KYMCO DINK50 Service Manual

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PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO DINK50.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 5 through 12 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 13 is the

removal/ installation of chassis. Section

16 states the testing and measuring

methods of electrical equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

www.PlanDeGraissage.org

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/CYLINDER/PISTON

KICK STARTER/DRIVE

PULLEY/CLUTCH/DRIVEN PULLEY

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

FUEL TANK

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT /

T HERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

TIR

HIGH-SPEED TIRE (TUBELESS TIRE)

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO DINK50

Page 1: Table Of Contents
PREFACE This Service Manual describes the TABLE OF CONTENTS technical features and servicing procedures for the KYMCO DINK50. GENERAL INFORMATION EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read them carefully before any LUBRICATION SYSTEM operation is started.
Page 2: Engine Serial Number
. GENERAL INFORMATION ENGINE SERIAL NUMBER --- 1- 0 TOOLS ----------------------------1-14 SPECIFICATION ----------------- 1- 1 LUBRICATION POINTS --------1-16 SERVICE PRECAUTIONS ------ 1- 3 WIRING DIAGRAM--------------1-17 TORQUE VALUES--------------- 1-13 CABLE & HARNESS ROUTING- 1-22 TROUBLESHOOTING-----------1-24 ENGINE SERIAL NUMBER Location of Engine Serial Number www.PlanDeGraissage.org...
Page 3: Specification
. GENERAL INFORMATION SPECIFICATIONS Name & Model No. SH10BA Overall length 1950mm Overall width 735mm Air cleaner type & No Paper element, wet Overall height 1180mm Lubrication oil 1.5. liters Wheel base 1350mm capacity Engine type Air cooled 2-stroke Fuel capacity 10.
Page 4 . GENERAL INFORMATION SPECIFICATIONS Name & Model No. SH10AA Overall length 1950mm Overall width 735mm Air cleaner type & No Paper element, wet Overall height 1180mm Lubrication oil 1.5 liters Wheel base 1350mm capacity Engine type 2stroke Water cooled Fuel capacity 10 liters Displacement 49.4cc...
Page 5: Service Precautions
. GENERAL INFORMATION SERVICE PRECAUTIONS  Make sure to install new gaskets, O- rings, circlips, cotter pins, etc. when reassembling.  When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 6 . GENERAL INFORMATION  Apply or add designated greases and lubricants to the specified lubrication points.  After reassembly, check all parts for proper tightening and operation.  When two persons work together, pay attention to the mutual working safety. ...
Page 7 . GENERAL INFORMATION  If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity  After operation, terminal caps shall be installed securely.  When taking out the connector, the lock on the connector shall be released before operation.
Page 8 . GENERAL INFORMATION  The connector shall be inserted completely. Snapping!  If the double connector has a lock, lock it at the correct position.  Check if there is any loose wire.  Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 9 . GENERAL INFORMATION  After clamping, check each wire to make sure it is secure.  Do not squeeze wires against the weld or its clamp.  After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 10 . GENERAL INFORMATION  Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight!  Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.  When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 11 . GENERAL INFORMATION  After routing, check that the wire harnesses are not twisted or kinked.  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 12 . GENERAL INFORMATION  Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) Grease : Apply grease for lubrication.
Page 13 . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) Item SH10BA SH10AA SH10BA SH10AA Cylinder head warpage 0.10 0.10   Piston O.D.(5mm from bottom of piston 38.970 38.9 38.970 38.9 38.90 38.90 skirt) Cylinder-to- piston clearance 0.03 0.07 0.10 0.10...
Page 14 . GENERAL INFORMATION FRAME Standard (mm) Service Limit (mm) Item SH10BA SH10AA SH10BA SH10AA Axle shaft runout   Radial Front wheel rim runout Axial Front shock absorber spring free length 200.0 200.0 182.8 182.8 Rear wheel rim runout Brake drum I.D. Front/rear Brake lining thickness Front/rear...
Page 15: Torque Values
. GENERAL INFORMATION TORQUE VALUES ENGINE Item Thread dia. (mm) Torque (kg-m) Remarks Cylinder head bolt BF7x115 1.5_ (cold) Clutch drive plate nut 3.5_ Clutch outer nut NH10 3.5_ Drive face nut NH12 5.0_ Oil check bolt 1.0_ Engine mounting bolt BF10x95 4.5_ Engine hanger bracket bolt...
Page 16: Tools
. GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Universal bearing puller Crankshaft bearing removal Lock nut wrench, 39mm Drive pulley disassembly/assembly Lock nut socket wrench Top cone race holding Lock nut wrench, Stem lock nut tightening Crankcase puller Crankcase disassembly Bearing remover set, 12mm Drive shaft bearing removal/installation...
Page 17 . GENERAL INFORMATION Tool Name Tool No. Remarks Drive shaft bearing installation Final shaft Bearing outer driver, 37x40mm bearing installation Crankshaft bearing installation Outer driver, 24x26mm Driven pulley bearing installation Pilot, 10mm Front wheel bearing installation Bearing driver pilot, 17mm Drive shaft bearing installation Snap ring pliers (close) Circlip removal/installation...
Page 18: Lubrication Points
. GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable parts JASO-FC or API-TC Cylinder movable parts Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts Grease Starter pinion movable parts Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified.
Page 19 . GENERAL INFORMATION Brake Master Cylinders Rear Stop Switch Front Stop Switch Throttle Cable Speedometer Cable Horn Pressure Type Fuel Tank Radiator Cap Breather Tube Water Hose Radiator 1-17 www.PlanDeGraissage.org...
Page 20 . GENERAL INFORMATION Winker Fuse Box Ignition Switch Fuel Filler Fuel Tank Breather Tube Fuel Tank Inlet Tube Water Hose Front Brake Fluid Tube Water Hoses 1-18 www.PlanDeGraissage.org...
Page 21 . GENERAL INFORMATION Front Stop Switch Throttle Cable Pressure Type Radiator Cap Fuel Filler Speedometer Fuel Tank Inlet Cable Tube Fuel Tank Breather Tube Fuel Unit Water Hose Wire Harness Throttle Cable Rear Brake Control Cable 1-19 www.PlanDeGraissage.org...
Page 22 . GENERAL INFORMATION Oil Meter Battery (+) Cable Battery (-) Cable Starter Relay CDI Unit Oil Filter Ignition Coil Fuel Tube Auto Bystarter Wire Fuel Pump Thermostat 1-20 www.PlanDeGraissage.org...
Page 23 . GENERAL INFORMATION Fuel Tube Wire Harness Fuel Pump Vacuum Tube Starter Motor Ignition Coil Throttle Oil Tube Cable Auto Bystarter CDI Unit Battery Fuel Tube Fuel Pump Oil Meter Starter Relay Ignition Coil Fuel Filter Wire Harness Spark Plug Fuel Unit Wire Air Injection Air Cleaner...
Page 24: Wiring Diagram
. GENERAL INFORMATION WIRING DIAGRAM SH10AA〉〈 1-22 www.PlanDeGraissage.org...
Page 25 . GENERAL INFORMATION WIRING DIAGRAM SH10BA〉〈 1-23 www.PlanDeGraissage.org...
Page 26: Troubleshooting
. GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw.  Empty fuel tank  Clogged float valve Fuel reaches Fuel does not  Clogged charcoal carburetor reach carburetor...
Page 27 . GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw.  Empty fuel tank  Clogged float valve Fuel reaches Fuel does not  Clogged charcoal carburetor reach carburetor canister ...
Page 28 . GENERAL INFORMATION Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks.  Carburetor not securely tightened No air leak Air leaks  Faulty intake manifold gasket  Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
Page 29 . GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation.  Clogged air cleaner Engine speed does  Clogged fuel filter Engine speed not increase  Clogged exhaust increases sufficiently muffler  Faulty auto bystarter ...
Page 30 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing.  Faulty CDI unit Incorrect timing Correct timing  Faulty A.C. generator Check carburetor air screw adjustment.  Mixture too rich (turn Correctly adjusted Incorrectly adjusted screw out)
Page 31 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing.  Faulty CDI unit Correct timing Incorrect timing  Loose A.C.G. stator  Faulty A.C. generator Check auto fuel valve for fuel supply.  Empty fuel tank Fuel flows freely Fuel flow ...
Page 32 . GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause  Worn or slipping drive belt  Broken ramp plate  Broken driven face spring Engine starts but  Separated clutch lining motor-cycle does not  Damaged driven pulley shaft move splines ...
Page 33: General Information
. GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal)  Weak shock spring Suspension is too soft  Excessive load  Shock damper oil leaking  Bent fork tube or shock rod Suspension is too hard ...
Page 34 . GENERAL INFORMATION OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn  Burned out fuse signals.  Weak or dead battery Signals dim, remain Signals operate ...
Page 35 . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals.  Burned out fuse  Weak or dead battery Signals operate Signals dim, remain  Faulty ignition switch properly on or don‘t...
Page 36 . GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Probable Cause Inspection/Adjustment Check operation of  Burned out fuse stop switch by  Weak or dead battery applying brake.  Faulty stop switch Stoplight does not Stoplight comes on ...
Page 37: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6 www.PlanDeGraissage.org...
Page 38: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS SCHEMATIC DRAWING www.PlanDeGraissage.org...
Page 39: Service Information
. EXHAUST MUFFLER/FRAME COVERS SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 3.5kg-m...
Page 40: Frame Covers Removal
. EXHAUST MUFFLER/FRAME COVERS Bolts/Nuts Center Cover Bolt FRAME COVERS REMOVAL REAR CARRIER & HAND RAIL REMOVAL Remove the met-in box: First remove the two bolts and two nuts attaching the met-in box. Remove the bolt attaching the center cover. Remove the met-in box.
Page 41 . EXHAUST MUFFLER/FRAME COVERS Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them backward. Side Cover Screws Seat Lock Wire Remove the right and left screws on the rear part of the frame body cover.
Page 42 . EXHAUST MUFFLER/FRAME COVERS FRONT UPPER COVER REMOVAL Remove the right and left rearview mirrors. Remove the two screws on the back of the front upper cover. Remove the two bolts on the front of the front upper cover. Disconnect the headlight wire connector. Remove the front upper cover.
Page 43: Exhaust Muffler Removal
. EXHAUST MUFFLER/FRAME COVERS Screws HANDLEBAR COVER REMOVAL Remove the two screws and one bolt attaching the handlebar rear cover. First remove the four screws attaching the handlebar front cover. Remove the handlebar front cover. Remove the handlebar rear cover. The installation sequence is the reverse of removal.
Page 44 . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ INSPECTION AND MAINTENANCE SCHEDULE..... 3- 1 BRAKE SYSTEM ..............3- 4 MOVING DEVICE..............3- 6 DAMPING DEVICE..............3- 7 POWER DRIVE SYSTEM ............3- 7 ELECTRICAL EQUIPMENT............. 3- 8 ENGINE................... 3- 9 OTHERS ..................
Page 45: Inspection And Maintenance Schedule
. INSPECTION/ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE (Note) 1. ○ means time for inspection. 2. ☆ means regular replacement for the specified parts. This inspection and maintenance schedule is based upon average riding conditions. Machines subjected to serve use, or ridden in unusually dusty areas, require more frequent servicing.
Page 46 . INSPECTION/ADJUSTMENT Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months Tire crack and damage ○ ○ ○ Groove Depth: Tire groove and Front: 0.8mm ○ ○ ○ abnormal wear Rear : 0.8mm Imbedded objects, ○...
Page 47 . INSPECTION/ADJUSTMENT Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months Performance and abnormal ○ ○ noise Conditions at low and high ○ ○ ○ Body speeds Exhaust smoke ○ ○ Air cleaner ○...
Page 48: Brake System
. INSPECTION/ADJUSTMENT BRAKE SYSTEM 20mm Front BRAKE LEVER Free Play》《 Measure the front and rear brake lever free plays. Free Play: Front: 10_ 20mm Rear: 10_ 20mm 20mm Rear <Front> “ ” Marks <Rear> △ If the free plays do not fall within the limits, turn the right and left adjusting nuts for adjustment.
Page 49: Inspection/Adjustment
3.INSPECTION/ADJUSTMENT <Front> “ ” Marks <Rear> △ BRAKE DRUM/SHOE Brake Shoe Wear》《 Replace the brake shoes if the arrow on the brake arm aligns with reference mark“ ” △ on the brake panel when the brake is fully applied. Brake Drum Wear/Damage》...
Page 50: Moving Device
. INSPECTION/ADJUSTMENT MOVING DEVICE TIRES Tire Pressure》《 Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. Tire Pressure (one rider) Front: 1.75 kg/cm_ Rear: 2.25 kg/cm_ Tire Size Cross-country Tire Front 110/70 − 12 Front Wheel Rear 130/70 −...
Page 51: Damping Device
3.INSPECTION/ADJUSTMENT DAMPING DEVICE SHOCK ABSORBERS Oil Leak/Damage》《 Fully apply the front brake and check the action of the front shock absorber by compressing it several times. Check the entire shock absorber assembly for looseness or damage. Check the action of the rear shock absorber by compressing it several times.
Page 52: Electrical Equipment
. INSPECTION/ADJUSTMENT ELECTRICAL EQUIPMENT IGNITION APPARATUS Gap, Wear and Spark Plug》《 Fouling Deposits Remove the frame center cover. Remove the spark plug cap and spark plug. Check the spark plug for wear, fouling and carbon deposits. Remove the fouling and carbon deposits Washer Damage with a spark plug cleaner or wire brush.
Page 53 3.INSPECTION/ADJUSTMENT Throttle Stop Screw ENGINE BODY At High and Low Speeds》《＊ The engine must be warm for accurate idle speed adjustment. Adjust the idle speed to the specified range by turning the throttle stop screw and air screw. Idle Speed: SH10BA: 2000±...
Page 54 . INSPECTION/ADJUSTMENT Wash the air cleaner element in detergent oil, squeeze out and allow to dry. ＊ Never use gasoline or organic vaporable oil with acid or alkali for washing. After washing, soak the element in clean engine oil SAE 15W-40# and squeeze out excess oil.
Page 55 3.INSPECTION/ADJUSTMENT Clean the oil filter screen with compressed air. Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level. Bleed air from the oil pump and oil lines. ＊...
Page 56: Others
. INSPECTION/ADJUSTMENT FUEL SYSTEM Throttle Grip Free Play》《 Measure the throttle grip free play. Free Play: 2_ If the throttle grip free play does not fall within the specified range, adjust by loosening the lock nut and turning the adjusting nut.
Page 57: Lubrication System
. LUBRICATION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION............4-2 TROUBLESHOOTING.............. 4-2 OIL PUMP REMOVAL ............. 4-3 OIL PUMP INSPECTION............4-3 OIL PUMP INSTALLATION.............4-4 OIL PUMP BLEEDING............. 4-5 OIL TANK ................4-6 www.PlanDeGraissage.org...
Page 58: Lubrication System
. LUBRICATION SYSTEM LUBRICATION SYSTEM www.PlanDeGraissage.org...
Page 59: Service Information
. LUBRICATION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump. • Bleed air from the oil pump if there is air between the oil pump and oil line. •...
Page 60: Oil Pump Removal
. LUBRICATION SYSTEM OIL PUMP REMOVAL Oil Pump Oil Outlet Line ＊ Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Remove the met-in box. (  2-4) Oil Inlet Line Control Cable Bolt...
Page 61: Oil Pump Installation
. LUBRICATION SYSTEM OIL PUMP INSTALLATION ＊ • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion. Grease or Engine Oil Control Cable Plate Install the oil pump onto the crankcase.
Page 62: Oil Pump Bleeding
. LUBRICATION SYSTEM OIL PUMP BLEEDING Intake Manifold Oil Outlet Line ＊ • Air in the oil lines will block oil flow and result in severe engine damage. • Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines.
Page 63: Oil Tank
. LUBRICATION SYSTEM OIL TANK Oil Meter OIL TANK REMOVAL Remove the seat and met-in box. (  2-3) Remove the battery. Remove the battery cover screw and the battery cover. Remove the oil meter connector. Remove the two bolts attaching the oil tank. Disconnect the oil inlet line.
Page 64: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION............5-1 ENGINE REMOVAL..............5-2 ENGINE INSTALLATION............5-4 www.PlanDeGraissage.org...
Page 65 . ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS • Parts requiring engine removal for servicing: Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4.5_ 5.5kg-m Engine hanger bracket bolt 4.5_ 5.5kg-m Rear shock absorber lower mount bolt 2.4_ 3.0kg-m Rear shock absorber upper mount bolt 3.5_ 4.5kg-m 3.5_ 4.5kg-m...
Page 66 . ENGINE REMOVAL/INSTALLATION Air Cleaner Case Band ENGINE REMOVAL Remove the frame body cover. (  2-5) Remove the two bolts attaching the air cleaner case. Loosen the band between the air cleaner and carburetor to remove the air cleaner case. Remove the carburetor cap.
Page 67 . ENGINE REMOVAL/INSTALLATION Rear Shock Absorber Lower Mount Bolt Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase. Remove the rear brake cable clamp and rear brake cable. Remove the cooling air tube band on the left crankcase cover and disconnect the cooling air tube.
Page 68 . ENGINE REMOVAL/INSTALLATION Engine Hanger ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary. Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal. ＊ Cables and wires should be routed properly.
Page 69: Cylinder Head/Cylinder/Piston
. CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ SERVICE INFORMATION............6-3 TROUBLESHOOTING.............. 6-3 CYLINDER HEAD..............6-4 CYLINDER/PISTON..............6-8 www.PlanDeGraissage.org...
Page 70: Cylinder Head/Cylinder/Piston
. CYLINDER HEAD/CYLINDER/PISTON SH10AA〉〈 Torque: 1.1_ 1.7kg-m (cold) Torque: 1.5_ 1.7kg-m www.PlanDeGraissage.org...
Page 71 . CYLINDER HEAD/CYLINDER/PISTON SH10BA〉〈 Torque: 0.8_ 1.2kg-m Torque: 1.1_ 1.7kg-m (cold) Torque: 1.5_ 1.7kg-m www.PlanDeGraissage.org...
Page 72: Service Information
. CYLINDER HEAD/CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. • Before disassembly, clean the engine to prevent dust from entering the engine. • Remove all gasket material from the mating surfaces. •...
Page 73: Cylinder Head
. CYLINDER HEAD/CYLINDER/PISTON Spark Plug Cap CYLINDER HEAD REMOVAL 〈 SH10AA〉 Remove the rear carrier. Remove the frame body cover. (  2-5) Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing. Exhaust muffler joint lock nut Remove the spark plug cap.
Page 74 . CYLINDER HEAD/CYLINDER/PISTON Spark Plug Cap CYLINDER HEAD REMOVAL　〈 SH10BA〉 Remove the rear carrier. Remove the frame body cover. (  2-5) Fan Cover/Engine Hood Remove the spark plug cap. Remove the three bolts attaching the fan cover to remove the fan cover. Remove the two joint lock nuts on the front of the exhaust muffler and then remove the two exhaust muffler lock bolts.
Page 75 . CYLINDER HEAD/CYLINDER/PISTON Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber ＊ Avoid damaging the combustion cham- ber wall and cylinder mating surface. Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
Page 76 . CYLINDER HEAD/CYLINDER/PISTON Cylinder Head Bolts Installation Cylinder head Bolts Install and tighten the cylinder head bolts diagonally in 2 or 3 times. Torque: 1.5_ 1.7kg-m Install the spark plug. Torque: 1.1_ 1.7kg-m Spark Plug Cylinder Head Spark Plug Engine Hood Engine Hood Installation SH10BA〉...
Page 77: Cylinder/Piston
. CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON CYLINDER REMOVAL Remove the met-in box and seat. Remove the frame body cover. Remove the cylinder head._6-4_ Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the cylinder. Remove the cylinder gasket.
Page 78 . CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. ＊ Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
Page 79 . CYLINDER HEAD/CYLINDER/PISTON ＊ The cylinder has an A mark or no mark on it. When replacing the cylinder with a new one, use a cylinder having the same mark as the old one. Measure the piston O.D. at a point 5mm from the bottom of the piston skirt.
Page 80 . CYLINDER HEAD/CYLINDER/PISTON PISTON RING INSPECTION Measure each piston ring end gap. Service Limits: Top/Second SH10BA: 0.40mm replace if over SH10AA: 0.40mm replace if over ＊ Set each piston ring squarely into the cylinder using the piston and measure the end gap. CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the...
Page 81 . CYLINDER HEAD/CYLINDER/PISTON Install a new cylinder gasket on the mating Cylinder Gasket surface between the cylinder and crankcase. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves. Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings.
Page 82: Kick Starter/Drive Pulley/Clutch/Driven Pulley
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION............7- 2 TROUBLESHOOTING.............. 7- 2 KICK STARTER............... 7- 3 DRIVE BELT ................7- 7 DRIVE PULLEY............... 7- 9 STARTER ONE-WAY CLUTCH DRIVE GEAR ......7-11 CLUTCH/DRIVEN PULLEY .............
Page 83 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY MODEL SH10BA.SH10AA Torque: 5.0_ 6.0kg-m Torque: 3.5_ 4.5kg-m Torque: 3.5_ 4.0kg-m www.PlanDeGraissage.org...
Page 84: Service Information
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS SH10BA SH10AA Item Standard (mm) Service Limit (mm) Standard (mm) Service Limit (mm) Drive pulley collar O.D. 20.01 20.02 24.24...
Page 85: Kick Starter
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Left Crankcase Cover KICK STARTER LEFT CRANKCAS E COVER REMOVAL Remove the drive belt cooling air tube connector circlip. Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration.
Page 86 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Return Spring Spindle Return Spring KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage.
Page 87 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover.
Page 88 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber.
Page 89: Drive Belt
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: SH10BA: 16.5mm replace if below SH10AA: 16.5mm replace if below ＊...
Page 90 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt. Drive Belt Drive Pulley Face Drive Belt...
Page 91: Drive Pulley
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Drive Pulley Face Starting Ratchet DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut. Remove the starting ratchet, 12mm washer and drive pulley face. 12mm Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE DISASSEMBLY...
Page 92 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Weight Roller Remove the weight rollers. MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: SH10BA: 12.4mm replace if below SH10AA: 12.4mm replace if below Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable...
Page 93 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Drive Pulley Face Install the drive belt on the crankshaft. Install the drive face, starting ratchet and washer, then tighten the 12mm drive face nut. Torque: 3.5_ 4.0kg-m ＊ Keep grease or oil off the drive belt and drive pulley faces.
Page 94 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Clutch Outer 10mm Clutch Outer Nut CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. (  7-7) Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut. Remove the clutch outer. Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley.
Page 95 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Remove the seal collar. Seal Collar Oil Seal Driven Pulley Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. O-rings Guide Roller Pin CLUTCH/DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage.
Page 96 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: SH10BA: 82.6mm replace if below SH10AA: 82.6mm replace if below Check the driven face assembly for wear or damage.
Page 97 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face.
Page 98 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up. Outer Driver, 24x26mm Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY AS SEMBLY First install the movable driven face onto the driven face.
Page 99 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 28mm drive plate nut. Tighten the 28mm nut to the specified torque. Torque: 5.0_ 6.0kg-m Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY...
Page 100: Final Reduction
. FINAL REDUCTION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION............8-2 TROUBLESHOOTING.............. 8-2 FINAL REDUCTION DISASSEMBLY........8-3 FINAL REDUCTION INSPECTION........... 8-3 FINAL REDUCTION ASSEMBLY..........8-6 www.PlanDeGraissage.org...
Page 101: Final Reduction
. FINAL REDUCTION www.PlanDeGraissage.org...
Page 102: Service Information
. FINAL REDUCTION SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.1 liter SPECIAL TOOLS Bearing remover set, 12mm Bearing remover set, 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver, 37x40mm Bearing outer driver, 32x35mm Bearing driver pilot, 17mm Bearing driver pilot, 15mm Bearing driver pilot, 12mm...
Page 103: Final Reduction Disassembly
. FINAL REDUCTION B o l t s FINAL REDUCTION DISAS- SEMBLY Remove the rear wheel. (  14-3) Remove the left crankcase cover. (  7-3) Remove the clutch/driven pulley. (  7-12) Drain the transmission gear oil into a clean container.
Page 104 . FINAL REDUCTION Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Final Shaft Bearing Countershaft Bearing Final Shaft Inspect the drive shaft and gear for wear or damage.
Page 105 . FINAL REDUCTION Drive Shaft Bearing BEARING REPLACEMENT (Transmission Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Set Bearing Outer Driver Handle A Drive new bearings into the transmission case cover.
Page 106: Final Reduction Assembly
. FINAL REDUCTION Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Bearing Outer Driver FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the left crankcase.
Page 107 . FINAL REDUCTION Dowel Pins Install the countershaft and gear into the left crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Countershaft Resin Washer Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.
Page 108 . FINAL REDUCTION After installation, fill the transmission case with the specified oil. ＊ • Place the motorcycle on its main stand on level ground. • Check the sealing washer for wear or damage. Specified Gear Oil: SAE90# Oil Capacity: at disassembly: 0.12 liter at change: 0.1 liter Install and tighten the oil check bolt.
Page 109 . A.C. GENERATOR __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION............9-3 A.C. GENERATOR REMOVAL..........9-4 A.C. GENERATOR INSTALLATION ........9-6 www.PlanDeGraissage.org...
Page 110: . A.c. Generator
. A.C. GENERATOR SH10AA〉〈 Torque: 0.8_ 1.2kg- 0.8~1.2kg-m Torque: 3.5_ 4.0kg- 3.5~4.0kg-m Torque: 0.6_ 1.0kg- 0.8~1.2kg-m Torque: 0.8_ 1.2kg- www.PlanDeGraissage.org...
Page 111 . A.C. GENERATOR SH10BA〉〈 Torque: 0.8_ 1.2kg- Torque: 3.5_ 4.0kg- Torque: 0.6_ 1.0kg- Torque: 0.8_ 1.2kg- www.PlanDeGraissage.org...
Page 112 . A.C. GENERATOR SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5_ 4.0kg-m SPECIAL TOOLS Flywheel puller Universal holder www.PlanDeGraissage.org...
Page 113 . A.C. GENERATOR Bolts SH10AA〉〈 A.C. GENERATOR REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the three bolts attaching the right crankcase cover and the cover. Hold the flywheel with an universal holder and then remove the 10mm flywheel nut. Universal Holder www.PlanDeGraissage.org...
Page 114 . A.C. GENERATOR Bolts SH10BA〉〈 A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover. Fan Cover Bolt Remove the cooling fan by removing the four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the 10mm flywheel nut.
Page 115 . A.C. GENERATOR Lock Nut Wrench Remove the A.C. generator flywheel using the flywheel puller. Flywheel Puller A.C. Generator Wire Connector Remove the A.C. generator wire connector. Stator Wire Clamp Remove the two pulser coil bolts and pulser coil from the right crankcase. Remove the pulser coil wire clamp from the right crankcase.
Page 116 . A.C. GENERATOR A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Holder Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key.
Page 117: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION............10-2 TROUBLESHOOTING.............. 10-2 CRANKCASE SEPARATION ............ 10-3 CRANKSHAFT REMOVAL............10-3 CRANKSHAFT INSPECTION ........... 10-4 CRANKSHAFT INSTALLATION..........10-5 CRANKCASE ASSEMBLY ............10-7 10-0 www.PlanDeGraissage.org...
Page 118: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT Torque: 0.8_ 1.2kg-m 10-1 www.PlanDeGraissage.org...
Page 119: Service Information
. CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine (  Section 5) Driven pulley (  Section 7) Carburetor (  Section 12) A.C.
Page 120: Crankcase Separation
. CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the crankcase attaching bolts. Crankcase Puller Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.
Page 121: Crankshaft Inspection
. CRANKCASE/CRANKSHAFT Remove the remaining bearing on the crankshaft side using the universal bearing puller. ＊ When separating the crankcase, the oil seals must be removed. Replace the oil seals with new ones. Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
Page 122: Crankshaft Installation
. CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit 0.150mm 0.100mm replace if over replace if over Play Check the crankshaft bearings for excessive play. The bearings must be replaced if they are noisy or have excessive play. Play Axial Radial CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults.
Page 123 Pilot, 20mm Crankcase Assembly Collar Install the crankshaft into the left crankcase. ＊ • Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crank- shaft bearings and connecting rod big end. • Apply grease to the lip of the oil seal and then install it.
Page 124: Crankcase Assembly
. CRANKCASE/CRANKSHAFT Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Assemble the crankcase halves. Crankcase Assembly Tool Crankcase Assembly Collar The distance between the right crankcase oil seal and crankcase surface is about 12.5±0.5 ＊...
Page 125 . CRANKCASE/CRANKSHAFT Oil Seal The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. 1.0mm Install and tighten the crankcase attaching bolts. ＊ After assembly, check the crankshaft for smooth operation. 10-8 www.PlanDeGraissage.org...
Page 126: Cooling System
. COOLING SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11- 1 SERVICE INFORMATION -------------------------------------------- 11- 2 TROUBLESHOOTING ------------------------------------------------- 11- 2 COOLING SYSTEM TESTING --------------------------------------- 11- 4 RADIATOR -------------------------------------------------------------- 11- 4 WATER PUMP ---------------------------------------------------------- 11- 8 THERMOSENSOR ------------------------------------------------------ 11-12 THERMOSTAT---------------------------------------------------------- 11-13 11-0...
Page 127: Cooling System
. COOLING SYSTEM SCHEMATIC DRAWING Torque: 1.0_ 1.4kg-m 11-1 www.PlanDeGraissage.org...
Page 128: Service Information
. COOLING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃...
Page 129 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water -9℃ -15℃ 360cc 825cc -25℃...
Page 130: Cooling System Testing
. COOLING SYSTEM COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the cap sealing surface before testing.
Page 131 . COOLING SYSTEM Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. RADIATOR REMOVAL Drain the coolant. (  3-9) Remove the overflow tube clamp and disconnect the overflow tube.
Page 132 . COOLING SYSTEM Loosen the hose band and disconnect the lower hose from the radiator. Lower Hose Radiator Remove the four screws and the radiator. Screws B o l t s RADIATOR BRACKET REMOVAL/ INSTALLATION Remove the two bolts to remove the radiator bracket.
Page 133 . COOLING SYSTEM Screws RADIATOR INSTALLATION Install the radiator on the radiator bracket with the four screws. Radiator Upper Hose Connect the upper and lower hoses and secure them with hose bands. Lower Hose Install the heat screen. Connect the overflow tube and secure with the tube clamp.
Page 134: Water Pump
. COOLING SYSTEM Screws Set the two tabs under the air duct into the grooves on the radiator lower part and then secure the radiator with the two screws. Fill the radiator with coolant. (  3-12) After installation, check for coolant leaks. Air Duct Water Pump WATER PUMP...
Page 135 . COOLING SYSTEM Bolts Water Pump Cover Remove the three bolts and the water pump cover, gasket and 1 dowel pins. Impeller Remove the three bolts attaching the right crankcase cover and the cover. Remove the water pump impeller. Mechanical Seal Inspect the mechanical (water) seal and inner bearing for wear or damage.
Page 136 . COOLING SYSTEM Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the outer. Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver. ＊ Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal.
Page 137 . COOLING SYSTEM Mechanical Seal WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new shaft inside must be installed to the impeller. Install the impeller onto the water pump assembly. Torque: 1.0_ 1.4kg-m Disk water pump Impeller Bolts Install the one dowel pins and a new gasket.
Page 138: Thermosensor
. COOLING SYSTEM Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION Thermosensor Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
Page 139: Thermostat
. COOLING SYSTEM Thermostat Housing Bolt THERMOSTAT THERMOSTAT REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the water hose from the thermostat housing. Remove the mounting bolt and the thermostat housing from the cylinder head. Thermosensor Wire Water Hose Bolts...
Page 140 . COOLING SYSTEM ＊ • Do not let the thermostat touch the pan as it will give a false reading. • Replace the thermostat if the valve stays open at room temperature. •Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70℃...
Page 141: Carburetor/Fuel Pump
. CARBURETOR/FUEL PUMP __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CARBURETOR/FUEL PUMP __________________________________________________________________________________ SERVICE INFORMATION............12- 2 TROUBLESHOOTING.............. 12- 2 THROTTLE VALVE DISASSEMBLY ........12- 3 THROTTLE VALVE INSTALLATION........12- 4 CARBURETOR REMOVAL............12- 5 AUTO BYSTARTER..............12- 6 FLOAT CHAMBER..............12- 8 FLOAT LEVEL INSPECTION ..........
Page 142: Carburetor/Fuel Pump
. CARBURETOR/FUEL PUMP 12-1 www.PlanDeGraissage.org...
Page 143: Service Information
. CARBURETOR/FUEL PUMP SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames.. • Note the locations of O-rings when disassembling and replace them with new ones during assembly. • All cables, fuel lines and wires must be routed and secured at correct locations. •...
Page 144: Throttle Valve Disassembly
. CARBURETOR/FUEL PUMP THROTTLE VALVE DIS- ASSEMBLY Remove the rear carrier. (  2-3) Remove the met-in box. (  2-4) Loosen the carburetor cap and remove the throttle valve. Carburetor Cap Throttle Valve Disconnect the throttle cable from the throttle valve.
Page 145: Throttle Valve Installation
. CARBURETOR/FUEL PUMP Remove the jet needle by removing the needle clip. Check the jet needle and throttle valve for Needle Clip wear or damage. Needle Retainer 2nd Notch (STD) Jet Needle Throttle Valve Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLA- TION Install the jet needle on the throttle valve and secure with the needle clip.
Page 146 . CARBURETOR/FUEL PUMP Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw. Throttle Stop Screw Carburetor Cap Tighten the carburetor cap. After installation, perform the following adjustments and inspections. • Throttle cable free play (  3-12) •...
Page 147: Auto Bystarter
. CARBURETOR/FUEL PUMP Remove the carburetor. Bolt AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5Ω (10 minutes minimum after stopping the engine) If the resistance exceeds 5Ω, replace the auto bystarter with a new one. After the engine stops for 30 minutes, connect a hose to the fuel enriching circuit and blow the hose with mouth.
Page 148 . CARBURETOR/FUEL PUMP Connect the auto bystarter yellow wire to the battery positive (+) terminal and green/ black wire to the battery negative (-) terminal and wait 5 minutes. Connect a hose to the fuel enriching circuit and blow the hose with mouth. If air can be blown into the hose, the auto bystarter is faulty and replace it with a new one.
Page 149: Float Chamber
. CARBURETOR/FUEL PUMP Screws Auto Bystarter AUTO BYSTARTER INSTALLATION Bolt Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Set Plate Screws Bolt FLOAT CHAMBER Remove the two float chamber screws and the float chamber.
Page 150 . CARBURETOR/FUEL PUMP Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
Page 151: Float Level Inspection
. CARBURETOR/FUEL PUMP Main Jet Needle Jet holder FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder. Install the air screw and throttle stop screw according to the rotations recorded. ＊ If the air screw must be replaced, be sure to perform the air screw adjustment again.
Page 152: Carburetor Installation
. CARBURETOR/FUEL PUMP O-rings CARBURETOR INSTALLATION ＊ When installation, do not allow foreign particles to enter the carburetor. Check the carburetor insulator and O-ring for wear or damage. Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts.
Page 153: Reed Valve
. CARBURETOR/FUEL PUMP Bolts REED VALVE REMOVAL Remove the rear carrier. Remove the frame body cover. Remove the four intake manifold bolts and gasket. Remove the reed valve and gasket. Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds.
Page 154: Fuel Pump Removal
. CARBURETOR/FUEL PUMP Outlet Tube FUEL PUMP REMOVAL Remove the frame center cover. Disconnect the fuel pump inlet, outlet and vacuum tubes. Remove the two fuel pump attaching bolts and the fuel pump. Vacuum Tube Fuel Strainer Inlet Tube Vacuum Tube Outlet FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws.
Page 155 . CARBURETOR/FUEL PUMP Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Suction Valve Outlet Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.
Page 156: Fuel Pump Installation
. CARBURETOR/FUEL PUMP Outlet Tube Vacuum Tube Inlet Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts. Connect the fuel pump inlet, outlet and vacuum tubes. Install the seat, met-in box and frame center cover.
Page 157 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 13- 1 SERVICE INFORMATION -------------------------------------------- 13- 2 TROUBLESHOOTING ------------------------------------------------- 13- 3 STEERING HANDLEBAR--------------------------------------------- 13- 4 FRONT WHEEL--------------------------------------------------------- 13- 5 FRONT BRAKE --------------------------------------------------------- 13- 8 FRONT SHOCK ABSORBER------------------------------------------ 13-14 FRONT FORK ----------------------------------------------------------- 13-17...
Page 158: Schematic Drawing
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 4.0_ 5.0kg-m 8.0_ 12kg-m 0.5_ 1.3kg-m 2.0_ 2.5kg-m 4.0_ 5.0kg-m 13-1 www.PlanDeGraissage.org...
Page 159: Service Information
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 160: Troubleshooting
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate • Insufficient tire pressure •...
Page 161: Steering Handlebar/Front Wheel/Front Brake/Front
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. (  2-6) Remove the front and rear brake master cylinder attaching bolts. Remove the front upper cover. (  2-5) Remove the front lower cover.
Page 162: Front Wheel
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Grip Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
Page 163 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
Page 164 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle A Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ Do not allow the bearings to tilt • while driving them in.
Page 165: Front Brake
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. (  2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector. Remove the brake fluid tube bolt.
Page 166 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.645mm Before assembly, inspect the lst and 2nd rubber cups for wear.
Page 167 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Connect the front stop switch wire connector. Install the handlebar covers. (  2-6) Stop Switch Wire Connector BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm. Add DOT-3 brake fluid to the brake reservoir.
Page 168 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Fluid Tube Bolt Bolts Brake Pad...
Page 169 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore. Service Limit: 25.45mm ASSEMBLY Clean all removed parts.
Page 170 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 2.5_ 3.5kg-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.
Page 171: Front Shock Absorber
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover. (  2-5) Remove the front lower cover. (  2-5) Remove the front wheel. (  13-5) Remove the front brake caliper. (  13-11) Remove the front shock absorber upper mount bolts.
Page 172 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending, damage or wear •Weak front shock absorber spring •Damper and damper rod bending •Oil seal damage or wear Measure the front shock absorber spring free length.
Page 173 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube. Set the front shock absorber tube in a vise and then tighten the lock nut.
Page 174: Front Fork
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. (  2-6) Remove the steering handlebar. (  13-4) Remove the front upper cover. (  2-5) Remove the front lower cover. (  2-5) Remove the front inner fender.
Page 175 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Outer Driver, 37x40mm Drive in new ball races. ＊ Be sure to drive the ball races into place completely. Outer Driver, 37x40mm Top Cone Race INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.
Page 176 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER __________________________________________________________________________________ SERVICE INFORMATION............14-2 TROUBLESHOOTING.............. 14-2 REAR WHEEL ................. 14-3 REAR BRAKE ................14-4 REAR SHOCK ABSORBER............14-7 14-0 www.PlanDeGraissage.org...
Page 177 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER 2.7kg-m 1.2kg-m 4.0kg-m 2.5kg-m 0.6kg-m 11.0kg-m 14-1 www.PlanDeGraissage.org...
Page 178: Rear Wheel/Rear Brake/Rear
. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Item Standard (mm) Service Limit (mm) Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness Rear shock absorber spring free length 235.7 218.7 TORQUE VALUES Rear axle nut 11.0_ 13.0kg-m Rear shock absorber upper mount bolt 3.5_...
Page 179: Rear Wheel
. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Rear Axle Nut REAR WHEEL REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the rear axle nut to remove the rear wheel.
Page 180: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER REAR BRAKE Remove the rear wheel. (  14-3) Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limit: 95.5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below ＊...
Page 181 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Wear Indicator Plate Brake Arm Bolt Remove the brake arm bolt to remove the brake arm, wear indicator plate and felt seal. Remove the brake cam. Brake Arm Brake Cam Grease REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
Page 182 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Brake Cable Brake Arm Install the brake arm pin. Connect the brake cable and install the adjusting nut. Install the rear wheel. Adjust the rear brake lever free play. (  3-4) Adjusting Nut Brake Arm Pin 14-6 www.PlanDeGraissage.org...
Page 183: Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Upper Mount Bolt REAR SHOCK ABSORBER REMOVAL Remove the rear carrier. (  2-3) Remove the met-in box. (  2-3) Remove the air cleaner case. (  5-2) Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber.
Page 184 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Spring INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Rod Damper Rubber Measure the rear shock absorber spring free length.
Page 185 . REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then install the lower mount bolt. Torque: Upper Mount Bolt: 3.5_ 4.5kg-m Lower Mount Bolt: 2.4_ 3.0kg-m Install the frame body cover.
Page 186: Fuel Tank
. FUEL TANK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL TANK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 FUEL TANK REMOVAL ---------------------------------------------- 15-3 FUEL STRAINER INSPECTION ------------------------------------- 15-3 15-0 www.PlanDeGraissage.org...
Page 187: Fuel Tank
. FUEL TANK SCHEMATIC DRAWING Intake Manifold (Vacuum) 15-1 www.PlanDeGraissage.org...
Page 188: Service Information
. FUEL TANK SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing the fuel tank, keep sparks and flames away from the working area. • When removing the fuel tank, the remaining fuel in the tank must be lower than _ of the fuel tank capacity to avoid gasoline overflowing.
Page 189: Fuel Tank Removal
. FUEL TANK Tube to Fuel Filler Fuel Strainer FUEL TANK REMOVAL Remove the floor board. (  2-4) Remove the leg shield . (  2-5) Disconnect the fuel unit wire connector. Remove the fuel tube between the fuel tank and the fuel filler.
Page 190: Battery/Charging System
. BATTERY/CHARGING SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6 16-0 www.PlanDeGraissage.org...
Page 191: Battery/Charging System
. BATTERY/CHARGING SYSTEM CHARGING SYSTEM LAYOUT Battery Regulator/Rectifier Fuse A.C. Generator CHARGING CIRCUIT Wire Harness R Ignition Switch Fuse Battery Auto Bystarter 5. 9Ω 10.2Ω Regulator/ Rectifier 16-1 www.PlanDeGraissage.org...
Page 192: Service Information
. BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention •...
Page 193: Troubleshooting
. BATTERY/CHARGING SYSTEM SPECIAL TOOLS Universal holder Flywheel puller TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in ignition system •...
Page 194: Battery
. BATTERY/CHARGING SYSTEM BATTERY Remove the seat and met-in box. (  2-3) Remove the battery. First disconnect the battery negative (-) cable and then the positive (+) cable. When disconnecting the battery positive (+) cable, do not touch the frame with tool;...
Page 195: Charging System
. BATTERY/CHARGING SYSTEM CHARGING SYSTEM CURRENT TEST ＊ Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Red Wire Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.
Page 196: Regulator/Rectifier Inspection
. BATTERY/CHARGING SYSTEM RESISTOR INSPECTION Remove the frame front cover. (  2-3) Measure the resistance between the resistor B pink wire and ground. Measure the resistance between the resistor A green/black wire and ground. Resistances: Resistor A: 9.9_ 10.5Ω Resistor B: 5.6_ 6.2Ω...
Page 197 . IGNITION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4 CDI UNIT INSPECTION----------------------------------------------- 17-4 17-0 www.PlanDeGraissage.org...
Page 198: Ignition System
. IGNITION SYSTEM IGNITION SYSTEM LAYOUT CDI Unit Ignition Switch Spark Plug Pulser Coil A.C. Generator IGNITION CIRCUIT Ignition Switch Br/L Spark Plug Ignition Coil Pulser Coil A.C. Generator 17-1 www.PlanDeGraissage.org...
Page 199: Service Information
. IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. (  1-28) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. • If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts. Inspect the CDI unit with a CDI tester •...
Page 200: Spark Plug
. IGNITION SYSTEM SPARK PLUG For spark plug inspection and adjustment, refer to page ( 3-5). IGNITION COIL INSPECTION Remove the seat and met-in box. (  2-3) Remove the ignition coil Ignition Coil Spark Plug CDI Tester Special Coupler (KB7) IGNITION COIL PERFORMANCE TEST Test the ignition coil using a CDI tester.
Page 201: A.c. Generator Inspection
. IGNITION SYSTEM A.C. GENERATOR INSPECTION For A.C. generator removal/installation, refer to pages 9-3 and 9-5. Disconnect the pulser coil wire coupler. Measure the pulser coil resistance between the blue/yellow wire and ground. A.C. Generator Connector Pulser Coil Wire Coupler Resistance (20℃...
Page 202 . IGNITION SYSTEM RESISTANCE INSPECTION Measure the resistance between the terminals. Replace the CDI unit if the readings are not within the specifications in the table below. ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.
Page 203: Starting System
. STARTING SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER RELAY INSPECTION ------------------------------------ 18-3 18-0 www.PlanDeGraissage.org...
Page 204: Starting System
. STARTING SYSTEM STARTING SYSTEM LAYOUT Stop Switches Starter Relay Starter Button Starter Motor STARTING CIRCUI Starter Button Fuse Ignition Switch Stoplight Battery Rear Front Stop Switch Starter Motor 18-1 www.PlanDeGraissage.org...
Page 205: Service Information
. STARTING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 7-14. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 206: Starter Motor
. STARTING SYSTEM STARTER MOTOR STARTER MOTOR REMOVAL Disconnect the starter motor cable. Remove the two bolts attaching the starter motor and remove the starter motor. The installation sequence is the reverse of removal. Mounting Bolts Starter Motor Cable Starter Relay STARTER RELAY INSPECTION Remove the battery cover.
Page 207: Switches/Horn/Fuel Unit/Thermostatic
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5 THERMOSTATIC SWITCH ------------------------------------------- 19-6 TEMPERATURE GAUGE --------------------------------------------- 19-6 INSTRUMENTS--------------------------------------------------------- 19-7 LIGHTS ------------------------------------------------------------------ 19-8...
Page 208: Electrical Equipment Layout
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Headlight Stop Switches Dimmer Switch Turn Signal Switch Horn Button Instruments Headlight Switch Ignition Switch Starter Button Horn Auto Bystarter Fuel Unit Thermosensor 19-1 www.PlanDeGraissage.org...
Page 209: Service Information
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS • After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT Electric tester SPECIAL TOOL Fuel unit wrench TROUBLESHOOTING...
Page 210: Switches
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. (  2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Position LOCK ○ ○ ○ ○ Ignition Switch ○...
Page 211 19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN BUTTON INSPECTION Remove the frame front covers. (  2-5) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Color BR/L BR/L Position FREE PUSH ○...
Page 212: Horn Inspection
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS 12V Battery HORN INSPECTION Remove the front upper cover. (  2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
Page 213: Temperature Gauge
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS OIL METER INSPECTION Oil Meter Remove the met-in box. (  2-4) Remove the frame body cover. (  2-4) Disconnect the oil meter wire connectors and remove the oil meter. Keep the oil meter float at the lower position.
Page 214: Instruments
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Speedometer Cable INSTRUMENTS REMOVAL Remove the front upper cover. (  2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. Wire Couplers Screws Screws Remove the four instrument cover and leg shield screws.
Page 215: Lights
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Wire LIGHTS HEADLIGHT BULB REPLACEMENT Remove the front upper cover. (  2-5) Disconnect the headlight and turn signal light wire couplers. Remove the rubber boot from the bulb socket. Remove the bulb socket and replace the bulb. Install the bulb socket, aligning the bulb socket tab with the groove.
Page 216 . HIGH-SPEED TIRE __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HIGH-SPEED TIRE (TUBELESS TIRE) __________________________________________________________________________________ HIGH-SPEED TIRE CONSTRUCTION & FEATURES ------------ 20- 2 HIGH-SPEED TIRE MAINTENANCE PRECAUTIONS ----------- 20- 4 HIGH-SPEED TIRE REMOVAL/INSTALLATION ---------------- 20- 5 HIGH-SPEED TIRE REPAIR------------------------------------------ 20-16 20-0 www.PlanDeGraissage.org...
Page 217 . HIGH-SPEED TIRE HIGH-SPEED TIRE CON- STRUCTION & FEATURES Tread CONSTRUCTION INNER LINER Inner Tube A layer of rubber (inner liner) which replaces the inner tube is stuck to the inside wall of the high-speed tire. The inner liner is made of thick rubber, a material that high-pressure air can not Circle Boundary Tire Shoulder...
Page 218 . HIGH-SPEED TIRE TIRE FLANGE BEVEL ANGEL If the tire flange radius is smaller than the Tire flange bevel angle is wheel rim radius, the tire and wheel can be Tire Shape larger than rim bevel angle locked tightly. Take the advantage of tire bead bevel angle to enlarge tire bead so that the tire and rim can combine with each other precisely.
Page 219 Install the valve from the inner side of the rim and then pull it out through the rim valve hole with a special tool. ＊ • Use only the KYMCO recommended air-tight valve. HIGH-SPEED TIRE FEATURES •Air will not release quickly when a nail is inserted into the tire.
Page 220 . HIGH-SPEED TIRE PRECAUTIONS FOR HIGH SPEED TIRE STORAGE STORAGE METHODS If the space within the tire bead of a high-speed tire is narrower than the width of its rim, it is hard to install the tire to the rim and pump air into the tire.
Page 221 . HIGH-SPEED TIRE HIGH-SPEED TIRE REMOVAL/INSTALLATION In comparison with the tube-tire, the following points must be noticed when removing and installing a high- speed tire. •When removing the high-speed tire, avoid damaging the tire bead (special plastic seat), tire liner (internal anti- leak material) and rim flange (bead base).
Page 222 Valve core assembly tool Valve assembly tool Rim valve used for high- speed tire Valve core High-speed tire High-speed tire Model: KYMCO DINK50 Tire size: 110/70-12 (Front) 130/70-12 (Rear) Make sure to use KYMCO- recommend high-speed tire and rim valve. 20-6 www.PlanDeGraissage.org...
Page 223 . HIGH-SPEED TIRE REMOVAL METHODS  Use the valve core assembly tool to take the valve core out and bleed air from the tire. ＊ When removing the valve core, be careful that the high tire pressure may force out the valve core. ...
Page 224 . HIGH-SPEED TIRE Apply vegetable soapy water to the area between the rim and tire and install the rim protector at the rim side. Then insert the tire iron to pry off the tire bead from the rim. At this time, the tire bead at the back side of the valve is in the rim groove completely.
Page 225 . HIGH-SPEED TIRE  The procedure is the same as  and . If 1/3 of the tire bead is separated from the rim, the whole tire is easily taken off. When 1/2 of the tire bead is pried off the rim, the tire will be easily removed by using only one tire iron.
Page 226 . HIGH-SPEED TIRE Take out the rim from the tire. Check the rim valve for damage. Replace any faulty parts. ＊ When the tire is replaced, replace the valve as a set. RIM VALVE REMOVAL Cut the rim valve from it bottom. ＊...
Page 227 . HIGH-SPEED TIRE RIM AND TIRE INSPECTION RIM INSPECTION Check the rim and remove rust and rubber materials from the rim. Air leak will be caused by rim deformation or cracks. When the tire or rim has cracks, do not repair them and immediately replace with a new one.
Page 228 . HIGH-SPEED TIRE Put the wheel horizontally and put the rim protector on the rim. Use 2 tire irons to install the tire bead into the rim slowly (30_ 50mm). Use 2 tire irons to install the tire bead for the last 50_ 60mm part.
Page 229 . HIGH-SPEED TIRE Install the rim protector and insert 2 tire irons at an interval of 30mm to install the tire bead into the rim. Press to hold the installed part of tire bead by knees. After 1/2 of tire bead is installed, insert 2 tire irons at an interval of 40mm to finish the installation in order.
Page 230 . HIGH-SPEED TIRE If 50_ 60mm of the tire bead is not installed, use 2 tire irons to install the rest part of tire bead. Use the valve core installer to install the valve core. Apply vegetable soapy water to both sides of the tire bead.
Page 231 . HIGH-SPEED TIRE In order to ensure that the tire and the rim are well combined, raise the wheel and rotate it. Press around the tire by hand for several times to see if the tire is perfectly combined with the rim. Pump the tire up to the specified tire pressure.
Page 232 . HIGH-SPEED TIRE HIGH-SPEED TIRE REPAIR Repair the tire using the repair methods and repair agents recommended by the manufacturers. REPAIR PROCEDURES First remove the tire from the wheel. Find the crack and mark it. Take out foreign objects and check if the tire can be repaired.
Page 233 KYMCO Clean Air System (For EURO 2) The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn.
Page 234 YM CO EC HNIC AL NF ORMATI ON Model_ ALL MODEL (For EURO 2) Date: 8.JAN.04 Subject_ KYMCO Clean Air System (For EURO 2) NO.: KTI-04002 Secondary Air Suction System Diagram (2-stroke) www.PlanDeGraissage.org...

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