HYOSUNG GT 650 Service Manual
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HYOSUNG GT 650 Service Manual

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GT 650
Fra 2004 og frem.
Servicemanual
Holtvej 8-10, Høruphav
6470 Sydals
Telefon: +45 73 15 11 00
Fax: +45 73 15 11 01
E-mail: info@scanmi.dk
www.scanmi.dk
CVR: 27 73 31 07

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Summary of Contents for HYOSUNG GT 650

  • Page 1 GT 650 Fra 2004 og frem. Servicemanual Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 E-mail: info@scanmi.dk www.scanmi.dk CVR: 27 73 31 07...
  • Page 2 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. 2003.

  • Page 3: 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 are listed on the previous page as GROUP INDEX, select the section where you are look- ing for.
  • Page 4 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 5 NOTE Difference between photographs and actual motorcycles depends on the markets.

  • Page 6: Table Of Contents

    GENERAL INFORMATION CONTENTS INFORMATION LABELS 1 - 1 1 - 1 GENERAL PRECAUTIONS 1 - 3 SERIAL NUMBER LOCATION 1 - 4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS 1 - 6 BREAK-IN PROCEDURES 1 - 6 CYLINDER CLASSIFICATION 1 - 7 EXTERIOR ILLUSTRATION SPECIFICATIONS 1 - 8...

  • Page 7: 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 8 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 9: 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 seri- al number is located on the left down of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. ◉...

  • Page 10: 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 SG 10W/40 �...

  • Page 11: Engine Coolant

    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 12: 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 13: Exterior Illustration

    1-7 GENERAL INFORMATION EXTERIOR ILLUSTRATION...

  • Page 14: Specifications

    GENERAL INFORMATION 1-8 SPECIFICATIONS DIMENSIONS AND DRY MASS I T E M Overall length 2,060 mm (81.1 in) Overall width 740 mm (29.1 in) Overall height 1,090 mm (42.9 in) Wheelbase 1,435 mm (56.5 in) Ground clearance 150 mm (5.9 in) Unladen mass 185 kg (408 lbs) ENGINE...
  • Page 15 1-9 GENERAL INFORMATION CHASSIS I T E M Front suspension Telescopic type Rear suspension Swingarm type Steering angle 30°(right & left) Caster 25.5° Trail 85 mm (3.35 in) Front brake Double disk brake Rear brake Disk brake Front tire size 120/60 - ZR 17 55W Rear tire size 160/60 - ZR 17 69W...
  • Page 16 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 - 1 2 - 1 PERIODIC MAINTENANCE CHART 2 - 2 LUBRICATION POINTS 2 - 3 MAINTENANCE PROCEDURES 2 - 3 VALVE CLEARANCE 2 - 5 SPARK PLUG EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2 - 6 2 - 7 AIR CLEANER...

  • Page 17: 2-1 Periodic Maintenance

    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 18: Lubrication Points

    PERIODIC MAINTENANCE 2-2 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 ⑥ Speedometer gear box ② Footrests pivot ⑦...

  • Page 19: Maintenance Procedures

    2-3 PERIODIC MAINTENANCE 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. ① The valve clearance specification is different for intake and exhaust valves.

  • Page 20: Engine

    PERIODIC MAINTENANCE 2-4 ● 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

    2-5 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 6,000 km, Replace Every 12,000 km. ● Remove the three radiator mounting bolts. WARNING The hot radiator and the hot engine can burn you. Wait until the radiator and the engine are cool enough to touch.

  • Page 22: Exhaust Pipe Nuts And Muffler Mounting Bolts

    PERIODIC MAINTENANCE 2-6 Check to see the worn or burnt condition of the elec- trodes. If it is extremly worn or burnt, replace the plug. And also replace the plug if it has a broken insula- tor, damaged thread, etc. ●...

  • Page 23: Air Cleaner

    2-7 PERIODIC MAINTENANCE AIR CLEANER ① Inspect Interval Clean Every 3,000 km, Replace Every 12,000 km. ② ● Remove the front and rear seat. ● The air cleaner is located under the fuel tank. Remove the fuel tank. ● Remove the four screw ①. ●...

  • Page 24: Fuel Hose

    PERIODIC MAINTENANCE 2-8 ● 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 �. Engine idle speed 1,300�1,500 rpm Engine tachometer : 09900 - 26006 �...

  • Page 25: Clutch

    2-9 PERIODIC MAINTENANCE CLUTCH ⑤ ② Inspect Interval Inspect Initial 1,000 km and Every 6,000 km. Clutch play should be 2 mm(0.08 in) as measured at the clutch lever holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the following way : ●...
  • Page 26 PERIODIC MAINTENANCE 2-10 Oil should be changed while the engine is warm. Oil fil- ter replacement at the above intervals, should be together with the engine oil change. � ● Keep the motorcycle upright. ● Place an oil pan below the engine, and drain the oil by removing the filler cap ①...

  • Page 27: Engine Oil Filter

    Before installing the oil filter cap, apply engine oil lightly to the new O-ring ③ ③ . . ◉ OIL FILTER INSTALLATION CAUTION When install the oil filter, necessarily, “HYOSUNG” INSERTION character and “16510HN910”part’ s NO. install to- DIRECTION ward the outside, otherwise can damage the engine.

  • Page 28: Drive Chain

    Hyosung motors genuine oil filter is also not usable for the motocycles. DRIVE CHAIN Inspect Interval Clean and Lubricate Every 1,000 km.
  • Page 29 2-13 PERIODIC MAINTENANCE ● Count out 21 pins (20 pitches) on the chain and mea- sure the distance between the two points. If the dis- tance exceeds the service limit, the chain must be replaced. Service limit Drive chain 319.4 mm 20pitch length (12.58 in) ◉...

  • Page 30: Brake System

    Some drive chain lubricants contain solvents and Clean the drive chain with kerosene only. additives which could damage the X-Orings in your chain. Use Hyosung chain lube or an equivalent that is specifically intended for use with X-Oring chains. BRAKE SYSTEM Inspect Interval [ BRAKE ] Inspect Initial 1,000 km and Every 6,000 km.
  • Page 31 2-15 PERIODIC MAINTENANCE WARNING The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix dif- ferent types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period.
  • Page 32 PERIODIC MAINTENANCE 2-16 [ Rear Brake ] ◉ FRONT AND REAR BRAKE FLUID REPLACE- ① MENT ● Place the motorcycle on a level surface and keep the handlebars straight. ● Remove the master cylinder reservoir cap and diaphragm. ● Suck up the old brake fluid as much as possible. ●...
  • Page 33 2-17 PERIODIC MAINTENANCE ◉ AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak- ing performance of the brake caliper.

  • Page 34: Steering

    PERIODIC MAINTENANCE 2-18 ◉ FRONT BRAKE LAMP SWITCH The front brake lamp switch is located beneath the front brake lever. Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward. (Refer to page 6-1) ◉...

  • Page 35: 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 2.25...

  • Page 36: Engine Coolant

    PERIODIC MAINTENANCE 2-20 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 37 2-21 PERIODIC MAINTENANCE ● Flush the radiator with fresh water if necessary. ● Install the water hose. ● Tighten the coolant drain bolt ① to the specified torque. Coolant drain bolt : 11~14 N∙ ∙ m (1.1~1.4 kg∙ ∙ m) ●...

  • Page 38: Radiator Hose

    PERIODIC MAINTENANCE 2-22 RADIATOR HOSE Inspect Interval Inspect Every 6,000km, Replace the radiator hose Every 4 years. Check to see the radiator hose for crack, damage or engine coolant leakage. If any defects are found, replace the radiator hoses with new ones.

  • Page 39: Compression Pressure

    2-23 PERIODIC MAINTENANCE COMPRESSION PRESSURE The compression of a cylinder is a good indicator of Low compression pressure can indicate any 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 40: Oil Pressure

    PERIODIC MAINTENANCE 2-24 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 41 ENGINE CONTENTS ENGINE REMOVAL AND REINSTALLATION 3 - 1 3 - 1 ENGINE REMOVAL 3 - 7 ENGINE REINSTALLATION 3 - 9 ENGINE DISASSEMBLY 3 - 9 STARTER MOTER 3 - 9 THERMOSTAT 3 - 10 2ND AIR VALVE CYLINDER HEAD COVER 3 - 10 PISTON 3 - 14...

  • Page 42: Engine Removal And Reinstallation

    3-1 ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL NOTE ① If the engine is dirtied, wash the machine with a suitable cleaner before removing the engine. ● Remove the front seat.(Refer to page 7-1) ● Remove the fuel tank.(Refer to page 4-1) ●...
  • Page 43 ENGINE 3-2 ◉ COOLING FAN ③ ● Disconnect the cooling fan thermo-switch lead wire coupler ①. ① ● Disconnect the radiator outlet hose ②. ● Disconnect the reserve tank hose ③. ● Remove the radiator mounting bolts. (Refer to page 5-2) ②...

  • Page 44: 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 45 ENGINE 3-4 ◉ ELECTRIC PARTS ● With take out the spark plug caps, remove the spark plug. [ Rear Cylinder ] [ Front Cylinder ] ● Remove the starter motor lead wire. ● Disconnect the engine coolant temperature sensor lead wire ①. ①...
  • Page 46 3-5 ENGINE ● Remove the engine ground lead wire ①. ① ● Disconnect the two magneto coupler ②. ● Disconnect the neutral switch terminal. ● Disconnect the side-stand switch lead wire couper ② ③. ③ ◉ ENGINE SPROCKET ● Remove the engine sprocket cover ④. ④...
  • Page 47 ENGINE 3-6 ● Remove the gearshift arm ①. ● Flatten the lock washer. ● Remove the engine sprocket nut ② and washer. ② NOTE When loosening the engine sprocket nut, depress the brake pedal. ① ● Remove the engine sprocket. NOTE I f i t i s d i f f i c u l t t o r e m o v e t h e e n g i n e s p r o c k e t , loosen the rear axle nut, c h a i n...

  • Page 48: 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 49 ENGINE 3-8 ◉ ENGINE SPOCKET ● Loosen the rear axle nut and chain adjusters, left and right. ● Install the engine sprocket. ● Tighten the engine sprocket nut ① to the specified torque. Engine sprocket nut : 130~160 N∙m (13.0~16.0 kg∙m) NOTE When tightening the engine sprocket nut, depress the rear brake pedal.

  • Page 50: 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 51: 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 52 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 53 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 54 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 55: 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 56: 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 57: 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 58: 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 59: Primary Drive Gear

    ENGINE 3-18 ● Remove the clutch sleeve hub ① and primary driv- en gear assembly ② . ① ② 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 60: 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 61 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 62: 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 63 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 wear of cams and journals if the engine has been noted Exhaust close to produce abnormal noise or vibration or a lack of out- put power.
  • Page 64 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 65: 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 66: Cam Chain Tension Adjuster

    3-25 ENGINE ◉ CAM CHAIN TENSION 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 ten- sion adjuster with a new one. ① ◉ CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner.
  • Page 67 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 in the vertical and horizontal directions.

  • Page 68: 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 69 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 70 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 71 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 72: 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 73 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 74 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 75 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 54 mm (2.126 in) Vernier calipers : 09900-20101 ◉...
  • Page 76 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 in 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 77 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 78 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 79 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 80: 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 81 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 ② ③ ① ③ ② ● Install the gearshift cam ④, and gearshift fork shaft ⑤, ⑥.
  • Page 82 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 83 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 gearshift cam plate bolt ①.
  • Page 84 3-43 ENGINE CAUTION 6 6 t t h h After the cam driven gear, cam guide, gearshift shaft and neutral cam stopper have been fitted, 5 5 t t h h confirm that gear change is normal while turning 4 4 t t h h the countshaft and driveshaft.
  • Page 85 ENGINE 3-44 ◉ CAM CHAIN TENSIONER ② ① ● Install the washer and cam chain tensioner ②, tighten the cam chain tensioner bolt ①. Cam chain tensioner bolt ③ : 8~12 N∙m(0.8~1.2 kg∙m) ● Install the cam chain ③. ◉ PRIMARY DRIVE GEAR Align the key groove and mark.
  • Page 86 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 87 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. ① ③ ② ● Install the clutch pressure plate ④, retainer, clutch ④...
  • Page 88 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 89 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 90: 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 91: Cylinder Head

    ENGINE 3-50 ◉ CYLINDER ● Apply BOND “1215”to the parting line of crankcase. ① 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 92 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 fit, it should be replaced if it doesn’...
  • Page 93 ENGINE 3-52 ◉ CAMSHAFT ASSEMBLY ● Distinguish the “EX”mark for the exhaust camshaft, the “IN”mark for the intake camshaft. ｜ ● With pull up the camshaft drive chain, align the “ F” mark of magneto rotor into the punching mark of magneto cover to turn the crankshaft.(Front cylinder) CAUTION ｜...
  • Page 94 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 camchain.
  • Page 95 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 tension adjuster are installed completely. Rotation Direction 1 Link 16 Link 16 Pin Exhaust Intake [Front cylinder]...
  • Page 96 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 97 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 98 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 ● Install the thermostat case ① along with the hose ②. ① NOTE Thermostat reassembly : Refer to page 5-9...

  • Page 99: Fuel System

    FUEL SYSTEM CONTENTS 4 - 1 FUEL TANK / FUEL COCK 4 - 2 FUEL PUMP 4 - 3 CARBURETOR CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
  • Page 100 4-1 FUEL SYSTEM FUEL TANK / FUEL COCK REMOVAL WARNING Gasoline is very explosive. Extreme care must be taken. Remove the front seat. (Refer to page 7-1) Remove the fuel tank mounting bolt, and take off the hooks. Disconnect the fuel hose and remove the fuel tank.

  • Page 101: Fuel Pump

    FUEL SYSTEM 4-2 REMOUNTING Remount the fuel tank and fuel cock in the reverse order of removal. CAUTION Gaskets must be replaced with new ones to prevent fuel leakage. Tighten the fuel cock bolts evenly. FUEL PUMP REMOVAL Remove the front seat and fuel tank. Disconnect the fuel hoses and vacuum hose INSPECTION...
  • Page 102 4-3 FUEL SYSTEM CARBURETOR...
  • Page 103 FUEL SYSTEM 4-4 LOCATION OF CARBURETOR I.D. The carburetor I.D. is stamped on the location on the carburetor as shown in the right photo. REMOVAL Remove the fuel tank. (Refer to page 4-1) Remove the fuel hose. Remove the throttle cables and choke cable Loosen the clamp screw and remove the carburetor.
  • Page 104 4-5 FUEL SYSTEM Remove the spring along with diaphragm Remove the jet needle cap spring retainer and jet needle Remove the float chamber body Remove the float assembly along with the needle valve by removing the pin.
  • Page 105 FUEL SYSTEM 4-6 Remove the valve seat Remove the main jet jet holder and pilot jet Remove the pilot screw counting and tightening the number of turn. NOTE Record the number of turn for the pilot screw when install to confer. INSPECTION Check the following parts for damage and clogging.

  • Page 106: 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 Bend the float arm as necessary to bring the height to the specified level.
  • Page 107 FUEL SYSTEM 4-8 Align the hole of the diaphragm with passage way on the carburetor body. Install the two screw and diaphragm cover CAUTION Never adjust CO adjust screw of the carbure- tor. If adjust at discretion, have a bad influence upon output of the engine as the two carburetor is disharmonious.

  • Page 108: Cooling System

    COOLING SYSTEM CONTENTS 5 - 1 ENGINE COOLANT 5 - 2 COOLING CIRCUIT 5 - 2 RADIATOR COOLING FAN COOLING FAN THERMO-SWITCH 5 - 7 ENGINE COOLANT TEMPERATURE SENSOR 5 - 8 THERMOSTAT 5 - 10 WATER PUMP...

  • Page 109: Engine Coolant

    5-1 COOLING SYSTEM ENGINE COOLANT Anti-freeze density Freezing point At the time of manufacture, the cooling system is filled with a 50 : 50 mixture of distilled water and ethylene gly- col anti-freeze. 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 (-24 )

  • Page 110: 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 2-20) Disconnect the cooling fan motor lead wire coupler and its thermo-switch lead wire coupler Remove the water hose and reserve tank from the radiator.

  • Page 111: Inspection And Cleaning

    5-3 COOLING SYSTEM Remove the radiator by mounting bolt. Remove the radiator. INSPECTION AND CLEANING Road dirt or trash stuck to the fins must be removed. Use of compressed air is recommended for this clean- ing. Fins bent down or dented can be repaired by straighten- ing them with the blade of a small screwdriver.
  • Page 112 COOLING SYSTEM 5-4 INSTALLATION The radiator reassembly can be performed in the reverse order of disassembly procedures. However, the following points must be observed in the reassembly operation. Install the radiator with the specified torque. Radiator mounting bolt : 8~12N m (0.8~1.2kg m) Pour engine coolant Refer to page 2-20 Bleed air from the cooling circuit...

  • Page 113: Cooling Fan

    5-5 COOLING SYSTEM COOLING FAN INSPECTION Disconnect the cooling fan motor lead wire coupler and its thermo-switch lead wire coupler Test the cooling fan motor for load current with an ammeter connected as shown in the illustration. The voltmeter is for making sure that the battery applies 12 volts to the motor.

  • Page 114: Cooling Fan Thermo-Switch

    COOLING SYSTEM 5-6 COOLING FAN THERMO-SWITCH REMOVAL Drain engine coolant. (Refer to page 2-20) Disconnect the cooling fan thermo-switch lead wire coupler Remove the cooling fan thermo-switch INSPECTION Check the thermo-switch closing or opening tempera- tures by testing it at the bench as shown in the figure. Connect the thermo-switch to a circuit tester and place it in the OIL contained in a pan, which is placed...

  • Page 115: Engine Coolant Temperature Sensor

    5-7 COOLING SYSTEM ENGINE COOLANT TEMPERA- TURE SENSOR REMOVAL Drain engine coolant. (Refer to page 2-20) Remove the front and rear seat. (Refer to page 7-1) Remove the fuel tank. (Refer to page 4-1) Disconnect the engine coolant temperature sensor lead wire coupler.

  • Page 116: Thermostat

    COOLING SYSTEM 5-8 THERMOSTAT REMOVAL Drain engine coolant. (Refer to page 2-20) Place a rag under the thermostat case. Remove the thermostat case cap. Remove the thermostat INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follwing manner.
  • Page 117 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 (Over 0.31in at 212 A thermostat failing to satisfy either of the two requirements, start-to-open temperature and valve...

  • Page 118: Water Pump

    COOLING SYSTEM 5-10 WATER PUMP REMOVAL AND DISASSEMBLY Drain engine coolant. (Refer to page 2-20) Drain engine oil. (Refer to page 2-10) Disconnect the water hoses Remove the water pump case and clutch cover. (Refer to page 3-16) NOTE Before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and clutch cover.
  • Page 119 5-11 COOLING SYSTEM Remove the water pump from the clutch cover. Remove the O-rings Remove the E-ring from the impeller shaft. Remove the impeller from the other side.

  • Page 120: Reassembly And Installation

    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 for abnormal noise and smooth rotation.
  • Page 121 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 Fill the bearing with engine oil until engine oil comes out from the hole of the bearing housing. Apply engine coolant to the O-ring Install a new O-ring.
  • Page 122 ELECTRICAL SYSTEM CONTENTS 6 - 1 LOCATION OF ELECTRICAL COMPONENTS 6 - 3 IGNITION SYSTEM 6 - 7 CHARGING SYSTEM STARTER SYSTEM AND 6 - 11 SIDE STAND IGNITION INTERLOCK SYSTEM 6 - 15 SWITCHES 6 - 16 LAMP 6 - 18 BATTERY...

  • Page 123: Location Of Electrical Components

    6-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Cooling fan motor Front brake lamp switch Turn signal relay Cooling fan thermo-switch Head lamp relay Side stand relay Cooling fan motor relay Rear brake lamp switch Side stand switch Starter motor...
  • Page 124 ELECTRICAL SYSTEM 6-2 Ignition coil (NO.1 & NO.2) Engine coolant temperature sensor Regulator / Rectifier Thermostat Magneto Gear position switch Fuse Igniter Pulse control unit...

  • Page 125: 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 ignition timing of pick-up with the electric energy of this battery and occur the 1st electric current.
  • Page 126 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 127 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. If spark doesn t emit or the spark bring out the orange color, replace the ignition coil.
  • Page 128 ELECTRICAL SYSTEM 6-6 IGNITER Using the pocket tester(R range), measure the resistance between the terminal in the following table. CAUTION Numberical value may differ a little according to the tester. Please remind that there may be a defect which can not be identified even though the measurement by using the tester indicates a low voltage.

  • Page 129: 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 130 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 of the regulator according 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 condition.
  • Page 131 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 If the tester reads under 13.5V or over 15.0 V, check the magneto no-load performance and regulator / rectifier.
  • Page 132 ELECTRICAL SYSTEM 6-10 REGULATOR / RECTIFIER Disconnect the coupler. Using the pocket tester ( range), measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the regu lator / rectifier. Pocket tester : 09900 - 25002 Unit : Tester probe PULSE CONTROL UNIT...

  • Page 133: Starter System And Side Stand Ignition Interlock System

    6-11 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK 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 134 ELECTRICAL SYSTEM 6-12 TRANSMISSION : Neutral - ON Side stand - Down Clutch lever - Pull SIDE STAND RELAY IGNITION SWITCH BATTERY IGNITION COIL NEUTRAL INDICATOR LIGHT DIODE SIDE STAND SW. SIDE STAND NEUTRAL DOWN POSITION SW. ON TRANSMISSION : Neutral - OFF Side stand - Up Clutch lever - Pull SIDE STAND RELAY...

  • Page 135: Starter Motor Inspection

    6-13 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire With loosening the bolt , remove the starter motor. Disassemble the starter motor. STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, crack or smoothness in the brush holder. If the brush has failed, replace the brush sub assy.
  • Page 136 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 on the housing with the line on the housing end. Apply SUPER GREASE A to the O-ring and remount the starter motor.
  • Page 137 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 LOCK HAZARD SWITCH STARTER SWITCH DIMMER SWITCH HORN SWITCH FRONT/REAR BRAKE LAMP SWITCH...
  • Page 138 ELECTRICAL SYSTEM 6-16 LAMP HEADLAMP TURN SIGNAL LAMP TAIL / BRAKE LAMP...

  • Page 139: 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 in the following illustration. If the continuity measured incorrect, replace the respective part.

  • Page 140: Chassis

    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. Prohibit positively battery from contacting to short, spark or firearms.
  • Page 141 6-19 ELECTRICAL SYSTEM Seal 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 142: Recharging Operation

    ELECTRICAL SYSTEM 6-20 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 which remaining elec- trolyte vaporize.
  • Page 143 CHASSIS CONTENTS EXTERIOR PARTS 7- 1 7 - 2 FRONT WHEEL FRONT BRAKE 7- 6 7 - 13 HANDLEBARS 7 - 15 FRONT FORK 7 - 23 STEERING REAR WHEEL 7- 26 REAR BRAKE 7- 30 REAR SHOCK ABSORBER 7- 32 7 - 33 SWING ARM...

  • Page 144: Exterior Parts

    7-1 CHASSIS EXTERIOR PARTS ◉ FRONT FENDER ● With the bolts removed, remove the front fender. ◉ REAR SEAT ● Remove the rear seat with the ignition key. ◉ FRONT SEAT ● To remove the front seat, pull the knob located under the rear seat.

  • Page 145: Front Wheel

    CHASSIS 7-2 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. CAUTION � When using a jack, take care not to cause scratches on the chassis.
  • Page 146 7-3 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 2-19. � FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle.
  • Page 147 CHASSIS 7-4 � WHEEL BEARING Inspect the play of the wheel bearings by fin g e r while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rota- tion. Replace the bearing in the following procedure if there is anything unusual.
  • Page 148 7-5 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. Brake disk bolt : 18~28 N∙m (1.8 ~2.8 kg∙m) THREAD LOCK “...

  • Page 149: Front Brake

    CHASSIS 7-6 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 150: Brake Fluid Replacement

    7-7 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 2-16 ◉...

  • Page 151: Caliper Inspection

    CHASSIS 7-8 ● 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 152: Caliper Reassembly

    7-9 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 153: Master Cylinder Disassembly

    CHASSIS 7-10 � � [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 154: Master Cylinder Inspection

    7-11 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 155 CHASSIS 7-12 ◉ 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 156: Handlebars

    7-13 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- ● Remove the handlebar balancer ① and grip ②. ②...
  • Page 157 CHASSIS 7-14 NOTE The gap � between the handlebar clamp and holder should be even. � � ● Align the mating face of clutch lever holders with the respective punch marks and tighten the bolt. ● Install the brake master cylinder. (Refer to page 7-12).

  • Page 158: Front Fork

    7-15 CHASSIS FRONT FORK...
  • Page 159 CHASSIS 7-16 ◉ REMOVAL AND DISASSEMBLY ● Remove the front fender. (Refer to page 7-1) ● Take off the front wheel. (Refer to page 7-2) ● Loosen the right and rear front fork upper and lower clamp bolts. ① ● Remove the front brake hose clamp. ●...
  • Page 160 7-17 CHASSIS ● 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 161 CHASSIS 7-18 ● 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 162 7-19 CHASSIS ■ 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 163 CHASSIS 7-20 ■ 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 164 7-21 CHASSIS ■ 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. ■ FORK SPRING ↓ ● Install the fork spring as shown in the illustration. ↑...

  • Page 165: Front Fork Setting

    CHASSIS 7-22 ● 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 7-4) ● Install the brake calipers. (Refer to page 7-9) ●...

  • Page 166: Steering

    7-23 CHASSIS STEERING ◉ ◉ REMOVAL AND DISASSEMBLY ● Take off the front wheel. (See page 7-2) ● Remove the four bolts and front fender. ● Take off the front fork. (See page 7-16)
  • Page 167 CHASSIS 7-24 ● Remove the handlebar clamp bolts. ● Remove the steering stem head nut ① and take off the steering stem upper bracket ②. ① ② ● Remove the steering stem nut ③ and draw out the steering stem. ③...
  • Page 168 7-25 CHASSIS ◉ 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 Reassemble and remount the steering stem in the ②...

  • Page 169: Rear Wheel

    CHASSIS 7-26 REAR WHEEL ◉ REMOVAL ● Raise the rear wheel off the ground with a jack or block. ● Loosen the drive chain adjuster ①, right and left. ● Disengage the drive chain from the rear sprocket. ① ①...
  • Page 170 7-27 CHASSIS ● Remove the rear wheel by removing the rear axle ①. ① ● Remove the brake disk. ● Remove the spacer ②. ③ ● Remove the rear sprocket ③ with mounting drum ④ ⑤ ④ from the rear wheel. ②...
  • Page 171 CHASSIS 7-28 ◉ INSPECTION WHEEL AXLE : Refer to page 7-3 WHEEL : Refer to page 7-3 WHEEL BEARING : Refer to page 7-4 TIRE : Refer to page 2-19 � REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and dam- age.
  • Page 172 7-29 CHASSIS ● Install the rear wheel. After installing the drive chain to the rear sprocket, adjust the drive chain by turning both chain adjusters ① . ② ● Tighten both chain adjuster lock nuts ② securely. ② ① ① ●...

  • Page 173: Rear Brake

    CHASSIS 7-30 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 174 7-31 CHASSIS ◉ Brake fluid replacement : Refer to page 2-16 ◉ Brake pad replacement : Refer to page 2-15 ◉ Disassembly of caliper : Refer to page 7-7 ◉ Inspection of caliper : Refer to page 7-8 ◉ Reassembly of caliper : Refer to page 7-9 ◉...

  • Page 175: Rear Shock Absorber

    CHASSIS 7-32 REAR SHOCK ABSORBER ◉ REMOVAL ● Remove the rear shock absorbers by removing their nuts. ◉ 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.

  • Page 176: Swingarm

    7-33 CHASSIS SWINGARM ◉ ◉ REMOVAL AND DISASSEMBLY ● Remove the rear wheel. (See page 7-26) ● Remove the rear shock absorber fitting nut and bolt. (See page 7-32) ● Remove the swingarm pivot nut. ● Remove the engine mounting lock nut with the spe- cial tool.
  • Page 177 CHASSIS 7-34 ● Remove the chain case. ● Remove the two spacers. ● Remove the bearing by using the special tools. Bearing remover (17 mm) : 09923-73210 Rotor remover sliding shaft : 09930-30102 ◉ INSPECTION � SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one.
  • Page 178 7-35 CHASSIS ◉ REASSEMBLY Reassemble the swingarm and rear shock absorber in the reverse order of disassembly. Pay attention to the following points : ● Press the needle bearings into the swingarm pivot using the special tool. Steering race installer : 09941 - 34513 ●...

  • Page 179: Servicing Information

    SERVICING INFORMATION CONTENTS 8 - 1 TROUBLESHOOTING 8 - 9 SPECIAL TOOLS 8 - 12 TIGHTENING TORQUE 8 - 14 SERVICE DATA 8 - 24 WIRE AND CABLE ROUTING WIRING DIAGRAM 8 - 28...

  • Page 180: 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. 3.
  • Page 181 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 182 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 183 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 184 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 185 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 186 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 187 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 188: Special Tools

    8-9 SERVICING INFORMATION SPECIAL TOOLS Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09900-20806 09900-20101 Vernier Caliper Thickness gauge Measure clearance of piston ring. Used to conveniently measure various dimensions. 09900-20201 09900-21109 Micrometer(0~25mm) Torque wrench Used for precise measurement (00~25mm measure ranges).
  • Page 189 SERVICING INFORMATION 8-10 Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09913-80112 09910-20115 Bearing installer Conrod holder Used to lock the crankshaft. Used to drive bearing in. 09910-32812 09915-63310 Crankshaft installer Compression gauge adapter Used to install the crankshaft in the crankcase.
  • Page 190 8-11 SERVICING INFORMATION Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09921-20210 09940-34561 Front fork assembling tool attachment D Bearing remover(12mm) Used with T-handle. Used to remove oil seal or bearing. 09940-50113 09923-73210 Bearing remover(17mm) Front fork oil seal installer Used to remove bearing with the rotor remove sliding shaft.

  • Page 191: Tightening Torque

    SERVICING INFORMATION 8-12 TIGHTENING TORQUE ENGINE ITEM 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 Magneto rotor bolt...
  • Page 192 8-13 SERVICING INFORMATION CHASSIS ITEM kg m Rear shock absorber mounting nut (Upper) 40 ~ 60 4.0 ~ 6.0 Rear shock absorber mounting nut (Lower) 40 ~ 60 4.0 ~ 6.0 Rear sprocket nut 20 ~ 30 2.0 ~ 3.0 Rear axle nut 90 ~ 140 9.0 ~ 14.0...

  • Page 193: Service Data

    SERVICING INFORMATION 8-14 SERVICE DATA VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT Valve diam. 31.0 (1.22) 25.5 (1.00) Valve clearance (When cold) 0.1 ~ 0.2 (0.004 ~ 0.008) 0.2 ~ 0.3 (0.008 ~ 0.012) Valve guide to valve stem clearance 0.020 ~ 0.047 (0.0008 ~ 0.0019) 0.030 ~ 0.057 (0.0012 ~ 0.0022) Valve stem deflection...
  • Page 194 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) Piston diam.
  • Page 195 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 Clutch cable play 2 (0.08) 2.62 (0.103) NO.
  • Page 196 8-17 SERVICING INFORMATION TRANSMISSION + DRIVE CHAIN Unit : mm (in) ITEM STANDARD LIMIT Primary reduction ratio 2.09 (71/34) Secondary reduction ratio 2.93 (44/15) 2.46 (32/13) 1.60 (32/20) 1.32 (29/22) Gear ratio 1.13 (27/24) 0.96 (25/26) 0.85 (23/27) Shift fork to groove clearance 0.5 (0.020) 0.10 ~ 0.30 (0.004 ~ 0.012) NO.1 &...
  • Page 197 SERVICING INFORMATION 8-18 CARBURETOR Unit : mm (in) ITEM SPECIFICATION Carburetor type BDSR39 TYPE(DOUBLE) Bore size Idle r.p.m. 1,300~1,500 rpm Float height 7 (0.28) 0.5~1.0 (0.02 ~ 0.04) Throttle cable play REAR FRONT Main jet (M.J.) Main air jet (M.A.J.) Jet needle (J.N.) 6E44-54-3...
  • Page 198 8-19 SERVICING INFORMATION THERMOSTAT+COOLING FAN+COOLANT ITEM STANDARD LIMIT Valve opening Thermostat valve operating temperature Valve full open Valve closing Over 8mm /100 Thermostat valve lift Approx. 125 Engine coolant temperature sensor resistance Approx. 48.5 Approx. 24 Approx. 15 OFF ON Approx.
  • Page 199 SERVICING INFORMATION 8-20 ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE BTDC 5 /1,500rpm Ignition timing Type CR8E 0.7~0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E Spark performance Over 8mm (0.32) 3.5 ~ 5.5 Primary Ignition coil resistance 20 ~ 31...
  • Page 200 8-21 SERVICING INFORMATION SUSPENSION Unit : mm (in) ITEM STANDARD LIMIT Front fork stroke 120 (4.72) 433.3 (17.1) 430 (16.9) Front fork spring free length Front fork oil type TELLUS #32 Front fork oil level 146mm(5.8 in) from end of outer tube (when maximum compressed without spring) Front fork oil capacity (each leg) 380cc...
  • Page 201 SERVICING INFORMATION 8-22 BRAKE + WHEEL Unit : mm (in) ITEM STANDARD LIMIT Rear brake pedal height 290 (11.4) [when one person riding from the ground] Brake disk thickness 4.0 (0.16) Front 3.0 (0.12) Rear 4.3 (0.17) 3.0 (0.12) Brake disk runout Front Rear 0.3 (0.012) Master cylinder bore...

  • Page 202: Tire Pressure

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

  • Page 203: Wire And Cable Routing

    SERVICING INFORMATION 8-24 WIRE AND CABLE ROUTING # Install to the order TURN SIG. RELAY HEAD LAMP RELAY (3EA) 09407-14403 WIRING HARNESS Rr. STOP S/W 09407-14403 WIRING HARNESS 09407-14403 ENGINE EARTH Rr. STOP S/W MOTOR LEAD WIRE Rr. STOP S/W IGNITER 09407-14403 WIRING HARNESS...
  • Page 204 8-25 SERVICING INFORMATION...
  • Page 205 SERVICING INFORMATION 8-26 59420HN910 - GUIDE COMP, L HANDLE S/W Rh 59410HN910 - GUIDE COMP, R CLUTCH LEVER S/W Ft. BRAKE HOSE CLUTCH LEVER CABLE HANDLE S/W Rh SPEEDOMETER CLUTCH LEVER S/W HANDLE S/W Lh HANDLE S/W Rh TURNSIGNAL L TURNSIGNAL R LOCK ASSY, STEERING WIRING HARNESS...
  • Page 206 8-27 SERVICING INFORMATION...

  • Page 207: Wiring Diagram

    SERVICING INFORMATION 8-28 WIRING DIAGRAM...
  • Page 210 Prepared by HYOSUNG MOTORS & MACHINERY INC. 2nd Ed. JUN. 2004. Manual No. 99000-94810 Printed in Korea...

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