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DAELIM HISTORY 125 Service Manual

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  • Page 2 HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for the SL125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the SERVICE INFORMATION maintenance schedule (Section 3).
  • Page 3 8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
  • Page 4 SERVICE INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
  • Page 5 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
  • Page 6 SERVICE INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
  • Page 7 SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
  • Page 8 SERVICE INFORMATION •Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire •Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
  • Page 9 SERVICE INFORMATION •Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. •The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
  • Page 10 SERVICE INFORMATION •In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.
  • Page 11 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...
  • Page 12 SERVICE INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 1,965 mm OVERALL WIDTH 690 mm OVERALL HEIGHT 1,230 mm WHEEL BASE 1,350 mm DIMENSIONS SEAT HEIGHT 780 mm GROUND CLEARANCE 120 mm DRY WEIGHT 125 kg GROSS WEIGHT 255 kg TYPE Underbone FRONT SUSPENSION / STROKE Telescopic / 77mm REAR SUSPENSION / STROKE...
  • Page 13 SERVICE INFORMATION ITEM SPECIFICATIONS TYPE / VENTURI BORE CV type ( vacuum ) 24.2 mm MODEL MARK BDS 26 - 112 CHOKE TYPE Auto-bystarter MAIN JET # 95 CARBURETOR 1 and ½ trust out PILOT SCREW INITIAL SETTING FLOAT LEVEL 13 mm IDLE SPEED 1.800±100 ( rpm )
  • Page 14 SERVICE INFORMATION TORQUE VALUES ENGINE THREAD DIA ITEM Q’TY TORQUE VALUE REFERENCE (mm) OIL FILTER CAP 1.1 kgf·m OIL DRAIN PLUG BOLT 2.5 kgf·m VALVE ADJUST SCREW LOCK NUT 0.8 kgf·m CYLINDER HEAD BOLT 1.0 kgf·m FLYWHEEL BOLT 5.5 kgf·m DRIVE FACE NUT 7.5 kgf·m CLUTCH OUTER BOLT...
  • Page 15 SERVICE INFORMATION THREAD DIA ITEM Q’TY TORQUE VALUE REFERENCE (mm) SIDE STAND PIVOT NUT 4.5 kgf·m FRONT / REAR BRAKE CALIPER BRACKET BOLT 2.7 kgf·m FRONT / REAR BRAKE CALIPER BLEEDER VALVE 0.6 kgf·m FRONT / REAR BRAKE CALIPER SLIDE PIN 2.3 kgf·m FRONT / REAR BRAKE CALIPER BRACKET PIN BOLT Apply locking agent...
  • Page 16 SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or CAUTION Indicates dangerous area. Serious vehicle part damage may result if instruction WARNING accident may result if instructions are not are not followed.
  • Page 17 SERVICE INFORMATION WIRING DIAGRAM CABLE GUIDE A.P. WINKER RELAY SOCKET COMP. SPEEDOMETER LIGHTING S/W UNIT DIMMER S/W UNIT WINKER S/W UNIT HEAD PIPE THROTTLE CABLE SPEEDOMETER CABLE PRESS TO ATTACH THE RR. BRAKE HOSE HORN S/W UNIT THROTTLE CABLE SEL. SECTION TO THE PIPE CABLE GUIDE HAZARD S/W UNIT STARTER S/W UNIT...
  • Page 18 SERVICE INFORMATION MASTER CYLINDER ASS'Y FR. BRAKE HOSE SPEEDOMETER CABLE THROTTLE CABLE MAIN S/W SEAT LOCK CABLE WIRE HARNESS WIRE HARNESS REGULATE RECTIFIER CDI UNIT FUEL TANK SPEEDOMETER CABLE I/G. COIL TAIL LIGHT STARTER MOTOR CABLE HEADLIGHT TRUNK LAMP AIR CLEANER TRUNK LAMP S/W PARKING BRAKE CABLE RH.
  • Page 19 2. LUBRICATION · · · · · · 2-1 OIL PUMP · · · · · · · · · · · · · · · · · · 2-4 SERVICE INFORMATION TROUBLESHOOTING · · · · · · · · · · 2-2 RADIATOR·...
  • Page 20 LUBRICATION TROUBLESHOOTING Oil level low •Oil consumption. •External oil leaks. •Worn piston ring or incorrect piston ring installation. •Worn valve guide or seal. Oil contamination •Oil or filter not changed often enough. •Faulty head gasket. •Worn piston rings. Low or no oil pressure •Clogged oil orifice.
  • Page 21 LUBRICATION ENGINE OIL LEVEL INSPECTION UPPER LINE ● Erect the motorcycle on the main stand. PROPER LINE ● Warm up the engine to heat the engine oil to an LOWER LINE appropriate level. ● Stop the engine, and check the oil level line on the sight-glass installed on the LH.
  • Page 22 LUBRICATION OIL FILTER ELEMENT CHANGE ●Drain engine oil. (⇨2-3) ●Loosen the 3 flange bolts securing the oil filter cover, remove the oil filter cover. ●Remove the oil filter element and oil filter spring. OIL FILTER COVER ●Change the oil filter element with a new one. ELEMENT ●Check if the oil filter seal is in good condition.
  • Page 23 LUBRICATION OIL PUMP DISASSEMBLY ●Loosen the screw securing the oil pump plate. PUMP PLATE PUMP BODY INNER ROTOR ●Remove the oil pump body and the oil pump plate. ●Clean the oil pump body, inner and outer rotors with PUMP SHAFT fresh cleaning oil.
  • Page 24 LUBRICATION OIL PUMP ASSEMBLY ●Clean all parts with fresh cleaning oil. PUMP PLATE PUMP BODY INNER ROTOR PUMP SHAFT OUTER ROTOR ROLLER2.5x11.8 ●Install the inner and outer rotors to the pump body. ●Assemble the pump shaft with setting pin. INNER ROTOR OUTER ROTOR ●Install the oil pump plate to the pump body.
  • Page 25 LUBRICATION RADIATOR REMOVAL ●Remove the front cover. (⇨4-3) ●Remove the front wheel. (⇨12-5) ●Loosen the 2 oil bolts and the 4 drain cock packings from the main pipe bracket. ●Loosen the 3 flange bolts securing the radiator. FLANGE ●Remove the radiator. BOLT CAUTION •Be careful not to damage the radiator when removing it.
  • Page 26 LUBRICATION RADIATOR INSTALLATION ●Tighten the 3 radiator setting flange bolts to the main pipe bracket. FLANGE BOLT RADIATOR ●Tighten the drain cock packings and oil bolts. TORQUE VALUE : 3.2kgf·m ●Install the front wheel. (⇨12-9) ●Install the front cover. (⇨4-3) CAUTION •Pay attention not to turn over the vehicle.
  • Page 27 LUBRICATION LUBRICATION POINTS Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it. FRONT BRAKE LEVER PIVOT THROTTLE GRIP STEERING HEAD BEARING...
  • Page 28 MEMO...
  • Page 29 3. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION · · · · · · 3-1 BRAKE PAD/SHOE· · · · · · · · · · 3-7 MAINTENANCE SCHEDULE ·· 3-3 BRAKE SYSTEM · · · · · · · · · · · · 3-7 FUEL LINE (FUEL TUBE) ·...
  • Page 30 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG 1.1kgf·m CYLINDER HEAD COVER BOLTS 1.0kgf·m VALVE ADJUSTING NUTS 1.1kgf·m TIMING HOLE CAP 0.6kgf·m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE...
  • Page 31 INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE ● Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN ●...
  • Page 32 INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) ● Remove the luggage box.(⇨4-4) FUEL PUMP ● Check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. FUEL TUBE THROTTLE GRIP OPERATION ●...
  • Page 33 INSPECTIONS / ADJUSTMENTS ● Be sure to allow the element to dry thoroughly before applying oil. Otherwise, the oil will be diluted by the and the filtering ability of the filter will be much less effective. ● Spread clean #80~90 gear oil on the element, rubbing inthoroughly over the surface with both hands, and then squeeze out any excess oil.
  • Page 34 INSPECTIONS / ADJUSTMENTS ● Loosen the lock nut with a valve wrench, and set valve ADJUSTER FEELER clearance to a prescribed level by turning the adjusting WRENCH GAUGE screw with a valve adjusting wrench. ● After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut.
  • Page 35 INSPECTIONS / ADJUSTMENTS BRAKE FLUID REAR FRONT MASTER CYLINDER MASTER CYLINDER ● Loosen the 3 screen setting screws securing the wind screen. ● Remove the oil cup cap covers. ● Check the oil level inside the front/rear brake reservoirs. If the oil level is near the lower limit line, remove the reservoir diaphragms and fill DOT 3 and DOT 4 brake fluid to the top limit line.
  • Page 36 INSPECTIONS / ADJUSTMENTS BRAKE LEVER FREE PLAY ● Check the free play after pulling the lever. FRONT : 10~20mm REAR : 10~20mm PARKING BRAKE FREE PLAY ADJUSTMENT ● Turn the adjuster nut to adjust the free play. ● After initial adjustment, check the operation of the parking brake light switch.
  • Page 37 INSPECTIONS / ADJUSTMENTS ● Check the side stand ignition cut-off switch : -Put the side stand up. -Start the engine. -Lower the side stand. The engine should stop as you put the side stand down. ● If there is a problem with the system, check the side stand switch.
  • Page 38 INSPECTIONS / ADJUSTMENTS WHEELS/TIRES NOTE •Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE ㎏ /㎠...
  • Page 39 4. EXTERNAL PARTS SERVICE INFORMATION · · · · 4-1 EXTERNAL PARTS REMOVAL / INSTALLATION · · 4-3 MAINTENANCE PRECEDURE · · · · 4-2 MUFFLER · · · · · · · · · · · · · · · · 4-12 SERVICE INFORMATION NOTE ●...
  • Page 40 EXTERNAL PARTS MAINTENANCE PROCEDURE NAMES OF FRAME COVERS 22 14 ● This chart shows arrows connected in the order of disassembling covers. ⑬ FLOOR SIDE ⑱ WIND SCREEN ① FRONT COVER ⑤ SEAT COVER ⑥ LUGGAGE BOX ⑲ FRONT HANDLE ②...
  • Page 41 EXTERNAL PARTS FRONT COVER ● Loosen the 4 special screws securing the inner box. ● Loosen the special screw securing the front of the front cover. ● Loosen the 2 special screws securing the front under cover. ● Draw the upper part of the front cover to remove it. ●...
  • Page 42 EXTERNAL PARTS FRONT UNDER COVER ● Remove the front fender. (⇨4-3) ● Remove the front wheel. ( ⇨12-5) ● Loosen the 4 tapping screws securing the inner box. ● Remove the floor mat, and loosen the 2 special screws securing the front of the floor panel. ●...
  • Page 43 EXTERNAL PARTS CENTER COVER ● Release the seat lock by turning the main switch key to open the seat. ● Loosen the flange bolt securing the frame, and remove the hinge pin, and then remove the seat. ● Loosen the plug maintenance cover setting special SEAT screw securing the center cover, remove the plug maintenance cover.
  • Page 44 EXTERNAL PARTS REAR CARRIER/BACK REST ● Remove the rear center cover. (⇨4-5) BACK REST ● Loosen the 2 flange bolts(R/L) securing the frame. ● Loosen the 2 flange bolts(R/L) securing the rear carrier. FLANGE BOLT ● Remove the rear carrier. SPECIAL BOLT ●...
  • Page 45 EXTERNAL PARTS REAR COMBINATION LIGHT ● Release the seat lock by turning the main switch key to open the seat. ● Remove the seat. ● Remove the following parts. -Luggage box (⇨4-4) -Center cover (⇨4-5) -Rear center cover (⇨4-5) -Rear carrier (⇨4-6) -Back rest (⇨4-6) -Body cover (⇨4-6) ●...
  • Page 46 EXTERNAL PARTS FLOOR PANEL ● Release the seat lock by turning the main switch key to open the seat. FLOOR MAT ● Remove the following parts. -Seat and center cover (⇨4-5) -Rear carrier and back rest (⇨4-6) -Floor mat -Body cover (⇨4-6) -RH./LH.
  • Page 47 EXTERNAL PARTS INNER BOX / INNER BOX LID ● Remove the following parts. -Front cover (⇨4-3) -Luggage box (⇨4-4) -Center cover (⇨4-5) -Rear center cover (⇨4-5) -Rear carrier and back rest (⇨4-6) -Body cover (⇨4-6) INNER BOX -Floor side cover (⇨4-7) -Floor panel (⇨4-8) ●...
  • Page 48 EXTERNAL PARTS WIND SCREEN / FRONT HANDLE COVER ● Loosen the 3 screen setting screws securing the front handle cover. ● Pulling the cover to the under slightly and remove the wind screen from the front handle cover groove. ● Loosen the 4 tapping screws (FR./RR.) securing the rear handle cover.
  • Page 49 EXTERNAL PARTS REAR WHEEL MUD GUARD ● Loosen the washer bolt securing the LH. crankcase. ● Loosen the washer bolt securing the RH. crankcase. ● Loosen the washer bolt securing EX. muffler bracket. ● Remove the rear wheel mud guard. ●...
  • Page 50 EXTERNAL PARTS MUFFLER EX. MUFFLER REMOVAL ● Loosen the 3 cap nuts securing the EX. pipe comp. ● Loosen the flange bolt securing the upper part of the RH. crankcase cover. FLANGE BOLT ● Loosen the rear brake hose setting bolt. ●...
  • Page 51 MEMO...
  • Page 52 FUEL SYSTEM FUEL TANK FUEL STRAINER FUEL PUMP CARBURETOR...
  • Page 53 5. FUEL SYSTEM AIR CLEANER · · · · · · · · · · · · · · 5-4 · · · · 5-1 SERVICE INFORMATION CARBURETOR · · · · · · · · · · · · · · 5-4 TROUBLESHOOTING ·...
  • Page 54 FUEL SYSTEM TROUBLESHOOTING Back firing The vehicle does not start. ● Ignition system is damaged. ● No gasoline in fuel tank. ● Mixture is too lean. ● Fuel is not coming out of carburetor. ● Too much fuel is flowing into cylinder. ●...
  • Page 55 FUEL SYSTEM FUEL TANK REMOVAL WARNING FUEL PUMP •Gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. ● Release the seat lock by turning the main switch key to FUEL TUBE FUEL TANK open the seat.
  • Page 56 FUEL SYSTEM AIR CLEANER FLANGE BOLT REMOVAL ● Remove the luggage box. (⇨4-4) ● Remove the center cover. (⇨4-5) AIR CLEANER ● Loosen the intake coupling band B securing the COUPLING carburetor, remove the air cleaner from the carburetor. BAND A ●...
  • Page 57 FUEL SYSTEM CARBURETOR DISASSEMBLY SCREW ● Remove the drain tube and air band hose. ● Loosen the 4 diaphragm cover setting screws. AIR BAND HOSE DRAIN TUBE ● Remove the diaphragm cover. ● Remove the diaphragm spring, diaphragm assembly. DIAPHRAGM DIAPHRAGM COVER DIAPHRAGM SPRING ●...
  • Page 58 FUEL SYSTEM FLOAT CHAMBER/FLOAT/JET FLOAT BODY ASS'Y DISASSEMBLY ● Loosen the 4 screws securing the float body. SCREW SCREW ● Remove the float pin, float, and float value. FLOAT VALVE FLOAT ● Check the float valve and valve seat for scores, scratches, clogging and damage.
  • Page 59 FUEL SYSTEM CARBURETOR CLEANING CARBURETOR BODY ● After removing all parts, blow open air and fuel passages in the carburetor body with compressed air. CAUTION •Cleaning the air and fuel passages with a piece of wire will damage the carburetor body or fuel pump. MAIN JET SLOW JET PLUNGER ASS'Y...
  • Page 60 FUEL SYSTEM FLOAT LEVEL INSPECTION ● Install the float valve, float, float pin. ● Measure the float level with the float level gauge. FLOAT LEVEL : 13 mm TOOL : FLOAT LEVEL GAUGE ● If the level is out of specification and the float arm lip can be bent, adjust the float level by bending the lip.
  • Page 61 FUEL SYSTEM CABURETOR INSTALLATION ● Install the carburetor to the carburetor insulator. ● Tighten the carburetor insulator band screw. ● Tighten the setting screw securing the carburetor and set plate. ● Install the fuel tube to the carburetor. ● Install the wiring coupler of the auto bystarter. ●...
  • Page 62 FUEL SYSTEM PILOT SCREW ADJUSTMENT PILOT SCREW THROTTLE ADJUSTMENT STOP SCREW ● Remove the luggage box. (⇨4-4) ● Remove the pilot jet rubber. ● Remove the plug maintenance cover. (⇨4-5) ① Turn the pilot screw clockwise until it seats lightly, then back it out to the specification given (1½).
  • Page 63 6. ENGINE REMOVAL SERVICE INFORMATION· · · · · · · · · · 6-1 ENGINE REMOVAL · · · · · · · · · · · · · · · · 6-2 SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness.
  • Page 64 ENGINE REMOVAL ENGINE REMOVAL ● Drain the engine oil. ● Release the seat lock by turning the main switch key to open the seat. ● Remove the following parts. -Luggage box (⇨4-4) -Center cover (⇨4-5) -Air cleaner (⇨5-4) -Carburetor (⇨5-4) ●...
  • Page 65 ENGINE REMOVAL ● Remove the RH./LH. radiator hose, remove the RH./LH. radiator hose from the frame setting clamp. RADIATOR HOSE ● Loosen the U-nut securing the engine hanger. ● Loosen the rear cushion lower bolt. ● Remove the engine. (with the rear swing arm and rear wheel attached) ●...
  • Page 66 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANKCASE COVER...
  • Page 67 7. LH. CRANKCASE COVER/KICK STARTER /CONTINUOUSLY VARIABLE TRANSMISSION INFORMATION· · · · · · 7-1 DRIVE BELT· · · · · · · · · · · · · · · · 7-6 SERVICE TROUBLESHOOTING· · · · · · · · 7-1 MOVABLE DRIVE FACE·...
  • Page 68 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANKCASE COVER REMOVAL ● Remove the 12 flange bolts securing LH. crankcase. KICK STARTER LH. CRANKCASE COVER PEDAL ● Remove the LH. crankcase cover. ● Remove the gasket and dowel pin. DOWEL PIN INSTALLATION ●...
  • Page 69 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION KICK STARTER REMOVAL ● Remove the LH. crankcase cover. (⇨7-2 ) LH. CRANKCASE COVER ● Rotate the kick starter spindle using the kick starter pedal, remove the kick driven gear and 13mm thrust washer. KICK DRIVEN GEAR SET ●...
  • Page 70 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● After removing the kick starter spindle from the return spring, remove the kick starter spindle from the LH. crankcase cover. KICK STARTER SPINDLE ● Remove the kick starter return spring, kick starter bush from the LH.
  • Page 71 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION KICK STARTER INSTALLATION KICK STARTER RETURN SPRING ● Install the kick spindle bush, spring in the LH. crankcase cover. ● Install the kick starter spindle, then install the return spring to the kick starter spindle. KICK STARTER SPINDLE ●...
  • Page 72 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE BELT REMOVAL ● Remove the LH. crankcase cover. (⇨7-2 ) ● Hold the clutch outer using the universal holder and remove the nut. ● Remove the clutch outer. TOOL: UNIVERSAL HOLDER CAUTION ·Use the special tool when loosening the lock nut. UNIVERSAL Holding the rear wheel or rear brake will damage the HOLDER...
  • Page 73 ● Replace the belt if the service limit is exceeded. SERVICE LIMIT : 20.5mm NOTE ·Use only a genuine DAELIM replacement drive belt. ·Do not get oil or grease on the drive belt or pulley faces. Clean off any grease or oil before reinstalling.
  • Page 74 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● Reinstall the driven pulley on the drive shaft with the DRIVE FACE drive belt attached. ● Hold the clutch outer using the universal holder. Tighten the nut to the specified torque. TORQUE VALUE : 5.0-6.0 kgf·m TOOL : UNIVERSAL HOLDER ●...
  • Page 75 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION MOVABLE DRIVE FACE INSPECTION WEIGHT ROLLER ● The weight rollers push on the movable drive face (by centrifugal force); worn or damaged weight rollers will interfere with this force. ● Check the rollers for wear or damage and replace as necessary.
  • Page 76 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● Install the movable drive face on the crank shaft. BOSS MOVABLE DRIVE FACE ● Squeeze the drive belt into the drive face groove and pull the drive belt over the drive face shaft. DRIVE BELT ●...
  • Page 77 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY REMOVAL ● Remove the LH. crankcase cover. ( 7-2) ) X h @ ) X ? g @ V / X g @ ? V / X ? f @ @ @ @ @ @ @ @ @ @ @ ? ? V / X f @ ? h f V / X ? e @ ? h f ? V / X e N 1 e...
  • Page 78 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● Remove the seal collar from the driven pulley. ● Remove the guide pins and guide pin rollers and the movable driven face. ● Remove the O-ring and oil seals from the movable driven face ●...
  • Page 79 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH / DRIVEN PULLEY INSPECTION Driven Face Bearing Inspection ● Check the inner bearing oil seal (if installed) for damage; replace as necessary. ● Check the needle bearing for damage or excessive play and replace as necessary. ●...
  • Page 80 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● Check the following; -Movable driven face for damage or excessive wear. -Guide pin groove for damage or deformation. ● Replace damaged or worn parts as necessary. ● Measure the I.D. of the movable driven face; replace if the service limit is exceeded.
  • Page 81 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH / DRIVEN PULLEY ASSEMBLY ● Install new oil seals and O-rings on the movable driven pulley face. ● Install the movable face on the driven pulley face. ● Install the guide pins, or guide pins and guide pin rollers. ●...
  • Page 82 LH. CRANKCASE COVER/KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY INSTALLATION ● Install the clutch / driven pulley and drive belt onto the drive shaft. ● Install the drive belt. ( 7-6) ) X h @ ) X ? g @ V / X g @ ? V / X ? f @ @ @ @ @ @ @ @ @ @ @ ? ? V / X f @ ? h f V / X ? e...
  • Page 83 MEMO...
  • Page 84 A.C GENERATOR / STARTER CLUTCH STATOR COMP FLYWHEEL COOLING FAN RH. SHROUD...
  • Page 85 8. A.C GENERATOR / STARTER CLUTCH SERVICE INFORMATION · · · · 8-1 RH. CRANKCASE COVER · · · · · · 8-4 SHROUD· · · · · · · · · · · · · · · · · · 8-2 STARTER REDUCTION GEAR ·...
  • Page 86 A.C GENERATOR / STARTER CLUTCH SHROUD RH. SHROUD REMOVAL ● Remove the following parts. -Luggage box (⇨4-5 ) -Center cover (⇨4-5 ) -Engine (⇨6-2 ) ● Loosen the RH. shroud 4 flange bolts and 4 tapping screws. LH. SHROUD ● Remove the RH. shroud. ●...
  • Page 87 A.C GENERATOR / STARTER CLUTCH ● Install the universal holder on the flywheel. ● If the universal holder connot be used, remove the LH. crankcase cover at the left side of the crankshaft, and FLANGE NUT hold the drive face with the drive face holder. ●...
  • Page 88 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR INSTALLTION ● Install the stator to the RH. crankcase cover. ● Clean the tapered portion of the crankshaft. ● Clean the inside part of the flywheel. SCREW ● Check the woodruff key, install the flywheel by aligning the groove with the woodruff key.
  • Page 89 A.C GENERATOR / STARTER CLUTCH ● Loosen the 9 RH. crankcase cover setting bolts. ● Remove the RH. crankcase cover. ● Remove the gasket and dowel pin. DOWEL PIN ● Remove the RH. crankcase cover oil seal. RH. CRANKCASE COVER ●...
  • Page 90 A.C GENERATOR / STARTER CLUTCH STARTER REDUCTION GEAR INSTALLATION REDUCTION GEAR SHAFT ● Install the starter reduction gear and shaft. ● Remove the gasket residues from the RH. crankcase. ● Install a new gasket and dowel pin. ● Tighten the RH. crankcase cover with setting bolts. ●...
  • Page 91 A.C GENERATOR / STARTER CLUTCH ● Remove the washer. ● Remove the starter driven gear and starter clutch. STARTER CLUTCH WASHER ● Check the starter driven gear and starter clutch for STARTER CLUTCH proper operation. ● Remove the starter clutch. STARTER CLUTCH INSPECTION ●...
  • Page 92 A.C GENERATOR / STARTER CLUTCH STARTER CLUTCH INSTALLATION ● Install the starter oneway clutch set, starter driven gear and needle bearing to the starter clutch assembly. ● Install the starter clutch to the RH. crankshaft. NOTE ·When installing the starter clutch, match it with the groove accurately STARTER ONEWAY CLUTCH SET ●...
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  • Page 94 CYLINDER HEAD / VALVES CAM COVER PLATE IN. VALVE ROCKER ARM CAM SHAFT HOLDER EX. VALVE ROCKER ARM CAM SHAFT COMP INLET VALVE EX. VALVE CARBURETOR INSULATOR CYLINDER HEAD COMP CYLINDER HEAD GASKET...
  • Page 95 9. CYLINDER HEAD / VALVES INFORMATION· · · · 9-1 VALVES · · · · · · · · · · · · · · · · · · 9-6 SERVICE TROUBLESHOOTING· · · · · · · · 9-2 VALVE GUIDES·...
  • Page 96 CYLINDER HEAD / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 37° (21.5mm) EX 37° (18.5mm) IN 45° (22.0mm) EX 45° (22.0mm) IN 55° (20.0mm) EX 55° (20.0mm) TROUBLESHOOTING Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test, or by tracing noises to the top-end with a sounding rod or stethoscope.
  • Page 97 CYLINDER HEAD / VALVES CAMSHAFT REMOVAL ● Remove the luggage box. (⇨4-4 ) ● Remove the center cover. (⇨4-5 ) ● Loosen the cylinder head cover bolts, remove the cover. ● Remove the shroud grommet B of the fan cover. NOTE ·The camshaft can be maintained without removing the engine.
  • Page 98 CYLINDER HEAD / VALVES ● Remove the cam chain from the camshaft. NOTE ·Take precautions not to allow the cam chain to drop into the crankcase. CAM CHAIN ● Remove the camshaft. ● Insert the 6mm bolt into the rocker arm shaft, and pulling bolts to remove the rocker arm shaft.
  • Page 99 CYLINDER HEAD / VALVES ● Manually turn the camshaft bearing outer race, and check if it turns smoothly. ● Check the bearing for wear or damage. CAUTION ·Be sure to check the valve clearance. CAMSHAFT BEARING CYLINDER HEAD REMOVAL ● Remove the engine from the frame. (⇨6-2 ) ●...
  • Page 100 CYLINDER HEAD / VALVES ● Remove the valve spring, valve cotter, retainer, spring and valve. Using the valve spring compressor. TOOL : VALVE SPRING COMPRESSOR NOTE ·To prevent the loss of tension, do not compress the valve spring more than necessary. ·Mark the disassembled parts so that they can be reassembled into the original position later.
  • Page 101 CYLINDER HEAD / VALVES VALVE GUIDES INSPECTION ● Insert the valve guide reamer from the combustion VALVE GUIDE chamber side and ream the guide to remove any carbon REAMER build-up before measuring the guide. NOTE ·Take care not to tilt or lean the reamer in the guide while reaming.
  • Page 102 CYLINDER HEAD / VALVES ● Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. TOOL : VALVE GUIDE DRIVER VALVE GUIDE CAUTION DRIVER ·Avoid damaging the head when driving the valve guide out.
  • Page 103 CYLINDER HEAD / VALVES ● Remove the valve and inspect the valve seat face. ● The valve seat contact should be within the specified width and evenly all around the circumference. If the valve seat width is not within specification, reface the valve seat.
  • Page 104 CYLINDER HEAD / VALVES ● Using a 55 degree cutter, remove the bottom ¼ of the old seat. 55° ● Using a 45 degree cutter, cut the seat to the proper width. SEAT WIDTH 45° ● If the contact area is too high on the valve, the seat must be lowered using a 37 degree flat cutter.
  • Page 105 CYLINDER HEAD / VALVES ● After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. NOTE ·Do not excessively press and turn the valve to set it as it may cause damage.
  • Page 106 CYLINDER HEAD / VALVES ● Tap the valve stems gently with a soft hammer to firmly seat the cotters. CAUTION ·Take necessary precautions not to damage the valve. ● Apply engine oil to the new O-ring, and assemble it to the carburetor insulator groove.
  • Page 107 CYLINDER HEAD / VALVES CAMSHAFT ASSEMBLY IN. VALVE EX. VALVE ● Apply engine oil to the rocker arm shaft, and assemble ROCKER ARM ROCKER ARM the rocker arm to the camshaft holder. EX. ROCKER IN. ROCKER CAM SHAFT ARM SHAFT HOLDER ARM SHAFT ●...
  • Page 108 CYLINDER HEAD / VALVES ● Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. ● Assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head.
  • Page 109 CYLINDER HEAD / VALVES ● Fix the tensioner shaft with a hard clip. CAM CHAIN TENSIONER LIFTER ● Assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. ● Tighten the tensioner mounting bolts. TORQUE VALUE : 1.2 kgf ·m CLIP ●...
  • Page 110 CYLINDER / PISTON CYLINDER TOP RING SECOND RING OIL RING CYLINDER GASKET PISTON 10-0...
  • Page 111 10. CYLINDER / PISTON SERVICE INFORMATION · · · · · · 10-1 PISTON / PISTON RING · · · · 10-3 TROUBLESHOOTING· · · · · · · · 10-1 CYLINDER INSTALLATION · · 10-5 CYLINDER· · · · · · · · · · · · · · · · · · 10-2 SERVICE INFORMATION GENERAL SAFETY ●...
  • Page 112 CYLINDER / PISTON CYLINDER REMOVAL ● Remove the engine from the frame. (⇨6-2 ) ● Remove the EX. pipe. (⇨4-12 ) ● Remove the camshaft. (⇨9-3 ) ● Remove the cylinder head. (⇨9-5 ) ● Remove the cam chain guide from the cylinder. ●...
  • Page 113 CYLINDER / PISTON WARPAGE INSPECTION FEELER GAUGE ● Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT : 0.02 mm NOTE STRAIGHT ·Any clearance between the cylinder and head due to EDGE...
  • Page 114 CYLINDER / PISTON ● Insert the piston ring into the bottom of the cylinder squarely, using the piston. ● Measure the end gap using a feeler gauge. Replace the ring if the service limit is exceeded. NOTE ·Always replace piston ring as a set. SERVICE LIMIT : TOP / SECOND : 0.50 mm FEELER GAUGE OIL RING (SIDE RAIL) : 1.10 mm...
  • Page 115 CYLINDER / PISTON PISTON / PISTON RING INSTALLATION ● Clean the piston heads, ring lands and skirts. ● Carefully install the piston rings onto the piston with MARK the markings facing up. NOTE ·Be careful not to damage the piston and rings during assembly.
  • Page 116 CYLINDER / PISTON ● Install new piston pin clips. CAUTION ·Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. PISTON PIN NOTE ·Take care not to drop the piston pin clip into the crankcase.
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  • Page 118 TRANSMISSION/CRANKSHAFT/CRANK CASE RH. CRANKCASE LH. CRANKCASE CRANKSHAFT 11-0...
  • Page 119 11. TRANSMISSION/CRANKSHAFT/CRANKCASE INFORMATION· · · · · · · · 11-1 CRANKSHAFT REMOVAL· · · · · · 11-7 SERVICE TROUBLESHOOTING · · · · · · · · · · 11-2 TRANSMISSION BEARING · · · · · · 11-8 TRANSMISSION ·...
  • Page 120 TRANSMISSION/CRANKSHAFT/CRANK CASE TORQUE VALUE CRANK CASE BOLT 1.0kg-m TOOLS -UNIVERSAL BEARING PULLER -BEARING REMOVER SET -REMOVER ASSEMBLY -REMOVER SHAFT -REMOVER HEAD -SLIDING WEIGHT -ASSEMBLY SHAFT TROUBLESHOOTING Engine Noise ● Connecting rod big and small ends loose. ● Crank pin bearing loose. Engine started but unable to move out ●...
  • Page 121 TRANSMISSION/CRANKSHAFT/CRANK CASE TRANSMISSION DISASSEMBLY ● Loosen the drain bolt, drain the mission oil. ● Remove the LH. crankcase cover. (⇨7-2 ) ● Remove the continuously variable transmission. (⇨SECTION 7 ) ● Remove the EX. muffler. (⇨4-12 ) ● Remove the rear swing arm. (⇨13-8 ) ●...
  • Page 122 TRANSMISSION/CRANKSHAFT/CRANK CASE ● Remove the final shaft and the counter shaft comp. FINAL SHAFT COUNTER SHAFT TRANSMISSION INSPECTION ● Check the drive shaft for wear or damage. DRIVE SHAFT ● Check the final shaft for wear or damage. FINAL SHAFT ●...
  • Page 123 TRANSMISSION/CRANKSHAFT/CRANK CASE TRANSMISSION BEARING INSPECTION ● Check that the bearing outer race fits the case tightly without play. ● Turn the inner race and check that the bearing turns smoothly and quietly. ● Replace the bearings if necessary. BEARING ● Install the bearing to the case with special tools. OUTER OUTER TOOLS : DRIVE HANDLE A...
  • Page 124 TRANSMISSION/CRANKSHAFT/CRANK CASE ● Install a new gasket and dowel pin. ● Tighten the transmission cover with the setting bolts. ● Install the following parts. -Rear wheel (⇨13-3 ) -Rear swing arm (⇨13-8 ) -Rear brake caliper (⇨14-6 ) -EX. muffler (⇨ 4-12 ) -Continuously variable transmission (⇨SECTION 7 ) OIL CHECK BOLT -RH.
  • Page 125 TRANSMISSION/CRANKSHAFT/CRANK CASE ● Remove the transmission bleeder tube. ● Remove the RH./LH. radiator hose from the RH. crankcase. ● Face the LH. crankcase downward, and remove the RH. RH. CRANKCASE crankcase from the LH. crankcase while tapping a few places on the LH. crankcase with a plastic hammer. NOTE ·Be careful not to distort the mating surface of the crank case during removal.
  • Page 126 TRANSMISSION/CRANKSHAFT/CRANK CASE CRANKSHAFT INSPECTION DIAL MEASURING ● Place the crankshaft on a stand or V-block, and measure POINT GAUGE the crankshaft runout using dial gauge. SERVICE LIMIT : RIGHT : 0.1 mm LEFT : 0.1 mm ● Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big FEELER GAUGE end as shown.
  • Page 127 TRANSMISSION/CRANKSHAFT/CRANK CASE TRANSMISSION BEARING REPLACEMENT BEARING REMOVER SET LH. crankcase ● Use special tools to remove the drive shaft bearing. TOOLS : BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD ● Remove the final shaft bearing and oil seal. ● Remove the countergear bearing. ●...
  • Page 128 TRANSMISSION/CRANKSHAFT/CRANK CASE CRANKCASE INSTALLATION ● Install the dowel pins and a new gasket. DOWEL PIN ● Install the cam chain to the LH. crankcase. LH. CRANKCASE ● Install the RH. crankcase to the LH. crankcase. NOTE RH. CRANKCASE ·Make sure that the gasket is completely attached without any clearance.
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  • Page 130 FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE STEERING STEM FORNT FORK FRONT DISK FORNT TIRE FRONT CASTING WHEEL 12-0...
  • Page 131 12. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION· · · · · · · · 12-1 FRONT WHEEL · · · · · · · · · · · · 12-5 TROUBLESHOOTING· · · · · · · · · · 12-2 FRONT FORK ·...
  • Page 132 FRONT WHEEL/FRONT FORK/STEERING TROUBLESHOOTING Hard steering ● Steering bearing adjustment nut too tight. ● Faulty steering stem bearings. ● Damaged steering stem bearings. ● Insufficient tire pressure. Steers to one side or does not track straight ● Unevenly adjusted right and left shock absorbers. ●...
  • Page 133 FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE FRONT HANDLE COVER REMOVAL ● Remove the following parts. -Back mirror -Front cover (⇨4-3 ) -Wind screen (⇨4-10 ) -Front handle cover (⇨4-10 ) -Remove the speedometer cable from the speedometer. -Rear handle cover (⇨4-10 ) ●...
  • Page 134 ·Check that the throttle grip moves smoothly. ·Adjust the throttle grip free play. (⇨3-4 ) ● Apply DAELIM Bond A to the inside surface of the grip and to the clean surface of the left handle bar. Wait 3~6 minutes and install the grip.
  • Page 135 FRONT WHEEL/FRONT FORK/STEERING ● Install the winker relay. FR/RR. MASTER CYLINDER ● Install the front / rear brake hose, speedometer cable, throttle cable to the handle cable guide. ● Install the rear handle cover. (⇨4-10 ) ● Install the front top cover. ●...
  • Page 136 FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL INSPECTION ● Check the front axle for deflection. Place the front axle on a V-block, and measure deflection with a dial gauge. SERVICE LIMIT : 0.2mm FRONT AXLE ● Place the front wheel on an inspection stand. Slowly turn the wheel, and check the rim for wobbles with a dial gauge.
  • Page 137 FRONT WHEEL/FRONT FORK/STEERING ● Remove the front brake collar A. RH. SIDE COLLAR ● Remove the dust seal and brake disk. ● Check the disk for defects. (⇨14-11 ) SPECIAL FLANGE BOLT BRAKE DISK DUST SEAL WHEEL BEARING REPLACEMENT ● Install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance BEARING collar.
  • Page 138 FRONT WHEEL/FRONT FORK/STEERING SPEEDOMETER GEAR REPLACEMENT ● Remove the speedometer gear and washer from the speedometer gear box. ● Check the gear for wear or damage. ● Install the washer. ● Apply grease to the speedometer gear prior to assembling. SPEEDOMETER GEAR BOX SPEEDOMETER GEAR FRONT BRAKE DISK FRONT TIRE...
  • Page 139 FRONT WHEEL/FRONT FORK/STEERING ● Align the wheel hub tangs with the slots of the speedometer gear retainer, and assemble the speedometer gear box seal. GEAR BOX RETAINER ● Apply grease to the dust seal rim. ● Install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box.
  • Page 140 FRONT WHEEL/FRONT FORK/STEERING FRONT FORK REMOVAL ● Remove the following parts. -Front cover (⇨4-3 ) -Front brake caliper (⇨14-6 ) -Front fender (⇨4-3 ) -Front wheel (⇨12-5 ) AXLE NUT ● When removing the front fork, loosen the fork pipe bolt lightly.
  • Page 141 FRONT WHEEL/FRONT FORK/STEERING NOTE ·If the socket bolt turns idle but cannot be removed, temporarily assemble the spring and the fork tube cap bolt first. VISE ·Hold the bottom case firmly with a vise, taking precautions not to distort or damage it. BRACKET ●...
  • Page 142 FRONT WHEEL/FRONT FORK/STEERING ● Remove the fork pipe from the bottom case. ● Remove the piston and rebound spring from the fork pipe. BOTTOM CASE FORK PIPE FRONT FORK INSPECTION ● Place the fork spring on a level place, and measure the free length.
  • Page 143 FRONT WHEEL/FRONT FORK/STEERING ● Wrap the bottom case with a piece of cloth, and fix it to the vise. ● Apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. TORQUE VALUE : 2.0kgf·m NOTE ·When a vise is used to hold the bottom case, do not SOCKET...
  • Page 144 FRONT WHEEL/FRONT FORK/STEERING ● Assemble the springs to the fork pipe. NOTE ·Install the spring with the smaller pitch side facing BOTTOM downward. FORK SPRING REBOUND SPRING ● Assemble the fork bolt to the fork pipe. FORK PIPE CAP BOLT FRONT FORK INSTALLATION ●...
  • Page 145 FRONT WHEEL/FRONT FORK/STEERING STEERING STEM FRONT COVER REMOVAL ● Remove the following parts. - Back mirror - Front cover (⇨4-3 ) - Wind screen (⇨4-10 ) - Front handle cover (⇨4-10 ) - Rear handle cover (⇨4-10 ) - Steering handle (⇨12-3 ) - Front caliper (⇨14-6 ) - Front fender (⇨12-3 ) - Front wheel (⇨12-5 )
  • Page 146 FRONT WHEEL/FRONT FORK/STEERING ● Remove the top cone race, upper ball assembly, steering stem. NOTE ·Place a shop towel under the steering stem to catch the steel balls. TOP CONE RACE UPPER BALL ASS'Y ● Check the upper ball assembly, top cone race for damage or abnormal wear and replace as necessary.
  • Page 147 FRONT WHEEL/FRONT FORK/STEERING ● Remove the steering top ball race from the head pipe. ● Remove the steering bottom ball race from the steering TOP THREAD stem. TOP CONE RACE UPPER BALL ASS'Y BALL RACE NOTE UNDER BALL ASS'Y BOTTOM CONE RACE ·Check all of the races and balls for damage or DUST SEAL HEAD PIPE...
  • Page 148 FRONT WHEEL/FRONT FORK/STEERING ● Temporarily install the RH./LH. front fork, and tighten the steering stem lock nut to the specified torque. TORQUE VALUE : 6~8 kgf·m FRONT FORK ● Install the brake hose clamp to the steering stem, and clamp the brake hose. ●...
  • Page 149 13. REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM · · · · · · 13-1 PARKING BRAKE ·· · · · · · · · · · 13-5 SERVICE INFORMATION TROUBLESHOOTING· · · · · · · · 13-2 REAR CUSHION · · · · · · · · · · ·13-7 REAR WHEEL ··...
  • Page 150 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM TROUBLESHOOTING Wobble or vibration in motorcycle ● Tire pressure incorrect ● Faulty tire ● Bent rim ● Loose wheel bearing ● Swing arm bushing worn ● Wheel out of balance Soft suspension ● Weak springs ● Rear damper improperly adjusted, oil leakage Hard suspension ●...
  • Page 151 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM REAR WHEEL REMOVAL REAR CALIPER ● Support the motorcycle on the main stand. ● Loosen the parking brake rod adjust nut B, and remove the parking brake cable. ● Remove the brake arm joint B from the rear parking brake arm.
  • Page 152 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM REAR WHEEL INSPECTION ● Check the rim for wobbles by rotating the wheel. DIAL GAUGE SERVICE LIMIT : Radical 2.0mm Axial 2.0mm TOOL : DIAL GAUGE REAR WHEEL INSTALLATION FINAL SHAFT ● Install the rear brake disk. ●...
  • Page 153 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM PARKING BRAKE REAR CALIPER REMOVAL ● Remove the EX. muffler. (⇨4-12 ) ● Remove the rear caliper assembly. (⇨14-6 ) ● Remove the rear swing arm. (⇨13-8 ) REAR SWING ARM ● Remove the rear wheel. (⇨13-3 ) REAR WHEEL INSPECTION ●...
  • Page 154 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM BRAKE SHOE DISASSEMBLY BRAKE SHOE ● Manually open the brake shoe and remove it. ● Remove the shoe spring from the brake shoe. BRAKE CAM DISASSEMBLY ● Loosen the adjust nut B, remove the brake arm joint B. ●...
  • Page 155 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM REAR CUSHION REMOVAL ● Remove the luggage box. (⇨4-4 ) ● Loosen the top and bottom rear cushion setting bolts. NOTE REAR ·Support the frame firmly prior to working. SETTING CUSHION BOLT DISASSEMBLY ● Install the compressor attachment as shown in the figure.
  • Page 156 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM REAR CUSHION INSTALLATION ● Install the spring, stopper rubber to the damper REAR CUSHION COMPRESSOR component. NOTE ·Install the spring with its narrow pitch side facing upward. ● Apply thread locking agent to the hex nut, and install the rear cushion compressor attachment on the damper rod.
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  • Page 158 BRAKE SYSTEM 14-0...
  • Page 159 14. BRAKE SYSTEM SERVICE INFORMATION· · · · · · 14-1 BRAKE CALIPER· · · · · · · · · · · · 14-6 TROUBLESHOOTING· · · · · · · · 14-1 MASTER CYLINDER· · · · · · · · · · 14-8 BRAKE FLUID/BLEEDING·...
  • Page 160 BRAKE SYSTEM BRAKE FLUID/BLEEDING MASTER CYLINDER BRAKE FLUID CHANGE CAUTION ·A contaminate disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. ·Replace contaminated pads, and remove pollutants from the disk completely. NOTE ·Check the brake fluid level often, and replenish new fluid as required.
  • Page 161 BRAKE SYSTEM < > When the brake bleeder is not available BLEEDER VALVE ● Fill the brake fluid up to the upper limit line. ● Connect the transparent bleeder hose to the bleeder valve and place the other end of the hose in a container. ①...
  • Page 162 BRAKE SYSTEM BRAKE PAD REPLACEMENT FRONT BRAKE PAD NOTE ·When replacing brake pads, replace whole set. ·Do not remove the brake hose when replacing brake pads. ● Open the lock plate tangs, and loosen the hanger pin. LOCK PLATE ● Loosen the 2 front brake caliper setting bolts from the front fork.
  • Page 163 BRAKE SYSTEM ● Install a new brake pad, lock plate, and hanger pin. ● Bend the lock plate tangs, and fix the hanger pin. ● Install the brake caliper into the RH. front fork. NOTE ·Be careful not to damage the brake pad. SETTING BOLTS REAR BRAKE PAD...
  • Page 164 BRAKE SYSTEM BRAKE CALIPER REMOVAL Front brake caliper SETTING ● Remove the brake oil bolt, the brake hose and oil bolt BOLTS washer from the brake caliper. ● Remove the caliper from the RH. front fork and remove the pad spring, hanger pin and brake pad. Rear brake caliper OIL BOLT ●...
  • Page 165 BRAKE SYSTEM BRAKE CALIPER INSPECTION Caliper Cylinder ● Check the caliper cylinder bore for scoring, scratches or other damage. Caliper Piston PISTON ● Check the caliper piston outer diameter part for scratches or other damage. DUST PLUG CALIPER BRAKE CALIPER ASSEMBLY LOCK PLATE BRACKET ●...
  • Page 166 BRAKE SYSTEM BRAKE CALIPER INSTALLATION Front brake caliper ● Install the brake caliper to the front fork, and connect the brake hose to the caliper, and install 2 sealing washers and the brake hose bolt. TORQUE VALUE : 3.5 kgf·m ●...
  • Page 167 BRAKE SYSTEM ● Remove the washer, piston, spring from the master MASTER CYLINDER SET cylinder. ● Clean the master cylinder, reserve, master piston with STOP the recommended brake fluid. SWITCH LEVER BOOT MASTER CYLINDER BODY CIR CLIP MASTER CYLINDER INSPECTION ●...
  • Page 168 BRAKE SYSTEM ● Install the primary cup with its concaved side toward the inner side of the master cylinder. ● Install the snap ring. TOOL : SNAP RING PLIERS CAUTION ·When installing the cups, do not allow the lips to turn inside out.
  • Page 169 BRAKE SYSTEM BRAKE DISK INSPECTION ● Measure the thickness of the disk. SERVICE LIMIT : 3.0 mm NOTE ·Measure the brake disk thickness at the several points and replace if the smallest measurement is less BRAKE DISK then the specified service limit. ●...
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  • Page 171 15. BATTERY/CHARGING SYSTEM INFORMATION· · · · · · · · · · 15-1 HEADLIGHT VOLTAGE INSPECTION · · 15-6 SERVICE CHARGING DEVICES LOCATION· · 15-2 REGULATOR/RECTIFIER INSPECTION· · 15-6 TROUBLESHOOTING· · · · · · · · · · · · 15-3 A.C.
  • Page 172 BATTERY/CHARGING SYSTEM CHARGING DEVICE LOCATION REGULATOR RECTIFIER BATTERY A.C.GENERATOR TRIPLE PHASE FULL WAVE RECTIFICATION METHOD FUSE MAIN SWITCH GREEN BLACK BATTERY LIGHTING SWITCH YELLOW YELLOW DIMMER SWITCH BROWN YELLOW PINK BLUE WHITE A.C.GENERATOR RESISTOR (5W 6.7 AUTO-BYSTARTER GREEN (5W 6.7 GREEN GREEN GREEN GREEN...
  • Page 173 BATTERY/CHARGING SYSTEM TROUBLESHOOTING No power (Key turned on) Low power (Engine running) ● Dead battery. ● Battery undercharged. ● Battery is failing. -Low fluid level. ● Charging system failure. -Low specific gravity. -Charging system failure. ● Disconnected battery cable. Intermittent power ●...
  • Page 174 BATTERY/CHARGING SYSTEM BATTERY REMOVAL ● Turn off the ignition switch. ● Remove the floor panel mat. ● Loosen the 2 battery cover setting screws, remove the SETTING battery cover. SCREW BATTERY COVER ● Disconnect the negative “⊖” battery cable first, and then disconnect the positive “⊕”...
  • Page 175 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION LEAK TEST ● Trun off the ignition switch, and disconnect the ground (-) cable from the battery. ● Connect an ampere meter between negative (-) terminal and ground cable. ● With the ignition switch off, measure the leakage current. LEAK CURRENT : Not to exceed 1mA TOOL : DIGITAL TESTER NOTE...
  • Page 176 BATTERY/CHARGING SYSTEM HEADLIGHT VOLTAGE INSPECTION ● Remove the front cover. (⇨4-3) NOTE ·Check voltage with the headlight coupler connected. ● After starting the engine, place the dimmer switch to HI and measure the headlight lighting voltage between the terminals connected to blue (+) and green (-) wires. ●...
  • Page 177 BATTERY/CHARGING SYSTEM REGULATOR RECTIFIER UNIT INSPECTION ● Provided that all inspections on the wire harness side are normal and there are no loose connections at the REGULATOR RETIFIER regulator rectifier coupler, inspect the regulator rectifier unit by measuring the resistance between the terminals. NOTE ·Resistance value will not be accurate if the probes touch your fingers.
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  • Page 179 16. IGNITION SYSTEM PULSE GENERATOR INSPECTION· · 16-4 SERVICE INFORMATION· · · · · · · · 16-1 IGNITION COIL INSPECTION· · · · 16-5 IGNITION DEVICES LOCATION· · 16-2 IGNITION TIMING INSPECTION· · 16-6 TROUBLESHOOTING· · · · · · · · · · 16-3 CDI UNIT INSPECTION ·...
  • Page 180 IGNITION SYSTEM IGNITION DEVICES LOCATION MAIN SWITCH IGNITION COIL A.C.GENERATOR DC. CDI UNIT IGNITION SYSTEM BLUE/YELLOW BLACK/YELLOW MAIN SWITCH BLACK SPARK PLUG GREEN FUSE BLACK PULSE GENERATOR /RED /BLUE SIDE STAND IGNITION COIL SWITCH CDI UNIT GREEN BATTERY GREEN GREEN GREEN 16-2...
  • Page 181 IGNITION SYSTEM TROUBLESHOOTING No spark at plug. UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. - Battery is undercharged (or operating force of the kick starter is weak).
  • Page 182 IGNITION SYSTEM CDI UNIT INSPECTION CDI IGNITION CIRCUIT INSPECTION NOTE ·Follow the steps described in the troubleshooting flow chart when servicing the ignition system. ● Release the seat lock with the main key. ● Remove the luggage box. (⇨4-4) ● Disconnect the coupler from the CDI unit, and check the ignition system circuits from the wiring coupler side.
  • Page 183 IGNITION SYSTEM IGNITION COIL INSPECTION IGNITION COIL ● Release the seat lock with the main key. ● Remove the luggage box. (⇨4-4) ● Remove the center cover. (⇨4-5) ● Remove the primary wire. NOTE ·Measure the peak voltage of the ignition coil primary side first.
  • Page 184 IGNITION SYSTEM IGNITION TIMING INSPECTION NOTE ·As the system uses the CDI unit, the ignition timing need not be adjusted. Check the ignition system if the ignition timing is incorrect. ● Start and warm up the engine. TIMING CHECK ● Remove the plug maintenance cover. ●...
  • Page 185 IGNITION SYSTEM REMOVAL ● Remove the floor mat. ● Remove the center cover. (⇨4-5) ● Remove the RH. floor side cover. (⇨4-7) ● Remove the coupler of the side stand switch. ● Remove the LH. floor side cover. (⇨4-7) ● Loosen the side stand switch mounting 2 bolts. ●...
  • Page 186 MEMO...
  • Page 187 17. STARTER SYSTEM INFORMATION· · · · · · · · 17-1 STARTER MOTOR · · · · · · · · · · · · 17-4 SERVICE STARTER DEVICES LOCATION· · 17-2 STARTER MAGNETIC SWITCH · · 17-7 TROUBLESHOOTING · · · · · · · · · · 17-3 SERVICE INFORMATION GENERAL SAFETY WARNING...
  • Page 188 STARTER SYSTEM STARTER DEVICES LOCATION STARTER SWITCH MAIN SWITCH BATTERY FUSE15A STARTER MAGNETIC SWITCH STARTER MOTOR STARTER SYSTEM CIRCUIT RED/WHITE FUSE MAIN SWITCH FRONT STOP SWITCH STARTER SWITCH BLACK YELLOW STARTER MOTOR /RED BATTERY GREEN STARTER MAGNETIC GREEN GREEN SWITCH REAR STOP SWITCH 17-2...
  • Page 189 STARTER SYSTEM TROUBLESHOOTING Starter motor will not turn. ● Check for a blown main fuse before servicing. ● Check that the stop light is correctly adjusted. ● Check that the side stand is positioned in the condition under which the engine can be started. Connect the starter motor (+) terminal to the With the ignition switch “ON”and squeeze battery positive terminal.
  • Page 190 STARTER SYSTEM STARTER MOTOR REMOVAL ● Release the seat lock with the main key. ● Remove the luggage box. (⇨4-4) FLANGE ● Remove the starter motor cable from the starter BOLTS magnetic switch. ● Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor.
  • Page 191 STARTER SYSTEM ● Remove the brush spring, and then remove the brush. ● Measure the brush length. Replace the brush if it is worn beyond the service limit. BRUSH SERVICE LIMIT : 5 mm TOOL : VERNIER CALIPER NOTE ·If replacement, replace with a brush holder set. ●...
  • Page 192 STARTER SYSTEM STARTER MOTOR ASSEMBLY ● Install the brush and brush spring to the brush hold set. ● Insert the brush terminal into the rear bracket, and install the terminal set and flange nut. ● Align the brush holder set with the rear bracket groove, and install the brush holder set.
  • Page 193 STARTER SYSTEM STARTER MAGNETIC SWITCH STARTER MOTOR CABLE REMOVAL ● Release the seat lock with the main key. ● Remove the luggage box. (⇨4-4) ● Remove the center cover. (⇨4-5) ● Remove the battery (+) cable from the starter magnetic switch terminal.
  • Page 194 STARTER SYSTEM OPERATION CHECK ● Disconnect the magnetic switch wire connector. ● Apply battery voltage between terminals, when the yellow / red wire is connected to the positive (+) battery terminal and the green / yellow wire to the negative (-) battery terminal. ●...
  • Page 195 18. LIGHTS/METER/SWITCHES SERVICE INFORMATION · · · · · · · · 18-1 HORN INSPECTION · · · · · · · · · · 18-4 TROUBLESHOOTING· · · · · · · · · · 18-1 MAIN SWITCH · · · · · · · · · · · · · · · · 18-4 HEADLIGHT ·...
  • Page 196 LIGHTS/METER/SWITCHES HEADLIGHT REMOVAL ● Remove the front cover. (⇨4-3 ) ● Disconnect the headlight wiring. ● Loosen the 4 setting bolts securing the front cover. ● Remove the headlight assembly. ● Install in the reverse order of removal. BULB REPLACEMENT NOTE HEADLIGHT COUPLER ·Before replacing the bulb, be sure to check the...
  • Page 197 LIGHTS/METER/SWITCHES REAR COMBINATION LIGHT BULB REPLACEMENT ● Loosen the 2 screws and remove the tail light lens. ● Remove the bulb from the tail light socket. ● Replace with a new bulb. ● Install in the reverse order of removal. NOTE ·Pay attention not to damage the tail light lens when removing it.
  • Page 198 LIGHTS/METER/SWITCHES HORN INSPECTION ● Remove the front cover. (⇨4-3) ● Remove the horn wiring, and connect a fully charged 12V battery. Check the sound quality for any abnormalities. ● Install in the reverse order of removal. HORN MAIN SWITCH REMOVAL ●...
  • Page 199 LIGHTS/METER/SWITCHES STARTER SWITCH LIGHTING SWITCH STARTER SWITCH LIGHTING SWITCH COLOR YELLOW/RED GREEN BROWN/ COLOR PINK BROWN BLACK WHITE TERMINAL FREE TERMI N AL PUSH DIMMER SWITCH WINKER SWITCH BROWN/ COLOR BLUE WHITE COLOR SKY BLUE GRAY ORANGE WHITE DIMMER TERMINAL TERMINAL SWITCH WINKER...
  • Page 200 LIGHTS/METER/SWITCHES PARKING BRAKE SWITCH INSPECTION PARKING BRAKE SWITCH COUPLER ● Remove the front cover. (⇨4-3) ● Disconnect the parking brake switch coupler, check for continuity between the terminals. -When the brake lever is pulled - CONTINUITY. -When the brake lever is released - NO CONTINUITY. BROWN/BLACK BLACK COLOR...
  • Page 201 WIRING DIAGRAM 19. WIRING DIAGRAM MINI...
  • Page 202 20. TROUBLESHOOTING ENGINE WON’T START OR HARD TO START · · · · · · · · · · · · · · · · · · · · · · 20-1 ENGINE STALLS, HARD TO START, ROUGH IDLING· · · · · · · · · · · · · · · · · · · · 20-2 POOR PERFORMANCE AT LOW SPEED AND IDLING ·...
  • Page 203 TROUBLESHOOTING ENGINE STALLS, HARD TO START, ROUGH IDLING CAUSE OF TROUBLE Open the drain screw, and check fuel Fuel not supplied to ·No fuel to fuel tank. flow to the carburetor. the carburetor. ·Clogged fuel tube. ·Clogged float valve. ·Clogged fuel tank cap. ·Clogged fuel strainer.
  • Page 204 TROUBLESHOOTING POOR PERFORMANCE AT LOW SPEED AND IDLING CAUSE OF TROUBLE Smoothly accelerate engine. Engine speed does not ·Clogged air cleaner. increase sufficiently. ·Insufficient fuel supply. ·Clogged fuel tank cap air hole Engine speed increases. ·Clogged muffler. Check the ignition timing. Abnormal ·Faulty CDI unit.
  • Page 205 TROUBLESHOOTING POOR OPERATION CLUTCH DRIVE / DRIVEN PULLEY CAUSE OF TROUBLE Engine starts but vehicle won’t move. ·Worn or damaged drive belt. ·Damaged ramp plate. ·Faulty weight roller. ·Faulty movable drive face. ·Damaged driven pulley weight shoe spring. ·Faulty transmission. ·Seized transmission.
  • Page 206 TROUBLESHOOTING POOR FRONT/REAR SUSPENSION PERFORMANCE CAUSE OF TROUBLE ·Weak cushion spring Soft suspension. ·Overloaded ·Oil leakage from damper unit ·Bent fork pipe or cushion rod Hard suspension. ·Worn slider Suspension noisy. ·Damaged cushion stopper rubber 20-5...
  • Page 207 SERVICE MANUAL 2001. 11. PRINTED NO COPY 2001. 11. PUBLICATION...
  • Page 208 HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #16-6, PIL-DONG 2KA, CHUNG-KU, SEOUL, KOREA TEL : (82-2) 2274-3171 / FAX : (82-2) 2269-7997 SM42-0111-01E...

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