DAELIM Besbi SC125 Service Manual
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DAELIM Besbi SC125 Service Manual

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  • Page 2 HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for the SC125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the SERVICE INFORMATION maintenance schedule (Section 3).

  • Page 3: Service Information

    8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
  • Page 4 SERVICE INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
  • Page 5 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
  • Page 6 SERVICE INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
  • Page 7 SERVICE INFORMATION CAUTION WHEN WIRING Each cord must be connected depending on its color. When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
  • Page 8 SERVICE INFORMATION Turn off the main switch before connecting/dis- When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
  • Page 9 SERVICE INFORMATION Insert the connector until the vinyl cover is fully When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. The opening of the vinyl cover must face at the ground Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
  • Page 10 SERVICE INFORMATION In case that the wire harness is contacted with the end or The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness is not pressed by the parts.

  • Page 11: Serial Number Location

    SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...
  • Page 12 SERVICE INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 1,820 mm OVERALL WIDTH 685 mm OVERALL HEIGHT 1,060 mm WHEEL BASE 1,300 mm DIMENSIONS SEAT HEIGHT 755 mm GROUND CLEARANCE 110 mm DRY WEIGHT 105 kg GROSS WEIGHT 235 kg TYPE Underbone FRONT SUSPENSION / STROKE Bottom link REAR SUSPENSION / STROKE...
  • Page 13 SERVICE INFORMATION ITEM SPECIFICATIONS TYPE / VENTURI BORE CV type ( vacuum ) 23 mm MODEL MARK PD24J CHOKE TYPE Auto-bystarter MAIN JET # 110 CARBURETOR PILOT SCREW INITIAL SETTING 2 and trust out FLOAT LEVEL 11 mm IDLE SPEED 1.600 100 ( rpm ) CLUTCH TYPE Automatic Transmission(V-belt)

  • Page 14: Torque Values

    SERVICE INFORMATION TORQUE VALUES ENGINE THREAD DIA ITEM Q’TY TORQUE VALUE REFERENCE (mm) OIL FILTER CAP 1.5 kgf m OIL DRAIN PLUG BOLT 2.5 kgf m VALVE ADJUST SCREW LOCK NUT 1.1 kgf m CYLINDER HEAD BOLT 1.1 kgf m FLYWHEEL BOLT 5.5 kgf m APPLY ENGINE OIL...
  • Page 15 SERVICE INFORMATION SH (Small Head) : Indicates 6mm bolt of 8mm flange head. ITEM TORQUE VALUE ITEM TORQUE VALUE 5mm BOLT, NUT 5mm SCREW 0.5 kgf m 0.4 kgf m 6mm BOLT, NUT 6mm SCREW 1.0 kgf m 0.9 kgf m 8mm BOLT, NUT 2.2 kgf m 6mm FLANGE BOLT, NUT...
  • Page 16 SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious CAUTION vehicle part damage may result if instruction WARNING accident may result if instructions are not are not followed.
  • Page 17 SERVICE INFORMATION WIRING DIAGRAM FR.WINKER FUEL PUMP FUEL STRAINER COMP. FUEL TANK AIR CLEANER ENGINE KICK IGNITION COIL COMP. KEY SET FUEL TANK MUFFLER C.D.I UNIT SAI PIPE 1-15...
  • Page 18 SERVICE INFORMATION SPEEDOMETER CABLE KEY SET WINKER RELAY HEADLIGHT CONTROLLER REG. RECTIFIER FR. BRAKE HOSE CARBURETOR INSULATOR RATIO CONTROLLER START SAI PIPE COMP. IGNITION COIL COMP. MAGNETIC SWITCH C.D.I UNIT COMP. 1-16...
  • Page 19 2. LUBRICATION SERVICE INFORMATION OIL FILTER ELEMENT CHANGE TROUBLE SHOOTING OIL PUMP ENGINE OIL LEVEL INSPECTION TRANSMISSION OIL INSPECTION ENGINE OIL CHANGE LUBRICATION POINTS SERVICE INFORMATION GENERAL SAFETY WARNING The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.
  • Page 20 LUBRICATION TROUBLE SHOOTING Oil level low Oil consumption naturally. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal. Oil contamination Oil or filter not changed often enough. Faulty head gasket. Worn piston rings. Low or no oil pressure Clogged oil orifice.

  • Page 21: Engine Oil Level Inspection

    LUBRICATION ENGINE OIL LEVEL INSPECTION Erect the motorcycle on the main stand. Warm up the engine to heat the engine oil to an appropriate level. Stop the engine, and loosen the oil level gauge and check the oil level line. ENGINE OIL CHANGE NOTE To completely and rapidly drain engine oil, warm up...
  • Page 22 LUBRICATION OIL PUMP REMOVAL Drain the engine oil. Remove the following parts : -Muffler ( 4-3) -Cooling fan cover -Cooling fan ( 8-2) -A.C. generator ( 8-4) -RH. crankcase cover ( 8-4) -Starter driven gear ( 8-6) -Reduction gear ( 8-5) -Starting clutch assembly ( 8-6) Remove the oil separator.
  • Page 23 LUBRICATION 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. INSPECTION Assemble the inner and outer rotors to the oil pump body correctly.
  • Page 24 LUBRICATION ASSEMBLY Clean all parts with fresh cleaning oil. Install the inner and outer rotors to the pump body. Install the oil pump plate to the pump body. Tighten the pan screw. NOTE After installing, check the oil pump to operate smoothly.
  • Page 25 LUBRICATION TRANSMISSION OIL INSPECTION Check the body and the connection of each engine component for any leak. Remove the oil check bolt and check to see if the oil overflows from the oil check hole. If only the small amount of oil overflows. fill the recommended transmission oil through the oil filler hole gradually.
  • Page 26 LUBRICATION LUBRICATION POINTS Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it.
  • Page 27 3. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION BRAKE FLUID MAINTENANCE SCHEDULE BRAKE PAD/SHOE FUEL LINE (FUEL TUBE) SIDE STAND THROTTLE GRIP OPERATION SUSPENSION AIR CLEANER BOLTS, NUTS, FASTENERS SPARK PLUG WHEELS/TIRES VALVE CLEARANCE STEERING HEAD BEARING CYLINDER COMPRESSION PRESSURE BATTERY CARBURETOR IDLE SPEED SERVICE INFORMATION WARNING The exhaust gas contains poisonous substance.
  • Page 28 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG 1.2kgf m CYLINDER HEAD COVER BOLTS 0.9kgf m VALVE ADJUSTING NUTS 1.1kgf m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE...

  • Page 29: Maintenance Schedule

    INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose.

  • Page 30: Air Cleaner

    INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) Remove the luggage box.( 4-4) Check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. THROTTLE GRIP OPERATION Check if the throttle grip operates smoothly in any steering position.

  • Page 31: Spark Plug

    INSPECTIONS / ADJUSTMENTS SPARK PLUG Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits. If the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug.

  • Page 32: Carburetor Idle Speed

    INSPECTIONS / ADJUSTMENTS CYLINDER COMPRESSION PRESSURE Start and warm up the engine. Stop engine, and remove the spark plug cap and spark plug. Install a compression gauge. Open the throttle completely, and crank the engine with the starter motor until the gauge reading rising. TOOL : COMPRESSION GAUGE NOTE The maximum reading is usually reached within 4~7...

  • Page 33: Brake Pad Replacement

    INSPECTIONS / ADJUSTMENTS CAUTION Brake fluid will damage painted, plastic or rubber parts. Mixing incompatible fluids can impair braking efficiency. Foreign materials can clog the system, causing a reduction or complete loss of braking ability. A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability.
  • Page 34 INSPECTIONS / ADJUSTMENTS SUSPENSION NOTE Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle’s safety and operation efficiency. FRONT WHEEL Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.

  • Page 35: Steering Head Bearing

    INSPECTIONS / ADJUSTMENTS STEERING HEAD BEARING NOTE Check the cable if it interferes with the handle operation. Lift the front wheel and check if the handle moves right and left smoothly. If the handles move heavily, check if the cable or electric cord interferes with the handle. If the handle moves satisfactorily, adjust the steering head bearing.
  • Page 36 MEMO...

  • Page 37: Table Of Contents

    4. EXTERNAL PARTS SERVICE INFORMATION FLOOR SIDE COVER MAINTENANCE PRECEDURE FLOOR PANDER FRONT FENDER UNDER COVER REAR WHEEL MUD GUARD BODY COVER MUFFLER CENTER COVER INNER COVER REAR FENDER METER COVER SEAT HANDLE COVER LUGGAGE BOX FRONT COVER REAR CARRIER SERVICE INFORMATION NOTE This section describes external parts removal/installation.

  • Page 38: Front Fender

    EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF COVERS This chart shows arrows connected in the order of disassembling covers. LUGGAGE BOX FRONT COVER UNDER HANDLE COVER REAR CARRIER UPPER/UNDER FRONT FENDER INNER COVER BODY COVER HEAD LIGHT CENTER COVER UPPER HANDLE COVER FLOOR SIDE COVER FLOOR PANEL...

  • Page 39: Rear Wheel Mud Guard

    EXTERNAL PARTS FRONT FENDER Remove. -The 3 special screw -The flange bolt of front fender B -Front fender B -Front fender A Install in the reverse order of removal. REAR WHEEL MUD GUARD Remove the 2 air cleaner washer bolts. Remove the mud guard securing the muffler .

  • Page 40: Inner Cover

    EXTERNAL PARTS INNER COVER Remove. -The 8 screws of inner cover -Floor side cover screw -Back holder -Front cover -Floor side cover -Floor panel -Inner cover Install in the reverse order of removal. METER COVER Remove. -Head light -Upper handle cover -Speedometer cable -Coupler and wire -Screw securing meter cover...

  • Page 41: Handle Cover

    EXTERNAL PARTS HANDLE COVER Remove. -Head light lim -Head light -The 4 tapping screws securing the under handle cover -Upper handle cover Install in the reverse order of removal. FRONT COVER Loosen the 1 special screw of front cover. Loosen the 8 tapping screws securing the inner cover. Loosen the 4 tapply screw securing the under cover.

  • Page 42: Floor Side Cover

    EXTERNAL PARTS FLOOR SIDE COVER Loosen the floor panel fixing bolt. Loosen the 2 screws and pull the floor side cover back ward to remove it. Install in the reverse order of removal. FLOOR PANEL Remove. -Floor side cover -4 washer bolts -Pull the floor panel backward to remove it Install in the reverse order of removal.

  • Page 43: Body Cover

    EXTERNAL PARTS BODY COVER Remove. -Luggage box -Rear carrier -The 4 washer screw -Body cover Install in the reverse order of removal. CENTER COVER Remove the body cover. Loosen the floor planel fixing bolt. Loosen the washer screw. Open the fuel lid with the key, and remove the center cover.

  • Page 44: Seat

    EXTERNAL PARTS SEAT Release the seat lock by turning the main switch key to open the seat. Loosen the flange nuts and remove the seat. Install in the reverse order of removal. LUGGAGE BOX Release the seat. Loosen the 3 flange bolts and the 2 cap nuts. Remove the luggage box.
  • Page 45 5. FUEL SYSTEM CARBURETOR SERVICE INFORMATION PILOT SCREW ADJUSTMENT 5-3 TROUBLESHOOTING FUEL PUMP 5-10 FUEL TANK SERVICE INFORMATION GENERAL SAFETY WARNING 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.
  • Page 46 FUEL SYSTEM TROUBLESHOOTING Back firing The vehicle does not start. Ignition system is damaged. No gasoline in fuel tank. Mixture is too lean. Fuel is not coming out of carburetor. Too much fuel is flowing into cylinder. No spark emitted from spark plug. Air cleaner is blocked.
  • Page 47 FUEL SYSTEM FUEL TANK REMOVAL WARNING Gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Remove the following parts. Luggage box. Center cover.
  • Page 48 FUEL SYSTEM Remove the carburetor. DISASSEMBLY Open the drain screw and drain the gasoline. Remove the drain tube and air band hose. Loosen the 4 diaphragm cover setting screws. Remove the diaphragm cover. Remove the diaphragm spring, diaphragm assembly. Remove the needle spring, spring holder, and jet needle from the diaphragm.
  • Page 49 FUEL SYSTEM INSPECTION Check the jet needle for wear, and if necessary, replace Check the vacuum piston for damage and if necessary, replace it. Check the diaphragm for damage, pin holes, wrinkles and bends and if necessary, replace it. NOTE It is easy to get a crack at the wrinkles part and bend part of the diaphragm, check it thronghly.
  • Page 50 FUEL SYSTEM Remove the main jet, main jet holder, needle jet, slow jet, pilot jet. NOTE Turn in the pilot jet and record the number of turns it takes before it seats lightly. Do not force the pilot screw against its seat ; the seat will be damaged.

  • Page 51: Float Level Inspection

    FUEL SYSTEM FLOAT CHAMBER/FLOAT/JET ASSEMBLY Install the needle jet, main jet holder, main jet and slow jet. Install the pilot screw O-ring washer, spring screw. FLOAT LEVEL INSPECTION Measure the float level with the float level gauge. FLOAT LEVEL : 11 mm TOOL : FLOAT LEVEL GAUGE Install the float valve, float, float pin(4).
  • Page 52 FUEL SYSTEM NOTE Be careful not to pinch the diaphragm, and to keep the spring straight. Install the auto bystarter wiring plate to the diaphragm, and tighten the 4 pan screws. Install the drain tube and air-hose. CABURETOR INSTALLATION Install the carburetor to the carburetor insulator. Tighten the carburetor insulator band screw.
  • Page 53 FUEL SYSTEM INSPECTION Check the carburetor insulator O-ring for wear or damage. Install in the reverse order of removal. PILOT SCREW ADJUSTMENT Remove the luggage box. Turn the pilot screw clockwise until it seats lightly, then back it out to the specification given (1 ). Warm up the engine to operating temperature (60 ).
  • Page 54 FUEL SYSTEM FUEL PUMP Removal. Luggage box Inlet,outlet, vacuum tuble in the fuel pump Loosen the 2 securing fuel pump, and remove the fuel pump Removal. Loosen the 4 body screw Remove the fuel pump. Check the fuel pump diaphram A and B for damage. Check the each gasket.
  • Page 55 FUEL SYSTEM Check the section valce, out valve and relief valve for damage and crack. Install in the reverse order of removal. 5-11...
  • Page 56 MEMO...
  • Page 57 ENGINE REMOVAL 6. ENGINE REMOVAL SERVICE INFORMATION ENGINE REMOVAL 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.
  • Page 58 ENGINE REMOVAL ENGINE REMOVAL Drain the engine oil. Release the seat lock by turning the main switch key to open the seat. Remove the following parts. -Luggage box -Air cleaner -Body cover -Carburetor Disconnect the A.C generator coupler and connector wiring connected to the A.C generator, disconnect the starter motor wiring cable.

  • Page 59: Engine Installation

    ENGINE REMOVAL Remove the nut from the engine hanger. Lifting the frame end lightly, remove the flange bolt securing engine hanger and seperate the frame from the engine. ENGINE INSTALLATION Install in the reverse order of removal. NOTE Take precautions not to damage wiring and cable. Take precautions not to damage the threaded part of bolts.
  • Page 60 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 61 7. LH. CRANKCASE COVER/KICK STARTER /CONTINUOUSLY VARIABLE TRANSMISSION SERVICE INFORMATION DRIVE BELT TROUBLE SHOOTING MOVABLE DRIVE FACE LH. CRANKCASE COVER DRIVEN PULLEY 7-11 KICK STARTER 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 oil contact.
  • Page 62 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANKCASE COVER REMOVAL Remove the kick start arm flange bolts and remove the kick start arm. Remove. Air cleaner 2 securing bolt Flange bolt securing LH. crankcase cover LH. crankcase cover Remove the gasket and dowel pin. INSTALLATION Install the new gasket and dowel pin after removing the gasket of the crankcase surface.
  • Page 63 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION KICK STARTER REMOVAL Remove. LH. Crankcase cover Movable drive face, driven pully Gasket Loosen the return spring stop plate securing bolt. Remove the return spring. Remove the starting shaft Remove the starting idle gear. Put the tool (pipe, etc)over the starting drive gear and remove it beating lightly with hammer.
  • Page 64 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION INSPECTION CHECK. The kick starting shaft for wear or damage The return spring for defects or damage Check the starting idle gear for wear or damage. INSTALLATION INSTALL. Driven gear Starting idle gear as arrow direction Return spring stop plate Install the movable drive face, driven pulley...
  • Page 65 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Install the LH. crankcase cover...
  • Page 66 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE BELT REMOVAL Remove the LH. crankcase cover. ( 7-2 ) Hold the clutch outer using the universal holder and remove the nut. Remove the clutch outer. TOOL: UNIVERSAL HOLDER CAUTION Use the special tool when loosening the lock nut. Holding the rear wheel or rear brake will damage the final reduction system.
  • Page 67 Replace the belt if the service limit is exceeded. SERVICE LIMIT : 19.0mm NOTE Use only a genuine DAELIM replacement drive belt. Do not get oil or grease on the drive belt or pulley faces. Clean off any grease or oil before reinstalling.
  • Page 68 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Install the drive face into the LH. crankshaft serration, then install the thrust washer, and install the flange nut temporarily. Tighten the nut to the specified torque using the drive face holder. TORQUE : 4.0 kgf m NOTE Install the drive face face accurately into the LH.crankshaft serration...
  • Page 69 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION MOVABLE DRIVE FACE INSPECTION Check the rollers for wear or damage and replace as necessary. Measure the O.D. of each roller, replace if the service limit is exceeded. SERVICE LIMIT : 17.9mm Measure the one side wear.. SERVICE LIMIT : 2mm Check the drive face boss for wear or damage and replace as necessary.
  • Page 70 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Install the movable drive face and movable drive face boss on the crank shaft. Install the drive belt into the drive face. Install the washer and nut temporarily on the drive face. Tighten the nut to the specified torque using the drive face holder.
  • Page 71 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY REMOVAL Remove the LH. crankcase cover. ( 7-2) Remove the drive face. ( 7-8) Hold the clutch outer using the universal holder and remove the flange nut, then remove the clutch outer. TOOLS : UNIVERSAL HOLDER DRIVE FACE HOLDER Remove the driven pulley sub assembly from the drive...
  • Page 72 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Remove the seal collar from the driven pulley. Remove the guide pins and guide pin rollers and the movable driven face. Remove the O-ring and oil seals from the movable driven face Remove the movable driven face. 7-12...
  • Page 73 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH / DRIVEN PULLEY INSPECTION Driven Face Bearing Inspection Check the inner bearing oil seal (if installed) for damage; replace as necessary. Check the needle bearing for damage or excessive play and replace as necessary. Turn the inner race of the outer bearing with your finger.
  • Page 74 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION 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. SERVICE LIMIT : 34.06 mm Check the driven face for damage or excessive wear;...
  • Page 75 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH / DRIVEN PULLEY ASSEMBLY Install new oil seals and O-rings on the movable driven pulley face. Install the movable face on the driven pulley face. Install the guide pins, or guide pins and guide pin rollers. Install the seal collar.
  • Page 76 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION INSTALLATION DRIVEN PULLEY ASS’Y Turn the driven pulley ass’y clockwise, enlarge the belt assembly groove to maximum. Install the drive belt into the driven pulley sub ass’y, and install to the drive shaft. Install the drive belt into the movable drive face. Install the drive face, and install the drive pulley nut temperarily.
  • Page 77 MEMO...
  • Page 78 A.C GENERATOR / STARTER CLUTCH...
  • Page 79 A.C GENERATOR / STARTER CLUTCH 8. A.C GENERATOR / STARTER CLUTCH SERVICE INFORMATION RH. CRANKCASE COVER SHROUD STARTER REDUCTION GEAR A.C GENERATOR STARTER CLUTCH SERVICE INFORMATION GENERAL SAFETY This section describes the removal and assembling of the A.C generator. For information on A.C generator inspection, refer to the section 15. The charging system can be maintained without removing the engine.
  • Page 80 A.C GENERATOR / STARTER CLUTCH SHROUD REMOVAL Remove the muffler. Remove the cooling fan cover. It could be possible to remove the upper hood, and low hood when disassemble the engine. A.C GENERATOR REMOVAL Remove the cooling fan cover. Loosen the 4 cooling fan bolts. Remove the A.C.G wiring coupler and connector connected to the wire harness.
  • Page 81 A.C GENERATOR / STARTER CLUTCH DISASSEMBLY 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, and hold the drive face with the drive face holder. Loosen the flange nut securing the fly wheel, and remove the flywheel using the A.C.G rotor puller.
  • Page 82 A.C GENERATOR / STARTER CLUTCH 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 flywheel with the universal holder, and tighten the flywheel nut with the specified torque.
  • Page 83 A.C GENERATOR / STARTER CLUTCH Remove the gasket and dowel pin. Remove the RH. crankcase cover oil seal. Check the oil seal for wear or damage and replace with a new one as necessary. STARTER REDUCTION GEAR REMOVAL Remove the RH. crankcase cover. Remove the startting clutch.
  • Page 84 A.C GENERATOR / STARTER CLUTCH STARTER REDUCTION GEAR INSTALLATION Install the starter reduction gear and shaft. Install the starting clutch. Remove the gasket residues from the RH. crankcase. Install a new gasket and dowel pin. Tighten the RH. crankcase cover with setting bolts. Install the following parts.
  • Page 85 A.C GENERATOR / STARTER CLUTCH Remove the washer. Remove the starter clutch. Check the starter clutch for proper operation. STARTER CLUTCH INSPECTION Remove the starter driven gear, needle bearing and starter oneway clutch set from the starter clutch assembly. Measure the outer diameter of the start clutch oneway set.
  • Page 86 A.C GENERATOR / STARTER CLUTCH STARTER CLUTCH INSTALLATION Install the starter oneway clutch set, starter driven gear and needle bearing to the starter clutch assembly. Install the starter clutch to the RH. crankshaft. NOTE When installing the starter clutch, match it with the groove accurately Install the thrust washer.
  • Page 87 MEMO...
  • Page 88 CYLINDER HEAD / VALVES...
  • Page 89 9. CYLINDER HEAD / VALVES SERVICE INFORMATION VALVES TROUBLESHOOTING VALVE GUIDES CAMSHAFT VALVE SEATS CYLINDER HEAD CYLINDER HEAD ASSEMBLY 9-12 VALVE SPRINGS CAMSHAFT ASSEMBLY 9-13 SERVICE INFORMATION GENERAL SAFETY The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed from the frame to maintain the cylinder head.
  • Page 90 CYLINDER HEAD / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT 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.
  • Page 91 CYLINDER HEAD / VALVES CAMSHAFT REMOVAL Remove the luggage box. Remove the center cover. Loosen the cylinder head cover bolts, remove the cover. NOTE The camshaft can be maintained without removing the engine. Turn the crankshaft to the left, and align the T mark of the flywheel with the index mark of the RH.
  • Page 92 CYLINDER HEAD / VALVES Remove the cam chain from the camshaft. NOTE Take precautions not to allow the cam chain to drop into the crankcase. Remove the camshaft. Insert the 5mm bolt into the rocker arm shaft, and pulling bolts to remove the rocker arm shaft. Remove the rocker arm.
  • Page 93 CYLINDER HEAD / VALVES Manually turn the camshaft bearing outer race, and check if it turns smoothly. Check the bearing for wear or damage. CAUTION Be sure to check the valve clearance. CYLINDER HEAD REMOVAL Luggage box. Body cover Engine from the frame. Carburetor Cylinder head cover Shroud comp (upper, under)

  • Page 94: Cylinder Head Inspection

    CYLINDER HEAD / VALVES Remove the valve spring, valve cotter, retainer, spring and valve. Using the valve spring compressor. TOOL : VALVE SPRING COMPRESSOR NOTE To prevent the loss of tension, do not compress the valve spring more than necessary. Mark the disassembled parts so that they can be reassembled into the original position later.
  • Page 95 CYLINDER HEAD / VALVES VALVE GUIDES INSPECTION Insert the valve guide reamer from the combustion chamber side and ream the guide to remove any carbon build-up before measuring the guide. NOTE Take care not to tilt or lean the reamer in the guide while reaming.
  • Page 96 CYLINDER HEAD / VALVES Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. TOOL : VALVE GUIDE DRIVER CAUTION Avoid damaging the head when driving the valve guide out. Apply oil to a new O-ring and install it onto a new valve guide.
  • Page 97 CYLINDER HEAD / VALVES 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. NOTE Valve faces and stem tips cannot be ground.
  • Page 98 CYLINDER HEAD / VALVES Using a 55 degree cutter, remove the bottom of the old seat. Using a 45 degree cutter, cut the seat to the proper width. If the contact area is too high on the valve, the seat must be lowered using a 37 degree flat cutter.
  • Page 99 CYLINDER HEAD / VALVES After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. NOTE Do not excessively press and turn the valve to set it as it may cause damage. Gently strike and set the valve. The seat surface may become worn on one side if the valve is set in the same position.
  • Page 100 CYLINDER HEAD / VALVES Tap the valve stems gently with a soft hammer to firmly seat the cotters. CAUTION Take necessary precautions not to damage the valve. Install the spark plug. TORQUE : 1.2 kgf CYLINDER HEAD ASSEMBLY Clean any gasket material from the cylinder mating surface. Install the cam chain guide to the cylinder.
  • Page 101 CYLINDER HEAD / VALVES CAMSHAFT ASSEMBLY Apply engine oil to the rocker arm shaft, and assemble the rocker arm to the camshaft holder. Tighten the rocker arm shaft with 5mm bolts, and align the bolt hole of the camshaft holder with the fitting side of the rocker arm shaft.
  • Page 102 CYLINDER HEAD / VALVES Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. Assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head.
  • Page 103 CYLINDER HEAD / VALVES 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 Remove the tensioner shaft clip from the tensioner lifter.
  • Page 104 CYLINDER / PISTON 10-0...
  • Page 105 10. CYLINDER / PISTON SERVICE INFORMATION 10-1 PISTON / PISTON RING 10-3 TROUBLE SHOOTING 10-1 CYLINDER INSTALLATION 10-6 CYLINDER 10-2 SERVICE INFORMATION GENERAL SAFETY Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins.
  • Page 106 CYLINDER / PISTON CYLINDER REMOVAL Remove the engine from the frame. Cylinder-head cover Cam shaft holder Cam shaft Cylinder head The cam chain guide from the cylinder The cylinder Remove the gasket and dowel pin. Carefully remove any adhering gasket material from the cylinder / head mating surface.
  • Page 107 CYLINDER / PISTON WARPAGE INSPECTION Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT : 0.05 mm NOTE Any clearance between the cylinder and head due to damage or warpage will result in compression leaks and reduced performance.
  • Page 108 CYLINDER / PISTON Insert the piston ring into the top of the cylinder squarely, using the piston. Measure the end gap using a feeler gauge. Replace the ring if the service limit is exceeded. NOTE Always replace piston ring as a set. SERVICE LIMIT : TOP / SECOND : 0.50 mm OIL RING (SIDE RAIL) : 1.10 mm TOOL : FEELER GAUGE...

  • Page 109: Piston Installation

    CYLINDER / PISTON PISTON / PISTON RING INSTALLATION Clean the piston heads, ring lands and skirts. Carefully install the piston rings onto the piston with the markings facing up. NOTE Be careful not to damage the piston and rings during assembly.
  • Page 110 CYLINDER / PISTON Install new piston pin clips. CAUTION Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. NOTE Take care not to drop the piston pin clip into the crankcase. Set the piston pin clip in the groove properly. Do not align the clip’s end gap with the piston cutout.
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  • Page 112 TRANSMISSION/CRANKSHAFT/CRANK CASE 11-0...
  • Page 113 11. TRANSMISSION/CRANK SHAFT/CRANK CASE CRANK SHAFT REMOVAL 11-7 SERVICE INFORMATION 11-1 TRANSMISSION BEARING 11-8 TROUBLE SHOOTING 11-2 CRANK SHAFT INSTALLATION 11-9 TRANSMISSION 11-3 CRANK CASE INSTALLATION 11-10 CRANK CASE REMOVAL 11-6 SERVICE INFORMATION GENERAL SAFETY This section describes how to remove the crank case and to maintain the transmission and the crankshaft. Service transmission without removing the engine from the vehicle.
  • Page 114 TRANSMISSION/CRANK SHAFT/CRANK CASE TORQUE VALUE CRANK CASE BOLT 1.0kg-m TOOLS -UNIVERSAL BEARING PULLER -BEARING REMOVER SET -REMOVER ASSEMBLY -REMOVER SHAFT -REMOVER HEAD -SLIDING WEIGHT -ASSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose. Crank pin bearing loose. Engine started but unable to move out Transmission damage.
  • Page 115 TRANSMISSION/CRANK SHAFT/CRANK CASE TRANSMISSION DISASSEMBLY Loosen the drain bolt, drain the mission oil. Remove the LH. crankcase cover. Driven pulley / drive face. Remove the EX. muffler. ( 4-3 ) Remove the rear wheel. ( 13-3) Loosen the transmission cover bolts. Remove the transmission cover.
  • Page 116 TRANSMISSION/CRANK SHAFT/CRANK CASE Remove the final shaft and the counter shaft comp. TRANSMISSION INSPECTION Check the drive shaft for wear or damage. Check the final shaft for wear or damage. Check the counter shaft for wear or damage. 11-4...
  • Page 117 TRANSMISSION/CRANK SHAFT/CRANK CASE TRANSMISSION BEARING INSPECTION Check that the bearing outer race fits the case tightly without play. Turn the inner race and check that the bearing turns smoothly and quietly. Replace the bearings if necessary. Install the bearing to the case with special tools. TOOLS : DRIVE HANDLE A OUTER DRIVER DRIVER PILOT...
  • Page 118 TRANSMISSION/CRANK SHAFT/CRANK CASE Install a new gasket and dowel pin. Tighten the transmission cover with the setting bolts. Install the following parts. -Rear wheel -EX. muffler -Continuously variable transmission -LH. crank case cover Remove the oil check bolt, and fill the recommended oil slowly.
  • Page 119 TRANSMISSION/CRANK SHAFT/CRANK CASE Face the LH. crankcase downward, and remove the RH. crankcase from the LH. crankcase while tapping a few places on the LH. crankcase with a plastic hammer. NOTE Be careful not to distort the mating surface of the crank case during removal.
  • Page 120 TRANSMISSION/CRANK SHAFT/CRANK CASE CRANKSHAFT INSPECTION Place the crankshaft on a stand or V-block, and measure the crankshaft runout using dial gauge. SERVICE LIMIT : RIGHT : 0.1 mm LEFT : 0.1 mm Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end as shown.
  • Page 121 TRANSMISSION/CRANK SHAFT/CRANK CASE TRANSMISSION BEARING REPLACEMENT LH. crankcase Use the special tools to remove the drive shaft bearing. TOOLS : BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD Remove the final shaft bearing and oil seal. Remove the counter gear bearing. Apply clean engine oil to a new bearing, and assemble it to the crankcase.

  • Page 122: Crankcase Installation

    TRANSMISSION/CRANKSHAFT/CRANK CASE CRANKCASE INSTALLATION Install the dowel pins and a new gasket. Pull the cam chain in order to check to see if the crankshaft hasembled or not. Install the RH. crankcase to the LH. crankcase. NOTE Make sure that the gasket is completely attached without any clearance.
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  • Page 125 12. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION 12-1 FRONT WHEEL 12-5 TROUBLE SHOOTING 12-2 FRONT FORK 12-8 STEERING HANDLE 12-3 STEERING STEM 12-10 SERVICE INFORMATION GENERAL SAFETY CAUTION Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance.
  • Page 126 FRONT WHEEL/FRONT FORK/STEERING TROUBLE SHOOTING Hard steering Steering bearing adjustment nut too tight. Faulty steering stem bearings. Damaged steering stem bearings. Insufficient tire pressure. Steers to one side or does not track straight Unevenly adjusted right and left shock absorbers. Bent front forks.
  • Page 127 FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE REMOVAL Remove the following parts. -Head light -Handle upper cover from the handle bar -Remove the speedometer cable from the speedometer. Loosen the front master cylinder holder bolts, remove the front master cylinder. Loosen the throttle housing fixing screw, remove the RH.
  • Page 128 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION Install the steering handle to the steering stem. Insert the flange bolt and tighten with locknut TORQUE VALUE : 3.92~4.9 kgf m NOTE Check that the throttle grip moves smoothly. Adjust the throttle grip free play to 2~6mm. Install in the reverse order of removal.
  • Page 129 FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL REMOVAL Loosen the axle nut. Support the vehicle securely under the engine to raise the front wheel. Loosen the oval screw securing the speedometer gear box, remove the speedometer cable. Remove the axle nut, front axle, front wheel. NOTE Do not operate brake lever after the front wheel is removed.
  • Page 130 FRONT WHEEL/FRONT FORK/STEERING Bearing Inspection Manually turn the bearing inner race, and replace if it makes noise or is worn. Check if the bearing outer race is accurately fitted into the wheel hub, and replace worn ones. Apply sufficient amount of grease to the bearing. Insert the right bearing with its seal surface facing outside.

  • Page 131: Front Wheel Installation

    FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY Install the gear box retainer. Install the side color into the LH.wheel Align the wheel hub tangs with the slots of the speedometer gear retainer, and assemble the speedometer gear box seal. Apply grease to the dust seal rim. Install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box.
  • Page 132 FRONT WHEEL/FRONT FORK/STEERING 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 FRONT FORK REMOVAL Remove the following parts.
  • Page 133 FRONT WHEEL/FRONT FORK/STEERING INSPECTION Check components for damage or abnormal wear. Replace defective parts with new ones. Place the spring on a level place, and measure the free length. SERVICE LIMIT : 215mm Set the fork pipe on a V-blocks, and measure fork pipe deflection by rotating with a dial gauge.
  • Page 134 FRONT WHEEL/FRONT FORK/STEERING Install the compressor attachement to the damper comp. Hold the bottom metal and tighten the locknut. Install the front cushion. Install the front wheel. STEERING STEM REMOVAL Remove the following parts. - Handle cover - Handle bar - front cover - front wheel NOTE...
  • Page 135 FRONT WHEEL/FRONT FORK/STEERING 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. Apply grease to the bottom cone race. Install the under ball assembly onto the bottom cone race making sure you have the correct amount.
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  • Page 137 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM SERVICE INFORMATION 13-1 REAR BRAKE 13-4 TROUBLE SHOOTING 13-2 REAR CUSHION 13-6 REAR WHEEL 13-3 SERVICE INFORMATION GENERAL SAFETY If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.
  • Page 138 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM TROUBLE SHOOTING Wobble or vibration in motorcycle Tire pressure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted, oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorber rod Suspension noise...
  • Page 139 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM REAR WHEEL REMOVAL Support the motorcycle on the main stand. Remove the muffler. Remove the rear wheel mud guard. Loosen the rear wheel fixing u-nut. Remove the rear wheel. REAR WHEEL INSPECTION Check the rim for wobbles by rotating the wheel. SERVICE LIMIT : Radical 2.0mm Axial 2.0mm TOOL : DIAL GAUGE...
  • Page 140 REAR WHEEL/REAR BRAKE/SUSPENSION/REAR SWING ARM Tighten the rear axle U-nut to the specified torque. TORQUE VALUE : 6.0~8.0 kgf m Install the EX. muffler. ( 4-12 ) Install the rear wheel mudguard. ( 4-11 ) NOTE After installing the parking brake, be sure to adjust the parking brake free play.
  • Page 141 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM DISASSEMBLY Manually open the brake shoe and remove it. Remove the shoe spring from the brake shoe. Loosen the brake arm fixing bolt. Remove the rear brake arm. Remove the rear brake cam. INSTALLATION Apply small amount of grease to the brake cam. Install the brake cam.
  • Page 142 REAR WHEEL/REAR BRAKE/SUSPENSION/REAR SWING ARM REAR CUSHION REMOVAL Remove the luggage box and body cover. Loosen the top and bottom rear cushion setting bolts. NOTE Support the frame firmly prior to working. DISASSEMBLY Install the compressor attachment as shown in the figure.
  • Page 143 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM INSTALLATION Install the spring, stopper rubber to the damper component. Apply thread locking agent to the hex nut, and install the rear cushion compressor attachment on the damper rod. Fix the upper metal, and tighten the hex nut. TORQUE VALUE : 4.0kgf m TOOLS : REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT...
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  • Page 145 BRAKE SYSTEM 14. BRAKE SYSTEM SERVICE INFORMATION 14-1 BRAKE CALIPER 14-4 TROUBLE SHOOTING 14-1 MASTER CYLINDER 14-6 BRAKE FLUID/BLEEDING 14-2 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.
  • Page 146 BRAKE SYSTEM BRAKE FLUID/BLEEDING BRAKE FLUID CHANGE CAUTION A contaminate disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. Replace contaminated pads, and remove pollutants from the disk completely. Check the brake fluid level often, and replenish new fluid as required.
  • Page 147 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. Squeeze the brake lever, then open the bleeder valve 1/2 turn, and close the valve.
  • Page 148 BRAKE SYSTEM BRAKE CALIPER REMOVAL Drain the brake fluid. Remove the brake tube bolt. Remove the flange bolt securing the caliper and remove front axle. CAUTION Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface. Wind the hose joint with cloth to prevent the brake fluid from leaking.
  • Page 149 BRAKE SYSTEM INSPECTION Check the caliper cylinder bore for scoring, scratches or other damage. Measure the inner diamater of caliper. SERVICE LIMIT:27.06 m Check the caliper piston outer diameter part for scratches or other damage. Measure the out diamater of piston. SERVICE LIMIT:26.91 m ASSEMBLY Clean the piston seal and the dust seal with the brake...
  • Page 150 BRAKE SYSTEM INSTALLATION Install the frontcaliper between the front fork and front axle. Tighten the caliper fixing bolts to the speciped torgue. TORQUE VALUE : 3.0 kgf m Install the brake hose to the caliper body with the 2 new oil bolt washer and oil bolt. Tighten the oil bolt to the specified torgue.
  • Page 151 BRAKE SYSTEM Remove the washer, piston, spring from the master cylinder. Clean the master cylinder, reserve, master piston with the recommended brake fluid. INSPECTION Check the piston periphery for scores, scratches or nicks and replace if necessary. Check the primary and secondary cups for wear. NOTE If there is any leak of fluid when installing new piston, it may indicate the side wear of the cylinder...
  • Page 152 BRAKE SYSTEM Install the primary cup with its concaved side toward the inner side of the master cylinder. Install the snap ring. TOOL : SNAP RING PLIERS CAUTION When installing the cups, do not allow the lips to turn inside out. Note the installation direction of the snap ring.
  • Page 153 15. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 15-1 CHARGING SYSTEM INSPECTION 15-5 CHARGING DEVICES LOCATION 15-2 A.C. GENERAR CHARGING COIL TROUBLE SHOOTING 15-3 INSPECTION 15-6 BATTERY 15-4 SERVICE INFORMATION WARNING Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.
  • Page 154 BATTERY/CHARGING SYSTEM CHARGING DEVICE LOCATION REGULATOR/ KEY SET IGNITION UNIT RECTIFIER C.D.I UNIT A.C GENERATOR 15-2...
  • Page 155 BATTERY/CHARGING SYSTEM TROUBLE SHOOTING 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. Intermittent power Disconnected battery cable. Main fuse burned out. Loose battery connection.
  • Page 156 BATTERY/CHARGING SYSTEM BATTERY REMOVAL Turn off the ignition switch. Remove the battery cover. Remove the battery. Disconnect the negative “ ” battery cable first, and then disconnect the positive “ ” cable. Install in the reverse order of removal. WARNING Disconnecting the positive “...

  • Page 157: Charging System Inspection

    BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION LEAK TEST Trun off the ignition switch, and disconnect the ground (-) cable from the battery. Connect an ampere meter between negative (-) terminal and ground cable. With the ignition switch off, measure the leakage current. LEAK CURRENT : Not to exceed 1mA TOOL : DIGITAL TESTER NOTE...
  • Page 158 BATTERY/CHARGING SYSTEM A.C GENERATOR COIL INSPECTION NOTE This test is done with the starter mounted to the engine. Release the seat lock with the main key. Disconnect the coupler of the A.C generator. Measure the resistance between the yellow leads. RESISTANCE VALUE : 1.0~1.5 (20 ) If the resistance values are much larger than the...
  • Page 159 IGNITION SYSTEM 16. IGNITION SYSTEM SERVICE INFORMATION 16-1 CDI UNIT INSPECTION 16-4 IGNITION DEVICES LOCATION 16-2 PULSE GENERATOR INSPECTION 16-4 TROUBLE SHOOTING 16-3 IGNITION COIL INSPECTION 16-5 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.
  • Page 160 IGNITION SYSTEM IGNITION DEVICES LOCATION KEY SET REGULATOR/ BATTRY C.D.I UNIT RECTIFIER IGNITION UNIT A.C GENERATOR 16-2...
  • Page 161 IGNITION SYSTEM TROUBLE SHOOTING No spark at plug. UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. Battery is undercharged (or operating force of the kick starter is weak).
  • Page 162 IGNITION SYSTEM CDI UNIT INSPECTION CDI IGNITION CIRCUIT INSPECTION NOTE Follow the steps described in the troubleshooting flow chart when servicing the ignition system. Release the seat lock with the main key. Remove the luggage box. Disconnect the coupler from the CDI unit, and check the ignition system circuits from the wiring coupler side.
  • Page 163 IGNITION SYSTEM IGNITION COIL INSPECTION Remove the luggage box. Remove the primary wire. NOTE Measure the peak voltage of the ignition coil primary side first. Since the resistance value of the primary coil is inherently very small, it is difficult to distinguish it from a shorted wire.
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  • Page 165 17. STARTER SYSTEM SERVICE INFORMATION 17-1 STARTER MOTOR 17-4 STARTER DEVICES LOCATION 17-2 STARTER MAGNETIC SWITCH 17-7 TROUBLE SHOOTING 17-3 SERVICE INFORMATION GENERAL SAFETY WARNING Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing serious injury.
  • Page 166 STARTER SYSTEM STARTER DEVICES LOCATION REGULATOR/ KEY SET RECTIFIER BATTRY IGNITION UNIT C.D.I UNIT A.C GENERATOR 17-2...
  • Page 167 STARTER SYSTEM TROUBLE SHOOTING Starter motor will not turn. Check for a blown main fuse before servicing. Check that the stop light is correctly adjusted. Check that the side stand is positioned in the condition under which the engine can be started. Connect the starter motor (+) terminal to the With the ignition switch ON and squeeze battery positive terminal.

  • Page 168: Starter Motor

    STARTER SYSTEM STARTER MOTOR REMOVAL Release the seat lock with the main key. Remove the luggage box. Remove the starter motor cable from the starter magnetic switch. Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor. Install in the reverse order of removal.
  • Page 169 STARTER SYSTEM 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 : 6.5 mm TOOL : VERNIER CALIPER NOTE If replacement, replace with a brush holder set. Check the commutator for : -Damage or abnormal wear.
  • Page 170 STARTER SYSTEM 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.
  • Page 171 STARTER SYSTEM STARTER MAGNETIC SWITCH REMOVAL Release the seat lock with the main key. Remove the luggage box. Remove the center cover. Remove the battery (+) cable from the starter magnetic switch terminal. Remove the starter motor cable from the starter magnetic switch terminal.
  • Page 172 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 the negative (-) battery terminal. If there is continuity between battery and motor terminal, it is normal.
  • Page 173 18. LIGHTS/METER/SWITCHES SERVICE INFORMATION 18-1 MAIN SWITCH 18-3 TROUBLE SHOOTING 18-1 HANDLE BAR SWITCH 18-3 HEADLIGHT 18-2 TRUNK LAMP SWITCH 18-4 FRONT WINKER BULB REPLACEMENT18-2 FRONT/REAR STOP SWITCH 18-4 TAIL LIGHT / REAR WINKER BULB FUEL UNIT 18-5 REPLACEMENT 18-2 SERVICE INFORMATION GENERAL SAFETY Connect the same color wires together.

  • Page 174: Bulb Replacement

    LIGHTS/METER/SWITCHES HEADLIGHT REMOVAL Remove the front cover. Disconnect the headlight. Remove the headlight coupler. Remove the valve socket from the rubber booth. Remove the rubber booth. Remove the bulb. NOTE Before replacing the bulb, be sure to check the switches for loose connection of the connectors. If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent early bulb failure.

  • Page 175: Main Switch

    STARTER SYSTEM LIGHTS/METER/SWITCHES MAIN SWITCH REMOVAL Remove the front cover. ( 4-3) Disconnect the main switch coupler. Release the lock, remove the main key cover. Remove the seat lock cable. Loosen the 3 screws and remove the main switch. Install in the reverse order of removal. INSPECTION Check for continuity between the terminals There should be continuity between the O---O positions...
  • Page 176 LIGHTS/METER/SWITCHES HORN SWITCH COLOR LIGHT GREEN BLACK TERMINAL FREE PUSH Install in the reverse order of removal. TRUNK LAMP SWITCH INSPECTION Release the seat lock with the main key, open the seat. Disconnect the trunk lamp switch, check for continuity between the terminals.
  • Page 177 LIGHTS/METER/SWITCHES FUEL UNIT REMOVAL Remove the front cover, inner cover. Remove the floor panel. NOTE Be careful not to damage the wire. Be careful not to damage the float arm. Check the base packing for damage. Measure the resistance between the upper and lower of fuel unit.
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  • Page 179 TROUBLESHOOTING 19. TROUBLESHOOTING ENGINE WON’T START OR HARD TO START 20-1 ENGINE STALLS, HARD TO START, ROUGH IDLING 20-2 POOR PERFORMANCE AT LOW SPEED AND IDLING 20-3 POOR OPERATION 20-4 ENGINE WON’T START OR HARD TO START CAUSE OF TROUBLE No fuel to fuel tank.
  • Page 180 TROUBLESHOOTING ENGINE STALLS, HARD TO START, ROUGH IDLING CAUSE OF TROUBLE Open the drain screw, and check fuel Fuel not supplied to No fuel to fuel tank. flow to the carburetor. the carburetor. Clogged fuel tube. Clogged float valve. Clogged fuel tank cap. Clogged fuel strainer.
  • Page 181 TROUBLESHOOTING POOR PERFORMANCE AT LOW SPEED AND IDLING CAUSE OF TROUBLE Smoothly accelerate engine. Engine speed does not Clogged air cleaner. increase sufficiently. Insufficient fuel supply. Clogged fuel tank cap air hole Engine speed increases. Clogged muffler. Check the ignition timing. Abnormal Faulty CDI unit.
  • Page 182 TROUBLESHOOTING POOR OPERATION CLUTCH DRIVE / DRIVEN PULLEY CAUSE OF TROUBLE Engine starts but vehicle won’t move. Worn or damaged drive belt. Damaged ramp plate. Faulty weight roller. Faulty movable drive face. Damaged driven pulley weight shoe spring. Faulty transmission. Seized transmission.
  • Page 183 TROUBLESHOOTING POOR FRONT/REAR SUSPENSION PERFORMANCE CAUSE OF TROUBLE Soft suspension. Weak cushion spring Overloaded Oil leakage from damper unit Hard suspension. Bent fork pipe or cushion rod Worn slider Suspension noisy. Damaged cushion stopper rubber 19-5...
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  • Page 185 20. WIRING DIAGRAM I GNI TI ON SW I TCH COMBI .MERER ASS’ Y .
  • Page 186 FUEL UNI T ENGI NE STOP SWI T CH I GNI TI ON SWI T CH PASS...
  • Page 187 SERVICE MANUAL 2007. 09 PRINTED 2007. 09 PUBLICATION...

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