engine.
● Remove the plug maintenance cover.
● Stop engine, and remove the spark plug cap and spark
plug.
● Install a compression gauge.
● Open the throttle completely, and crank the engine with
the starter motor until the gauge reading rising.
TOOL : COMPRESSION GAUGE
•The maximum reading is usually reached within 4~7

seconds.
COMPRESSION PRESSURE : 15±2 kgf/cm2
● If the pressure is low, check the following:

-Inadequate valve clearance adjustment
-Valve leakage
-Leakage from the cylinder head gasket
-Piston/cylinder worn
● If pressure is high, check the following:
-Carbon deposits on the piston head, and cylinder head.
2-6
CARBURETOR IDLE SPEED

● Remove the plug maintenance cover.
•Verify all engine adjustments satisfy specifications.

Make adjustments, if necessary.
•Heat the engine to make accurate idling inspection
and adjustment. Stand the vehicle on the main stand.
•Turn the throttle stop screw and make adjustments to
prescribed idling speed.
IDLING SPEED: 1,700±100rpm
OIL
OIL
OIL CHECK
CHECK
CHECK BOLT
BOLT
BOLT FINAL REDUCTION GEAR OIL
•Erect the main stand prior to beginning work.
● Erect the main stand prior to beginning work.

● Stop the engine and remove the oil check bolt.
● Check the oil level through the oil check hole.
● If the oil level is below, fill the oil (SAE90#).
● Install and tighten the oil check bolt.
•Make sure that the sealing washer is good condition.
GEAR OIL REPLACEMENT

● Remove the oil check bolt.
● Remove oil drain bolt and drain oil completely.
● Install and tighten the oil drain bolt.
TORQUE VALUE : 0.98kgf·m
•Make sure that the sealing washer is good condition.

● Fill the recommended oil(SAE90#).
OIL
OIL DRAIN
OIL DRAIN BOLT
DRAIN BOLT
BOLT GEAR OIL CAPACITY
At disassembling: 200cc At replacing: 180cc
DRIVE BELT
● Remove the L.crankcase cover.
● Check the drive belt for wear or damage. Check
scheduled maintenance period, replace the new drive
belt if possible.
2-7
COOLANT LEVEL INSPECTION

● Erect the main stand prior to beginning work.
● Check the coolant level of the reserve tank.
● The level should be between the “UPPER” and
“LOWER” level lines.
● Fill the coolant with the reserve tank up to the
“F” (upper level).
•Unless the coolant is refilled or replaced, the engine

temperature too high or low.
•Fill to the “F”(UPPER LEVEL) line.
COOLANT REPLACEMENT
● Remove the drain bolt and drain the coolant. (Tilt the
vehicle to the right in order to assure complete and
rapid draining.)
● Remove the radiator cap.
● Install the drain bolt.
● Fill the radiator with new coolant.
COOLANT CAPACITY : 1,400±20cc
RADIATOR CAPACITY : 1,000±20cc
RESERVE TANK CAPACITY : 400±20cc
● Start the engine. Bleed air from the coolant and check
the level of coolant.
● Install the radiator cap.
● Fill the coolant with the reserve tank up to the upper
level.
2-8
BRAKE FLUID
● Remove the brake fluid cover.
● Check the oil level inside the front brake reservoir. If
the oil level is near the lower limit line, remove the
reservoir diaphragm and fill DOT 3 and DOT 4 brake
fluid to the top limit line.
● If the brake fluid reaches the lower limit line, check the
entire brake system for leaks.
•Brake fluid will damage painted, plastic or rubber

parts.
•Mixing incompatible fluids can impair braking
efficiency.
•A leak in the brake system can lead to reduced
braking effiency and possible loss of braking ability.
BRAKE PAD/SHOE
BRAKE PAD REPLACEMENT
● Check the brake pads for wear.
● If the red mark on the pad reaches the brake disc,
replace the pads.
•Replace the brake pads in sets.
BRAKE SYSTEM
● Check the front brake hose for cracks or damage. If any
leaks are found, replace immediately.
● Check the brake rod for looseness or damage, and
replace it if necessary.
BRAKE LEVER FREE PLAY

● Check the free play after pulling the lever.
FRONT : 10~20mm
REAR : 10~20mm
2-9
SIDE STAND
● Erect the main stand.
● Pull the lower end of the side stand, and see if it moves
freely.
● If the side stand does not move smoothly, apply grease
to the pivot area.
● If the side stand moves too freely, check the side stand
spring.
● Check the axial movement of the side stand.
● Check the side stand ignition cut-off switch :

-Put the side stand up.
-Start the engine.
-Lower the side stand. The engine should stop as you
put the side stand down.
● If there is a problem with the system, check the side
stand switch.
SIDE STAND
SWITCH
SUSPENSION
•Do not ride motor cycle with an unsatisfactory

suspension. Loose or worn suspension parts will lead
to deterioration in the vehicle’s safety and operation
efficiency.
FRONT WHEEL
● Hold the brake lever, and compress the front cushion
up and down several times to check the operating
conditions.
● Check the front fork for oil leakage, parts damage or
looseness.
REAR WHEEL
● Compress the near cushion up and down several times
to check the operating conditions.
● Check the rear fork for oil leakage, parts damage or
looseness.
2-10
BOLTS, NUTS, FASTENERS

● Check all nuts and bolts of the frame during the regular
maintenance to check if they meet the prescribed
torque value.
F ● Check all pins, clips, hose clamps and cable stays.
WHEELS/TIRES
•Check the tire pressure when the tires have been

cooled off. Check the tread (the part making contact
with the road surface) and side for wear, cracks or
damage. Replace damaged tires.
STANDARD PRESSURE
㎏f/㎠ (kpa)
ITEM FRONT WHEEL REAR WHEEL
DRIVER ONLY 2.00(200) 2.00(200)
DRIVER AND A PASSENGER 2.00(200) 2.25(225)
● Check the tread depth at the tire center.

● If the tread depth has reached the service limit, replace
the tire.
SERVICE LIMIT : 0.5mm
STEERING HEAD BEARING
•Check the cable if it interferes with the handle

operation.
● Lift the front wheel and check if the handle moves right
and left smoothly. If the handles move heavily, check if
the cable or electric cord interferes with the handle. If
the hadle moves satisfactorily, adjust the steering head
bearing.
2-11
MEMO

3. EXTERNAL PARTS
SERVICE INFORMATION···· 3-1 UNDER COVER· ········ 3-5

SEAT··············· 3-2 HANDLE COVER· ······· 3-5
········· 3-2
PILLION SEAT· FRONT COVER· ········ 3-5
·· 3-2
LUGGAGE BOX TOP COVER· WINDSCREEN· ········ 3-6
REAR GRIP··········· 3-2 ·· 3-6
FRONT UNDER COVER A·
3
LUGGAGE BOX· ········ 3-3 ·· 3-6
FRONT UNDER COVER B·
CENTER COVER· ······· 3-3 INNER COVER········· 3-7
BODY SIDE COVER······ 3-3 SPEEDOMETER COVER··· 3-7
BODY COVER· ········· 3-4 FRONT FENDER· ······· 3-8
REAR FENDER· ········ 3-4 REAR WHEEL MUDGUARD·· 3-8
FLOOR SIDE COVER······ 3-4 MUFFLER· ··········· 3-8
FLOOR PANEL········· 3-4 ············ 3-8
EX. PIPE·
SERVICE INFORMATION
● This section describes external parts removal/installation.

● Do not apply unreasonable force when disassembling covers, to prevent possible damage.
● A muffler is hot. Do not service it immediately after the engine is stopped.
3-1
EXTERNAL PARTS
SEAT
● Release the seat lock by turning the main switch key to
open the seat.
● Loosen the flange nuts and remove the seat.
● Install in the reverse order of removal.
PILLION SEAT
open seat.
● Pull the pillion seat forward and remove it.
LUGGAGE BOX TOP COVER

● Loosen the 5 Tapping screws and remove the top cover.
REAR GRIP
● Remove the rear grip cap (R.L)
● Loosen the 4 special bolts.
3-2
EXTERNAL PARTS
LUGGAGE BOX
● Remove the seat.
● Remove the pillion seat.
● Remove the luggage box top cover.
● Loosen the screws on the seat catch.
● Loosen the open stay nuts.
● Loosen the washer bolts.
● Remove the wire for the trunk lamp.
CENTER COVER
● Remove the floor mat.
● Loosen the 2 washer screws and 1 special screw.
BODY SIDE COVER

● Remove the center cover.
● Loosen the 2 washer screws.
● Loosen the 2 tapping screws securing the body side
cover on the inside of the body cover.
•Remove the air duct cover in dissembling LH. body

side cover.
3-3
EXTERNAL PARTS
BODY COVER
● Remove the Rr. Grip R/L
● Remove the following parts
- Seat
- Luggage box
- Center cover
- Body side cover
● Loosen the special screw
● Loosen the body cover clip (R/L)
● Remove the wire for the tail light and pull the body
cover backward.
● Install in the reverse order of removal
REAR FENDER
● Remove the body cover
● Loosen the 4 washer bolts and remove the Rr. fender
FLOOR SIDE COVER

● Remove the center cover
● Loosen the 3 body cover clips, 2 washer screws and 1
tapping screw in back side of left
● Remove the floor mat
FLOOR PANEL
● Remove the floor side cover
● Loosen the 6 washer bolts
● Pull the floor panel backward to remove it
3-4
EXTERNAL PARTS
UNDER COVER
● Loosen the 4 special screws (R/L, 2Ea for each) to
remove the under cover
HANDLE COVER
● Loosen the washer screw and tapping screw securing
the under handle cover
● Loosen the screw in the top of the upper handle cover
● Remove the under handle cover
● Loosen the 2 screws (R/L) in the upper handle cover
securing the steering handle
FRONT COVER
● Loosen the 2 tapping screws securing the fornt cover
● Loosen the 2 tapping screws securing the inner cover
3-5
EXTERNAL PARTS
WINDSCREEN
● Remove the front cover
● Loosen the 4 washer bolts and remove the windscreen
FRONT UNDER COVER A

● Remove the front cover and windscreen
● Loosen the 2 washer bolts in the top of the front under

cover
● Loosen the 2 tapping screws
FRONT UNDER COVER B

● Loosen the 2 flange bolts
3-6
EXTERNAL PARTS
INNER COVER
● Remove the front cover and windscreen
● Remove the coolant reserve tank
● Remove the fuel tube clip
● Remove the breather tube
● Loosen the 3 screws securing the inner cover
● Remove the bag holder
● Loosen the 2 tapping screws securing the speedometer
cover
SPEEDOMETER COVER
● Remove the speedometer cable
● Remove the coupler and wire
● Loosen the 2 tapping screws secring the speedometer
cover
3-7
EXTERNAL PARTS
FRONT FENDER
● Loosen the 4 screws (R/L, 2Ea for each)
REAL WHEEL MUDGUARD

● Loosen the 2 flange bolts of RH.
● Loosen the flange bolt securing the air cleaner and
mudguard
● Remove the air cleaner
● Loosen the washer bolt securing the mudguard
MUFFLER
● Loosen the muffler flange bolt securing Ex. pipe comp.
● Loosen the 3 bolts securing the Rr. Fork
● Remove the Ex. muffler comp.
•Never performing the maintenance of the muffler

right after stopping the vehicle because the muffler is
extremely hot.
EX. PIPE
● Loosen the 2 cap nuts securing the cylinder comp.
● Pull the Ex. Pipe comp. downward to remove it
•Replace the packing when assemblying the muffler

and Ex. pipe comp.
3-8
MEMO

LUBRICATION SYSTEM
ROCKER ARM SHAFT
CRANK SHAFT
OIL FILTER SCREEN OIL PUMP
4-0
4. LUBRICATION SYSTEM
SERVICE INFORMATION ····4-1 ····· 4-3

ENGINE OIL CHANGE·
····· 4-2
TROUBLESHOOTING· OIL PUMP ··········· 4-4
ENGINE OIL LEVEL INSPECTION ·4-3 · 4-6
OIL PUMP ASS’Y ASSEMBLY·
SERVICE INFORMATION 4
GENERAL SAFETY
1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
2. Used engine oil may cause skin cancer if repeatedly left in contect with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after
handling the used oil.
3. The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
1.1ℓ (After disassembly)
OIL CAPACITY 0.9ℓ (After Oil change)
0.95ℓ (After Oil filter change)
API service classification : SJ grade

Viscosity : SAE10W-30/15W 40#
RECOMMENDED (Use appropriate type of oil with viscosity satisfying
OIL the atmospheric temperature
In your riding area based on the table shown on the
right side.)
-10 0 10 20 30 40℃
4-1
LUBRICATION SYSTEM
TROUBLESHOOTING
Oil level low
•Oil consumption.
•External oil leaks.
•Worn piston ring or incorrect piston ring installation.
•Worn valve guide or seal.
Oil contamination
•Oil or filter not changed often enough.
•Faulty head gasket.
•Worn piston rings.
Low or no oil pressure

•Clogged oil orifice.
•Incorrect oil being used.
4-2
LUBRICATION SYSTEM
ENGINE OIL LEVEL INSPECTION

OIL
OIL LEVEL
OIL LEVEL GAUGE
LEVEL GAUGE
GAUGE
● Erect the motorcycle on the main stand.
● Warm up the engine to heat the engine oil to an
appropriate level.
● Stop the engine, and check the oil level line on the
sight-glass installed on the LH. crank case cover.
● If the oil level is between the lower and higher sight-
glass oil level line, oil level is satisfactory. If the oil
level is below or near the lower level mark, add the
recommended engine oil.
ENGINE OIL CHANGE
•To completely and rapidly drain engine oil, warm up

engine and erect the motorcycle on its side stand.
● Loosen the oil drain plug bolt and drain engine oil.
● Tighten the oil drain plug bolt.
TORQUE VALUE : 1.4 kgf·m

OIL
OIL
OIL DRAIN
OIL DRAIN BOLT
DRAIN BOLT
DRAIN BOLT
BOLT
•It is extremely important to replace oil filter or clean

the oil filter screen at the first maintenance interval
(after 1,000Km).
•Clean the oil filter screen every 4,000Km.
•Clean the filter screen with fresh cleaning oil.
•Check the hole cap O-ring for satisfactory condition.
•Tighten the hole cap with specified tightening
torque.
TAPPET
TAPPET ADJUSTING
TAPPET ADJUSTING HOLE
ADJUSTING HOLE CAP
HOLE CAP
CAP
● Loosen the special screw, remove the plug maintenance
cover.
● Fill the recommended oil after opening oil filter cap of
cylinder head cover.
OIL CAPACITY : 1.1ℓ(After disassembly)

0.9ℓ(After Oil change)
0.95ℓ(After Oil filter change)
● API service classification : SJ grade.

● Start the engine and keep it idle for a few minutes.
● Stop the engine and check the oil level. If the oil level
is low, add the recommended engine oil.
● Check on oil leaks.
4-3
LUBRICATION SYSTEM
OIL PUMP
REMOVAL
● Drain cooling water.
● Remove the following parts.
- RH. crank case cover
- A.C generator
- Starting clutch gear comp
- Oil seperator cover and attaching bolt
OIL
OIL
OIL SEPERATOR
SEPERATOR
SEPERATOR COVER
COVER
COVER
● Remove the circlip.

OIL PUMP
OIL
OIL PUMP DRIVE
PUMP DRIVE SPROCKET
DRIVE SPROCKET
SPROCKET
● Remove the oil pump drive sprocket.
● Remove the oil pump drive sprocket chain.
CIRCLIP
CIRCLIP
CIRCLIP
● Loosen the 2 oil pump bolts.

OIL
OIL
OIL PUMP
PUMP
PUMP ● Remove the oil pump.
BOLTS
BOLTS
BOLTS
OIL PUMP DISASSEMBLY

●Loosen the screw securing the oil pump plate.
●Remove the oil pump body and the oil pump plate.
●Clean the oil pump body, inner and outer rotors with
fresh cleaning oil.
4-4
LUBRICATION SYSTEM
OIL PUMP INSPECTION

●Assemble the inner and outer rotors to the oil pump
body.
●Measure the pump body clearance.

TOOL : FEELER GAUGE
●Measure the rotor tip clearance.
●Measure the pump side clearance.
OIL PUMP ASSEMBLY

●Clean all parts with fresh cleaning oil.
●Install the inner and outer rotors to the pump body.
●Assemble the pump shaft with dowel pin.
4-5
LUBRICATION SYSTEM
● Install in accordance with the hole of the dowel pin
and pump cover.
● Tighten the pan screw.
•After installing, check the oil pump to operate

smoothly.
OIL PUMP INSTALLATION

ARROW
ARROW
ARROW MARK
MARK
MARK OIL
OIL PUMP
OIL PUMP
PUMP
●Tighten the 2 bolts to the oil pump and oil separetor.
●Check the pump shaft to rotate smoothly.
●Aligh the arrow mark of the oil pump.
BOLTS
BOLTS
BOLTS
OIL PUMP
PUMP DRIVE
DRIVE SPROCKET
SPROCKET
●Install the pump chain on the oil pump drive sprocket.
OIL
OIL PUMP DRIVE SPROCKET
●Install the circlip aroud the pump shaft.
CIRCLIP
CIRCLIP
CIRCLIP
●Install the oil separetor cover.

OIL
OIL
OIL PUMP
PUMP
PUMP CABLE
CABLE
CABLE STAY
STAY
STAY
●Install the starting clutch gear comp.
OIL
OIL
OIL SEPERATOR
SEPERATOR
SEPERATOR COVER
COVER
COVER
4-6
MEMO

FUEL SYSTEM
5-0
5. FUEL SYSTEM
SERVICE INFORMATION ·· 5-1 JETS/SCREW REMOVAL· ·· 5-6

TROUBLESHOOTING ·····5-2 AUTO BYSTARTER INSPECTION
FUEL TANK········· 5-3 /REMOVAL·········· 5-7
CARBURETOR ··· 5-3 FLOAT LEVEL········ 5-7
VACCUM CHAMBER REMOVAL· ·5-4 · 5-8
AIR CUT-OFF VALVE (A.C.V)·
·5-5
VACCUM PISTION INSPECTION· ACCELERATING PUMP· ··· 5-9
FLOAT CHAMBER REMOVAL· ·· 5-5 ········ 5-9
FUEL PUMP·
··· 5-6
FLOAT VALVE INSPECTION· 5
SERVICE INFORMATION
GENERAL SAFETY
● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore,
the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas.
● Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly
ventilated area.
● Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions.
● Pay particular attention to the position of O-ring. Replace with new ones when disassembled.
● If it is desired to store a vehicle for a period longer than 3 weeks, drain gasoline out of the carburetor float chamber.
Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits, and idling may
become unstable.
SPECIFICATIONS
FUEL TANK CAPACITY : 11ℓ
RESERVE FUEL CAPACITY: 2.8ℓ
CARBURETOR
ITEM STANDARD
TYPE/THROTTLE BORE CVK 30
MODEL MARK CVK056A
MAIN JET No. #102
PILOT SCREW OPENING 2½±½
FLOAT LEVEL 18.5mm
IDLING SPEED 1,700±100rpm
TOOL
FLOAT LEVEL GAUGE
5-1
FUEL SYSTEM
TROUBLESHOOTING
The vehicle does not start. Back firing
● No gasoline in fuel tank. ● Ignition system is damaged.

● Fuel is not coming out of carburetor. ● Mixture is too lean.
● Too much fuel is flowing into cylinder.
● No spark emitted from spark plug.
● Air cleaner is blocked.
● Suction system is experiencing secondary intake of air. Insufficient power and high fuel consumption.
● Using low quality gasoline.
● Starter is damaged. ● Air cleaner is blocked.
● Throttle cable is working improperly. ● Ignition system is damaged.
● Fuel tank is functioning improperly. ● Mixture is too rich.
Idle is unstable and engine turns off after starting. Air/Fuel mixture is extremely lean
● Starter is damaged. ● Fuel jet is blocked.

● Ignition system is damaged. ● Float valve is damaged.
● Using low qualty gasoline. ● Oil level is low.
● Suction system is experiencing secondary intake of air. ● Bad ventilation of air in tank cap.
● Idle is adjusted improperly. ● Fuel strainer screen is blocked.
● Air screw is adjusted improperly. ● Fuel tube is bent, creased or blocked.
● Compression pressure is low. ● Suction system is receiving secondary suction of air.
● Air/Fuel mixture is either too lean or rich.
● Carburetor is blocked.
Air/Fuel mixture is extremely rich.
Mis-firing occurs when driving at high speeds. ● Air jet is blocked.

● Float valve is damaged.
● Ignition system is damaged. ● Oil level is too high.
● Mixture is too lean. ● Starter is damaged.
● Air cleaner is blocked.
5-2
FUEL SYSTEM
FUEL TANK
REMOVAL
•Gasoline is extremely flammable. Avoid fire during

work, and pay particular attention to electric sparks.
Furthemore, the evaporated (gasified) gasoline is
highly explosive. Work in a well-ventilated areas.

FUEL
FUEL TANK
FUEL TANK
TANK open the seat.
- Luggage box. (⇨4-4)
- Floor panel leg.
- Center cover.
- Rear center cover.
- Rear carrier/Back rest.
- Body cover.
● Remove the fuel tube from the fuel tank.
● Remove the tube between the fuel tank and the fuel
filter.
● Remove the fuel vapor tub.
● Remove the fuel tank.
● Install in the revers order of removal
•After removing the fuel tank, be sure to close the

fuel tank cap.
AUTO
AUTO BYSTARTER
AUTO BYSTARTER
BYSTARTER CARBURETOR
REMOVAL
● Remove the seat.
● Remove the fuel tube and the vaccum tube.
● Remove the wiring coupler of the auto bystarter.
5-3
FUEL SYSTEM
● Loosen the throttle cable lock nut, and remove the
throttle cable from the carburetor.
● Loosen the air cleaner connecting tube band and the
carburetor intake manifold band.
● Remove the carburetor
VACUUM CHAMBER REMOVAL

● Loosen the drain screw and drain the fuel from the float
chamber.
● Remove the two vacuum chamber cover screws and

the cover.
● Remove the compression spring and vacuum piston.
5-4
FUEL SYSTEM
● Remove the needle holder, spring and jet needle from
the piston.
•Be careful not to damage the vacuum piston

diaphragm.
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
VACUUM PISTON INSPECTION
● Inspect the vacuum piston and jet needle for wear or
damage.
● Inspect the diaphragm for deterioration and tears.
VACCUM
VACCUM
VACCUM PISTION
PISTION
PISTION
JET
JET
JET NEEDLE
NEEDLE
NEEDLE
NEEDLE
NEEDLE HOLDER
NEEDLE HOLDER
HOLDER
FLOAT CHAMBER DISASSEMBLY

● Remove the three float chamber screws and the float
chamber.
SCREWS
SCREWS
SCREWS
● Remove the float pin, float and float valve.
FLOAT
FLOAT VALVE
FLOAT VALVE
VALVE FLOAT
FLOAT
FLOAT PIN
PIN
PIN
5-5
FUEL SYSTEM
FLOAT
FLOAT
FLOAT VALVE
VALVE
VALVE FLOAT VALVE INSPECTION
● Inspect the float valve seat contact area for wear.
FLOAT VALVE
FLOAT
FLOAT VALVE SEAT
VALVE SEAT
SEAT
JETS/SCREWS REMOVAL
● Inspect the float valve seat contact area for wear.
•Before removing the pilot screw, turn the pilot screw

clockwise until it seats lightly and record the rotating
turns.
•Do not force the pilot screw against its seat to avoid
seat damage.
PILOT
PILOT
PILOT SCREW
SCREW
SCREW (P.S)
(P.S)
(P.S)
● Remove the main jet, needle jet holder and needle jet.
MAIN
MAIN
MAIN JET
JET
JET ● Remove the slow jet.
SLOW
SLOW
SLOW JET
JET
JET
● Clean the removed the main jet, needle jet holder,

needle jet and slow jet with detergent oil.
NEEDLE
NEEDLE JET
NEEDLE JET
JET •Be sure to use clean detergent oil.
NEEDLE
NEEDLE
NEEDLE JET
NEEDLE JET
JET
HOLDER
HOLDER
HOLDER
MAIN
MAIN JET
MAIN JET
JET
SLOW
SLOW JET
SLOW JET
SLOW JET
JET
5-6
FUEL SYSTEM
AUTO BYSTARTER
INSPECTION/REMOVAL
AUTO BYSTARTER INSPECTION
● Measure the resistance between the auto bystarter wire
terminals.
Resistance : 10Ω(minutes minimum after stopping
the engine)
•If the reading is not within the limit, replace the auto
bystarter with a new one.
● Connect the hose to the fuel enriching circuit of the

AUTO
AUTO
AUTO BYSTARTER
BYSTARTER
BYSTARTER carburetor. Connect the auto bystarter green/back wire
to the positive (+) terminal of a battery and black/white
to the neagtive (-) terminal. Wait 5 minutes and blow
the hose with mouth. If the passage is blocked, the auto
bystarter is normal.
● Disconnect to auto bystarter from the battery. Wait 30
minutes and blow the hose with mouth. If air can be
blown into the hose, the auto bystarter is normal.
AUTO
AUTO
AUTO BYSTARTER
BYSTARTER
BYSTARTER SCREWS
SCREWS
SCREWS
AUTO BYSTARTER REMOVAL
● Remove the one set plate screw and set plate and then
remove the auto bystarter from the carburetor body.
SET
SET PLATE
SET PLATE
SET PLATE
PLATE
● Check the auto bystarter valve and needle for nicks,

wear or damage.
● If any faulty part is found, replace the auto bystarter
with a new one.
BYSTARTER
BYSTARTER VALVE
BYSTARTER VALVE
BYSTARTER VALVE
VALVE
BYSTARTER
BYSTARTER NEEDLE
BYSTARTER NEEDLE
BYSTARTER NEEDLE
NEEDLE
5-7
FUEL SYSTEM
AIR
AIR
AIR CUT-OFF
AIR CUT-OFF VALVE
CUT-OFF VALVE
CUT-OFF COVER
VALVE COVER
VALVE COVER
COVER
AIR CUT-OFF VALVE (A.C.V)
A.C.V REMOVAL
● Remove the two screws and the air cut-off valve cover.
● Remove the spring, diaphragm and O-rings.

● Inspect the diaphragm and spring for wear or damage.
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
SPRING
SPRING
SPRING
COVER
COVER
COVER
COVER
CARBURETOR BODY CLEANING

● Blow compressed air through all passages of the
carburetor body.
•Make sure that no fuel jet is clogged.
● Install the O-ring onto the air-cut-off valve body

O-RING
O-RING
O-RING securely.
•Install the O-ring with the flat face toward the valve
body side.
● Install the diaphragm, spring, and cover.
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
COVER
COVER
COVER SPRING
SPRING
SPRING
SPRING
COVER
5-8
FUEL SYSTEM
● Install and tighten the two screws attaching the air cut-
off valve cover.
● Connect the hose.
SCREWS
SCREWS
SCREWS
ACCELERATING PUMP
DISASSEMBLY
● Remove the two accelerating pump cover screws and
accelerating pump cover.
● Remove the spring and accelerating pump diaphragm.
SCREWS
SCREWS
SCREWS
INSPECTION
● Inspect the accelerating pump diaphragm for cracks,
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM damage or deterioration. Replace if necessary.
● Assemble the accelerating pump in the reverse order of
disassembly.
COVER
COVER
COVER
O-RING
O-RING
O-RING
AUTO
AUTO BYSTARTER
AUTO BYSTARTER
BYSTARTER SCREWS
SCREWS
SCREWS
SCREWS AUTO BYSTARTER
INSTALLATION
● Install the auto bystarter and set plate.
● Install and tighten the two screws.
•Insert the auto bystarter into the carburetor body

until it bottoms and position the set plate into the
upper groove in the bystarter.
•Install the set plate with its round face facing down.
5-9
FUEL SYSTEM
FLOAT LEVEL INSPECTION

● Install the float valve, float and float fin.
● Measure the float level at the location of the main jet
(just contacting the float valve)
Float Level : 18.5±1.0mm
● Replace the float if the level is incorrect.
● Check the operation of the float and then reinstall the
float chamber.
VACUUM CHAMBER ASSEMBLY

VACUUM
VACUUM
VACUUM PISTON
PISTON
PISTON
● First install the jet needle and spring into the vacuum
chamber and then install the needle holder.
NEEDLE
NEEDLE
NEEDLE HOLDER
HOLDER
HOLDER JET
JET
JET NEEDLE
NEEDLE
NEEDLE
● Install the vacuum piston into the carburetor body.

VACUUM
VACUUM
VACUUM PISTON
PISTON
PISTON ● Install the spring.
● Install the vacuum chamber cover and tighten it with
the two screws.
•Be careful not to let the diaphragm slip.

•If the diaphragm cannot be positioned correctly
because of expansion, dry the diaphragm before
installation.
SPRING
SPRING
SPRING DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
● Check the heater with battery.

● If the heater is getting hot, means the heater without
problem, otherwise the heater has to be changed.
HEATER
HEATER
HEATER
HEATER
5-10
FUEL SYSTEM
AIR
CARBURETOR INSTALLATION
THROTTLE
THROTTLE CABLE
THROTTLE CABLE
CABLE AIR
AIR CLEANER
AIR CLEANER CONNECTING
CLEANER CONNECTING
CONNECTING
TUBE BAND
TUBE
TUBE BAND
BAND ● Tighten the drain screw.
● Install the carburetor onto the intake manifold and
tighten the band.
● Install the air cleaner connecting tube and tighten the
band.
● Connect the throttle cable to the carburetor.
•After connecting the throttle cable, adjust the throttle

grip free play to 2~6mm.
INTAKE
INTAKE
INTAKE MANIFOLD
INTAKE MANIFOLD BAND
MANIFOLD BAND
BAND
FUEL
FUEL
FUEL TUBE
TUBE
TUBE
● Connect the auto bystarter wire.
● Connect the fuel tube and vacuum tube to the
carburetor.
● Perform the following inspections and adjustments:
- Throttle grip free play
- Idle speed
● Install the seat, met-in box and frame center cover.
AUTO
AUTO BYSTARTER
AUTO BYSTARTER WIRE
BYSTARTER WIRE
WIRE
FUEL PUMP
REMOVAL
● Remove the frane center cover.
● Disconnect the fuel pump inlet, outlet and vacuum
tubes.
● Remove the two fuel pump attaching bolts and the fuel
pump.
FUEL
FUEL
FUEL PUMP
PUMP
PUMP
DISASSEMBLY
INLET
INLET
INLET
INLET VACCUM
VACCUM
VACCUM TUBE
TUBE
TUBE
● Remove the four fuel pump body screws.
OUTLET
OUTLET
OUTLET
OUTLET
5-11
FUEL SYSTEM
● Disassemble the fuel pump.
● Inspect the fuel pump diaphragms A and B for damage.

● Inspect each gasket for damage.
● Inspect the suction valve, outlet valve and relief valve

in the fuel pump body for damage, cracks or foreign
matters.
•Measure the fuel pump output. Start the engine and

disconnect the fuel outlet fube and place a clean
container under the tube to check the fuel output.
OUTPUT : 40CC / 1,700rpm / 10 seconds
FUEL
FUEL
FUEL PUMP
PUMP
PUMP
5-12
MEMO

COOLING SYSTEM
6-0
6. COOLING SYSTEM
SERVICE INFORMATION· ·· 6-1 RADIATOR DISASSEMBLY· · 6-5
TROUBLESHOOTING· ···· 6-2 · 6-6
THERMOSTATIC SWITCH INSPECTION·
COOLANT· ·········· 6-3 RADIATOR ASSEMBLY· ··· 6-6
· 6-3
COOLING SYSTEM INSPECTION· WATER PUMP· ········ 6-7
COOLING SYSTEM TEST· ·· 6-4 THERMOSENSOR· ····· 6-11
RADIATOR· ········· 6-4 THERMOSTATIC· ······ 6-12
SERVICE INFORMATION
6
•Do not remove the radiator cap if the coolant temperature is over 100°C. Removing the cap while the engine is hot
and the coolant is under pressure may cause serious scalding. When the temperature is below, carefully remove the
cap with a cloth.
•Cooling system service should be done while the engine is cool.
•Radiator coolant is toxic. Keep it away from skin, eyes and clothes.
- If any coolant gets on your skin or clothes, rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them with water and consults a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- Especially pay attention to reserve the coolant. Keep out of reach of children.
● Do not remove the radiator cap except to refill or drain the cooling system after servicing the cooling system.
● Avoid spilling coolant on painted surfaces. If contaminated, wash in water immediately.
● After disassembling or servicing the cooling system, check for leaks with a radiator cap tester.
SPECIFICATIONS
RADIATOR CAP RELIEF PRESSURE 0.9 0.1kg/cm2
BEGIN TO OPEN 80 2 C
THERMOSTAT
TEMPERATURE FULLY OPEN 90 C
VALVE LIFT 3.5~4.5mm
RADIATOR: 1000 20cc
COOLANT CAPACITY Total system 1400 20cc
RESERVE TANK : 400 20cc
TORQUE VALUES :
WATER PUMP IMPELLER : 0.98~1.37㎏f·m
WATER PUMP COVER BOLT: 0.78~1.18㎏f·m
6-1
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
● Faulty temperature gauge or thermo sensor

● Air in cooling system
● Faulty thermostat stuck (Thermostat stuck closed)
● Passages blocked in radiator, hoses or water jacket
● Faulty fan motor switch
● Faulty water pump
Engine temperature too low or unstable
● Faulty temperature gauge or thermo sensor

● Faulty thermostat stuck (Thermostat stuck open)
● Faulty fan motor switch
Coolant leaks
● Faulty water pump mechanical seal

● Damaged or deteriorated O-rings
● Faulty radiator cap
● Damaged or deteriorated gasket
● Loose hose connection or clamp
6-2
COOLING SYSTEM
COOLANT
RADIATOR
COOLANT INSPECTION
WATER
● Radiator coolant mixes the distilled water.
•Coolant mixes the distilled water and radiator

coolant base solution with about 5°C of tolerance in
COOLANT respect to the minimum temperature.
RADIATOR COOLANT MIXTURE CHART

(ANTICORROSIVE AND ANTIFREEZE) •Radiator coolant is toxic. Keep it away from skin, eyes
and clothes.
When the whole capacity of coolant is 2000cc (Unit:cc) - If any coolant gets on your skin or clothes, rinse
Minimum temperature Mixture Ratio Hydrometer thoroughly with soap and water.
-9 C 20% 400 1,600 - If any coolant gets in your eyes, rinse them with water
-16 C 30% 600 1,400 and consults a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle
-25 C 40% 800 1,200 and consult a physician immediately.
-37 C 50% 1,000 1,000 - Especially pay attention to reserve the coolant. Keep
-44.5 C 60% 1,100 900 out of reach of children.
HYDROMETER COOLING SYSTEM INSPECTION

COOLANT GRAVITY TEST
•Follow the hydrometer manufacturer’s instructions.
● Check the coolant gravity using a hydrometer.

● Look for contamination of the coolant.
COOLANT GRAVITY CHART

COOLANT TEMPERATURE °C
0 5 10 15 20 25 30 35 40 45 50
COOLANT RATIO %
5 1.009 1.009 1.008 1.009 1.007 1.006 1.005 1.003 1.001 0.999 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.049 0.047 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
6-3
COOLING SYSTEM
COOLING SYSTEM TEST
RADIATOR CAP ● Install the redicator cap onto the radiator tester.
● Press it with specified pressure and it must keep the
pressure for at least six seconds.
RADIATOR TESTER
·Apply water to the cap sealing surface before the

test.
Radiator Cap Relief Pressure : 0.9±0.15kg/com2
RADIATOR
INSPECTION
● Remove the front cover.
● Remove the under cover A.
● Inspect the radiator soldered joints and seams for leaks.

● Blow dirt out from between core fins with compressed
air.
REMOVAL
● Drain the coolant.
● Disconnect the air vent tube from the radiator filler.
● Remove the overflow tube clamp and disconnect the
overflow tube.
AIR
AIR BENT
AIR BENT TUBE
BENT TUBE
TUBE
6-4
COOLING SYSTEM
● Loosen the hose band and disconnect the upper hose
UPPER
UPPER
and lower hose from the radiator.
UPPER HOSE
HOSE
HOSE
● Disconnect the thermostatic switch wire coupler.
● Disconnect the fan motor wire coupler.
LOWER
LOWER
LOWER HOSE
HOSE
HOSE
BOLTS
BOLTS
BOLTS ● Remove the 2 bolts and 1nut on the radiator.
NUT
NUT
NUT
● Remove the 3bolts and then remove the fan/shround

from the radiator.
● Check fan motor by battery.
FAN
FAN MOTOR
FAN MOTOR
MOTOR
6-5
COOLING SYSTEM
CHECK THERMOSTATIC SWITCH
● When coolant temperature lower then 83~87°
C the
thermostatic switch OFF.
● When coolant temperature over 88~92°C the
thermostatic switch ON.
● Install the fan shroud on the radiator with the 3 bolts.

FAN
FAN
FAN BOLT
BOLT
BOLT
RADIATOR INSTALLATION
● Install the radiator on the radiator bracket with the 2
bolts and 1 nut.
● Connect the upper and lower hoses and secure them

with hose bands.
● Connect the thermostatic switch wire and fan motor
wire couplers.
6-6
COOLING SYSTEM
● Connect the overflow tube and secure with the tube
clamp.
● Fill the radiator with coolant.
● Connect the vent tube to the radiator filler.
● After installation, check for coolant leaks.
·If you want to refill the coolant, the following

procedure must be checked.
1. Please make the radiator filler and the air vent tube
to tbe separated.
2. Then start th engine, filled in the coolant till the
coolant flowed out from the air vent tube.
3. Put the air vent tube on.
● Install the front cover.
WATER PUMP
MECHANICAL SEAL (WATER SEAL)
INSPECTION
● Inspect the telltale hole for signs of mechanical seal
coolant leakage.
● If the mechanical seal is leaking, remove the right
crankcase cover and replace the mechanical seal.
TELLTALE
TELLTALE
TELLTALE HOLE
HOLE
HOLE
WATER PUMP
WATER
WATER PUMP
PUMP
WATER PUMP/IMPELLER REMOVAL

● Remove the coolant inlet hose and outlet hose.
INLET
INLET
INLET HOSE
HOSE
HOSE
OUTLET
OUTLET
OUTLET HOSE
HOSE
HOSE
6-7
COOLING SYSTEM
● Remove the 4 bolts and the water pump cover.
● Remove the gasket and 2 dowel pins.
BOLTS
BOLTS
BOLTS
BOLTS
BOLTS
BOLTS
BOLTS
● Remove the water pump impeller.
·The impeller has left hand threads.
WATER
WATER
WATER PUMP
PUMP
PUMP IMPELLER
IMPELLER
IMPELLER
● Inspect the mechanical (water) seal and seal washer for

wear or damage.
·The impeller has left hand threads.
WATER PUMP SHAFT REMOVAL

● Disconnect the water hose from the right crankcase
cover.
● Remove the eight bolts attaching the right crankcase
cover.
6-8
COOLING SYSTEM
● Remove the water pump bearing snap ring from the
water pump assembly.
WATER
WATER
WATER PUMP
PUMP
PUMP SHAFT
SHAFT
SHAFT ● Remove the water pump shaft and inner bearing.
SNAP
SNAP RING
SNAP RING
RING
● Remove the water pump shaft outer bearing.
MECHANICAL SEAL REPLACEMENT

● Drive the mechanical seal out of the water pump
assembly from the inside.
● Drive in a new mechanical seal using a mechanical

seal driver.
·Apply sealant to the right crankcase cover fitting

surface of a new mechanical seal and then drive in
the mechanical seal.
6-9
COOLING SYSTEM
WATER PUMP SHAFT INSTALLATION
SNAP
SNAP RING
SNAP RING
SNAP RING
RING ● Drive a new water pump shaft outer bearing into the
WATER
WATER
WATER PUMP
PUMP
PUMP SHAFT
SHAFT
SHAFT water pump assembly from the inside.
INNER
INNER BEARING
INNER BEARING
INNER BEARING
BEARING
● Install the water pump shaft and shaft inner bearing

WATER
WATER
WATER PUMP
PUMP
PUMP SHAFT
SHAFT
SHAFT into the waster pump assembly.
● Install the snap ring to secure the inner bearing
properly.
● Install the dowel pins and a new gasket and then install
the water pump assembly to the right crankcase cover.
● Tighten the 8 bolts to secure the right crankcase cover.
·When installing the water pump assembly, aligning

the groove on the water pump shaft with the tab on
the oil pump shaft.
WATER PUMP / IMPELLER

SEAL
SEAL
SEAL WASHER
SEAL WASHER (PORECELAIN)
WASHER (PORECELAIN)
WASHER (PORECELAIN)
(PORECELAIN) INSTALLATION
● When the mechanical seal in replaced, a new seal
washer must be in stalled to the impeller.
IMPELLER
IMPELLER
IMPELLER
6-10
COOLING SYSTEM
● Install the impeller onto the water pump shaft.
·The impeller has left hand thread.
● Install the 2 dowel pins and a new gasket.
DOWEL
DOWEL
DOWEL PIN
PIN
PIN
● Install the water pump cover and tighten the 4 bolts.

BOLTS
BOLTS
BOLTS
BOLTS
BOLTS
BOLTS
THERMOSENSOR
REMOVAL
● Remove the seat, met-in box and center cover.
● Disconnect the thermosensor wire.
● Remove the thermosensor.
THERMOSENSOR
THERMOSENSOR
THERMOSENSOR
6-11
COOLING SYSTEM
INSPECTION
THERMOSENSOR
● Suspen the thermosensor in a pan of water over a
burner and measure the resistance through the sensor
as the water heats up.
Temperature(°C) 50 80 100 120

Resistance(Ω) 154 52 27 16
THERMOMETER
INSTALLATION
● Apply a sealant to the themosensor threads and install
it into the thermostat housing.
● Connect the thermosensor wire.
● Fill the radiator with coolant.
● Install the center cover, met-in box and seat.
·Be sure to bleed air from the cooling system.
THERMOSTAT
THERMOSTAT
THERMOSTAT
THERMOSTAT
REMOVAL
● Remove the seat, met-in box and center cover.
● Disconnect the thermosensor wire from the
thermosensor.
● Disconnect the water hose from the thermostat
housing.
● Disconnect the air vent tube from the thermostat
housing.
● Remove the mounting bolt and the thermostat housing
from the cylinder head.
WATER
WATER
WATER HOSE
HOSE
HOSE AIR
AIR
AIR VENT
VENT
VENT TUBE
TUBE
TUBE ● Remove the 2 bolts and separate the thermostat
housing halves.
● Remove the thermostat from the thermostat housing.
6-12
COOLING SYSTEM
INSPECTION
● Suspend the thermostat in a pan of water over a burner
THERMOSTAT
and gradually raise the water temperature to check its
operation.
THERMOMETER Technical Data

Begins to open 80 2 C
Full-open 90 C
Valve lift 3.5~4.5mm
·Do not let the thermostat touch the pan as it will give
a false reading.
·Replace the thermostat if the valve stays open at
room temperature.
·Test the thermostat after it is opened for about 5
minutes and hold the temperature at 70 C
INSTALLATION
·Replace the O-ring with a new one and apply grease

to it.
6-13
MEMO

7. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION·············· 7-1

ENGINE REMOVAL················· 7-2
ENGINE INSTALLATION ·············· 7-3
SERVICE INFORMATION
GENERAL SAFETY
•Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness.
•Attach tape to the frame to protect it during the engine removal or installation.
7
● Drain the coolant before removing the engine.
● After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the water jacket.
● Start the engine to check for coolant leaks.
TORQUE VALUES :
ENGINE HANGER BOLT (ENGINE) : 4.9㎏f·m
(FRAME) : 3.9㎏f·m
SPECIFICATIONS :
● ENGINE DRY WEIGHT : 30Kg
● ENGINE OIL CAPACITY : 1.1 ( disassembly)
● COOLANT CAPACITY
● TOTAL CAPACITY : 1,400±20cc
● RADIATOR CAPACITY : 1,000±20cc
● RESERVE TANK CAPACITY : 400±20cc
7-1
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
● Disconnect the battery ⊖ cable.
● Remove the frame body cover.
● Disconnect the engine ⊖ cable.
● Disconnect the A.C generator, auto bystarter, spark
plug, thermosensor wire couplers and connectors.
● Disconnect the engine fuel tube.
● Disconnect the water hose.
● Disconnect the starter motor wire from the starter

relay.
● Disconnect the fuel tube and vacuum tube.

● Disconnect the vacuum tube from the air cut-off valve
(ACV)
● Disconnect the throttle cable from the carburetor.
● Remove the brake fluid tube bolt of the rear brake

caliper.
● Remove the rear brake caliper bolt and the rear brake
caliper.
7-2
● Remove the R/L rear shock absorber upper mount
REAR
REAR
REAR SHOCK
SHOCK
SHOCK ABSORBER
ABSORBER
ABSORBER UPPER
UPPER
UPPER MOUNT
MOUNT
MOUNT BOLTS
BOLTS
BOLTS bolts.
● Remove the engine mounting bolt and pull out the

engine.
● Remove the engine hanger bolts to remove the engine

BUSHING hanger.
● Inspect the engine hanger bushing stopper rubber for
wear or damage.
ENGINE INSTALLATION
● Tighten the engine mounting nut.
7-3
● Tighten the rear shock absorber upper mount bolts.
After installation, inspect and adjust the following:

● Throttle grip free play.
● Fill the rear brake reservoir with brake fluid and bleed
air from the rear brake.
● Fill the cooling system with coolant and start the
engine to bleed air from the system.
7-4
MEMO

LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION
8-0
8. LH. CRANKCASE COVER/CONTINUOUSLY
VARIABLE TRANSMISSION
··· 8-1
SERVICE INFORMATION· ·········8-3
DRIVE PULLY·
·····8-1
TROUBLESHOOTING· ··· 8-7
CLUTCH DRIVEN PULLY·
· 8-2
LH. SIDE COVER REMOVAL·
SERVICE INFORMATION
● Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil contact.
● Do not operate starter motor while the L. crank case front cover is removed.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER 40.000~40.025mm 40.06mm
8
DRIVE FACE COLLAR OUTER DIAMETER 39.965~39.955mm 39.85mm
DRIVE BELT WIDTH 23.6~24.4mm 22.0mm
CLUTCH LINING WICTH 3.963~4.037mm 2.0mm
CLUTCH OUTER AND INNER DIAMETER 153.0~153.2mm 153.5mm
WEIGHT ROLLER OUTER DIAMETER 22.92~23.08mm 22.0mm
DRIVEN FACE BOSS OUTER DIAMETER 26.960~26.974mm 26.90mm
MOVABLE DRIVEN FACE INNER DIAMETER 27.052~26.989mm 27.13mm
TORQUE VALUES :
DRIVE FACE NUT : 8.82~9.8㎏f·m
CLUTCH OUTER NUT : 4.9~5.88㎏f·m
CLUTCH DIRVE PLATE NUT : 4.9~5.88㎏f·m
TROUBLESHOOTING
Engine starts but motorcycle does not work. Vehicle unable to run at the maximum speed,
● Drive belt worn. or lack of output
● Ramp plate damaged. ● Drive belt worn.
● Clutch shoe worn or damaged. ● Defective movable driven face spring.
● Movable driven face spring cut. ● Weight roller worn.
● Pulley face contaminated.
Engine stops, or the vehicle runs suddenly,
after starting.
● Clutch shoe spring cut.
8-1
AIR
AIR
AIR TUBE
TUBE
TUBE BAND
BAND
BAND
LH. CRANKCASE COVER
REMOVAL
● Remove the bolts securing LH. side cover.
● Loosen the air tube screw.
● Remove the air tube.
● Loosen the LH. cover bolts.

LH.
LH. COVER
LH. COVER
COVER ● Remove the LH. crankcase cover.
● Remove the and dowel pin.
INSTALLATION
● Install the gasket and dowel pin.
● Install the LH. side cover.
● Install the cable clamp.
● Install the LH. side cover bolts.
LH.
LH.
LH. SIDE
SIDE
SIDE COVER
COVER
COVER
● Install the air tube and tighten it with the band screw.
AIR
AIR TUBE
AIR TUBE BAND
TUBE BAND
BAND
8-2
DRIVE FULLEY
LOCK WASHER/LOCK NUT
REMOVAL
● Remove the LH. crankcase cover.
● Loosen the Drive face flange nut with the drive face
holder.
LOCK NUT ● Remove the drive face.
WRENCH
● Remove the drive bolt from the movable drive face.
INSPECTION
● Check the drive bolt for cracks sepuration or abnormal
or excessive wear.
● Inspect the drive belt width.
SERVICE LIMIT : 22.0mm replace if below
COLLAR
COLLAR
COLLAR
COLLAR ● Remove the movable drive face assembly.
● Remove the drive pulley collar.
8-3
RAMP
RAMP PLATE
RAMP PLATE
RAMP PLATE
PLATE
DISASSEMBLY
● Remove the ramp plate.
● Remove the weight rollers.

WEIGHT
WEIGHT ROLLERS
WEIGHT ROLLERS
ROLLERS
·Check the pump shaft to rotate smoothly.
● Check the weight roller for wear or damage.

● Measure the weight roller O.D.
SERVICE LIMIT : 22mm replace if below
● Measure the movable drive face bushing I.D.

SERVICE LIMIT : 27.13mm replace if over
8-4
● Check the drive pully collar for damage or wear.
● Measure the O.D of the drive pully collar sliding
surface.
ASSEMBLY
● Install the weight rollers into the movable face.

WEIGHT
WEIGHT
WEIGHT ROLLERS
ROLLERS
ROLLERS
● Install the ramp plate.

RAMP
RAMP PLATE
RAMP PLATE
PLATE
8-5
● Insert the drive pulley collar into the movable drive
DRIVE
DRIVE
DRIVE PULLEY
PULLEY
PULLEY COLLAR
COLLAR
COLLAR face.
● Install the movable drive face onto the crankshaft.
● Lay the drive belt on the driven pulley.

● Set the drive belt on the drive pulley collar.
● Install the washer and drive nut into the drive pulley
face temperarilly.
8-6
● Hold the dirve pulley with the drive face holder and
DRIVE FACE tighten the drive face nut.
·Do not get the grease on the drive belt or drive

pulley faces.
CLUTCH/DRIVEN PULLEY
FLANGE NUT ● Remove the left crankcase cover.
● Remove the drive pulley and drive belt.
CLUTCH OUTER ● Hold the clutch outer with the universal holder and
remove the clutch outer nut.
● Remove the clutch outer.
UNIVERSAL HOLDER
INSPECTION
● Inspect the clutch outer for wear or damage.
● Measure the clutch outer I.D.
● Check the clutch shoes for wear or damage.

● Measure the clutch lining thickness.
8-7
LOCK NUT WRENCH

CLUTCH/DRIVEN PULLEY
LOCK NUT DISASSEMBLY
● Hold the clutch/driven pulley assembly with the clutch
spring compressor.
● Set the tool in a vise and remove the clutch drive plate
nut. (39mm)
CLUTCH SPRING
COMPRESSOR
● Loosen the clutch spring compressor and

disassemlble the clutch/driven pulley assembly.
● Remove the seal collar.
● Pull out the guide roller pins and guide rollers.

MOVABLE DRIVEN FACE
● Remove the movable driven face from the driven face.
OIL SEAL ● Remove the oil seal from the movable driven face.
O-RING
GUIDE PIN
INSPECTION
● Measure the driven face spring free length.
8-8
● Check the driven face assembly for wear or damage.
● Measure the driven face O.D.
MOVABLE GUIDE GROOVE

DRIVEN FACE
● Check the movable driven face for wear or damage.

DRIVEN FACE
● Measure the movable driven face I.D.
DRIVEN PULLEY FACE BEARING

REPLACEMENT
● Remove the inner needle bearing out of the driven
pulley face.
● Remove the snap ring and drive the outer bearing out
of the driven face.
● Apply grease to the outer bearing.
● Install a new outer bearing into the driven face with the
sealed end facing up.
● Seat the snap ring in its groove.
● Apply grease to the driven face bore areas (9~9.5g)
8-9
● Press a new needle bearing into the driven face.
NEEDLE BEARING
BALL BEARING (INNER)
(OUTER)
CLUTCH DISASSEMBLY
CIRCLIPS
CIRCLIPS
CIRCLIPS
● Remove the circlips and retainer plate to disassemble
the clutch.
•Keep grease off the clutch linings.
CLUTCH
CLUTCH
CLUTCH LINING
LINING
LINING CLUTCH ASSEMBLY
● Install the damper rubbers on the drive plate pins.

● Install the clutch weights/shoes and clutch springs onto
the drive plate.
● Install the retainer plate and secure with the circlips.
8-10
CLUTCH/DRIVEN PULLEY ASSEMBLY

MOVABLE DRIVEN FACE OIL SEAL ● Clean the pulley faces and remove any grease from
them.
● Apply frease to the O-ring and install them onto the
moveable driven face.
O-RING
GUIDE PIN
● Install the movable driven face onto the driven face.

● Apply grease to the guide rollers and guide roller pins
DRIVEN FACE and then install them into the holes of the driven face.
● Install new seal collar.

● Remove any excessive grease.
·Be sure to clean the driven face off any grease.

·Set the driven pulley assembly, driven face spring
and clutch assembly onto the clutch spring
compressor
● Tighten the drive flate nut temperily.

LOCK NUT WRENCH ● Set teh tool invise and righten the drive plate nut to the
specified torque.
LOCK NUT
CLUTCH SPRING
COMPRESSOR
8-11
●Install the clutch/driven pulley onto the drive shaft.
● Install the clutch outer.

CLUTCH OUTER ● Hold the clutch outer with the universal holder.
● Install and tighten the clutch outer nut.
● Install the drive belt.

● Install the LH. crankcase cover.
FLANGE NUT UNIVERSAL HOLDER
8-12
MEMO

A.C GENERATOR/STARTER CLUTCH
9-0
9. A.C GENERATOR / STARTER CLUTCH
SERVICE INFORMATION······ 9-1 FLYWHEEL INSTALLATION· ··· 9-4

·9-2
R. CRANKCASE COVER REMOVAL· STATOR INSTALLATION· ·····9-5
STARTER CLUTCH········· 9-3 ·9-5
R. CANKCASE COVER INSTALLATION·
SERVICE INFORMATION
● Drain the coolant before removing the right crankcase cover.
● Be careful not to drain the coolant when the engine temperature in high. (Perform this operation when the engine is
cold.)
● Drain the engine oil into a clean container before removing the right crankcase cover.
● When the right crankcase cover is installed, fill with the recommended engine oil and coolant.
● Then, bleed air from the water jacket.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Large end side clearance 22.026~22.045mm 22.15mm
Connecting rod large end right angle direction clearance 42.195~42.208mm 41.5mm 9
TORQUE VALUES
FLYWHEEL NUT : 5.39~6.37kgf·m
9-1
RIGHT CRANKCASE COVER

REMOVAL
BOLTS
BOLTS
BOLTS
● Disconnect the water hoses from the right crankcase
cover.
● Remove the 9 bolts securing the right crankcase cover
and the cover.
● Loosen the 2 puler coil screws and disconnect pulser
coil.
WATER
WATER
WATER INLET
INLET
INLET HOSE
HOSE
HOSE
SCREWS
SCREWS
SCREWS
SCREWS STATOR REMOVAL
PULSE
PULSE COIL
PULSE COIL
PULSE COIL
COIL
BOLTS
BOLTS
BOLTS ● Remove the three A.C. generator stator bolts and the
stator.
·When removing the pulse coil and stator, be careful

not to damage them to avoid shorted or broken wire.
A.C.
A.C.
A.C. GENERATOR
A.C. GENERATOR STATOR
GENERATOR STATOR
GENERATOR STATOR
STATOR
FLYWHEEL
FLYWHEEL
FLYWHEEL HOLDER
FLYWHEEL HOLDER
HOLDER
FLYWHEEL REMOVAL
● Hold the flywheel with a flywheel holder and remove
the flywheel nut.
FLYWHEEL
FLYWHEEL
FLYWHEEL
● Remove the flywheel with a flywheel puller.
FLYWHEEL
FLYWHEEL
FLYWHEEL PULLER
PULLER
PULLER
9-2
START
START
START REDUCTION
REDUCTION
REDUCTION GEAR
GEAR
GEAR STARTER CLUTCH
REMOVAL
● Remove the starter clutch gear comp.
START
START
START CLUTCH
CLUTCH
CLUTCH GEAR
GEAR
GEAR COMP
COMP
COMP
● Remove the starter reduction gear and shaft.
STARTER
STARTER
STARTER REDUCTION
REDUCTION
REDUCTION GEAR
GEAR
GEAR INSPECTION
● Inspect the starter clutch gear comp for wear or
damage.
● Measure the starter clutch gear comp I.D. and O.D.
SERVICE LIMITS:
I.D. : 22.15mm replace if over
O.D.: 41.50mm replace if below
● Inspect the starter reduction gear and shaft for wear or

STARTER
STARTER
STARTER REDUCTION
REDUCTION
REDUCTION GEAR
GEAR
GEAR damage.
9-3
● Remove the starter one-way clutch rollers, plungers
and springs.
START
START
START REDUCTION
REDUCTION
REDUCTION GEAR
GEAR
GEAR INSTALLATION
● Install the starting clutch gear comp onto the
crankshaft.
● Install the starter reduction gear and shaft.
START
START CLUTCH
START CLUTCH GEAR
CLUTCH GEAR COMP
GEAR COMP
COMP
FLYWHEEL INSTALLATION
KEY
KEY
KEY
FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL ● Install the flywheel onto the crankshaft by aligning the
key on the crankshaft with the groove in the flywheel.
GROOVE
GROOVE
GROOVE
● Hold the flywheel with the flywheel holder and tighten

the flywheel nut.
FLYWHEEL
FLYWHEEL
FLYWHEEL
9-4
PULSE
PULSE COIL
PULSE COIL
COIL STATOR INSTALLATION
● Install the A.C. generator stator on the RH. crankcase
cover and secure it with the 3 bolts.
● Install the pulse coil on the RH. crankcase cover and
secure it with the 2 scerws.
● Install the wire grommet in the groove in the RH.
crankcase cover securely.
DOWEL
DOWEL PINS
DOWEL PINS
DOWEL PINS
PINS R. CRANKCASE COVER
INSTALLATION
● Install the 2 dowel pins and a new gasket.
RH.
RH. CRANKCASE
RH. CRANKCASE COVER
CRANKCASE COVER
COVER ● Install the RH. crankcase cover over the crankcase,
aligning the water pump shaft groove with the oil
pump shaft.
● Tighten the 9 RH. crankcase cover bolts.
● Connect the water hoses to the RH. crankcase cover.
● Add the recommended engine oil.
● Fill the cooling system with the specified coolant.
·Be sure to bleed air from the water jacket after filling
ALIGNING
ALIGNING
ALIGNING WATER
WATER PUMP
WATER PUMP SHAFT
PUMP SHAFT
SHAFT the coolant.
OIL
OIL PUMP
OIL PUMP SHAFT
PUMP SHAFT
SHAFT
9-5
CYLINDER HEAD / VALVE
10-0
10. CYLINDER HEAD/CYLINDER/PISTON
······· · 10-1
SERVICES INFORMATION·
CYLINDER HEAD COVER········· 10-1
CAM SHAFT··············· 10-2
CYLINDER HEAD············· 10-4
SERVICE INFORMATION
● Drain the coolart from the radiator and water.
● Apply oil to valve guide and valve arm when assemblying.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT(mm)
IN 0.10 -
VALVE CLEARANCE (COLD)
EX 0.10 -
CYLINDER HEAD COMPRESSION PRESSURE 15kg/cm2 -
CYLINDER HEAD WARPAGE _ 0.05
IN 34.2987 34.14
CAMSHAFT CAM HEIGHT
EX 34.1721 34.02
IN 10.00~10.015 10.10
VALVE ROCKER ARM I.D.
EX 10.00~10.015 10.10
VALVE ROCKER ARM SHAFT O.D.
IN 9.972~9.987 9.9 10
EX 9.972~9.987 9.9
IN 1.2 1.8
VALVE SEAT WIDTH
EX 1.2 1.8
IN 4.990~4.975 4.925
VALVE STEM O.D.
EX 4.970~4.955 4.915
IN 5.00~5.012 5.03
VALVE GUIDE I.D.
EX 5.00~5.012 5.03
IN 0.010~0.037 0.08
VALVE STEM-TO-GUIED CLEARANCE
EX 0.030~0.057 0.10
TORQUE VALUES
CYLINDER HEAD CAP NUT : 2.45kgf·m
VALVE CLEARANCE ADJUSTING NUT : 0.88kgf·m
CYLINDER HEAD COVER BOLT : 0.78~1.18kgf·m
10-1
CYLINDER HEAD COVER

REMOVAL
● Remove the cylinder head cover 4 bolts and then
remove the cylinder head cover.
CAM
CAM
CAM CHAIN
CHAIN
CHAIN TENSIONER
TENSIONER
TENSIONER
CAMSHAFT
REMOVAL
● Turn the A.C. generator flywheel so that the “T” mark
on the flywheel aligns with the index mark on the
crankcase.
● Hold the round hole on the camshaft gear facing up
and the location is the top dead center on the
compression stroke.
● Remove the 2 bolts attaching cam chain tensioner and
the tensioner.
ROUND
ROUND
ROUND HOLE
HOLE
HOLE
● First remove the 2 bolts between the cylinder head and

CAMSHAFT
CAMSHAFT HOLDER
CAMSHAFT HOLDER
CAMSHAFT HOLDER
HOLDER cylinder.
● Remove the 4 cap nuts securing cylinder head.
·Diagonally loosen the cylinder head cap nuts in 2 or

3 times.
BOLTS
BOLTS
BOLTS CAP
CAP NUTS
CAP NUTS
NUTS
CAMSHAFT
CAMSHAFT HOLDER
CAMSHAFT HOLDER
HOLDER
● Remove the camshaft holder and dowel pins.
10-2
CAM
CAM CHAIN ● Remove the camshaft gear from the cam chain to
CAM CHAIN
CHAIN
remove the camshaft.
CAMSHAFT
CAMSHAFT GEAR
CAMSHAFT GEAR
CAMSHAFT GEAR
GEAR
INSPECTION
● Check each cam lobe for wear or damage.
● Measure the cam lobe height.
SERVICE LIMITS:
IN : 34.14mm replace if below
EX: 34.02mm replace if below
● Check each camshaft bearing for play or damage.

CAMSHAFT
CAMSHAFT
CAMSHAFT BEARING
BEARING
BEARING Replace the camshaft assembly with a new one if the
bearings are noisy or have excessive play.
CAMSHAFT HOLDER DISASSEMBLY

VALVE
VALVE ROCKER
VALVE ROCKER ARMS
ROCKER ARMS
ARMS ● Remove the valve rocker arms.
ROCKER
ROCKER
ROCKER ARM
ARM SHAFT
ARM SHAFT
SHAFT
10-3
CAMSHAFT
CAMSHAFT HOLDER
CAMSHAFT HOLDER
HOLDER
CAMSHAFT HOLDER INSPECTION
● Inspect the camshaft holder, valve rocket arms and
rocker arm shafts for wear or damage.
·If the valve rocker arm contact surface is worn,

check each cam lobe for wear or damage.
ROCKER ARM
ROCKER
ROCKER ARM SHAFT
ARM SHAFT
SHAFT
● Measure the I.D. of each valve rocket arm.

SERVICE LIMITS:
IN : 10.10mm replace if over
EX: 10.10mm replace if over
● Measure each rocker arm shaft O.D.

SERVICE LIMITS:
EX: 9.90mm replace if below
CYLINDER HEAD
REMOVAL
● First drain the coolant from the radiator and water
jacket, then remove the thermostat water hose.
● Remove the camshaft.
● Remove the carburetor and intake manifold.
● Loosen the bolt securing the thermostat housing and
the thermostat housing.
● Remove the cylinder head.
BOLT
BOLT
BOLT
CYLINDER
CYLINDER HEAD
CYLINDER HEAD GASKET
HEAD GASKET
GASKET ● Remove the dowel pins and cylinder head gasket.
CYLINDER
CYLINDER
CYLINDER ● Remove the cam chain guide.
● Remove all gasket material from the cylinder head
mating surface.
CAM
CAM
CAM CHAIN
CHAIN
CHAIN TENSIONER
TENSIONER
TENSIONER SLIPPER
SLIPPER
SLIPPER
10-4
DISASSEMBLY
CYLINDER
CYLINDER
CYLINDER HEAD
HEAD
HEAD
● Remove the valve spring cotters, retainers, springs,
spring seats and valve stem seals using a valve spring
compressor.
·Be sure to compress the valve springs with a valve

spring compressor.
·Mark all disassembled parts to ensure correct
reassembly.
VALVE
VALVE
VALVE SPRING
SPRING
SPRING COMPRESSOR
COMPRESSOR
COMPRESSOR
● Remove carbon deposits fron the exhaust port and

COMBUSTION
COMBUSTION CHAMBER
COMBUSTION CHAMBER
CHAMBER combustion chamber.
·Be careful not to damage the cylinder head mating

surface.
INSPECTION
STRAIGHT
STRAIGHT
STRAIGHT EDGE
EDGE
EDGE
● Check the spark plug hole and valve areas for cracks.
● Check the cylinder head for warpage with a straight
edge and feeler gauge.
SERVICE LIMITS : 0.05mm replace or replace if
over
FEELER GAUGE
FEELER
FEELER GAUGE
GAUGE
● Measure the free length of the inner and outer valve

springs.
SERVICE LIMITS:
INNER (IN, EX) : 29.5mm replace if below
OUTER(IN, EX) : 39.5mm replace if below
10-5
● Inspect each valve for bending, burning, scratches or
abnormal stem wear.
● Check valve movenment in the guide.
● Measure each valve stem O.D.
SERVICE LIMITS:
EX : 4.925mm replace if below
ASSEMBLY
● Install the valve spring seats and stem seals.
● Lubricate each valve stem with engine oil and insert
the valves into the valve guides.
VALVE
VALVE
VALVE SPRING
SPRING
SPRING COMPRESSOR
COMPRESSOR
COMPRESSOR
● Tap the valve stems gently with a plastic hammer to

PLASTIC
PLASTIC HAMMER
PLASTIC HAMMER
PLASTIC HAMMER
HAMMER firmly seat the cotters.
·Be careful not to damage the valves.
CYLINDER
CYLINDER
CYLINDER HEAD
HEAD
HEAD
INSTALLATION
● Install the cam chain guide.
● Install the dowel pins and a new cylinder head gasket.
CAM CHAIN
CHAIN GUIDE
GUIDE DOWEL PINS
DOWEL
DOWEL PINS
PINS
CAM
CAM CHAIN GUIDE
10-6
● Install the cylinder head and take out the cam chain.
CAM
CAM CHAIN
CAM CHAIN
CHAIN
● Assemble the camshaft holder.

VALVE
VALVE
VALVE ROCKER
ROCKER
ROCKER ARMS
ARMS
ARMS
● First install the intake and exhaust valve
● rocker arms ; then install the rocker arm shafts.
·Install the exhaust valve rocket arm shaft on the

“EX” side of the camshaft holder and the exhaust
rocker arm shaft is shorter.
·Clean the intake valve rocket arm shaft off any
grease before installation.
·Align the cutout on the exhaust valve rocker arm
shaft with the bolt of the camshaft holder.
CAMSHAFT
CAMSHAFT
CAMSHAFT HOLDER
HOLDER
HOLDER
CAMSHAFT INSTALLATION
ROUND
ROUND
ROUND HOLE
HOLE
HOLE
PUNCH
PUNCH
PUNCH MARKS
MARKS
MARKS ● Turn the A.C. generator flywheel so that the “T” mark
on the flywheel aligns with the index mark on the
crankcase.
● Keep the round hole on the camshaft gear facing up
and align the punch marks on the camshaft gear with
the cylinder head surface
● Install the cam chain over the camshaft gear.
CAM
CAM
CAM CHAIN
CHAIN
CHAIN
● Install the dowel pins.
DOWEL
DOWEL PINS
DOWEL PINS
DOWEL PINS
PINS
10-7
● Install the camshaft holder, washers and nuts on the
WASHERS
WASHERS
WASHERS cylinder head.
● Tighten the 4 cylinder head nuts and the 2 bolts
between the cylinder head and cylinder.
TORQUE :
Cylinder head cap nut : 2.45kgf·m
Cylinder & cylinder head bolt : 0.78~1.18kgf·m
·Apply engine oil to the threads of the cylinder head

cap nuts.
·Diagonally tighten the cylinder head cap nuts in 2~3
BOLTS
BOLTS
BOLTS NUTS
NUTS
NUTS times.
·First tighten the cylinder head cap nuts and then
tighten the bolts between the cylinder and cylinder
TENSIONER
TENSIONER SCREW
TENSIONER SCREW
SCREW head to avoid cracks.
● Turn the cam chain tension screw counter clockwise to

release it.
● Apply engine oil to a new O-ring and install it.

O-RING
O-RING
O-RING
● Tighten the cam chain tension cap screw.
·Be sure to install the gasket into the groove properly.
CYLINDER HEAD COVER

CYLINDER
CYLINDER HEAD
CYLINDER HEAD COVER
HEAD COVER
COVER INSTALLATION
● Adjust the valve clearance.
● Install a new cylinder head cover O-ring and install the
cylinder head cover.
·Be sure to install the O-ring into the groove properly.
● Install and tighten the cylinder head cover bolts.

10-8
MEMO

CYLINDER/PISTON
11-0
11. CYLINDER / PISTON
··· 11-1
SERVICE INFORMATION· · 11-5
PISTON RING INSTALLATION·
TROUBLESHOOTING ·····11-1 PISTON INSTALLATION·····11-6
CYLINDER REMOVAL······11-2 CYLINDER INSTALLATION· ·· 11-6
PISTON REMOVAL······· 11-2
SERVICE INFORMATION
GENERAL SAFETY
● Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
● Take care not to damage the cylinder wall and piston.
● Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT (mm)
I.D. 72.705~72.715 72.80
WARPAGE 0.01 0.05
CYLINDER
CYLINDRICITY 0.01 0.05
TRUE ROUNDNESS 0.01 0.05
RING-TO-GROOVE TOP 0.2 0.09
CLEARANCE SECOND 0.015~0.050 0.09
TOP 0.1~0.25 0.50 11
PISTON, RING END GAP SECOND 0.15~0.30 0.50
PISTON RING OIL RING 0.25~0.7 -
PISTON O.D. 72.67~72.69 72.6
PISTON-TO-CYLINDER CLEARANCE 0.010~0.040 0.01
PISTON PIN HOLE I.D 17.002~17.008 17.04
PISTON PIN O.D 16.994~17.000 16.96
PISTON-TO-PISTON PIN CLEARANCE 0.002~0.014 0.02
CONNECTING ROD SMALL END I.D. BORE 17.016~17.034 17.06
TROUBLESHOOTING
● When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white
smoke is found, it means that the piston rings are worn, stuck or broken.
Comperssion too low or uneven compression Excessive smoke from exhaust muffler
● Worn or damaged cylinder and piston ring ● Worn or damaged piston rings
● Worn, stuck or broken piston rings ● Worn or damaged cylinder and piston
Comperssion too high Abnormal noise piston

● Excessive carbon build-up in combustion ● Worn cylinder, piston and piston rings
● chamber or on piston head ● Worn piston pin hole and piston pin
● Incorrectly installed piston
11-1
CYLINDER/PISTON
CYLINDER
CYLINDER
CYLINDER
CYLINDER REMOVAL
● Remove the cylinder head.
● Remove the water hose from the cylinder.
● Remove the cam chain guide.

CAM
CAM
CAM CHAIN
CHAIN
CHAIN GUIDE
GUIDE
GUIDE ● Remove the cylinder.
● Remove the cylinder gasket and dowel pins.

GASKET
GASKET
GASKET ● Clean any gasket material from the cylinder surface.
DOWEL
DOWEL PINS
DOWEL PINS
PINS
PISTON
PISTON RINGS
PISTON RINGS
RINGS PISTION REMOVAL
● Remove the piston pin clip.
● Remove the piston pin out of the piston.
PISTON
PISTON
PISTON ·Place a clean shop towel in the crankcase to keep the
piston pin clip from falling into the crankcase.
PISTON
PISTON PIN
PISTON PIN
PIN
11-2
CYLINDER/PISTON
● Install the piston, piston pin and piston rings.
● Remove the piston rings.
·Take care not to damage or break the piston rings

during removal.
● Clean carbon deposits from the piston ring grooves.
● Install the piston rings onto the piston.

● Measure the piston ring-to-groove clearance.
SERVICE LIMITS :
TOP : 0.09mm replace if over
2ND : 0.09mm replace if over
● Remove the piston rings and insert each piston ring

into the cylinder bottom.
·Use the piston head to push each piston ring into the
cylinder.
● Measure the piston ring end gap.

SERVICE LIMITS : 0.5mm replace if over
● Measure the piston pin hole I.D.

11-3
CYLINDER/PISTON
● Measure the piston pin O.D.
SERVICE LIMITS : 16.96mm replace if below
● Measure the piston O.D.
·Take measurement at 9mm from the bottom and 90°

to the piston pin hole.
SERVICE LIMITS : 72.60mm replace if below
● Measure the piston-to-piston pin clearance.

CYLINDER INSPECTION
● Inspect the cylinder bore for wear or damage.
over
● Measure the cylinder-to-piston clearance.

SERVICE LIMITS : 0.1mm replace or replace if over
● The true roundness is the difference between the values

measured in X and Y directions.
(4 CYCLE ENGINE) ● The cylindricity (difference between the values
IN EX measured at the three levels) is subject to the
maximum value calculated.
TOP SERVICE LIMITS :
TRUE ROUNDNESS : 0.09mm replace or replace
if over
MIDDLE
CYLINDRICITY : 0.09mm replace or replace if
over
BOTTOM
11-4
CYLINDER/PISTON
● Inspect the top of the cylinder for warpage.
over
● Measure the connecting rod small end I.D.

PISTION RING INSTALLATION

● Install the piston rings onto the piston.
● Apply engine oil to each piston ring.
TOP RING
·Be careful not to damage the piston and piston rings
SECOND RING
during assembly.
·All rings should be installed with the markings
facing up.
·After installing the rings, they should rotate freely
SIDE RAIL
withlout sticking.
OIL RING
·stagger the ring end gaps as the figure shown.
SIDE RAIL
IN
TOP
SECOND
11-5
CYLINDER/PISTON
PISTION INSTALLATION
● Remove any gasket material from the crankcase
surface.
·Be careful not to drop foreign matters into the

crankcase.
● Install the piston, piston pin and a new piston pin clip.
·Position the piston “IN” mark on the intake valve

side.
·Place a clean shop towel in the crankcase to keep the
PISTON
PISTON
PISTON piston pin clip from falling into the crankscase.
PISTON
PISTON
PISTON PIN
PIN
PIN CLIP
CLIP
CLIP PISTON
PISTON PIN
PISTON PIN
PIN
GASKET
GASKET
GASKET
GASKET
CYLINDER INSTALLATION
● Install the dowel pins and a new cylinder gasket on the
crankcase.
DOWEL
DOWEL PINS
DOWEL PINS
PINS
CYLINDER
CYLINDER
CYLINDER
CYLINDER
● Coat the cylinder bore, piston and piston rings with
clean engine oil.
● Carefully lower the cylinder over the piston by
compressing the piston rings.
·Be careful not to damage or break the piston rings.

·The piston ring end gaps should not be parallel with
or at 90°to the piston pin.
11-6
CYLINDER/PISTON
● Install the cam chain guide.
·Insert the tab on the cam chain guide into the

cylinder groove.
● Install the cylinder gasket and dowel pins.

● Connect the water hohse to the cylinder.
● Install the cylinder head.
● Tighten the cylinder base bolt.
DOWEL
DOWEL
DOWEL PIN
PIN
PIN
11-7
CRANKSHAFT/CRANKCASE
12-0
12. CRANKSHAFT/CRANKCASE
··· 12-1
SERVICE INFORMATION· CRANKSHAFT INSPECTION·· 12-4
TROUBLESHOOTING ·····12-2 · 12-5
CRANKCASE INSTALLATION·
CRANKCASE REMOVAL· ··· 12-3
SERVICE INFORMATION
GENERAL SAFETY
● This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.
● When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent
damaging the mating surfaces.
● When installing the crankcase, do not use an iron hammer to tap it.
● The following parts must be removed before separating the crakcase.
Cylinder head
Cylinder/piston
Right crankcase cover/drive and driven pulley
A.C. generator/starter clutch
Rear wheel/rear shock absorber
Starter motor
Oil pump
SPECIFICATIONS
ITEM STANDARD(mm) SERVICE LIMIT(mm)
Connecting rod big end side clearance 0.15~0.55mm 0.60mm
CRANK
SHAFT Connecting rod big end radial clearance 0~0.008mm 0.05mm 12
Runout - 0.10mm
TORQUE VALUES
CRANKCASE BOLT : 0.78~1.08kgf·m
CAM CHAIN TENSIONER SIPPER BOLT : 0.78~1.18kgf·m
12-1
TOOL
Universal bearing puller
Bearing remover set
Remover ass’y
Remover shaft
Remover head
Slieding weight
Assembly shaft
TROUBLESHOOTING
Excessive engine noise
● Excessive bearing play
● Excessive crankpin bearing play
● Worn piston pin and piston pin hole
12-2
CAM
CAM CHAIN
CAM CHAIN TENSIONER
CHAIN TENSIONER SLIPPER
TENSIONER SLIPPER
SLIPPER
CRANKCASE REMOVAL
● Remove the cam chain tensioner slipper bolt.
● Remove the cam chain tensioner slipper and cam
chain.
● Loosen the 3 bolts securing the RH. crankcase.
BOLT
BOLT
BOLT
● Remove the LH. crankcase.
LEFT
LEFT CRANKCASE
LEFT CRANKCASE
CRANKCASE
● Place the crankcase with the LH. crankcase down and

RH.
RH.
RH. CRANKCASE
CRANKCASE
CRANKCASE remove the RH. crankcase from the LH. crankcase.
·Never use a driver to pry the crankcase mating

surfaces apart.
● Remove the gasket and dowel pins.
LH.
LH. CRANKCASE
LH. CRANKCASE
LH. CRANKCASE
CRANKCASE
● Remove the crankshaft from the RH. crankcase.

LH.
LH. CRANKCASE
LH. CRANKCASE
CRANKCASE
CRANK
CRANK SHAFT
CRANK SHAFT
SHAFT
12-3
LH.
LH. CRANKCASE
LH. CRANKCASE
LH. CRANKCASE
CRANKCASE ● Remove the oil seal from the LH. crankcase.
● Install a new drive shaft oil seal.
OIL
OIL
OIL SEAL
SEAL
SEAL
CRANKCASE INSPECTION
● Measure the connecting rod big end sied clearance.
● Measure the connecting rod small end I.D.

● Measure the crankshaft runout.

12-4
● Measure the crankshaft bearing play.
SERVICE LIMITS :
PLAY PLAY
AXIAL : 0.20mm replace if over
RADIAL : 0.05mm replace if over
AXIAL RADIAL
CRANKCASE INSTALLATION
● Clean off all gasket material from the crankcase mating
surfaces.
·Avoid damaging the crankcase mating surfaces.
● Install a new oil seal into the LH. crankcase.
OIL
OIL
OIL SEAL
SEAL
SEAL
● Place the LH. crankcase down and install the

crankshaft into the LH. crankcase.
·Avoid damaging the oil seal.

·Apply grease to the lip of the oil seal.
12-5
● Install the two dowel pins and a new gasket.
DOWEL
DOWEL
DOWEL PINS
PINS
PINS
● Place the RH. crankcase over the crankshaft and onto

the LH. crankcase.
·Install the RH. crankcase squarely and do not tap it

with an iron or plastic hammer.
● Install and tighten the R/L and left crankcase bolts.

● Install the cam chain.

● Install the cam chain tensioner slipper.
● Install the tighten the cam chain tensioner slipper bolt.
12-6
MEMO

FINAL REDUCTION
13-0
13. FINAL REDUCTION
···· 13-1
FINAL REDUCTION INSPECTION·
······ 13-1
TROUBLESHOOTING· · 13-4
FINAL REDUCTION ASSEMBLY·
· 13-2
FINAL REDUCTION DISASSEMBLY·
SERVICE INFORMATION
SPECIFICATIONS
Specified Oil : SAE 90#
Oil Capacity:
At disassembly : 0.2 liter
At change : 0.18 liter
TORQUE VALUES
Transmission case cover bolt : 1.17~2.16kgf·m
Cam chain tensioner : 0.78~1.18kgf·m
SPECIAL TOOLS
Bearing remover, 12mm
Bearing remover, 15mm
Pilot, 12mm
Pilot, 15mm
TROUBLESHOOTING
13
Engine starts but motorcycle won’t move
● Damaged transmission
● Seized or burnt transmission
Abnormal noise
● Worn, seized or chipped gears
● Worn, bearing
Oil leaks
● Oil level too high
● Worn ro damaged oil seal
13-1
FINAL REDUCTION
BOLTS
BOLTS
BOLTS FINAL REDUCTION
DISASSEMBLY
● Remove the exhaust muffler.
● Remove the rear brake caliper.
● Remove the RH. rear shock absorber.
● Remove the rear fork.
● Remove the rear wheel.
● Remove the left crankcase cover.
● Remove the clutch/driven pulleys.
● Drain the transmission gear oil into a clean container.
● Remove the transmission case cover bolts.
FINAL SHAFT
FINAL
FINAL SHAFT
SHAFT
● Remove the transmission case cover.

● Remove the gasket and dowel pins.
DRIVE
DRIVE SHAFT
DRIVE SHAFT
SHAFT ● Remove the final gear and countershaft.
FINAL GEAR
FINAL
FINAL GEAR
GEAR
COUNTER
COUNTER
COUNTER SHAFT
SHAFT
SHAFT
FINAL REDUCTION
COUNTER SHAFT
COUNTER
COUNTER SHAFT
SHAFT
INSPECTION
● Inspect the countershaft and gear for wear or damage.
● Inspect the final gear and final shaft for wear, damage
or seizure.
13-2
FINAL REDUCTION
● Check the LH. crankcase bearings for excessive play
COUNT
COUNT
COUNT SHAFT
COUNT SHAFT BEARING
SHAFT BEARING
SHAFT BEARING
BEARING and inspect the oil seal for wear or damage.
FINAL
FINAL
FINAL SHAFT
SHAFT
SHAFT BEARING
BEARING
BEARING DRIVE
DRIVE
DRIVE SHAFT
SHAFT
SHAFT BEARING
BEARING
BEARING
● Inspect the drive shaft and gear for wear or damage.

● Check the transmission case covers bearings for
excessive play and inspect the final shaft bearing oil
seal for wear or damage.
•Do not remove the transmission case cover except

for necessary part replace-ment. When replacing the
drive shaft, also replace the bearing and
FINAL
FINAL
FINAL SHAFT
SHAFT
SHAFT
BEARING REPLACEMENT
BEARING
BEARING
BEARING REMOVER,
REMOVER,
REMOVER, 15mm
15mm
15mm
(TRANSMISSION CASE COVER)
● Remove the transmission case cover bearings using the
bearing remover.
● Remove the final shaft oil seal.
● Drive new bearings into the transmission case cover.

PILOT,
PILOT, 15mm
PILOT, 15mm
PILOT, 15mm
15mm
13-3
FINAL REDUCTION
BEARING REPLACEMENT
(TRANSMISSION CASE COVER)
● Remove the transmission case cover bearings using the
bearing remover.
● Remove the final shaft oil seal.
● Drive new bearings into the left crankcase.

● Install a new drive shaft oil seal.
FINAL REDUCTION
ASSEMBLY
● Install the drive shaft into the left crankcase.
DRIVE
DRIVE
DRIVE SHAFT
SHAFT
SHAFT
● Install the final gear and final shaft into the left
crankcase.
13-4
FINAL REDUCTION
● Install the countershaft and gear into the left crankcase.
● Install the resin washer onto the counter-shaft.
● Install the dowel pins and a new gasket.
COUNTERSHAFT
COUNTERSHAFT
COUNTERSHAFT
● Install the transmission case cover.
● Install and tighten the transmission case cover bolts.

● Install the clutch/dirven pulley.
● Install other removed parts in the reverse order of
removal.
● After installation, fill the ransmission case with the

specified oil.
•Place the motorcycle on its main stand on level

ground.
•Check the oil-sealing washer for wear or damage.
OIL
OIL
OIL CHECK
OIL CHECK BOLT
CHECK BOLT
CHECK HOLE
BOLT HOLE
BOLT HOLE
HOLE
● After installation, fill the ransmission case with the
specified oil.
SPECIFIED GEAR OIL : SAE90#
OIL CAPACITY :
At disassembly : 0.2
At change : 0.18
● Install and tighten the oil check bolt.
● Start the engine and check for oil leaks.
● Check the oil level from the oil check bolt hole and add
DRAIN
DRAIN BOLT
DRAIN BOLT
BOLT the specified oil to the proper level if the oil level is
low.
13-5
FRONT WHEEL/FRONT FORK/STEERING/BRAKE
14-0
14. FRONT WHEEL/FRONT FORK/STEERING/BRAKE
···· 14-1
FRONT WHEEL INSTALLATION·
····· 14-2
TROUBLESHOOTING· ········ 14-7
FRONT BRAKE·
STEERING HANDLE ······ 14-3 BRAKE FLUID ········ 14-10
FRONT WHEEL ········ 14-4 BRAKE CALIPER ······· 14-12
FRONT WHEEL BEARING ··· 14-5 ········· 14-14
FRONT FORK·
········ 14-6
SPEEDOMETER· STEERING STEM ······· 14-19
SERVICE INFORMATION
GENERAL SAFETY
● Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking
performance. If contaminated, replace the pad with a new one, and clean the disk.
● Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged.
● Place a jack underneath the engine to support the 2-wheeled vehicle.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT (mm)
AXLE SHAFT RUNOUT - 0.2mm
RADICAL - 2.0mm
FRONT WHEEL RIM RUNOUT
AXIAL - 2.0mm
FRONT SHOCK ABSORBER SPRING FREE LENGTH 240.6mm 233mm
BRAKE DISK THICKNESS 3.8~4.2mm 3.0mm
BRAKE DISK RUNOUT - 0.30mm 14
TOP BRAKE CALIPER PISTON O.D. 26.94~26.97mm 26.91mm
TOP BRAKE CALIPER CYLINDER I.D. 27.00~27.05mm 27.00mm
UNDER BRAKE CALIPER PISTON O.D. 33.90~33.93mm 33.87mm
UNDER BRAKE CALIPER CYLINDER I.D. 33.96~34.01mm 34.01mm
TORQUE VALUES
STEERING STEM LOCK NUT 7.84~11.76㎏·m

STEERING TOP CONE RACE 0.49~1.27㎏f·m
FRONT SHOCK ABSORBER BOLT 1.98~2.45㎏f·m
FRONT AXLE NUT 4.41~4.9㎏f·m
BRAKE CALIPER BOLT 2.45~3.43㎏f·m
14-1
TROUBLESHOOTING
Hard steering Brake lever hard
● Steering bearing adjustment nut too tight. ● Clogged brake system
● Faulty steering stem bearings. ● Sticking caliper piston
● Damaged steering stem bearings. ● Caliper not sliding properly
● Insufficient tire pressure. ● Clogged fluid passage
● Worn caliper piston seal
Steers to one side or does not track straight ● Sticking or worn master cylinder piston
● Unevenly adjusted right and left shock absorbers. ● Bent brake lever
● Bent front forks.
● Bent front axle : wheel installed incorrectly. Brake drags
● Contaminated brake pad or disk
Front wheel wobbling ● Misaligned wheel
● Bent rim. ● Worn brake pad or disk
● Worn front wheel bearings. ● Warped or deformed disk
● Faulty tire. ● Caliper not sliding properly
● Axle nut not tightened properly. ● Hydraulic system contaminated with dust
● Wheel out of balance.
Soft suspension
● Weak fork springs.
● Insufficient fluid in front forks.
Hard suspension
● Incorrect fluid weight in front forks.
● Front fork air pressure incorrect.
● Bent fork tubes.
● Clogged fluid passage.
● Clogged anti-dive orifice.
Front suspension noise

● Worn slider or guide bushings.
● Insufficient fluid in forks.
● Loose front fork fasteners.
● Lack of grease in speedometer gear box.
Brake lever soft or spongy

● Air in hydraulic system
● Mixed brake fluid and wet
● Contaminated brake pad or disk
● Worn caliper piston seal
● Worn master cylinder piston seal
● Worn brake pad
● Contaminated caliper inside
● Caliper not sliding properly
● Worn brake pad or disk
● Low brake fluid level
● Clogged fluid passage
● Warped or deformed brake disk
● Sticking or worn caliper piston
● Sticking or worn master cylinder piston
● Contaminated master cylinder inside
● Bent brake lever
14-2
STEERING HANDLE
REMOVAL
● Remove the upper handle cover and the under handle
cover from the handle bar.
● Loosen the bolts securing the front and rear break
master cylinder.
● Remove the front cover, front under cover and
speedometer cover.
● Loosen the 4 screws securing the housing.

● Disconnect the throttle cable from the throttle grip and
remove the throttle grip from the handlebar.
SCREWS
SCREWS
SCREWS
SCREWS
● Remove the handlebar lock nut and take out the bolt.
● Remove the handlebar.
LOCK
LOCK NUT
LOCK NUT
LOCK NUT
NUT
INSTALLATION
● Install the handlebar onto the steering stem and install
the handlebar collar, lock nut and bolt.
● Tighten the bolt, to the specified torque.
14-3
● Lubricate the throttle grip front end with grease and
then install the throttle grip.
● Connect the throttle cable to the throttle grip.
● Install the right and left handlebar switches and tighten
the screws.
·Adjust the throttle grip free play to the specified

range of 2~6mm.
● Install the front and rear brake master cylinders.

BRAKE
BRAKE
BRAKE MASTER
MASTER
MASTER CYLINDER
CYLINDER
CYLINDER
·Install the brake master cylinders by aligning the

index marks.
FRONT WHEEL
REMOVAL
● Jack the motorcycle front wheel off the ground.
● Remove the front axle nut to pull out the axle.
● Remove the front wheel and the speedometer gear unit.
AXLE
AXLE
AXLE NUT
NUT
NUT
INSPECTION
DIAL GAUGE AXLE RUNOUT
● Set the axle in V blocks and measure the runout using a
dial gauge.
● The actual runout is 1/2 of the total indicator reading.
AXLE
14-4
WHEEL RIM
● Check the wheel rim runout.
SERVICE LIMIT :
DIAL GAUGE
DIAL
DIAL GAUGE
GAUGE
BEARING
FRONT WHEEL BEARING
INSPECTION
● Turn the inner race of each bearing with your finger to
see if they turn smoothly and quietly Also check if the
outer race fits tightly in the hub.
● Replace the bearings if the races do not turn smoothly,
quietly, or if they fit loosely in the hub.
WHEEL BEARING REPLACEMENT

● Install the bearing remover head and the remover shaft
on the wheel, and remove the bearing and distance
collar.
·Always replace bearings in pairs, and never use old

bearings.
TOOLS : BEARING REMOVER HEAD
BEARING REMOVER
● Apply sufficient amount of grease to the bearing.

● Insert the right bearing with its seal surface facing
outside.
● Do not tilt the bearing. Insert accurately.
● Upon assembling the distance collar, insert the left
bearing with its seal surface facing outside.
TOOLS : DRIVER HANDLE A

DRIVER PILOT
OUTER DRIVER
·The bearing inserted in the last must be inserted until

it contacts with the distance collar.
·Excessively inserted bearing can cause damage the
opposite side bearing.
14-5
SPEEDOMETER GEAR REPLACEMENT
● Remove the speedometer gear and washer from the
speedometer gear box.
● Check the gear for wear or damage.
● Install the washer.
● Apply grease to the speedometer gear prior to
assembling.
● Install the washer.
● Apply grease to the speedometer gear unit and install.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETER GEAR
GEAR BOX
GEAR BOX
BOX
BOX SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETER GEAR
SPEEDOMETER GEAR
GEAR
FRONT WHEEL ASSEMBLY

● Apply grease to the left side dust seal rim.
● Install the left side dust seal.
● Install the brake disk.
● Install disk bolts.
DUST
DUST SEAL
DUST SEAL
SEAL
● Install the left side collar.
RH.
RH.
RH. SIDE
SIDE
SIDE COLLAR
COLLAR
COLLAR
● Install the speedometer gear unit by aligning its

retaining pawl with the hub cutout.
GEAR
GEAR
GEAR BOX
BOX
BOX RETAINER
RETAINER
RETAINER
14-6
FRONT WHEEL/FRONT FORK/STEERING
● Apply grease to the dust seal rim.
● Install the dust seal, and align the tangs of the
speedometer gear retainer with the gear groove to
assemble the speedometer gear box.
SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETER GEAR BOX
GEAR BOX
BOX
FRONT WHEEL INSTALLATION

● Insert the front wheel between the front forks.
● Insert the disk, taking precautions not to damage the
pad, and assemble the wheel.
● Align the slots of the speedometer gear with the tangs
of the left fork slider.
● Insert the front axle into the speedometer gear box and
the wheel hub.
FRONT
FRONT AXLE
FRONT AXLE
AXLE
● Install the axle nut.

● Install the speedometer cable, and tighten with screws.
● Place the front wheel on the ground, and tighten the
axle nut to the specified torque.
TORQUE VALUE : 5.0-7.0 kgf·m
AXLE NUT
AXLE
AXLE NUT
NUT
FRONT WHEEL
BRAKE MASTER CYLINDER
REMOVAL
● Remove the handlebar covers.
● First drain the brake fluid from the hydraulic brake
system.
● Disconnect the front stop switch wire connector.
● Remove the brake fluid tube bolt.
● Remove the two bolts securing the brake master
cylinder.
● Remove the brake master cylinder.
14-7
·When servicing the brake system, use shop towels to

cover rubber and plastic parts and coated surfaces to
avoid being contaminated by brake fluid.
·When removing the brake fluid tube bolt, be sure to
plug the tube end to avoid brake fluid leakage.
DISASSEMBLY
● Remove the Fr/Rr stop switch.
● Take out the boot and circlip from the master cylinder.
TOOLS : SNAP RING PLIERS
CIR
CIR
CIR CLIP
CLIP
CLIP
MASTER
MASTER
MASTER ● Remove the washer, piston, spring from the master
STOP CYLINDER
STOP
STOP CYLINDER SET
CYLINDER SET
SET cylinder.
SWITCH
SWITCH
SWITCH
SWITCH ● Clean the master cylinder, reserve, master piston with
the recommended brake fluid.
LEVER
LEVER
LEVER
BOOT
BOOT
BOOT MASTER
MASTER
MASTER
CIR
CIR
CIR CLIP
CLIP
CLIP CYLINDER
CYLINDER
CYLINDER BODY
BODY
BODY
INSPECTION
PISTON
PISTON
PISTON ● Check the piston periphery for scores, scratches or
nicks and replace if necessary.
● Check the primary and secondary cups for wear.
SECONDARY
SECONDARY
SECONDARY CUP
CUP
CUP PRIMARY
PRIMARY
PRIMARY CUP
CUP
CUP
14-8
·If there is any leak of fluid when installing new

piston, it may indicate the side wear of the cylinder
by the direction of the piston contacting face. In this
case, the master cylinder must be replaced also.
● Check the master cylinder for scores, scratches or nicks

and replace if necessary.
ASSEMBLY
OIL CUP CAP
BOOT DIAPHRAGM PLATE

CIR CLIP
DIAPHRAGM
·Replace the piston, spring, cups and snap ring as a
SPRING
set.
·Be sure that each part is free from dust or dirt before
WASHER reassembly.
MASTER CYLINDER ·When cleaning with the brake fluid, use the specified
BODY
brake fluid.
● Coat the piston, cup with the fresh brake fluid and
LEVEL STOP SWITCH install it on the piston. Install the spring with its larger
diameter end toward the master cylinder.
·When installing the cups, do not allow the lips to

turn inside out.
·Note the installation direction of the snap ring.
·Be certain that the snap ring is seated firmly in the
groove.
● Install the primary cup with its concaved side toward
the inner side of the master cylinder.
● Install the snap ring.
● Install the rubber boot in the groove properly.
TOOL : SNAP RING PLIERS
BOOT
BOOT
BOOT
INSTALLATION
SETTING
SETTING BOLTS
SETTING BOLTS
SETTING BOLTS
BOLTS
● Install the front / rear master cylinder to the handle bar.
·Install the holder with its “UP” mark facing

upwards, and align the holder joint with the punch
mark on the handle bar.
·Tighten the holder upper bolt first.
14-9
● Install the brake hose to the master cylinder with 2 new
sealing washers and the hose bolt.
TORQUE VALUE : 2.5~3.5 kgf·m
● Loosen the 2 flat screws, remove the oil cup cap,

diaphragm plate and diaphragm.
● Fill the brake fluid, and bleed air.
● Install the diaphragm, diaphragm plate and the oil cup
cap, tighten the 2 flat screws.
OIL
OIL BOLT
OIL BOLT
BOLT
BRAKE FLUID
·A contaminate disk or pad reduces braking power.

Do not allow the disk or pad to be contaminated by
oil.
·Replace contaminated pads, and remove pollutants
from the disk completely.
·Check the brake fluid level often, and replenish new
fluid as required. Do not spill fluid on painted,
plastic or rubber parts.
● Remove the wind screen.

● Remove the oil cup cap, diaphragm plate and
diaphragm from the master cylinder.
● Connect the bleeder hose to the bleeder valve. Loosen
the bleeder valve, and pump the brake lever repeatedly.
● When there is no more fluid flowing out of the bleeder
valve, stop pumping the brake lever.
AIR BLEEDING
<When the brake bleeder is available>
● Fill the reservoir with DOT 3 or 4 brake fluid up to the
BRAKE BLEEDER upper level.
브레이크 브리더
·To prevent chemical changed, do not use different

types of brake fluid.
● Connect the recommended brake bleeder to the bleeder

valve.
● Loosen the bleeder valve while pumping the brake
lever.
● Repeat this operation until the brake fluid flows out of
the brake bleeder.
● Add brake fluid.
14-10
·Check the fluid level often, and replenish fluid if the

amount of fluid is reduced to the lower level.
·Read the user’s manual carefully prior to
disassembling or using the brake bleeder.
·Protect the bleeder valve with tape to prevent air
from entering the bleeder valve.
● Repeat the above procedures until no air bubbles

appear in the bleeder hose.
● Squeeze the bleeder valve and operate the brake lever
to check the ingress of air.
<When the brake bleeder is not available>

BLEEDER VALVE
브리더 밸브
● Fill the brake fluid up to the upper limit line.

● Connect the transparent bleeder hose to the bleeder
valve and place the other end of the hose in a container.
① Squeeze the brake lever, then open the bleeder

valve 1/2 turn, and close the valve.
브리더
BLEEDER 호스
HOSE ·Do not release the brake lever until the bleeder valve
재사용 엄금
NO REUSE has been closed.
·Check the brake fluid level often while bleeding the
system to prevent air from being pumped into the
system.
② Release the brake lever slowly and wait several
seconds after it reaches the end of its travel.
③ Repeat the above steps ① and ② until bubbles
cease to appear in the fluid at the end of the hose.
● Check the fluid level often, and add fluid if the fluid
level is near the lower level.
● If no air leaks out of the bleeder hose, operate the brake
lever to check the presence of air.
● Tighten the bleeder valve.
TORQUE VALUE : 0.4~0.7 kgf·m
● Be sure that the brake fluid is up to the upper level of

the master cylinder and refill if necessary
● Reinstall the diaphragm, diaphragm plate and oil cup
cap.
14-11
BRAKE CALIPER
REMOVAL
● First drain the brake fluid from the hydraulic brake
system.
● Remove the brake fluid tube bolt.
● Remove the two bolts securing the brake master
cylinder.
● Remove the brake caliper.
·Pay attention not to let the brake fluid adhere to the

parts because it can damage the painted surface.
·Wind the hose joint with cloth to prevent the brake
fluid from leaking.
·Clean the removed parts with the brake fluid and
make sure that the each port isn’t clogged with the
compressed air.
·Keep the removed parts in order to avoid dust from
adhering.
DISASSEMBLY
● Remove the slide pin, the LH. bracket, the pin bush, the
boot and the pin boot, and the pin bolt from the caliper.
● If there is any wear or damage in the boot, replace it
with a new one.
● Wind the caliper with cloth to prevent the piston or
brake fluid from leaking.
● Remove the piston from the caliper while blowing the
low-pressure air in the opening of the brake hose.
·Never use the high-pressure air or bring the air gun

too close.
·Never touch the inside of the caliper
● Disassemble the piston seal and the dust seal
·Pay attention not to damage the inner surface of the

caliper.
● Clean the piston and the inside of the caliper and

remove the oil from the seal groove.
14-12
INSPECTION
● Check the caliper cylinder bore for scoring, scratches
or other damage.
● Measure the caliper I.D.
● Check the piston for scratches or wear.

● Measure the piston O.D. with a micrometer gauge.
● Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper. Install the piston in
the caliper with the groove side of the piston facing the
pad.
PISTON
PISTON
PISTON
CALIPER
CALIPER
CALIPER
DUST
DUST
DUST SEAL
SEAL
SEAL
PISTON
PISTON SEAL
PISTON SEAL
PISTON SEAL
SEAL
14-13
● Apply the silicone grease to the boot.
● Connect the boot to the portion of the caliper.
● Install the pad spring in the caliper.
● Install the caliper pin bolt and the slide pin in the
caliper.
● Install the brake pad and the hanger pin in the caliper.
● Install the front caliper to the front fork

● Tighten the bolt to the specified torque.
● Connect the brake hose to the caliper and install 2

sealing washers and oil bolt.
● Tighten the oil bolt to the specified torque
● Fill the brake fluid to the upper limit line and bleed air.
FRONT FORK
REMOVAL
-Front under cover
-Front brake caliper
-Front fender
-Front wheel
● When removing the front fork, loosen the fork pipe

bolt lightly.
·Support the vehicle securely under the engine not to

turn over it.
·Loosen the fork pipe bolt, but do not remove it.
● Loosen the 4 setting bolts securing the RH./LH. front

fork, remove the RH./LH. front fork.
● After removal of RH. front fork, loosen the flange bolt
and remove the front brake hose clamp A.
14-14
DISASSEMBLY
● Remove the fork pipe bolt.
SPRING
·If the screw is completely loosened, the fork tube

cap bolt may spring out by the force of the spring.
Take due precautions.
·Remove the fork spring, and expand and release the
fork pipe several times to drain fork oil.
● Wrap the bottom case with a piece of cloth, and

remove the socket bolt.
SOCKET
SOCKET
SOCKET BOLT
BOLT
BOLT
·If the socket bolt turns idle but cannot be removed,

VISE temporarily assemble the spring and the fork tube
cap bolt first.
·Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.
BRACKET
● Remove the dust seal.
DUST
DUST
DUST SEAL
SEAL
SEAL
14-15
● Remove the oil seal stop ring.
OIL
OIL
OIL SEAL
SEAL
SEAL
STOPPER
STOPPER RING
STOPPER RING
STOPPER RING
RING
● Remove the oil seal.
·Take precautions not to damage the interior and

exterior rim of the bottom case.
OIL
OIL SEAL
OIL SEAL
SEAL
● Remove the fork tube from the bottom case.

● Remove the piston and rebound spring from the fork
tube.
BOTTOM CASE
FORK TUBE
FRONT FORK INSPECTION
● Place the fork spring on a level place, and measure the

free length.
● If the free length deviates from the service limit,
replace the spring with a new one.
TOP BOTTOM ● Check components for damage or abnormal wear.
Replace defective parts with new ones.
SERVICE LIMIT : FORK SPRING 235mm
● Set the fork pipe on a V-blocks, and measure fork pipe

deflection by rotating with a dial gauge.
SERVICE LIMIT : Replace if the deflection is greater

than 0.2mm
14-16
● Check the slider bush contact face.
● If the slider bush is extensively damaged, replace the
bottom case.
FORK TUBE
FRONT FORK ASSEMBLY
● Wash parts with clean oil prior to assembling.

BOTTOM CASE ● Assemble the rebound spring and thd fork piston to the
fork tube.
● Assemble the fork tube to the bottom case.
FORK TUBE
● Wrap the bottom case with a piece of cloth, and fix it to

the vise.
● Apply screw locking agent to the socket bolt thread,
and assemble the socket bolt to the fork piston.
·When a vise is used to hold the bottom case, do not

insert the case itself but insert the bracket.
● Apply ATF to a new oil seal.

● Assemble the oil seal to the bottom case.
FORK SEAL DRIVER
● Insert the oil seal with special tools until the attachment
groove of the bottom case set ring is exposed.
TOOLS : FORK SEAL DRIVER

FORK SEAL DRIVER FORK SEAL DRIVER BODY
ATTACHMENT
14-17
● Install the oil seal stopper ring
OIL
OIL
OIL SEAL
SEAL
SEAL ● Accurately assemble the oil seal stop ring to the bottom
STOPPER
STOPPER RING
STOPPER RING
RING case.
● Install the dust seal.

FORK OIL ● Fill a prescribed amount of automatic transmission
fluid(ATF) into the fork tube.
CAPACITY : 90cm3
OIL ● Slowly press the fork tube 2-3 times to discharge air.
LEVEL
FORK
OIL
● Assemble the spring to the fork pipe.
·Install the spring with the smaller pitch side facing

downward.
FORK
FORK
FORK PIPE
PIPE
PIPE CAP
CAP
CAP BOLT
BOLT
BOLT
● Assemble the fork bolt to the fork pipe.
14-18
● Install the front fork to the steering stem.
● Install the front fork setting bolts.
● Install the brake hose clip A to the RH. front fork.
STEERING STEM
REMOVAL
-Handle cover
-Handle bar
-Front cover
-Front under cover
-Inner cover
-Front wheel
-Front fork
·Be careful not to turn over the vehicle.
● Remove the steering stem nut using the steering stem

nut socket.
TOOL : STEERING STEM NUT SOCKET
● Remove the steering top thread nut using the steering

stem socket.
TOOL : STEERING STEM SOCKET
● Remove the top cone race.

● Check the upper ball assembly, top cone race and ball
race for damage or abnormal and replace as necessary.
● Check the bottom cone race for wear and damage.
14-19
● Remove the steering top ball race from the head pipe.
● Remove the steering bottom race.
·Check all of the races and balls for damage or

abnormal wear and replace as necessary.
·If the vehicle has been involved in an accident,
examine the area around the steering head for crack.
INSTALLATION
● Install the steering head dust seal washer and dust seal
onto the steering stem.
● Press in the steering bottom cone race using the
steering stem driver.
● Install the under ball ass’y into the steering stem.
TOOL : STEERING STEM DRIVER
● Install the steering stem into the head pipe.
● Install the steering upper ball ass’y into the steering
stem.
● Install the top cone race and steering top thread onto
the steering head.
● Tighten the top thread to specified torque, then loosen
the top thread 1/8 turn
● Recheck that the steering stem moves smoothly

without play or binding.
● Tighten the steering stem lock nut temporarily.
TOOLS : STEERING STEM LOCK NUT SOCKET

STEERING STEM SOCKET
● Install the following parts.

- Front fork
- Front wheel
- Inner cover
- Front under cover
- Front cover
- Handle bar
- Handle cover
14-20
MEMO

REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM
15-0
15. REAR WHEEL/BRAKE/SUSPENSION/SWING ARM
··· 15-1
SERVICE INFORMATION· ········· 15-5
REAR WHEEL·
····· 15-2
TROUBLESHOOTING· ··· 15-6
REAR CUSHION ADJUST·
········· 15-3
REAR BRAKE· REAR CUSHION ········ 15-6
·········· 15-5
REAR FORK·
SERVICE INFORMATION
● During servicing, keep oil or grease off the brake pads and brake disk.
● Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to
clean brake assemblies. Use a brake cleaner, designed to minimize the hazard caused by airborne asbestos fibers.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT(mm)
REAR WHEEL RIM RUNOUT - 2.0
REAR SHOCK ABSORBER SPRING FREE LENGTH 232.9 235
REAR BRAKE DISK THICKNESS 3.5~3.8 3.0
REAR BRAKE DISK RUNOUT - 0.30
REAR BRAKE MASTER CYLINDER I.D. 14.000~14.040 14.050
REAR BRAKE MASTERCYLINDER PISTON O.D. 13.950~13.980 13.940
TORQUE VALUES :
EXHAUST MUFFLER LOCK BOLT 2.94~3.92㎏f·m

REAR AXLE NUT 7.84~9.8㎏f·m
REAR SHOCK ABSORBER LOWER MOUNT BOLT 1.96~2.94㎏f·m
REAR SHOCK ABSORBER UPPER MOUNT BOLT 3.92㎏f·m
REAR BRAKE CALIPER BOLT 1.96~2.94㎏f·m
15
15-1
REAR WHEEL / BRAKE / SUSPENSION / SWING ARM
TROUBLESHOOTING
Wobble or vibration in motorcycle
● Tire pressure incorrect
● Faulty tire
● Bent rim
● Loose wheel bearing
● Swing arm bushing worn
● Wheel out of balance
Soft suspension
● Weak springs
● Rear damper improperly adjusted, oil leakage
Hard suspension
● Rear damper improperly adjusted
● Bent shock absorber rod
Suspension noise
● Loose fasteners
● Worn shock
15-2
REAR BRAKE
REMOVAL
● Remove the muffler.
● Loosen the rear break tube bolt and remove the break
tube.
● Loosen 2 bolts and remove rear break caliper.
INSPECTION
● Inspect break pad and disk.
● Measure the break disk thickness.
SERVICE LIMIT : 3mm
CALIPER
CALIPER
CALIPER BRACKET
BRACKET
BRACKET
DISASSEMBLY
● Remove the rear break caliper.
● Inspect caliper assembly.
● Remove the pad spring, slide pin, caliper bracket, and
boot from the caliper body.
● Check the boot for wearand damage and replace if
necessany.
● Wind the caliper facing down with cloth to prevent the

piston or break fluid from leaking.
● Remove the piston from the caliper while blowing the
low-pressure air in the opening of the break hose.
·Never use the high-pressure air or bring the air gun

too close.
·Never touch the inside of the caliper
15-3
● Disassemble the piston seal and the dust seal.
PISTON
PISTON
PISTON SEAL
SEAL
SEAL DUST SEAL
DUST
DUST SEAL
SEAL ● Clean the piston and inside of caliper with break fluid.
INSPECTION
● Check the caliper cylinder bore for scoring, scratches
or other damage.
● Measure the caliper I.D.
● Inspect piston surface for scratch or damage.

● Measure the piston O.D.
CALIPER
CALIPER
CALIPER
CALIPER
BRAKE CALIPER ASSEMBLY
● Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper. Install the piston in
PISTON
PISTON SEAL
PISTON SEAL
SEAL the caliper with the groove side of the piston facing the
pad.
DUST
DUST SEAL
DUST SEAL
SEAL
PISTON
PISTON
PISTON
PISTON
BOOT
BOOT
BOOT
BOOT
● Apply the silicone grease to the pin bush.
● Connect the pin bush to the portion of the caliper.
● Install the pad spring in the caliper.
● Install the caliper pin bolt and the caliper bracket in the
caliper.
● Install the break pad in the caliper.
CALIPER
CALIPER
CALIPER
PAD
PAD SPRING
PAD SPRING
SPRING BRACKET
BRACKET
BRACKET
BRACKET
15-4
INSTALLATION
● Install the brack caliper to the front fork and tighten the
bolt to specified torque.
● Connect the brcakhose to the caliper body and tighten 2

oil bolts and washers to specified torque.
● Fill the break fluid to te upper limit line and bleed air.
REAR FORK
● Remove the muffler.
● Remove the rear breake caliper.
● Loosen the lower bolt securing the RH. rear cushion.
● Loosen 2 bolts securing the mud guard.
● Loosen the axle nut and remove the collar.
● Loosen 2 bolts securing the engine and remove the rear
fork.
● Rotate the inner bearing with finger and check it for

smooth operation.
● Check the malfunction and replace if necessary.
REAR WHEEL
REMOVAL
● Remove the exhaust muffler.
● Remove the rear brake caliper.
● Remove the rear fork.
● Remove the rear axle collar.
● Remove the rear wheel.
15-5
INSPECTION
● Measure the rear wheel rim runout.
SERVICE LIMIT :
ASSEMBLY
TORQUE VALUE
Rear cushion lower bolt: 1.96~2.94kgf·m
Rear axle nut: 7.84~9.8kgf·m
REAR CUSHION ADJUST

● Adjust the cushion spring according to the load
condition.
● The rear cushion can be adjusted as below.
1 - 2 - 3 - 4 - 5
soft medium hard
REAR CUSHION
REMOVAL
● Remove the air cleaner.
● Remove the upper bolt.
● Remove the lower bolt.
● Remove the rear cushion.
15-6
INSTALLATION
15-7
CHARGING SYSTEM
REGULATOR RECTIFIER
MAIN SWITCH
A.C. GENERATOR
16-0
16. CHARGING SYSTEM
······ 16-1
CHARGING SYSTEM INSPECTION·
········ 16-2
TROUBLESHOOTING· A.C. GENERATOR INSPECTION·· 16-4
BATTERY ·············· 16-2 · 16-5
REGULATOR RECTIFIER INSPECTION·
SERVICE INFORMATION
·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
·Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
·If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.
·This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
·When charging the battery, remove the battery from the frame and do not open stopper.
·There is the possibility of damaging the regulator/rectifier, etc. if the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
● If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that the
battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss in
battery strength.
● It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
● If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
● For information on generator disassembly, refer to section 8.
SPECIFICATIONS 16
ITEM STANDARD VALUES
Capacity 12V - 10AH (MF)
BATTERY
Terminal-to-terminal voltage (When fully charged) 13.0 - 13.2V
Charging coil resistance value ( 20°
C) 0.6 - 1.6Ω
A.C.GENERATOR
rpm at charging start 1,300rpm
REGULATOR /RECTIFIER Regulator voltage 14.5±0.5V
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER
16-1
CHARGING SYSTEM
TROUBLESHOOTING
No power (Key turned on) Low power (Engine running)

● Dead battery. ● Battery undercharged.
-Low fluid level. ● Battery is failing.
-Low specific gravity. ● Charging system failure.
-Charging system failure.
● Disconnected battery cable. Intermittent power
● Main fuse burned out. ● Loose battery connection.
● Faulty ignition switch. ● Loose charging system connection.
● Loose starting system connection.
Low power (Key turned on) ● Loose connection or short circuit in ignition system.
● Battery undercharged. ● Loose connection or short circuit in lighting system.
-Low fluid level.
-Low specific gravity. Charging system failure
● Charging system failure. ● Loose, broken or shorted wire or connection.
● Loose battery connection. ● Faulty regulator rectifier.
● Faulty A.C generator.
CHARGING SYSTEM
Measure battery current leakage. INCORRECT

Check the regulator rectifier.
CORRECT CORRECT
·Shorted harness wire.
·Faulty ignition switch.
INCORRECT
Inspect the charging voltage. OVER 15V ·Faulty regulator rectifier.
UNDER 14V
14~15V ·Battery is failing
Check the voltage between the battery line and ·Open circuit in wire harness.
ABNORMAL
ground wire of regulator rectifier. ·Poorly connected coupler.
NORMAL
Check the resistance of the charging coil at INCORRECT ·Check the charging coil of theA.C
the charging coil line of regulator rectifier generator.
coupler.
NORMAL
·Poorly connected A.C generator coupler.
CORRECT ABNORMAL
·Faulty charging coil.
Check the regulator rectifier. ABNORMAL ·Faulty regulator rectifier.
NORMAL
·Faulty battery.
16-2
CHARGING SYSTEM
BATTERY
● Remove the seat and luggage box.
● Loosen the screws secuning the battery cover and
remove the battery cover.
● Remove the battery.

● First disconnect the negative “⊖” battery cable, and
then disconnect the positive “⊕” cable.
·When disconnecting the battery positive ⊕ cable, do

not touch the frame with tool ; otherwise it will cause
short circuit and sparks to fire the fuel.
● The installation sequence is the reverse of removal.
·First connect the positive ⊕ cable and then negative

⊖ cable to avoid short circuit.
BATTERY (OPEN-CIRCUIT VOLTAGE) INSPECTION

● Remove the battery cover.
● Disconnect the battery terminals from the battery.
● Measure the voltage between the battery terminals.
- FULLY CHARGED : 13.2V
- INSUFFICIENTLY CHARGED : UNDER 12.3V
TOOL : DIGITAL TESTER
·Use a voltmeter that will accurately indicate 0.1V

difference.
·When measuring the battery volate after charging,
leave it for at least 30 minutes, or the accurate results
cannot be obtained because the battery voltage
fluctuates just after charging.
● Connect the charger positive (+) cable to the battery
positive (+) terminal.
● Connect the charger negative (-) cable to the battery
negative (-) terminal.
·Keep flames and sparks away from a charging

battery.
·Turn power ON/OFF at the charger, not at the
battery terminals to prevent sparks near the battery.
BATTERY CHARGER
·Charge the battery according to the current specified
on the battery.
·During quick charging, the battery temperature
should not exeeed 45° C
16-3
CHARGING SYSTEM
CHARGING SYSTEM INSPECTION

LEAK TEST
● Trun off the ignition switch, and disconnect the ground
(-) cable from the battery.
● Connect an ampere meter between negative (-)
terminal and ground cable.
● With the ignition switch off, measure the leakage current.
LEAK CURRENT : Not to exceed 0.5A(max)

TOOL : DIGITAL TESTER
·When measuring current using a tester, set it to a

large range, and then bring it down the range to an
appropriate level.
·Current flow larger than the range selected may blow
AMPERE METER out the fuse in the tester.
·While measuring current, do not turn the ignition on.
BATTERY TERMINAL
A sudden surge of current may blow out the fuse in
the tester.
EARTH CABLE
A.C. GENERATOR INSPECTION
·This test can be made without removing the stator

from the engine. Disconnect the yellow wire from
the auto bystarter.
● Remove the frame center cover.

● Disconnect the A.C. generator connector.
● Measure the resistance between the yellow wires.

● Replece the stator if resistance value is high or there is
continuity between each yellow wire and ground.
● Resistance : yellow~yellow 0.6~1.6Ω
16-4
CHARGING SYSTEM
REGULATOR RECTIFIER INSPECTION

● Remove the regulator rectifier coupler.
● Measure each terminal.
RESISTANCE VALUE Unit : ㏀, (20℃)

Tester ⊕
Tester ⊖ R B Y Y Y G
R 0-5 1-3 1-3 1-3 1-4
B ∞ ∞ ∞ ∞ 25-40K
Y ∞ 1-4 ∞ ∞ 1-4
Y ∞ 1-4 ∞ ∞ 1-4
Y ∞ 1-4 ∞ ∞ 1-4
G ∞ 25-40K ∞ ∞ ∞
● Replace the regulator rectifier unit if the resistance

value between the terminals is abnormal.
16-5
IGNITION SYSTEM
BATTERY
REGULATOR RECTIFIER
IGNITION UNIT
MAIN SWITCH
A.C. GENERATOR
IGNITION UNIT
17-0
17. IGNITION SYSTEM
····· 17-1
A.C. GENERATOR INSPECTION·
······· 17-2
TROUBLESHOOTING· ··········· 17-4
IGNITION UNIT·
··· 17-3
IGNITION COIL INSPECTION·
SERVICE INFORMATION
GENERAL SAFETY
● Follow the steps described in the troubleshooting flow chart when servicing the ignition system.
● The CDI unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
● The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing.
● Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
● Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
● A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
● This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
● Conduct inspection on the main switch by referring to the wiring diagram continuity chart.
SPECIFICATIOS
ITEM STANDARD VALUE
SPARK PLUG NGK DPR7EA9
SPARK PLUG GAP 0.8~1.0mm
PRIMARY COIL 1.5~3.5
IGNITION COIL RESISTANCE SECONDARY WITHOUT PLUG CAP 12~16
COIL WITH PLUG CAP 17~21
PULSER COIL RESISTANCE 50~170
TOOLS
DIGITAL TESTER
PVA MULTI-TESTER
CDI TESTER
BATTERY TESTER
17
17-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug.
UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)
1. The multitester impedance is too low.

2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
IGNITION COIL PRIMARY VOLTAGE
3. The sample timing of the tester and measured pulse were not
Low peak voltage.
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in ignition system.
5. Faulty ignition coil.
6. Faulty ignition unit (in case when above No. 1~5 are normal).
1. Incorrect peak voltage adaptor connections.

2. Faulty ignition switch.
3. Loose or poorly connected ignition unit connector.
No peak voltage.
4. Open circuit or poor connection in ground cord of the CDI unit.
5. Faulty peak voltage adaptor.
6. Faulty ignition unit (in case when above No. 1~5 are normal).
Peak voltage is normal, but no spark 1. Faulty spark plug or leaking ignition coil secondary current ampere.
jumps at plug. 2. Faulty ignition coil.
1. The multitester impedance is too low.

2. Cranking speed is too slow.
PULSE GENERATOR
- Battery is undercharged (or operating force of the kick starter is

weak).
Low peak voltage.
3. The sample timing of the tester and measured pulse were not
synchronized.(System is normal if measured voltage is over the
standard voltage at least once.)
4. Faulty pulse generator (in case when above No. 1~3 are normal).
1. Faulty peak voltage adaptor.

No peak voltage.
2. Faulty pulse generator.
17-2
IGNITION SYSTEM
IGNITION COIL INSPECTION

● Remove the seat lock with the main key.
● Remove the primary wire.
·Since the resistance value of the primary coil is

inherently very small, it is difficult to distinguish it
from a shorted wire.
● Measure the resistance between the two terminals of

the ignition primary coil.
● If the resistance value is within the specified range the
coil is good.
● If resistance is ∞ (infinite), replace the coil with a new
one.
STANDARD VALUE : 1.5~3.5Ω
● With the spark plug cap on, measure the resistance

between the primary coil terminal and the spark plug
cap.
● If the resistance value is within the specified range,
then the coil is good.
● If the resistance is ∞ (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.
STANDARD VALUE : 17~21 ㏀
● Measure resistance between the primary coil terminal

and high-tension cord.
● If the resistance value is within the specified range,
then the coil is good.
● If the resistance is ∞ (open wire), replace the coil with
a new one.
STANDARD VALUE : 12~16 ㏀
REPLACEMENT
● Remove the high-tension cord from the plug, remove
the plug cap.
● Remove the wire from the ignition coil.
● Remove the primary wire from the ignition coil.
● Loosen the ignition coil fixing bolt securing the frame,
Remove the ignition coil.
17-3
IGNITION SYSTEM
A.C. GENERATOR INSPECTION

EXCITER/PUISE COIL INSPECTION
● Disconnect the A.C. generator connector.
● Measure the exciter coil resistance between the
black/white wire terminal and ground.
·Black/white~Ground 23~35 ㏀
● Disconnect the pulser coil wire coupler.

● Measure the pulser coil resistance between the
blue/white and green/white wire terminals.
·Black/white~Green/white 50~170 ㏀
IGNITION UNIT
INSPECTION
● Measure the resistance between terminals.
B/W G/B G L/Y G/GR
V/R V/B V/G G/W B/Y
Unit : Ω
(+) L/Y B/Y G/R G/W B/W G/B V/R V/B V/G G
(-)
L/Y 67~125K 36~67K 110~200K 36~67K 36~67K

B/Y 11~22M 11~22M 0.5~2K 11~22M 11~22M 11~22M 11~22M
G/GR
G/W 67~125K 36~67K 110~200K 36~67K 36~67K

B/W 11~22M 0.5~2K 11~22M 11~22M 11~22M 11~22M 11~22M
G/B
V/R 36~67K 36~67K 72~133K 2~5K 2~5K

V/B 110~200K 110~200K 72~133K 72~133K 72~133K
V/G 36~67K 36~67K 2~5K 72~133K 0.1~1
G 36~67K 36~67K 2~5K 72~133K 0.1~1
17-4
MEMO

STARTER SYSTEM
STOP SWITCH
BATTERY
MAIN SWITCH
STARTER MOTOR
CABLE (STARTER MOTOR)
STOP LAMP
BATTERY
+ CABLE
18-0
18. STARTER SYSTEM
···· 18-1
SERVICE INFORMATION· STARTER MOTOR ······ 18-3
TROUBLESHOOTING ····· 18-2 STARTER MAGNETIC SWITCH · 18-5
SERVICE INFORMATION
GENERAL SAFETY
·Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.
● The starter motor can be maintained without removing the engine from the vehicle.
● A weak battery may be unable to turn the starter motor quickly enough, or, supply adequate ignition current.
● The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over.
● The engine may not be turned over if the stop switch is faulty.
SPECIFICATION
ITEM STANDARD VALUE SERVICE LIMIT
STARTER MOTOR BRUSH LENGTH 12.5 mm 5 mm
TORQUE
STARTER MOTOR MOUNTING BOLT : 0.67~1.08kgf·m
STARTER MOTOR CASE SCREW : 0.29~0.49kgf·m
STARTER CLUTCH BOLT : 0.98~1.37kgf·m
18
18-1
STARTER SYSTEM
TROUBLESHOOTING
Starter motor will not turn.
● Check for a blown main fuse before servicing.

● Check that the stop light is correctly adjusted.
● Check that the side stand is positioned in the condition under which the engine can be started.
Connect the starter motor (+) terminal to the

With the ignition switch“ON”and squeeze battery positive terminal. (Because a large
the brake lever, check for “a click” sound CLICKS amount of current flows, do not use thin
from starter magnetic switch. (⇨17-7) wires). (⇨17-4)
Starter motor does not turn.

NO CLICK.
Starter motor turns.
● Faulty starter motor.
● Loose or disconnected
Disconnect starter magnetic switch coupler, wire or cable.
and check the starter magnetic switch coil
NO CONTINUITY. ● Faulty starter switch.
ground wire. (⇨17-7)
● Faulty side stand switch.
● Loose or poor contact at connector.
CONTINUITY. ● Open circuit in wire harness.
Connect the starter magnetic switch coupler.

Measure the starter magnetic voltage at the NO VOLTAGE. ● Faulty ignition switch or starter switch.
starter magnetic switch coupler. (⇨17-7) ● Loose or poor contact at connector.
● Open circuit in wire harness.
VOLTAGE MEASURED.
● Faulty brake stop switch.
Check the starter magnetic switch operation. NORMAL ● Loose or poor contact at starter magnetic
(⇨17-8) switch coupler.
ABNORMAL ● Faulty starter magnetic switch.
Starter motor turns slowly.

● Low specific gravity in battery. (or dead battery)
● Poorly connected battery terminal cable.
● Poorly connected starter motor cable.
● Faulty starter motor.
● Poorly connected battery ground cable.
● Damaged or worn brush.
Starter motor and engine turns, but engine does not start.
● Faulty ignition system.
● Engine problems.
Starter motor turns, but engine does not turn over.

● Starter motor is running backwards.
-Brushes assembled improperly.
-Case assembled improperly.
-Terminals connected improperly.
● Faulty starter clutch.
● Damaged starter gear.
18-2
STARTER SYSTEM
STARTER MOTOR
● Release the seat lock with the main key.
● Remove the core tubeband from the carbureter
● Remove the starter motor cable from the starter
magnetic switch.
● Loosen the 2 flange bolts securing the engine case,
remove the battery earth cable and starter motor.
DISASSEMBLY
● Release the two starter motor case screws, front cover,
rear cover, motor case and other parts.
INSPECTION
● Inspect the removed parts for wear, damage or
discooration. Replace if necessary.
● Clean the commutator if there is metal powder between
the seaments.
● Check for continuity between pairs of the commutator

segments and there should be continuity.
18-3
STARTER SYSTEM
● Make a continuity check between individual
commutator segments and the armature shaft. There
should be no coninuity.
● Measure the length of the brushes.

SERVICE LIMIT : 8.5m replace if below
● Check the continuity between brush ⊕and cord

terminal.
- Normal if there is continuity.
● Check the continuity between cord terminal and case.

- Normal if there is no continuity.
18-4
STARTER SYSTEM
● Check if the needle bearing in the front cover turns
freely and has no excessive play. Replace if necessary.
● Check the dust seal for wear or damage.
ASSEMBLY
● Apply grease to the dust seal in the front cover.
● Install the brushes onto the brush holders.
● Apply a thin coat of grease to the two ends of the
armature shaft.
● Insert the commutator into the front cover.
● Install a new O-ring to the front cover.

● Install the starter motor case, aligning the tab on the
motor case with the groove on the front cover.
● Tighten the starter motor case screws.
STARTER MAGNETIC SWITCH

INSPECTION
● Check if the starter magnetic switch “clicks” when it is
turned ON.
-Clicks →·Poorly connected battery terminal and
motor terminal of the switch. (Check
the starter magnetic switch)
-No clicks →·No starter magnetic switch input
voltage. (Faulty relay ground line and
starter magnetic switch)
18-5
STARTER SYSTEM
REMOVAL
● Release the seat lock with the main key.
● Remove the battery (+) cable from the starter magnetic
switch terminal.
● Remove the starter motor cable from the starter
magnetic switch terminal.
● Disconnect the yellow / red connector and green /
yellow connector from the wire harness.
● Remove the starter magnetic switch from the switch
setting bracket securing the frame.
Starter magnetic switch voltage

● Measure the voltage between the yellow / red wire (+)
and ground at the starter magnetic switch connector.
● If battery voltage appears only when the starter switch

is pressed, it is normal.
Starter magnetic switch ground line

● Disconnect the wire connector from the starter
magnetic switch and check for continuity between the
ground wire (green / yellow) and ground.
OPERATION CHECK
● Disconnect the magnetic switch wire connector.
● Apply battery voltage between terminals, when the
yellow / red wire is connected to the positive (+)
battery terminal and the green / yellow wire to the
negative (-) battery terminal.
● If there is continuity between battery and motor

terminal, it is normal.
18-6
MEMO

MEMO

19. LIGHTS/SWITCHS/HORN
SERVICE INFORMATION···· 19-1 HEADLIGHT CONTROLLER · 19-4

TROUBLESHOOTING· ····· 19-1 · 19-5
COOLANT TEMPERATURE GAUGE·
MAIN SWITCH········ 19-2 THROTTLE POSITION SENSOR· · 19-5
HANDLE SWITCH······· 19-2 · 19-6
HEADLIGHT BULB REPLACEMENT·
HORN············ 19-3 FRONT WINKER REPLACEMENT··· 19-6
FUEL UNIT·········· 19-3 TAI LIGHT/REAR WINKER BULB
THERMOSTATIC SWITCH···· 19-4 REPLACEMENT· ······· 19-6
· 19-4
HEATER CONTROLLER UNIT· FUSE CAPACITY · 19-7
SERVICE INFORMATION
GENERAL SAFETY
● Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
● All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
● Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
● The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.
TROUBLESHOOTING
Light not turned on when the main switch is ON Fuel meter indicator malfunctioning
● Faulty light bulb ● Coupler separated.
● Faulty switch ● Harness disconnected.
● Faulty or disconnected wiring ● Float operation malfuction.
● Fuse cut ● Fuel unit damaged.
● Battery discharged
Fuel meter needle unstable
Dim headlight ● Coupler loose.
● Battery discharged ● Fuel unit damaged.
● Wiring and switch resistance high ● Meter damaged.
Headlight Hi-Low bean cannot be charged

● Faulty light bulb
● Faulty dimmer switch
19
19-1
LIGHTS/SWITCH/HORN
MAIN SWITCH
● Remove the front covers.
● Disconnect the ignition switch wire couplers.
● Check for continuity between the wire terminals.
RED/WHITE BLACK
OFF
ON
HANDLE SWITCH
● Remove the headlight.
● Disconnect the connector of handle switch.
● Check for continuity between teminals.
● Remove the Fr. cover.
● Remove the coupler wire.
● Test each teminal of handle switch.
HEADLIGHT SWITCH
LIGHTING
BAT3 TL HL
OFF
P
H
COLOR Br/L Br Br/W
WINKER SWITCH
BAT3 TL HL
R
N
L
COLOR GREY SKY BLUE ORANGE
HORN SWITCH
HO BAT3
FREE
PUSH
COLOR GREEN BLACK
19-2
LIGHTS/SWITCH/HORN
PASSING SWITCH
BAT3 HI
HI
COLOR BLACK BLUE
WINKER SWITCH
BAT3 HI LO BAT3
HI
(N)
LO
COLOR BROWN/WHITE BLUE WHITE BLACK
HORN
● Remove the horn from the wire connector.
● Connect the horn terminal with 12V battery.
● Normal if it sounds.
FUEL UNIT
● Remove the foor panel.
● Be cover full not to be damaged for the wire.
● Check the base packing for damage.
● Measure the resistance between the fuel unit upper and
lower.
COLOR UPPER LOWER

Y/W~B/W 1.8~1.2Ω 70~130Ω
19-3
LIGHTS/SWITCH/HORN
THERMOSTATIC SWITCH
● Remove the front covers.
● Start and run engine to make the water temperature
reaches 85° C~90° C and check if the cooling fan motor
operates.
● Lower the water temperature to 85° C and check if the
fan motor stops.
● If the fan motor does not start, disconnect the wires

from the thermostatic switch and then connect a jumper
wire between the wire harness and thermosensor wires
(black and green wires).
● Turn the ignition switch ON.

● The thermostatic switch is faulty if the cooling fan
motor runs properly.
● If it does not start, check for voltage between the fan
motor coupler wire terminals (black~green).
● If there is no voltage, check for the following:
● Blown or faulty fuse.
● Loose terminals or connectors.
● Shorted wire in the wire harness.
HEATER CONTROLLER UNIT

● Open ignition switch to check if the brown blue wire of
it is enough voltage.
● Put the heater controller unit in refrigerator.
● Start engine after keeping the temperature under
0° C.
● Check if the yellow wire of heater controller unit has
output voltage. Start engine and if the temperature of
heater controller unit is under 0° C
● Check if the white/yellow wire of heater controller unit
has output voltage.
● If it has not any voltage, it is damaged.
19-4
LIGHTS/SWITCH/HORN
HEADLIGHT CONTROLLER
● When the main switch turns ON, the headlight (low),
meter illumination, taillight, position light and license
light turns on during a second and turns off.
● If the engine RPM becomes over 1,100rpm, the
headlight (low), the meter illumination, taillight,
position light and license light turns on
CORD
A TERMINAL : EARTH
B TERMINAL : NONE
SZ1-LC
C TERMINAL : NONE
D TERMINAL : SW. 1
E TERMINAL : BATTERY
F TERMINAL : PULSER(INPUT)
COOLANT TEMPERATURE GAUGE

● If the gauge needle indicates the red zone when idling
or running, turn the main switch OFF.
● Wait until the engine is cool and perform the following.
● Disconnect the wire from the thermo sensor.
● Ground the thermo sensor wire with a jumper wire.
● Turn the main switch ON. Disconnect the thermo
sensor wire from the ground immediately if the gauge
needle moves fully to H. (If it moves fully to H, the
gauge can be damaged.)
THROTTLE POSITION SENSOR

V/A V/G V/B
V/A 4~6
V/G 4~6 0~5 1
V/B 0~5 1
19-5
LIGHTS/SWITCH/HORN
HEADLIGHT BULB REPLACEMENT

● Remove the front cover.
● Remove the headlight coupler and winker coupler.
● Remove the bulb socket of rubber boots.
● Remove the rubber boots.
● Replace the headlight bulb.
•When replacing the bulb, be sure not to put finger

and contaminated gloves prints on the headlight
bulb, as they may create hot spots on the bulb and
cause is to fail.
•Note the following when replacing the bulb.
- Do not replace while the headlight is ON. After it
is turned OFF, be sure to let it cool down before
servicing.
- Wear clean gloves while replacing the bulb. Do not
put finger prints on the headlight bulb.
- If you touch the bulb with your bare hands, clean it
with a cloth moistened with alcohol and clean it
with a clean cloth again.
- Be sure to install the rubber cover after replacing
the bulb.
FRONT WINKER BULB

REPLACEMENT
● Loosen the 2 screws, remove the winker lens.
● Replace the winker bulb.
TAILLIGHT/REAR WINKER BULB

REPLACEMENT
● Loosen the 2 screws of taillight.
● Remove the taillight lens and winker lens.
● Replace the taillight bulb and winker bulb.
19-6
LIGHTS/SWITCH/HORN
FUSE CAPACITY
Fuse A 30A Charging, combi S/W, trunk lamp,
regulator
Winker relay, meter lighting, horn,
15A headlight (HI), front/rear stop switch,
Fuse B
taillight, heater control, fuel meter, water
temp. meter
Fuse C 10A Ignition coil, auto bi-starter
Fuse D 10A Fan motor
Fuse F 10A Headlight (LO)
COUPLER CONNECTION
● Connect the coupler corefully according to the type of
vehicle.
TYPE SPEC. COLOR

EXPORT WHITE
DOMESTIC BLACK
● If headlight switch in mounted wiht the vehicle,

connect the white colored coupler only.
● If hazard switch is mounted with the vehicle connect
HEAD LIGHT RELAY the black colored coupler only.
THERMO SWITCH RELAY
WINKER RELAY
EARTH CABLE
MAIN WIRE BATTERY BOX

HARNESS
DOMESTIC USE ONLY EXPORT USE ONLY
(COUPLER COLOR : BLACK) (COUPLER COLOR : WHITE
"EXPORT" MARKED)
19-7
MEMO

20
20-1
FUEL UNIT
COMB. SW.
SIDE
A B C D F BAT 2
STAND
BAT 3
BAT 2
SWITCH
Y/R
Br/L
G
Br
G/Y
B
BATTERY
G/Gr
G/W
B/W
G/B
V/G
V/R
V/B
B/Y
L/Y
G
R R
M 12V 10AH
B/W
L Y B
G/B
B/L
Y/W
L/W
B
G
4P MINI
R
G/R
Y/R
(W/PRF.)
6P MINI
R/W
3P MINI
B
G R 2P MINI
G
(W/PRF.)
R/W
R/W
B/Br
3P MINI
Br/L
R/Y
B
B/G
R
G/Y
Y/R
G/W
Br/L
G/Gr
Br
B
2P MINI
L/Y
2P MINI
V/R
V/G
V/B
2P
G R
Y/W
B/W
B/W
L/W
(ENGINE)
G/B
V/G
G/R
V/R
G
V/B
6P
G
B/W
B/G
MINI 2P MINI
6P
R
MINI
G/Y
R/W
B
Y/R
Br/L
G/Y
Gr
Sb
O
Y/R
G
R/W
G ENGINE
2P MINI
Sb Sb EARTH
Br/L
Br/L
G/Y
Br
Y/R
P
G G
FRAME
EARTH
Br
G
Br/L
G
Br
METER ILLUM.
12V 1.7WX2
Br
G Sb
COMBINATION METER ASS'Y.
2P MINI G
Br/G
Br/W
FUEL Y/W RH. RR. WINKER

METER L/W 12V 10W
Br/L Sb Sb
G/Y G/Y G/Y
6P MINI
G G G G G
Br Br Br Br Br
WATER Br/L
O O O O
TEMP. G/L
METER G
Sb Sb STOP & TAIL LIGHT
6P MINI
Br/L Br/L 12V 21/5W

G/L G/L
Y/W Y/W
L/W L/W G
L L L O
HIGH BEAM
14V 3W G
TURN RH. Sb LH. RR. WINKER
Br/L
Gr
14V 3W 12V 10W
G
G
TURN LH.
G
P
O
14V 3W G
2P MINI
Lg/R
L/B
G
2P MINI
B
Br/G
2P MINI
G G Br Br
O O G G
G G
W W
4P
LICENSE LIGHT
L L 12V 5W
Br Br
HEAD LIGHT(LOW)
Br/W
Br/L
W L Sb O Gr Lg G/Y
B/Br
12V 55W THERMO SW. RELAY
L/B
20. WIRING DIAGRAM
9P MINI G B R/W
Br/L
Y Y Y
W/Y
G 2P
G/W
W/Y
L/Y
Y Y Y G Y G
W G
G/R
G/B
Br/W
Sb Gr Lg 4P 3P
B
W L O G/Y
G/L
B L
2P MINI
G 3P 4P MINI
G B R Y Y Y 2P MINI
Br
W/Y
EMI L1 L2 G
W/Y
COMP Y Y Y B G Y G
G/W
G/Y
L/Y
C
Br/W
POSITION LIGHT W L B Sb O Gr Lg B

12V 5W B L Lg/R G G G
THERMO
Br/W
Br/G
R/Y
SIGNAL
P
HL HL
LO(BAT4) HI (BAT3) R L W HO BAT3
HEAT
Br/L
UNIT
BAT4
L/Y
G 2P MINI
G P
E
2P W/P
I.C
Lg
G
WINKER,DIMMER,PASSING,HORN S/W. RR. STOP SW.
L
L B
REGULATOR HEATER
FILLER CAP
CONTROL HEATER
G/Gr
HEAD LIGHT(HIGH) RECTIFIER
CARB.
12V 55W
B/W
LIGHT RELAY FAN THERMO ACG
MOTOR SWITCH
IGNITION
COIL
COMB. SW. START HAZARD WINKER HORN DIMMER PASSING SIDE STAND SW. TRUNK LAMP LIGHTING
BAT2 BAT3 ST E W R L W R L Ho BAT3 BAT 4 HI LO BAT 3 BAT3 Hi BAT3 IGN BAT2 BAT2 BAT3 TL HL V VIOLET Br BROWN
B BLACK O ORANGE
ON FREE OFF R FREE Hi FREE FREE FREE OFF Y YELLOW Sb SKY BLUE
L BLUE Lg LIGHT GREEN
OFF PUSH HAZ N PUSH (N) PUSH STAND PUSH P G GREEN P PINK
LOCK COLOR Y/R G COLOR Gr Sb O L COLOR Lg B Lo COLOR B L COLOR B/L B COLOR R R H R RED Gr GRAY
W WHITE
COLOR R/W B COLOR Gr Sb O COLOR Br/W L W B COLOR Br/L Br Br/W COLOR COMB : GROUND/MARKING
MEMO

SERVICE MANUAL
2004. 9. PRINTED
2004. 9. PUBLICATION NO COPY

HEAD OFFICE (FACTORY)
#58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA
TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524
OVERSEAS SALES OFFICE
#13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA
TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997
SM50-0409-01E

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Contents of this manual and specifications are COOLING SYSTEM 6

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GENERAL SAFETY 1-1 TORQUE VALUES 1-12

CAUTION WHEN WIRING

•Recheck the condition of contact, securing and

•Insert the lock of the coupler until the lock is fully

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

OVERALL LENGTH 2,110 mm

TYPE Water cooled 4 cycle SOHC engine

TYPE / VENTURI BORE CVK type/30 mm

CLUTCH TYPE Automatic Transmission

IGNITION SYSTEM Full-Transistor

COOLANT/MIXTURE RATIO LG-Caltex Oil CX AF EQUIV/40%

FUEL CONSUMPTION RATIO 43km/ (50km/h)

ITEM Q’TY THREAD DIA TORQUE VALUE REFERENCE

ITEM Q’TY THREAD DIA TORQUE VALUE REFERENCE

STANDARD TORQUE VALUES

ITEM TORQUE VALUE ITEM TORQUE VALUE

5mm BOLT, NUT 0.5 kgf·m 5mm SCREW 0.4 kgf·m

SYMBOL MEANING SYMBOL MEANING

The following symbols indicate oil adding, oil change, or parts.

The following abbreviations are used in this manual.

LUBRICATION POINTS REFERENCE

STARTER IDLE GEAR

STARTER ONE-WAY CLUTCH THREAD LOCTITE APPLIES

A.C. GENERATOR CONNECTOR

WATER PASS TUBE A

TRANK LAMP WIRE

FUEL UNIT COUPLER DRAIN TUBE

THEROMO SWITCH WIRE

REGULATOR RECTIFIER RADIATOR CAP HOSE

STARTER MAGNETIC SWITCH

FUEL TUBE (CARBURETOR)

E.M.I. UNIT COMP.

E.M.I. CORD(FAN MOTOR)

RADIATOR CAP HOSE

THERMO SWITCH WIRE

WATER PASS TUBE B

FUEL TUBE (INSULATOR)

FUEL TUBE (INSULATOR)

FUEL WATER PASS TUBE B

FUEL TUBE (FUEL TANK)

WATER HOSE B RR. STAY

WATER HOSE A WATER PIPE A

WATER HOSE CLAMP WATER PIPE B

RR. BRAKE HOSE PIPE

HEAD LIGHT RELAY

THERMO SWITCH RELAY

HEAD LIGHT CONTROLLER

BATTERY EARTH CABLE

HEADLIGHT CONTROLLER CODE

THERMO SWITCH RELAY

FUSE BOX ASS'Y

BATTERY EARTH CABLE

FUEL TUBE (INSULATOR)

FUEL TUBE (FUEL TANK)