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Motron BREEZY 50 2021 Service Manual

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SERVICE MANUAL
BREEZY 50

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Summary of Contents for Motron BREEZY 50 2021

  • Page 1 SERVICE MANUAL BREEZY 50...

  • Page 2: Group Index

    GROUP INDEX 1.GENERAL INFORMATION/TROUBLE DIAGNOSIS................-17- 2.MAINTENANCE INFORMATION.......................-33- 3. LUBRICATION SYSTEM..........................-41- 4. FUEL INJECTION SYSTE..........................-62- 5. REMOVAL OF ENGINE..........................-71- 6. CYLINDER HEAD/VALVE..........................-85- 7. CYLINDER/PISTON............................-94- 8. V-BELT DRIVING SYSTEM/KICK STARTER..................-108- 9. FINAL DRIVING MECHANISM........................-115- 10. A.C. GENERATOR/STARTING CLUTCH....................-122- 11. CRANKCASE/CRANKSHAFT........................-130- 12. BODY COVER...............................-143- 13.

  • Page 3: Table Of Contents

    1.GENERAL INFORMATION/TROUBLE DIAGNOSIS CONTENTS SYMBOLS AND MARKS....................1-1 GENERAL SAFETY.....................1-2 SERVICE PRECAUTIONS..................1-3 SPECIFICATIONS....................... 1-9 TORQUE VALUES (ENGINE).................1-10 TORQUE VALUES (FRAME).................. 1-11 TROUBLES DIAGNOSIS..................1-12 LUBRICATION POINTS..................1-16 －１－...

  • Page 4: Symbols And Marks

    GENERAL INFORMATION/TROUBLE DIAGNOSIS SYMBOLS AND MARKS Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 5: General Safety

    GENERAL INFORMATION/TROUBLE DIAGNOSIS1-2 GENERAL SAFETY Battery Carbon monoxide  Battery emits explosive gases; flame is strictly If you must run your engine, ensure the place is prohibited. Keep the place well ventilated well ventilated. Never run your engine in a when charging the battery.

  • Page 6: Service Precautions

    GENERAL INFORMATION/TROUBLE DIAGNOSIS SERVICE PRECAUTIONS  Always use with genuine parts and  Never bend or twist a control cable to recommended oils. Using non-designed prevent stiff control and premature worn parts for motorcycle may damage the out. motorcycle.  Special tools are designed for remove ...
  • Page 7 GENERAL INFORMATION/TROUBLE DIAGNOSIS1-4  The length of bolts and screws for assemblies,  Remove residues of the old gasket cover plates or boxes is different from one or sealant before reinstallation, another, be sure they are correctly installed. grind with a grindstone if the In case of confusion, Insert the bolt into the contact surface has any damage.

  • Page 8: General Information/Trouble Diagnosis

    GENERAL INFORMATION/TROUBLE DIAGNOSIS  Lubricate rotation face with  Before battery removal operation, it has specified lubricant on the lubrication to remove the battery negative (-) cable points before assembling. firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
  • Page 9 GENERAL INFORMATION/TROUBLE DIAGNOSIS1-6  Before terminal connection, check if the boot is crack or the terminal is loose.  When separating a connector, it locker has to be unlocked firstly. Then, conduct the service operation.  Insert the terminal completely. Check if the terminal is covered by the boot.
  • Page 10 GENERAL INFORMATION/TROUBLE DIAGNOSIS  Do not let the wire harness contact with  Protect wires or wire harnesses with rotating, moving or vibrating components electrical tape or tube if they contact a as routing the harness. sharp edge or corner. Thoroughly clean the surface where tape is to be applied.
  • Page 11 GENERAL INFORMATION/TROUBLE DIAGNOSIS 1-8  Do not let the wire harness been twisted  With sand paper to clean rust on as installation. connector 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...

  • Page 12: Specifications

    GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS Model Breezy 50 Engine cod BN139QMB Item Specification Length Front shock absorber Telescopic fork 1780 Width Rear shock absorber Unit swing Height Clutch type Auto centrifugal clutch 1115 Wheel base Transmission C.V.T. 1220 83kg (Front:33kg Net Weight Front tire 90/70-12 or100/60-12 Rear:50kg)

  • Page 13: Torque Values (Engine)

    GENERAL INFORMATION/TROUBLE DIAGNOSIS1-10 TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) A.C. generator flange bolt 0.8~1.2 L side cover plate pan screw 0.5~0.7 RR. brake shoe anchor fixing 1.5~2.0 Rear brake arm flange bolt 0.7~1.1 Engine oil filter screen cover 1.0~2.0 Crankcase bolts 0.8~1.2...

  • Page 14: Torque Values (Frame)

    1-11 GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting Hex socket bolt for 4.0~5.0 steering handlebar Mounting nut for steering rod 25.4 1.0~2.0 Cone seat for steering rod 25.4 0.2~0.3 Front wheel shaft nut 5.0~7.0 Rear wheel shaft nut 11.0~13.0...

  • Page 15: Troubles Diagnosis

    GENERAL INFORMATION/TROUBLE DIAGNOSIS1-12 TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Press the fuel injector feed pipe and confirm whether there is fuel in the feed 1. Check the fuel amount in the fuel tank 2.
  • Page 16 GENERAL INFORMATION/TROUBLE DIAGNOSIS 1-13 B. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Incorrect ignition timing Abnormal Normal (malfunction of ECU or AC Generator) Check for any air sucked in through the throttle body 1.
  • Page 17 GENERAL INFORMATION/TROUBLE DIAGNOSIS1-14 D. Engine runs sluggish (High speed) Check and adjustment Fault condition Probable causes Check ignition timing Malfunction of ECU Normal Abnormal Malfunction of AC Generator Check the fuel pump supply condition Good Insufficient fuel in the Poor fuel tank Pressed or clogged fuel pipe Check if fuel injector clogged...

  • Page 18: Clutch, Driving And Driving Pulley

    1-15 GENERAL INFORMATION/TROUBLE DIAGNOSIS E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved. 4.

  • Page 19: Lubrication Points

    GENERAL INFORMATION/TROUBLE DIAGNOSIS1-16 LUBRICATION POINTS －１７－...
  • Page 20 2.MAINTENANCE INFORMATION CONTENTS PRECAUTIONS IN OPERATION............2-1 PERIODICAL MAINTENANCE SCHEDULE........2-2 LUBRICATION SYSTEM..............2-3 Fuel System....................2-4 AIR CLEANER..................2-5 THROTTLE VALVE OPERATION............. 2-5 CRANKCASE VENTILATION............. 2-6 VALVE CLEARANCE ADJUSTMENT..........2-6 VALVE CLEARANCE INSPECTION AND ADJUSTMENT...2-7 IGNITION SYSTEM................2-8 SPARK PLUG...................2-8 CYLINDER COPMRESSION PRESSURE..........2-9 DRIVING SYSTEM.................

  • Page 21: Precautions In Operation

    MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION Specification Fuel Tank Capacity 5.0L±0.2 L capacity 0.7 L Engine Oil change 0.6 L capacity 0.14 L Transmission Gear oil change 0.13 L Clearance of throttle valve 2~6 mm Spark plug CR7HSA Gap: 0.6~0.7 mm “F”...

  • Page 22: Maintenance Information

    MAINTENANCE INFORMATION PERIODICAL MAINTENANCE SCHEDULE 1 year Mainte 1 Month 3 month 6 month nance Item Initial 300KM Every12000K Every1000KM Every3000KM Every6000KM Code ☆ Air cleaner ☆ Fuel filter ☆ Oil filter ☆ Engine oil change Replacement for every 1000km Tire pressure Battery inspection Brake &...

  • Page 23: Lubrication System

    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 2-3 minutes then stop,  wait about 2-3 more minutes allowing engine oil to settle before checking the oil level. Remove dipstick to check the oil level.

  • Page 24: Fuel System

    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. Remove the oil drain plug and drain gear oil into a measurement cup.

  • Page 25: Air Cleaner

    MAINTENANCE INFORMATION AIR CLEANER Element Remove left side cover. Remove 6 screws from the air cleaner cover. Remove element of air cleaner (2 bolts). Check the element if dirt or damaged. Replace it with new one if dirt or damaged. Caution ...

  • Page 26: Crankcase Ventilation

    MAINTENANCE INFORMATION Primary adjustment is conducted from button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. CRANKCASE VENTILATION Caution Pull out the plug from draining hose to clean deposits. ...

  • Page 27: Valve Clearance Inspection And Adjustment

    MAINTENANCE INFORMATION VALVE CLEARANCE INSPECTION AND ADJUSTMENT Check & adjust valve clearance with feeler gauge. Valve clearance (IN/EX): 0.12±0.02 mm/0.12±0.02 mm Loosen fixing nut and turn the adjustment nut for Caution adjustment. It has to make sure that valve-rocker arm is ...

  • Page 28: Ignition System

    MAINTENANCE INFORMATION Caution  Ignition system is set by manufacturer so it IGNITION SYSTEM can not be adjusted. Ignition timing  Ignition timing check procedure is for checking whether function is in normal or not. Remove right side cover.Remove ignition timing hole cap located on the cooling fan cap, or remove the cooling fan cap.

  • Page 29: Cylinder Copmression Pressure

    MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Open the seat. Remove the luggage box. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.

  • Page 30: Steering System

    2-10 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 and check if turning is smoothly.

  • Page 31: Front Disc Brake System

    2-11 MAINTENANCE INFORMATION FRONT DISC BRAKE SYSTEM BRAKE SYSTEM HOSE Make sure the brake 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 32: Added Brake Fluid

    2-12 MAINTENANCE INFORMATION ADDED BRAKE FLUID Brake fluid cap Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL Low limit RUN brake fluid. Caution  Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

  • Page 33: Rear Brake

    2-13 MAINTENANCE INFORMATION BRAKE CONFIRMATION Check the wearing terrain on caliper pad, and replace the pad if friction surface reach the sign “A” of wear. Limit for use: friction disc 5.0mm brake disc 3.0mm REAR BRAKE Brake Free Play: 10～20mm Measure free play of rear brake level at the end of the lever.

  • Page 34: Brake Light Switch

    2-14 MAINTENANCE INFORMATION Brake light switch BRAKE LIGHT SWITCH The brake light switch is to lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. WHEEL/TIRE Check if both front and rear tire pressure are within specification.

  • Page 35: Battery

    2-15 MAINTENANCE INFORMATION BATTERY Battery Removal Remove the 2 screws on the floor panel. Remove battery cap. (2 nuts) Battery cables removal: 1.At first, remove the negative “-” cable. 2.Then, remove the positive “+” cable. Remove the battery. If there is some rust on battery posts, clean it with steel brush.

  • Page 36: Lubrication System

    3.LUBRICATION SYSTEM CONTENTS MECHANISM DIAGRAM....................3-1 OPERATIONAL PRECAUTIONS................3-2 ENGINE OIL........................3-3 CLEANING ENGINE OIL STRAINER................ 3-3 OIL PUMP........................3-4 GEAR OIL........................3-7 －３４－...

  • Page 37: Mechanism Diagram

    LUBRICATION SYSTEM MECHANISM DIAGRAM －３５－...

  • Page 38: Operational Precautions

    LUBRICATION SYSTEM OPERATIONAL PRECAUTIONS General Information This chapter contains maintenance operations for the engine oil pump, engine oil and  gear oil. Oil viscosity Specifications Engine oil quantity Disassembly 0.7L. Replacement 0.6L. Oil viscosity SG or SAE 10W-40 or equivalent Gear Oil Capacity Disassembly 0.14L.

  • Page 39: Engine Oil

    LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 40: Oil Pump

    LUBRICATION SYSTEM OIL PUMP Oil Pump Removal bolts Remove the alternator (refer to chapter10). Remove the engine right crankcase cover. Remove the one-way clutch and starting drive gear (1 nut). Make sure that the pump axle can be rotated freely. Remove the oil pump cover (2 bolts), Remove the oil pump fixing flat screw .
  • Page 41 LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm 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 42 LUBRICATION SYSTEM Oil Pump Installation Install the oil pump (2 bolts). Install oil pump outer cover (2 bolts). Install the starting gear and the alternator. (Refer to chapter 10) －４０－...

  • Page 43: Gear Oil

    LUBRICATION SYSTEM GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand. Turn off engine and remove both engine oil filling bolt and oil draining bolt. Remove gear oil filling hole bolt and place a measurement cup under the draining plug.
  • Page 44 4.Fuel Injection System CONTENTS EFI System Diagram..................4-1 EFi System Introduction................4-2 EFI System Components................4-3 EFI System Location..................4-4 Precautions in Operation General information........4-5 EFI SYSTEM.....................4-6 Fuel Pump / Fuel Unit................. 4-18 －４２－...

  • Page 45: Efi System Diagram

    Fuel Injection System EFI System Diagram －４３－...

  • Page 46: Efi System Introduction

    Fuel Injection System EFi System Introduction fuel and air. Based on 4-stroke SOHC engine, displacement 50c.c. electronically Electronic fuel injection system controlled fuel injection. The O2 sensor separates the three major processes enhances the efficiency of the catalytic into three different devices: converter, by dynamically controlling the 1.

  • Page 47: Efi System Components

    Fuel Injection System EFI System Components －４５－...

  • Page 48: Efi System Location

    Fuel Injection System EFI System Location －４６－...

  • Page 49: Precautions In Operation General Information

    Fuel Injection System Precautions in Operation General information Warning Caution Fuel pressure release procedure: Disconnect the fuel pump relay, switch on and press the start switch for a few seconds to crank the engine. Specification Item Torque value Engine temperature sensor： Idle speed 1800±150 rpm 0.74~0.88 kgf-m O2 sensor：...

  • Page 50: Efi System

    Fuel Injection System EFI SYSTEM 1. Introduction Because of the EFI, there are many possibilities for the engine issues. In other word, one issue may be caused by the mechanical problem or the EFI components. And the diagnostic tools cannot 100% indicate the root cause. So this manual shows the way to dig out the root cause with the help of the diagnostic tools.

  • Page 51: Operation

    Fuel Injection System 2) The multimeter below means the digital type. Pointer-type is forbidden. 3) If the malfcode shows the voltage is low, it means maybe the wire is short to ground. If the malfcode shows the voltage is high, it means maybe the wire is short to battery. If the malfcode shows the components signal abnormal, it means the wire is open or short to other wires.
  • Page 52 Fuel Injection System Step 5 Remove the connector, and use the multimeter to check Next whether the voltage between pin B and D is about 5V. Check the harness Check whether the following pins is short to ground: pin 31, Next pin 28, pin 23 of the ECU and pin A, D, B of the connector.
  • Page 53 Fuel Injection System Next Step 5 Remove the connector, and use the multimeter to check whether the resistance between pin B and D is reasonable Next according to the temperature. Next Remove the connector and check whether the voltage Check harness between pin B and D is about 5V.
  • Page 54 4-10 Fuel Injection System Malfcode：P0305/P0306 Information：O2S 1 Circuit Low/High Voltage ITEM OPERATION RESULT NEXT STEP next Connect the diagnostic tool, and ignition on. Harness issue Use multimeter to check whether the connection between pin B of the oxygen sensor and pin 16 of the ECU is open, and Next whether the pin B of sensor is short to pin A.
  • Page 55 4-11 Fuel Injection System Malfcode：P0560/P0562 Information：FPR Coil Circuit Low/High Voltage or Open ITEM OPERATION RESULT NEXT STEP next Connect the diagnostic tool, and ignition off Change the pump Wait about 30s. Remove the fuel pump relay, ignition on. Next Check whether voltage of the relay feeder ear is about 12V Harness issue Check whether the feeder ear is short to ground or open.
  • Page 56 4-12 Fuel Injection System 5. Maintenance depending on the performance. Before issue analysis, please check: 1) The MIL works well. 2) Clear the history malfcode. 3) When the malfcode comes again, note the conditions. Check the appearance 1) Whether there is leakage of the fuel pipe or not. 2) Whether there is block/leakage or damage of the intake pipe.
  • Page 57 4-13 Fuel Injection System Next gear box oil. Check the engine Check whether the engine rotation resistance is Help too big or not. ITEM OPERATION RESULT NEXT STEP Next Check weather the fuel pump pressure is about Check the pump. 250kPa at idle.
  • Page 58 4-14 Fuel Injection System dry the plug and combustion chamber. Pull out the spark plug, check whether it is wet or not Next Engine is good Check whether the cylinder pressure is normal or not Check the engine  Unstable idle OPERATION RESULT NEXT STEP...
  • Page 59 4-15 Fuel Injection System ITEM OPERATION RESULT NEXT STEP  High idle Adjust the cable Check whether the throttle cable is stuck Next Change the TB Check whether the idle pintle has been adjusted Next Maintenance Check whether there is any leakage of the intake Next pipe.
  • Page 60 4-16 Fuel Injection System Check the engine help Check whether the exhaust pipe is blocked or not maintenance ITEM OPERATION RESULT NEXT STEP  Backfire Next Pull out the spark plug, check whether the spark over is normal. Check the ignition system Next Check whether the timing is right Adjust the timing...
  • Page 61 4-17 Fuel Injection System Oxygen Sensor P0050 O21S Heater Circuit High Voltage COBDM_O21Heater_HI Heater Circuit O21S Heater Circuit Low Voltage or P0049 COBDM_O21Heater_LO (OXYAHD) Open P0610 Fuel Injector Circuit High Voltage COBDM_INJA_HI Fuel Injector IFuel Injector Circuit Low Voltage or P0609 COBDM_INJA_LO Open...

  • Page 62: Fuel Pump / Fuel Unit

    4-18 Fuel Injection System Fuel Pump / Fuel Unit Removal Open the seat. Remove 4 bolts in the front of the luggage box. Disconnect the fuel pump couplers. Disconnect the fuel unit couplers Remove the fuel pipes. Remove the fuel pump lock bolts. Remove the fuel pump and fuel unit.
  • Page 63 4-19 Fuel Injection System Check if the fuel filter is contaminated Fuel filter or clogged. Replace it with new one if necessary. Fuel pressure regulator Installation Install in the reverse order of removal. Caution ● Do not bend the fuel unit float arm ●...
  • Page 64 4-20 Fuel Injection System Fuel Tank Removal Disconnect the fuel pump and the fuel unit coupler. Remove fuel pipe. Remove the fuel cut valve pipe. Remove the fuel tank (4 lock bolts). Installation Install in the reverse order of removal. Caution ●...
  • Page 65 5. REMOVAL OF ENGINE CONTENTS MECHANISM DIAGRAM..................5-1 OPERATIONAL PRECAUTIONS................ 5-2 ENGINE REMOVAL....................5-3 REMOVAL OF ENGINE SUSPENSION BUSHING......... 5-6 ENGINE SUSPENSION FRAME................5-7 INSTALLATION OF ENGINE................5-8 －６３－...

  • Page 66: Removal Of Engine

    REMOVAL OF ENGINE MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5 kgf-m －６４－...

  • Page 67: Operational Precautions

    REMOVAL OF ENGINE 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. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3.

  • Page 68: Engine Removal

    REMOVAL OF ENGINE ENGINE REMOVAL Auto by-start connector Open the seat. Remove the rear carrier (3 bolts ). Remove the luggage box assembly (4 Pulse bolts ). generator Remove the body cover (4 screws, 3 bolts). connector Remove the power connector of auto by- start.
  • Page 69 REMOVAL OF ENGINE Remove the fuel pipe, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and remove the air cleaner guide. Remove the exhaust muffler (Bolts × Bolts×2 2, Cap Nuts × 2). Cap nuts×2 Remove the rear wheel (Nut ×...
  • Page 70 REMOVAL OF ENGINE Remove the rear brake. Remove the rear shock absorber lower bolt. Loose the strap screw of engine left guide, and then remove the engine left guide. Remove the engine suspension nuts and bolts (engine side), and then remove the engine.

  • Page 71: Removal Of Engine Suspension Bushing

    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 / presser, Φ28mm &Φ20mm, to press the bushing out, and replace it with new one. Engine suspension bushing: Φ28mm Rear shock absorber bushing: Φ20mm Pressing out...

  • Page 72: Engine Suspension Frame

    REMOVAL OF ENGINE ENGINE SUSPENSION FRAME Bolt of engine suspension frame (left side) Removal Remove the left side bolt of engine suspension frame. Remove the right side bolt of engine suspension frame. Bolt of engine suspension frame (right side) Check if the engine suspension frame bushing and cushion rubber for damage.

  • Page 73: Installation Of Engine

    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  Notice both feet and hands safety for squeezing as engine installation.
  • Page 74 6.CYLINDER HEAD/VALVE CONTENTS MECHANISM DIAGRAM........................ 6-1 PRECAUTIONS IN OPERATION....................6-2 TROUBLE SHOOTING........................6-3 CAMSHAFT REMOVAL........................6-4 CYLINDER HEAD REMOVAL....................... 6-6 CYLINDER HEAD DISASSEMBLY....................6-6 CYLINDER HEAD INSPECTION....................6-7 VALVE SEAT INSPECTION AND....................6-9 SERVICE............................. 6-9 CYLINDER HEAD REASSEMBLY....................6-11 CYLINDER HEAD INSTALLATION....................6-12 VALVE CLEARANCE ADJUSTMENT..................6-13 －７２－...

  • Page 75: Cylinder Head/Valve

    CYLINDER HEAD/VALVE MECHANISM DIAGRAM 1.0~1.4 kgf-m 1.0~1.4 kgf-m 0.7~1.1 kgf-m 1.8~2.2 kgf-m 1.0~1.4 kgf-m 1.0~1.4 kgf-m －７３－...
  • Page 76 CYLINDER HEAD/VALVE PRECAUTIONS IN OPERATION General Information  This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm.  Cylinder head service cannot be carried out when engine is in frame. Specification unit: mm Item...

  • Page 77: Trouble Shooting

    CYLINDER HEAD/VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure. Low compression pressure 1.

  • Page 78: Camshaft Removal

    CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head cover 4 bolts and then remove the cylinder head cover. Shroud 4 bolts screw Loosen the screw of camshaft chain adjuster and remove O-ring.
  • Page 79 CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the cylinder head. Camshaft Inspection Inspect cam lobe height for damaged. Service Limit IN: Replacement when less than 25.5mm EX: Replacement when less than 25.1 Inspect the camshaft bearing for looseness or wear out.

  • Page 80: Cylinder Head Removal

    CYLINDER HEAD/VALVE CYLINDER HEAD REMOVAL Remove double seat, luggage box and front center cover. Remove the engine (refer to Chapter 5). Remove the cooling fan cover. Remove the engine shroud . Remove the camshaft sprocket. Remove the 2 cylinder head mounting bolts dowel pins from cylinder head left side cover.

  • Page 81: Cylinder Head Inspection

    CYLINDER HEAD/VALVE After removed valve cotters, release the valve cotters compressor and then take out spring retainer, valve spring and valves. Caution In order to avoid to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch. Special Service Tool: Valve spring compressor.
  • Page 82 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→ 4.900mm EX→ 4.900mm Valve guide Caution Before measuring the valve guide, clean carbon deposits with reamer.

  • Page 83: Valve Seat Inspection And

    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 84 6-10 CYLINDER HEAD/VALVE Valve seat inspection Roughness If the valve seat is too width, narrow or rough, correct it. Valve seat width Service limit: 1.6mm Check the contact condition of valve seat. 45° Valve seat grinding The worn valve seat has to be grinded with valve seat chamfer cutter.

  • Page 85: Cylinder Head Reassembly

    6-11 CYLINDER HEAD/VALVE Coat the valve seat surface with red paint. Contact surface too high Install the valve through valve guide until the valve contacting with valve seat, slightly press Old valve seat down the valve but do not rotate it so that a width seal track will be created on contact surface.

  • Page 86: Cylinder Head Installation

    6-12 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 to loosing spring tension, do not compress the spring too much. Its length is based on the installation of latch. Special tool: valve spring compressor Tap valve stem to make valve retainer and valve stem sealing properly.

  • Page 87: Valve Clearance Adjustment

    6-13 CYLINDER HEAD/VALVE VALVE CLEARANCE ADJUSTMENT Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to Especial tool standard value, hold adjustment bolt and then tighten the adjustment nut.
  • Page 88 7.CYLINDER/PISTON CONTENTS MECHANISM DIAGRAM..................7-1 PRECAUTIONS IN OPERATION...............7-2 CYLINDER REMOVAL..................7-3 PISTON REMOVAL....................7-5 PISTON RING INSTALLATION................. 7-7 PISTON INSTALLATION..................7-8 －８６－...

  • Page 89: Mechanism Diagram

    CYLINDER/PISTON MECHANISM DIAGRAM 0.8~1.2kgf-m －８７－...

  • Page 90: Precautions In Operation

    CYLINDER/PIST 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 39.010—39.015 39.019 Bend/wrap age Less than 0.05 0.050 Cylinder Roundness Less than 0.01 0.050 Cylindrical Less than 0.05...

  • Page 91: Cylinder Removal

    CYLINDER/PISTON CYLINDER REMOVAL 2 bolts Cylinder Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-adjuster. Cam chain Cam chain guide auto-adjuster 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 92 CYLINDER/PISTON Cover the holes of crankcase and cam chain with a piece of cleaning 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 93: Piston Removal

    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 94 CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 13.04mm Measure the inner diameter of connecting rod small end. Service Limit: 13.06mm Measure the inner diameter of piston pin hole. Service Limit: 13.04mm Calculate clearance between piston pin and its hole.

  • Page 95: Piston Ring Installation

    CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston skirt. 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 96: Piston Installation

    CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Piston pin Install new piston pin snap ring. Caution  Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 97 8. V-BELT DRIVING SYSTEM/KICK STARTER CONTENTS MECHANISM DIAGRAM..................8-1 MAINTENANCE DESCRIPTION...............8-2 LEFT CRANKCASE COVER................8-3 Installation of the left crankcase cover..............8-3 DRIVING BELT..................... 8-4 SLIDING PULLEY....................8-6 Inspection......................... 8-9 Clutch lining......................8-10 Driven pulley spring....................8-10 Driven pulley......................8-10 Clutch Block Replacement................... 8-11 Installation of clutch/driven pulley..............8-13 －９５－...

  • Page 98: Mechanism Diagram

    V-BELT DRIVING SYSTEM/KICK STARTER MECHANISM DIAGRAM 5.5~6.0kgf-m 5.5~6.0kgf-m 1.0~1.5kgf-m 5.0~6.0kgf-m －９６－...

  • Page 99: Maintenance Description

    V-BELT DRIVING SYSTEM/KICK STARTER MAINTENANCE DESCRIPTION Precautions in operation General information ‧ 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 18.50...

  • Page 100: Left Crankcase Cover

    V-BELT DRIVING SYSTEM/KICK STARTER LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (2 bolts) Remove kick starter arm. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent. Remove engine left-side cover (8 bolts). Installation of the left crankcase cover Install the left crankcase cover.

  • Page 101: Driving Belt

    V-BELT DRIVING SYSTEM/KICK STARTER DRIVING BELT Removal Remove left crankcase cover. Hold the driving pulley with a universal fixture, and then remove the nut and driving pulley. Universal fixer Hold driving pulley with universal fixture, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
  • Page 102 V-BELT DRIVING SYSTEM/KICK STARTER Installation Pull out the driving pulley and then insert the driving belt into the driving pulley. Sliding driven Caution pulley Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.

  • Page 103: Sliding Pulley

    V-BELT DRIVING SYSTEM/KICK STARTER SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Universal fixture Remove the driving belt from the pulley. Sliding pulley Remove sliding pulley set and driving pulley hub from crankshaft.

  • Page 104: Inspection

    V-BELT DRIVING SYSTEM/KICK STARTER Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.

  • Page 105: V-Belt Driving System/Kick Starter Arm

    V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install siding pulley assembly onto crankshaft. Sliding pulley Crankshaft Pulley hub...
  • Page 106 V-BELT DRIVING SYSTEM/KICK STARTER ARM CLUTCH/DRIVEN PULLEY Special nut wrench Disassembly Remove driving 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. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut...

  • Page 107: Clutch Lining

    8-10 V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch lining Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 2.5mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 163.7mm Free length Driven pulley...

  • Page 108: Clutch Block Replacement

    8-11 V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch Block Replacement Driving plate Remove snap and washer, and the remove Spring clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption rubber Check if shock absorption rubber is damage or deformation.
  • Page 109 8-12 V-BELT DRIVING SYSTEM/KICK STARTER ARM Install snap ring and mounting plate onto setting pin. Snap ring Replacement of driven pulley bearing Remove inner bearing. Oil seal Caution Outer bearing  If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.

  • Page 110: Installation Of Clutch/Driven Pulley

    8-13 V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation of clutch/driven pulley Oil seal Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Specified grease O-ring Install sliding pulley onto driven pulley. Guide pin Sliding pulley Oil seal...
  • Page 111 9. FINAL DRIVING MECHANISM CONTENTS MECHANISM DIAGRAM..................9-1 OPERATIONAL PRECAUTIONS................9-2 DISASSEMBLY OF FINAL DRIVING MECHANISM.........9-3 INSPECTION OF FINAL DRIVING MECHANISM..........9-3 BEARING REPLACEMENT................... 9-4 RE-ASSEMBLY OF FINAL DRIVING MECHANISM........9-6 －１０９－...

  • Page 112: Final Driving Mechanism

    FINAL DRIVING MECHANISM MECHANISM DIAGRAM Countershaft Final driving shaft Final driving gear Countershaft gear Driving gear 0.8~1.2 kgf-m 2.0~2.4 kgf-m －１１０－...

  • Page 113: Operational Precautions

    FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 0.8~1.2 kgf-m Recommended gear oil:85W-90 Gear oil drain plug 1.0~1.4 kgf-m Oil quantity: 0.14L. (0.13L when Gear oil filling bolt 0.8~1.2 kgf-m replacing) Tools Special service tools Inner type bearing puller Outer type bearing puller...

  • Page 114: Disassembly Of Final Driving Mechanism

    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 (7bolts) and then remove the cover and the final driving shaft.

  • Page 115: Bearing Replacement

    FINAL DRIVING MECHANISM Final driving Check bearings on gear box and cover. Rotate each bearing’s inner ring with fingers. Final driving gear Countershaft gear Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box &...
  • Page 116 FINAL DRIVING MECHANISM Press out the driving shaft from the crankcase. Remove oil seal from the gear box. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution Using the bearing protector as pressing out the driving shaft from the left crankcase.

  • Page 117: Re-Assembly Of Final Driving Mechanism

    FINAL DRIVING MECHANISM RE-ASSEMBLY OF FINAL DRIVING Countershaft Final shaft MECHANISM Install final shaft and final shaft driven gear, countershaft. Final shaft driven gear Install the setting pins(2 pins) and new gasket. Dowel pins Gasket Apply with grease onto the oil seal lip of final driving shaft.
  • Page 118 10. A.C. GENERATOR CONTENTS MECHANISM DIAGRAM ..................... 10-1 PRECAUTIONS IN OPERATION ................10-2 A.C. GENERATOR REMOVAL ..................10-3 RIGHT CRANKCASE COVER INSTALLATION ............ 10-4 MOUNTED COIL SET INSTALLATION ..............10-5 FLYWHEEL INSTALLATION ..................10-6 －１１６－...

  • Page 119: Mechanism Diagram

    10-1 A.C. GENERATOR MECHANISM DIAGRAM 5.0~6.0kgf-m 9.0~10.0kgf-m 1.0~1.4kgf-m 1.5~2.0kgf-m 1.3~1.7kgf-m －１１７－...

  • Page 120: Precautions In Operation

    10-2 A.C. GENERATOR PRECAUTIONS IN OPERATION General information  Refer to chapter 5: Engine removal and installation  Refer to chapter 1: The troubleshooting and inspection of A.C. generator  Refer to chapter 16: The service procedures and precaution items of starter motor Torque value: Flywheel nut 5.0~6.0kgf-m...

  • Page 121: A.c. Generator Removal

    10-3 A.C. GENERATOR A.C. GENERATOR REMOVAL Pulse generator Coil Flywheel Cooling fan shroud Cooling fan Cable guide Drain out the engine oil. Exhaust muffler Remove the body cover. Remove the exhaust muffler. (3 bolts, 2 nuts) Remove the fan shroud. (5 bolts) Cooling fan shroud Remove the fan.
  • Page 122 10-4 A.C. GENERATOR 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 Remove the connectors of the A.C.

  • Page 123: Right Crankcase Cover Installation

    10-5 A.C. GENERATOR 9 bolts RIGHT CRANKCASE COVER INSTALLATION 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: Flywheel Installation

    10-6 A.C. GENERATOR FLYWHEEL INSTALLATION Make sure that there is no magnetic powder. If so, clean up it. Align insert on crankshaft with the flywheel groove, and then install the flywheel. Hold the flywheel with flywheel holder, and tighten its nut. Torque value: 5.0~6.0kgf-m Special service tool: Universal fixtur...
  • Page 125 11. CRANKCASE/CRANKSHAFT CONTENTS MECHANISM DIAGRAM..................11-1 OPERATIONAL PRECAUTIONS................11-2 DISASSEMBLY OF CRANKCASE..............11-3 CRANKSHAFT INSPECTION................11-5 Bearing Inspection....................11-5 ASSEMBLY OF CRANKCASE................11-6 －１２３－...

  • Page 126: Crankcase/Crankshaft

    11-1 CRANKCASE/CRANKSHAFT MECHANISM DIAGRAM 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 －１２４－...

  • Page 127: Operational Precautions

    11-2 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 and piston Chapter 7 V-belt Drive pulley Chapter 8...

  • Page 128: Disassembly Of Crankcase

    11-3 CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 2 bolts Remove the 2 bolts from the right crankcase. Remove the cam chain tensioner (hex socket 1 hex socket bolt bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
  • Page 129 11-4 CRANKCASE/CRANKSHAFT Remove the crankshaft from the right crankcase. Caution  The left and right bearings of crankshaft is to press-fit onto the crankshaft. Remove gasket and dowel pins (2). Scrape gasket residues off the crankcase contact surface. Caution  Do not damage contact surface of the crankcase.

  • Page 130: Crankshaft Inspection

    11-5 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 131: Assembly Of Crankcase

    11-6 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 dowel pins then install two dowel pins and new crankcase gasket.
  • Page 132 11-7 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 (19.8x30x5). Special service tools: the oil seal installer (19.8x30x5) －１３０－...
  • Page 133 12. BODY COVER CONTENTS OUTER PARTS........................12-1 MAINTENANCE INFORMATION..................12-3 FRONT PANEL........................12-4 HANDLE COVER.......................12-6 TOP OF TOO BOX......................12-7 BODY COVER/REAR CARRIER..................12-8 /GLOVE BOX/REAR FENDER..................12-8 GLVE BOX FRONT COVER..................12-11 FLOOR PEDALS......................12-11 LIFT/RIGHT SIDE COVER.....................12-11 FRAME FLOOR....................... 12-12 FENDER BACK........................12-12 －１３１－...

  • Page 134: Body Cover

    12-1 BODY COVER OUTER PARTS number photograph name number photograph name Rear view mirror Front circumference Before the Lower front wall instrument cover connection Rear carrier lid of a kettle Decorative pieces on the front panel Left/Right guard strip Instrument shell SEAT ASSY Glove box BODY COVER...

  • Page 135: Body Cover

    12-2 BODY COVER FLOOR PANEL CLIP ASSY CENTER Glove box cover Front fender before hold-all Front fender back VIN NUMBER COVER Frame fender Front fender back Rear wheel fender －１３３－...

  • Page 136: Maintenance Information

    12-3 BODY COVER MAINTENANCE INFORMATION Body covers disassemble sequence: Decorative pieces on the Front handle cover Rear carrier front panel Front panel Rear handle cover BODY COVER Glove box cover Tool box connector Front fender back hold-all Seat FLOOR PANEL Glove box Frame fender/Front fender...

  • Page 137: Front Panel

    12-4 BODY COVER FRONT PANEL Removal: Remove the Front panel trim. No need to remove screw fixing, buckle type installation） Remove the mounting screws and bolt. Remove the mounting screws and bolt. －１３５－...

  • Page 138: Installation

    12-5 BODY COVER Remove the mounting screws and bolt.(8 screw) Remove the front under cover 2 mounting screws Between the front under cover and the frame . Installation: Install according to the reverse procedure of removal. Caution With the clipper to fix the end-section of the handlebar cover.

  • Page 139: Handle Cover

    12-6 BODY COVER HANDLE COVER Removal Remove the mounting screws (6 screws) between the front handle cover and the rear handle cover. Remove the front handle cover. Remove the speedometer cable. Remove the rear handlebar cover. (2 screws) Removed the rear handle cover. Installation: Install according to the reverse procedure of removal.

  • Page 140: Top Of Too Box

    12-7 BODY COVER TOP OF TOO BOX Remove the 6 mounting screws between the front cover and the front inner box. Remove the hook screw bolt from theTop of toolbox . Remove the main switch cover. Remove the front cover and front under cover. Remove the 6 mounting screws between the floor panel and the front inner box.

  • Page 141: Body Cover/Rear Carrier

    12-8 BODY COVER Remove the Tool box connector. Installation Install the inner box A and the front inner box B accordingto the reverse procedure of removal. BODY COVER/REAR CARRIER /GLOVE BOX/REAR FENDER Removal Open the seat. Remove 4 bolts in front of the Glove box. Remove 3 bolts the Rear Carrier .
  • Page 142 12-9 BODY COVER Remove the 2 mounting bolts of the rear fender. Remove the 2 mounting screws the Battery cover. Remove the 4 mounting screws the Box front cover and glove box front cover. －１４０－...
  • Page 143 12-10 BODY COVER Remove entire the body cover between the body cover and the frame. Then you can do further disassembly. Remove the rear carrier. Remove the glove box. Remove the rear fender. Remove the left/right body cover Installation Install the body cover and rear carrier and glove box according to the reverse procedure of removal.

  • Page 144: Glve Box Front Cover

    12-11 BODY COVER GLVE BOX FRONT COVER Removal Remove the 2 screws . Remove the glove box front cover. Installation Install the front center cover according to the reverse procedure of removal. FLOOR PEDALS Removal Remove the 4 bolts from the luggage box. Remove the front center cover LIFT/RIGHT SIDE COVER Removal...

  • Page 145: Frame Floor

    12-12 BODY COVER FRAME FLOOR Removal Remove the floor panel. Remove the left/right side cover. Remove the left/right side 4 mounting bolts between the under cover and frame. Installation Install the under cover according to the reverse procedure of removal. FENDER BACK Remove front wheels.
  • Page 146 13. BRAKE CONTENTS MECHANISM DIAGRAM................13-1 Front Disc Brake System................13-1 MECHANISM DIAGRAM................13-2 Rear Drum Brake System................13-2 MAINTENANCE INFORMATION..............13-3 TROUBLE DIOGNOSIS DISC BRAKE............13-4 HYDRAULIC BRAKE SYSTEM INSPECTION..........13-5 BRAKE FLUID REPLACEMENT/ AIR-BLEED......... 13-6 BRAKE CALIPER................... 13-7 BRAKE DISC....................13-8 BRAKE MASTER CYLINDER..............

  • Page 147: Mechanism Diagram

    13-1 BRAKE MECHANISM DIAGRAM Front Disc Brake System 1.Cap 2.Diaphragm 3.Master Cylinder 4.Piston Set 5.Dust Cap 6.Front Brake Hose ASSY 7.Front Brake Caliper ASSY B 8.Piston 9.Oil Seal 10.O-ring 11.Pad ASSY 12.Spring 13.Caliper Holde A.Master Cylinder Bolt B.Brake Hose Bolt C.Bleed Valve D.Caliper Bolt Caution：...

  • Page 148: Mechanism Diagram

    13-2 BRAKE MECHANISM DIAGRAM Rear Drum Brake System 1 RR. RIM COMP. 3.5X12 2. TIRE 120/70-12 3. RIM VALVE Z2-01-1 4. BRAKE SHOE KIT 5. SPRING(BLACK) 6. CAM SHAFT 7. CAM SHAFT LEVER, ASSY 8. BRAKE INDICATOR PLATE 9.TENSION SPRING 10.

  • Page 149: Maintenance Information

    13-3 BRAKE MAINTENANCE INFORMATION Precautions in Operation Caution Installing lining dusts 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 150: Trouble Diognosis Disc Brake

    13-4 BRAKE TROUBLE DIOGNOSIS DISC BRAKE Soft brake lever Uneven brake  Air inside the hydraulic system  Dirty brake lining/disc  Hydraulic system leaking  Poor wheel alignment  Worn master piston  Clogged brake hose  Worn brake pad ...

  • Page 151: Hydraulic Brake System Inspection

    13-5 BRAKE HYDRAULIC BRAKE SYSTEM INSPECTION 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 152: Brake Fluid Replacement/ Air-Bleed

    · 13-6 BRAKE Remove the master cylinder cap and diaphragm. Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. Clean dirty brake disc. CAUTION The dirty brake lining or disc will reduce the brake performance.

  • Page 153: Brake Caliper

    13-7 BRAKE BRAKE CALIPER Removal 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. Remove two caliper bolts and the caliper. Make sure the brake lining condition.

  • Page 154: Brake Disc

    13-8 BRAKE BRAKE DISC Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. Allowable limit: 2.0 mm Remove the brake disc from wheel. Check the disc for deformation and bend.
  • Page 155 13-9 BRAKE Inspection Check the master cylinder for damage or scratch. 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. Allowable limit: 11.055 mm Measure the outer diameter of the piston.

  • Page 156: Rear Drum Brake

    13-10 BRAKE INSTALLATION Place the master cylinder onto handlebar, and install the split ring and bolts. “UP” mark on the split ring should face upward. Align the split ring on the master cylinder seat with the alignment point on the handlebar.
  • Page 157 13-11 BRAKE Check Check whether the brake drum and the brake shoes are abraded. Replace it if necessary. Measure the maximum brake shoe thickness and the maximum inner diameter of brake drum. * Note • Measure with micrometer. • Measure the brake shoe thickness and the inner diameter of brake drum If the thickness of the brake shoe is below the required value for...
  • Page 158 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER CONTENTS MECHANISM DIAGRAM................14-1 PRECAUTIONS IN OPERATION............14-2 TROUBLE DIAGNOSIS................14-2 STEERING HANDLE.................14-3 FRONT WHEEL..................14-4 FRONT SHOCK ABSORBER..............14-9 FRONT FORK/STEERING COLUMN............14-9 －１５６－...

  • Page 159: Steering/Front Wheel/Front Shock Absorber

    14-1 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER MECHANISM DIAGRAM 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 3.1~3.5kgf-m 2.4~3.0kgf-m 5.0~7.0kgf-m －１５７－...

  • Page 160: Precautions In Operation

    14-2 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.  Be careful not to allow oil or grease get on brake drum or linings. Torque values Front wheel axle 5.0~7.0kgf-m...

  • Page 161: Steering Handle

    14-3 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE REMOVAL Remove handle front & rear covers and the Master cylinder front cover (refer to chapter 12). Seat Split Front Disc Brake ring Remove the 2 bolts of the brake master cylinder, and then take out the master cylinder and the split ring.

  • Page 162: Front Wheel

    14-4 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a wrench to hold the handlebar bolt and Bolt then remove the nut. Take out the handlebar after removed the bolt. Installation Install the handlebar according to the reverse procedure of removal. Apply with some grease onto the handlebar moving parts when installing the acceleration handlebar seat, acceleration handlebar, and acceleration cable.
  • Page 163 14-5 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: 0.2 mm. Wheel axle Wheel Rim Place the wheel onto a rotated bracket. Turn the wheel with hand and measure its wobble value with a dial gauge.
  • Page 164 14-6 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Remove the left axle ring and dust seal. Speedometer gear dust seal DISC BRAKE Remove the dust seal on the right side of speedometer gear. Remove the bearing with the inner type Bearing spacer bearing remover. Take out the bearing spacer and then Bearing remove the other bearing.
  • Page 165 14-7 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. This two example will to louse the bearing. Speedometer gear dust seal DISC BRAKE Disc Brake...
  • Page 166 14-8 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc (drum brake) or speedometer gear box. Caution Contaminated brake lining will reduce brake performance so the brake lining, brake drum and disc must be free of grease.

  • Page 167: Front Shock Absorber

    14-9 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER Removal Remove the front fender, front lower spoiler, front guard, 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 168 14-10 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a plastic hammer to tap the steering column slightly, and then remove the top ball bearing seat. Remove the lower-end cone bearing seat on the frame with a punch. Caution Do not damage the frame and the steering column.
  • Page 169 15. REAR WHEEL/REAR SHOCK ABSORBER CONTENTS MECHANISM DIAGRAM................15-1 PRECAUTIONS IN OPERATION..............15-2 EXHAUST MUFFLER..................15-3 REAR WHEEL....................15-3 REAR SHOCK ABSORBER................15-4 －１６７－...

  • Page 170: Rear Wheel/Rear Shock Absorber

    15-1 REAR WHEEL/REAR SHOCK ABSORBER MECHANISM DIAGRAM 3.5~4.5kgf-m 2.4~3.0kgf-m 1.0~1.4kgf-m 11.0~13.0kgf-m 3.0~3.6kgf-m －１６８－...

  • Page 171: Precautions In Operation

    15-2 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 Thickness of rear brake lining Torque values: Rear axle nut 11.0~13.0kgf-m...

  • Page 172: Exhaust Muffler

    15-3 REAR WHEEL/REAR SHOCK ABSORBER EXHAUST MUFFLER Cap Nuts x 2 Removal Remove the front-end nut of the exhaust muffler. (nuts 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 173: Rear Shock Absorber

    15-4 REAR WHEEL/REAR SHOCK ABSORBER REAR SHOCK ABSORBER Removal Remove the luggage box. (bolts x 4) Remove the left & right body covers. (screws x 4, bolts x 3) Remove the air cleaner bolts (bolts x2) Remove the lower nut of the rear shock absorber (bolt x 1) Remove the upper nut of the rear shock absorber (bolt x 1)
  • Page 174 16. ELECTRICAL EQUIPMENT CONTENTS MECHANISM DIAGRAM................16-1 PRECAUTIONS IN OPERATION..............16-2 SPECIFICATION....................16-3 TROUBLE DIAGNOSIS..................16-4 BATTERY......................16-5 VOLTAGE REGULATOR INSPECTION............16-8 ALTERNATOR CHARGING COIL..............16-9 IGNITION COIL....................16-9 PULSE GENERATOR..................16-11 STARTING SYSTEM..................16-12 METER.......................16-13 HEAD LIGHT....................16-15 FRONT TURN SIGNAL.................. 16-16 MAIN SWITCH/HORN................... 16-17 HANDLE SWITCH..................

  • Page 175: Electrical Equipment

    16-1 ELECTRICAL EQUIPMENT MECHANISM DIAGRAM －１７３－...

  • Page 176: Precautions In Operation

    16-2 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. ...

  • Page 177: Specification

    16-3 ELECTRICAL EQUIPMENT SPECIFICATION Charging System Items Specification Capacity/type 12V 6Ah STD:0.6A/5~10hrs, emergency charging: Charging rate 6A/0.5hrs Battery Voltage Full charged 13.5V (20℃) Under charged 12.3V Capacity 12V / 6.2A Lighting coil resistance (20℃) Between yellow-green: 0.8±0.1Ω Alternator Charging coil resistance (20℃) Between white-green: 0.6±0.1Ω...

  • Page 178: Trouble Diagnosis

    16-4 ELECTRICAL EQUIPMENT TROUBLE DIAGNOSIS No voltage Intermittent power supply Battery discharged  The connector of the charging  The cable disconnected  system becomes loose The fuse is blown  Poor connection of the battery cable  Improper operation of the main switch ...

  • Page 179: Battery

    16-5 ELECTRICAL EQUIPMENT BATTERY Removal Remove the battery cover. CAUTION Electrolyte (diluted sulfuric acid) is very  toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, and then send to hospital.

  • Page 180: Voltage Check

    16-6 ELECTRICAL EQUIPMENT VOLTAGE CHECK With a digital voltage meter or multi- meter to measure battery voltage. Voltage: Fully charged: 13.0 – 13.2V (at 20℃) Undercharged: Below 12.3 V (at 20℃) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal.
  • Page 181 16-7 ELECTRICAL EQUIPMENT digital voltmeter Charging Voltage/Current Inspection ammeter Caution  Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.1 V. If undercharged, the current changes dramatically. ...

  • Page 182: Voltage Regulator Inspection

    16-8 ELECTRICAL EQUIPMENT VOLTAGE REGULATOR INSPECTION Remove the front cover. (screws 4 x 2). Remove the front cover mounting bolt(bolt x 1)and remove the left/right turnlight wiring connector. check the continuity between main wire terminals according to following method. Main wire circuit inspection Item (wire color) Judgment Check voltage between...

  • Page 183: Alternator Charging Coil

    16-9 ELECTRICAL EQUIPMENT ALTERNATOR CHARGING COIL Caution The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 3P connector of the alternator. Measure the resistance between the white wire on yellow wire with a multi-meter.
  • Page 184 16-10 ELECTRICAL EQUIPMENT Spark plug confirmation Remove the spark plug and install a good plug into plug cap, and then ground it to engine ground. Make sure its spark condition. If it is in not good or burnt spark plug, replace the spark plug with new one.

  • Page 185: Pulse Generator

    16-11 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. Standard value: 3-5 kΩ...

  • Page 186: Starting System

    16-12 ELECTRICAL EQUIPMENT STARTING SYSTEM Starting Circuit Starter magnetic switch Starter magnetic switch inspection Turn main switch to "on", and operate the brake lever. Then press starting button to check if there a click sound. It is normal if there is a click sound. Remove the luggage box.

  • Page 187: Meter

    16-13 ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the battery cover. Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the starting motor power wire. Remove the starting motor mounting bolts and motor.
  • Page 188 16-14 ELECTRICAL EQUIPMENT Remove the rear handle cover. Remove the meter mounting screws. Take out the meter. Inspection Check conductance of wires by multi-meter. SP：Speedometer light: (+)---Brown (-) ---Black/white HI：High beam indicator: (+)---Blue (-)---Black/white TU：Winker indicator(+)： Orange (RH) Light blue (LH) (-)---Black/white Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from...

  • Page 189: Head Light

    16-15 ELECTRICAL EQUIPMENT HEAD LIGHT Headlight Replacement Rear the front cover. Disconnect the headlight wire connector. Install the head light in reverse order of removal. Turn the main switch ON/OFF to check if the light has been installed properly after installation. Caution The headlight is led and cannot be replaced alone.

  • Page 190: Front Turn Signal

    16-16 ELECTRICAL EQUIPMENT FRONT TURN SIGNAL Replacement Remove the front cover. Remove the wire connector of the turn signal light. Caution The headlight is led and cannot be replaced alone. If it is broken, please replace the whole headlight. Installation Install the turn signal light in reverse order of removal.

  • Page 191: Main Switch/Horn

    16-17 ELECTRICAL EQUIPMENT MAIN SWITCH/HORN Main Swith Check Remove the headlight connector and the front cover. Disconnect main switch leads connector. Check connector terminals for continuity. Replacement Remove the main switch connector and fixing bolts (bolts x Remove the main switch. Install a new main switch and tighten the bolts.

  • Page 192: Handle Switch

    16-18 ELECTRICAL EQUIPMENT HANDLE SWITCH Remove the front handle cover. Disconnect the connector of the handle switch. Check the continuity of follow pins listed below columns. Engine on& off Starting switch High/Low beam switch/passing Horn switch －１９０－...

  • Page 193: Side Stand Switch

    16-19 ELECTRICAL EQUIPMENT Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever. If the switch damaged, replace it with new one. Horn Remove the front cover. Connect the light blue wire on the horn to the battery positive (+) terminal, and the green wire to the battery negative...

  • Page 194: Usb

    16-20 ELECTRICAL EQUIPMENT (This motorcycle is equipped with USB interface USB output voltage for DC5V can charge your mobile device). Check connector terminals for continuity. If the connection is normal, it needs to be replaced. USB check First turn on the power lock to measure Black and green wires on the USB connector.Use the DCto measure the black line and the green Line voltage.
  • Page 195 17-Wiring diagram －１９３－...
  • Page 196 The copyright lies with the company/manufacturer: KSR Group GmbH Im Wirtschaftspark 15 3494 Gedersdorf Austria Copyright ©2021 All rights reserved. This manual is protected by copyright. Reproduction in mechanical, electronic or any other form without the written permission of the manufacturer is prohibited.

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