Sym EuroMX 125 Service Manual
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Sym EuroMX 125 Service Manual

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CONTENTS
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HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATIONS

SERVICE MANUAL

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Summary of Contents for Sym EuroMX 125

  • Page 1: Service Manual

    CONTENTS FORWARD HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS SERVICE MANUAL...
  • Page 2 Home page Contents Forward This service manual contains the technical data of each component inspection and repair for the SANYANG Euro MX 125 motorcycle. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.
  • Page 3 Home page Contents How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for SANYANG Euro MX 125 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

  • Page 4: Table Of Contents

    Home page Contents Page Content Index 1-1 ~ 1-16 General Information / Trouble Diagnosis 2-1 ~ 2-18 Service Maintenance Information 3-1 ~ 3-8 Lubrication System 4-1 ~ 4-14 Fuel System 5-1 ~ 5-10 Engine Removal 6-1 ~ 6-16 Cylinder Head / Valve 7-1 ~ 7-8 Cylinder / Piston 8-1 ~ 8-14...
  • Page 5 Home page Contents Model illustration Battery / Fuse Spark plug Winker relay AC. Generator Horn IG. Coil / Start relay Fuel tank Headlight Carburetor Frame number Seat lock Front winker light Tail light Rear winker light Air cleaner Gear oil Inspection plug Gear oil drain Engine number...
  • Page 6 (Recommended oil: KING MATE G-3 oil) Grease King Mate G-3 is recommended. (KING MATE G-3) King Mate gear oil (SYM HYPOID GEAR OIL ) is recommended. Gear oil (SAE 85W-140) Apply sealant, medium strength sealant should be used unless Locking sealant otherwise specified.

  • Page 7: General Safety

    This chapter Contents 1. General Information/Trouble Diagnosis General safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a • Battery emits explosive gases; flame is closed area. Run your engine in an open area, if you have to run your engine in a closed area, be strictly prohibited.

  • Page 8: Service Precautions

    This chapter Contents 1. General Information/Trouble Diagnosis Service Precautions • Always use with SANYANG genuine parts and • Never bend or twist a control cable to prevent recommended oils. Using non-designed parts stiff control and premature worn out. for SANYANG motorcycle may damage the motorcycle.
  • Page 9 This chapter Contents 1. General Information/Trouble Diagnosis • The length of bolts and screws for assemblies, • Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if another, be sure they are correctly installed.
  • Page 10 This chapter Contents 1. General Information/Trouble Diagnosis • Lubricate the rotation face with specified • Before battery removal operation, it has to lubricant on the lubrication points before remove the battery negative (-) cable firstly. assembling. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
  • Page 11 This chapter Contents 1. General Information/Trouble Diagnosis • Before terminal connection, check if the boot is • When separating a connector, it locker has to crack or the terminal is loose. be unlocked firstly. Then, conduct the service operation. • Insert the terminal completely. Check if the terminal is covered by the boot.
  • Page 12 This chapter Contents 1. General Information/Trouble Diagnosis • Do not let the wire harness contact with • Protect wires or wire harnesses with electrical rotating, moving or vibrating components as tape or tube if they contact a sharp edge or routing the harness.
  • Page 13 This chapter Contents 1. General Information/Trouble Diagnosis • Do not let the wire harness been twisted as • With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust • Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering...

  • Page 14: Specifications

    This chapter Contents 1. General Information/Trouble Diagnosis Specifications Maker SANYANG MODEL HF12W-6 Overall Length 1945 mm Front TELESCOPE Suspension System Overall Width 700 mm Rear UNlT SWING Overall Height 1160 mm Front 100 / 90-12 (61L) Tire Specifications Wheel Base 1335 mm Rear 130 / 70 –12 (64L)

  • Page 15: Torque Values (Engine)

    This chapter Contents 1. General Information/Trouble Diagnosis Torque Values (Engine) Thread Dia. Torque Item Q’ty Remarks (mm) Value(Kg-m) Cylinder head bolts 1.0~1.4 Cylinder head nuts 2.0~2.4 Cylinder/cylinder head two-ends 0.7~1.1 Tighten to crankcase bolts Cylinder head left bolts 1.0~1.4 Valve adjustment fixing nuts 0.7~1.1 Apply oil to thread Cylinder head left cover bolts...

  • Page 16: Torque Values (Frame)

    This chapter Contents 1. General Information/Trouble Diagnosis Torque Values (Frame) Thread Dia. Torque Item Q’ty Remarks (mm) Value(Kg-m) Mounting bolt for steering 4.0~5.0 handlebar 25.4 1.0~2.0 Mounting nut for steering rod 25.4 0.2~0.3 Cone seat for steering rod 5.0~7.0 Front wheel shaft nut 11.0~13.0 Rear wheel shaft nut 0.15~0.3...

  • Page 17: Troubles Diagnosis

    This chapter Contents 1. General Information/Trouble Diagnosis Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain bolt to check if there is gasoline 2.
  • Page 18 This chapter Contents 1. General Information/Trouble Diagnosis B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 0. Air cleaner clogged 1. Poor fuel supply Engine speed can be Engine speed can not 2.
  • Page 19 This chapter Contents 1. General Information/Trouble Diagnosis C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Normal Abnormal Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor Good...
  • Page 20 This chapter Contents 1. General Information/Trouble Diagnosis E. Clutch, driving and driving pulley FAULT CONDITIONS PROBABLE CAUSES 1. Drive belt worn out or deformation 2. Ramp plate of movable drive face damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved.

  • Page 21: Parts To Be Greased

    This chapter Contents 1. General Information/Trouble Diagnosis Parts To Be Greased Acceleration cable/ Front & rear brake lever pivot Seat lock catch Steering shaft bearing Main stand pivot Side stand pivot Speedometer gear/ Rear wheel bearing front wheel bearing 1-16...
  • Page 22 Home page Contents 2. Maintenance Information Precautions In Operation ..2-1 Spark Plug ........2-8 Periodical Maintenance Cylinder Compression Schedule ........2-2 Pressure........2-9 Lubrication System....2-3 Driving System ......2-9 Gear Oil ........2-4 Steering System ....... 2-10 Fuel System........ 2-4 Suspension System ....

  • Page 23: Periodical Maintenance Schedule

    This chapter Contents 2. Maintenance Information Periodical Maintenance Schedule Maintenance Initial 1 Month 3 month 6 month 1 year item Code 300KM every1000KM every3000KM every6000KM every12000KM ☆Air cleaner ☆2nd air jet cleaner ☆Fuel filter ☆Oil filter ☆Engine oil change Replacement for every 1000km Tire pressure Battery inspection Brake &...

  • Page 24: Lubrication System

    This chapter Contents 2. Maintenance Information Lubrication System Engine Oil Capacity Caution The vehicle must be parked on a level • ground when checking oil capacity. Run the engine for 3-5 minutes then stop, • wait about 3-5 more minutes allowing engine oil to settle before checking the oil level.

  • Page 25: Gear Oil

    This chapter Contents 2. Maintenance Information Gear Oil Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole.

  • Page 26: Air Cleaner

    This chapter Contents 2. Maintenance Information Air Cleaner 6 screws Air element Remove the air cleaner cover (6 screws). Remove the lock plate from the element of air cleaner. Check the element if dirt or damaged. If it dirt, clean it with solvent and then soap it into cleaning engine oil after cleaned.

  • Page 27: Crankcase Ventilation

    This chapter Contents 2. Maintenance Information Primary adjustment is conducted from button Adjustment nut side of cable on the throttle body. Loosen fixing nut, and adjust by turning the adjustment nut for its free-play. Tighten the fixing nut, and check acceleration operation condition after adjusted.

  • Page 28: Valve Clearance Inspection And Adjustment

    This chapter Contents 2. Maintenance Information Valve Clearance Inspection And Adjustment Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX): 0.12 ± 0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve rock-arm is be adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.

  • Page 29: Ignition System

    This chapter Contents 2. Maintenance Information Ignition System F mark Ignition Timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition Ignition timing check procedure is for lamp checking whether CDI function is in normal or Remove right side cover.

  • Page 30: Cylinder Compression Pressure

    This chapter Contents 2. Maintenance Information Cylinder Compression Pressure Warn up engine and then turn off the engine. Remove the luggage box and the center cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the foot-starting lever.

  • Page 31: Steering System

    This chapter Contents 2. Maintenance Information Steering System Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly.

  • Page 32: Disk Brake System (Front Disk Brake)

    This chapter Contents 2. Maintenance Information Disk Brake System (Front Disk Brake metals hose Brake) Brake System Metal Hoses Make sure the brake metal hoses for corrosion or leaking oil, and also check brake system for leaking. Brake Fluid Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit.
  • Page 33 This chapter Contents 2. Maintenance Information Brake Lining Wear The indent mark on brake lining is the wear limitation. Brake lining Replace the brake lining if the wear limit mark wear limit closed to the edge of brake disc. Caution It is not necessary to remove brake hose when replacing the brake lining.

  • Page 34: Drum Brake System

    This chapter Contents 2. Maintenance Information Drum Brake System Rear Brake Free Play: (Drum brake) Measure free play of rear brake level at the end 10∼20mm of the lever. Free play: 10-20 mm Measure the free play of the front brake lever at the end of the lever.

  • Page 35: Wheel / Tire

    This chapter Contents 2. Maintenance Information Wheel / Tire Check if both front & rear tires’ pressure is in correct. Caution Tire pressure check should be done as cold tire. Appointed tire pressure Tire size Front tire Rear tire Load for Tire pressure 1.75 2.25...

  • Page 36: Battery

    This chapter Contents 2. Maintenance Information Battery Battery Removal Remove right cover. (3 screws) Battery cables removal: 1. At first, remove the negative “-” cable. 2. Then, remove the positive “+” cable. 3. Remove the battery. If there is some rust on battery posts, clean it with steel brush.

  • Page 37: Special Service Tools Catalogue

    Special Service Tools Catalogue (ψ22mm) (ψ30mm) Alternator fly wheel Puller/presser for Puller/presser for Name Name Name remover crankcase bushing crankcase bushing Parts no. SYM-3110A01 Parts no. SYM-1120310 Parts no. SYM-1120320 Presser for crankcase Valve spring Valve spring Name Name Name bushing compressor compressor Parts no.
  • Page 38 2. Maintenance Information (6301) (6203/6004UZ) (6204) Bearing installer ψ Name Bearing installer Name Bearing installer Name 17mm Parts no. SYM-9610000 Parts no. SYM-9110400 Parts no. SYM-9620000 (20*32*6) (27*42*7) (25*40*8) Name Oil seal installer Name Oil seal installer Name Oil seal installer Parts no.
  • Page 39 This chapter Contents 2. Maintenance Information NOTE: 2-18...
  • Page 40 Contents Home page 3. Lubrication System Mechanism Illustration ....3-1 Oil Pump Disassembly ....3-4 Operational Precautions:... 3-2 Oil Pump Inspection ....3-5 Trouble Diagnosis ...... 3-2 Oil Pump Re-assembly ....3-5 Engine Oil ........3-3 Oil Pump Installation ....3-6 Cleaning Engine Oil Strainer..

  • Page 41: Operational Precautions

    (Recommended King-Mate serial oils) Gear Oil Disassembly 110 c.c. Replacement 100 c.c. Oil viscosity of gear oil SAE 85W-140 (Recommended King-Mate gear oil series SYM HYPOID GEAR OIL) unit: mm Items Standard (mm) Limit (mm) Inner rotor clearance 0.12 Oil pump Clearance between outer rotor and body 0.12...

  • Page 42: Engine Oil

    This chapter Contents 3. Lubrication System Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 43: Oil Pump Removal

    This chapter Contents 3. Lubrication System Oil Pump Removal Remove the alternator (refer to chapter 10). Remove the engine right cover. Remove the one-way clutch and starting gear (1 nut). Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 screws), and then the oil pump driving gear clamp and the gear.

  • Page 44: Oil Pump Inspection

    This chapter Contents 3. Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit：below 0.12mm Check clearance between inner and outer rotors. Limit: below 0.12mm Check clearance between rotor side face and pump body. Limit: below 2.0 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body.

  • Page 45: Oil Pump Installation

    This chapter Contents 3. Lubrication System Install driving gear and clamp. Caution Install the oil pump cover and fixing pin properly. Oil Pump Installation Install the oil pump (3 screws). Caution The elliptical hole on the driving gear is not match with the screw hole.

  • Page 46: Gear Oil

    And then, tighten the bolt. Torque Value: 1.0~1.4 kgf-m ※Recommended to apply with SYM HYPOID GEAR OIL (SAE 85W-140) Start engine and run it for 2~3 minutes.
  • Page 47 This chapter Contents 3. Lubrication System NOTES:...
  • Page 48 Contents Home page 4. FUEL INJECTION SYSTEM Mechanism Illustration..... 4-1 Float Chamber ......4-8 Precautions In Operation ..4-2 Installation Of Carburetor ..4-9 Trouble Diagnosis ....4-3 Idle Speed Adjustment ....4-9 Carburetor Removal ....4-4 Fuel Tank........4-10 Air Cut-off Valve......

  • Page 49: Precautions In Operation

    This chapter Contents 4. FUEL INJECTION SYSTEM Precautions In Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend or twist throttle valve cable. Damaged cable will make unstable drive ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.

  • Page 50: Trouble Diagnosis

    This chapter Contents 4. FUEL INJECTION SYSTEM Trouble Diagnosis Poor engine start Power insufficiency and fuel consuming No fuel in fuel tank Fuel system clogged Clogged fuel tube Malfunction of ignition system Too much fuel in cylinder No spark from spark plug (malfunction of ignition system) Clogged air cleaner Mixture too lean...

  • Page 51: Carburetor Removal

    This chapter Contents 4. FUEL INJECTION SYSTEM Carburetor Removal Throttle Vacuum hose valve cable Remove the trunk. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Disconnect auto by-starter connectors. Release the clamp strip of air cleaner.
  • Page 52 This chapter Contents 4. FUEL INJECTION SYSTEM Remove fuel needle seat, spring, and injector Fuel needle needle. seat Check if the vacuum piston for wear out, crack or Fuel needle other damage. spring Check if the diaphragm for damage or crack. Cautions Injector needle...

  • Page 53: Air Cut-Off Valve

    This chapter Contents 4. FUEL INJECTION SYSTEM Air Cut-off Valve Removal Remove the vacuum hose clamp and then the vacuum hose. Screws ×2 Remove the screws (screw x 2) of the air cut-off valve and its cover. Remove the spring and vacuum diaphragm. Check if the diaphragm for deterioration or crack.

  • Page 54: Auto By-Starter

    This chapter Contents 4. FUEL INJECTION SYSTEM Auto By-Starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the auto by-starter with a new one if resistance value exceeds standard.

  • Page 55: Float Chamber

    This chapter Contents 4. FUEL INJECTION SYSTEM Float Chamber Float Disassembly Float pin Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. Screws × 4 Checking Check float needle valve and valve seat for drop Drain bolt difference damage, wear out, dirty or clogged.

  • Page 56: Installation Of Carburetor

    This chapter Contents 4. FUEL INJECTION SYSTEM Installation Install main jet, fuel needle jet seat, fuel needle jet, slow speed jet and fuel amount adjustment screw. Cautions Set the adjustment screw in according to Fuel amount number of turns noted before it was adjustment screw removed.

  • Page 57: Fuel Tank

    This chapter Contents 4. FUEL INJECTION SYSTEM Fuel Tank Removal of fuel unit. Open the seat. Remove the luggage box assembly. (bolt x 4, screw x 1) Remove the rear carrier. ( bolt x 4) Remove both the left and right body covers. (screw x 4, bolt x 2) Remove the fuel unit coupler.
  • Page 58 This chapter Contents 4. FUEL INJECTION SYSTEM Removal of fuel tank Bolt x 3 Open the seat. Remove the luggage box assembly. (bolt x 4, screw x 1) Remove the body cover. (screw x 4) Remove the rear lamp and rear fender assembly. (screw x 4) Bolt on each side x 1 Remove the fuel inlet.
  • Page 59 This chapter Contents 4. FUEL INJECTION SYSTEM Loosen the fuel inlet clamper and then remove the fuel vapor return hose. Fuel vapor return hose Remove the fuel hose and then remove the fuel tank. Caution Be sure that the fuel in the fuel bank had been drain out clearly before removing.

  • Page 60: Air Cleaner

    This chapter Contents 4. FUEL INJECTION SYSTEM Air Cleaner Remove the air cleaner cover. (screw x 6) Screw x 6 Remove the air cleaner assembly. Installation: Install the air cleaner in reverse procedure of removal. Procedures for cleaning air cleaner element: (sponge type only) 1.clean.
  • Page 61 This chapter Contents 4. FUEL INJECTION SYSTEM NOTE: 4-14...
  • Page 62 Contents Home page 5. REMOVAL OF ENGINE Operational Precautions ... 5-1 Engine Suspension Frame ..5-8 Engine Removal ......5-2 Installation Of Engine ....5-9 Removal Of Engine Suspension Bushing ....5-7 Operational Precautions General Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame.

  • Page 63: Engine Removal

    This chapter Contents 5. REMOVAL OF ENGINE Engine Removal Remove the battery cap (screw ×3). Remove the battery negative (-) cable. Remove the battery positive (+) cable. Open the seat. Remove the luggage box assembly. (bolt x 4, screw x 1) Remove center cover.
  • Page 64 This chapter Contents 5. REMOVAL OF ENGINE Remove the spark plug. Remove the engine temperature sensor connector. Caution Open the latch located under the temperature sensor before disconnect it so that the connector can be pull out and not be damaged.
  • Page 65 This chapter Contents 5. REMOVAL OF ENGINE Loosen the clamp of the air cleaner duct, and Inlet pipe clamp then remove the duct. Loosen the clamp of the inlet pipe, and then remove the carburetor. Air cleaner duct clamp Remove the kick starter arm.(bolt×1) Remove the engine left cover protecting cover.
  • Page 66 This chapter Contents 5. REMOVAL OF ENGINE Remove the rear-end bolts of exhaust muffler. (Bolt ×3) Remove the exhaust muffler. Bolt x 3 Remove the rear wheel and muffler rear bracket. (nut x 1) Nut ×1 Remove the rear brake adjustment nut. Rear brake adjustment nut Engine suspension removal Remove the rear shock absorber lower bolt.
  • Page 67 This chapter Contents 5. REMOVAL OF ENGINE Remove the side hole cap of cooling fan. Side hole cap Remove the engine suspension nuts, and then remove the bolt from the side hole. Caution With a bracket to support the engine to prevent from it damage by falling down as removing the engine.
  • Page 68 This chapter Contents 5. REMOVAL OF ENGINE Removal Of Engine Suspension Bushing If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / pressor, Ø 28mm & Ø 20mm, to press the bushing out, and replace it with new one.
  • Page 69 This chapter Contents 5. REMOVAL OF ENGINE Engine Suspension Frame Removal Remove the right side bolt of engine suspension frame. Engine suspension bolt (right side) Remove the left side bolt of engine suspension frame. Engine suspension bolt (left side) Check if the engine suspension frame bushing and cushion rubber for damage.
  • Page 70 This chapter Contents 5. REMOVAL OF ENGINE Installation Of Engine Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones. Install the engine according to the reversing order of removal. Caution Note both feet and hands safety for squeezing as engine installation.
  • Page 71 This chapter Contents 5. REMOVAL OF ENGINE NOTE: 5-10...

  • Page 72: Cylinder Head / Valve

    Contents Home page 6. Cylinder Head/Valve Mechanism Illustration....6-1 Valve Stem Replacement ..6-9 Precautions In Operation...6-2 Valve Seat Inspection And Service ..........6-10 Troubleshooting ......6-3 Cylinder Head Reassembly ..6-12 Cylinder Head Removal .....6-4 Cylinder Head Installation ..6-14 Cylinder Head Disassembly ..6-6 Valve Clearance Adjustment ..

  • Page 73: Precautions In Operation

    This chapter Contents 6. Cylinder Head/Valve Precautions In Operation General Information • This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. • Cylinder head service cannot be carried out when engine is in frame. Specification Unit: mm Item...

  • Page 74: Troubleshooting

    This chapter Contents 6. Cylinder Head/Valve Troubleshooting Engine performance will be effected by troubles on engine top-end. The troubles usually can be determinated or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle • Low compression pressure Low compression pressure 1.

  • Page 75: Cylinder Head Removal

    This chapter Contents 6. Cylinder Head/Valve Cylinder Head Removal Bolt x 2 Remove: Remove the cooling fan cover. (screw x 2, bolt x Screw x 2 Remove the right cover of engine. (screw x 4) Down Screw x 2 Screw x 2 Remove the left cover of engine.
  • Page 76 This chapter Contents 6. Cylinder Head/Valve Turn the flywheel in counter clockwise motion with T type wrench until the “T” mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position.

  • Page 77: Cylinder Head Disassembly

    This chapter Contents 6. Cylinder Head/Valve Cylinder Head Disassembly Remove the adjustment hole cap for the EX & IN valve clearance. (bolt x 6) Adjustment hole cap Firstly, remove the camshaft stopper, and then Stopper drive a 6mm bolt into camshaft. Finally, remove the camshaft and rocker arm.

  • Page 78: Cylinder Head Inspection

    This chapter Contents 6. Cylinder Head/Valve Remove valve, valve stem and valve spring. Cylinder Head Inspection Camshaft Inspect cam lobe height for damaged. Service Limit: IN: Replacement when less than 25.29mm EX: Replacement when less than 25.12mm Inspect the camshaft bearing for looseness or wear out.
  • Page 79 This chapter Contents 6. Cylinder Head/Valve Remove cylinder head gasket and 2 lock pins. Lock pin Remove chain plate. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution • Do not damage the matching surfaces of cylinder and cylinder head.

  • Page 80: Valve Stem Replacement

    This chapter Contents 6. Cylinder Head/Valve Valve Stem Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter. Service Limit: IN→4.90 mm EX→4.90 mm Valve Guide Caution...

  • Page 81: Valve Seat Inspection And Service

    This chapter Contents 6. Cylinder Head/Valve Hold the cylinder head, and then press out old valve guide from combustion chamber side. Valve guide driver 13 mm Tool: Valve guide driver: 5 mm 5.0mm (0.15in) Caution • Check if new valve guide is deformation after pressed it in.
  • Page 82 This chapter Contents 6. Cylinder Head/Valve Valve Seat Inspection If the valve seat is too width, narrow or rough, Roughness correct it. Valve seat width Service limit: 1.6 mm Check the contact condition of valve seat. Valve Seat Grinding The worn valve seat has to be grinded with valve seat chamfer cutter.

  • Page 83: Cylinder Head Reassembly

    This chapter Contents 6. Cylinder Head/Valve Coat the valve seat surface with red paint. Install the valve through valve guide until the Contact surface valve contacting with valve seat, slightly press too high down the valve but do not rotate it so that a seal Old valve seat track will be created on contact surface.
  • Page 84 This chapter Contents 6. Cylinder Head/Valve Use valve spring compressor to press valve spring. Install valve split locks and release the valve compressor. Caution In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve split locks in which can be removed.

  • Page 85: Cylinder Head Installation

    This chapter Contents 6. Cylinder Head/Valve Install the camshaft onto the cylinder head and EX rocker arm shaft Lock plate then the rocker arm and the rocker arm shaft. Lock the lock plate after rotate the rocker arm shaft to properly position. Caution There is different shapes on the top-end of rocker arm shaft.
  • Page 86 This chapter Contents 6. Cylinder Head/Valve Tighten the cylinder head right side cover. (bolt x Bolt x 2 With flat screwdriver, turn the cam sprocket tensioner in counter-clockwise motion so that the tensioner is pushed out to contact the cam chain plate tightly.

  • Page 87: Valve Clearance Adjustment

    This chapter Contents 6. Cylinder Head/Valve Install the cooling fan cover. (screw x2, bolt x 2) Bolt x 2 Screw x 2 Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge.

  • Page 88: Cylinder / Piston

    Home page Contents 7. Cylinder/Piston Mechanism Illustration ....7-1 Piston Removal ......7-5 Precautions In Operation ...7-2 Piston Inspection ......7-5 Trouble Diagnosis.......7-2 Piston Ring Installation ....7-7 Cylinder Removal......7-3 Piston Installation .......7-8 Cylinder Inspection.....7-4 Cylinder Installation....7-8 Mechanism Illustration 0.8~1.2 kgf-m...

  • Page 89: Precautions In Operation

    This Chapter Contents 7. Cylinder/Piston Precautions In Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit: mm Item Standard Limit 52.400~52.410 52.500 － 0.050 Bend/wrapage Cylinder － Cylindrical roundness 0.050 －...

  • Page 90: Cylinder Removal

    This Chapter Contents 7. Cylinder/Piston Cylinder Removal Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-tensioner. Bolt x 2 Remove cam chain plate. Remove cylinder. Remove cylinder gasket and lock pins. Clean the residues attached onto the matching surfaces of cylinder and crankcase.

  • Page 91: Cylinder Inspection

    This Chapter Contents 7. Cylinder/Piston Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.

  • Page 92: Piston Removal

    This Chapter Contents 7. Cylinder/Piston Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 93 This Chapter Contents 7. Cylinder/Piston Measure the outer diameter of piston pin. Service Limit: 14.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06 mm Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.

  • Page 94: Piston Ring Installation

    This Chapter Contents 7. Cylinder/Piston Piston Ring Installation Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution • Do not damage piston and piston rings as installation. •...

  • Page 95: Piston Installation

    This Chapter Contents 7. Cylinder/Piston Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution • Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 96 Contents Home page 8. V-Belt Driving System/Foot Starter Mechanism Illustration ..... 8-1 Foot Starter.........8-3 Maintenance Description..8-2 Drive Belt ........8-4 Trouble Diagnosis ..... 8-2 Movable Drive Face ....8-6 Left Crankcase Cover ....8-3 Clutch / Driven Pulley ....8-9 Mechanism Illustration 5.0~6.0 kgf-m 5.0~6.0 kgf-m 5.0~6.0 kgf-m...

  • Page 97: Maintenance Description

    This Chapter Contents 8. V-Belt Driving System/Foot Starter Maintenance Description PRECAUTIONS IN OPERATION • Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. • Driving belt and driving pulley surface must be free of grease. Specification Unit: mm Item Standard value Limit...

  • Page 98: Left Crankcase Cover

    This Chapter Contents 8. V-Belt Driving System/Foot Starter Left Crankcase Cover Removal of Crankcase Cover Remove body cover. Remove foot starter lever. ( bolt x 1) Remove the outer cover of engine left-side cover. (screw x 3) Loosen vent strap on the front-left side of cover, and then remove the vent.

  • Page 99: Drive Belt

    This Chapter Contents 8. V-Belt Driving System/Foot Starter Drive Belt Removal Remove left crankcase cover. Hold drive face with universal fixture, and remove nut and drive face. Universal fixer Hold the clutch outer with the universal fixture, and the remove the nut and the clutch outer . Caution Using special service tools for tightening or loosening the nut.
  • Page 100 This Chapter Contents 8. V-Belt Driving System/Foot Starter Installation Pull out the driven face and then insert the drive belt into the driven pulley. Sliding Caution driven face Pull out sliding driven face and then insert the drive belt into the driven pulley so that the drive belt set can be installed onto pulley more easily.

  • Page 101: Movable Drive Face

    This Chapter Contents 8. V-Belt Driving System/Foot Starter Movable Drive Face REMOVAL Remove left crankcase cover. Hold drive face with universal fixture, and then remove drive face nut. Remove drive face. Universal fixture Take out the drive belt from the drive face. Movable drive face Remove movable drive face set and drive face boss from crankshaft.
  • Page 102 This Chapter Contents 8. V-Belt Driving System/Foot Starter Inspection The operation of movable drive face is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the ramp plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.
  • Page 103 This Chapter Contents 8. V-Belt Driving System/Foot Starter Apply with grease 4~5 g to inside of drive face boss hole, and install drive face boss. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install movable drive face assembly onto Movable drive face...

  • Page 104: Clutch / Driven Pulley

    This Chapter Contents 8. V-Belt Driving System/Foot Starter Clutch / Driven Pulley Special nut wrench DISASSEMBLY Remove drive belt and clutch / driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much.
  • Page 105 This Chapter Contents 8. V-Belt Driving System/Foot Starter Clutch lining Measure each clutch lining thickness. Replace Clutch lining it if exceeds service limit. Service limit: 2.0 mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 123.4 mm Driven pulley Check following items:...
  • Page 106 This Chapter Contents 8. V-Belt Driving System/Foot Starter Clutch Block Replacement Spring Driving Remove snap and washer, and the remove plate clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption Check if shock absorption rubber is damage or rubber...
  • Page 107 This Chapter Contents 8. V-Belt Driving System/Foot Starter Install snap ring and mounting plate onto setting pin. Snap ring REPLACEMENT OF DRIVEN PULLEY BEARING Remove inner bearing. Oil seal Outer bearing Caution • If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
  • Page 108 This Chapter Contents 8. V-Belt Driving System/Foot Starter INSTALLATION OF CLUTCH/DRIVEN PULLEY Oil seal ASSEMBLY Install new oil seal and O-ring onto sliding driven face. Apply with specified grease to lubricate the inside of sliding driven face. Specified grease O-ring Install sliding driven face onto driven face.
  • Page 109 This Chapter Contents 8. V-Belt Driving System/Foot Starter NOTE: 8-14...

  • Page 110: Final Driving Mechanism

    Home page Contents 9. Final Driving Mechanism Mechanism Illustration ....9-1 Inspection Of Final Driving Mechanism........9-3 Operational precautions.... 9-2 Bearing Replacement....9-4 Trouble Diagnosis...... 9-2 Re-Assembly Of Final Driving Disassembly of Final Driving Mechanism .........9-6 Mechanism ......... 9-3 Mechanism Illustration Final driving shaft Countershaft Final driving gear...

  • Page 111: Operational Precautions

    This Chapter Contents 9. Final Driving Mechanism Operational precautions Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 2.0~2.4 kgf-m Recommended oil: KING MATE serial gear oils Gear oil drain plug 1.0~1.4 kgf-m Oil quantity: 110 c.c. (100 c.c. when replacing) Gear oil filling bolt 0.8~1.2 kgf-m Tools...

  • Page 112: Disassembly Of Final Driving Mechanism

    This Chapter Contents 9. Final Driving Mechanism Disassembly of Final Driving Mechanism Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7 bolts) and then remove the cover and the final driving shaft. Remove gasket and setting pin.

  • Page 113: Bearing Replacement

    This Chapter Contents 9. Final Driving Mechanism Check bearings on gear box and cover. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box & cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 114 This Chapter Contents 9. Final Driving Mechanism Press out the driving shaft from the gear box. Remove oil seal from the gear box. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution •...

  • Page 115: Re-Assembly Of Final Driving Mechanism

    Torque: 2.0~2.4 kgf-m Install the clutch/sliding driving pulley. Install the driving pulley, belt and left crankshaft cover. Install the rear wheel. Add gear oil. ※Recommended usage: SYM HYPOID GEAR OIL (SAE 85W-140) (110 cc: standard capacity) (100 cc: when replacement) 7 bolts...

  • Page 116: Alternator / Starting Clutch

    Contents Home page 10. Alternator/Starting Clutch Mechanism Illustration ....10-1 Starting Clutch ......10-5 Precautions in Operation ..10-2 Right Crankcase Cover Installation ..........10-8 Alternator Removal....10-3 Mounted Coil Set Installation. 10-8 Alternator Coil Set Removal ...10-4 Flywheel Installation ....10-8 Right Crankcase Cover Removal ........10-4 Mechanism Illustration 5.0~6.0 kgf-m...

  • Page 117: Precautions In Operation

    This Chapter Contents 10. Alternator/Starting Clutch Precautions in Operation General information Refer to chapter 5: Engine removal and installation Refer to chapter 1: The troubleshooting and inspection of alternator Refer to chapter 16: The service procedures and precaution items of starter motor Specification Unit: mm Item...

  • Page 118: Alternator Removal

    This Chapter Contents 10. Alternator/Starting Clutch Alternator Removal Flywheel Crankshaft position sensor Fan shroud Coil Cable guide Drain out the engine oil. Remove the right side cover. ( 4 screws) Remove the exhaust muffler. (2 bolts, 2 nuts) Remove the fan shroud. (2 screws) Remove the cooling fan shroud.

  • Page 119: Alternator Coil Set Removal

    This Chapter Contents 10. Alternator/Starting Clutch Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller. Flywheel puller Pulse generator coupler...

  • Page 120: Starting Clutch

    This Chapter Contents 10. Alternator/Starting Clutch Starting Clutch Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen mounting nut and Mounting nut gasket. Special service tools: Anti-loosen mounting nut socket Universal fixture Caution The mounting nut is left-turn thread.
  • Page 121 This Chapter Contents 10. Alternator/Starting Clutch Check the starting driven gear for wear or damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Check the starting idle gear and shaft for wear or damage.
  • Page 122 This Chapter Contents 10. Alternator/Starting Clutch Installation Install the components in the reverse procedures of removal. Plug Spring Caution Add adhere seal onto the thread of hex socket bolt. Roller Torque value: 1.0~1.4 kgf-m Clutch body Clutch cover Starting clutch Installation Install idle gear shaft and idle gear.

  • Page 123: Right Crankcase Cover Installation

    This Chapter Contents 10. Alternator/Starting Clutch Right Crankcase Cover Installation 8 bolts Install setting pin and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.
  • Page 124 This Chapter Contents 10. Alternator/Starting Clutch Install the cooling fan. (4 bolts) Cooling fan Install the cooling fan shroud. ( 3 screws) Install the rear bracket mounting bolts. (2 bolts) Install the exhaust pipe. (2 bolts, 2 nuts) Install the right side cover. (4 screws) Add some engine oil according to specified quantity.
  • Page 125 This Chapter Contents 10. Alternator/Starting Clutch NOTE: 10-10...

  • Page 126: Crankcase/Crankshaft

    Contents Home page 11. Crankcase/Crankshaft Mechanism Illustration ....11-1 Disassembly Of Crankcase ..11-3 Operational precautions..11-2 Crankshaft Inspection....11-4 Trouble diagnosis ....11-2 Assembly Of Crankcase ..11-5 Mechanism Illustration 1.5~2.0 kgf-m 1.0~1.4 kgf-m 0.7~1.0 kgf-m 0.8~1.2 kgf-m 0.8~1.2 kgf-m 3.5~4.5 kgf-m 11-1...

  • Page 127: Operational Precautions

    This Chapter Contents 11. Crankcase/Crankshaft Operational precautions General Information • This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. • Complete following operations before disassembling crankcase. Engine Chapter 5 Cylinder head Chapter 6 Cylinder/ piston Chapter 7 V-belt Drive pulley...

  • Page 128: Disassembly Of Crankcase

    This Chapter Contents 11. Crankcase/Crankshaft Disassembly Of Crankcase Hex-socket bolt x 1 Remove the cam chain tensioner (hex socket bolt x 1) from the left crankcase side. Remove the 2 bolts from the right side of Screw x 2 crankcase, and then remove the right crankcase. Remove the crankshaft from the left crankcase.

  • Page 129: Crankshaft Inspection

    This Chapter Contents 11. Crankcase/Crankshaft Crankshaft Inspection Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radical clearance of the big end at the vertical directions. Service limit : 0.05 mm Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.

  • Page 130: Assembly Of Crankcase

    This Chapter Contents 11. Crankcase/Crankshaft Assembly Of Crankcase Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.
  • Page 131 This Chapter Contents 11. Crankcase/Crankshaft Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer (25x37x6). Special service tools: the oil seal installer (25x37x6) 11-6...
  • Page 132 Contents Home page 12. Body Cover Mechanism Illustration .... 12-1 Luggage Box ......12-8 Maintenance Information ..12-2 Rear Carrier ......12-9 Front Cover....... 12-3 Body Cover ......12-10 Handlebar Cover ...... 12-4 Left & Right Side-Foot Plates 12-11 Front Fender......12-5 Left & Right Side-Covers..12-11 Front Under Spoiler ....

  • Page 133: Maintenance Information

    This Chapter Contents 12. Body Cover Maintenance Information Body covers disassemble sequence: Handlebar Rear Front cover Center cover Cover Handlebar Left/right Front fender Luggage box & seat side cover Handlebar front Front under Spoiler Rear carrier cover Inner cover Body cover Left/Right foot Rear fender / plates...

  • Page 134: Front Cover

    This Chapter Contents 12. Body Cover Front Cover Removal Remove the 8 mounting screws from the inside of front inner cover. Screw x 8 Remove the upper screw (screw x 1) from the Screw x 1 front fender. Remove the front light wire coupler. Front light wire coupler Remove the front cover.

  • Page 135: Handlebar Cover

    This Chapter Contents 12. Body Cover Handlebar Cover Screw x 5 Removal Remove the handlebar rear cover (screw x 5). Disconnect the wire connectors of left & right switches. Remove the handlebar rear cover. Caution • Open the hooks on the two end-section of the handlebar cover as removing the cover.

  • Page 136: Front Fender

    This Chapter Contents 12. Body Cover Front Fender Removal Remove the speedometer cable.(screw x 1) Screw ×1 Remove the front fender screws. (left & right x 2) Left & right screws x 2 Remove the front fender. Installation Install according to the reverse procedure of removal.

  • Page 137: Front Under Spoiler

    This Chapter Contents 12. Body Cover Front Under Spoiler Removal Remove the front fender, front cover. Remove the screw (screw x 2) from the top-end of front under spoiler. Screw on each side ×1 Remove the inner cover screw. (left & right each side x 1) Screw on each side x 1 Remove 2 screws on the left &...
  • Page 138 This Chapter Contents 12. Body Cover Inner Cover Removal Remove the front cover and front under spoiler firstly. Remove the mounting bolts (2 bolts) of floor Panel. Bolt x 2 Ignition switch cap Remove 1 bolt and ignition switch cap. Bolt ×1 Take out the front inner cover.

  • Page 139: Center Cover

    This Chapter Contents 12. Body Cover Center Cover Removal Remove the 1 upper screw inside of the luggage box. Remove the lower 2-screws in front of the center cover. Take out the center cover. Installation Install according to the reverse procedure of removal.

  • Page 140: Rear Carrier

    This Chapter Contents 12. Body Cover Rear Carrier Bolt x 4 Removal Remove the hex-socket bolts (bolt x 4) of the rear carrier. Caution Do not open the fuel tank cap as removing the bolts so that prevent from bolts falling into the fuel tank.

  • Page 141: 12. Body Cover

    This Chapter Contents 12. Body Cover Body Cover Screws and bolt on each side Removal Remove the rear carrier, luggage box and seat firstly. Remove the body cover mounting screws and bolts. (1 screw and 1 bolt on each side) Remove 2 screw in rear of the body cover.

  • Page 142: Left & Right Side-Foot Plates

    This Chapter Contents 12. Body Cover Left & Right Side-Foot Plate Screws x 2 Removal Remove the foot plate connection screws. (2 screws on left & right each side) Remove the rear bolts. (1 bolt on left & right each side) Remove the side foot plate.

  • Page 143: Floor Panel

    This Chapter Contents 12. Body Cover Floor Panel Bolt x2 Removal • Remove the center cover, luggage box, body side covers, and body cover firstly. • Remove the front mounting bolts (bolt x 2) of the floor panel. Remove the battery cover. (screw x 3) Screw x 3 Remove the battery bracket (screw x 2) and power cables.

  • Page 144: Rear Fender

    This Chapter Contents 12. Body Cover Rear Fender Bolt x 2 Removal Remove the upper bolts (bolt x 2) from the rear fender. Remove the left & right side bolt (1 bolt on each side) from the rear fender. Remove the rear turning signal lamp wire, and then the rear fender.
  • Page 145 This Chapter Contents 12. Body Cover NOTES: 12-14...

  • Page 146: Brake System

    Home page Contents 13. Brake Front Disc Brake System..13-1 Brake Fluid Replacement/Air-Bleed ... 13-6 Rear Drum Brake System ..13-2 Brake Caliper ......13-7 Precautions in Operation ..13-3 Brake Disc........ 13-8 Trouble Diagnosis....13-4 Brake Master Cylinder .... 13-8 Hydraulic Brake System Inspection .........

  • Page 147: Rear Drum Brake System

    This Chapter Contents 13. Brake Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-2...

  • Page 148: Precautions In Operation

    This Chapter Contents 13. Brake Precautions in Operation Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. • The brake caliper can be removed without removing the hydraulic system.

  • Page 149: Trouble Diagnosis

    This Chapter Contents 13. Brake Trouble Diagnosis DISC BRAKE Soft brake lever Uneven brake 1. Air inside the hydraulic system 1. Dirty brake lining/disc 2. Hydraulic system leaking 2. Poor wheel alignment 3. Worn master piston 3. Clogged brake hose 4.

  • Page 150: Hydraulic Brake System Inspection

    This Chapter Contents 13. Brake Hydraulic Brake System Inspection Hose connection Inspection Visual inspect for brake fluid leaking or damage. Check if brake hose connection loosen with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components.

  • Page 151: Brake Fluid Replacement/Air-Bleed

    This Chapter Contents 13. Brake Remove the master cylinder cap and diaphragm. Screw Add good quality brake fluid and it has to add Master cylinder same brand brake fluid into the master cylinder. Clean dirty brake disc. Diaphragm plate MAX. CAUTION Diaphragm The dirty brake lining or disc will reduce the...

  • Page 152: Brake Caliper

    This Chapter Contents 13. Brake Brake Caliper Removal Bolts x 2 Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hoses. CAUTION • Do not spill brake fluid on painted surfaces. •...

  • Page 153: Brake Disc

    This Chapter Contents 13. Brake Brake Disc Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several Brake places. Replace the disc if it has exceeded the disc service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disc from wheel.
  • Page 154 This Chapter Contents 13. Brake Inspection Master Check the master cylinder for damage or scratch. cylinder Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
  • Page 155 This Chapter Contents 13. Brake INSTALLATION Master cylinder Place the master cylinder onto handlebar, and Mounting install the split ring and bolts. The “UP” mark on seat the split ring should face upward. Punch Align the split ring on the master cylinder seat point with the alignment point on the handlebar.

  • Page 156: Drum Brake System Inspection

    This Chapter Contents 13. Brake DRUM BRAKE SYSTEM INSPECTION BRAKE DRUM Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the asbestos dust. Caution Inhaling asbestos dust may cause respiration system disorder even cancer.
  • Page 157 This Chapter Contents 13. Brake Slightly grind the brake lining surfaces with sand-paper to clean the surfaces. Brake cam Caution Braking efficiency will be reduced if brake lining is contaminated by oil or grease. Anchor Brake spring Brake BRAKE PANEL Removal Remove the brake arm bolt and then remove the brake arm, wear indicator, brake return...
  • Page 158 Contents Home page 14. Steering/Front Wheel/Front Shock Absorber Mechanism Illustration.....14-1 Front Wheel....... 14-4 Precautions in Operation ..14-2 Front shock absorber ....14-7 Trouble diagnosis.....14-2 Front fork/steering column..14-7 Steering Handlebar....14-3 Mechanism Illustration 4.0~5.0 kgf-m 1.0~2.0 kgf-m 0.2~0.3 kgf-m 2.4~3.0 kgf-m 3.1~3.5 kgf-m 5.0~7.0 kgf-m 14-1...

  • Page 159: Precautions In Operation

    This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Precautions in Operation General Information • Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. •...

  • Page 160: Steering Handlebar

    This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Steering Handlebar Master cylinder REMOVAL Remove handlebar front & rear cover and the front cover (refer to chapter 12). Disc Brake Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring.

  • Page 161: Front Wheel

    This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Front Wheel Removal Speedometer Support body bottom and lift front wheel free of cable ground. Remove the screw, and disconnect speedometer cable from the gear box. Remove the wheel axle nut and pull out the axle. Then, remove the front wheel.
  • Page 162 This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Disassembly Remove the left axle ring and dust seal. Bearing Remove the dust seal on the right side of speedometer gear. Remove the bearing with the inner type bearing remover. Take out the bearing spacer and then remove the Wheel side other bearing.
  • Page 163 This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Caution Do not install used bearing and replace the bearing once it has been removed. Do not the bearing in tile motion when installing. Tool: C-type compressor or bearing compressor. Both samples will damage bearing Align the flange part on the speedometer gear with the slot of wheel hub, and then install the speedometer gear box.

  • Page 164: Front Shock Absorber

    This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber Front shock absorber Removal Remove the front fender, front under spoiler, front cover, and front wheel as well as front brake components. Remove the brake fluid hose clipper or cable guide on the left shock absorber. (bolt x 1) As for disc brake, remove the cable guide on the right shock absorber.
  • Page 165 This Chapter Contents 14. Steering/Front Wheel/Front Shock Absorber With a plastic hammer to tap the steering ball race slightly, and then remove the top ball bearing race. Remove the lower-end cone bearing race on the frame with a punch. Caution Do not damage the frame and the steering race.
  • Page 166 Home page Contents 15. Rear Wheel / Rear Shock Absorber Mechanism Illustration.....15-1 Exhaust Muffler ......15-3 Precautions in Operation ..15-2 Rear Wheel........ 15-3 Trouble Diagnosis ....15-2 Rear Shock Absorber ....15-4 Mechanism Illustration 3.5~4.5kgf-m 2.4~3.0kgf-m 0.8~1.2kgf-m 10.0~12.0kgf-m 3.2~3.8kgf-m 3.2~3.8kgf-m 15-1...

  • Page 167: Precautions In Operation

    This Chapter Contents 15. Rear Wheel / Rear Shock Absorber Precautions in Operation General Information As for the wheel removal, service, and installation procedures, please refer to the service manual of high speed tire. Specification Unit: mm Items Standard Limit Radial Wheel wobbling Axial...

  • Page 168: Exhaust Muffler

    This Chapter Contents 15. Rear Wheel / Rear Shock Absorber Exhaust Muffler Nuts x 2 Removal Remove the front-end nut of the exhaust muffler. (nut x 2) Remove the bolts. (bolts x 3) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal.

  • Page 169: Rear Shock Absorber

    This Chapter Contents 15. Rear Wheel / Rear Shock Absorber Rear Shock Absorber Removal Remove the luggage box. (bolt x4, screw x1) Remove the body cover. (screw x 4) Remove the air cleaner. (bolt x2) Bolt x 2 Bolt x 1 Remove the under bolt of the rear shock absorber.

  • Page 170: Electrical Equipment

    Contents Home page 16. Electrical Equipment Mechanism Illustration ....16-1 Ignition System ......16-9 Precautions In Operation ..16-2 Starting System......16-12 Specification......16-3 Meter........16-14 Trouble diagnosis ....16-4 Light / Light Bulb....16-16 Battery........16-4 Switch / Horn ......16-18 Charging system......16-5 Fuel Gauge Unit......16-21 Mechanism Illustration Horn Winker relay Horn switch / Winker switch /...

  • Page 171: Precautions In Operation

    This Chapter Contents 16. Electrical Equipment Precautions In Operation Charging System When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water. Battery must be taken out from scooter when charging the battery.

  • Page 172: Specification

    This Chapter Contents 16. Electrical Equipment Specification Charging System Items Specification Capacity/type 12V6Ah / YTX7A-BS Charging rate STD:0.6A/5~10hrs, emergency charging: 6A/0.5hrs Battery Full charged 13.1V Voltage (20℃) Under charged 12.3V Capacity 12V / 6.2A Alternator Lighting coil resistance (20℃) Between yellow-green: 0.1-0.8Ω Charging coil resistance (20℃) Between white-green: 0.2-1.0Ω...

  • Page 173: Trouble Diagnosis

    This Chapter Contents 16. Electrical Equipment Trouble diagnosis No power supply Intermittent power supply Dead battery Loose charging system connection • • Disconnect battery cable Loose battery cables • • Fuse burned out Loose connection or short-circuit in discharging • •...

  • Page 174: Charging System

    This Chapter Contents 16. Electrical Equipment Charging system Charging wire circuit Main switch Fuse Battery Alternator Regulator Charging Connect the battery charger’s positive (+) terminal to battery’s positive (+) post. Connect the battery charger’s positive (-) terminal to battery’s positive (-) post. Standard Charging current 0.9A...
  • Page 175 This Chapter Contents 16. Electrical Equipment Current Leakage Test Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the Battery (-) terminal battery. Connect an ammeter between the negative cable terminal and the battery negative terminal (as shown on left diagram).
  • Page 176 This Chapter Contents 16. Electrical Equipment Caution Main switch Do not use short-circuit cable. • It is possible to measure the current by • connecting an ammeter between the battery positive terminal and the cable position terminal, however, while the starter motor is activated, the surge current of the motor draws from the battery may damage the ammeter.
  • Page 177 This Chapter Contents 16. Electrical Equipment REGULATOR INSPECTION Remove the rear carrier. (refer to chapter 12, section 8) Remove the body cover. (refer to chapter 12, section 8) Disconnect the 5P connector of the regulator. Measurement Item Standard Value point Main switch Battery voltage connection wire...

  • Page 178: Ignition System

    This Chapter Contents 16. Electrical Equipment Ignition System Ignition System Circuit Green Blue / Yellow Black / Black / Red Yellow Exciter coil Black / White C.D.I. set Green Pulsator Main switch Ignition Coil Spark plug Alternator CDI UNIT Removal Remove the battery cover, then the CDI unit can be removed from the battery cover.
  • Page 179 This Chapter Contents 16. Electrical Equipment IGNITION COIL Ignition coil Removal Remove the luggage box, central cover. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix bolts for the ignition coil, and remove the coil. Install the coil in reverse order of removal.
  • Page 180 This Chapter Contents 16. Electrical Equipment Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7-12 kΩ(20℃) Remove the spark plug cap, measure the resistance between plug cap side and green terminal.

  • Page 181: Starting System

    This Chapter Contents 16. Electrical Equipment Starting System Starting Circuit Main switch Battery Fuse 10A Start motor Brake switch Start relay Green / yellow Start switch Start Relay Inspection Turn main switch to "on", and operate the brake lever. Then press start button to check if there a click sound.
  • Page 182 This Chapter Contents 16. Electrical Equipment START MOTOR REMOVAL Remove the luggage box. (chapter 12, section 6) Remove the air cleaner. (chapter 4, section 10) Remove the battery negative terminal. Remove the battery positive terminal and the start motor wire from the big terminal of start relay.

  • Page 183: Meter

    This Chapter Contents 16. Electrical Equipment Meter Removal Remove the front cover. (chapter 12, section 4) Remove the power coupler of the meter. Remove the rear cover of the handlebar. (chapter 12, section 3) Remove the odometer cable. 速度錶導線 Remove the winker relay coupler. Winker relay coupler 16-14...
  • Page 184 This Chapter Contents 16. Electrical Equipment Remove the front cover of handlebar. (chapter 12, Screw x 4 section 3) Screw x 4 Remove the instrument panel assembly. (screw x 4) Disassemble the instrument seat and the instrument. (screw x 2) Instrument Panel Installation Install the panel in reverse procedure of removal.

  • Page 185: Light / Light Bulb

    This Chapter Contents 16. Electrical Equipment Light / Light Bulb Headlight Bulb Replacement Remove the front cover. (chapter 12, section 4) Disconnect the headlight wire connector, and then remove the rubber boot. Press down the bulb spring locker and then remove the locker with turning it in CCW motion.
  • Page 186 This Chapter Contents 16. Electrical Equipment Front Turn Signal Light Bulb Replacement Remove the light outer cover of the turn signal light. (screw x 2) Remove the light inner cover of the turn signal lamp. (screw x 1) Replace the bulb with new one. Rear Turning Signal Light Replacement Pry out the light cover from the preset slot onto the lower parts of cover.

  • Page 187: Switch / Horn

    This Chapter Contents 16. Electrical Equipment Switch / Horn Main Switch Inspection Remove front fender. (bolts x2, screws x4) Disconnect main switch leads connector. Check connector terminals for continuity. BAT1 BAT2 Location LOCK ● ● ● ● ● ● Black/ Wire color Black Green...
  • Page 188 This Chapter Contents 16. Electrical Equipment Handlebar switch Remove the rear handlebar cover. (chapter 12, section 3) Disconnect the connector of the handlebar switch. Check the continuity of follow pins listed below columns. Start switch Start motor FREE switch ● ●...
  • Page 189 This Chapter Contents 16. Electrical Equipment Turn signal light switch Turn signal light switch ● ● FROM R ● ● PUSH OFF FROM L ● ● Horn switch ● ● Light Wire color Gray Orange blue Horn Remove the front fender. Connect 12V power to the 2 pins on the horn.
  • Page 190 This Chapter Contents 16. Electrical Equipment Fuel Gauge Unit Fuel gauge unit remove Open the seat cushion Remove the luggage box assembly (bolts x4, screw x1) Remove the rear carrier (bolts x4) Remove the central cover (screws x 2) Remove the left & right body covers (bolts x 2, screw x 4).
  • Page 191 This Chapter Contents 16. Electrical Equipment NOTE: 16-22...

  • Page 192: Wiring Diagram

    Contents Home page 17. Wiring Diagram 17-1...
  • Page 193 Home page Contents 17. Wiring Diagram NOTE: 17-2...

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