SANYANG INDUSTRY CO. XS125-K Service Manual
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SANYANG INDUSTRY CO. XS125-K Service Manual

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DK Version 1.0 2009
SERVICE MANUAL
XS 125-K

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Summary of Contents for SANYANG INDUSTRY CO. XS125-K

  • Page 1 DK Version 1.0 2009 SERVICE MANUAL XS 125-K...
  • Page 2 PREFACE PREFACE l This shop manual describes the technical feature and servicing procedures for the SANYANG XS125-K. l All information, illustrations, directions and specifications included in this publication are base on SANYANG XS125-K. l SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever.

  • Page 3: Table Of Contents

    CONTENTS CONTENTS GENERAL INFORMATION................1 INSPECTION/ADJUSTMENT ................2 LUBRICATION SYSTEM................3 ENGINE REMOVAL/INSTALLATION ............4 CYLINDER HEAD/VALVE ................5 CYLINDER/PISTON ..................6 CLUTCH/OIL PUMP/GEAR SHIFT..............7 A.C. GENERATOR ..................8 CRANK SHAFT/CRANK CASE/TRANSMISSION........9 CARBURETOR ....................10 HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ......11 REAR WHEEL/REAR SUSPENSION.............12 BATTERY/CHARGING SYSTEM ..............13 IGNITION SYSTEM ..................14 SWITCHES/HORN...................15 WIRING DIAGRAM ..................16...

  • Page 4: General Information

    1.GENERAL INFORMATION SERVICE RULES ........1-1 TORQUE VALUES .........1-3 SPECIFICATIONS ........1-2 TROUBLE SHOOTING ......1-4 SERVICE RULES: (1)Use new packings, gaskets,O-rings and cotter (5)Clean all removed parts in or with solvent, and pins space and clipes whenever reassembling. lubricate their sliding surfaces upon disassembly. (2)When tightening bolts or nuts, begin on center or (6)Coat or fill parts with specified grease where larger diameter bolts and tighten them in criss-...
  • Page 5 1.GENERAL INFORMATION SPECIFICATIONS ITEM XS125-K Overall length 2040mm Overall width 750mm Overall height 1100mm DIMENSIONS Wheel base 1280mm Ground clearance 150mm Dry weight 130kg Type Single pipe Front suspension and travel Telescope 165mm Rear suspension and travel Swing arm 63mm 2.25Kg/C ㎡...
  • Page 6 1.GENERAL INFORMATION ENGINE TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf ・ Starting clutch outer bolt socket 100~150 Cylinder stud bolt 80~120 Shift drum stopper hex bolt 80~120 Gear shift cam hex bolt 80~120 Cylinder stud bolt 180~220 Cylinder head cap nut 280~300 Driven gear hex bolt 100~150...

  • Page 7: Inspection/Adjustment

    1.GENERAL INFORMATION Torque specifications listed below for respective locations. TROUBLE SHOOTING A. HARD START OR CANNOT START inspection adjustment cause symptom loosen carburetor drain screw, check inner side for no gasoline in the tank gasoline fuel tube between gasoline tank and carburetor clogged.
  • Page 8 1.GENERAL INFORMATION B. ROTATION ROUGH (LACKS POWER) cause inspection adjustment symptom start engine and slightly air cleaner clogged apply fuel fuel tube clogged air hole on the fuel tank cap blocked engine speed up exhaust tube clogged engine speed can't up auto air cut faulty carburetor vacuum diaphragm worn adjust ignition timing use...

  • Page 9: A.c. Generator

    1.GENERAL INFORMATION C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED) inspection adjustment cause symptom ignition timing adjustment faulty CDI unit normal abnormal faulty A.C.Generator valve gap adjust faulty adjust carburetor fuel adjusting screw lean mixture(loosen screw) adjust OK adjust faulty rich mixture(tighten screw) carburetor gasket...
  • Page 10 1.GENERAL INFORMATION D. ROTATION ROUGH (HIGH SPEED) cause symptom inspection adjustment ignition timing adjustment faulty CDI unit normal abnormal faulty pulse generator valve clearance adjustment poor adjustment normal abnormal valve seat faulty check auto fuel cup for fuel supplied. too little fuel in the fuel tank normal abnormal fuel tube, fuel filter clogged...
  • Page 11 1.GENERAL INFORMATION E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE) inspection adjustment symptom cause measure battery voltage. and then start engine battery voltage battery voltage rise to reach battery life can't rise normal value,after faulty battery engine stops, the voltage return to original.
  • Page 12 1.GENERAL INFORMATION F.SPARK PLUG NO SPARK cause Inspection adjustment symptom replace with new spark plug and test again. spark wear of spark strong original spark plug no spark faulty Check spark cap and high voltage cable for slack no slack slack spark plug cap slack...
  • Page 13 2.INSPECTION/ADJUSTMENT ENGINE FRAME MAINTENANCE SCHEDULE ....2-2 AIR CLEANER........2-12 SERVICE INFORMATION......2-3 CLUTCH ADJUSTMENT ......2-12 ENGINE OIL/OIL FILTER......2-4 BRAKE ADJUSTMENT......2-13 SPARK PLUG ..........2-5 DRIVE CHAIN ADJUSTMENT .....2-14 COMPRESSION TEST ......2-6 WHEELS/RIM .........2-15 VALVE CLEARANCE.......2-7 SUSPENSION ........2-16 IGNITION TIMING........2-8 STEERING ..........2-17 CAM CHAIN TENSION ADJUSTMENT ..2-9 BATTERY..........2-17 THROTTLE GRIP ADJUSTMENT....2-10 HEAD LIGHT AIM........2-18...
  • Page 14 2.INSPECTION/ADJUSTMENT Periodical Maintenance Schedule From the sales date: 3000 km-6 months / 9.000 km-18 months / 15.000 km-30 months 6000 km-12 months / 12.000 km-24 months / 18.000 km-36 months The following services; A and B continuously for every +3.000 km or 6 months. The service intervals must be upheld within a maximum of + 10% C=Cleaning I=Inspection (replacement if necessary) A=Adjustment L=Lubrication R=Replacement Service...
  • Page 15 2.INSPECTION/ADJUSTMENT SERVICE INFORMATION SPECIFICATLON ENGINE FRAME Oil capacity 1.1～1.5 liter Clutch lever free play 10-20mm Spark plug NGK DR7EA Drive chain stack 10-20mm Spark plug gap 0.6-0.7mm Front brake lever free play 10-20mm Valve clearance IN 0.10mm Rear brake pedal free play 20-30mm 0.15mm Throttle grip free play...

  • Page 16: Oil Level Check

    2.INSPECTION/ADJUSTMENT OIL/OIL FILTER OIL LEVEL CHECK Start and warm up the engine for few minutes,then stop the engine. Check the oil level with oil level gauge after a few minutes. If the oil level is near the lower mark,fill the crankcase to the upper level mark with the recommended grade oil.

  • Page 17: Spark Plug

    2.INSPECTION/ADJUSTMENT OIL FILTER SCREEN CLEANING OIL FILTER SCREEN Remove the oil filter cap, oil filter screen and drain the COVER engine oil. Operate the kick starter several times to drain residual oil completely. Clean the oil filter screen with compressed air. Install the oil filter screen, spring and screen cap.
  • Page 18 2.INSPECTION/ADJUSTMENT COMPRESSION TEST Warm up the engine. Stop the engine .Remove spark plug .Insert the compression gauge. ELECTRICAL Push in the choke lever .Open the throttle grip fully. START ENGINE Electrical start engine several times. NOTE: Ÿ Watch for compression leaking at the gauge connection.
  • Page 19 2.INSPECTION/ADJUSTMENT VALVE CLEARANCE ALIGN NOTE: MARK Inspect and adjust the valve clearance while the engine is cold. Remove the timing inspection hole cap and crankshaft hole cap. Rotate the generator rotor counterclockwise and align the “ T” mark on the generator rotor with the index mark in the left crankcase ALIGN (piston must be at T.D.C.of the compression...

  • Page 20: Ignition Timing

    2.INSPECTION/ADJUSTMENT Install the valve adjuster caps and generator cap. NOTE: Check the O-ring for damage and spread oil before installing the caps. O-RING IGNITION TIMING The C.D.I.ignition timing is not adjustable. If the ignition timing is not correct ,check the C.D.I.unit and A.C.generator and replace any faulty parts.
  • Page 21 2.INSPECTION/ADJUSTMENT Inspect the C.D.I unit with C.D.I tester. Replace the faulty C.D.I unit. SWITCH C.D.I. normal C.D.I faulty 1. OFF no sparks ------- 2. P no sparks ------- 3. EXT no sparks sparks 4. ONI sparks no sparks 5. ONZ sparks no sparks CAM CHAIN TENSIONER...
  • Page 22 2.INSPECTION/ADJUSTMENT CARBURETOR THROTTLE GRIP FREE PLAY Check throttle grip free play. Free play:2-6mm THROTTLE GRIP ADJUSTMENT Loosen the lock nut and turn the adjuster to adjust. ADJUSTER NUT 2-10...

  • Page 23: Idling Speed Adjustment

    2.INSPECTION/ADJUSTMENT IDLING SPEED ADJUSTMENT Warm up the engine. Turn the stop screw to obtain the idling speed of 1100rpm. Turn the air screw to the maximum speed,then turn the stop screw to obtain the specified idling speed. Idling speed:1500±100 rpm. NOTE: Turn the air screw clockwise for making fuel –...

  • Page 24: Air Cleaner

    2.INSPECTION/ADJUSTMENT AIR CLEANER Remove the left side cover. Remove the air cleaner cover. Remove the air cleaner element. NOTE: Clean the cleaner element periodically.(Refer to maintenance schedule.) SCREWS Assemble air cleaner element in reverse order of disassemble. AIR CLEANER ELEMENT CLUTCH ADJUSTMENT CLUTCH LEVER FREE PLAY Measure the clutch free play at the tip of the clutch...

  • Page 25: Free Play Adjustment

    2.INSPECTION/ADJUSTMENT FREE PLAY ADJUSTMENT Loosen the lock nut and turn the adjuster. Turn the adjuster ,clockwise for decreasing the free play ,counterclockwise for increasing the free play. LOCK NUT ADJUSTER NUT BRAKE ADJUSTMENT FRONT BRAKE LEVER FREE PLAY Measure the brake free play at the tip of the brake 10~20mm lever.

  • Page 26: Rear Brake Pedal Adjustment

    2.INSPECTION/ADJUSTMENT REAR BRAKE PEDAL FREE PLAY Measure the brake pedal free play before the brake start to engage. Free play :20-30mm 20~30mm REAR BRAKE PEDAL ADJUSTMENT Turn the brake adjuster nut clockwise to decrease the free play and counterclockwise to increase the play. CAUTION: The adjuster nuts indentation should seat against the brake arm pin properly.
  • Page 27 2.INSPECTION/ADJUSTMENT Loose the rear wheel axle nut for adjusting. ADJUSTING NUTS Turn the adjusting nuts on both adjusters as necessary. CAUTION: Tighten the axle nut. TORQUE:1000-1200 ・ Recheck the drive chain slack and free wheel rotation. Lubricate the drive chain with chain lubricant. WHEEL/RIM Front 2.25 kg/c ㎡...

  • Page 28: Front Suspension

    2.INSPECTION/ADJUSTMENT SUSPENSION FRONT SUSPENSION Check the action of the front forks by compressing them several times with the front brake applied . If there are abnormal noises or rattles ,check all the fasteners and tighten them to the specified torque. TORQUE: Front fork top bridge bolt :100-140 kgf ・...
  • Page 29 2.INSPECTION/ADJUSTMENT STEERING Raise the front wheel off the ground and check that the handlebar rotates freely.If the handlebar moves unevenly ,binds or has vertical movement,adjust the steering head nut. BATTERY Inspect the battery fluid level ,if the fluid level nears the lower level mark,fill with distilled water to the upper level mark .

  • Page 30: Headlight Aim

    2.INSPECTION/ADJUSTMENT HEADLIGHT AIM Adjust vertically by turning headlight up and down with the headlight bolts loosening. Fasten the bolts after adjustment. ADJUST NUTS STOPLIGHT SWITCH STOPLIGHT SWITCH The stoplight should come on when the brake pedal is depressed 20mm from the standard pedal position.If the action is abmormal, adjust by turning the stoplight switch adjusting nut.

  • Page 31: Lubrication System

    3.LUBRICATION SYSTEM CAM SHAFT OIL LINE OF CAM SHAFT PISTON MAIN SHAFT OIL ORIFICE OF CRANKSHAFT OIL PUMP COUNTER SHAFT OIL FILTER...
  • Page 32 3.LUBRICATION SYSTEM TROUBLE SHOOTING......3-1 SERVICE INFORMATION..... 3-1 TROUBLE SHOOTING OIL LEVEL TOO LOW 1. Natural consumption 2. Oil leaks 3. Worn piston rings OIL CONTAMINATION 1. Oil not changed often enough 2. Faulty cylinder head gasket OIL PRESSURE TOO LOW 1.

  • Page 33: Engine Removal/Installation

    4.ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION......4-1 ENGINE INSTALLATION.......4-4 ENGINE REMOVAL........4-2 SERVICE INFORMATION GENERAL INSTRUCTIONS The following parts can be serviced with the engine installed on the frame: Ÿ Generator Ÿ Clutch Ÿ Oil pump Ÿ Cam shaft / Rocker arm Ÿ Shift spindle Ÿ...
  • Page 34 4.ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil. Turn the fuel cock to “ OFF” and disconnect the fuel tubes and all connect tubes. Remove the right and left side covers. Remove the gear change pedal and left crank case LEFT CRANKCASE RR.COVER rear cover.
  • Page 35 4.ENGINE REMOVAL/INSTALLATION Remove the clutch cable. CLUTCH CABLE Remove the spark plug cap. Remove the muffler. Loosen carburetor clip. Separate the carburetor pipe and the cylinder head by CLIP removing the attaching bolts. Remove the crankcase breather tube. BREATHER TUBE ADJUSTING NUT Loosen the rear wheel axle nut.

  • Page 36: Engine Installation

    4.ENGINE REMOVAL/INSTALLATION Remove the front engine hanger bolt. NOTE: Places jack or padded block under the engine before removing the front engine hanger. Disconnect the starter motor wire. FRONT ENGINE HANGER BOLT BOLTS Remove the 10mm bolts of the rear engine hanger. Remove the engine.

  • Page 37: Cylinder Head/Valve

    5. CYLINDER HEAD/ VALVE TROUBLE SHOOTING ......5-1 VALVE GUIDE REPLACEMENT ..5-8 SERVICE INFORMATION......5-2 ..5-9 VALVE SEAT INSPECTION/REFACING CAM SHAFT REMOVAL .......5-3 VALVE SEAT GRINDING ......5-10 ..5-4 CYLINDER HEAD ASSEMBLY.....5-13 CYLINDER HEAD/ROCKER ARM REMOVAL CYLINDER HEAD DISASSEMBLY..5-6 CYLINDER HEAD INSTALLATION..5-14 ...5-7 CAM SHAFT INSTALLATION....5-15 VALVE/VALVE GUIDE INSPECTION TROUBLE SHOOTING...

  • Page 38: General Instructions

    5.INSPECTION/ADJUSTMENT SERVICE INFORMATION GENERAL INSTRUCTIONS Camshaft, rocker arm shaft and rocker arm can be serviced with the engine installed on the frame. Camshaft lubrication oil is fed to the cylinder head through an oil control orifice in the engine case. Be sure this orifice is not clogged and the O-ring and dowel pins are in place before installing the cylinder head.

  • Page 39: Camshaft Removal

    5. CYLINDER HEAD/ VALVE CAMSHAFT REMOVAL NOTE: The camshaft, rocker arm and rocker arm shaft can be serviced with the engine installed on the frame. Remove the cam sprocket cover. CAM SPROCKET COVER “O” MARK INDEX MARK Remove the crankshaft hole cap and the timing inspection hole cap.

  • Page 40: Cylinder Head

    5.INSPECTION/ADJUSTMENT CYLINDER HEAD CAM CHAIN TENSIONER BOLT REMOVAL Remove the cam chain tensioner bolt. Remove the 8mm bolt. Remove the 4 cylinder head nuts. Remove the dowel pins. Remove cam chain tensioner. Remove the cylinder head. 8mm BOLT Remove the rocker arm shaft. Remove the rocker arms.

  • Page 41: Camshaft Inspection

    5. CYLINDER HEAD/ VALVE CAMSHAFT INSPECTION Inspect the cams of the camshaft for wear. Service limit: Inlet: 31.25mm Exhaust: 30.87mm ROCKER ARM INSPECTION Inspect the rocker arm I.D. and the rocker arm for wear, damage or clogged oil holes. Rocker arm I.D. Service limit: φ12.018mm ROCKER ARM SHAFT INSPECTION Inspect rocker arm shaft for wear or damage.

  • Page 42: Cylinder Head Inspection

    5.INSPECTION/ADJUSTMENT CYLINDER HEAD DISASSEMBIY Remove carbon deposits from the combustion chamber. Remove valve spring and valve spring and valve with a valve spring compressor. VALVE SPRING RETAINER VALVE COTTER CYLINDER HEAD INSPECTION Remove gasket from cylinder head with a scraper. Check the cylinder head for crack.
  • Page 43 5. CYLINDER HEAD/ VALVE VALVE/VALVE GUIDE INSPECTION Inspect valves for scratches, burning or wear. Check the valve movement in the guide. Measure the valve stem O.D. Service limit: Intake: ∮5.42mm Exhaust:∮5.40mm NOTE: Remove any carbon buildup before checking the valve guide I.D. Guide I.D.

  • Page 44: Valve Guide Replacement

    5.INSPECTION/ADJUSTMENT VALVE GUIDE VALVE GUODE REMOVER REPLACEMENT Drive out the valve guide from the combustion chamber side with a 5mm valve guide remover. NOTE: When driving out the valve guide, do not damage the cylinder head. Install the new valve guide from the top of the cylinder head, and ream it with a reamer, then clean the cylinder head.
  • Page 45 5. CYLINDER HEAD/ VALVE VALVE SEAT INSPECTION/ REFACING Clean intake and exhaust valves to remove carbon deposits. Apply a light coating of prussian blue to each valve face. Insert each valve into the guide and rotate them two cycles. Remove the valve and inspect the face. CAUTION: If the valve face is burned or damaged or unevenly, replace the valve.
  • Page 46 5.INSPECTION/ADJUSTMENT VALVE SEAT GRINDING 60° NOTE: Follow the instructions described in the cutter instruction manual. 32° 45° Remove any roughness from the seat by applying 4~5 kg pressure, turning the cutter left and right. 4~5kg NOTE: Add engine oil to the face when operating. CUTTER CUTTER HOLDER TURN RIGHT AND LEFT...
  • Page 47 5. CYLINDER HEAD/ VALVE Using a 32 degree cutter, remove 1/4 of the existing valve seat material. CUTTER VALVE SEAT Remove the bottom 1/4 of the old seat by using a 60 degree cutter. CUTTER Finish the seat to the proper width by using a 45 CUTTER degree cutter.
  • Page 48 5.INSPECTION/ADJUSTMENT If the contact area is too high on the valve,the seat must be lowered using a 37.5 degree cutter, then CUT TOP END finish with a 45 degree cutter. CONTACT AREA TOO HIGH If the contact area is too low on the valve,the seat CONTACT AREA TOO LOW must be raised using a 63.5 degree cutter, then finish with a 45 degree cutter.
  • Page 49 5. CYLINDER HEAD/ VALVE VALVE CYLINDER HEAD ASSEMBLY Compress the valve springs with a valve spring compressor and install the valve cotters into the valve retainer. CAUTION: Do not compress the valve spring more than necessary. SPRING RETAINER VALVE COTTER NOTE: Install a new valve stem seal when assembling.
  • Page 50 5.INSPECTION/ADJUSTMENT CYLINDER HEAD INSTALLATION ROCKER ARM CAMSHAFT AND CAMSPROCKET ASSEMBLY NOTE: Rocker arms must be installed at the right position. Clean the cylinder head gasket surface of any gasket material. Install the new gasket, O-ring and dowel pins and chain guide. NOTE: Do not allow dust and dirt to enter the cylinder.
  • Page 51 5. CYLINDER HEAD/ VALVE CAM SHAFT INSTALLATION Rotate the generator rotor and align the "T" mark with the index mark. Install the camshaft comp. When intalling camshaft set, please take care that.The line on the camsprocket should be in parallel with the surface of cylinder head.(The IN/EX cam should be faced down).
  • Page 52 KNOCKING OR ABNORMAL NOISE 2. Improper installation of piston rings. 1. Worn piston or cylinder. 2. Excessive carbon build-up 3. Scored or scratched piston or cylinder wall. SERVICE INFORNATION GENERAL STRUCTIONS XS125-K ITEM STANDARD CERVICE LIMIT Cylinder I.D. 56.495～56.515mm 56.52mm Cylinder Runout 0.05mm...

  • Page 53: Cylinder/Piston

    Avoid damaging the cylinder gasket surface during this operation. CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. NOTE: According to the right picture measure the cylinder runout. Service limit: ITEM XS125-K Runout 0.05mm Taper 0.05mm I.D. 56.52mm...

  • Page 54: Piston Removal

    6. CYLINDER/PISTON PISTON REMOVAL Remove the piston pin clip with pliers. Press the piston pin out of piston, remove the piston. NOTE: Avoid the clip falling into the crankcase. PISTON / PISTON RING INSPECTION Measure the piston ring-to-ring groove clearance. Service limit .
  • Page 55 6.CYLINDER/PISTON Measure the piston O.D. at the skirt. Service limit: 56.48mm NOTE: Measure the piston O.D. at a point from the bottom. Calculate the piston-to-cylinder clearance. Service limit:0.11mm Measure the piston pin bore I.D. Service limit:15.05mm Measure the piston pin O.D. Service limit:14.994mm Measure the top/second ring thickness.

  • Page 56: Piston Ring Installation

    6. CYLINDER/PISTON PISTON RING INSTALLATION Install the piston rings. TOP RING NOTE: SECOND Ÿ Avoid piston and piston ring damage during RING installation. Ÿ All rings should be installed with the markings OIL RING facing up. Ÿ After installation, the piston rings should be free to rotate in the grooves.

  • Page 57: Piston Installation

    6.CYLINDER/PISTON PISTON INSTALLATION Install the piston, piston pin and piston pin clip. NOTE: Ÿ Position the "IN" mark on the piston to the carburetor side. Ÿ Do not let the piston pin clip fall into the crankcase. NOTE: PISTON PIN CLIP Ÿ...

  • Page 58: Clutch/Oil Pump/Gear Shift

    7.CLUTCH/OIL PUMP/GEAR SHIFT TROUBLE SHOOTING ......7-1 OIL PUMP ..........7-7 SERVICE INFORMATION......7-1 GEARSHIFT LINKAGE......7-9 ...7-2 ..7-11 RIGHT CRANKCASE COVER REMOVAL RIGHT CRANKCASE COVER INSTALLATION CLUTCH...........7-2 TROUBLE SHOOTING Faulty clutch operation can be corrected by adjusting the clutch lever free play. CLUTCH SPINS WHEN ACCELERATING HARD SHIFTING 1.
  • Page 59 7.CLUTCH/OIL PUMP/GEAR SHIFT RIGHT CRANKCASE COVER REMOVAL Drain oil from the engine. Disconnect the clutch cable. Remove the kick starter arm. Remove the right crankcase cover. CLUTCH CABLE CLUTCH CLUTCH REMOVAL Remove the clutch lifter rod. Remove the oil filter rotor cover. LIFTER ROD FILTER ROTOR COVER Remove the 16mm lock nut with a lock nut wrench.

  • Page 60: Clutch Spring Inspection

    7.CLUTCH/OIL PUMP/GEAR SHIFT Remove the bearing, clutch bolt, clutch lifter plate and CLUTCH BOLT clutch spring. CLUTCH LIFTER PLATE CLUTCH SPRING INSPECTION Measure the clutch springs free length. Service limit: 28.6mm Remove the 20mm set ring. SET RING Remove the clutch center, disks, plates and pressure plate.
  • Page 61 7.CLUTCH/OIL PUMP/GEAR SHIFT CLUTCH CENTER CLUTCH OUTER CLUTCH PLATE CLUTCH PRESSURE CLUTCH FRICTION DISC INSPECTION Replace the clutch disks if they have any score or discoloration. Measure the clutch friction disk thickness. SERVICE LIMIT: 2.8mm CLUTCH PLATE INSPECTION Check the plates for warpage on a surface plate using a feeler gauge.
  • Page 62 7.CLUTCH/OIL PUMP/GEAR SHIFT Remove the 20 mm washer and clutch outer. 20mm WASHER CLUTCH OUTER INSPECTION Check the clutch outer for cracks or indentation. WASHER CLUTCH OUTER INSTALLATION Install the clutch outer, 20mm washer on the main shaft. NOTE: When installing the washer, it should fit with the main shaft groove.
  • Page 63 7.CLUTCH/OIL PUMP/GEAR SHIFT LOCK NUT Install and tighten the 20mm set ring. BEARING Install the clutch springs, lifter plate and tighten the bolts. Install the bearing. NOTE: Tighten the bolts in a crisscross pattern in two or three steps. TORQUE :80-120 kgf ・...

  • Page 64: Oil Pump Disassembly

    7.CLUTCH/OIL PUMP/GEAR SHIFT OIL PUMP OIL PUMP OIL PUMP REMOVAL Remove the right crankcase cove. Remove the oil filter rotor. Remove the oil pump cover. OIL PUMP DRIVE GEAR Remove the oil pump drive gear. Remove the 6 mm screws and oil pump. 6mm SCREWS OIL PUMP PLATE OIL PUMP DISASSEMBLY...
  • Page 65 7.CLUTCH/OIL PUMP/GEAR SHIFT Measure the outer rotor-to-body clearance. Service limit: 0.40mm Measure the rotor-to-cover clearance. NOTE: Measure the clearance with the gasket installed. Service limit: 0.11mm DRIVE SHAFT DRIVE GEAR OIL PUMP ASSEMBLY Install the oil pump drive gear and gear shaft on the pump body.

  • Page 66: Oil Pump Installation

    7.CLUTCH/OIL PUMP/GEAR SHIFT O-RING OIL PUMP INSTALLATION Install new O-rings. Install the oil pump to the right crankcase. OIL PUMP GEARSHIFT LINKAGE GEARSHIFT LINKAGE DISASSEMBLY Remove the clutch. Remove the gearshift pedal. Remove the gearshift spindle. GEARSHIFT SPINDLE...
  • Page 67 7.CLUTCH/OIL PUMP/GEAR SHIFT GEARSHIFT CAM GEARSHIFT DRUM Remove the gearshift drum stopper arm. STOPPER ARM Remove the gearshift cam. Check each part for wear or damage. GEARSHIFT SPINDLE 4MM ROLLER GEARSHIFT LINKAGE ASSEMBLY Install the four 4mm roller. Align the hole of the gearshift cam with the roller, then install the gearshift cam.
  • Page 68 7.CLUTCH/OIL PUMP/GEAR SHIFT CLUTCH DRIVE GEAR Install the gearshift spindle. NOTE : Align the gearshift return spring on the projection of the crankcase. Check the gearshift linkage for smooth operation. Install the clutch, oil pump and oil filter rotor. OIL PUMP RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket.
  • Page 69 8. A.C.GENERATOR SERVIE INFORMATION .......8-1 ..8-3 LEFT CRANKCASE COVER INSTALLATION ....8-2 STARTER MOTOR REMOVAL ...8-4 LEFT CRANKCASE COVER REMOVAL FLYWHEEL REMOVAL......8-2 ..8-4 STARTER DRIVEN GEAR REMOVAL FLYWHEEL INSTALLATION ....8-3 STARTER MOTOR GEAR SET ..8-4 SERVIE INFORMATION GENERAL INSTRUCTION This section covers removal and installation of the AC generator and starter motor. These operation can be done with the engine installed in the frame.
  • Page 70 8. A.C.GENERATOR LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE COVER COVER REAR COVER REMOVAL Remove the gearshift pedal. Remove the left crankcase rear cover. Disconnect the AC generator and pulse generator wire connector. Remove the left crankcase cover. NOTE: Generator stator is in the left crankcase cover, it can be removed by removing the attaching screws.

  • Page 71: Generator

    8. A.C.GENERATOR STATOR COIL INSPECTION NOTE : This inspection can be made with the stator in the frame. Check the starter for continuity. Continuity should exist between: Yellow and pink, Black/red and ground, Blue/white and green/white Pink,yellow,blue/white and green/white should not continue with the ground.

  • Page 72: Starter Motor Removal

    8. A.C.GENERATOR BOLTS STARTER MOTOR REMOVAL Disconnect the starter motor wire from the motor.. Remove the starter motor by removing the bolts. ELECTRIC CONNECTOR STARTER DRIVEN GEAR REMOVAL Remove the left crankcase cover . Remove the flywheel. Remove the starter driven gear. STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER MOTOR...

  • Page 73: Crank Shaft/Crank Case/Transmission

    CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER TROUBLE SHOOTING ......9-1 TRANSMISSION DISASSEMBLY..9-5 SERVICE INFORMATION......9-2 TRANSMISSION ASSEMBLY....9-8 CRANKCASE SEPARATION ....9-2 KICK STARTER DISASSEMBLY..9-10 CRANKSHAFT REMOVAL ....9-3 CRANKCASE ASSEMBLY....9-11 TROUBLE SHOOTING HARD TO SHIFT CRANKSHAFT NOISE 1. Shift fork bent 1. Worn connecting rod big end bearing 2. Shift fork shaft bent 2.
  • Page 74 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER CRANKCASE SEPARATION Remove the right crankcover and interial parts. (7-3~ 7-13) Remove left cover and interial parts.

  • Page 75: Crankshaft Inspection

    CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER Remove the left crankcover all 6mm attaching bolts. Separate the left crankcase from the right crankcase. Remove the gasket and dowel pins. CRANKSHAFT REMOVAL CRANKCASE Remove the left crankcase. Remove the crankshaft. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge.
  • Page 76 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER Support the crankshaft bearings on a V-block and measure the runout using a gauge. NOTE: Coat the bearing and connecting rod big end with engine oil before installation. Service limit: 0.050mm Measure the connecting rod small end I.D. Connecting rod small end I.D. Service limit: ∮15.08mm FREE PLAY CRANKSHAFT BEARING...

  • Page 77: Transmission Disassembly

    CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER SHIFT FORK TRANSMISSION SHAFT DISASSEMBLY Remove the crankshaft. Remove the shift fork shaft. Remove the shift drum. Remove the shift forks. COUNTER MAIN SHAFT SHIFT DRUM SHAFT SHIFT FORK SHAFT SHIFT DRUM SHIFT FORK SHIFT FORK AND SHIFT FORK SHAFT INSPECTION Check the shift fork for wear, bending or damage.
  • Page 78 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER Measure the shift fork shaft O.D. Service limit: 11.976mm SHIFT DRUM INSPECTION Check the gearshift drum for wear or damage. Disassemble the transmission gears. Check each gear for wear or damage and replace if necessary. Check the crankcase oil orifice for clogged, blowing through with compressing air if necessary.
  • Page 79 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER Check the crankcase bearings, replace them if they have excessive free play or noisy. FREE PLAY FREE PLAY AXIAL RADIAL BEARING INSTALLATION Install the bearings into the left, right crankcase with special tools. NOTE: Install the bearing horizontally, to prevent bearing damage.

  • Page 80: Transmission Assembly

    CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER TRANSMISSION ASSEMBLY NOTE: Before assembling,coat each gears with engine oil. Counter shaft Main shaft Driver sprocket Assemble the gears of the countershaft and mainshaft. NOTE: Seat the snap ring in the ring groove properly.
  • Page 81 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER Install the crankshaft assemblies in the right crankcase. Install the mainshaft and countershaft assemblies in CRANKSHAFT the right crankcase. NOTE: Keep the thrust washers in place during installation. MAINSHAFT Install the mainshaft, countershaft and shift forks. SHIFT FORK Install the gearshift drum. Install the shift fork shaft.
  • Page 82 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER KICK STARTER DISASSEMBLY Remove the kick starter spindle assembly. KICK STARTER SPINDLE Remove the kick starter spindle from the engine. Remove the thrust washer and drive ratchet. Measure the I.D. of the pinion. Service limit:24.96mm Measure the pinion sliding O.D. of the spindle. Service limit:24.80mm 9-10...
  • Page 83 CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER KICK STARTER ASSEMBLY Reverse the operation of diassembly for assembing. CRANK CASE ASSEMBLY Install the gasket and dowel pins. Install the left crankcase on the right crankcase. NOTE: Make sure that the gasket is in place. 9-11...

  • Page 84: Carburetor

    10. CARBURETOR TROUBLE SHOOTING ......10-1 ..10-5 FLOAT/FLOAT VALVE/JETS ASSEMBLY SERVICE INFORMATION......10-1 FLOAT/LEVEL ADJUSTMENT.....10-5 CARBURETOR REMOVAL....10-2 THROTTLE VALVE ASSEMBLY..10-5 THROTTLE VALVE DISASSEMBLY...10-2 CARBURETOR INSTALLATION...10-6 10-3 FLOAT/FLOAT VALVE/JETS DISASSEMBLY TROUBLE HOOTING 7. Air leaking into intake pipe ENGINE CRANKS BUT NOT START 8.

  • Page 85: Carburetor Removal

    10. CARBURETOR CARBURETOR REMOVAL Disconnect the fuel line. Disconnect the all connect tubes. Drain fuel from the carburetor. WARNING: Keep away from flames or sparks. Wipe up spilled gasoline at once. CARBURETOR Loosen the carburetor band. BAND NEEDLE SPRING THROTTLE VALVE DISASSEMBLY THROTTLE CABLE Disconnect the throttle cable.
  • Page 86 10. CARBURETOR Remove the carburetor assembly. FLOAT/FLOAT VALVE/JETS DISASSEMBLE Remove the float chamber body. WARNING: Pour the float chamber gasoline into the tank Pull out the float pin, remove the float and float valve. FLOAT PIN FLOAT VALVE INSPECTION WEAR OR DAMAGE inspect the float valve surface for wear or damage.
  • Page 87 10. CARBURETOR Remove the main jet, needle jet and needle jet holder. NOTE: Avoid damage to the jets. MAIN JET NEEDLE JET NEEDLE JET HOLDER AIR SCREW Remove the air screw. NOTE Before removeing air screw, record the number of relations until it rests lightly so it can be returned to its original position.
  • Page 88 10. CARBURETOR FLOAT /FLOAT VALVE/ JETS ASSEMBLY Install the stop screw, air screw, main jet, needle jet and needle jet holder. NOTE: Do not damage jets at the time of assembly. MAIN JET FLOAT LEVEL 24mm ADJUSTMENT If the float level is too high or too Iow,bend the float arm for adjusting.

  • Page 89: Carburetor Installation

    10. CARBURETOR Connect the throttle cable. NOTE: Route the throttle cable end through the adjuster and the carburetor top. Make sure that the throttle cable is pulled tightly. NOTE: When installing the throttle valve, align the throttle vale groove with the pilot screw. Throttle stop screw CARBURETOR INSTALLATION...

  • Page 90: Headlight/Steering/Front Wheel/Front Fork

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK TROUBLE SHOOTING ......11-1 HANDLE BAR .........11-3 SERVICE INFORMATION......11-1 FRONT WHEEL ........11-4 HEADLIGHT..........11-2 FRONT FORK..........11-7 METER.............11-3 STEERING STEM........11-8 TROUBLE SHOOTING FRONT WHEEL WOBBLING SOFT SUSPENSION 1. Axle not tightened properly 1. Weak rear fork spring 2.Worn front wheel bearing 2.

  • Page 91: Headlight Installation

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK screw HEADLIGHT HEADLIGHT REMOVAL Remove the headlight screw. Remove the headlight case. Disconnect the wire connector. HEADLIGHT WIRING Route the wires through the headlight Connect the wires Color-to-color. HEADLIGHT INSTALLATION Install the headlight. Install the headlight case aligning the mark to the holder, tighten the bolts.
  • Page 92 11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK METER METER REMOVAL Remove the headlight case . Disconnect each wire and connector. Disconnect the meter cables. Remove the setting screws. Remove the meter. setting screws HANDLEBAR HANDLEBAR REMOVAL Remove the wire harness. Remove the light switch and throttle cable, remove the turn signal switch assembly.

  • Page 93: Front Wheel

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK NOTE: Coat the throttle grip hole with grease. Install the winker switch assembly. NOTE: Align the punch mark on the handlebar with the split in the housing. FRONT WHEEL FRONT WHEEL REMOVAL Raise the front wheel off the ground by placing a block under the engine.

  • Page 94: Front Brake

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK FRONT BRAKE FRONT BRAKE DISC INSPECTION DISC BRAKE Replace the brake pads if the wear indicator mark is pointed. Measure the brake disc thickness. Service limit: 3.5mm FRONT BRAKE DISASSEMBLY Remove the caliper by removing the two caliper mounting bolts.
  • Page 95 11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK BRAKE SHOES FRONT BRAKE PANEL INSPECTION Remove the brake shoes and springs. Remove the brake arm and brake cam. Remove the speedmeter drive gear and dust seal. BRAKE ARM BRAKE CAM FRONT BRAKE PANEL ASSEMBLY Install a new dust seal.

  • Page 96: Front Wheel Installation

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK FRONT WHEEL INSTALLATION Install the front wheel. Install the axle shaft from the right side. Tighten the axle nut. TORQUE: 600-800 kgf ・ Connect the speedometer cable. FRONT FORK FRONT FORK REMOVAL Remove the front wheel. Remove the brake caliper bolts.

  • Page 97: Front Fork Installation

    11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK If the front fork is too soft or too hard, refill or drain the shock absorber fluid. Shock absorber fluid: CUSHION OIL Standard capacity :160c.c Recommeded LIQUI MOLY FRONT FORK INSTALLATION Install the front fork from the bottom. NOTE: Turn the front fork left and right by hand while installing.
  • Page 98 11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK STEERING STEM DISASSEMBLY Remove the front fork top bridge bolts. NOTE: Do not let the steel balls fall. Remove the steel balls cone brace,steering stem and steel balls. Check the top and bottom cone races and steel balls for wear or damage and replace if necessary.
  • Page 99 11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK Grease the steel balls and cone races, install the steering stem. Install the steering top nut and tighten it until snug against the upper cone race. Back the op nut out 1/8 turn to let steering stem be able to rotor freely.

  • Page 100: Rear Wheel/Rear Suspension

    12. REAR WHEEL/REAR SUSPENSION TROUBLE SHOOTING ......12-1 SHOCK ABSORBER ......12-6 SERVICE INFORMATION......12-1 REAR FORK ..........12-8 REAR WHEEL.........12-2 REAR BRAKE PEDAL......12-9 REAR BRAKE PANEL......12-5 TROUBLE SHOOTING HARD SUSPENSION 1. Bent damper shaft WOBBLE OR VIBRATION IN 2. Faulty shock absorber stopper rubber MOTORCYCLE SUSPENSION NOISE 1.

  • Page 101: Axle Inspection

    12. REAR WHEEL/REAR SUSPENSION REAR WHEEL REAR WHEEL REMOVAL Raise the rear wheel off the ground on the main stand. Remove the exhaust muffler. Disconnect the brake rod from the brake arm. ADJUSTING NUT Disconnect the brake torque link from the brake panel.
  • Page 102 12. REAR WHEEL/REAR SUSPENSION BEARING FREE PLAY INSPECTION Shake the bearing back and forth and spin it by hand, replace it with a new one if it is noisy or has excessive free play. WHEEL RIM RUNOUT INSPECTION Check the rim runout by placing the wheel in a turning stand.
  • Page 103 12. REAR WHEEL/REAR SUSPENSION FINAL DRIVEN SPROCKET ASSEMBLY Install the drive sprocket and new lock plates on the driven flange and tighten them with the bolts and nuts. TORQUE:240~300 kg f・cm Bend up the lock plate tabs against the nuts. Install the driven flange on the wheel hub.
  • Page 104 12. REAR WHEEL/REAR SUSPENSION Measure the brake drum I.D. Service limit: ∮152mm REAR BRAKE PANEL BRAKE CAM BRAKE ARM NOTE: Grease the place as figure. BRAKE SHOE BRAKE SHOE INSPECTION Measure the lining thickness. Service limit: 2.0mm BRAKE SHOE REPLACEMENT Separate the brake shoes with the brake cam.

  • Page 105: Shock Absorber

    12. REAR WHEEL/REAR SUSPENSION Install the hold arm. Install the brake linkage. Adjust the drive chain tension (2-13). Drive chain slack: 10 ～ 20mm Tighten the chain tension adjusters. Tighten the axle nut. TORQUE: 1000～1200 kg f ・ Apply engine oil to the drive chain. Install the step bar and the muffler.
  • Page 106 12. REAR WHEEL/REAR SUSPENSION SPRING COMPRESSOR Remove the spring and rubber. SHOCK ABSORBER SPRING INSPECTION Measure the shock absorber spring free length. Service limit: 183mm Check the shock absorber for noisy or leaks. SHOCK ABSORBER ASSEMBLY HOLDER NOTE: Install the spring with the tightly wound coils at the top.

  • Page 107: Chain Adjuster

    12. REAR WHEEL/REAR SUSPENSION REAR FORK REAR FORK REMOVAL Remove the muffler. Remove the rear wheel (12-3). Remove the rear shock absorber (12-9). Remove the drive chain cover. Remove the rear fork mounting bolts. REAR FORK REAR FORK DISASSEMBLY/ASSEMBLY BUSH NOTE: Drive the bushings out with a soft hammer, making CHAIN ADJUSTER...

  • Page 108: Rear Shock Absorber

    12. REAR WHEEL/REAR SUSPENSION REAR FORK INSTALLATION Install the rear fork. TORQUE: 800~1000 kgf・cm Install the rear shock absorber and rear wheel. Install the muffler. REAR BRAKE PEDAL Remove the muffler. Remove the brake linkage rod. Remove the brake light switch spring. Remove the brake return spring.

  • Page 109: Battery/Charging System

    13. BATTERY/CHARGING SYSTEM TROUBLE SHOOTING ......13-1 BATTERY..........13-3 SERVICE INFORMATION......13-2 CHARGING SYSTEM......13-4 TROUBLE SHOOTING NO POWER --- KEY TURNED ON 1. Dead battery -- Battery electrolyte evaporated -- Battery not charged -- Charging system failure 2. Disconnected battery cable 3. Main fuse burned out 4.
  • Page 110 13. BATTERY/CHARGING SYSTEM CHARGING SYSTEM FAILURE 1. Loose broken or shorted wire 2. Faulty voltage regulator 3. Faulty generator 4. Battery undercharged SERVICE INFORMATION GENERAL INSTRUCTIONS 1. Battery acid level should be checked and refill with distilled water when necessary. 2.

  • Page 111: Battery Installation

    13. BATTERY/CHARGING SYSTEM BATTERY BATTERY REMOVAL AND INSTALLATION Remove the right side cover. Disconnect the battery negative cable first, then the battery positive cable. Disconnect the battery band, remove the battery. BATTERY INSTALLATION Put the battery on the battery rack. Install the battery band.

  • Page 112: Charging System

    13. BATTERY/CHARGING SYSTEM Connect the charger positive(+) cable to the battery positive (+) terminal, negative (-) cable to the battery negative (-) terminal. Charge the battery until the specific gravity of the electrolyte is 1.260-1.280 (20℃/68℉ ) Charging current: 0.7A max. WARNING: Before charging a battery, remove the cap from each cell.
  • Page 113 13. BATTERY/CHARGING SYSTEM STATOR COILS TEST NOTE: This test can be made with the stator on the frame. Disconnect and measure the A.C. generator connectors with a multi-meter. Conductivity should exit between : Pink- yellow,blue/white-green/white,black/red-ground. Pink,yellow,blue/white,green/white should not conduct electricity with ground. RECTIFIER RECTIFIER Disconnect the rectifier connector and check its...

  • Page 114: Ignition System

    14. IGNITION SYSTEM TROUBLE SHOOTING ......14-1 IGNITION COIL ...........14-3 SERVICE INFORMATION......14-2 TROUBLE SHOOTING ENGINE CRANKS BUT NOT START Green/white Blue/white 1. No sparks at the spark plug 2. Improper ignition timing 3. Faulty plug Black/ yellow NO SPARKS AT THE SPARK PLUG 1.
  • Page 115 14. IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTION This section contains the ignition system. Be sure that the battery is fully charged before diagnosing troubles in the ignition system. Also refer to the following pages: Spark plug Ignition timing adjustment SPECIFICATIONS Spark plug: NGK DR7EA Spark plug gap:...
  • Page 116 14. IGNITION SYSTEM IGNITION COIL IGNITION COIL IGNITION COIL REMOVAL Remove the seat. Remove the fuel tank. Remove the spark plug cap. Disconnect all wires to the ignition coil. Remove the ignition coil. IGNITION COIL TEST Check the ignition coil output using a tripolar tester. NOTE: Follow the instructions described in the user manual.

  • Page 117: Switches/Horn

    15. SWITCHES/HORN TROUBLE SHOOTING ......15-1 HEADLIGHT SWITCH ......15-3 SERVICE INFORMATION......15-2 START/HAZARD SWITCH.....15-3 MAIN/DIMMER SWITCH ......15-3 ..15-4 FRONT/REAR BRAKELIGHT SWTICH WINKER/HORN SWITCH.......15-3 HORN SWTICH ........15-4 HEADLIGHT SWITCH ......15-3 TROUBLE SHOOTING NO LIGHTS COME ON WHEN IGNITION SWITCH IS TURNED ON: 1. Battery low 2.
  • Page 118 15. SWITCHES/HORN SERVICE INFORMATION GENERAL INSTRUCTIONS All electrical wires are color-coded. Check the color before connecting wires. All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. A conductivity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a galvanometer or voltmeter to the terminals or connections.

  • Page 119: Main Switch

    15. SWITCHES/HORN MAIN SWITCH DIMMER SWITCH WIRE COLOR WIRE COLOR BLACK/ BROWN/ WHITE BLUE GREEN BLACK BROWN BROWN/WHITE WHITE Br/W Br/R SWITCH POSITION SWITCH POSITION ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ WINKER SWITCH HORN SWITCH WIRE COLOR WIRE COLOR...
  • Page 120 15. SWITCHES/HORN FRONT BRAKELIGHT SWITCH Check that the front brakelight switch for conductivity between the BLACK and GREEN/YELLOW wires. The switch is normal if there is conductivity with the front brake applied. STOP SWITCH REAR BRAKELIGHT SWITCH The switch is normal if there is conductivity with the rear brake applied.

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