HYOSUNG Aquil GV650 Service Manual
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HYOSUNG Aquil GV650 Service Manual

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FOREWORD
This manual contains an introductory description on
HYOSUNG
inspection/service and overhaul of its main components.
Other information considered as generally known is not
included.
Read GENERAL INFORMATION section to familiarize
yourself with outline of the vehicle and MAINTENANCE
and other sections to use as a guide for proper inspec-
tion and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
� This manual has been prepared on the basis of the
latest specification at the time of publication.
If modification has been made since then,
difference may exist between the content of this
manual and the actual vehicle.
�
I
llustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual vehicle exactly
in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
� COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2005.
and procedures for its
HYOSUNG MOTORS & MACHINERY INC.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL SYSTEM
COOLING SYSTEM
ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMATION
1
2
3
4
5
6
7
8

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Summary of Contents for HYOSUNG Aquil GV650

  • Page 1 HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer. HYOSUNG MOTORS & MACHINERY INC. � COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2005.

  • Page 2: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. As the title of these sections is listed on the previous page as GROUP INDEX, select the section where you are look- ing for.
  • Page 3 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Apply THREAD LOCK “1324” . Data beside it indicates specified torque. Apply oil.
  • Page 4 NOTE Difference between photographs and actual motorcycles depends on the markets.

  • Page 5: Table Of Contents

    GENERAL INFORMATION CONTENTS INFORMATION LABELS ………………………………………………… 1 - 1 GENERAL PRECAUTIONS …………………………………………… 1 - 1 SERIAL NUMBER LOCATION ………………………………………… 1 - 3 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS …… 1 - 4 BREAK-IN PROCEDURES ……………………………………………… 1 - 6 CYLINDER CLASSIFICATION …………………………………………...

  • Page 6: General Precautions

    1-1 GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. WARNING Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION 1-2 WARNING � If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent. � When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

  • Page 8: Serial Number Location

    1-3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine serial number is located on the left downside of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. ◉...

  • Page 9: Fuel, Oil And Engine Coolant Recommendations

    GENERAL INFORMATION 1-4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS ◉ FUEL Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is recommended. ◉ ENGINE OIL ▣ ENGINE OIL SPECIFICATION Classification system Grade Over SL 10W/40 ※...
  • Page 10 Hyosung recommends the use of HYOSUNG COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

  • Page 11: Break-In Procedures

    GENERAL INFORMATION 1-6 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN”before subjecting the engine to maximum stresses.

  • Page 12: Exterior Illustration

    1-7 GENERAL INFORMATION EXTERIOR ILLUSTRATION...

  • Page 13: Specifications

    GENERAL INFORMATION 1-8 SPECIFICATIONS ◉ DIMENSIONS AND DRY MASS I T E M Overall length 2,430 mm (95.7 in) Overall width 840 mm (33.1 in) Overall height 1,155 mm (45.5 in) Wheelbase 1,665 mm (65.6 in) Ground clearance 160 mm (6.3 in) Mass 220 kg (485 lbs) ◉...
  • Page 14 1-9 GENERAL INFORMATION ◉ CHASSIS I T E M Front suspension Telescopic type Rear suspension Swingarm type Steering angle 35°(right & left) Caster 35° Trail 160 mm (6.3 in) Front brake Double disk brake Rear brake Disk brake Front tire size 120/70 - ZR 18 59W Rear tire size 180/55 - ZR 17 73W...
  • Page 15 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ………………………… 2 - 1 PERIODIC MAINTENANCE CHART …………………………………… 2 - 1 LUBRICATION POINTS ………………………………………………… 2 - 3 MAINTENANCE PROCEDURES …………………………………… 2 - 4 VALVE CLEARANCE …………………………………………………… 2 - 4 SPARK PLUG …………………………………………………………… 2 - 6 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS………...

  • Page 16: Periodic Maintenance Schedule

    2-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. CAUTION More frequent servicing should be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART ▣...
  • Page 17 PERIODIC MAINTENANCE 2-2 ▣ FUEL TANK STAY has the “fuel tank stay” under the seat. Use the “fuel tank stay” to inspect the engine or the other parts easily. ◆ USE OF FUEL TANK STAY ● Place the motorcycle on the side stand. ●...

  • Page 18: Lubrication Points

    2-3 PERIODIC MAINTENANCE LUBRICATION POINT Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. ① Clutch lever holder and clutch cable ⑤ Speedometer gear box ② Passenger footrests pivot ⑥...

  • Page 19: Maintenance Procedures

    PERIODIC MAINTENANCE 2-4 MAINTENANCE PROCEDURES This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE Inspect Interval Inspect Initial 1,000 km and Every 6,000 km. CAUTION The clearance specification is for COLD state. ② ① The valve clearance specification is different for intake and exhaust valves.
  • Page 20 2-5 PERIODIC MAINTENANCE ● If the clearance is out of specification, first remove the cam chain tensioner, camshaft housing, camshaft. To install the tappet shim at original position, record the shim NO. and clearance to present by “A” , “B” , “C”...

  • Page 21: Spark Plug

    PERIODIC MAINTENANCE 2-6 SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 6,000 km, Replace Every 12,000 km. ● Remove the four radiator cover mounting bolts. ● Remove the four radiator mounting bolts. WARNING The hot radiator and the hot engine can burn you.

  • Page 22: Exhaust Pipe Bolts And Muffler Mounting Bolts

    2-7 PERIODIC MAINTENANCE Remove the carbon deposit with wire or pin and adjust the spark plug gap to 0.7�0.8 mm (0.028~0.032 in), measuring with a thickness gauge. Spark plug gap 0.7�0.8 mm (0.028~0.032 in) Thickness gauge : 09900 - 20806 Check to see the worn or burnt condition of the elec- trodes.

  • Page 23: Air Cleaner

    PERIODIC MAINTENANCE 2-8 ① AIR CLEANER Inspect Interval Clean Every 3,000 km, ② Replace Every 12,000 km. ● Remove the seat. ● The air cleaner is located under the fuel tank. Remove the fuel tank. ● Remove the four air cleaner inlet guide mounting ③...

  • Page 24: Carburetor

    2-9 PERIODIC MAINTENANCE CARBURETOR Inspect Interval Inspect Initial 1,000 km and Every 6,000 km. ◉ IDLE SPEED NOTE Make this inspection when the engine is hot. ● Connect an engine tachometer to the high ten- sion cord. Start up the engine and set its speed at any- where 1,300 and 1,500 rpm by turning throttle stop screw �.

  • Page 25: Fuel Hose

    PERIODIC MAINTENANCE 2-10 FUEL HOSE Inspect Interval Inspect Initial 1,000 km and Every 6,000 km, Replace every 4 years. ● Remove the seat. (Refer to page 7-1) ● Remove the fuel tank. (Refer to page 4-1) ● Remove the frame cover. (Refer to page 7-2) Inspect the fuel hoses for damage and fuel leakage.
  • Page 26 2-11 PERIODIC MAINTENANCE ▣ FOOTREST POSITION ADJUSTMENT has 2 type of the footrest position, right and left. To change the position, remove the footrest mounting bolt ①, footrest boss cap ② and bolt ③. Install the bolt ① to the desired position and footrest boss cap ②, bolt ③...

  • Page 27: Engine Oil

    PERIODIC MAINTENANCE 2-12 ENGINE OIL Inspect Interval Replace Initial 1,000 km and Every 6,000 km. Necessary amount of engine oil Oil change 3,000 ㎖ Filter change 3,200 ㎖ Overhaul engine 3,400 ㎖ SAE 10W/40 Engine oil type API Over SL Oil should be changed while the engine is warm.
  • Page 28 2-13 PERIODIC MAINTENANCE ● Start up the engine and allow it to run for sever- al minutes at idling speed. ● Turn off the engine and wait about three minutes, then check the oil level through the inspection win- dow. If the level is below mark “L” , add oil to “F” level. If the level is above mark “F”...

  • Page 29: Engine Oil Filter

    Use HYOSUNG MOTORS GENUINE OIL FILTER only, since the other make’ s genuine filters and after-market parts may differ filtering perfor- mance and durability, which could cause engine damage or oil leaks. Hyosung motors genuine oil filter is also not usable for the motocycles.

  • Page 30: Drive Belt

    2-15 PERIODIC MAINTENANCE DRIVE BELT Inspect Interval Inspect Every 1,000 km. Visually check the drive belt for the possible defects listed below. (Support the motorcycle by the jack or block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) NOTE ●...
  • Page 31 PERIODIC MAINTENANCE 2-16 ● Recheck the drive belt slack after tightening the rear axle bolt. WARNING Be careful not to touch the muffler when it is hot : a hot muffler can burn you. CAUTION The drive belt for this motorcycle is made of the special material.

  • Page 32: Brake System

    2-17 PERIODIC MAINTENANCE BRAKE SYSTEM Inspect Interval [ BRAKE ] Inspect Initial 1,000 km and Every 6,000 km. [ BRAKE HOSES & BRAKE FLUID ] Inspect Initial 1,000 km and Every 6,000 km. Replace the brake hoses Every 4 years, CAUTION Replace the brake fluid Every 2 years.
  • Page 33 PERIODIC MAINTENANCE 2-18 ▣ FRONT AND REAR BRAKE PAD REPLACEMENT ● Remove the brake caliper. ● Remove the brake pads. ● To reassemble, reverse the above sequence. Front brake caliper mounting bolt : 18~28 N∙m (1.8~2.8 kg∙m) Rear brake caliper mounting bolt : 18~28 N∙m (1.8~2.8 kg∙m) [ Left side of Front Brake ] [ Right side of Front Brake ]...
  • Page 34 2-19 PERIODIC MAINTENANCE ● Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. ● Close the air bleeder valve and disconnect the transparent hose. Fill the reservoir with new brake fluid to the upper line.
  • Page 35 PERIODIC MAINTENANCE 2-20 ● Squeeze and release the brake lever several times in rapid succession and sqeeze the lever fully with- out releasing it. Loosen the bleeder valve by turn- ing it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of L L O O W W E E R R the brake lever causing it to touch the handlebar...

  • Page 36: Steering

    2-21 PERIODIC MAINTENANCE STEERING Inspect Interval Inspect Initial 1,000 km and Every 6,000 km. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground, with the wheel straight...

  • Page 37: Tire

    The use of tires other than those specified may cause instability. It is highly recommended to SOLO RIDING DUAL RIDING COLD INFLATION use a HYOSUNG Genuine Tire. TIRE PRESSURE kgf/cm KPa kgf/cm Front 2.25 33.0...

  • Page 38: Engine Coolant

    2-23 PERIODIC MAINTENANCE ENGINE COOLANT Inspect Interval Replace the engine coolant Every 2 years. ▣ ENGINE COOLANT LEVEL CHECK ● Keep the motorcycle upright. ● Check the engine coolant level by observing the full line(F) and lower line(L) on the engine coolant reserve tank.
  • Page 39 PERIODIC MAINTENANCE 2-24 ▣ OPEN THE RADIATOR CAP Remove the right front side cover ① to operate the radiator cap ③. To disassemble the right front side cover ①, remove ① the two mounting bolt ②. WARNING You can be injured by scalding fluid or steam if you open the radiator cap when engine is hot.

  • Page 40: Radiator Hose

    2-25 PERIODIC MAINTENANCE ▣ AIR BLEEDING THE COOLING CIRCUIT ● Add engine coolant up to the raditor cap inlet. ● Support the motorcycle upright. ● Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. ●...

  • Page 41: Compression Pressure

    PERIODIC MAINTENANCE 2-26 COMPRESSION PRESSURE The compression of a cylinder is a good indicator of Low compression pressure can indicate some of the its internal condition. following conditions : The decision to overhaul the cylinder is often based ● Excessively worn cylinder wall on the results of a compression test.

  • Page 42: Oil Pressure

    2-27 PERIODIC MAINTENANCE OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 2.0 ~ 6.0 ㎏/㎠ (at 60 ℃∙3,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered. ▣...
  • Page 43 ENGINE CONTENTS ENGINE REMOVAL AND REINSTALLATION …………………… 3 - 1 ENGINE REMOVAL ……………………………………………………… 3 - 1 ENGINE REINSTALLATION …………………………………………… 3 - 7 ENGINE DISASSEMBLY ………………………………………………… 3 - 9 STARTER MOTER ……………………………………………………… 3 - 9 THERMOSTAT …………………………………………………………… 3 - 9 2ND AIR VALVE ………………………………………………………… 3 - 10 CYLINDER HEAD COVER ………………………………………………...

  • Page 44: Engine Removal And Reinstallation

    3-1 ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL ① NOTE If the engine is dirtied, wash the machine with a suitable cleaner before removing the engine. ● Remove the seat. (Refer to page 7-1) ● Remove the fuel tank. (Refer to page 4-1) ●...
  • Page 45 ENGINE 3-2 ▣ COOLING FAN ● With the two mounting bolts ② removed, remove the right front side cover ①. ● Remove the radiator cap bolt ③. ① ③ ② ● Remove the four radiator cover mounting bolts. ● Remove the radiator cover. ●...

  • Page 46: Clutch Cable

    3-3 ENGINE ▣ CARBURETOR ● Remove the carburetor after removed the intake pipes. (Refer to page 4-4) ● Disconnect the vacuum hoses ①. ① ▣ CLUTCH CABLE ● Disconnect the clutch cable end out of clutch lever. ● Disconnect the clutch cable end out of clutch release arm.
  • Page 47 ENGINE 3-4 � � ▣ ELECTRIC PARTS ● By taking out the spark plug caps, remove the spark plug. [ Front Cylinder ] [ Rear Cylinder ] ● Remove the starter motor lead wire. ● Disconnect the engine coolant temperature sensor ①...
  • Page 48 3-5 ENGINE ● Remove the engine ground lead wire ①. ① ● Disconnect the two magneto coupler ②. ③ ② ● Disconnect the neutral switch terminal ③. ● Disconnect the side-stand switch lead wire couper ④. ④ ▣ ENGINE PULLEY ●...
  • Page 49 ENGINE 3-6 ● Remove the gearshift arm ①. ● Flatten the lock washer. ● Remove the engine pulley nut ② and washer. ② NOTE When loosening the engine pulley nut, depress the brake pedal. ① ● Remove the engine pulley. NOTE If it is difficult to remove the engine pulley, loosen the rear axle bolt, belt adjusters ③...

  • Page 50: Engine Reinstallation

    3-7 ENGINE ENGINE REINSTALLATION CAUTION Reinstall the engine in the reverse order of engine Set the part � � of engine mounting bolt ① ① align removal. center line by the hand temporarily and install the engine mounting bolt to the specified ●...
  • Page 51 ENGINE 3-8 ▣ ENGINE PULLEY ● Loosen the rear axle bolt ① and belt adjusters ②, left and right. ● Install the engine pulley. ② ① ② ● Tighten the engine pulley nut ③ to the specified torque. Engine pulley nut : 130~160 N∙m (13.0~16.0 kg∙m) NOTE When tightening the engine pulley nut,...

  • Page 52: Engine Disassembly

    3-9 ENGINE ENGINE DISASSEMBLY CAUTION Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. STARTER MOTOR ● Remove the starter motor. ● Remove the gear position switch. ●...

  • Page 53: 2Nd Air Valve

    ENGINE 3-10 2ND AIR VALVE ● Remove the 2nd air valve ① with the bracket. ① CYLINDER HEAD COVER ● Remove the cylinder head cover. ● To set the piston at TDC (Top Dead Center). CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter-clockwise.
  • Page 54 3-11 ENGINE � [ Rear Cylinder ] ● With the three bolts removed, remove the cam chain guide NO.2 ①. ① ● Remove the camshaft housing ②. NOTE Mark an identification of assembly location on ② each removed parts so that each will be restored to the original position during reassembly.
  • Page 55 ENGINE 3-12 ● Loosen the cylinder head base bolt. ● Loosen the six cylinder head bolts. NOTE When loosening the cylinder head bolts, loosen each bolt little by little diagonally. ● Remove the chain guide NO.1 and cylinder head. ● Remove the tappet and the shim. CAUTION Draw out the tappet and shim with the strong magnet not to be scratched.
  • Page 56 3-13 ENGINE CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly. ● Compress the valve spring by using the special tool. Valve spring compressor : 09916-14510 Valve spring compressor attachment : 09916-14520 ●...

  • Page 57: Piston

    ENGINE 3-14 ● Remove the rear cylinder head and cylinder with the Rear Cylinder same manner of the front cylinder head and cylinder removal. Front Cylinder PISTION ● Place a clean rag over the cylinder base to prevent piston pin circlips from dropping into crankcase. Remove the piston pin circlips with long-nose pliers.

  • Page 58: Magneto Rotor

    3-15 ENGINE ● Remove the starter idle shaft ①, starter idle gear ②. ② ① MAGNETO ROTOR ● With the magneto rotor held immovable using the special tool, loosen the rotor nut. Conrod holder : 09910-20115 ● Remove the magneto rotor by using the special tool. Rotor remover : 09930-30165 ●...

  • Page 59: Clutch Cover

    ENGINE 3-16 ● Remove the cam chain tensioner ①. ① CLUTCH COVER ② ● Remove the clutch release arm ②. ● Remove the clutch cover bolts. ● Remove the clutch cover ③. ③ ④ NOTE When remove or inspect the clutch drive and driven plate, remove only the clutch pressure cover ④...

  • Page 60: Clutch

    3-17 ENGINE CLUTCH ● With the primary drive gear held immovable using the special tool, remove the clutch spring mounting bolts diagonally. Conrod holder : 09910-20115 ● Remove the disk pressure ①. ① ● Remove the clutch drive plates NO. 1 and driven plates.

  • Page 61: Primary Drive Gear

    ENGINE 3-18 ● Remove the clutch sleeve hub ① and primary driv- en gear assembly ② . ② ① PRIMARY DRIVE GEAR ● With the crankshaft held immovable using special tool, remove the primary drive gear nut ③. ● Remove the water pump drive gear ④ and primary drive gear ⑤.

  • Page 62: Gearshift Shaft

    3-19 ENGINE ● Remove the pin ① and shim. ● With the three screws loosened, remove the oil pump ②. ② ① GEARSHIFT SHAFT ● Draw out the gearshift shaft ③. ③ ● Remove the gearshift cam stopper ④. ● Loosen the gearshift cam plate bolt ⑤. ⑤...
  • Page 63 ENGINE 3-20 ● Remove the mission oil pipe mounting bolt. ● Separate the crankcase into 2 parts, right and left, with a special tool. Crankcase separator : 09920-13120 CAUTION When separating the crankcase, necessarily, remove it after installed the special tool (Crankcase separator) on the side of clutch.

  • Page 64: Engine Component Inspection And Service

    3-21 ENGINE ● Remove the crankshaft by using the special tool. Crankcase separator : 09920-13120 ENGINE COMPONENT INSPECTION AND SERVICE CAUTION Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Front cylinder”...
  • Page 65 ENGINE 3-22 ◉ CAMSHAFT (T.D.C) The camshaft should be checked for runout and also for (B.T.D.C) (A.T.D.C) Intake open Exhaust close wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out- put power.
  • Page 66 3-23 ENGINE ● Inspect the tappet for wear and scratch. If modification or scratch is present, replace the tap- pet. ● When you checked the valve clearance, if the valve clearance is wide please replace the present shim into thick one, if the valve clearance is narrow please replace the present shim into thin shim.

  • Page 67: Valve Spring

    ENGINE 3-24 ◉ VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power out- put and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measur ing their free length and also by the force required to compress them.

  • Page 68: Cam Chain Tensioner

    3-25 ENGINE ◉ CAM CHAIN TENSIONER ADJUSTER Check that the push rod slides smoothly with the lock shaft handle ① clockwise. If it does not slide smoothly, replace the cam chain ① tensioner adjuster with a new one. ◉ CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner.
  • Page 69 ENGINE 3-26 ◉ PISTON-TO-CYLINDER CLEARANCE To determine the piston-to-cylinder clearance, calculate the difference between the cylinder bore and outside diameter of the piston. Standard Service limit Piston-to-cylin- 0.045~0.075 mm 0.120 mm der clearance (0.0018~0.0030 in) (0.0047 in) ◉ PISTON PIN HOLE BORE Using a dial calipers, measure the piston pin hole bore both the vertical and horizontal directions.

  • Page 70: Piston Ring End Gap Inspection

    3-27 ENGINE ◉ PISTON RING END GAP INSPECTION Insert the piston ring squarely into the cylinder using the piston head. Measure the end gap with a thickness gauge. If the gap exceeds the service limit, replace the piston ring. Piston ring end gap Standard (Assembly condition) 0.20~0.35 mm...
  • Page 71 ENGINE 3-28 ◉ OVERSIZE RINGS ▣ Oversize piston ring The following two types of oversize piston ring are used. They bear the following identification numbers. Oversize piston ring 0.5 mm 1.0 mm ▣ Oversize oil ring The following two types of oversize oil ring are used. They bear the following identification marks.

  • Page 72: Crankshaft Runout

    3-29 ENGINE ◉ CONROD BIG END SIDE CLEARANCE INSPECTION Using a thickness gauge, measure the side clearance at the conrod big end. If the measurement is out of stan- dard value, measure the conrod big end and the crank pin widths individually to determine which one is to be replaced.

  • Page 73: Starter Clutch

    ENGINE 3-30 ◉ STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand(the gear turns in only one direction). The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch.

  • Page 74: Oil Jet

    3-31 ENGINE ◉ DISASSEMBLY ● Remove the bush using the special tool. Bearing remover (20~35 mm) : 09923-74510 ◉ OIL JET ① ▣ REMOVAL ● Remove the oil jet ①, ② from the right crankcase half. ② ● Remove the oil jet ③ from the left crankcase half. NOTE If it is difficult to remove the oil jet, use a sting.
  • Page 75 ENGINE 3-32 ▣ INSPECTION AND CLEANING ● Check the oil jets for clogging. ● If they are clogged, clean their oil passage with a proper wire and compressed air. ▣ INSTALLATION ● Fit the new O-ring to each oil jets. CAUTION Use the new O-ring to prevent oil leakage.
  • Page 76 3-33 ENGINE ▣ REASSEMBLY ● Drive in the oil seal using the special tool. Bearing installer : 09913-75820 ● Install the circlip. ◉ CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
  • Page 77 ENGINE 3-34 ◉ CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring. Service limit Clutch spring free length 51 mm (2.008 in) Vernier calipers : 09900-20101 ◉...
  • Page 78 3-35 ENGINE ◉ GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture. ◉ TRANSMISSION ▣ INSPECTION ◈ GEAR-SHIFTING FORK Using a thickness gauge, check the clearance between the groove of its gear and shifting fork. The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.
  • Page 79 ENGINE 3-36 CAUTION � Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded Thrust and a new circlip must be installed. � When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft.
  • Page 80 3-37 ENGINE ◉ CRANKCASE play play ▣ BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is anything unusual.
  • Page 81 ENGINE 3-38 ● Remove the bearing ①. Bearing installer : 09913-76010 ① CAUTION The removed bearing should be replaced with a new one. ◈ LEFT CRANKCASE BEARING ● Remove the oil seals ② and ③. Oil seal remover : 09913-50121 ③...

  • Page 82: Engine Reassembly

    3-39 ENGINE ◈ LEFT CRANKCASE BEARING ● Drive in the bearings ①, ② and ③. ③ Bearing installer : 09913-70122 Bearing installer : 09913-76010 ② ① ● Install the oil seals ④ and ⑤. ● Apply SUPER GREASE “A”on the lip of oil seal. SUPER GREASE “A”...
  • Page 83 ENGINE 3-40 ◉ TRANSMISSION ● Install the transmission. ◉ GEARSHIFT CAM AND GEARSHIFT FORKS ● Install the gearshift fork NO.1 ①, NO.2 ②, and NO.3 ③. ① ③ ② ① ③ ② ● Install the gearshift cam ④, and gearshift fork shaft ⑤, ⑥.
  • Page 84 3-41 ENGINE ● Apply BOND “1215”to the right crankcase. BOND “1215” CAUTION � Application of BOND “1215”must be per- formed within a short period of time. � Take extreme care not to let BOND “1215” enter into the oil hole or bearing. ●...
  • Page 85 ENGINE 3-42 ● Apply the SUPER GREASE “A”to the driveshaft O- ring and oil seal lip. SUPER GREASE “A” ● Install the driveshaft spacer. ● Install the oil seal retainer. ▣ GEARSHIFT CAM STOPPER ● Apply a small quantity THREAD LOCK “1324” to the ①...
  • Page 86 3-43 ENGINE CAUTION After the cam driven gear, cam guide, gearshift 5 5 t t h h shaft and neutral cam stopper have been fitted, confirm that gear change is normal while turning 4 4 t t h h the countshaft and driveshaft. If gear change is 3 3 r r d d not obtained, it means that assembly of gears or installation of gear shifting fork is incorrect.
  • Page 87 ENGINE 3-44 ◉ CAM CHAIN TENSIONER ① ② ● Install the washer and cam chain tensioner ②, tighten the cam chain tensioner bolt ①. ③ Cam chain tensioner bolt : 8~12 N∙m (0.8~1.2 kg∙m) ● Install the cam chain ③. ◉...
  • Page 88 3-45 ENGINE ◉ PRIMARY DRIVEN GEAR NOTE Apply the engine oil to the inside face of primary driven gear bearing. ● Install the primary driven gear assembly. ◉ CLUTCH ② ● Install the clutch sleeve hub ①, lock washer ②. ①...
  • Page 89 ENGINE 3-46 � � Direction of inside � � NO. 2 Drive plate � NO. 1 Drive plate ● Install the clutch release rack ①, bearing ② and washer ③. ③ ① ② ● Install the clutch pressure plate ④, retainer, clutch ④...
  • Page 90 3-47 ENGINE ● Install the clutch cover, and tighten the clutch cover bolts securely. ● Install the clutch release arm as following : Stopper screw ① Turn the clutch release shaft toward(This time, mark on the shaft align outside contact line the Clutch release stopper screw) the right.
  • Page 91 ENGINE 3-48 ◉ MAGNETO ROTOR ● Fit the key into the key slot on the crankshaft. ● With the magneto rotor, install the starter clutch on the crankshaft. ● Apply a small quantity of THREAD LOCK “1324”to the threaded parts of crankshaft. THREAD LOCK “1324”...

  • Page 92: Piston Ring

    3-49 ENGINE ◉ MAGNETO COVER ● Install the new gasket and dowel pin. ● Apply oil to the each gear, bearing and starter clutch. ● Install the magneto cover and tighten the magneto cover bolts. Magneto cover bolt : 10 N∙m (1.0 kg∙m) ◉...

  • Page 93: Cylinder Head

    ENGINE 3-50 ◉ CYLINDER ① ● Apply BOND “1215”to the parting line of crankcase. BOND “1215” ● Place the dowel pin ① and new gasket on the crankcase. CAUTION Make sure to replace the gasket with a new one. ● Apply the engine oil to the conrod small end, piston and the piston rings.
  • Page 94 3-51 ENGINE CAUTION Pay caution to prevent the cam chain from drop- ping into the crankcase. ● Tighten the cylinder head base bolt. Cylinder head base bolt : 8~12 N∙m (0.8~1.2 kg∙m) ● Install the tappet and shim. CAUTION Tappet With the tappet fitted, it should be replaced if it doesn’...
  • Page 95 ENGINE 3-52 ◉ CAMSHAFT ASSEMBLY ● Distinguish the “EX”mark for the exhaust camshaft, the “IN”mark for the intake camshaft. ｜ ● With pulling up the camshaft drive chain, align the “ F”mark of magneto rotor into the punching mark of magneto cover to turn the crankshaft.
  • Page 96 3-53 ENGINE ● The “1F”arrow of exhaust camshaft sprocket should be toward the outside and aligned with the plane of FRONT cylinder head. At that time, the “2”arrow of exhaust camshaft sprocket should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into cam chain.
  • Page 97 ENGINE 3-54 CAUTION The cam chain is installed to the all of three sprocket. Be sure to lie the crankshaft until the two holder and cam chain tensioner adjuster are installed completely. 1 Link 16 Link Rotation Direction Exhaust Intake [Front cylinder] Rotation Direction 16 Link...
  • Page 98 3-55 ENGINE ● Put the intake or exhaust camshaft housing to the cylinder head upper surface. ● Tighten the camshaft housing bolt with the specified torque diagonally. CAUTION The camshaft housing bolt is made of the special material. This bolt is superior at the degree of hardness more than the different high tension bolt.
  • Page 99 ENGINE 3-56 ● Turn the crankshaft about 10 times counter-clock- wise ( ) on the basis of the magneto rotor. ● If the valve clearance is within standard after mea- sured the valve clearance, begin the next operation. If it is out of stanadard, adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim.
  • Page 100 3-57 ENGINE ● Install the rear cylinder head and cylinder with the Rear Cylinder same manner which installed the front cylinder head and cylinder. Front Cylinder ◉ THERMOSTAT ① ● Install the thermostat case ① along with the hose ②. NOTE Thermostat reassembly : Refer to page 5-9...

  • Page 101: Fuel System

    FUEL SYSTEM CONTENTS FUEL TANK / FUEL COCK …………………………………………… 4 - 1 FUEL PUMP ………………………………………………………………… 4 - 2 CARBURETOR ……………………………………………………………… 4 - 3 CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
  • Page 102 4-1 FUEL SYSTEM FUEL TANK / FUEL COCK ◉ REMOVAL WARNING Gasoline is very explosive. Extreme care must be taken. ● Remove the seat. (Refer to page 7-1) ● Remove the fuel tank mounting bolts and fuel tank bracket mounting bolt. ●...

  • Page 103: Fuel Pump

    FUEL SYSTEM 4-2 ◉ REMOUNTING ① Remount the fuel tank and fuel cock in the reverse order of removal. CAUTION ● ● Gaskets ① ① and ② ② must be replaced with new ones to prevent fuel leakage. ● ● Tighten the fuel cock bolts evenly. ②...
  • Page 104 4-3 FUEL SYSTEM CARBURETOR...
  • Page 105 FUEL SYSTEM 4-4 ◉ L O C A T I O N O F C A R B U R E - TOR I.D.NO. The carburetor I.D. is stamped on the location on the carburetor as shown in the right photo. ◉...
  • Page 106 4-5 FUEL SYSTEM ● Remove the spring ① along with diaphragm ②. ② ① ● Remove the jet needle cap ③, spring ④, retainer ⑤, and jet needle ⑥. ③ ④ ⑤ ⑥ ● Remove the float chamber body ⑦. ⑦...
  • Page 107 FUEL SYSTEM 4-6 ● Remove the valve seat ①. ● Remove the main jet ②, jet holder ③ and pilot jet ④. ④ ② ③ ① ● Remove the pilot screw ⑤ counting and tightening the number of turn. NOTE Record the number of turn for the pilot screw when install to confer.

  • Page 108: Float Height Adjustment

    4-7 FUEL SYSTEM ◉ FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Measure the float height � while the float arm is � just contacting the needle valve using vernier calipers. Float height � � 7 mm (0.28 in) Vernier calipers : 09900 - 20101 ●...
  • Page 109 FUEL SYSTEM 4-8 ● Align the hole ① of the diaphragm with passage way on the carburetor body. ① ● Install the two screws ② and diaphragm cover ③. ② ③ CAUTION Never adjust “CO adjust screw”� of the carbure- tor.

  • Page 110: Cooling System

    COOLING SYSTEM CONTENTS ENGINE COOLANT ……………………………………………………… 5 - 1 COOLING CIRCUIT ……………………………………………………… 5 - 2 RADIATOR …………………………………………………………………… 5 - 2 COOLING FAN ……………………………………………………………… 5- 5 COOLING FAN THERMO-SWITCH ………………………………… 5- 6 ENGINE COOLANT TEMPERATURE SENSOR ………………… 5 - 7 THERMOSTAT ………………………………………………………………...

  • Page 111: Engine Coolant

    5-1 COOLING SYSTEM ENGINE COOLANT Anti-freeze density Freezing point -31℃ (-24℉) At the time of manufacture, the cooling system is filled with a 50 : 50 mixture of distilled water and ethylene gly- -40℃ (-40℉) col anti-freeze. -55℃ (-67℉) This 50 : 50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above ℃...

  • Page 112: Cooling Circuit

    COOLING SYSTEM 5-2 COOLING CIRCUIT RESERVE TANK RADIATOR FRONT CYLINDER HEAD FRONT CYLINDER THERMOSTAT WATER PUMP REAR CYLINDER REAR CYLINDER HEAD RADIATOR ◉ REMOVAL ● Drain engine coolant. (Refer to page 2-24) ① ● With the two mounting bolts ② removed, remove the right front side cover ①.

  • Page 113: Inspection And Cleaning

    5-3 COOLING SYSTEM ● Disconnect the cooling fan thermo-switch lead wire coupler ①. ● Disconnect the radiator inlet hose ②. ② ① ● Disconnect reserve tank hose ③. ● Disconnect the cooling fan motor lead wire coupler ④ ④. ③ ●...
  • Page 114 COOLING SYSTEM 5-4 Fins bent down or dented can be repaired by straighten- ing them with the blade of a small screwdriver. ◉ INSPECTION OF WATER HOSE Any water hose found in a cracked condition or flattened or water leaked must be replaced. Any leakage from the connecting section should be cor- rected by proper tightening.

  • Page 115: Cooling Fan

    5-5 COOLING SYSTEM COOLING FAN ① ◉ INSPECTION ● Remove the radiator cover. (Refer to page 5-2) ● Disconnect the cooling fan motor lead wire coupler ① and its thermo-switch lead wire coupler ②. Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.

  • Page 116: Cooling Fan Thermo-Switch

    COOLING SYSTEM 5-6 COOLING FAN THERMO- SWITCH ◉ REMOVAL ● Drain engine coolant. (Refer to page 2-24) ● Remove the radiator cover. (Refer to page 5-2) ● Disconnect the cooling fan thermo-switch lead wire coupler ①. ② ● Remove the cooling fan thermo-switch ②. ①...

  • Page 117: Engine Coolant Temperature Sensor

    5-7 COOLING SYSTEM ENGINE COOLANT TEM- ① PERATURE SENSOR ◉ REMOVAL ● Drain engine coolant. (Refer to page 2-24) ● Remove the seat. (Refer to page 7-1) ● Remove the fuel tank. (Refer to page 4-1) ● Remove the carburetor. (Refer to page 4-4) ●...

  • Page 118: Thermostat

    COOLING SYSTEM 5-8 THERMOSTAT ◉ REMOVAL ● Drain engine coolant. (Refer to page 2-24) ● Place a rag under the thermostat case. ● Remove the thermostat case cap. ● Remove the thermostat ①. ① ◉ INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follwing manner.
  • Page 119 5-9 COOLING SYSTEM ● ● Keep on heating the water to raise its temperature. ● ● Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8.0 mm (0.31 in). � Standard Thermostat valve lift � � Over 8.0mm at 100℃...

  • Page 120: Water Pump

    COOLING SYSTEM 5-10 WATER PUMP ◉ REMOVAL AND DISASSEMBLY ① ● Drain engine coolant. (Refer to page 2-24) ③ ● Drain engine oil. (Refer to page 2-12) ● Remove the water pump cover. ● Remove the radiator outlet hose cover. ●...
  • Page 121 5-11 COOLING SYSTEM ● Remove the water pump ① from the clutch cover. ① ● Remove the O-rings ②. ② ● Remove the E-ring ③ from the impeller shaft. ③ ● Remove the impeller ④ from the other side. ④...
  • Page 122 COOLING SYSTEM 5-12 ● Remove the bearing. NOTE If there is no abnormal noise, bearing removal is not necessary. ◉ INSPECTION ▣ BEARING Inspect the play of the bearing by hand while it is in the water pump case. Rotate the inner race by hand to inspect abnormal noise and smooth rotation.
  • Page 123 5-13 COOLING SYSTEM ● Apply SUPER GREASE “A” to the impeller shaft. SUPER GREASE “A” ● Install the impeller to the water pump body. ● Fix the impeller shaft with the E-ring ①. ● Fill the bearing with engine oil until engine oil comes out from the hole of the bearing housing.

  • Page 124: Electrical System

    ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS ………………… 6 - 1 IGNITION SYSTEM ………………………………………………………… 6 - 3 CHARGING SYSTEM …………………………………………………… 6 - 7 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM ………………… 6 - 11 SWITCHES …………………………………………………………………… 6 - 15 LAMP ……………………………………………………………………………...

  • Page 125: Location Of Electrical Components

    6-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ④ ③ ⑤ ⑦ ① ② ⑥ ① Battery ⑤ Engine coolant temperature sensor ⑦ Front brake lamp switch ② Head lamp relay ⑥ Thermostat ③ Side stand relay ④ Cooling fan motor relay ⑩...
  • Page 126 ELECTRICAL SYSTEM 6-2 ⑬ ⑫ ⑪ ⑭ ⑮ ⑪ Ignition coil (NO.1 & NO.2) ⑫ Regulator / Rectifier ⑭ Cooling fan motor ⑬ Turn signal relay ⑮ Cooling fan thermo-switch � � � � � Fuses � Magneto � Gear position switch �...

  • Page 127: Ignition System

    6-3 ELECTRICAL SYSTEM IGNITION SYSTEM is started as the battery discharged ignition system without a contact point. The battery ignition system is composed a rotor with four rotor tip, the igniter, the ignition coil and battery. This system ignites after get signal from igni- tion timing of pick-up with the electric energy of this battery and occur the 1st electric current.
  • Page 128 ELECTRICAL SYSTEM 6-4 ◉ INSPECTION ▣ MAGNETO U s i n g t h e p o c k e t t e s t e r , m e a s u r e t h e r e s i s - t a n c e between the lead wires in the following table.

  • Page 129: Ignition Coil

    6-5 ELECTRICAL SYSTEM ▣ IGNITION COIL ● Pull out the spark plug. ● Place it on the cylinder head after installing it at the plug cap to obtain ground. ● Push the electric starter switch to rotate the starter motor, to have the test of sparking performance. ●...
  • Page 130 ELECTRICAL SYSTEM 6-6 ▣ IGNITER ㏀ Using the pocket tester(R × 1 range), measure the resistance between the terminal in the following table. Pocket Tester : 09900 - 25002 CAUTION � Numberical value may differ a little according to the tester. �...

  • Page 131: Charging System

    6-7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator / rectifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current, then it charges the battery.
  • Page 132 ELECTRICAL SYSTEM 6-8 When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the voltage between points � and � of the regulator accordingly becomes high, and when it reaches the adjusted voltage of the control unit, consequently the control unit becomes “ON”condition. On the “ON”con- dition of the control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become “ON”...
  • Page 133 6-9 ELECTRICAL SYSTEM ◉ INSPECTION ▣ CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC volt- age between the battery terminal � and �. If the tester reads under 13.5V or over 15.0 V, check the magneto no-load performance and regulator / rectifier.
  • Page 134 ELECTRICAL SYSTEM 6-10 ▣ REGULATOR / RECTIFIER ● Disconnect the coupler. ● Using the pocket tester (× 1 ㏁ range), measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the regu lator / rectifier. Unit : ㏁...

  • Page 135: Starter System And Side Stand Ignition Interlock System

    6-11 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTER- LOCK SYSTEM ◉ STARTER SYSTEM DESCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever position switch, igniter, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery. Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
  • Page 136 ELECTRICAL SYSTEM 6-12 ▣ TRANSMISSION : Neutral - “ON” Side stand - Down Clutch lever - Pull SIDE STAND RELAY “ON” IGNITION SWITCH “ON” BATTERY IGNITION COIL NEUTRAL INDICATOR LIGHT DIODE SIDE STAND SW. SIDE STAND NEUTRAL “DOWN POSITION” SW. “ON” ▣...

  • Page 137: Starter Motor Removal

    6-13 ELECTRICAL SYSTEM ◉ STARTER MOTOR REMOVAL AND DISASSEMBLY ● Disconnect the starter motor lead wire. ● With loosening the bolts ①, remove the starter motor. ● Disassemble the starter motor. ① ◉ STARTER MOTOR INSPEC- TION ▣ CARBON BRUSH Inspect abnormal wear, crack or smoothness of the brushes in the brush holder.
  • Page 138 ELECTRICAL SYSTEM 6-14 ▣ STARTER MOTOR REASSEMBLY Reassemble the starter motor. Pay attention to the following points : ● Reassembly the starter motor as shown in the illustration. ● Align the mark ① on the housing with the line ② ①...

  • Page 139: Switches

    6-15 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Pocket tester : 09900 - 25002 IGNITION SWITCH ENGINE STOP SWITCH ○ ○ ○ ○ STARTER SWITCH HAZARD SWITCH ○...

  • Page 140: Lamp

    ELECTRICAL SYSTEM 6-16 LAMP ◉ HEADLAMP ◉ TURN SIGNAL LAMP ◉ TAIL / BRAKE LAMP...

  • Page 141: Combination Meter

    6-17 ELECTRICAL SYSTEM ◉ COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. ▣ INSPECTION Using the pocket tester, check the continuity between lead wires (Blue color coupler) in the follow- ing illustration. If the continuity measured incorrect, replace the respective part.

  • Page 142: Battery

    ELECTRICAL SYSTEM 6-18 BATTERY ◉ CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas. If you don’ t follow the instruction in the below, there may be a explosion and severe accident. Therefore, please pay attention to the following points. ●...
  • Page 143 6-19 ELECTRICAL SYSTEM Seal ③ Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery’ s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any fluid to spill. CAUTION The pouring of electrolyte may not be done if the electrolyte container is pushed slopely.

  • Page 144: Recharging Operation

    ELECTRICAL SYSTEM 6-20 ⑤ Separation of electrolyte container After confirming that you entered the electrolyte into battery completely, remove the electrolyte containers from the battery. CAUTION Draw the empty receptacle out slowly because there may be a chance remaining electrolyte vaporize.
  • Page 145 CHASSIS CONTENTS EXTERIOR PARTS ………………………………………………………… 7- 1 FRAME COVER …………………………………………………………… 7 - 2 SEAT TAIL COVER & SEAT TAIL COVER BRACE …………… 7 - 4 FRONT WHEEL …………………………………………………………… 7 - 6 FRONT BRAKE …………………………………………………………… 7-10 HANDLEBARS ……………………………………………………………… 7 - 17 FRONT FORK ………………………………………………………………...

  • Page 146: Exterior Parts

    7-1 CHASSIS EXTERIOR PARTS ◉ FRONT FENDER ● Remove the three bolts for rightside and the two bolts for lelfside. ● Remove the front fender. ◉ SEAT ● To remove the seat, remove the seat mounting bolt on the rearside of the seat. ●...

  • Page 147: Frame Cover

    CHASSIS 7-2 FRAME COVER ◉ RIGHT DECORATION COVER ● With the right decoration cover mounting screw ① removed, remove the right decoration cover ②. ② ①...
  • Page 148 7-3 CHASSIS ◉ LEFT DECORATION COVER ● With the left decoration cover mounting screw ① ② removed, remove the left decoration cover ②. ① ◉ RIGHT FRONT SIDE COVER ④ The right front side cover is used to operate the radiator cap.

  • Page 149: Seat Tail Cover & Seat Tail Cover Brace

    CHASSIS 7-4 SEAT TAIL COVER & SEAT TAIL COVER BRACE ● Remove the seat. (Refer to page 7-1) ● Remove the rear shock absorber upper bolts inside of frame, right and left. ● Install the rear shock absorber upper bolts with the frame in the outside direction temporarily.
  • Page 150 7-5 CHASSIS ● Remove the battery ① and relay ②, ③, ④. ① ● Disconnect the rear turn signal lamp coupler and ② rear combination lamp coupler ⑤. ③ ④ ⑤ ● Remove the two bolts ⑥. ⑥ ● With the two bolts ⑦ removed, remove the seat tail cover and seat tail cover brace.

  • Page 151: Front Wheel

    CHASSIS 7-6 FRONT WHEEL ◉ REMOVAL ● Loosen the axle pinch bolt ①, right and left. ● Loosen the front axle ②. ● Raise the front wheel off the ground with a block or jack. ② CAUTION When using a jack, take care not to cause scratches on the chassis.
  • Page 152 7-7 CHASSIS ● Remove the brake disk, right and left. [Left front brake] [Right front brake] ◉ INSPECTION AND DISASSEMBLY ▣ TIRE For inspection of the tire : Refer to page 2-22. ▣ FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle.
  • Page 153 CHASSIS 7-8 ▣ WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is anything unusual.

  • Page 154: Brake Disk

    7-9 CHASSIS ▣ BRAKE DISK Make sure that the brake disk is clean and free of any greasy matter. ● Apply THREAD LOCK “1324”to the right and left disk mounting bolts and tighten them to the speci- fied torque. THREAD LOCK “ 1324 ” Brake disk bolt : 18~28 N∙m (1.8 ~2.8 kg∙m) [Left front brake]...

  • Page 155: Front Brake

    CHASSIS 7-10 FRONT BRAKE WARNING � Do not mix brake fluid with different brand. � Do not use a brake fluid kept in an open container or stored for long period of time. � To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.

  • Page 156: Brake Fluid Replacement

    7-11 CHASSIS CAUTION Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause discoloration or crack. ◉ BRAKE FLUID REPLACEMENT ● For replacing procedure of brake fluid : Refer to page 2-18 ◉...

  • Page 157: Caliper Inspection

    CHASSIS 7-12 ● Remove the brake caliper holder ①. ① ● Using an air gun, push out the caliper piston. WARNING � Place a rag over the piston to prevent it from popping out and flying and keeping hand off the piston.

  • Page 158: Caliper Reassembly

    7-13 CHASSIS ◉ CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly procedures and observe the following points. CAUTION � Wash the caliper components with fresh brake fluid before reassembly. Do not wipe off brake fluid after washing the components. �...
  • Page 159 CHASSIS 7-14 � � [Right front brake] ◉ BRAKE DISK INSPECTION Check the brake disk for damage or cracks. Measure the thickness using the micrometer. Replace the brake disk if the thickness is less than the service limit or if damage is found. Service limit Brake disk thickness 3.0 mm (0.12 in)

  • Page 160: Master Cylinder Inspection

    7-15 CHASSIS ● Remove the two clamp bolts and take off the mas- ter cylinder. ● Remove the two fitting screws and separate the cap and diaphragm. ● Detach the dust seal boot ① and remove the circlip. ● Pull out the piston/cup set ② and spring ③. ③...
  • Page 161 CHASSIS 7-16 ◉ MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disassembly. Pay attention to the following points : CAUTION � Wash the master cylider components with new brake fluid before reassembly. � When washing the components, use the speci- fied brake fluid.

  • Page 162: Handlebars

    7-17 CHASSIS HANDLEBARS ① ◉ HANDLEBARS RIGHT SIDE PARTS REMOVAL ● Remove the right handlebar switches. ● Disconnect the brake lamp switch lead wires and remove the master cylinder. (Refer to page 7-15) ● Remove the handlebar balancer ① and grip ②. ②...
  • Page 163 CHASSIS 7-18 ● Remove the handlebar mounting bolts, right and left. ● Remove the handlebar ① . ① ◉ REMOUNTING Perform the remounting work in the reverse order of the r e m o v a l p r o c e d u r e s w h i l e o b s e r v i n g t h e following instructions.
  • Page 164 7-19 CHASSIS ● A p p l y S U P E R GREASE “A ”t o t h e t h r o t t l e Throttle grip cables. SUPER GREASE “ A ” ● Install the throttle cable and returning cable to the throttle grip ①, ②.

  • Page 165: Front Fork

    CHASSIS 7-20 FRONT FORK...
  • Page 166 7-21 CHASSIS ◉ REMOVAL AND DISASSEMBLY ● Remove the front fender. (Refer to page 7-1) ● Take off the front wheel. (Refer to page 7-6) ● Loosen the right and rear front fork upper ① and lower clamp bolts. ● Remove the front brake hose clamp. ●...
  • Page 167 CHASSIS 7-22 ● Remove the outer tube ① from the inner tube. ① ● Invert the front fork and stroke the inner rod several times to let out fork oil. ● Under the inverted condition of front fork, drain oil to hold it for a few time.
  • Page 168 7-23 CHASSIS ● Remove the dust seal ① and the oil seal stopper ring ②. ② ● Remove the oil seal ③ and oil seal retainer ④ by using the special tool. ① ② ③ ④ Oil seal remover : 09913-50121 CAUTION The removed oil seal must be replaced with a new one.
  • Page 169 CHASSIS 7-24 ▣ INNER ROD/DAMPER ROD Move the inner rod by hand to examine it for smooth- ness. If any abnormal points are found, replace inner rod/damper rod with a new one. ◉ REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly.

  • Page 170: Fork Oil

    7-25 CHASSIS ▣ FORK OIL ● Place the front fork vertically without spring. ● Compress it fully. ● Pour specified front fork oil up to the top level of the outer tube. ● Move the inner rod slowly more than ten times until bubbles do not come out from the oil.
  • Page 171 CHASSIS 7-26 ▣ FRONT FORK INNER ROD LOCK NUT ● Adjust the height � of the inner rod threads by turn- � ing the lock nut ① at 11mm(0.43 in) as shown in illustration. ① ▣ FORK SPRING ↓ ● Install the fork spring as shown in the illustration. ↑...

  • Page 172: Front Fork Setting

    7-27 CHASSIS ● Install the left front fork in the same manner as the right one. ● Install the front fender and tighten its mounting bolts with finger. ● Install the front wheel. (Refer to page 7-8) ● Install the brake calipers. (Refer to page 7-13) ●...

  • Page 173: Steering

    CHASSIS 7-28 STEERING ◉ ◉ REMOVAL AND DISASSEMBLY ● Take off the front wheel. (Refer to page 7-6) ● Remove the front fender. (Refer to page 7-1) ● Take off the front fork. (Refer to page 7-21)
  • Page 174 7-29 CHASSIS ● With the instrument panel mounting bolts and instru- ment panel bracket mounting bolts removed, remove the instrument panel. (Refer to page 7-17) ● Remove the handlebar mounting bolts, right and left. ● Remove the handlebar. (Refer to page 7-18) ●...
  • Page 175 CHASSIS 7-30 ◉ INSPECTION Inspect and check the removed parts for the following abnormalities. ∙Handlebar distortion. ∙Handlebar clamp wear. ∙Abnormality operation of bearing. ∙Worn or damaged races. ∙Distortion of steering stem. ◉ ◉ REASSEMBLY ② Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps : ●...

  • Page 176: Rear Wheel

    7-31 CHASSIS REAR WHEEL ◉ REMOVAL ● Raise the rear wheel off the ground with a jack or block. ● With the four mounting bolts, remove the engine pul- ley cover.
  • Page 177 CHASSIS 7-32 ● With the four mounting bolts, remove the drive belt cover. ● Loosen the drive belt adjuster ① , right and left. ● Disengage the drive belt from the rear pulley. ① ① ● Remove the rear axle bolt ② . ●...
  • Page 178 7-33 CHASSIS ● With the disk mounting bolts removed, remove the rear brake disk cover and brake disk. ● Remove the spacer ①. ● Remove the rear pulley ② with mounting drum ③ ① ④ ③ ② from the rear wheel. NOTE Before separating the rear pulley and mounting drum, slightly loosen the rear pulley bolts.
  • Page 179 CHASSIS 7-34 ▣ REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and dam- age. Replace the rear wheel shock absorber if there is any- thing unusual. ▣ REAR PULLEY Inspect the pulley’s teeth for wear. If they are worn, replace the pulley and drive belt as a set.
  • Page 180 7-35 CHASSIS ● After installing the drive belt to the rear pulley, adjust the drive belt by turning both belt adjusters ① . ● Tighten both belt adjuster lock nuts ② securely. ② ① ① ②...

  • Page 181: Rear Brake

    CHASSIS 7-36 REAR BRAKE WARNING � Do not mix brake fluid with different brand. � Do not use a brake fluid kept in an open container or stored for a long period. � To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.
  • Page 182 7-37 CHASSIS ◉ Brake fluid replacement : Refer to page 2-18 ◉ Brake pad replacement : Refer to page 2-18 ◉ Disassembly of caliper : Refer to page 7-11 ◉ Inspection of caliper : Refer to page 7-12 ◉ Reassembly of caliper : Refer to page 7-13 ◉...

  • Page 183: Rear Shock Absorber

    CHASSIS 7-38 REAR SHOCK ABSORBER ◉ REMOVAL ● Remove the rear shock absorbers by removing their bolts and nuts.
  • Page 184 7-39 CHASSIS ◉ INSPECTION Inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one. CAUTION Do not attempt to disassemble the rear shock absorber. It is unserviceable. ◉...

  • Page 185: Swingarm

    CHASSIS 7-40 SWINGARM ◉ ◉ REMOVAL AND DISASSEMBLY ● Remove the rear wheel. (Refer to page 7-31) ● Remove the exhaust pipes and muffler. (Refer to page 3-3)
  • Page 186 7-41 CHASSIS ● Remove the engine pulley cover and drive belt cover. ● With the rear shock absorber lower bolts removed, disconnect the rear shock absorber from swingarm. ● Remove the swingarm mounting lock nut. ● Remove the swingarm pivot nut. ●...
  • Page 187 CHASSIS 7-42 ◉ INSPECTION ▣ SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one. ▣ SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge. If the pivot shaft exceeds the service limit, replace it with a new one.
  • Page 188 7-43 CHASSIS ◉ REASSEMBLY Reassemble the swingarm and rear shock absorber in the reverse order of disassembly. Pay attention to the following points : ● Install the swingarm and tighten the swingarm pivot shaft, nut and swingarm mounting lock nut with the special tool to the specified torque.

  • Page 189: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING …………………………………………………… 8 - 1 SPECIAL TOOLS ………………………………………………………… 8 - 9 TIGHTENING TORQUE ………………………………………………… 8 - 12 SERVICE DATA …………………………………………………………… 8 - 14 WIRE AND CABLE ROUTING ………………………………………… 8 - 24 WIRING DIAGRAM ………………………………………………………… 8 - 30...

  • Page 190: Troubleshooting

    8-1 SERVICING INFORMATION TROUBLESHOOTING ◉ ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard 1. Valve clearance out of adjustment. Adjust. to start. 2. Worn valve guides or poor seating of valves. Repair or replace.
  • Page 191 SERVICING INFORMATION 8-2 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from transmission 1. Gears worn or rubbing. Replace. 2. Badly worn splines. Replace. 3. Primary gears worn or rubbing. Replace. 3. Badly worn bearings. Replace. Noise seems to come from water pump 1.
  • Page 192 8-3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win- exhaust smoke dow, drain out excess oil. 2. Worn piston rings or cylinder. Replace. 3. Worn valve guides. Replace.
  • Page 193 SERVICING INFORMATION 8-4 ◉ CARBURETOR Complaint Symptom and possible causes Remedy Trouble with 1. Starter jet is clogged. Clean. starting. 2. Starter pipe is clogged. Clean. 3. Air leaking from a joint between starter body and carburetor. Check starter body and carburetor for tightness, adjust and replace gasket.
  • Page 194 8-5 SERVICING INFORMATION ◉ ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective igniter. Replace. Spark plug soon 1. Mixture too rich. Adjust carburetor. become fouled with 2.
  • Page 195 SERVICING INFORMATION 8-6 ◉ BATTERY Complaint Symptom and possible causes Remedy “Sulfation” acidic 1. Not enough electrolyte. Add distilled water, if the battery white powdery has not been damaged and substance or spots “sulfation”has not advanced on surfaces of too far, and recharge. cell plates.
  • Page 196 8-7 SERVICING INFORMATION ◉ CHASSIS Complaint Symptom and possible causes Remedy Steering feels too 1. Steering stem nut overtightened. Adjust. heavy or stiff. 2. Worn bearing or race in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust.
  • Page 197 SERVICING INFORMATION 8-8 ◉ BRAKES Complaint Symptom and possible causes Remedy Poor braking 1. Not enough brake fluid in the reservoir. Refill to level mark. (FRONT and REAR) 2. Air trapped in brake fluid circuit. Bleed air out. 3. Pads worn down. Replace.

  • Page 198: Special Tools

    8-9 SERVICING INFORMATION SPECIAL TOOLS Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09900-20101 09900-20806 Vernier Caliper Thickness gauge Used to conveniently measure various dimensions. Measure clearance of piston ring. 09900-20201 09900-21109 Micrometer (0~25mm) Torque wrench Used for precise measurement (00~25mm measure ranges). Measure torque of tightening.
  • Page 199 SERVICING INFORMATION 8-10 Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09910-32812 09915-64510 Crankshaft installer Compression gauge Used to install the crankshaft in the crankcase. Measure cylinder compression. 09910-32813 09915-74510 Crankshaft installer adapter Oil pressure gauge Used to with the crankshaft installer. Measure oil pressure of 4-stroke engine.
  • Page 200 8-11 SERVICING INFORMATION Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09923-74510 09941-50111 Bearing remover (20~35mm) Wheel bearing remover Used to remove bearing with the rotor remove sliding shaft. Used to remove wheel bearing. 09943-74111 09930-30102 Front fork oil level gauge Rotor remove sliding shaft Used to drain the fork oil to the specified level.

  • Page 201: Tightening Torque

    SERVICING INFORMATION 8-12 TIGHTENING TORQUE ◉ ENGINE ITEM N∙m kg∙m Coolant temperature sensor Coolant drain bolt 11 ~ 14 1.1 ~ 1.4 Cooling fan mounting bolt 8 ~ 12 0.8 ~ 1.2 Cooling fan motor mounting bolt Cooling fan thermo-switch Radiator mounting bolt 8 ~ 12 0.8 ~ 1.2...
  • Page 202 8-13 SERVICING INFORMATION ◉ CHASSIS ITEM N∙m kg∙m Rear shock absorber mounting nut (Upper) 20 ~ 30 2.0 ~ 3.0 Rear shock absorber mounting bolt (Lower) 35 ~ 55 3.5 ~ 5.5 Rear pulley bolt 20 ~ 30 2.0 ~ 3.0 Rear axle bolt 90 ~ 140 9.0 ~ 14.0...

  • Page 203: Service Data

    SERVICING INFORMATION 8-14 SERVICE DATA ◉ VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT 31.0 (1.22) — — — Valve diam. 25.5 (1.00) — — — 0.1 ~ 0.2 (0.004 ~ 0.008) — — — Valve clearance (When cold) 0.28 ~ 0.32 (0.011 ~ 0.013) —...
  • Page 204 8-15 SERVICING INFORMATION ◉ CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT Compression pressure 14kg/cm (at 500 rpm) 12 kg/cm Piston to cylinder clearance 0.045 ~ 0.075 (0.0018 ~ 0.0030) 0.120 (0.0047) Cylinder bore 81.500 ~ 81.515 (3.2087 ~ 3.2093) 81.575 (3.2116) 81.440 ~ 81.455 (3.2063 ~ 3.2069) Piston diam.
  • Page 205 SERVICING INFORMATION 8-16 ◉ OIL PUMP ITEM STANDARD NOTE 2.0 ~ 6.0 kg/cm Oil pressure — — — (at 60 ℃, 3,000 rpm) Oil pump reduction ratio 1.3 (45/34) — — — ◉ CLUTCH Unit : mm (in) ITEM STANDARD LIMIT —...
  • Page 206 8-17 SERVICING INFORMATION ◉ TRANSMISSION + DRIVE BELT Unit : mm (in) ITEM STANDARD LIMIT Primary reduction ratio 2.09 (71/34) — — — Secondary reduction ratio 2.79 (78/28) — — — 2.46 (32/13) — — — 1.78 (32/18) — — — 1.38 (29/21) Gear ratio —...
  • Page 207 SERVICING INFORMATION 8-18 ◉ CARBURETOR Unit : mm (in) ITEM SPECIFICATION Carburetor type BDSR39 TYPE(DOUBLE) Bore size ф 39 1,300~1,500 rpm Idle r.p.m. Float height 7 (0.28) Throttle cable play 0.5~1.0 (0.02 ~ 0.04) REAR FRONT Main jet (M.J.) 122.5 Main air jet (M.A.J.) Jet needle...
  • Page 208 8-19 SERVICING INFORMATION ◉ THERMOSTAT + COOLING FAN + COOLANT ITEM STANDARD LIMIT Valve opening 88℃ Valve full open 100℃ Thermostat valve operating temperature 83℃ Valve closing Over 8mm /100℃ Thermostat valve lift 60℃ Approx. 125Ϊ 85℃ Approx. 48.5Ϊ Engine coolant temperature sensor resistance 110℃...
  • Page 209 SERVICING INFORMATION 8-20 ◉ ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE Ignition timing BTDC 5� /1,500rpm Type CR8E 0.7~0.8 (0.028 ~ 0.032) Hot type Spark plug CR7E Standard type CR8E Cold type CR9E Spark performance Over 8mm (0.32) 3.5 ~ 5.5 Ϊ Primary Ignition coil resistance 20 ~ 31 ㏀...
  • Page 210 8-21 SERVICING INFORMATION ◉ SUSPENSION Unit : mm (in) ITEM STANDARD LIMIT Front fork stroke 130 (5.12) — — — Front fork spring free length 470 (18.5) — — — TELLUS #32 — — — Front fork oil type 215mm (8.5 in) from end of outer tube —...
  • Page 211 SERVICING INFORMATION 8-22 ◉ BRAKE + WHEEL Unit : mm (in) ITEM STANDARD LIMIT Rear brake pedal height — — — 408 (16.1) [when one person riding from the ground] 4.0 (0.16) Front 3.0 (0.12) Brake disk thickness 4.3 (0.17) Rear 3.0 (0.12) Brake disk runout...

  • Page 212: Tire Pressure

    8-23 SERVICING INFORMATION ◉ TIRE PRESSURE NORMAL RIDING COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kg/㎠ kg/㎠ 2.25 33.0 2.25 33.0 FRONT 2.50 36.0 2.90 42.0 REAR ◉ FUEL + OIL NOTE ITEM SPECIFICATION Gasoline used should be graded 91 octane or higher. Fuel type An unleaded gasoline is recommened.

  • Page 213: Wire And Cable Routing

    SERVICING INFORMATION 8-24 WIRE AND CABLE ROUTING...
  • Page 214 8-25 SERVICING INFORMATION...
  • Page 215 SERVICING INFORMATION 8-26...
  • Page 216 8-27 SERVICING INFORMATION 09407-20406 09407-20406 HANDLE S/W HANDLE S/W CLUTCH LEVER S/W 09407-20406 09407-20406 COUP. HANDLE S/W Lh WIRING HARNESS 09404-06405 L/WIRE, FT TURN R/L FT TURN L L/WIRE, C/LEVER S/W HEAD LAMP COUP. FT TURN R 09407-20406...
  • Page 217 SERVICING INFORMATION 8-28 L/WIRE BATTERY MINUS FRONT CRANK CASE R VIEW A (ENGINE EARTH INSTALLATION DIRECTION) VIEW Ｂ PIPE FRAME Lh WIRING HARNESS SIDE L "#1" MARK WELDING CLAMP PARTS (3EA)
  • Page 218 8-29 SERVICING INFORMATION FRONT CYLINDER REAR CYLINDER CAUTION FOR HIGHTENTION CORD INSTALLATION DIRECTION FRAME WIRING HARNESS WELD CLAMP WELDING CLAMP OPERATION METHOD...

  • Page 219: Wiring Diagram

    SERVICING INFORMATION 8-30 WIRING DIAGRAM...
  • Page 222 Prepared by HYOSUNG MOTORS & MACHINERY INC. 1st Ed. JUL. 2005. Manual No. 99000-51210 Printed in Korea...

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Aquila 2005

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