Daelim B-Bone 125cc Service Manual 27MB

SM57-0902-01E

How to use this manual

This manual explains how to maintain procedure for theSN125 manufactured by DAELIM MOTOR CO., LTD.

To ensure safety and optimal operating conditions of thevehicle, carry out regular inspections according to themaintenance schedule(Section 2).Sections 1 through 2 provide information on overallvehicle; section 3, assembly and disassembly proceduresfor external components, and section 4 describesmaintenance procedure for the engine, frame andelectrical systems.To facilitate use of this manual, each page starts withdisassembly and system diagrams, each page starts withdisassembly and system diagrams, service information,and troubleshooting guide.

Contents of this manual and specifications are subjectto change without prior notice for improvement ofvehicle quality.No part of this publication may be reproduced withoutwritten permission of DAELIM Motor Co.,Ltd.,

Service Information 1

2

3

4

6

7

8

9

10

11

14

16

17

18

19

Inspections / Adjustments

External Parts

Lubrication System

5EMS(Engine Management System)

Fuel System

Engine Removal / Installation

LH, Crank Case CoverContinuously Variable Transmission

A.C Generator / Starter Clutch

Cylinder Head / Valves

Cylinder Head / Piston

12Transmission / Crank ShaftCrank Case

Rear Wheel / Suspension / Rear Swing Arm

Charging System

15Brake System

Ignition System

Starter System

Lights / Switches / Horn

20Wiring diagram(Euro2,Euro3)

Contents

Eng

ine

Fram

eE

lect

rica

lG

ener

al

13Front Wheel / Front Fork/ Steering

SERVICE INFORMATION

1

1-1

1. SERVICE INFORMATION

SERIAL NUMBER LOCATION······ 1-1SPECIFICATIONS·················· 1-2TORQUE VALUES·················· 1-4STANDARD TORQUE VALUES······ 1-5SYMBOLS/ABBREVIATIONS········ 1-5

WIRING DIAGRAM·················· 1-6GENERAL SAFETY·················· 1-10SERVICE RULES···················· 1-10CAUTION WHEN WIRING·········· 1-14

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

1-2

SERVICE INFORMATION

7.1

1.2

stroke SOHC

ATDC

1,910mm750mm1,090mm1,360mm755mm126mm130kg277kg

602.00

2.25

25

80

90/70

13.8 380

(6.8 )

1.01.05

※ "( )" MARKED CONTENTS APPLY TO EURO 2 ONLY

90mm

1-3

SERVICE INFORMATION

※“( )”MARKED CONTENTS APPLY TO EURO2 ONLY

ITEM SPECIFICATIONS

CV type ( vacuum ) / '“24.2 mm

CVK

Auto-bystarter

# 95

2½

17 mm

1.700±100 rpm

Automatic Transmission

3.000

2.786

ECU (C.D.I)

Closed type (MF) 12V 10AH

CR8EH -9 (NGK)

0.8 - 0.9 mm

15A, 30A (15A)

Starter motor

12V 55W / 12V 55W

12V 5W

12V 10W×4

12V 21 / 5W

LED

LED

LED

12V 5W

TYPE / VENTURI BORE

MODEL MARK

CHOKE TYPE

MAIN JET

PILOT SCREW INITIAL SETTING

FLOAT LEVEL

IDLE SPEED

CLUTCH TYPE

PRIMARY REDUCTION

SECONDARY REDUCTION

IGNITION SYSTEM

BATTERY TYPE / CAPACITY

SPARK PLUG

SPARK PLUG GAP

FUSE CAPACITY

STARTING SYSTEM

HEADLIGHT ( HIGH / LOW )

POSITION LIGHT

WINKER LIGHTS ( FR / RR )

TAIL / STOP LIGHT

HIGH-BEAM PILOT

WINKER PILOT

METER LIGHTS

LICENSE LAMP

(CARBURETOR)

DRIVE TRAIN

ELECTRICALSYSTEM

1-4

SERVICE INFORMATION

SERVICE INFORMATION

1-5

1-6

SERVICE INFORMATION

1-7

SERVICE INFORMATION

1-8

SERVICE INFORMATION

1-9

SERVICE INFORMATION

1-10

SERVICE INFORMATION

GENERAL SAFETYWARNING1. 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 thebattery 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 afterengine 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 orrecommended parts.

2. Before maintenance, remove deposit or dust from thechasis.

3. Store the parts of each system discriminatively to installeach part in the right place.

4. After removing gasket, O-ring, piston pin clip and cotterpin, always replace them with the new one. Whenremoving the snap ring, it can be easily missed aftertransformation or installation.

1-11

SERVICE INFORMATION

9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not tosoak with gasoline or oils.

10. Recommended grease must be applied to or filled inthe specified place.

7. Align the bolts to uniform the tightening points beforetightening them when you don’t know the bolt length.

8. Bolts, nuts and pieces must be tightened from the biggerdiameter to the smaller one, from inside to outside anddiagonally with the specified torque.

5. Clean the parts after the overhaul and before the test andremove the cleaning oil with compressed air. Apply oilto seal face during installation.

6. Check necessary place and measure necessary dataduring installation. When installing, return to the statebefore removing.

11. Maintenance needed to use the specialized tools mustperformed with the right tool.

12. Never reuse the ball bearing removed with the ballapplied pressure when removing press-fitted thebearing.

1-12

SERVICE INFORMATION

13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually.

•Replace the ball bearing having excessive axial/longitudinal hanging.

•Wipe the ball bearing likely to have hanging withcleaning oil.(except double-sided sealed type ballbearing)

•Replace the ball bearing of which press-fitted part isslacked at the case or shaft.

14. Pay attention to installation direction in case of thesingle-sided sealed ball bearing. Install the open-direction or double-sided sealed bearing in the waythat the face marked with manufacturer and sizeshould direct to the outer axle.

15. When blowing the ball bearing with compressed airafter cleaning, keep the race from rotating. High speedrotation of the race may damage the bearing. Prior toinstallation, apply oil or grease to the bearing.

16. Install the snap ring so that chamfered side directs tothe load-applied side. After installation, check theproper installation by rotating the snap ring.

17. Check each part for proper tightening and operationafter installation.

18. The brake fluid and coolant can damage the paintedplastic or rubber parts. Keep these parts fromcontacting with them and wash these parts with waterin case of contact.

SINGLE-SEALED TYPE DOUBLE-SEALED TYPE

OPEN TYPE

SNAP RING

CHAMFERED EDGE

MANUFACTURER’S NAME, BEARING No.

19. Install the oil seal so that the manufacturer markedsurface directs outer surface.(direction not coveredwith oil)

•Pay attention not to bend or damage the lip•Apply the grease to the lip

20. Connect the tube until the tube fully inserted in thejoint. Install the clip if it is supplied. Replace the tubehaving slacked end.

MANUFACTURER’S NAME

CAVITY

CLIP

FITTING

1-13

SERVICE INFORMATION

21. Keep the pneumatic system interior or the engine interior from the infiltration of dust.

22. Install the gasket mounted in the contact surface ofeach case of the engine while removing gasketmaterial completely. Remove damaged contact surfaceby wiping with the oil stone equally.

23. Pay attention not to bend the cable excessively.Transformed or damaged cable may cause malfunctionor damage.

24. Install the boots with the installing groove by insertingthe boots into the groove.

BOOTS

1-14

SERVICE INFORMATION

•Each cord must be connected depending on its color.When connecting different cord, attach color tubearound the connector. Connect the coupler to theconnector with same color and same pin number.

•Identify the two-colored cord by main color first andthen striped color .

•When measuring voltage or resistance of the cordterminal using tester, contact the tester plug behind ofthe coupler. Pay attention not to open the cord terminaland contact the tester plug from the front of the couplerin case of water-proof coupler.

•Recheck the condition of contact, securing andcontinuity of each part after maintenance.

•When connecting the battery, the plus terminal must beconnected first.

•After connecting the terminal, apply the grease to theterminal.

•When disconnecting the battery, the minus terminalmust be disconnected first.

•Make sure that the tool such as spanner do not contactwith the frame.

•Connect covers to the terminal after maintenance.

•If the fuse is short-circuited, find out the cause andrepair. Replace with the fuse having the specifiedcapacity.

•If there is rust in the terminal, remove the rust with sandpaper prior to connecting.

CAUTION WHEN WIRING

BLACK CORD

WHITE COUPLER.

WHITE

RED STRIPE

RED STRIPE

WHITE / RED CORD

TESTER PLUG

WHITE TUBEBLACK TUBE

VALIDATIONOF CAPACITY!

REMOVETHERUST!

1-15

SERVICE INFORMATION

•Insert the lock of the coupler until the lock is fullysecured.

•Turn off the main switch before connecting/dis-connecting.

•Release the lock to disconnect the lock of the coupler.•The lock of the coupler has two types according to

releasing method(press type and pull type) so release itproperly according to the shape.

- Typical releasing method of the coupler is illustrated inthe following.

•When disconnecting the coupler, disconnect it whileholding the coupler body. Pull while holding the wireharness cord and do not remove the coupler connection.

•Release the lock by inserting the coupler slightly andthen narrowing connection to remove the coupler.

•Pay attention not to damage the vinyl cover of thecoupler.

•Check to see if there is bended terminal and secure it toavoid disconnecting.

•If the wire harness coating is damaged, repair bywinding vinyl tape or replace it.

•Prior to connecting the connector, make sure that thecover is not damaged and the mess terminal is notopened.

1-16

SERVICE INFORMATION

•Wire band must be secured firmly in the specifiedlocation of the frame. In case of aluminium band, securethe wire harness to the coated part.

•Secure the wire harness firmly using the clamp.

•Insert the connector until the vinyl cover is fully insertedinto the terminal.

•The opening of the vinyl cover must face at the grounddirection but in case of the plain connector, the drainingopening must face at the sky direction.

•When removing T-start, broaden the groove of T-startusing the wiring driver and release the torque.

•Connect the harness and the hose to T-start and theninsert until the groove is locked.

•When removing T-start from the frame, replace it withthe new one.

•In case of the weld clamp, do not clamp in the weldedpart.

•When clamping the wire harness, make sure that theharness is not contacted with the shaft or rotating part.

•When clamping the wire, pay attention not to contactwith hot part.

•The wire harness must be routed without contactingwith the end of the lamp or any sharp edge.

•The wire harness must be routed without contactingwith the end of the bolt or the piece.

WIRING DRIVERDRAINING HOLE GROOVE SIDE

1-17

SERVICE INFORMATION

•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harnessis not pressed by the parts.

•In case that the wire harness is contacted with the end orthe sharp edge, protect both parts with tube or tape.

•The wire must not hang down or be pulled excessively.

•Do not twist the wire harness. •Wire the wire harness not to be pulled or expandedwhen the handle is turned to the right or the leftcompletely. Avoid excessive bending or chewing andinterference with the engine.

•Prior to using the tester, please read the manual care-fully and understand the contents.

•When testing the resistance of the tester, the zeroadjustment must be performed before testing.

•Do not drop or throw the parts especially semiconductorcontained parts because these parts may be damaged bythe impact of the drop.

NOT TO PULL!

Is this measurement range orconfiguration in accord

with the manual?

MEMO

2-1

INSPECTIONS/ADJUSTMENTS

2

2. INSPECTIONS/ADJUSTMENTS

2-12-32-42-42-52-52-6

2-62-72-7

2-72-72-82-82-82-92-92-102-102-102-11

SERVICE INFORMATION···

MAINTENANCE SCHEDULE ···

FUEL LINE·········

THROTTLE GRIP OPERATION ··

AIR CLEANER·······

SPARK PLUG········

VALVE CLEARANCE·····

CYLINDER COMPRESSIONRESSURE·········

CARBURETOR IDLE SPEED··TRANSMISSION OIL·····

ENGINE OIL········

DRIVE BELT··········

BRAKE FLUID·········

BRAKE PAD··········

BRAKE SYSTEM········

SIDE STAND·········

SUSPENSION·········

BOLTS, NUTS, FASTENERS···

WHEELS/TIRES········

STEERING STEM·······

LUBRICATION POINTS····

2-2


2-3


2-4


FUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMP FUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBE

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THROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIPTHROTTLE GRIP

CARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETOR

ADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUT

THROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLETHROTTLE CABLE


ADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTADJUST NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUT

RUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBERRUBBER

2-5


•Hand-tighten the spark plug before using a wrench totighten to the specified torque.

Remove the spark plug maintenance cover.

•The air cleaner element made of dry process paperfilter.

•Do not clean by compressed air blowing.

Check the element, if it is dirty or damaged replace it.

0.8 ~ 0.9mm

CHECK WASHERFOR DAMAGE

CHECK FORCRACKS

CHECK GAP,DEPOSITS

CYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLT

SPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAPSPARK PLUG CAP

AIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENTAIR CLEANER ELEMENT

AIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENERAIR CLENER

2-6


spark plug maintenance.

- Floor panel ass'y.

fan cover.Remove the shroud B grommet of the timit hoile capon the RH. shroud.

Loosen the 4 cylinder head bolts.

FEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGE

COMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGECOMPRESSION GAUGE

TIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAPTIMINCT HOlLE CAP COOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FAN

ADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCHADJUST WRENCH


TAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREWTAPPET ADJUST SCREW

CYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEADCYLINDER HEAD


2-7


CARBURATOR IDLE SPEEDErect the motorcycle on the mainstand.Remove the rear fender, center cover.Verify all engine adjustments satisfy specifications.

Make adjustment, If necessary.Heat the engine to make accurate idling inspection and

adjustment.Turn the throttle stop screw and make adjustments to

prescribed idling speed.

IDLE SPEED : 1,700±±100RPM

•Do not over adjustment the pilot screw. it could beeffect to starting. (refer to page 6-9)

TRANSMISSION OILINSPECTOIN Remove the LH. crank case. (-> 8-2)

Remove the bolt and check the oil on oil check hole. If the oil level is low(80W/90), add the oil. Install oil check bolt.

•Make sure that the oil sealing washer is goodcondition.

•Erect the motorcycle on the main stand.

•Erect the motorcycle on the main stand.

ENGINE OILINSPECTOIN

Start the engine and let it be warm fully.Stop the engine. check the oil level line of the LH.

crank case cover oil sight glass.It is good if the oil surface is between the lower level

line and upper that of the sight glass. If the oil level isnear the lower level line or below that, full to theupper level line with the recommended oil.

DRIVE BELT

Remove the LH. crankcase cover.Check the drive belt for wear or damage.Check schedule maintenance period, replace the new

drive belt if possible.

THROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREW

PILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREW

OIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASS

UPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPER

MIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLEMIDDLELOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWERLOWER

DRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACE DRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELT DRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEY

DRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLT TAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAPTAPPET ADJUSTING HOLE CAP

OIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLEOIL CHECK HOLE

2-8


FREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAYFREE PLAY

BRAKE FLUIDCheck the oil level inside the front brake reservoir.

If the oil level is near the lower limit line, remove the reservoir diaphrag mand fill DOT3 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 SYSTEMCheck the front brake hose for cracks or damage.

If any leaks are found,replace immediately

BRAKE LEVER FREE PLAYCheck the free play after pulling the lever.

FRONT: 10~20mmREAR: 10~20mm

BRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVER

ROD MARK

BRAKE PAD

ROD MARK

BRAKE PAD

•If the brake pad is worn severely brake fluid levelcan be down.

BRAKE PAD

BRAKE PAD REPLACEMENTCheck the brake pads for wear. If the rod mark on the pad reaches the brake

disc, replace the pads.

MASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDERMASTER CYLINDER

CHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASSCHECK GLASS

REAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEREAR BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSEDUBLE BRAKE HOSE

FRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPERFRONT CALLIPER

FRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSEFRONT BRAKE HOSE REAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPER

2-9


SIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STAND

SIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STANDSIDE STAND

GREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASE

SIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCH

2-10


1.782.29

STEERING STEM

FRONT WHEEL2.00(29 psi)

2.25(32 psi)

REAR WHEEL2.00(29 psi)

2.25(32 psi)

ITEMDRIVER ONLY

DRIVER AND A PASSENGER

/STANDARD PRESSURE

TIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GANGETIRE PRESSURE GAUGE

2-11


LUBRICATION POINTS

Use general grease unless specified here.Apply oil or grease to the other sliding surfaces not shown here.

CONTROL CABLE LUBRICATIONPeriodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning.Change it when the cable lengthened.

RR. BRAKE LEVER PIVOTTHROTTLE GRIP

STEERING HEAD BEARING

WHEEL BEARINGMAIN / SIDE STAND PIVOT

WHEEL BEARING / SPEDOMETER GEAR

MEMO

3-1

EXTERNAL PARTS

3

SERVICE INFORMATION ···3-1MAINTENANCE PROCEDURE ··3-2INNER BOX ·········3-3FRONT COVER ········3-3FRONT FENDER········3-4FRONT UNDER COVER ····3-4SEAT············3-5REAR FENDER ·······3-5REAR UPPER COVER ····3-5REAR UNDER COVER ····3-5

SEAT SUPPORT PIPE·····3-6CENTER COVER ·······3-6TRUSS PIPE ········3-7FLOOR SIDE COVER ·····3-7FLOOR PANEL ·······3-7UNDER COVER ······· 3-8REAR WHEEL MUDGUARD ··3-8SPEEDOMETER ·······3-8MUFFLER··········3-9

3-2

EXTERNAL PARTS

MAINTENANCE PROCEDURE

NAME OF FRAME COVERS

This chart shows arrows connected in the order of disassembling covers.

INNER BOX

FR. COVER

FR. FENDER

FR. WHEEL

FR. UNDER COVER

SEAT

RR. FENDER

RR. UPPER COVER

RR. UNDER COVER

SEAT SUPPORT PIPE

CENTER COVER UNDER COVER

TRUSS PIPE RR. WHEEL MUDGUARD

FLOOR SIDE COVER

BATTERY COVER

FLOOR PANEL

3-3

EXTERNAL PARTS

INNER BOX REMOVAL / ASSEMBLYLoosen the 6 tapping screws securing the

front side cover

FRONT COVER REMOVAL/ASSEMBLYLoosen the 2 washer screw securing the

headlight case. Remove the headlight.

Remove the speedometer cable, headlightcable coupler (left and right)

Loosen the flange bolt securing the headlightcase.

Remove the case.

Release the lock by turning the cap securing themain key remove the cap.

Loosen the tapping screw securing inner box.Remove the inner box.Install in the reverse order of removal.

INNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOXINNER BOX

FRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVERFRONT COVER


TAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREW

HEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHT

WASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREW

HEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLEHEAD LIGHT CABLE

FRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVERFRONT SIDE COVER


3-4

EXTERNAL PARTS

Remove the speedometer cable andspeedometer.

Loosen the 6 tapping screw securing the frontside cover.

Loosen the 3 special screw securing the frontcover and remove the front cover.

Install in the reverse order of removal

FRONT FENDER REMOVAL/ASSEMBLY Loosen the 4 special screws (R/L).Remove the wire grommet.Remove the front fender.Install in the reverse order of removal.

FRONT UNDER COVER REMOVAL/ASSEMBLY Loosen the 4 tapping screws (R/L) securing

the front of the floor panel.Loosen the 2 flange bolts securing the front

under cover.Loosen the 4 washer screws (R/L) securing

front of the floor side cover.

SPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLE

SPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETER

SPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREW

SPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREW FRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDERFRONT FENDER

FRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVERFRONT UNDER COVER



FLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVER

3-5

EXTERNAL PARTS

SEAT REMOVAL/ASSEMBLYRelease the seat lock at the back of seat.Loosen the 2 flange nuts and remove the seat.Install in the reverse order of removal.

REAR FENDERREMOVAL/ASSEMBLYLoosen the 2 special bolts.Loosen the 2 washer bolts and remove the rear

fender.Remove the tail light cable.Install in the reverse order of removal.

Remove the front under cover.Install in the reverse order of removal.

REAR UPPER COVERREMOVAL/ASSEMBLYPull the behind of the rear upper cover to

remove it.Install in the reverse order of removal.

SEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEAT

WASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLT REAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDERREAR FENDER


REAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVERREAR UPPER COVER

3-6

EXTERNAL PARTS

HANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERHANDLE COVERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPERUPPER

REAR UNDER COVERREMOVAL/ASSEMBLYLoosen the 4 special screw (R/L) securing the

rear under cover.Remove it by opening the rear under cover.Install in the reverse order of removal.

SEAT SUPPORT PIPEREMOVAL/ASSEMBLYRemove the rear upper cover.Remove the rear fender.the bar end cap B.

Loosen the 4 flange bolts securing the seatsupport.

Loosen the cap bolt securing the truss pipe andremove the support pipe.

Install in the reverse order of removal.

CENTER COVERREMOVAL/ASSEMBLYRemove the rear upper and rear fender.Remove the seat support pipe.Loosen the 2 tapping screws and 2 flange bolts.Remove the center cover.Install in the reverse order of removal.


REAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVERREAR UNDER COVER

SEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEATSEAT SEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORTSEAT SUPPORT

BAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP BBAR END CAP B

FLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLT

CAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLTCAP BOLT

TAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREW FLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLT

CENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVER

TRUSS PIPEREMOVAL/ASSEMBLYRemove the bar end cap B.Loosen the flange bolt.Loosen the 4 cap bolts.Remove the truss pipe.Install in the reverse order of removal.

FLOOR SIDE COVERREMOVAL/ASSEMBLYLoosen the 6 special screws LH., RH. in floor

side cover and loosen the 4 tapping screwsRH., LH.

Remove the floor side cover (R/L).Install in the reverse order of removal.

FLOOR PANELREMOVAL/ASSEMBLYRemove the rear fender and upper cover.Remove the support pipe.Remove the truss pipe.

Remove the center cover.Remove the batery and loosen the flange bolt

securing under.Remove the fuel cap neck.

3-7

EXTERNAL PARTS

SPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREWSPECIAL SCREW FLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERFLOOR SIDE COVERTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREWTAPPING SCREW

BATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVER

FLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVERCENTER COVER


FUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECKFUEL CAP NECK

3-8

EXTERNAL PARTS

Remove the inner box.Remove the floor side cover.Loosen the tapping screw securing the floor panel

and remove the floor panel.Install in the reverse order of removal.

UNDER COVERREMOVAL/ASSEMBLYRemove the floor side cover.

Loosen the special screw (R/L) and remove

the under cover.


REAR WHEEL MUD GUARDREMOVAL/ASSEMBLYLoosen the air cleaner and 3 washer bolts

securing mud guard.

Remove the rear wheel mud guard.


SPEEDO METERREMOVAL/ASSEMBLYRemove the headlight, speedometer coupler

and cable.

Remove the speedometer cable.

UNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVERUNDER COVER


WASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLTWASHER BOLT

REAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARDREAR WHEEL MUD GUARD

SPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLESPEEDOMETER CABLE

Remove the inner box.Loosen the 2 flange bolts securing the pilot

box.

Remove the speedometer cable.Install in the reverse order of removal.

MUFFLER REMOVAL/ASSEMBLYLoosen the washer bolt securing the brake hose

clamp.Loosen the 3 hex cap nut securing Ex. Pipe

comp.Loosen the 2 flange bolt securing the muffler

comp.

Remove the Ex. muffler comp.

EX. PIPELoosen the 2 flange nuts securing the cylinder

comp.Pull the Ex. pipe comp downward to remove it.Install in the reverse order of removal.

•Never performing the maintenance of the mufflerright after stopping the vehicle because the muffleris extremely hot.

•Replace the packing when assemblying the mufflerand Ex. pipe comp.




FLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUTFLANGE NUT

HEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAPHEX CAP

3-9

EXTERNAL PARTS

MEMO

4-1

LUBRICATION SYSTEM

4-14-24-34-3

4-44-74-8

4-4

4

4-2

LUBRICATION SYSTEM

Inclusion of water.

Low or no oil pressure

Close oil valve relief.Clogged oil strainer.Worn and faulty oil pump.Internal oil leaks.Inadequate oil viscosity.Shout of oil quantity.Oil pump drivegear or sprocket it is not right.

4-3

LUBRICATION SYSTEM

OIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASSOIL SIGHT GLASS

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDIELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

UPPERMIDDLELOWER

Loosen the oil drain plug bolt and drain engine oil. Tighten the oil drain plug bolt.

TORQUE VALVE : 1.4kgf m

OIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLTOIL DRAIN PLUG BOLT TAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAP

OIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREENOIL FILTER SCREEN

OIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL FILTER SCREEN SPRINGOIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAROIL COLLAR

TAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAPTAPPER ADJUST HOLE CAP

ENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELINGENGINE OIL REFUELING

4-4

LUBRICATION SYSTEM

FLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTS

OIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVEROIL FILTER COVER

REDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEARREDUCTION GEAR

OIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENTOIL FILTER ELEMENT

OIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEAL

START DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEARSTART DRIVEN GEAR

OIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMP

FLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSFLAT SCEWSOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMP

4-5

LUBRICATION SYSTEM

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.

OIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFT INNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTOR

PUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODY

FEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGEFEELER GAUGE

PLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATEPLATE

OUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTORBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODYBODY

DRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEAR

4-6

LUBRICATION SYSTEM

INNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTORINNER ROTOR

OUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOROUTER ROTOR

PUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODYPUMP BODY OIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFTOIL PUMP SHAFT

OILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTOILPUMP SHAFTROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLERROLLER

U NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUTU NUT DRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEARDRIVEN GEAR

OIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMP

(9-6)(9-5)

(9-4)(9-2)

(9-2)(14-6)

(15-8)(3-9)

4-7

LUBRICATION SYSTEM

OIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOROIL RADIATOR

OIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLTOIL BOLT

RADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVERRADIATOR COVER

RADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBERRADIATOR RUBBER

RADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLARRADIATOR COLLAR


4-8

LUBRICATION SYSTEM

RADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATORRADIATOR

OIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLTOIL CHECK BOLT

AC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAPAC GENERATOR CAP

(8-2)

(8-2)

5-1

EMS(Engine Management System)

5

5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS 5-2

2. THE COMPONENT PARTS OF THE EMS 5-3

3.TERMINAL ARRANGEMENT OF THE ECU 5-4

4. WIRING DIAGRAM OF THE ECU 5-4

5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) 5-5

- Self diagnostic function 5-5

- Fail safe function 5-6

- How to check the fault code 5-7

- How to show the fault code 5-8

- How to read the fault code 5-8

- Fault code table 5-9

- How to remove the fault code 5-10

- EMS trouble shooting 5-10

6. ECU (Electronic Control Unit) 5-11

7. THROTTLE BODY 5-12

8. INJECTOR 5-16

9. MAPAT (Manifold Air pressure Sensor temperature sensor) 5-18

10. TPS (Throttle Position Sensor) 5-22

11. ETS (Engine Temperature Sensor) 5-25

12. ISA (Idle Speed Actuator) 5-28

13. O2(Oxygen) SENSOR 5-31

14. MIL 5-34

15. CKP (Crank Position sensor) 5-35

16. FUEL PUMP 5-39

17. HOW TO USE THE SCAN WHEN THE ECU IS INITIALIZED 5-42

18. HOW TO USE THE SCAN WHEN THE ISA PWM ADJUSTING 5-44

19. HOW TO USE SCAN WHEN THE IGNITION TIMING IS CHECK 5-45

20. HOW TO USE SCAN WHEN THE ENGINE REVOLUTION IS CHECKING 5-46

5-2


1. CAUTION WHEN REPAIRING THE EMS PARTS.

If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity.

Do not use the electlic wires or others instead of the fuse.Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop.

Do not touch the ECU terminal, because it may be damaged by the static.

The ignition key off when assembly and disassembly of the ECU coupler. otherwise, it might be damage to ECU.

Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts

While engine operating, do not disassembly the battery terminal.otherwise, it might cause damaged the EMS parts.

Use the specitied voltmeter and resistance meter.

5-3


2. THE COMPONENT PARTS OF THE EMSEMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.

1) INTAKE SYSTEMAs a system which controls and measures air to be necessary for combustion in engine, the intake systemis composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, aircleaner and ISA(Idle Speed Actuator), etc.In idling, because throttle value is almost closed, the idle status of engine shall be controlled by meansthat idle speed control system is installed in order to control small of quantity of air being necessary forcombustion.

2) FUEL SYSTEMAs a system to supply required fuel for consumption in engine combustion chamber from fuel tank toinjector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, divisionpipe and injector.The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter. Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure ofintake system.Injector sprays fuel into the intake system by injection signals of ECU.

3) IGNITION SYSTEMThe ignition system is composed of spark plug which makes ignition spark, a spark timing control part tocontrol proper spark time in cylinder, high-voltage system, and so forth.

4) CONTROL SYSTEM①Various sensors to move electric signals converted by checking the current engine status② Input interface which works various processes like regulating voltage levels, removal of noise, A/D

conversion, amplifying of inputted signals from above sensors.③Micro-computer which decides output value through various calculating, arithmetic and logic

processing.④Output interface to amplify the above output signals.⑤Actuator being mechanically worked by receiving the amplified output signals.

(Intake pressure sensor+Intake temperature)

5-4


3. TERMINAL ARRANGEMENT OF THE ECU

RemarksECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected.

4. WIRING DIAGRAM OF THE ECU

5-5


5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)SELF-DIAGNOSTIC FUNCTIONThe EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operationnormally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL(malfunction indicator lamp). It gives the rider that malfunction has occurred in the system.However, the ECU takes fail-safe function, it enables to drive only temporary when that happen. Normally, the MIL illuminates for 3 seconds, when the main key is turned on.

Remarks 1If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMS’sfail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.

Remarks 2It might not be able to starting and driving when following problems happen.- Crankposition sensor- Injector- Fuel pump

when the ignition key ON.

The MIL on and blink(when this function detects a malfunction in the system)

MIL

OFF

ONStarting and driving are temporary

Unable

MIL

ON

Blink

MIL on continuously, when the engine operating

MIL blinks, when the main key is turn on (engine is stop)

SPEEDOMETER ODOMETER

FUEL GAUGE

MALFUNCTION INDICATOR LAMP

DIRECTIONINDICATOR LAMP

HIGH BEAMINDICATOR

Able to engine start

Unable to engine start

5-6


FAIL-SAFE FUNCTIONIf the ECU checks something wrong , the vehicle can be driven by its fail safe function.However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operationcan be impossible.

If there is something wrong in the EMS, it has fail safe function in order for engine towork and to cover a minimum driving of vehicle.

: MIL on/offINTAKE

MIL

INTAKE

: MIL on

on

INTAKE

INTAKEThe value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order.

intake

intake

The value of intake temperature is fixed as a temperature just before when the intake pressure sensor is out of order.

! CAUTION

If the MIL on and blink, starting and driving are temporary by fail safefunction, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.In this case, safe repairing of vehicle shall be required.

5-7


HOW TO CHECK THE FAULT CODEThere are two methods of checking the fault codes.1) Use the MIL in the speedometer.2) The diagnostic tool.

First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnosticmethods for each part)

Second) The diagnostic tool (refer to scan user’s manual.)Turn off the ignition keyDisassemble the rh.side coverThe coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.

(The coupler to check the malfunction of vehicle is placed in the rh.side cover)Turn on the ignition keyPress the power button of diagnostic toolChecks according to diagnostic procedure of diagnostic tool.

The wireharness to check the ECUThis wireharness is connected with the ECU and main wireharness

It has two couplers to check the terminals.First coupler) ECU no.1~20 Second coupler) ECU no.21~40

Arrangement of ECU PINFirst coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connectedSecond coupler) ECU no.36,38 were not connected

Wire color to check the malfunction diagnosis

-P/W : PINK/WHITE

-P/Y : PINK/YELLOW

-B : BLACK

-G : GREEN

Coupler to check the malfunction diagnosis

The diagnostic Tool.

The wireharness to check the ECU

5-8


HOW TO SHOW THE FAULT CODEThere are two methods to show the Fault codes.

First, the methods to show in engine operationIn engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without thelight on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code,stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can beverified.(refer to the fault code table)

Second,the ways of indication only turn on the ignition key.When only ignition key is on and if the defect of each part brings out, the MIL keeps showingthe Fault code of defect part repeatedly in order to give defect information to driver.

If the MILon when engine is working, engine is able to be operated by fail safe. However, in the event thatInjector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started

HOW TO READ THE FAULT CODEThe fault codes are showed as 2 digits on the MIL of EMS. Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed. E.g. ) The Fault code of ISA

If many problems will happened in the EMS parts at the same time only one fault code is displayed by thepriority, however, the ECU is remembers all the fault codes.After revise the code, remove the memorized fault code by the method of warm up.(5-10) (Refer to remove the fault codes)

When the vehicle is checked using the diagnosis tool.- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.

1 flashing cycle : 0.5 sec

1.5 sec 3 sec

ON

OFF

! CAUTION

5-9


FAULT CODES TABLE

Faultcode no.

Priorityorder

DescriptionMIL INDICATION

(The number of blinks)

- No failure00

1 Injection valve failure(IV)21

2 Idle speed actuator failure (ISA)22

3 Electrical fuel pump failure (EFP)23

4Intake Manifold absolute pressure signal failure (IMP)

12

5 Throttle position signal failure (TPS)13

6 O2 sensor heater output failure (LSH)24

7 Lambda signal failure (VLS)14

8 Engine temperature signal failure (TENG)15

9 Breathing air temperature signal failure(TBA)

16

11 Malfunction indicate lamp failure (MIL)28

5-10


HOW TO REMOVE THE FAULT CODERemove the fault codes in two ways;

First) Full warm up

1. Starting the engine. - The MIL blinks continuously because the ECU memorized the fault code yet.

2. Full warm up the engine (keep idling five minutes)3. Turn off the ignition key after full warm up the engine4. Turn on the ignition key again, and check whether the fault code is disappeared or not.

After full warm up, it is possible to check the fault code is removed with the ignition key on/off.

If many problems happened in the EMS parts at the same time, only one defect code will is displayedby the priority order.Even thought repair a fault and remove the memorized fault code, another fault code blinks. at this time, revise the fault and remove the memorized fault code by the warm up.

Second) Malfunction diagnosis tool (refer to the scan user’s manual)

EMS TROUBLE SHOOTINGInspection before diagnosis

Inspection the following before malfunction diagnosis.•Quantity of engine oil and leakage

Quantity of fuel and leakageBlocked of air cleanerCondition of batteryFree play of throttle cableCutting of fuseLeakage of emission gasConnection of each coupler

5-11


REMOVERemove the seat support pipe.Remove the center cover.

Remove the ECU coupler.

Loosen the 4 flange bolts and remove theECU.

ASSEMBLYAssembly is the reverse order of removal.

6. ECU (ELECTRONIC CONTROL UNIT)

Before disassemble, the key is off.

! CAUTION

Be sure to assemble the ECU ground wire.(The color is green)

! CAUTION

SEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPE


ECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECUECU


❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❶❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷❷

7. THROTTLE BODY

Remove the seat support pipe.Remove the center cover.

Loosen the screw securing air cleaner connectingtube band.

Remove the throttle body and air cleaner.

Remove the gasoline in fuel tube.Disconnect fuel tube securing inject cap.Disconnect injector, MAPAT, throttle sensor, ISA

coupler.Disconnect throttle cable.Loosen the 2 flange bolts securing insulator and

remove the throttle body ass’y.

Remove the each component parts securingthrottle body and check.

5-12



SCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREWSCREW

Do not disconnect both the throttle adjust screwand adjust nut.

! NOTE

THROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATOR

THROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODYTHROTTLE BODY ISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISA

ISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISA

TPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPSTPS


MAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSORMAPAT SENSOR


THROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFTTHROTLE SHAFT THROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVETHROTTLE VALVE

DISCONNECT THE THROTTLE BODYDisconnect fuel tank and air cleaner.Remove the gasoline in fuel tube.Disconnect fuel tube securing injector cap.Disconnect TPS, ISA, MAPAT, injector coupler.Disconnect throttle cable.

Do not disconnect both the throttle adjust screwand adjust nut.

! CAUTION

REMOVELoosen the throttle body 2 bolts securing the

insulator.Disconnect the TPS (Throttle position sensor).Disconnect the ISA(Idle speed actuator).Disconnect the MAPAT.

CHECKING THE THROTTLE BODYChecking the TPS.Checking the ISA.Checking the MAPAT.

Checking the throttle shaft.Checking the valve.Assembly is the reverse order of removal. Install the O-ring on the throttle body.

Do not disconnect the throttle valve.

! CAUTION

5-13


CHECKING THE INSULATORCheck the O-ring.Check the insulator inside.Check the insulator cap inside.

ASSEMBLY OF THE INSULATORAssemble is the reverse order of removal.Assemble the O-ring to insulator. Install the insulator to the throttle body.Torque : 1.0 kgf m

DISASSEMBLE THE INSULATORDisconnect injector cap bolt.Disconnect injector and injector cap at the

same time from the insulator.Disconnect injector and injector cap.

Remove the injector and check.

ASSEMBLY OF THE THROTTLE BODYAssemble is the reverse order of removal.Assemble the O-ring to the insulator.

Assemble the insulator to the throttle body.Torque : 1.0 kgf m

! CAUTIONReplace the o-ring with new one.

INSTALLATION OF INSULATOR ANDTHROTTLE BODY Installation of insulator and throttle body in the

reverse order of removal.Check the o-ring when the insulator assembly.Assemble the insulator gasket.

Install the assembled insulator and throttlebody to the cylinder head.

Torque : 1.2 kgf m

! CAUTIONReplace the gasket with new one.

INJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAP

5-14


ADJUSTMENT OF THROTTLE CABLEAssemble the throttle cable.Adjust the free play of throttle grip.

ADJUSTMENT OF IDLE SPEEDACTUATOR (ISA)A vehicle is assembled in the state which

engine operation is possible.Loosen the maintenance cover and the adjust-

screw is makes possible to adjust.The coupler to check the malfunction of

vehicle is connected to the coupler ofdiagnostic tool.

Turn on the ignition key.Press the power-button of diagnostic tool.The vehicle is warms up enough to adjust the

idling speed.

The vehicle is warms up enough to adjust theidling speed.

ENGINE TEMPERATURE : OVER 100IDLE SPEED ACTUATOR : APROXIMATELY 20%

INSPECTION OF SENSOR AND ACTUATORConnect each sensor and the actuator coupler.Check the ISA.Check the TPS.Check the MAPAT sensor.

! CAUTIONBe sure to the valve of TPS is whether the

standard valve after it became assembly.Check the MAPAT sensor.

! CAUTIONThe ECU is always initilized, before the engine

is starting.

5-15



5-16


REMOVETurn off the ignition key.Disconnect the injector coupler.

! CAUTION

Be sure to check the engine is coolingbecause a little gasoline remains, It could bestill hot.

Be sure to inject the gasoline, after removethe coupler from the ignition coil. It could bedamaged for the fire, sparked on the sparkplug.

! NOTICE

8. INJECTOR

Before disassemble, the key is off.

INJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAPINJECTOR CAP INJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTOR


INJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTOR

Loosen the injector cap bolt.

Disconnect the injector.

ASSEMBLYAssemble is the reverse order of removal.

5-17


CHECKING METHODS BY FAULT CODESChecking of the Injector circuit

The fault code is displayed by MIL

Checking Circuit

Coupler terminal is based on wire harness.Checking Procedure

1) Turn off the ignition key.2) Check to see if the injector coupler has come loose or the wire is peeling off.

If there is no problem, measured the resistance of injector.3)Disassemble the injector coupler and measure the resistance between injector terminals.

The resistance of injector : 14.5±0.7[ ], 20

Remarks : measuring unit for resistance : resistance ‘ R ‘ [ ]4)If there is no problem, check the continuity between each terminal and ground.

The resistance between each terminal and ground : ∞[ ]If resistance value is not normal, replace injector with the new one.

5)If the resistance is normal, turns on the ignition key - If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.

6) Measure between the voltage of coupler.Measuring terminal : BLACK/RED electric wire ~ groundMeasuring voltage : battery voltage – 1.0[V]over

Remarks : Measuring unit of voltage : voltage [V] 7) If the measured voltage is normal,

Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)

If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks

8) If the measured voltage is not normal, Check the Black/Red electric wire to see if they have been broken or have short-circuited.Check the fuel pump relay.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

INJECTOR FUEL PUMP RELAY

ECU 40 : INJECTOR control 39 : FUEL PUMP control

5-18


Located on the left-side of the throttle body.

REMOVEDisconnect the MAPAT circuit sensor coupler.Loosen the 2 MAPAT circuit sensor screws.


Disconnect the MAPAT sensor.

! CAUTION

9. MAPAT (Mainfold Air pressure sensor Temperature sensor)

Before disassembly, the key is off.





5-19

EMS(Engine Management System)Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit

Fault code number is displayed by MIL

The Fault code of intake pressure sensor The Fault code of intake temperature sensor

Checking circuit

Coupler terminal is based on the side of wire-harness

Checking Procedure1) Turn off the ignition key .2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.

If there is normal, measured the input voltage of MAPAT’s coupler.3) Disassemble the coupler of MAPAT and turn on the ignition key4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)’s coupler.

Input voltage : 4.5 ~ 5.5[V] Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal

Remarks : Measuring unit of voltage : voltage [V]

If voltage value is not normal,Check to see if the ECU coupler is loose or if there is a bad contact.Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ to see if they have been broken short-circuited

Remark : refer to (5-20) if the intake pressure sensor is brokenrefer to (5-20) if the intake temperature sensor is broken

5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

ECU

MAPAT

3 : Inhalation pressure sensor GROUND 26 : 5V voltage 27 : IMP 28 : TBA

3 : Intake pressure sensor ground26 : 5V voltage 27 : IMP 28 : TBA

5-20


Checking of the intake pressure sensor

1) If voltage value is normal, turn off the ignition key.Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler

2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-11 )

3) Turn on the ignition key. Start engine and operate idle.4) Measure the voltage of intake pressure sensor for ECU check.

Measuring the voltage of intake pressure sensor.Measuring terminal : ECU No. 27(P/L:PINK/BLUE)

~ ECU No.3(P/G : PINK/GREEN)Measuring voltage : 0.1[V] ~ 4.8[V]

Remarks : Measuring unit of voltage : Voltage [V] The voltage of air pressure;20[kPa]: 0.719 ~ 0.859[V]107[kPa]: 4.154 ~ 4.294[V]

5) If the measured voltage is not normal,Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been brokenor have short- circuited.

Replace the MAPAT sensor with the new one and it rechecks.

If measuring voltage is normal,Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or haveshort- circuited if there is a bad contact.badness of terminal No. 3, No. 26, No.27 of ECU coupler.

If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.

WIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESSWIRE HARNESS

5-21

EMS(Engine Management System)Checking of the intake temperature sensor

1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.

Resistance of intake pressure sensor : 2000±100[Ω], 25±1Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)

Remarks : Measuring value for resistance : Resistance[ ]The Voltage of air pressure;24 ~ 26[ ] : 1800~2200[ ]99 ~ 101[ ] : 161~206[ ]

3) If measuring resistance is not normal,Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal, Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 3, No. 26, No. 27 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

4) Turn on the ignition key. Start the engine and idling. 5) Measure the voltage of intake pressure sensor for ECU check.

Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No.28(TBA)

~ ECU No.3(IMP GROUND)- Measuring voltage: 0.1[V] ~ 4.9[V]

Remarks : Measuring unit of voltage : Voltage [V]

6) If the measured voltage is not normal,Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been brokenor have short- circuited.

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal, Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 3, No. 26, No.28 of ECU coupler.

If the electric wire is no problem, ECU is broken. Replace ECU with the new one, it rechecks.

7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-22


REMOVEDisconnect the TPS coupler.Loosen 2 TPS screws.

Disconnect the TPS.

Located on the left side of throttle body.

! CAUTION

10. TPS(Throttle position Sensor)






5-23


CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number is displayed by MIL

Checking circuit

The coupler terminal is based on the side of wire-harness

Checking Procedure1) Turn off ignition key .2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.

If there is no defect, measure the input voltage of TPS. 3) Disassemble the TPS coupler4) Turn on the IGNITION KEY.

Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)Measure the terminal voltage of TPS’s coupler.Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit of voltage : voltage [V]

If voltage value is not normal,Check to see if the ECU coupler is loose if there is bad contact.Check the ‘GR/B’’ electric wire, ‘W/R’ electric wire, ‘GR /L’ electric wire to see if they have beenbroken or have short- circuited.

5) If the value of voltage is normal, turn off the ignition key.

ECU

4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS

TPS

5-24


Checking Procedure6) Check continuty between the Sensor Ground Terminal of TPS and Earth.

The continuty TPS : 0[ ],20±1Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ ]

7) If not problem, measure the resistance of TPS. By turning round throttle grip, measure the resistance.The resistance of TPS If the throttle is totally closed : 0.9~1.6[k ],20±1If the throttle is totally opened : 2.3~2.6[k ],20±1Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE)

~ ECU No.4 (W/R : WHITE/RED)

Remarks : Measuring value of resistance : Resistance[k ]

8) If resistance and the continuty are not abnormal. Adjust correctly the position of TPS Replace the TPS with the new one and re-check.

9) If resistance and continuty are normal, connect the TPS coupler.10) Turn on the ignition key. 11) Measure the TPS voltage of wire-harness to check the ECU.

Rotate the throttle lever, measure the voltage Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE)

~ ECU No.4 (W/R : WHITE/RED)Output voltage of TPS-If the throttle is totally closed : 4.0~5.5[V] -If the throttle is totally opened : 0.1~0.6 [V]

Remarks : Measuring unit for voltage : Voltage [V]

12) If the measured voltage is abnormal,Replace the TPS with the new one, and re-check.

If the measured voltage is normal, Check the ‘GR/B’ electric wire, ‘GR/L’ electric wire, ‘W/R’ electric wire to see if they have been broken orhave short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler.

If there is no problem in wires, ECU has broken down. Replace ECU with the new one, and recheck.

13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-25


REMOVEDisconnect the ETS coupler.

Situated at the back of the cylinder head.Remove the RH. shroud.

! CAUTION

11. ETS(Engine Temperature Sensor)



Disconnect the ETS.

RH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUD

ETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETSETS

5-26


1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) Fault code number is displayed by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of wire-harness

Checking Procedure1) Turn off the ignition key .2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad.

If there is no defect, measure the input 5 voltage of ETS.3) Disassemble the coupler of ETS4) Turn on ignition key.

Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Measure the terminal voltage of ETS’s coupler.Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit for voltage : voltage [V]

If the voltage value is not normal,Check to see if the ECU coupler is loose if there is bad contact.Check the ‘G/L’’ electric wire, ‘W/R’ electric wire, ‘W/R’ electric wire to see if they have beenbroken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key.6) Disassemble the coupler of ETS, and measure the resistance of ETS.

Resistance of ETS :1.6[k ]~10.6[k ],20 ~80Measuring terminal : Each terminal of ETS

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [k ]

ECU 4 : SENSOR GROUND 20 : ETS

ETS

5V SUPPLY VOLTAGE

5-27


6-1) If the measured value is not normal, Replace the ETS with the new one, recheck.

If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or ifthe ECU coupler is a bad contact ( No.4, No. 20.)

If the electric wire is no problem, ECU is broken. Replace ECU with the new one, recheck.

6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

Checking Procedure1) Disassembly

Disassemble the ETS(Engine Temperature Sensor) : (Refer to ETS disassembly) 2) Check the ETS(Engine Temperature Sensor)

Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.Read the temperature of thermometer depending upon oil temperature’s change and tester’s value.

Characters of ETS

Measuring unit of resistance : Resistance ‘ R ‘[k ]

If the value of resistance is high or out of the standard value, replace the ETS with the new one.

1)Be careful do not fell down the ETS, because its weakness.

2)Be careful the ETS and the thermometer do not to touched to oil bowl.

3)Be careful oil temperature will not raised more than measurement temperature.

3) InstallAssembly is the reverse order of removal. Tighten the ETS to the specified torque.

ETS torque : 3.0[kgf m]

Temperature

20

80

110

Resistance value

10.6[k ]~14.4[k ]

1.35[k ]~1.65[k ]

0.57[k ]~0.69[k ]

! CAUTION

5-28


REMOVEDisconnect the ISA coupler.

Loosen 2 ISA screws.

Located on the throttle body.Remove the center cover.

! CAUTION

12. ISA(Idle Speed Actuator)


Remove the ISA.


ISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLERISA COUPLER

ISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAISAINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTORINJECTOR

ISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREWISA SCREW

5-29


1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.Showing of defects codes by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of the wire-harness

CHECK PROCEDURE1) Turn off ignition key .2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.

If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of ISA, measure the resistance

between ISA terminals.ISA resistance : 31.5~ 38.5[ ],20

remarks : Measuring unit of resistance : Resistance ‘R’[ ]

4) If there is not problem, check about the level of electricity flow between each terminal,and between each ground.

Resistance between each terminal , and between each ground : ∞[ ]If measure resistance value is not normal, replace with the new one Disassembly and Assembly : refer to ( 5-28 )

remarks : Measuring unit for resistance : Resistance ‘R’[ ]

ISA FUEL PUMP RELAY

ECU


5-30


CHECK PROCEDURE5) If the measured resistance and continuty is abnormal.

Replace ISA with the new one, and recheck.

6) If resistance and continuty is normal, connect the coupler of ISA. 7) Turn on ignition key8) Measure ISA voltage of wire-harness to check ECU.

Measuring terminal : B/R electric wire ~ EARTHOutput voltage of ISA : Battery Voltage [V]

Remarks : Voltage measuring unit : Voltage [V]

If the measured voltage is normal,Check the ‘B/R’ electric wire, ‘L/G’ electric wire, ‘W/R’ electric wire to see if they have been broken orhave short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler. If there is no problem in wires, ECU has broken down. Replace ECU with the new one, recheck.

If the measured voltage is abnormal, Check the ‘B/R’’ electric wire, ‘L/G’ electric wire, ‘W/B’ electric wire to see if they have beenbroken or have short- circuited.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code.

5-31


Remove the O2 sensor on the muffler.

Check the O2 sensor.

REMOVELocated on the exhaust pipe.Disconnect the RH. floor side cover.Disconnect the O2 sensor coupler.

! CAUTION

13. O2(Oxygen) SENSOR



O2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLERO2 SENSOR COUPLER

O2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSOR

O2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSORO2 SENSOR

! CAUTIONTake precaution not to impact on the O2 sensor.

5-32


1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT Fault code number is displayed by MIL

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.

CHECKING CIRCUIT

Coupler terminal is based on the side of Wire-Harness.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER1) Turn off the ignition key.2) Check the O2(oxygen) coupler is loose, or bad.

If there is no defect, measure the input voltage of O2(oxygen)3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key4) Measure input voltage of oxygen(O2)sensor coupler

Input voltage : Battery voltage[V] Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler(B/BR : BLACK/BROWN) ~ EARTH

Remarks : Measuring unit of Voltage : Voltage[V]

ECU

OXYGEN SENSOR

2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER

Lamda

34 : OXYGEN SENSOR GROUND

5-33


CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATERIf the voltage value is abnormal,

Check to see if the ECU coupler is loose or if there is bad contact.Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have beenbroken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key. Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22Measuring terminal (side of wire-harness) : oxygen(O2)3 terminal of sensor coupler Remarks : Measuring unit of Resistance : Resistance ‘R’[ ]

6) If the measured resistance is abnormal, Replace the oxygen(O2)sensor with new one and recheck it.

If the measured resistance is normal, Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have beenbroken or have short- circuited.

If the electric wire is no problem, the ECU is broken. Replace the ECU with new one, and recheck it.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key2) Check the O2(oxygen) coupler is loose, or bad.

If there is no defect, measure the input voltage of O2(oxygen) 3) The wire harness to check the ECU is connected to the ECU with a ECU coupler

Refer to the ECU assembly/disassembly (5-4) 4) Turn on the ignition key5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.

Measuring terminal: (V :VIOLET) ~ (V/B:VIOLET/BLACK)Output voltage of oxygen(O2) sensor : 0.1~0.8[V]

Remark : measuring unit of voltage : voltage[V] Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf m]

If the measured voltage is normal, Check the ‘V’ electric wire, ‘V/B’ electric wire to see if they have been broken orhave short- circuited if there is a bad contact of terminal

No. 2, No. 12 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,Check the ‘V’ electric wire, ‘V/B’ electric wire, ‘W/B’ electric wire to see if they have beenbroken or have short- circuited.

6) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

5-34


14.CHECKING OF MILFault code number is displayed by MIL

CHECKING CIRCUIT

CHECK PROCEDURE1) Turn off ignition key.2) Check the ESS coupler is loose, or bad.

If there is no problem.3) Turn on the ignition key. 4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.

If there is no lighting, check the lamp.But If the lamp is working for 3 second,

5) Measure the MIL voltage of wire harness to check ECU.Measuring terminal : (B) electric wire ~ (G)electric wire => Output voltage: battery voltageMeasuring terminal : (B/Y)electric wire ~ (G)electric wire => output voltage: 9V~15V

Remarks : measuring unit of voltage : voltage[V]

If the measured voltage is normal,Check the ‘R/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see if they have been broken orhave short- circuited if there is a bad contact of terminal No. 24 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and rechecks it.

If the measured voltage is abnormal,Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see if they have beenbroken or have short- circuited.

6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code.

MALFUNCTION INDICATOR LAMP(MIL)

ECU24 : MALFUNCTION INDICATOR LAMP OUTPUT

5-35


Remove the RH. shroud.Remove the cooling fan.Remove the fly wheel.

Remove the 3 screws securing ACG stator.Remove the 2 screws securing CKP.

REMOVERemove the center cover.Remove the ACG coupler.Remove the CKP coupler.CKP is located inside the RH. crank case

cover.

! CAUTION

15. CKP(Crank Position Sensor)


Check the ACG stator and position sensor.Take precaution not to use the stator comp (18

terminal) like the carburetor type stator.

RH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMPRH. SHROUD COMP

CRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSORCRANK POSITION SENSOR

5-36


MEASUREMENT PVADisconnect the ACG (L/G) connector.Connect the (+)cord of PVA tester to the green

terminal or ground wire.Connect the (-)cord of PVA tester to the blue

terminal.Crank the engine with the starter motor and

measure the peak voltage of crank positionsensor coil.

HIGHEST VOLTAGE : 1.5V Over.TOOL : PVA Multy tester.

Assembly is the reverse order of removal.

MEASUREMENT RESISTANCERemove the seat.Remove the LH. side cover.Disconnect the ACG coupler and (L/G)

connector.Measure the resistance between G and L.STANDARD : 80~150Ω(20)

CHECKING OF CKP(Crank PositionSensor)

Check the fly wheel.Fly wheel for the EMS system have 10 spots

on the fly wheel protrusion. It is different withcarburetor type.

Check the mark or contamination on theprotrusion.


! CAUTIONWhen replace the fly wheel, check the 10 spots

of protrusion part.

5-37


CHECK THE CIRCUIT OF CKPFault code number is displayed by MIL

CHECKING CIRCUIT

CHECK PROCEDURE1) Turn ON ignition key.2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.

When start up the ENGINE SINK ON change “OFF’ to “ON”, it’s okay.Check if ENGINE SINK ON is OFF while start up.- Remove the A.C. generator.- If there are over 10 spots on the flywheel protrusion, replace it.- Check the CKP is working or NOT (metal residue)

3) Turn OFF ignition key, check the breaking of A.C GEN CKP.Check the A.C. GEN CKP resistance.- measuring resistance : 80 ~ 150[Ω]

ECU 핀 번호

30 : 크랭크 신호 _ A22 : 크랭크 신호 _ B

청색

22 30

적색

청색 녹색

ECU PIN NUMBER

30 : CRANK SIGNAL-A

22 : CRANK SIGNAL-B

GREEN BLUE

REDBLUE

5-38


4) Check if crank signal A,B wires is breaks or not.Remove the ECU, connect wire harness for inspection to wire harness of vehicle.Check the wiring of crank signal A- Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP.- Measuring resistance : 0 ~ 1[Ω]

Check the wiring of crank signal B- Measure terminal : No. 22 pin of wire harness for inspection - Blue wire of coupler of CKP.- Measuring resistance : 0 ~ 1[Ω]

5) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

CKP_B CKP_A1 2

CKP_B CKP_A1 2

Blue

Red

5-39


Remove the fuel hose.Remove the fuel pump coupler.

Loosen the 4 fuel pump setting place screws.

REMOVEFuel pump is located inside the fuel tank.Remove the fuel filler cap.Remove the floor panel.

! CAUTION

16. FUEL PUMP

Make sure that the key is off before assembly.

Remove the fuel pump.


FUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLERFUEL PUMP COUPLER

FUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACEFUEL PUMP SETTING PLACE

FUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBEFUEL TUBE

FUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAPFUEL FILLER CAP

5-40


CONNECTOR WIRING

LOCATION FUNCTION COLOR

C

D

B

A FUEL UNIT

FUEL UNIT2

PUMP (+)

GROUND

YELLOW

GREEN

RED

BLACK

The terminal arrangement of the fuel pump(The following color chart is the internal color of the fuel pump)

FUEL PUMP

5-41


Check the fuel pump.Remove the fuel pump.Measure the resistance between terminals.

The float position is based on tank bottom plate.Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)

wire of fuel unit terminal

※Remark : measuring unit of resistance : resistance[Ω]If the measured resistance value is out of standard at float position, replace the fuel unit.

The FLOAT position

F : 140.5[mm]

1/2 : 83.5[mm]

E : 28.5[mm]

Terminals resistance [Ω]

40 ±5[Ω]

220 ±5[Ω]

400±3[Ω]

CHECK THE BLOW PRESSURE OF FUEL PUMP- Blow pressure : 3.0 Bar- After remove fuel tube from the injector, turn the ignition key ON/OFF 3

times, when the fuel come out about 100cc over, it’s Okay.If under 100cc, check the fuel pump. Replace it if necessary.

(Be sure to the resistance of battery is over 12.6V)


5-42


The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.

Turn the lgnition key on.Press the power button of the diagnostic tool.Press the enter button in the initial screen.Press the enter in the vehicle diagnosis screen.

Press the enter button on the resetting ECU values.

Press the rest button on the following screen.

If the enter-key is press than the ECU will reset.

17.HOW TO USE THE SCAN WHEN ECU IS INITIALIZED

5-43


Press the enter button when it is ready

When the ECU was initialized. turn off the lgnitionkey and then turn on the ignition key.

The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.

Turn the lgnition key on.Press the power button of the diagnosis tool.Press the enter button on the initial screen.Press the button at the vehicle diagnostic screen.

Press the enter button on the current data.

By looking the displayed figure on the ISA PWM, adjust the throttle adjust screw.

18.HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING


5-44


5-45

The coupler to check the malfunction of vehicle isconnected to the coupler of diagnostic tool.

Turn the lgnition key.Start the engine.Press the power button of the diagnosis tool.Press the enter button on the initial screen.Press the enter button on the vehicle diagnosis screen.


To check the ignition angle

19.HOW TO USE THE SCAN WHENTHE IGNITION TIMING IS CHECKING


The coupler to check the malfunction of vehicle isconnected to the coupler of diagnostic tool.

Turn the lgnition key.Start the engine.Press the power button of the diagnosis tool.Press the enter button on the initial screen.Press the enter button on the vehicle diagnosis screen.


Check the engine rpm on the engine speed

20.HOW TO USE THE SCAN WHENENGINE REVOLUTION IS CHECKING

5-46

MEMO

MEMO

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 poorlyventilated 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 1 month, 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 maybecome unstable.

SPECIFICATIONS

FUEL TANK CAPACITY : 7.2ℓRESERVE FUEL CAPACITY : 1.2ℓ

CARBURETOR SPECIFICATIONS

TOOL

FLOAT LEVEL GAUGE

6-1

6. FUEL SYSTEM

6

SERVICE INFORMATION ·· 6-1TROUBLESHOOTING···· 6-2FUEL TANK········ 6-3CARBURETOR······· 6-3

FLOAT CHAMBER/FLOAT/JET·6-5CARBURETOR INSULATOR· 6-8PILOT SCREW ADJUSTMENT 6-9FUEL PUMP········6-11

ITEM

VENTURI BORE

SETTING SERIES MARK

MAIN JET No.

FLOAT LEVEL

PILOT SCREW INITIAL OPENING

IDLING SPEED

THROTTLE GRIP FREE PLAY

SPECIFCATUIONS

CV TYPE/Ø24.2mm

CVK 166 (A)

#95

17mm

2 ½

1,700 ± 100rpm

2-6mm

FUEL SYSTEM

! WARNING

! CAUTION

6-2

FUEL SYSTEM

TROUBLESHOOTING

The vehicle does not start.

No gasoline in fuel tank. Fuel is not coming out of carburetor. Too much fuel is flowing into cylinder. Air cleaner is blocked. No spark emitted from spark plug.

Idle is unstable and engine turns off after starting.

Faulty idle adjustment. Excessively lean or rich mixture. Air cleaner is blocked. Suction system is experiencing secondary intake of air. Clogged fuel system. Auto bystarter is damaged. Ignition system is damaged. Using low quality gasoline. Air screw is adjusted improperly. Carburetor is blocked. Compression pressure is low.

Air/Fuel mixture is extremely lean

Fuel jet is blocked. Bad ventilation of air in tank cap. Fuel strainer screen is blocked. Fuel tank is bent, creased or blocked. Float valve is damaged. Oil level is low. Suction system is receiving secondary suction of air. Fuel pump is incorrect flow of oil.

Air/Fuel mixture is extremely rich.

Float valve is damaged. Oil level is too high. Air jet is blocked. Auto bystarter is damaged. Air cleaner is blocked.

Back firing

Ignition system is damaged. Mixture is too lean.

Mis-firing occurs when driving at high speeds.

Ignition system is damaged. Mixture is too lean.

Insufficient power and high fuel consumption.

Air cleaner is blocked. Ignition system is damaged. Mixture is too lean.

6-3

FUEL SYSTEM

FUEL TANK

REMOVAL

Release the seat lock by turning the main switch key toopen the seat.

Remove the following parts.- Rear fender.- Seat support pipe.- Center cover.- Truss pipe.- Battery.- Floor panel. Remove the fuel unit wiry coupler. Remove the fuel strainer tube. Remove the flange nut. Remove the fuel tank. Install in the revers order removal.

CARBURETOR

REMOVAL- Rear fender.- Center cover.- Air cleaner connecting tube band.

CRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPECRADLE PIPE

TRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMPTRUSS PIPE COMP

FLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANEL


SEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPESEAT SUPPORT PIPE


FUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAPFUEL CAP

FUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANK

FUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNITFUEL UNIT

FUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBEFUEL STRAINER TUBE

AIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BANDAIR CLEANER CONNECTING BAND

CARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETORCARBURETOR INSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATOR

FLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANELFLOOR PANEL


Gasoline is extremely flammable. Avoid fire duringwork, and pay particular attention to electric sparks.Furthermore, the evaporated (gasified) gasoline is highlyexplosive. Work in a well-ventilated areas.

! WARNING

After removing the fuel tank be sure to closethe fuel tank cap.(Gasoline is extremely flemmable)

! CAUTION

6-4

FUEL SYSTEM

Loosen the throttle cable lock nut and remove thethrottle cable from the carburetor.

Remove the fuel tube. Remove the auto bystarter wiring. Loosen the screw on the carburetor insulation band. Remove the carburetor.

REMOVAL Loosen the special pan screw on the carburetor top set. Remove the top set.

Remove the top set cover. Remove the compression spring, vacuum piston comp.

Remove the spring seat, jet needle.

THROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUTTHROTTLE CABLE LOCK NUT

TOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SET

SPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREWSPECIAL PAN SCREW

COMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRINGCOMPRESSION SPRING

VACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMPVACUUM PISTON COMP

VALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SET

6-5

FUEL SYSTEM

INSPECTION Check the needlejet for wear and replace if necessary. Check the vacuum piston for damage and replace if

necessary. Check the diaphragm for damage pin holes, wrinkles

and bends and replace if necessary.

FLOAT CHAMBER / FLOAT /JET

DISASSEMBLY Loosen the 4 screws securing float chamber set.

Remove the float pin, float and float valve

Check the float valve and valve seat for scores,scratches, clogging and damage replace if necessary.

Check the float valve operation.

VACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTONVACUUM PISTON

JET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLEJET NEEDLE

VALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SETVALVE PLATE SET

PAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREWPAN SCREW

FLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SET

ARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINARM PINFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SET

FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP FLOAT COMP

FLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SETFLOAT VALVE SET

MAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETMAIN JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JETSLOW JET

Check the diaphragm adequately for crack inthe wrinkle area and bend area.

! NOTE

Do not damage the jets. because it made ofsoft material and also do not use the wirewhen cleaning the air and fuel passage.Otherwise it will damage to the carburetorbody, eventually it will be effect the engine.Namely, it is cause of bad condition of engine.

! CAUTION

6-6

FUEL SYSTEM

Remove the main jet, needle jet holder, needle jet, slowjet, screw set, diaphragm comp, compression spring.

Clean the jet and hole of carburetor body with blow thecompressed air.

CARBURETOR BODY

TOP SET

COMPRESSION SPRING

FLOAT CHAMBER SETSCREW SET

AUTO BYSTARTER SET

NEEDLE JET HOLDER

MAIN JET #95

SLOW JET

NEDDLE JET COMP

VACUUM PISTON COMP

FLOATVALVE SET

FLOAT COMP

DIAPHRAGM COMP

Turn in the pilot jet and record the number ofturns it takes before it seats lightly.Do not force the pilot screw against its seat;The seat will be damaged.

! NOTE

6-7

FUEL SYSTEM

ASSEMBLY Install the needle jet, needle jet holder, main jet and

slow jet. Tighten the pilot jet until it seat lightly, then turn it out

as much as number recorded during removal. Install the pilot jet rubber.

Install the float valve set, float comp, float pin. Measure the float level with the float valve gauge.

FLOAT LEVEL : 13 mmTOOL : FLOAT COMP LEVEL GAUGE

Install the float chamber set. Install the stay plate set and 4 pan screws.

Install the valve plate set, compression spring in thevacuum piston comp.

Install the diaphragm cover with its cutout aligned withthe cover.

Place the top set on the spring. Tighten the 2 special pan screws.

SCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SETSCREW SET

FLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SETFLOAT CHAMBER SET

TOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SETTOP SET

Be sure to replace the float chamber body O-ringwith the new one.

! NOTE

Install the jet needle aligned with the grooves.

! NOTE

6-8

FUEL SYSTEM

CABURETOR INSTALLATION Install the carburetor to the carburetor insulator. Tighten the carburetor insulator band screw. Install the fuel tube to the carburetor. Intall the wiring coupler of the auto bystarter. Install the throttle cable to the carburetor. Intall the air cleaner. Install the center cover.

CABURETOR INSULATORREMOVAL Remove

- Center cover.- Air cleaner.- Carburetor.

Remmove the fuel pump negative pressure tube. Loosen the carburetor insulator 2 setting nuts. Remove the carburetor insulator. Remove the carburetor insulator band. Install the reverse order of removal.

COMPRESSSTRAIGHT


INSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATORINSULATOR


AIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BANDAIR CLEANER CONNECTING TUBE BAND

Install the drain tube and air-hose.

Be careful not to pinch the diaphragm, and tokeep the spring straight.

! NOTE

After adjusting the carburetor, check thethrottle grip free play.

! NOTE

6-9

FUEL SYSTEM

INSPECTION Check the carburetor insulator O-ring for wear or

damage. Install in the reverse order of removal.

PILOT SCREW ADJUSTMENT

USING THE EMISSION ANALYZER (CO,HC) Open the seat and remove the center cover.① Turn the pilot screw clockwise until it seats lightly,

then back it out to the specification given(1½).②Warm up the engine to operating temperature (60).③ Adjust the idle speed with the throttle stop screw.

IDLE SPEED : 1,700 ±± 100RPM

④ Extend the hose (60Cm) at the tail pipe, and insert theprobe of the emission analyzer to the tail pipe, andadjust the pilot screw with a ⅛, the Co to became3~4%.

⑤ Adjust by the throttle stop screw, repeat steps ④ and⑤ until accord the idle rpm (1,800rpm) and the Co(3~4%).

O-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RINGO-RING

EMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZEREMISSION ANALYZERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLER

PILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREW



Before adjustment the pilot screw, check thefollowing items.- Fuel system electrical system for troubling.- Do not force the pilot screw against its seat ;

The seat will be damaged.- Spark plug for cleaning and gap adjusting.- Valve clearance for adjusting.- Emission analyzer for correction.Exhaust gas contains poisonous substance.Do not adjusting for a long period of time in aclosed, or poorly ventilated area.

! NOTE

6-10

FUEL SYSTEM

PILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREW THROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREW

PILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREWPILOT SCREW THROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREWTHROTTLE STOP SCREW

ACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATIONACCELERATION


⑥When idling, check to see if the rotation is smoothlyand to return is nomal.

Install the center cover.

If the engine cannot be adjusted by turning thepilot screw within a ¼ turn, check for otherengine problems.

! CAUTION

EMISSION ANALYZER IS NOT EXIST① Turn the pilot screw clockwise until it seats lightly,

then back it out to the specification given(1½).②Warm up the engine to operating temperature (60).③ Adjust the idle speed with the throttle stop screw.

IDLE SPEED : 1,700 ±± 100RPM

Before adjustment the pilot screw, check thefollowing items.- Fuel system electrical system for troubling.- Do not force the pilot screw against its seat ;

The seat will be damaged.- Spark plug for cleaning and gap adjusting.- Valve clearance for adjusting.

! NOTE

④When idling, check to see if the rotation is smoothlyand to return is normal.

⑤ Turn the throttle stop screw until the 1,000RPM, andcheck the stopping of engine.If the engine is stop, adjust the pilot screw with a ⅛,and repeat step ④ and ⑤.

6-11

FUEL SYSTEM

⑥ After the final test of the starting and driving, readjustif necessary.

If the engine cannot be adjusted by turning thepilot screw within a ¼ turn, check for otherengine problems.

! CAUTION

DISASSEMBLY Loosen the 4 screws securing the fuel pump.

Remove the fuel pump. Check the diaphragm A and B of fuel pump for

damage.

FUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMPFUEL PUMP




FUEL PUMPREMOVE

- Center cover.- Inlet, outlet, vacuum tube.- 2 bolts securing the fuel pump.- Fuel pump.

6-12

FUEL SYSTEM


After install the fuel pump, check the blowingquantity of fuel in the outlet tube.

! NOTE

Check the gaskets.

Check the suction valve, outlet valve and relief valvefor damage and crack.


7-1

ENGINE REMOVAL/INSTALLATION

7. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION····· 7-1ENGINE REMOVAL/INSTALLATION·7-2

SERVICE INFORMATION

GENERAL SAFETY

NOTE•Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to

damage the frame, engine, cable or harness.•Attach tape to the frame to protect it during the engine removal or installation.

The following works can be carried out without removing the engine from the vehicle body.

-TRANSMISSION (SECTION 12)-STARTING CLUTCH (SECTION 9)-OIL PUMP (SECTION 4)-A.C. GENERATOR (SECTION 9)-START MOTOR (SECTION 18)-CONTINUOUSLY VARIABLE TRANSMISSION (SECTION 8)-CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 10,11)-EX. MUFFLER (SECTION 3)-CARBURETOR (SECTION 6)-REAR SWING ARM (SECTION 14)

Items to be worked after removing engine.-CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING

Engine oil capacity : 1.1ℓ - When disassembled.

TORQUE VALUES :

ENGINE HANGER BOLT (FRONT) : 2.7f·m(REAR) : 3.5f·m

7

7-2


ENGINE REMOVALDrain the engine oil.Release the seat lock by turning the main switch key to

open the seat.Remove the following parts.

- Rear under cover.- Air cleaner (2-5)- Carburetor (6-3)

Disconnect the ACG coupler and connector wiringconnected to the ACG, disconnect the starter motorwiring cable.

Disconnect the high-tension cord from the engine.Remove the bleeder tube from the cylider hesd cover.

Remove- Muffler- Rear brake caliper- Swing arm- Rear wheel mudguard

Loosen the U nut. Remove the rear wheel.

Remove the RH. shroud. Remove the RH. radiater hose.

DRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLTDRAIN PLUG BOLT

MUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLER

MUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARDMUDGUARD


BRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSEBRAKE HOSE

REAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEELREAR WHEEL

RADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSERADIATER HOSE

7-3


Loosen the rear cushion under bolt.

Remove the SAI tube from the secondary air filterassembly.

Loosen the 10mm U nut from the engine hanger. Lifting the frame back side and remove the flange bolt

securing engine hanger and disassemble the frame andengine.

REAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UNDER BOLT

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

SECONDARYAIR FILTER

REAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHION

ISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBEISA TUBE

ENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATEENGINE HANGER PLATETake precautions not to damage wiring andcable.Take precautions not to damage the thread partof bolts.Arrange the cable tube and wring in the rightpositions.

! NOTE

ENGINE INSTALLATION Install in the reverse order of removal.

TORQUE :

ENGINE HANGER NUT (FRONT) : 4.5f·m

(REAR) : 4.5f·m

Check the following after the engine is installed.- Engine oil- Electric systems

8-0

LH. CRANKCASE COVER/CONTINUOUSLY VARIABLETRANSMISSION

LH. CRANK CASE COVER

8-1

8. LH. CRANKCASE /CONTINUOUSLY VARIABLE TRANSMISSION

SERVICE INFORMATION

GENERAL SAFETY

Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oilcontact.

Do not operate starter motor while the LH. crank case front cover is removed.

Take precautions not ot apply the grease oil to the movable drive face or weight roller.

SPECIFICATIONS

8

SERVICE INFORMATION···8-1TROUBLESHOOTING···· 8-1LH. CRANK CASE COVER·· 8-2DRIVE BELT······· 8-3

ITEM STANDARD SERVICE LIMIT

MOVABLE DRIVE FACE BUSHING INNER DIAMETER 24.000-24.013mm 24.05mm

DRIVE FACE BOSS OUTER DIAMETER 23.980-23.993mm 23.96mm

DRIVE BELT WIDTH 22mm 20.5mm

WEIGHT ROLLER OUTER DIAMETER 19.95-20.02mm 19.50mm

CLUTCH OUTER AND INNER DIAMETER 125.0-125.2mm 125.5mm

DRIVEN FACE SPRING PLAY 140mm 135mm

DRIVEN FACE OUTER DIAMETER 33.965-33.985mm 33.785mm

DRIVEN FACE INNER DIAMETER 34.000-34.025mm 34.060mm

TROUBLESHOOTING

Engine starts but motorcycle does not work. Drive belt worn. Ramp plate damaged. Clutch shoe worn or damaged. Movable driven face spring cut.

Engine stops, or the vehicle runs suddenly,after starting. Clutch shoe spring cut.

Vehicle unable to run at the maximum speed,or lack of output Drive belt worn. Defective movable driven face spring. Weight roller worn. Pulley face contaminated.

MOVABLE DRIVE FACE····8-5CLUTCH/DRIVEN PULLEY ASSEMBLY··8-8DRIVEN FACE INSPECTION· 8-10DRIVE PULLEY INSTALLATION·8-13

! NOTE

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

LH. CRANKCASE COVER

DISASSEMBLY

Remove the air cleaner and flange bolt securing B stay. Remove the flange bolts securing LH. crankcase.

Remove the LH. crankcase cover. Remove the gasket and dowel pin.

INSTALLATION

Install the new gasket and dowel pin after removing thegasket of the crankcase surface.

Install the LH. crankcase cover. Install the air cleaner and B stay and tighten the flange

bolt.

8-2


LH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKETLH. COVER GASKET

DRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACE DRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEY

AIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANERAIR CLEANER

LH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVERLH. CRANK CASE COVER

Tighten the bolts diagonally with specifiedtightening torque.Be sure to replace a new gasket and dowel pin.

! NOTE

B-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAYB-STAY

DRIVE BELT

REMOVAL Remove the LH. crankcase cover. Loosen the drive face setting flange nut 12mm using

the drive face holder and remove the drive face.

TOOL : DRIVE FACE HOLDER

8-3


Loosen the clutch outer setting nut using the universalholder.

TOOL : UNIVERSAL HOLDER

Enlarge the driven pulley belt groove with the drivebelt in place as photo.

Remove the driven pulley sub assembly with the drivebelt in place.

Remove the drive belt from the driven pulley sub ass’y.

DRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDERDRIVE FACE HOLDER

DRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEY


DRIVE BELT


Squeeze the drive belt into the pulley groove asshown so that it slackens enough to remove thedriven pulley from the drive shaft.

! CAUTION

DRIVE BELT INSPECTION Check the drive belt for cracks, pry separation and

wear, replace as necessary. Measure the width of the drive belt as shown.

SERVICE LIMIT : 20.5mm

DRIVE BELT INSTALLATION Turn the pulley clockwise and spread the face apart

while installing the drive belt and install the drive beltto the driven pulley ass’y.

Install the driven pulley sub ass’y on the drive belt. Install the drive belt to the movable drive face apart.

Temporarity install the driven pulley and flange nut. Hold the clutch outer using the universal holder and

tighten the flange nut with the specified torque.

8-4


COG

WIDTH

DRIVEN PULLEY SUB ASS’Y

DRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELT


Use only a genuine DAELIM replacement drive belt.Do not get oil or grease on the drive belt or pulleyfaces. Clean off any grease or oil before reinstalling.

! NOTE

Do not rotate the movable drive face to becamethe original position until the driven pulley tobe installed completely to the drive shaft.

! NOTE

Install the drive face to the LH. crank shaft. Install the rear axel collar and temporaily install the

flange nut. Tighten the flange nut to the specified torque using the

drive face holder.

TORQUE VALVE : 7.0~8.0kgf··mTORQUE VALVE : 5.0~6.0kgf··mTOOL : DRIVE FACE HOLDER

UNIVERSAL HOLDER

8-5



MOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACEMOVABLE DRIVE FACE

DRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSSDRIVE FACE BOSS

RAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATE MOVABLE DRYFACE COMP

MOVABLE DRYFACE COMP





















WEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLER

SLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECESLIDE PIECE

FACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSSFACE BOSS

When installing the drive face match it whenthe LH. crank shaft serration accurately.

! CAUTION

MOVABLE DRIVE FACE

REMOVAL Remove the LH. crank case cover. Hold the drive face holder on drive face. Remove the drive face nut, rear axel collar, drive face.

TOOL : DRIVE FACE HOLDER

Remove the movable drive face and drive face boss.

Remove the ramp plate, weight rollers and oil sealfrom movable drive face.

MOVABLE DRIVE FACE INSPECTION Check the rollers for wear or damage. Measure the O.D. of each roller.


Measure the abnormal wear.

SERVICE LIMIT : LESS THAN 2.0mm

MOVABLE DRIVE FACE INSTALLATION Install the weight roller on the movable drive face. Apply the inside of the movable drive face with the

specified amount of grease.

SPECIFIED GREASE : ALVANIA EP2GREASE APPLICATION : 0.5~1.5 g

Install the movable drive face boss.

Install the movable drive face boss and movable driveface to the LH. crank shaft.

Check the drive face boss for wear or damage andreplace as necessary.

Measure the O.D. of the drive face boss. Replace theboss if the service limit is exceeded.


Measure the I.D. of the drive face . Replace it if theservice limit is exceeded.

Movable drive face inner diameter.


8-6


WEIGHT ROLLER

MOVABLE DRIVE FACE

BOSS

RAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATERAMP PLATE GREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASEGREASE

WEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLERWEIGHT ROLLER

OIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEAL


Do not get the grease on the drive face. Removeany misplaced grease with a degreasing agent.Use only the specified grease in the specified amount.

! NOTE

Install the drive belt into the movable drive face.

Install the drive face in to the LH. crank shaft, andinstall the rear axcel collar.

Tighten the flange nut into the drive face.

Install the LH. crankcase cover.

Tighten the nut to the specified torque using the driveface holder.

TORQUE VALVE : 7.0~8.0kgf··mTOOL : DRIVE FACE HOLDER

8-7


DRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACEDRIVE FACE

REAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLARREAR AXCEL COLLAR



Tighten the drive face nut to the specifiedtorque.

! NOTE

8-8



LOCK NUT WRENCH

LOCK NUT

CLUTCH SPRING COMPRESSOR

DRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRINGDRIVEN FACE SPRING

SPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDESPRING GUIDEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATEDRIVE PLATE

DRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMPDRIVEN FACE COMP

DRIVEN PULLEYREMOVAL Remove the LH. crankcase cover. Remove the drive face. Hold the clutch outer using the universal holder and

remove the 12mm flange nut, then remove the drivenpulley.

TOOL : DRIVE FACE HOLDERUNIVERSAL HOLDER

DISASSEMBLY Remove the special nut.

TOOL : CLUTCH SPRING NUTLOCK NUT WRENCH

Remove the driven pulley sub assembly from the driveshaft.

Remove the drive belt.

Remove the drive plate, driven face spring and drivenface spring guide.

8-9


Remove the seal collar from the driven pulley.

Remove the guide pins and guide pin rollers and themovable driven face.

Remove the O-ring from movable driven face.

Remove the oil seal from the movable driven face.

Remove the movable driven face.

SEAL COLLAR

MOVABLE DRIVEN FACE

MOVABLE DRIVEN FACE

DRIVEN FACE

OIL SEAL

O-RING

GUIDE PIN

GUIDE PIN

OIL SEAL

O-RING

GUIDE PINGUIDE ROLLER PIN

GUIDE ROLLER

8-10


OUTER BALL BEARINGINNER NEEDLE BEARING

MOVABLE DRIVEN FACE SPRING

FREELENGTH

VERNIERCALIPER

CLUTCH OUTER

CLUTCH SHOE

DRIVEN PULLEY INSPECTIONDRIVEN FACE BEARING INSPECTION Check the each parts. Check the driven face needle bearing(inner) for

damage or excessive play and replace as necessary. Turn the inner race of the ball bearing with your finger.

Check that the bearing turns smoothly and quietly, andthat the bearing outer race fits securely.

Replace the bearing (8-11).

MOVABLE DRIVEN FACE SPRING INSPECTION Measure the free length of the driven pulley spring and

replace if the service limit is exceeded.

SERVICE LIMIT : 135mmTOOL : VERNIER CALIPER

CLUTCH OUTER Measure the I.D. at shoe contact surface of the clutch

outer. Replace the outer if the service limit is exceeded.


CLUTCH SHOE INSPECTION Check the clutch shoe for wear or damage. Measure the thickness of each shoe.


8-11


MOVABLE DRIVEN FACE GUIDE GROOVE

DRIVE FACE

OUTER BEARING

SNAP RING

SEALED SIDE

INNER NEEDLEBEARING

OUTER BEARING

SNAP RING

SPECIFIED GREASE

INNER REARING

INNER BEARING

Check the following;- Movable driven face for damage or excessive wear.- Guide pin groove for damage or deformation.

Replace damaged or worn parts as necessary. Measure the I.D. of the movable driven face; replace if

the service limit is exceeded.


Check the driven face for damage or excessive wear;replace as necessary.

Measure the O.D. of the driven face; replace if theservice limit is exceeded.


Install in a new inner bearing.

TOOLS : BEARING DRIVEN ATTACHMENTDRIVE PILOT

DRIVEN FACE BEARING REPLACEMENT Remove the inner bearing. Remove the snap ring then drive out the outer bearing

toward the inner bearing side. Drive a new outer bearing into place with the sealed

end toward the outside. Install the snap ring securely. Apply the specified amount of specified grease as

shown.

GREASE APPLICATION : 9.0~9.5 g

Install the cir-clip fimly to the groove.Install the inner-bearing using a hydraulic press.

! NOTE

8-12


OIL SEAL

O-RING

MOVABLE DRIVEN FACE

DRIVEN FACEGUIDE PIN

SEAL COLLAR

LOCK NUT WRENCH

CLUTCH SPRING COMPRESSOR

GUIDE PINGUIDE ROLLER PIN

GUIDE ROLLER

DRIVEN FACE / MOVABLE DRIVEN FACE

Install new oil seal and O-ring on the movable drivenpulley face.

Install the movable face on the driven pulley face. Install the guide rollers and guide pins.

Install the seal collar.

DRIVEN PULLEY SUB ASS’Y Install the spring guide, driven face, drive plate ass’y. Compress the assembly by turning the tool handle until

the special nut can be installed. Clamp the clutch spring compressor in a vise and

tighten the lock nut to the specified torque using thelock nut wrench.

TORQUE VALVE : 5.5kgf··m

Remove the spring compressor.

TOOL : CLUTCH SPRING COMPRESSORLOCK NUT WRENCH

8-13


DRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELTDRIVE BELT



‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fi‚fi” fi‚fiDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEYDRIVEN PULLEY

Install the clutch onter into driven pulley sub ass’y andflange nut.

Hold the clutch outer using drive universal holder,install the flange nut to the specified torque.

TORQUE VALVE : 5.5kgf··mTOOL : UNIVERSAL HOLDER

Install the LH. crank case cover, and tighten the flangebolt.

Install the drive face, rear axcel collar drive pulley nut. Tighten to the specified torque using drive face holder.

TORQUE VALVE : 7.0~8.0kgf··mTOOL : DRIVE FACE HOLDER

CLUTCH/DRIVEN PULLEY INSTALLATION

Turning the driven pulley ass’y rightside, extend thebelt assemble groove maximum.

Install the drive belt into driven pulley sub ass’y, installthe drive shaft.

Install the drive belt into movable drive face..

9-0

A.C GENERATOR / STARTER CLUTCH

COOLING FAN

FLY WHEEL

STARTER COMP

SAI LID VALVE

9

999

999

9-1


9

16.

9-2


SHROUDREMOVAL

Remove the following parts.- RR. Inner- SAI Tube- RH. / LH. Pillion step holder- Muffler comp

A.C GENERATORREMOVAL

Loosen the rear cushion under cover. Loosen the 3 bolts securing RH. shroud. Remove the SAI. Remove the shroud.

Loosen the 3 cooling fan bolts. Remove the A.C.G. wiring from the A.C.G. wiring

setting clamp securing the engine and frame.

Loosen the RH. shroud 4 flange bolts and 4 tappingscrews.

Remove the RH. shroud. Loosen the LH. shroud setting screw. Remove the LH. shroud. Install in the reverse order of removal.

SAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBESAI TUBE

COOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FAN

RH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUDRH. SHROUD


LH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUDLH. SHROUD

SETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREWSETTING SCREW

SAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVE

FLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMPFLYWHEEL COMP

9-3


A.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLERA.C.G COUPLER

RH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVERRH. CRANK CASE COVER

FLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEELFLYWHEEL

A.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLERA.C.G ROTOR PULLER


STARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMP

Install the universal holder on the flywheel. If the universal holder connot be used, remove the LH.

crankcase cover at the left side of the crankshaft, andhold the drive face with the drive face holer.

Loosen the flange nut securing the fly wheel, andremove the flywheel using the A.C.G rotor puller.

Loosen the fan screw securing the starter comp andremove the starter comp on the RH.crankcase cover.

Disconnect the A.C.G wire coupler.

TOOL : A.C.G ROTOR PULLERUNIVERSAL HOLDERDRIVE FACE HOLDER

Insert the puller shaft and remove the flywheelafter inserting the A.C.G rotor puller andsecuring it with spanner.

The flywheel may easily removed if you rotatethe puller while tapping the puller shaft withmetal hammer.

Always use a holder and a puller to remove theflywheel. Do not try to remove the flywheel byhammering directly on it. The crankshaft orcomponents could be damaged.

After removing the flywheel, check thewoodruff key for damage and wear.

! CAUTION

9-4


SAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPESAI PIPE


COOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FANCOOLING FAN

STARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMPSTARTER COMP


SAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVESAI REED VALVE

A.C GENERATOR INSTALLTION Install the stator to the RH. Crankcase cover. Clean the tapered portion of the crankshaft. Clean the inside part of the flywheel. Check the woodruff key, install the flywheel by

aligning the groove with the woodruff key.

Temporarily install the flywheel nut, hold the flywheelwith the universal holder, or remove the LH. crankcasecover and tighten the flywheel nut with the specifiedtorque.

TORQUE VALVE : 5.0~6.0kgf mTOOL : UNIVERSAL HOLDER

Hold the drive face with drive face holder and installthe cooling fan.

Install the LH. crankcase cover.

TORQUE : 0.8~1.2kgf m

Install the RH. Shroud. Connect the A.C.G wiring coupler and connector to the

wire harness, and install the wiring with the clamp. Install rear under cover. Install the muffler.

RH. CRANKCASE COVER Remove the following parts.

- Rear under cover.- Ex. Muffler.- Rear swing arm.- RH shroud.- Cooling fan.- A.C.G starter comp.- SAI reed valve.

Loosen the flange bolt securing the RH. Crankcasecover.

Remove the RH crankcase cover.

9-5


Remove the RH. Crankcase cover gasket and dowelpin.

STARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCH

OIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMP





STARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEARSTARTER REDUCTION GEAR

SHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFTSHAFT

GASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKET

DOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PINDOWEL PIN

9-6


STARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCHSTARTING CLUTCH

RH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVERRH CRANK CASE COVER




SPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKET

STARTER REDUCTION GEARINSTALLATION Install the starter reduction gear and shaft. Remove the gasket residues from the RH. Crankcase.

Install a new gasket and dowel pin. Tighten the RH. Crankcase cover with flang bolts. Install the following parts.

- A.C.Generator- Cooling fan- RH. Shroud- Rear swing arm- Rear caliper- EX. Muffler- Rear under cover- Pillion step holder

STARTER CLUTCH

REMOVAL Remove the following parts.

- Rear under cover- EX. Muffler- Rear swing arm- RH. Crankcase cover

Loosen the starter clutch lock nut with a special socket.

TORQUE VALVE : 9.5kgf mTOOL : SPECIAL SOCKET (12.7X28X120)

DRIVE FACE HOLDER

9-7


THRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHER

LOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUT

OIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAROIL PUMP DRIVE GEAR

OIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMPOIL PUMP

STARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER DRIVEN GEARSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SET

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BBBBBBBBBBBBBBBBBBBBBB

NEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARINGNEEDLE BEARING

Remove the thrust washer. Remove the starter driven gear and starter clutch.

Check the starter driven gear and starter clutch forproper operation.

Remove the starter clutch.

STARTER CLUTCH INSPECTION Check the starting clutch assembly for proper

operation. Remove the starter driven gear, needle bearing and

starter oneway clutch set from the starter clutchassembly.

Check the starter driven gear for wear or damage. Measure the inner diameter of the starter driven gear.

SERVICE LIMT : A : 32.10 mmB : 39.53 mm

9-8


STARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SETSTARTER ONEWAY CLUTCH SET

SPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKETSPECIAL SOCKET

THRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHERTHRUST WASHER

LOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUTLOCK NUT


Hold the drive face with the drive face holder. Tighten the lock nut with specified torque.

TORQUE VALVE : 9.5kgf mTOOL : SPECIAL SOCKET (12.7X28X120)

DRIVE FACE HOLDER

Install the following parts.- RH. Crankcase cover- A.C Generator- Cooling fan- RH. Shroud- Rear swing arm- Rear caliper- EX. Muffler- Rear under cover- Pillion step holder

MEMO

10-0

CYLINDER HEAD / VALVES

FLANGE NUT

IN VALVE ROCKER ARM

CAM SHAFT HORDER

CAM SHAFT COMP

INLET VALVE

CYLINDER HEAD COMP

CYLINDER HEAD GASKET

EX. VALVE ROCKER ARM

EX. VALVE

CARBURETOR INSULATOR

SAI PIPE

10-1

10. CYLINDER HEAD / VALVES

SERVICE INFORMATION

GENERAL SAFETY

The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removedfrom the frame to maintain the cylinder head.

The oil of camshaft oil is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinderhead.

SPECIFICATIONS10

SERVICE INFORMATION·· 10-1TROUBLESHOOTING····10-2CAMSHAFT········ 10-3CYLINDER HEAD····· 10-5VALVE SPRINGS ······ 10-6

VALVES ········· 10-6VALVE GUIDES······ 10-7VALVE SEATS ······ 10-8CYLINDER HEAD ASSEMBLY·10-12CAMSHAFT ASSEMBLY···10-13

TORQUE VALUES

CAM CHAIN TENSIONER PIVOT BOLT 1.0 kgf·mSPARK PLUG 1.2 kgf·mCAMSHAFT HOLDER 8mm NUT 2.0 kgf·mCAM CHAIN TENSIONER MOUNTING BOLT 1.2 kgf·mCAM CHAIN TENSIONER SEALING SCREW 0.4 kgf·mCYLINDER HEAD COVER BOLT 0.9kgf·mCYLINDER HEAD BOLT 1.1 kgf·mTAPPET ADJUST NUT 0.8 kgf·m

ITEM STANDARD VALUE SERVICE LIMIT

Unit : mm

ROCKER ARM

CAM HEIGHT

VALVE STEM OUTER DIAMETER

VALVE SPRING FREE LENGTH

CLEARANCE BETWEEN

STEM AND GUIDE

CAMSHAFT

VALVE

VALVE GUIDE

ROCKER ARM INNER DIAMETER 12.016 - 12.034 12.060

ROCKER ARM SHAFT OUTER DIAMETER 11.982 - 12.000 11.950

IN 33.835 - 33.995 33.625

EX 33.984 - 34.144 33.765

IN 37.21 36.90

EX 37.21 36.90

IN 4.972 - 4.984 4.920

EX 4.952 - 4.964 4.900

VALVE GUIDE INNER DIAMETER IN,EX 5.000 - 5.012 5.030

IN 0.016 - 0.040 0.090

EX 0.036 - 0.060 0.120

VALVE SEAT WIDTH 0.8 - 1.0 1.4

CYLINDER HEAD WARPAGE - -


TOOLS

VALVE GUIDE REAMERVALVE GUIDE DRIVERVALVE SPRING COMPRESSORVALVE SEAT CUTTERSEAT CUTTER IN 37°(21.5mm)

EX 37°(18.5mm)IN 45°(22.0mm)EX 45°(22.0mm)IN 55°(20.0mm)EX 55°(20.0mm)

TROUBLESHOOTING

Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,or by tracing noises to the top-end with a sounding rod or stethoscope.

10-2


Low comperssion Valves

-Incorrect valve adjustment (see section 3)-Burned or bent valves-Incorrect valve timing-Broken valve spring-Uneven valve seating

Cylinder head-Leaking or damage head gasket-Warped or cracked cylinder head

Cylinder, piston (see section 11)

Excessive white smoke Worn valve guide or valve stem Damaged valve stem seal Worn or damaged piston ring

Rough idle Low cylinder compression

Compression too high Excessive carbon build-up on piston or combustion

chamber

Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn camshaft Worn rocker arm and / or shaft Loose or worn cam chain Worn or damaged cam chain tensioner Damaged cylinder head gasket Incorrect spark plug installation

Turn the crankshaft to the left, and align the “T”markof the flywheel with the index mark of the RH.crankcase cover.

Verify that the piston is located at the top dead center.(Make all camshaft lobes face downward.)

If all camshaft lobes face upward, rotate the crankshaftto the left for 1 turn (360°), and align the “T”markwith the index mark once again.

Loosen the pan screw of the cam chain, remove thetensioner flange bolts and tensioner lifter.

Loosen the 4 camshaft holder 8mm nuts. Remove the camshaft holder from the cylinder head.

10-3


TENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFTTENSIONER LIFT

FLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUTFLANGENUT CAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDER

SPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTSSPECIAL BOLTS

CYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVERCYLINDER HEAD COVER

T-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARK

FAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREWFAN SCREW

CAMSHAFT

REMOVAL Remove the following parts.

- Rear fender- Seat support pipe- Center cover- Truss pipe- Floor panel

Loosen the special bolt securing the cylinder headcover and remove the cover.

Remove the cam chain from the camshaft.

Remove the camshaft.

Insert the 6mm bolt into the rocker arm shaft, andpulling bolts to remove the rocker arm shaft.

Remove the rocker arm. Remove the other side rocker arm shaft and rocker arm

in the same sequence.

CAMSHAFT INSPECTION Check the rocker arm and rocker arm shaft for wear or

damage. Measure the inner diameter of the rocker arm.

SERVICE LIMIT : 12.060 mm

Measure the outer diameter of the rocker arm shaft.SERVICE LIMIT : 11.950 mm

Check the cam lobes of the camshaft for wear ordamage.

Measure the height of the cam lobe.SERVICE LIMIT : IN : 33.625 mm

EX: 33.765 mm

10-4


CAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFT

MICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METERMICRO METER

INNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETERINNER DIAMETER

OUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETEROUTER DIAMETER

ROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFTROCKER ARM SHAFT

Take precautions not to allow the cam chain to dropinto the crankcase.

! NOTE


Manually turn the camshaft bearing outer race, andcheck if it turns smoothly.

Check the bearing for wear or damage.

CYLINDER HEAD Remove the following parts.- Rear fender- Seat support pipe- Center cover- Truss pipe- Floor panel- RH. LH. shroud- Cylinder head cover- Cam shaft- EX. Pipe- Cylinder head

Remove the cylinder head gasket, dowel pin andcamchain guide from the cylinder.

DISASSEMBLY Remove the carburetor insulator. Remove the spark plug from the cylinder head.

10-5


CAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARINGCAMSHAFT BEARING


CYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKETCYLINDER HEAD GASKET

CAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAINCAMCHAIN

SPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUG


FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

FLANGE

BOLTS

Be sure to check the valve clearance.

! CAUTION

Remove the valve spring, valve cotter, retainer, springand valve. Using the valve spring compressor.TOOL : VALVE SPRING COMPRESSOR

CYLINDER HEAD INSPECTION Remove the carbon deposits from the inside of the

combustions chamber.

Check the spark plug assembling hole and the valveseat for cracks.

Using a square and a feeler gauge, check the cylinderhead distortion.SERVICE LIMIT : 0.1 mm

VALVE SPRINGS Measure the free length of the inner and outer valve

springs.


VALVES Inspect each valve for bending, burning, scratches or

abnormal wear. Insert the valves in their original positions in the

cylinder head.Check that each valve moves up and down smothly,without binding.

Measure and record the valve stem outer diameter inthree places along the valve guide sliding area.SERVICE LIMIT : IN : 4.920 mm

EX: 4.900 mm Replace the valve with a new one if the service limit is

exceeded.

10-6


VALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRING


VALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRING

VALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVE

To prevent the loss of tension, do not compress thevalve spring more than necessary.

Mark the disassembled parts so that they can bereassembled into the original position later.

! NOTE

Take precautions not to damage the cylinder headgasket attachment.

! NOTE

Replace the valve spring with new one if the length ofany one is less than the service limit.

! NOTE

VALVE GUIDESINSPECTION Insert the valve guide reamer from the combustion

chamber side and ream the guide to remove any carbonbuild-up before measuring the guide.

TOOL : VALVE GUIDE REAMER

Measure and record each valve guide inner diameter.SERVICE LIMIT : 5.030 mm

Measure the guide-to-stem clearance with a dialindicator while rocking the stem in the direction ofnormal thrust.SERVICE LIMIT : IN : 0.090 mm

EX: 0.120 mm Measure the inner diameter of the new valve guide. If

the clearance is not within the service limit, replace thevalve.

REPLACEMENT

Heat the cylinder head to 130°C - 140°C (275°F - 290°F). Support the cylinder head and drive the old guides out

of the combustion chamber side of the cylinder head.TOOL : VALVE GUIDE DRIVER

10-7


VALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMERVALVE GUIDE REAMER

VALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDE

VALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVERVALVE GUIDE DRIVER

Take care not to tilt or lean the reamer in the guidewhile reaming.

Rotate the reamer clockwise, never counterclockwisewhen inserting and removing.

! NOTE

Avoid damaging the head when driving the valvegiude out.

! NOTE

Do not heat the cylinder head beyond 150°C (300°F).Use temperature indicator sticks, available from

welding supply stores, to be sure the cylinder head isheated to the proper temperature.

Using a torch to heat the cylinder head may causewarping.

Wear insulated gloves to avoid burns when handlingthe heated cylinder head.

Refinish the valve seats whenever the valve guides arereplaced to prevent uneven seating.

! CAUTION

Apply oil to a new O-ring and install it onto a newvalve guide.

Drive the new guide in from the camshaft side of thecylinder head while the cylinder head is still heated.

TOOL : VALVE GUIDE DRIVER

When reaming new valve guides, insert the valve guidereamer from the combustion chamber side.

TOOL : VALVE GUIDE DRIVER

Reface the valve seats and clean the cylinder headthoroughly to remove any metal particles.

VALVE SEATSINSPECTION Clean all intake and exhaust valves thoroughly to

remove carbon deposits. Apply a light coating of Prussian Blue to each valve

face.

10-8


Take care not to tilt or lean the reamer in the guidewhile reaming.

Otherwise, the valve is installed slanted, that causes oilleaks from the stem seal and improper valve seatcontact and results in the valve seat refacing not ableto be performed.

Use cutting oil on the reamer during this operation.Rotate the reamer clockwise, never counterclockwise

when inserting and removing.

! NOTE

VALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDEVALVE GUIDE

VALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVE

Remove the valve and inspect the valve seat face. The valve seat contact should be within the specified

width and evenly all around the circumference.If the valve seat width is not within specification,reface the valve seat.

Measure the valve seat width.STANDARD VALUE : 0.8-1.0 mmSERVICE LIMIT : 1.4 mm

VALVE SEAT REFACING Reface the worn valve seat by using valve seat cutters

and grinders.

Using a 45 degree cutter, remove any roughness orirregularities from the seat.

Using a 37 degree cutter, remove ¼ of the existingvalve seat material.

10-9


Valve faces and stem tips cannot be ground. If a valveface or stem tip is rough, worn unevenly, or contactsthe seat improperly, the valve must be replaced.

! NOTE

Follow the refacer manufactuer’s operating instructions.Reface the valve seat whenever the valve guide has been

replaced.Be careful not to grind the seat more than necessary.

! NOTE

37

37

45

55

VALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEATVALVE SEAT

ROUGHNESS

Using a 55 degree cutter, remove the bottom ¼ of theold seat.

Using a 45 degree cutter, cut the seat to the properwidth.

If the contact area is too high on the valve, the seatmust be lowered using a 37 degree flat cutter. Refinish the seat to specifications, using a 45 degreefinish cutter.

If the contact area is too low on the valve, the seat mustbe raised using a 55 degree inner cutter.Refinish the seat to specifications, using a 45 degreefinish cutter.

10-10


55

45

37

55

SEAT WIDTH

CONTACT TOO HIGH

CONTACT TOO LOW

After cutting the valve seat, apply lapping compound tothe valve face, and insert the valve with a valve guidereamer.

IN/EX VALVE ASSEMBLY Install the valve spring and new stem seals. Lubricate each valve stem with molybdenum disulfide

grease and insert the valve into the valve guide. Check the valve moves up and down smoothly.

For valve spring with varying pitch, install the valvesprings with the narrow pitch end facing down.

Install the spring retainers. Compress the valve springs with the valve spring

compressor and install the valve cotters.

TOOL : VALVE SPRING COMPRESSOR

10-11


VALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSORVALVE SPRING COMPRESSOR

CYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDER VALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVEVALVESPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRINGSPRING

RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER RETAINER

COTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTERCOTTER

STEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEALSTEM SEAL

Do not excessively press and turn the valve to set it as itmay cause damage. Gently strike and set the valve.

The seat surface may become worn on one side if thevalve is set in the same position. Turn the valve slightlywhen setting it.

Take precautions not to allow compound to get into theclearance between the stem and guide while the valve isbeing set.

! NOTE

Compressing the valve spring more than necessarywhen installing the valve cotters may cause loss ofvalve spring tension.

! CAUTION

NARROW PITCH

Tap the valve stems gently with a soft hammer tofirmly seat the cotters.

Apply engine oil to the new O-ring, and assemble it tothe carburetor insulator groove.

Tighten the carburetor insulator with mounting bolts. Install the cam chain tensioner, and assemble pilot.

TORQUE : 1.0 kgf ·m

Install the spark plug.

TORQUE : 1.2 kgf ·m

CYLINDER HEAD ASSEMBLY Clean any gasket material from the cylinder mating surface. Install the cam chain guide to the cylinder. Install the dowel pins and new gasket.

Install the cylinder head.

10-12


VALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRINGVALVE SPRING



CYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDER GASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKETGASKET


CAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAIN

Take necessary precautions not to damage the valve.

! CAUTION

CAMSHAFT ASSEMBLY

Apply engine oil to the rocker arm shaft, and assemblethe rocker arm to the camshaft holder.

Tighten the rocker arm shaft with 6mm bolts, and alignthe bolt hole of the camshaft holder with the fitting sideof the rocker arm shaft.

Check the camshaft assembly for abnormal condition,and place it on the cylinder head.

Put the cam chain and cam sprocket on the camsprocket.

Slowly rotate the crankshaft counterclockwise, andalign the “T”mark of the flywheel with the index markof the RH. crank case cover.

10-13


EX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFTEX. ROCKER ARM SHAFT

CAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDERCAM SHAFT HOLDER

IN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFTIN. ROCKER ARM SHAFT

IN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMIN. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARMEX. VALVE ROCKER ARM

T-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARKT-MARK

CAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFTCAM SHAFT CAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAINCAM CHAIN


Take precautions not to allow the cam chain to comeoff the camshaft timing gear while turning thecamshaft.

! CAUTION

Apply engine oil to the camshaft, and install it on thecylinder head with the cam thread facing downward.

Assemble the cam chain and cam sprocket aftermatching the cam sprocket timing mark in parallel withthe top of the cylinder head.

Install the dowl pins on the cylinder head. Install the cam shaft holder.

Install the cam cover plate. Apply engine oil to the threaded part; install the

camshaft holder nut and bolts, and tighten them drivingwith 2 - 3 times.TORQUE VALUE : 2.0 kgf ·m

Remove the pan screws and seals from the cam chaintensioner lifter.

Rotate the tensioner shaft clockwise with a smalldriver, and insert the shaft into the body completely.

10-14



TIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARKTIMING MARK


The hole of the camshaft holder and the fitting sectionof the rocker arm shaft fit section must be in alignment.

Of IN and EX, the shorter rocker arm should beinstalled on the IN side.

! CAUTION

If the cam chain tensioner lifter is dropped, the shaftwill advance by the spring force.

! CAUTION

Fix the tensioner shaft with a hard clip. Assemble a new gasket to the tensioner lifter, and

install the tensioner lifter on the cylinder. Tighten the tensioner mounting bolts.

TORQUE VALUE : 1.2 kgf ·m

Remove the tensioner shaft clip from the tensionerlifter. Assemble the O-ring and pan screws to thetensioner lifter.


Fill clean engine oil into the operating parts of thecylinder head.

Adjust the valve clearance.

VALVE CLEARANCE : INHALE 0.12 ±± 0.02mmEXHALE 0.12 ±± 0.02mm

Remove oil from the cylinder head cover grooves, andaccurately assemble the gasket to the cover.

Install the cylinder head cover. Tighten the cylinder head cover bolts.


Install the carburetor insulator.. Install in the reverse order of removal.

10-15


HARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIPHARDCLIP TENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTERTENSIONER LIFTER




11-0

CYLINDER / PISTON

CYLINDER

CYLINDER GASKET

PISTON

TOP RING

SECOND RING

OIL RING

11-1

11. CYLINDER / PISTON

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 thecylinder 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

TROUBLESHOOTING

Comperssion too low Overheating Worn piston Excessive carbon build-up on top of piston Worn, damaged piston ring Worn cylinder

Abnormal noiseExcessive smoke Worn cylinder and piston Worn cylinder, piston or piston rings Worn connecting rod small end bearing or piston pin Improper installation of piston ring Damaged piston ring Scored or scratched piston or cylinder wall Excessive carbon build-up on top of piston

11

SERVICE INFORMATION··· 11-1TROUBLESHOOTING···· 11-1CYLINDER········· 11-2

PISTON / PISTON RING ··11-3CYLINDER INSTALLATION · 11-6


Unit : mm

56.100 mm

0.050 mm

0.005 mm

0.020 mm

55.825 mm

15.040 mm

14.960 mm

0.020 mm

0.110 mm

0.080 mm

0.50 mm

1.10 mm

0.200 mm

15.060 mm

0.040 mm

56.000 - 56.010 mm

-

-

-

55.925 - 55.945 mm

15.002 - 15.008 mm

14.994 - 15.000 mm

0.002 - 0.014 mm

0.040 - 0.067 mm

0.025 - 0.052 mm

0.10 - 0.25 mm

0.20 - 0.70 mm

0.055 - 0.090 mm

15.010 - 15.028 mm

0.010 - 0.034 mm

INNER DIAMETER

TAPER

OUT-OF-ROUND

HEAD CONTACT WARPAGE

PISTON SKIRT OUTER DIAMETER

PISTON PIN HOLE INNER DIAMETER

PISTON PIN OUTER DIAMETER

PISTON-TO-PISTON PIN CLEARANCE

CYLINDER

PISTON RING-TO-GROOVE CLEARANCE

PISTON RINGJOINT GAP

TOP

SECOND

TOP / SECOND

OIL RING (SIDE RAIL)

PISTON,

PISTON PIN,

PISTON RING

CYLINDER-TO-PISTON CLEARANCE

CONNECTING ROD SMALL END INNER DIAMETER

GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN

CYLINDER / PISTON

11-2

CYLINDER / PISTON

CYLINDER GAUGE

TOP

MIDDLE

BOTTOM

CYLINDERREMOVAL

Remove EX. pipe. Remove the cylinder head cover. Remove the cam shaft. Remove cylinder head. Remove the cam chain guide from the cylinder. Remove cylinder

Remove the gasket and dowel pin. Carefully removeany adhering gasket material from the cylinder / headmating surface. Do not scratch the surface.

WEAR INSPECTION

Inspect the cylinder wall for scratches and wear. Measure and record the cylinder inner diameter at three

levels in both an X and Y axis. Take the maximum reading to determine the cylinder

wear.


Measure the piston outer diameter. Calculate the piston-to-cylinder clearance. Take the

maximum reading to determine the clearance.


Calculate the cylinder for out-of-round at three levels inan X and Y axis. Take the maximum reading todetermine the out-of-round.

Calculate the cylinder for taper at three levels in an Xand Y axis. Take the maximum reading to determinethe taper.

If any of the cylinder measurements exceed the servicelimits, replace the cylinder.SERVICE LIMIT : OUT-OF-ROUND : 0.005 mm

TAPER : 0.05 mm

CAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDECAM CHAIN GUIDE

CYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDER

CYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKET

PISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTONPISTON

CYLINDER GAUGE

Take care not to damage the cylinder mating surface.

! NOTE

TOP

MIDDLE

BOTTOM

11-3

CYLINDER / PISTON

PISTON RING

WARPAGE INSPECTION

Check the cylinder for warpage by placing a straightedge and feeler gauge across the stud holes. Replacethe cylinder if the service limit is exceeded.


PISTON / PISTON RINGREMOVAL

Remove the piston pin clip using a pair of pliers. Press the piston pin out of the piston.


PISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIPPISTON PIN CLIP


Any clearance between the cylinder and head due todamage or warpage will result in compression leaksand reduced performance.

! NOTE

Place a clean shop towel over the crankcase to preventthe possibility of the clip falling into the crankcase.

! NOTE

Do not damage or scratch the piston.Do not apply side force to the connecting rod.Do not let the clip fall into the crankcase.

! NOTE

Do not damage to the piston by piston ring whenremoving.

! NOTE

Measure the clearance between the piston ring andpiston grooves.

SERVICE LIMIT : TOP : 0.110 mmSECOND : 0.080 mmOIL RING : 0.280 mm

Inspect the piston for wear or damage.

INSPECTION

Clean carbon deposits from the piston. Inspect the piston rings for movement by pressing the

rings. The rings should be able to move in its groovewithout catching.

Spread each piston ring and remove it by lifting it up ata point just opposite the gap.

PISTON RING

11-4

CYLINDER / PISTON

11-5

CYLINDER / PISTON

TOP RING

SECOND RING

MARK

R

TOP RING

SECOND RING

SIDE RAIL

SIDE RAIL

OIL

RING

PISTON

20mm

SPACER

CRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING RODCRANK SHAFT CONNECTING ROD

11-6

CYLINDER / PISTON

CYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKETCYLINDER GASKET



CYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDERCYLINDER

PIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIPPIN CLIP

(10-12)(10-13)

(10-5)(3-9)

(7-3)

MEMO

12-0

TRANSMISSION/CRANKSHAFT/CRANK CASE

12

12-112-212-312-6

12-712-812-912-10

12-1

TRANSMISSION/CRANKSHAFT/CRANKCASE

12

(SECTION 4-4)(SECTION 7)

(SECTION 9)(SECTION 8)

(SECTION 8)

(SECTION 12)

(SECTION 10 AND 11)

TORQUE VALUECRANK CASE BOLT 1.0kg-m

TOOLS-UNIVERSAL BEARING PULLER-BEARING REMOVER SET-REMOVER ASSEMBLY-REMOVER SHAFT-REMOVER HEAD-SLIDING WEIGHT-ASSEMBLY SHAFT

TROUBLESHOOTINGEngine Noise Connecting rod big and small ends loose. Crank pin bearing loose.

Engine started but unable to move out Transmission damage. Transmission seized.

Noise during operation Gear worn, overheated, or cranked. Bearing worn.

Oil leaks Excessive oil level. Oil seal worn or damaged.

12-2


12-3


8-2

3-9

15-814-3

8

14-6

TRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVER SPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLTSPECIAL BOLT

COUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFT FINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFT

DRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFTDRIVE SHAFT

TRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVERTRANSMISSION COVER


12-4


FINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFTFINAL SHAFT


COUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFTCOUNTER SHAFT


DRIVE SHAFT

12-5


Install the bearing to the case with special tools.

TOOL : DRIVE HANDLE AOUTER DRIVERDRIVER PILOT


BALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARINGBALL BEARING

OUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER HANDLEOUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVER

DRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOT

CRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLARCRANK ASSEMBLY COLLAR

CRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFTCRANK ASSEMBLY SHAFT



12-6


Replace the new oil seal on the transmissioncover.Insrall the transmission cover.

FLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTSFLANGE BOLTS

ENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINEENGINE

MISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVERMISSION COVER

Loosen the 8 RH./LH. crankcase setting bolt. Remove the transmission bleeder tube. Remove the RH./LH. radiator hose from the RH.

crankcase.

12-7


RH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASE

LH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASE

CRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFT



CRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARINGCRANK BEARING

RH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASERH. CRANK CASE

UNIVERSAL REARING PULLER


12-8

X

Y

DIAL GAUGE

FILLER GAUGE

DIAL GAUGE

OIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEALOIL SEAL LH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASELH. CRANK CASE

BEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARING


MEASURING POINT

12-9


TOOL : CRANK SHAFT ASSEMBLER

BEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SETBEARING REMOVER SET

DRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE ADRIVER HANDLE A

OUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVEROUTER DRIVER

DRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOTDRIVER PILOT


CRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLYCRANK SHAFT ASSEMBLY

12-10


Install the crankcase. Install the engine on the frame. (7-3)


CRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFTCRANK SHAFT LH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASELH. CRANKCASE

MEMO

13-0

FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE

STEERING STEM

FRONT FORK

FRONT TIRE

FRONT WHEEL

FRONT DISK

13-1

13. FRONT WHEEL/FRONT FORK/STEERING

SERVICE INFORMATION

GENERAL SAFETY

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

TORQUE VALUES

STEERING STEM LOCK NUT 7.84~11.76 f·mSTEERING TOP CONE RACE 0.49~1.27 f·mFRONT CUSHION BOLT 1.98~2.45 f·mFRONT AXLE NUT 4.41~4.9 f·mBRAKE CALIPER BOLT 2.45~3.43 f·m

13

SERVICE INFORMATION····13-1TROUBLESHOOTING····· 13-2STEERING HANDLE ····· 13-3FRONT WHEEL ······· 13-4FRONT WHEEL BEARING··· 13-5

SPEEDOMETER GEAR····13-6FRONT WHEEL INSTALLATION·13-7FRONT FORK ········13-7STEERING STEM ······13-12

RADICAL

AXIAL

ITEM

AXLE SHAFIT DEFLECTION

FRONT CUSHION SPRING FREE LENGTH

STANDARD VALUE (mm)

-

-

-

266.3

SERVICE LIMIT (mm)

0.2

2.0

2.0FRONT WHEEL RIM DEFLECTION

! CAUTION


13-2


TROUBLESHOOTING

Hard steering Steering top cornice too tight. Damaged steering stem steel ball. Faulty steering ball race, cone race. Insufficient tire pressure. Tire is worn.

Steers to one side or does not track straight Bent front fork. Bent front axle. Bent frame. Tire is worn or modification. Worn wheel bearing.

Front wheel wobblingBent rim.Faulty wheel bearing.

Hard to rotate the wheel. Faulty wheel bearing.

Soft suspension Weak fork spring.

Front cushion noise Loose front fork fasteners.

13-3


STEERING HANDLEREMOVAL Loosen the bolts securing the front and rear break

master cylinder.

Disconnect the throttle cable from the throttle grip.

Remove the handle grip from the handlebar.

Remove the cap on the handle upper holder. Loosen the hexbolt securing handle bar and remove the

steering handle comp.



RH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIPRH. HANDLE GRIP

MASTER CYLINDERHOLDER






















LH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIPLH. HANDLE GRIP

HANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIPHANDLE GRIP

HEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTSHEX SOCKET BOLTS

HANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDER

13-4


INSTALLATION Align the line of the steering handle to the handle under

holder. Install the handle upper holder using the hexbolt, to the

specified torgue.

TORQUE : 3.92 - 4.9f·m


FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground. Loosen the flange bolt securing the front caliper to

remove the caliper. Loosen the axle nut, speedometer cable setting screw

and remove the wheel.

INSPECTIONAXLE RUNOUT

Set the axle in V blocks and measure the runout using adial gauge.

The actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT : 0.2mm replace if over

FRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPER

FRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEFRONT AXLEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGE


HANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDERHANDLE UPPER HOLDER

STEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLESTEERING HANDLE

HANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDERHANDLE UNDER HOLDER

Adjust the throttle grip free play to thespecified range of 2-6mm.

! NOTE

13-5


ROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATIONROTATION

BEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEADBEARING REMOVER HEAD


13-6


SPEEDOMETER GEAR

INSPECTION

Remove the speedometer gear from the speedometergear box.

Apply grease to the speedometer gear unit and install.

ASSEMBLY

Apply grease to left side dust seal rim. Install the left side dust seal. Install the brake disk. Install disk bolts.

TORQUE VALUE : 4.0 ~4.5 kgf·m

Install the front wheel side collar.

Install the speedometer gear unit by aligning itsretaining pawl with the hub cutout.

SPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOX SPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEARSPEEDOMETER GEAR

GEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHERGEAR WASHER

BEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARINGBEARING

DUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEALDUST SEAL

FRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLARFRONT WHEEL SIDE COLLAR

GEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINER

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 RH. fork slider. Insert the front axle into the speedometer gear box and

the wheel hub.

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

Apply grease to the dust seal rim. Install the dust seal, and align the tangs of the

speedometer gear retainer with the gear groove toassemble the speedometer gear box.

FRONT FORK REMOVAL Remove the following parts.

-Front brake caliper -Front fender -Front wheel

13-7


SPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOX

GEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINERGEAR BOX RETAINER

SPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOXSPEEDOMETER GEAR BOX

PARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPARTPART

AXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUTAXLE NUT

FRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLEFRONT WHEEL AXLE

FRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPERFRONT CALIPER

13-8


DISASSEMBLY Remove the fork pipe bolt.

Wrap the bottom case with a piece of cloth, andremove the socket bolt.

When removing the front fork, loosen the flange boltlightly.

Loosen the 4 setting bolts securing the RH./LH. frontfork, remove the RH./LH. front fork.

After removal of RH. front fork, loosen the flange boltand remove the front brake hose clamp A.

STEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMP


FRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLTFRONT FORK BOLT

FRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPEFRONT FORK PIPE

SOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLTSOCKET BOLT

Support the vehicle securely under the engine notto turn over it.Loosen the flange bolt, but do not remove it.

! NOTE

If the screw is completely loosened, the fork tubecap bolt may spring out by the force fo the spring.Take due precautions.Remove the fork spring, and expand and releasethe fork pipe several times to drain fork oil.

! NOTE

If the socket bolt turns idle, but cannot beremoved, temporarily assemble the spring andthe fork tube cap bolt first.Hold the bottom case firmly with a vise, takingprecautions not to distort or damage it.

! NOTE

13-9


Remove the oil seal stop ring.

Remove the dust seal.

Remove the fork pipe from the bottom case. Remove the cution spring, pipe seat and oil lock piece

from the fork pipe.

Check and inspect the each parts.


OIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RING

BOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASE

BOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASEBOTTOM CASE

FRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRINGFRONT CUSHION SPRING FORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLTFORK BOLT

FORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEATPIPE SEAT


RESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRINGRESOUND SPRING

OIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECEOIL LOCK PIECE

Take precaution not to damage the interior andexterior rim of the bottom case.

! NOTE

13-10


FRONT FORK ASSEMBLY

Wash parts with clean oil prior to assembling. Assemble the rebound spring and the fork piston to the

fork tube. Assemble the fork pipe to the bottom case.

Wrap the bottom case with a piece of cloth, and fix it tothe vise.

Apply screw locking agent to the socket bolt thread,and assemble the socket bolt to the fork piston.

TORQUE VALUE : 2.0kgf·m

FRONT FORK INSPECTION

Place the fork spring on a level place, and measure thefree length.

If the free length deviates from the service limit,replace the springs with new ones.

Check components for damage or abnormal wear.Replace defective parts with new ones.

SERVICE LIMIT : FORK SPRING : 266.3mm

Set the fork pipe on a V-blocks, and measure fork pipedeflection by rotating with a dial gauge.

SERVICE LIMIT : Replace if the deflection is greaterthan 0.2mm

Check the slider bush contact face. If the slider bush is extensively damaged, replace the

bottom case.

FRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRINGFRONT FORK SPRING

FORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPEFORK PIPE

OIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RINGOIL SEAL STOP RING

When a vise is used to hold the bottom case, do notinsert the case itself but insert the bracket.

! NOTE

Install the dust seal. Fill a prescribed amount of automatic transmission

fluid(ATF) into the fork tube.

CAPACITY : 90cc

Slowly press the fork tube 2-3 times to discharge air.

Assemble the springs to the fork pipe.

13-11


Install the oil seal stopper ring. Accurately assemble the oil seal stop ring to the bottom

case.

Apply ATF to a new oil seal. Assemble the oil seal to the bottom case. Insert the oil seal with special tools until the attachment

groove of the bottom case set ring is exposed.

TOOLS : FORK SEAL DRIVERFORK SEAL DRIVER BODY

FORK SEAL DRIVER

FORK OIL OIL LEVEL


Install the spring with the smaller pitch side facingdownward.

! NOTE

STEERING STEM REMOVAL Remove the following parts.

- Handle cover- Rear handle cover- Front cover- Handle bar- Front wheel

Remove the steering stem lock nut with steering stemlock nut socket.

Remove the steering top nut with steering stem socket.

13-12


ASSEMBLY Align the part of groove with the setting bolt

connection.

Tighten the front fork setting bolt to the specifiedtorque.

TORQUE VALUE : 7.5 kgf·m

Assemble the fork bolt to the fork pipe.

STEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEMSTEERING STEM

FORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLTFORK PIPE BOLT

FRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORKFRONT FORK


FLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTFLANGE BOLTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTU-NUTSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLARSETTING HANDLE COLLAR

HANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMPHANDLE POST COMP

STEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKETSTEERING STEM SOCKET

STEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUTSTEERING STEM LOCK NUT

Be careful not to turn over the vehicle.

! NOTE

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

Insert 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 ⅛ turn.

TORQUE VALUE : 0.15~0.25 kgf·m

Recheck that the steering stem moves smoothlywithout play or binding.

Tighten the steering stem lock nut temporarily.

TOOLS : STEERING STEM LOCK NUT SOCKETSTEERING STEM SOCKET

Install the following parts-Front fork-Front wheel-Steering handle-Inner box

13-13


Remove the steering top ball race from the head pipe. Remove the steering bottom ball race. Check the ball race for wear and damage, if necessary,

replace it.

Remove the front fork. Check the steel ball, cone race and ball race for damage

and wear if possible, replace it. Check the bottom cone race for wear and damage.

STEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUTSTEERING TOP THREAD NUT

STEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMPSTEERING STEM COMP

STEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS Y

STEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS YSTEERING UNDER BALL ASS Y

14-0

REAR WHEEL/SUSPENSION/REAR SWING ARM

14-1

14. REAR WHEEL / SUSPENSION / REAR SWING ARM

SERVICE INFORMATION

Use the specified tire lever and rim protector to remove or assemble tires to protect the rim from being damage.

SPECIFICATIONS

TORQUE VALUES :

REAR CUSHION UPPER BOLT 3.5~4.5f·mREAR CUSHION UNDER BOLT 3.5~4.5f·mREAR CUSHION ROD LOCK NUT 3.0~4.5f·mREAR AXLE NUT 6.0~8.0f·m

14

SERVICE INFORMATION··· 14-1

TROUBLESHOOTING···· 14-2

REAR WHEEL··········14-3

REAR CUSHION ·······14-5

REAR SWING ARM·······14-6


! CAUTION

REAR WHEEL RIM RUN OUT

REAR CUSHION SPRING FREE LENGTH

-

219 mm

2.0 mm

215 mm


TROUBLESHOOTING

Wobble or vibration in motorcycle Bent wheel tire Faulty tire Axle not tightened properly Insufficient air in tire 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

14-2


14-3


REAR WHEEL REMOVAL Support the motorcycle on the main stand. Remove the muffler.

Remove the rear brake caliper assembly with brake hosefrom the rear swing arm.

Loosen the rear axle nut. Remove the rear swing arm.

Remove the rear wheel inside collar.

Remove the rear wheel.

REAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARM

REAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLAR


REAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISKREAR BRAKE DISK

MUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLERMUFFLER

14-4


DIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGEDIAL GAUGE



REAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR SWING ARMREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLARREAR WHEEL INSIDE COLLAR

Install the EX. muffler.

(14-6)

14-5


REAR CUSHION REMOVAL Remove the upper bolt. Remove the lower bolt. Remove the rear cushion.

DISASSEMBLY Install the compressor attachment as shown in the

figure. Install the cushion on the cushion compressor, and

compress the spring.

TOOL : REAR CHUSION COMPRESSORATTACHMENTREAR CHUSION COMPRESSOR

Fix the upper metal and loosen the hex nut. Remove the upper metal. Remove the hex nut, upper metal, stopper rubber and

the spring from the rear damper comp.

INSPECTION Measure the rear cushion spring free length. Check the damper rod for deflection or damage.

SERVICE LIMIT : 215mm

REAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHIONREAR CUSHION

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

UNDER

BOLTS

REAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSORREAR CUSHION COMPRESSOR

ATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENT

ATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENTATTACHMENT

UPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METALUPPER METAL

REAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRINGREAR CUSHION SPRING

FREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTHFREE LENGTH

14-6


REAR SWING ARMREMOVAL Remove the EX. Muffler.

Remove the rear brake caliper. Loosen the rear axle U-nut. Remove the rear swing arm.

Install the rear cushion. Tighten the top and bottom of the cushion with bolts.

TORQUE VALVE : UPPER SIDE : 3.5~4.5kgf mLOWER SIDE : 3.5~4.5kgf m

INSTALLATION Install the spring, stopper rubber to the damper comp. Apply thread locking agent to the hex nut, and install

the rear cushion compressor attachment on the damperrod.

Fix the upper metal, and tighten the hex nut.

TORQUE VALVE : 3.0~4.5kgf mTOOLS : REAR CHUSION COMPRESSOR ATTACHMENT

REAR CHUSION COMPRESSOR

Install the spring with the smaller pitch sidefacing downward.

! NOTE


REAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPERREAR BRAKE CALIPER

14-7


DISASSEMBLY Disassemble the rear wheel outside collar from the rear

swing arm. Disassemble the oil seal (28 x 42 x 7) and radial ball

bearing (6302UU).

OUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAROUTSIDE COLLAR



INSTALLATION Install in the reverse order of removal. Install the rear swing arm to the rear wheel axle bolt. Tighten the rear wheel axle nut.


Install the rear caliper. Install the muffler.

MEMO

MEMO

15-0

BRAKE SYSTEM

15-1

BRAKE SYSTEM

15. BRAKE SYSTEM

SERVICE INFORMATION

GENERAL SAFETY

Do not allow foreign material to enter the system when replenishing brake fluid. To prevent chemical changes, do not mix different types of brake fluid. Do not use the old brake fluid again. Brake fluid can cause damage to painted, plastic, and rubber surfaces. Take precaution not to allow parts to be

contaminated by the brake fluid. Do not reuse sealing washers. Clean the disassembled parts with brake fluid, and check for any clogged passage with compressed air. Bleed the brake hose after removing it. 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.

SPECIFICATIONS

15

SERVICE INFORMATION····15-1TROUBLESHOOTING·····15-2BRAKE FLUID········ 15-3FRONT BRAKE PAD REPLACEMENT··15-5REAR BRAKE PAD······ 15-6

FRONT BRAKE CALIPER·· 15-6REAR BRAKE CALIPER··· 15-8MASTER CYLINDER·····15-11BRAKE DISK········ 15-13

ITEM STANDARD SERVICE LIMIT

FRONT BRAKE CALIPER PISTON A O.D 33.928-33.878mm 33.848mm

FRONT BRAKE CALIPER CYLINDER A I.D 33.96-34.01mm 34.01mm

FRONT BRAKE CALIPER PISTON B O.D 25.33-25.37mm 25.30mm

FRONT BRAKE CALIPER CYLINDER B I.D 25.41-25.46mm 25.46mm

REAR BRAKE DISK THICKNESS 4.0mm 3.0mm

REAR BRAKE DISK RUNOUT - 3.0mm

REAR BRAKE MASTER CYLINDER I.D 13.5mm 13.543mm

REAR BRAKE MASTER CYLINDER PISTON O.D 13.5mm 13.378mm

REAR CALIPER CYLINDER I.D 34.0mm 34.039mm

REAR CALIPER PISTON O.D 34.0mm 33.914mm

15-2

BRAKE SYSTEM

TROUBLESHOOTING

Brake lever / pedal soft or spongy Air bubbles in the hydraulic system. Leaking hydraulic system. Contaminated brake pad / disk . Worn caliper piston seal. Worn master cylinder piston seal. Worn brake pad. Contaminated caliper. Caliper not sliding properly. Worn brake pad / disk. Low fluid level. Clogged fluid passage. Warped / deformed brake disk. Sticking / worn caliper piston. Sticking / worn master cylinder piston. Worn brake disk. Contaminated master cylinder. Bent brake lever / pedal.

Brake lever / pedal hard Clogged / restricted brake system. Sticking / worn caliper piston. Caliper not sliding properly. Clogged / restricted fluid passage. Worn caliper piston seal. Sticking / worn master cylinder piston. Bent brake lever / pedal.

Brakes grab or pull to one side Contaminated brake pad / disk. Misaligned wheel. Clogged / restricted brake hose. Warped / deformed brake disk. Caliper not sliding properly. Clogged / restricted brake hose joint.

Brakes drag Contaminated brake pad / disk. Misaligned wheel. Worn brake pad / disk Warped / deformed brake disk. Caliper not sliding properly. Hydraulic system contaminated with dust.

15-3

BRAKE SYSTEM

FRONT BRAKE AIR BLEEDING

<When the brake bleeder is available> Fill the reservoir with DOT 3 or 4 brake fluid up to the

upper level.

Remover the fluid maintenance lid. 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.

Connect the recommended brake bleeder to the bleedervalve.

Loosen the bleeder valve while pumping the brakelever.

Repeat this operation until the brake fluid flows out ofthe brake bleeder.

Add brake fluid.

Repeat the above procedures until no air bubblesappear in the bleeder hose.

Squeeze the bleeder valve and operate the brake leverto check the ingress of air.


FR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVEFR. BRAKE BREEDER VALVE

CALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPERCALIPER

BREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVE

FR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDERFR. BRAKE MASTER CYLINDER

FRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVERFRONT BRAKE LEVER

BRAKE BREEDER

BRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUID

A contaminate disk or pad reduces brakingpower. Do not allow the disk or pad to becontaminated by oil.

Replace contaminated pads, and removepollutants from the disk completely.

Check the brake fluid level often and replenishnew fluid as required.

Do not spill fluid on painted, plastic or rubberparts.

! CAUTION

To prevent chemical changed.Do not usedifferent type of brake fluid.

! CAUTION

BRAKE FLUID

Check the fluid level often and replenish fluidif the amount of fluid is reduced to the lowerlevel.

Read the user’s manual carefully prior todisassembling or using the brake bleeder.

Protect the bleeder valve with tape to preventair from entering the bleeder valve.

! NOTE

15-4

BRAKE SYSTEM

<When the brake bleeder is not available>

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 bleedervalve 1/2 turn, and close the valve.

② Release the brake lever slowly and wait severalseconds after it reaches the end of its travel.

③ Repeat the above steps ① and ② until bubblescease to appear in the fluid at the end of the hose.

Check the fluid level often, and add fluid if the fluidlevel is near the lower level.

If no air leaks out of the bleeder hose, operate the brakelever to check the presence of air.

Tighten the bleeder valve.TORQUE VALUE : 0.4~0.7 kgf·m

DIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATEDIAPHRAGM PLATE

REAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPERREAR CALIPER

RR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVERR. BRAKE BREEDER VALVE

FR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVERFR. BRAKE LEVER

BREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVEBREEDER VALVE

BREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSEBREEDER HOSE

Do not release the brake lever until the bleeder valvehas been closed.

! NOTE

Be sure that the brake fluid is up to the upper level ofthe master cylinder and refill if necessary

Reinstall the diaphragm, diaphragm plate and oil cupcap.TORQUE VALUE : 1.0 kgf·m

REAR BRAKE BLEEDLING (INTERLOCK)

The rear brake is apply to interlocking system, whensqueezing the right side brake lever, the front and rearbrake works at once.

① Fill the brake fluid up to the upper limit line.② Connect the breeder hose to the breeder valve on

the rear caliper and bleed air.

15-5

BRAKE SYSTEM

RR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVERRR. BRAKE LEVER

FR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVEFR. BREEDER VALVE FR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSEFR. BRAKE HOSE

HANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PIN


BRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PAD

③ If no air leaks out of the breeder hose after operatethe brake lever, stop pumping it.

④ Connect the breeder hose to the breeder valve onthe front caliper and bleed air.

⑤ Fill the brake fluid up to the upper limit line andinstall the diaphragm, plate and oil cup cap.

⑥ Install the fluid maintenance lid.

FRONT BRAKE PAD

REPLACEMENT

Loosen the hanger pin on the front caliper.

Remove the brake caliper from the front fork. Loosen the hanger pin from the brake pad. Install the hanger pin to the new brake pads. Install the brake caliper to the front fork.

When replacing brake pads, replace whole set.Do not remove the brake hose when replacing brake

pads.

! NOTE

15-6

BRAKE SYSTEM

FRONT BRAKE CALIPER

REMOVAL

Drain the brake fluid. Loosen the oil bolt securing the brake hose. Loosen the 2 bolts securing the caliper.

RR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPER

HANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PIN

LOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATE

RR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PADRR. BRAKE PAD

FR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPER

PAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRINGPAD SPRING

REAR BRAKE PAD

REPLACEMENT

Flatten the lock plate pawl and loosen the hanger pin.

Loosen the rear brake bolt and remove the brakecaliper.

Loosen the new brake pad, lock plate, hanger pin andreplace the pads.

Install in the revers order of removal.

When replacing brake pads, replace whole set.Do not remove the brake hose when replacing brake

pads.

! NOTE

Avoid spilling fluid on painted, plastic or rubber parts.

! NOTE

Keep oil off the brake disk or pad, because thecontaminated brake disk or pads reduce the brakingperformance if contaminated. Replace the pad with anew one and clean the disk.

! CAUTION

15-7

BRAKE SYSTEM

INSPECTION

Check the caliper cylinder bore for scoring, scratches,or other damage.

Measure the caliper cylinder I.D.

SERVICE LIMIT : CYLINDER I.D.A : 34.01mmCYLINDER I.D.B : 25.46mm

Check the caliper piston outer diameter part forscratches or other damage.

Measure the piston outer diameter.

SERVICE LIMIT : PISTON O.D.A : 33.848MMPISTON I.D.B : 25.30MM


PISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEALPISTON SEAL


AIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUN

CALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODY


Pay attention not to damage the inner sunface of thecaliper.

! NOTE

Never use the high-pressure air or bring the air gun tooclose.

Never touch the inside of the caliper.

! CAUTION

DISASSEMBLY

Remove the pad spring, pad comp, caliper bracket,boot from the caliper body.

Wrap the caliper with a piece of cloth to avoid pistonand brake fluid leakage and facing the pistondownward.

Remove the piston from the caliper while blowing thelow-pressure air in the opening of the brake hose.

Disassemble the piston seal and the dust seal.

Clean the piston and inside of the caliper with the brakefluid.

15-8

BRAKE SYSTEM

LH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODYLH CALIPER BODY

PISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON APISTON A

HANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PINHANGER PIN RH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODYRH CALIPER BODY

PISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON BPISTON B



FR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPERFR. CALIPER

RR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPERRR. CALIPER

RR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSE

BRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PADBRAKE PAD

ASSEMBLY

Clean the piston seal and the dust seal with the brakefluid and install them in the caliper.

Install the piston in the caliper with the groove side ofthe piston facing the pad.

INSTALLATION

Install the brake caliper to the from fork, and front axle. Install the caliper to the specified torgue.


Install the brake hose to the caliper body with the new2 oil bolts washer and oil bolts.

Install the oil bolt to the specified torgue.


Fill the brake fluid, and bleed air.

Install the RH./LH. caliper body. Install the socket bolt. Install pad spring to the caliper. Install caliper hanger pin bolt to the pad comp and

caliper bracket to the caliper body. Install the brake pad to the caliper.

REAR BRAKE CALIPER

REMOVAL

Loosen the rear brake hose bolt and remove the brakehose.

Loosen the 2 bolts and remove the rear brake caliper.

15-9

BRAKE SYSTEM




AIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUNAIR GUN

CALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODYCALIPER BODY

DISASSEMBLY

Remove the rear brake caliper. Check the caliper assembly. Remove the pad spring, slide pin, caliper bracket and

boot from the caliper body. If there is any wear or damage in the boot, replace it

with a new one.

Wrap the caliper with a piece cloth to avoid piston andbrake fluid leakage and facing the piston downward.

Remove the piston from the caliper, while blowing thelow-pressure air in the opening of the brake hose.

Disassemble the piston seal and the dust seal. Clean the piston and inside of the caliper with the brake

fluid.

Never use the high-pressure air or bring the air gun tooclose.

Never touch the inside of the caliper.

! CAUTION

INSPECTION

Check the caliper cylinder bore for scoring scratches orother damage.

Measure the caliper cylinder I.D

CYLINDER I.D.B : 25.07mm

Check the caliper piston outer diameter part forscratches or other damage.

Measure the piston outer diameter .


15-10

BRAKE SYSTEM

DUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUGDUST PLUG

LOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATELOCK PLATE

CALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKETCALIPERBRACKET

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

CALIPERCOMP

PADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPADPAD


RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)RH.SIM(DC)


PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL

PISTONSEAL


RR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSERR. BRAKE HOSE

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

HANGERPIN

ASSEMBLY

Clean the piston seal and dust seal with the brake fluidand install them into the grooved side of the caliperwith the grooved side toward the pad.

Coat the cyliton grease to the boot. Connect the boot to the piston of the caliper.

INSTALLATION

Tighten the caliper hanger pin bolt, and install thecaliper bracket in the caliper.

Install the rear brake hose in the caliper.

15-11

BRAKE SYSTEM

MASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SETMASTER CYLINDER SET

LEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVERLEVER

MASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYMASTER CYLINDER BODYCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPCIR CLIPBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOTBOOT

STOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SWSTOP SW

PIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLTPIVOT BOLT BRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVERBRAKE LEVER



MASTER CYLINDER

REMOVAL

Drain the front rear brake fluid. Remove the front rear stop switch. Loosen the brake hose oil bolt. Loosen the master cylinder holder bolt. Remove the master cylinder.

Brake fluid causes damage to the painted, plastic orrubber parts. Do not spill fluid on these parts.

If contaminated, gently wipe off the fluid with a pieceof cloth or wash in water. Close hose joints properly toprevent leakage of brake fluid.

Clean the disassembled parts with brake fluid, and usecompressed air to verify each passage is not clogged.

Do not allow the disassembled parts to becontaminated by waste material or dust.

! CAUTION

DISASSEMBLY

Remove the front / rear stop switches. Remove the piston boot, cir clip from the master

cylinder.

TOOL : SNAP RING PLIERS

Remove the washer piston spring from the mastercylinder.

Clean the master cylinder, reserve, master piston withthe recommended brake fluid.

15-12

BRAKE SYSTEM


SECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUPSECONDARY CUP PRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUPPRIMARY CUP

OIL CUP CAP

BOOTCIR CLIP

WASHER

LEVER STOP SW

MASTERCYLINDER BODY

DIAPHRAGM

DIAPHRAGMPLATE

SPRING

INSPECTION

Check the piston periphery for scores, scratches ornicks replace if necessary.

Check the primary and secondary cups for wear.

Check the master cylinder for scores, scratches or nicksand replace if necessary.

Apply the recommendatory brake fluid to the cup,cylinder and inside of cylinder, and install the spring,primary cup, piston.

If there is any leak of fluid, when installingnew piston, it may indicate the side wear of thecylinder by the direction of the pistoncontacting face. In this case, the mastercylinder must be replaced also.

! NOTE

ASSEMBLY

Replace the piston, spring, cups and snap ringas a set.

Be sure that each part is free from dust or dirtbefore reassembly.

When cleaning with the brake fluid, use thespecified brake fluid.

! CAUTION

When installing the cups, do not allow to closethe cup ends.

Install the spring with it’s smaller direction ofcoil ends toward the piston.

Install the side of primary cup toward thespring.

! CAUTION

Install the cir clip to the master cylinder groove firmly.

TOOL : SNAP RING PLIERS

Install the boot to the master cylinder.

15-13

BRAKE SYSTEM

BRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLTBRAKE HOSE OIL BOLT

FR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISK

FR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISKFR. BRAKE DISK

RR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISK

RR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISKRR. BRAKE DISK

INSTALLATION

Install the front rear master cylinder to the handle.

Install the holder with its “UP” mark facingupwards, and align the holder joint with thepunch mark on the handle bar.

Tighten the holder upper bolt first.

! NOTE

Install the brake hose to the master cylinder with 2 newsealing washers and the hose bolt.


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.

BRAKE DISK

INSPECTION

Measure the brake disk for the thickness.

SERVICE LIMIT : 3.0mmTOOL : MICRO METER

Check the brake disk for wobbles.

SERVICE LIMIT : 0.02MMTOOL : DIAL GAUGE

16-0

CHARGING SYSTEM

15A

16-1

16. CHARGING SYSTEM

SERVICE INFORMATION

·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is createdduring charging battery.

·Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss ofeye 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 specialcare when performing maintenance and especially when replacing parts. Not all regular battery equipment iscompatible 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 performingmaintenance 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 thebattery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss inbattery strength.

It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited andif a state develops where voltage is not created between the terminals, the regulator will not operate and excessivevoltage will develops where voltage is not created between the terminals, the regulator will not operate and excessivevoltage 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 batteryability to store electricity is reduced.

For information on generator disassembly, refer to section 9.

16

SERVICE INFORMATION·····16-1TROUBLESHOOTING······ 16-2BATTERY ···········16-3

CHARGING SYSTEM INSPECTION· 16-4A.C. GENERATOR INSPECTION···16-5REGULATOR RECTIFIER INSPECTION·16-5

ITEM STANDARD VALUES

SPECIFICATIONS

Capacity

Terminal-to-terminal voltage (When fully charged)

Charging coil resistance value ( 20°C )

rpm at charging start

12V - 10AH (MF)

13.0 - 13.2V

0.1 - 1.0Ω

1,500rpm

TOOLSDIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER

BATTERY

A.C.GENERATOR

REGULATOR /RECTIFIER Regulator voltage 14.5 ± 0.5V

! WARNING

! CAUTION

CHARGING SYSTEM

16-2

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. Check the regulator rectifier.

·Battery is failing

·Open circuit in wire harness.·Poorly connected coupler.

·Shorted harness wire.·Faulty ignition switch.

·Faulty regulator rectifier.

·Check the charging coil of theA.Cgenerator.

·Faulty regulator rectifier.

·Faulty battery.

Inspect the charging voltage.

Check the voltage between the battery line andground wire of regulator rectifier.

Check the resistance of the charging coil atthe charging coil line of regulator rectifiercoupler.

Check the regulator rectifier.

CORRECT

INCORRECT

INCORRECT

CORRECT

·Poorly connected A.C generator coupler.

·Faulty charging coil.ABNORMAL

NORMAL

ABNORMAL

INCORRECT

ABNORMAL

OVER 15V

14~15VUNDER 14V

NORMAL

NORMAL

CORRECT

16-3

CHARGING SYSTEM

BATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVERBATTERY COVER

BATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERYBATTERY


CABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLE CABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLECABLE

BATTERY REMOVAL

Loosen the screws securing the battery cover andremove the battery cover.

Remove the battery. Disconnect the negative “⊖” battery cable first, and

then disconnect the positive “⊕” cable. The installation sequence is the reverse of removal.

BATTERY (OPEN-CIRCUIT VOLTAGE) INSPECTION Remove the battery cable. Disconnect the battery terminals from the battery. Measure the voltage between the battery terminals.

FULLY CHARGED : 13.0-13.2VINSUFFICIENTLY CHARGED : UNDER 12.3VTOOL : DIGITAL TESTER

Connect the charger positive (+) cable to the batterypositive (+) terminal.

Connect the charger negative (-) cable to the batterynegative (-) terminal.

Use a voltmeter that will accurately indicate 0.1Vdifference.

When measuring the battery volate after driving, leaveit for at least 30 minutes, or the accurate results cannotbe obtained because the battery voltage fluctuates justdriving.

! NOTE

The rapid charging could be possible to reduce thebattery life and cause of damage.

Avoid the rapid charging except emergency.Be sure to the battery charging is not allow to exceed

the specified changing time and current.

! NOTE

16-4

CHARGING SYSTEM

AMPERE METER

BATTERY TERMINAL

EARTH CABLE

MAIN FUSETERMINAL

MAIN FUSE

CHARGING SYSTEM INSPECTIONLEAK 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 allow to exceed 0.5ATOOL : DIGITAL TESTER

When measuring current using a tester, set it to a largerange, and then bring it down the range to anappropriate level.

Current flow larger than the range selected may blowout the fuse in the tester.

While measuring current, do not turn the ignition on. Asudden surge of current may blow out the fuse in thetester.

! NOTE

Be sure that the battery is fully charged beforeperforming this test.

The amount of current flow may change abruptly if notsufficiently charged. Use a battery whose voltagebetween its terminals is 13.0 – 13.2V

! NOTE

Take precaution not to control the tester or wiringwhen flowing the current.

It can cause the damage for the other parts byoverflowing the current.

! NOTE

CHARGING VOLTAGE INSPECTION

If the brobes are connected in reverse order, theregistered current flow direction when charging anddischarging the battery will be reversed as well.

After warming up the engine, replace the battery with afully charged battery.

Connect a tester between the battery terminals. Connect a RPM tester to the high-tension cord. Start the engine, gradually increase the engine speed

and measure the charging voltage and charging current.CHARGING CURRENT : 0~0.5A / 5,000rpmCONTROL VOLTAGE : 14.5±0.5V / 5,000rpmTOOLS : RPM TESTER, DIGITAL TESTER


16-5

CHARGING SYSTEM

This test can be made without removing the statorfrom the engine. Disconnect the wellow wire from theauto bystarter.

! NOTEAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLER

WINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYWINKER RELAYMAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.MAGNETIC SW.

CDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNITCDI UNIT

IGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COILIGNITION COIL

REGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIER

REGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIERREGULATOR RECTIFIER

AC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLERAC GENERATOR COUPLER

A.C GENERATOR INSPECTION

Release the rear under cover. Disconnect the A.C generator connector.

Measure the resistance between the yellow wires. Replace the stator if resistance value is high or there is

continuity between each yellow wire and ground. Resistance : yellow~yellow 0.6~1.6Ω

REGULATOR RECTIFIERINSPECTION Remove the center cover. Remove the regulator rectifier coupler. Measure each terminal.

R

B

Y

Y

Y

G

Y

1-3

∞

∞

∞

∞

Y Y G1-3 1-3 1-4

∞ ∞ 25-40k

∞ ∞ 1-4

∞ 1-4

∞ 1-4

∞ ∞

0-5

∞

∞ 1-4

∞ 1-4

∞ 1-4

∞ 25-40k

R B

Unit : Ω

Replace the regulator rectifier unit if the resistancevalue between the terminals is abnormal.

EURO 2

R

G

Y

Y

Y

G

28~36

∞

∞

∞

R

28~36

∞

∞

∞

Y Y Y∞ ∞ ∞

∞ ∞ ∞

∞ ∞

∞ ∞

∞ ∞

Unit : , (20)EURO 3Tester ⊕

Tester ⊖

+ _

AC.

GENERATOR

B/Y

PULSE

GENERATOR

BATTERY(12V 10AH) UNIT

SIDE STANDSWITCH IGNITION

COIL SPARKPLUG

G

R

MAINSW

FUSE(15A) G

G

B/W P B G/B

B/Y G B/Y

HE

AD

LIG

HT

RE

LAY

IGNITION SYSYTEM

17-0

IGNITION SYSTEM

17-1

17. IGNITION SYSTEM

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. (SECTION 20)

SPECIFICATIONS

17

SERVICE INFORMATION····17-1TROUBLESHOOTING·····17-2CDI UNIT·········· 17-3PULSE GENERATOR INSPECTION· 17-3

IGNITION COIL INSPECTION·· 17-4IGNITION TIMING INSPECTION·17-5SIDE STAND IGNITION CUT-OFF SWITCH·········· 17-5

ITEM STANDARD VALUE

IGNITION COILRESISTANCE VALUE 20 SECONDARY COIL

PRIMARY COIL 0.1 ~ 0.2 Ω

7.3 ~ 11.0

3.6 ~ 4.6

90 ~150 Ω

NGK CR8EH-9

0.8~0.9mm

WITH PLUG CAP

WITHOUT PLUG CAP

PULSE GENERATOR COIL RESISTANCE VALUE

SPARK PLUG

SPARK PLUG GAP

TOOLS DIGITAL TESTERPVA MULTI-TESTERDC-CDI TESTER

IGNITION SYSTEM

TROUBLESHOOTINGNo spark at plug.

17-2

IGNITION SYSTEM

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).3. The sample timing of the tester and measured pulse were not

synchronized. (System is normal if measured voltage is over thestandard voltage at least once.)

4. Poorly connected connectors or an open circuit in ignition system.5. Faulty ignition system control circuit such as side stand switch.6. Faulty ignition coil.7. Faulty CDI unit (in case when above No. 1~6 are normal).

1. Incorrect peak voltage adaptor connections.2. Faulty ignition switch.3. Loose or poorly connected CDI unit connector.4. Open circuit or poor connection in ground cord of the CDI unit.5. Faulty ignition system control circuit such as side stand switch.6. Faulty peak voltage adaptor.7. Faulty CDI unit (in case when above No. 1~6 are normal).

1. Faulty spark plug or leaking ignition coil secondary current ampere.2. Faulty ignition coil.



synchronized.(System is normal if measured voltage is over thestandard voltage at least once.)



synchronized.(System is normal if measured voltage is over thestandard voltage at least once.)

1. Faulty peak voltage adaptor.

1. Faulty peak voltage adaptor.

Low peak voltage.

No peak voltage.

Peak voltage is normal, but no sparkjumps at plug.

Low peak voltage.

Low peak voltage.

No peak voltage.

No peak voltage.

IGN

ITIO

N C

OIL

PR

IMA

RY

VO

LTA

GE

PU

LSE

GE

NE

RA

TO

RE

XC

ITE

CO

IL

17-3

IGNITION SYSTEM

CDI UNIT INSPECTION (EURO2)CDI IGNITION CIRCUIT INSPECTION

Release the seat lock with the main key. Remove the rear under cover. Disconnect the coupler from the CDI unit, and check the

ignition system circuits from the wiring coupler side.Inspection Items

If there are a normality in the diagonosis above, and ifthere is no spark at plug, check the CDI unit andignition coil by using a CDI tester.TOOLS : CDI TESTER

DIGITAL TESTER

Replace the CDI unit if faulty. Install in the reverse order of removal.

PULSE GENERATOR INSPECTIONRESISTANCE MEASUREMENT Release the seat lock with the main key. Remove the rear under cover. Disconnect the A.C generator 4P coupler and the blue /

yellow wire connector.Measure the resistance between the green and blue / yellow.

STANDARD VALUE : 90~150Ω (20)

PVA MEASUREMENTDisconnect the A.C generator blue / yellow wire connector. Connect the peak voltage adaptor probes to the pulse

generator wire terminal of the wire harness sideconnector and ground.

Crank the engine with the kick starter or starter motorand measure the peak voltage of pulse generator.PEAK VOLTAGE : OVER 1.5VTOOL : PVA MULTI TESTER


ITEM

GROUND WIRE

IGNITION COIL(PRIMARY COIL)

PULSEGENERATOR

MAINSWITCH

Check that there is battery voltage betweenmain switch wire (black) and ground wirewhen the ignition is ON

Check that the resistance of coil (between blue /yellow and green) is within the specified range.( 90~150Ω) (20)

Check that the resistance of coil (between black/ yellow and green) is within the specified range.( 0.1~0.2Ω) (20)

Check continuity between ground and frame.

INSPECTION



PULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORDPULSE CORD

Follow the steps described in the troubleshooting flowchart when servicing the ignition system.

! NOTE

Read tester manual carefully prior to using the tester.

! NOTE

17-4

IGNITION SYSTEM







IGNITION COIL INSPECTION Remove the rear under cover. Remove the primary wire.

Measure the resistance between the two terminals ofthe ignition primary coil.

If the resistance value is within the specified range thecoil is good.

If resistance is ∞ (infinite), replace the coil with a newone.STANDARD VALUE : 0.1~0.2Ω

With the spark plug cap on, measure the resistancebetween the primary coil terminal and the spark plugcap.

If the resistance value is within the specified range,then the coil is good.

If the resistance is ∞ (open wire), disconnect the sparkplug cap and measure the secondary coil resistance.

STANDARD VALUE : 7.3~11.0

Without the spark plug cap, measure the resistancebetween the primary coil terminal and high-tensioncode.

If the resistance value is within the specified range,then the coil is good.

If the resistance is ∞ (infinite), replace the coil withnew one.

STANDARD VALUE : 3.6~4.6

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. Install in the reverse order of removal.

Since the resistance value of the primary coil isinherently very small, it is difficult to distinguish itfrom a shorted wire..

! NOTE

17-5

IGNITION SYSTEM

IGNITION TIMING INSPECTION

Warm up the engine.

SIDE STAND IGNITION CUT-OFF SWITCHINSPECTION Remove the coupler of the side stand switch linked to

the wire.

Check for continuity between the terminal as shownbelow;

As the system uses the CDI unit, the ignition timingneed not be adjusted, Check the ignition system if theignition timing is incorrect.

! NOTE

Read the instruction for timing light operation.

! NOTETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLETIMING HOLE

RH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUDRH SHROUD

TIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHTTIMING LIGHT

SIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCH

SIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWNSIDE STAND DOWN

SIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UPSIDE STAND UP

SIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCHSIDE STAND SWITCH

Connect the timing light to the high-tension cord. Start the engine and let it idle.

IDLE SPEED : 15。。BTDC 1,600rpm

The ignition timing is correct if the “F” mark alignswith the index mark on the case.

Increase the engine speed by turning the throttle stopscrew and make sure the “F” mark begins to movecounterclockwise when the engine speed atapproximately 4,000 rpm.


ITEM

OFF(Side stand is

retracted)

GREEN ANDBLACK/WHITE

CONTINUITY

NOCONTINUITY

GREEN ANDBLACK/WHITE

ON(Side stand is

lowered)

TERMINAL SPECIFICATION

18-0

STARTER SYSTEM

M

CABLE CABLE

STARTERRELAY

STARTERMOTOR

BATTERY(12V 10AH

FUSE

Y/R

STARTERSWITCH

REARSTOP

SWITCH

G/YSTOP LAMP

G/Y

FRONTSTOP

SWITCH

B

MAINSWITCH

G

STARTER SYSTEM

18-1

18. STARTER SYSTEM

SERVICE INFORMATION

GENERAL SAFETY

·Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causingserious 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

18

SERVICE INFORMATION···· 18-1TROUBLESHOOTING ·····18-2

STARTER MOTOR ······ 18-3STARTER MAGNETIC SWITCH · 18-6

ITEM

STARTER MOTOR BRUSH LENGTH

STANDARD VALUE

10.2 mm

SERVICE LIMIT

5 mm

TOOLSDIGITAL TESTERVERNIER CALIPER

! WARNING

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.

With the ignition switch “ON”and squeezethe brake lever, check for a“click” soundfrom starter magnetic switch. (17-6)

Connect the starter motor (+) terminal to thebattery positive terminal. (Because a largeamount of current flows, do not use thinwires). (17-3)

Faulty starter motor.

Loose or disconnectedwire or cable.

Faulty starter switch. Faulty side stand switch. Loose or poor contact at connector. Open circuit in wire harness.

Faulty ignition switch or starter switch. Loose or poor contact at connector. Open circuit in wire harness. Faulty brake stop switch.

Loose or poor contact at starter magneticswitch coupler.

Faulty starter magnetic switch.

Disconnect starter magnetic switch coupler,and check the starter magnetic switch coilground wire. (17-6)

Connect the starter magnetic switch coupler.Measure the starter magnetic voltage at thestarter magnetic switch coupler. (17-6)

Check the starter magnetic switch operation.(17-7)

CLICKS

NO CLICK.Starter motor does not turn.

Starter motor turns.

CONTINUITY.

VOLTAGE MEASURED.

NO CONTINUITY.

NO VOLTAGE.

NORMAL

ABNORMAL

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

18-3

STARTER SYSTEM

STARTER MOTOR

REMOVAL

Remove the starter motor cable from the startermagnetic switch.

Loosen the 2 flange bolts securing the engine case,remove the battery earth cable and starter motor.


DISASSEMBLY Remove the starter motor cable. Before disassembling the starter motor mark the

position of the case and cover so the starter can beassembled correctly later.

Loosen the starter motor case bolts and remove themotor cover.

INSPECTION Check for continuity of the starter motor case.

-Between cord terminal“⊕” and bracket“⊖”: normalif no continuity.

-Between cord terminal and brush : normal if there iscontinuity.

If abnormal, replace with a new one.

Loosen the brush terminal setting nut, remove thebrush holder set.

Check for continuity between “⊕” and “⊖” terminalsof the brush holder.

If there is continuity, replace with a new one.

Always turn the ignition switch OFF before servicingthe starter motor. The motor could suddenly start,causing serious injury.

Accurately tighten the battery earth cable.

! NOTE

SETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLT

RR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKET

BRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSH

CORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINALCORD TERMINAL

STARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLESTARTER MOTOR CABLE

ASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARKASSEMBLY MARK

STARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTOR

STARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTORSTARTER MOTOR


BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER BRUSH HODER

BRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SETBRUSH HODER SET

Remove the brush spring, and then remove the brush. Measure the brush length. Replace the brush if it is

worn beyond the service limit.SERVICE LIMIT : 5 mmTOOL : VERNIER CALIPER

Check the commutator for :-Damage or abnormal wear. → Replace with a newone.

-Discoloration of the commutator bar. → Replace witha new one.

-Metallic debris between commutator bars.→ Clean itoff.

Check for continuity between pairs of commutatorbars.

Make a continuity check between individualcommutator bars and the armature shaft.

There should be no continuity.

Check the needle bearing and oil seal.-Do not rotate smoothly. → Replace with a new one.-Damage oil seal. → Replace with a new one.

18-4

STARTER SYSTEM

COMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATORCOMMUTATOR



BRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSHBRUSH

If replacement, replace with a brush holder set.

! NOTE

18-5

STARTER SYSTEM

BRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SETBRUSH HOLDER SET



FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET FR. BRACKET YOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKEYOKE RR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKETRR. BRACKET

MARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARKMARK

SETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLTSETTING BOLT

STARTER MOTOR ASSEMBLY Install the brush and brush spring to the brush hold set. Insert the brush terminal into the rear bracket, and

install the terminal set and flange nut. Align the brush holder set with the rear bracket

groove, and install the brush holder set. Apply grease to both ends of the armature shaft, and

install the 2 washers. Push and hold the brush inside the rear bracket, and

insert the armature into the rear bracket groove.

Align the yoke with the rear bracket mark, and installthe yoke to the amature.

Align the front bracket with the yoke mark, and installthe front bracket.

Tighten the 2 set bolts.

The sliding surfaces of the brushes can be damaged ifthey are not installed properly.

When inserting the armature into the case, hold thearmature tightly to keep the magnet from pulling thearmature against the case.

! CAUTION

When installing the cover, take care to preventdamaging the oil seal lip with the shaft.

Overtightening the starter motor cable terminal nutsmay cause the inside the starter motor, resulting inserious damage to the inner connectors.

! CAUTION

STARTER MAGNETIC SWITCHREMOVAL

Remove the center cover and battery cover. 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. Install in the reverse order of removal.

INSPECTION

Check if the starter magnetic switch “clicks” when it isturned ON.-Clicks →·Poorly connected battery terminal and

motor terminal of the switch. (Checkthe starter magnetic switch)

-No clicks →·No starter magnetic switch inputvoltage. (Faulty relay ground line andstarter magnetic switch)

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 switchis pressed, it is normal.

Starter magnetic switch ground line

Disconnect the wire connector from the startermagnetic switch and check for continuity between theground wire (green / yellow) and ground.

18-6

STARTER SYSTEM

STARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCHSTARTER MAGNETIC SWITCH



18-7

STARTER SYSTEM

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 thenegative (-) battery terminal.

If there is continuity between battery and motorterminal, it is normal.


MEMO

19-1

19. LIGHTS/SWITCHES/HORN

TROUBLESHOOTING

Light not turned on when the main switch is ON Faulty light bulb Faulty switch Faulty or disconnected wiring Fuse cut Battery discharged

Dim headlight Battery discharged Wiring and switch resistance high

Headlight Hi-Low bean cannot be charged Faulty light bulb Faulty dimmer switch

Fuel meter indicator malfunctioning Coupler separated. Harness disconnected. Float operation malfuction. Fuel unit damaged.

Fuel meter needle unstable Coupler loose. Fuel unit damaged. Meter damaged.

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 oran 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 resistancewithin circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to checkthe circuit resistance value.

19

SERVICE INFORMATION···· 19-1TROUBLESHOOTING·····19-1HEADLIGHT ·········19-2FRONT WINKER ·······19-2REAR TAIL LIGHT······ 19-3REAR WINKER······· 19-3

SPEEDOMETER······· 19-3MAIN SWITCH········ 19-4HANDLE BAR SWITCH ···· 19-4HORN SWITCH ········19-5FRONT/REAR STOP SWITCH·· 19-5FUEL GAUGE········19-6

LIGHTS/SWITCHES/HORN

19-2


HEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHTHEAD LIGHT

WASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREWWASHER SCREW

HEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULBHEAD LIGHT BULB

FRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKERFRONT WINKER

WINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULBWINKER BULB

HEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKETHEAD LIGHT SOCKET

HEADLIGHT BULBREMOVAL Loosen the washer screw securing the headlight. Disconnect the headlight wiring. Install in the reverse order of removal.

BULB REPLACEMENT

Pull off the headlight socket. Replace with a new bulb. Install in the reverse order of removal.

When replacing the bulb, be sure not to putfinger and contaminated gloves prints on theheadlight bulb, as they may create hot spots onthe 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 cooldown 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 alcoholand clean it with a clean cloth again.

- Be sure to install the rubber cover afterreplacing the bulb.

! NOTE

FRONT WINKERBULBS REPLACEMENT Press the lock on the side of the winker base. Remove the winker lens. Remove the bulb from the socket and replace with a

new bulb.


Pay attention not to damage the lens.Do not apply excessive force when removing

the lens.

! NOTE

19-3


TAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULBTAIL & STOP BULB

REAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKER

REAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKERREAR WINKER


SPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERSPEEDOMETERPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOXPILOT BOX

REAR TAIL LIGHTASSEMBLY REPLACEMENT Remove the rear upper cover. Loosen the 2 screws securing the rear tail light. Remove the coupler link to the tail light. The tail light is LED light so, replace it with assembly

parts. Install in the reverse order of removal.

Pay attention not to damage the lens.Do not apply excessive force when removing

the lens.Check the installation of the tail light and lens

seal accurately.

! NOTE

REAR WINKERBULB REPLACEMENT

Press the lock on the side of the winker base andremove the rear winker cover.

Remove the winker lens. Remove the bulb from the socket and replace with a

new bulb. Install in the reverse order of removal.

SPEEDOMETERREMOVAL

Remove the inner box. Remove the headlight. Remove the wiring coupler and speedometer cable. Loosen the flange bolt securing the pilot box on the

inner box and remove the speedometer set.

Loosen the bolt securing the pilot box from thespeedometer set and remove the speedometer assembly.


19-4


MAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCHMAIN SWITCH

MAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINALMAIN SWITCH TERMINAL

DIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCHDIMMER SWITCH

PASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCHPASSING SWITCH

WINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCHWINKER SWITCH

HORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCHHORN SWITCH

MAIN SWITCH REMOVAL Remove the front cover. Disconnect the ignition switch wire couplers.

Check for continuity between the wire terminal.

RED BLACK

OFF

ON

R

N

L

COLOR

HANDLE BAR SWITCH Disconnect the connector of handle switch. Check for continuity between terminals.

WINKER SWITCH

PASSING SWITCH

W

GRAY

RED BLACK

SKY BLUE ORANGE

R L

HI

(N)

LO

COLOR

DIMMER SWITCHBAT4

BROWN/WHITE BLUE WHITE

HI LO

BAT2 HI

HI

COLOR

19-5


FRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCHFRONT STOP SWITCH

REAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCHREAR STOP SWITCH

HORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORNHORN

HEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCHHEADLIGHT SWITCH

STARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCHSTARTER SWITCH

STARTER SWITCH

YELLOW / RED GREEN

ST E

FREE

PUSH

COLOR

HORN SWITCH

LIGHT GREEN BLACK

HO BAT2

FREE

PUSH

COLOR

HORN Remove the wire connector from the horn. Connect the horn terminal with 12V battery. Normal if it sounds.

FRONT / REAR STOP SWITCHINSPECTION Remove the front handle cover. Check for continuity between the black and green /

yellow wire terminals inside the speedometer assembly.-When the brake lever is pulled - CONTINUITY.-When the brake lever is released - NO CONTINUITY.

OFF

P

H

COLOR

HEADLIGHT SWITCHBAT2

Br/L Br P

TL HL

19-6


FUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANKFUEL TANK

UNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAPUNIT SET CAP

FUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGEFUEL GAUGE

BASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKINGBASE PACKING

FUEL GAUGE Remove the floor panel. Remove the unit set cap, and remove the fuel gauge.

Take precaution not to damage the wire. Check the base packing for damage.

Inspect the fuel gauge.

OFF

FUEL CHECK

COLOR

FUEL GAUGEFUEL

YELLOW / WHITE GREEN

1.2 L

E ETCTHERMISTER

MEMO

MEMO

20-1. WIRING DIAGRAM (EURO-2)WIRING DIAGRAM

20-2. WIRING DIAGRAM (EURO-3)WIRING DIAGRAM

SERVICE MANUAL

2009. 02 PRINTED2009. 02 PUBLICATION

CCOOPPYY PPRROOHHIIBBIITT

SM57-0902-01E

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Daelim B-Bone 125cc Service Manual 27MB