DAELIM NS125DLX Service Manual
  1. Manuals
  2. Brands
  3. DAELIM Manuals
  4. Scooter
  5. NS125DLX
  6. Service manual

DAELIM NS125DLX Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE MANUAL

Advertisement

Table of Contents
loading

Related Manuals for DAELIM NS125DLX

Summary of Contents for DAELIM NS125DLX

  • Page 1 SERVICE MANUAL...

  • Page 2: Table Of Contents

    Transmission/Crankshaft/Crank Case vehicle quality. ● ● No part of this publication may be reproduced without Front Wheel/Front Fork/Steering written permission of DAELIM Motor Co., Ltd.. Rear Wheel/Brake/Suspension Brake System Charging System/Battery Ignition System...

  • Page 3: Service Information

    Removal/Installation Safety 1. Use only the genuine Daelim or Daelim-recommended parts and lubricants. 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, piston pins, clips, cotter pins (split pins), etc. when reassembling them.
  • Page 4 Service Information Identification Numbers Frame serial number Engine serial number...
  • Page 5 Service Information Specifications Item Specifications Overall length 1,970mm Overall width 700mm Overall height 1,110mm Dimensions Wheel base 1,350mm Seat height 765mm Ground clearance 130mm Dry weight 110kg Curb weight 240kg Type Underbone Front suspension/stroke Telescopic/97mm Rear suspension/stroke Swing arm/74mm Front tire size/type 120/70-13/Tubeless Rear tire size/type 130/60-13/Tubeless...
  • Page 6 Service Information Item Specifications Type/Venturi bore CV type(vacuum)24.2mm Model mark BDS 26 92 H1 Choke type Autoby-starter Carburetor Main jet 92.5 Pilot screw initial setting 3 and 1/4 trust out Float level 17.5 Idle speed 1,600±100(rpm) Clutch type Automatic Transmission Drive Train Primary reduction 3.231(42/14)
  • Page 7 Service Information Torque Values Engine Torque value Item Q’ty Thread dia(mm) Remarks kg.m(N.m,ft-lb) Oil filter cap 1.5(15, 11) Valve adjust screw lock nut 1.1(11, 8) Kick starter pedal bolt 1.2(12, 8) Flywheel bolt 5.5(55, 40) Apply engine oil Drive face bolt 5.5(55, 40) Clutch outer bolt 5.5(55, 40)
  • Page 8 Service Information Torque value Item Q’ty Thread dia(mm) Remarks kg.m(N.m,ft-lb) Brake caliper bracket bolt 2.7(27, 20) Brake caliper bleeder valve 0.6(6, 4.3) Brake caliper slide pin (socket bolt) 2.3(23, 17) Brake caliper pin bolt 1.8(18, 13) Apply locking agent Brake pad pin bolt 1.8(18, 13) Master cylinder reservoir cap 0.13(1.3, 0.94)
  • Page 9 Service Information Symbols/Abbreviations The following symbols are used in this manual to represent job-related warnings or cautions. Symbol Meaning Symbol Meaning Indicates important work. Minor WARNING injury or vehicle part damage may Indicates dangerous area. Serious result if instruction are not followed. accident may result if instructions CAUTION are not followed.
  • Page 10 Service Information Cable & Harness Routing Note the following when routing cables and wire harnesses: ● A loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. ● Do not squeeze wires against the weld or its clamp.
  • Page 11 Service Information Winker relay Front brake master cylinder Rear brake cable Speedometer Cable Stop switch connector Front winker connector Front winker connector Main switch Charge socket connector Front brake hose Side stand switch connector Packing lever Chage socket Horn Radiator Front brake hose Throttle cable Radiator hose...
  • Page 12 Service Information CDI unit Ignition coil Radiator hose CDI unit Ignition coil Fuel filter Throttle cable Fuel pump Side stand switch Rear brake cable 1-10...

  • Page 13: Lubrication

    Lubrication 2. Lubrication Service information Oil Filter Element Change Troubleshooting Oil Pump Engine Oil Level Check Radiator Engine Oil Change Lubrication Points Service Information General Safety WARNING 1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.
  • Page 14 Lubrication Troubleshooting Oil level too low - high oil consumption ● External oil leaks ● Worn piston rings ● Worn valve guide or seal Oil contamination ● Oil or filter not changed often enough ● Head gasket faulty ● Worn piston rings Low oil pressure ●...
  • Page 15 Lubrication Engine Oil Level Check ● Erect the motorcycle on the main stand. ● Warm up the engine to heat the engine oil to an appropriate level. ● Stop the engine, and check the oil level line on the sight-glass installed on the L. crank case cover. Sight-glass ●...
  • Page 16 Lubrication Oil Filter Element Change ● Drain engine oil. (⇨ 2-3) ● Remove the oil filter cover bolts, filter cover, filter element and spring. Oil filter cover ● Change the oil filter element with a new one. Element ● Check the relief valve inside the oil filter cover for satisfactory operation.
  • Page 17 Lubrication ● Remove the oil pump. Pump body Pump plate ● Clean the oil pump body, inner and outer rotors Pump shaft with fresh cleaning oil. Inner Setting Outer rotor rotor Inspection ● Assemble the inner and outer rotors to the oil pump ●...
  • Page 18 Lubrication Removal/Installation ● Remove the inner and outer rotors from the pump body. ● Clean all parts with fresh cleaning oil. ● Install the inner and outer rotors. Pump body Pump plate ● Assemble the pump shaft with setting pins. Pump shaft Inner Setting...
  • Page 19 Lubrication Radiator Removal/Installation ● Remove the front wheel. ● Remove the front cover, front side cover and inner box. ● Loosen the flange bolt(3EA), oil bolt and remove the radiator from the main pipe bracket. Radiator bolts Radiator bracket Radiator collar Radiator Flange bolt...
  • Page 20 Lubrication Inspection ● Check the damage or oil leaks from the radiator. Radiator Installation Radiator ● Assemble the radiator to the main pipe bracket. ● Tighten the oil bolt. ● Install the inner box. ● Install the front side cover. bolts...
  • Page 21 Lubrication Lubrication Points Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. Control Cable Lubrication Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it.
  • Page 22 MEMO...

  • Page 23: Inspections/Adjustments

    Inspections/Adjustments 3. Inspections/Adjustments Service Information Brake Pad Regular Inspection Schedule Brake System Fuel Line Brake Lever Free Play Throttle Grip Operation Headlight Adjustment Air Cleaner Side Stand Spark Plug Suspension Valve Tappet Clearance Bolts and Nuts Cylinder Compression Pressure Wheels/Tires Carburetor Idling Steering Head Bearing 3-10...
  • Page 24 Inspections/Adjustments Torque Values Spark plug 1.1kg–m, (11N.m, 8ft–lb) Cylinder head cover bolts 1.0kg–m, (10N.m, 7ft–lb) Valve adjusting nuts 1.1kg–m, (11N.m, 8ft–lb) Timing hole cap 0.6kg–m, (6N.m, 4.3ft–lb) Tools Wrench, 8×9mm Adjusting wrench Compression gauge...
  • Page 25 ＊＊ Steering head bearing ＊ Should be received by an authorized DAELIM dealer, unless the owner has proper tools and service data and not mechanically qualified. ＊＊ In the interest of safety, we recommended these items be served only by an authorized DAELIM dealer.
  • Page 26 Inspecitions/Adjustments Fuel Line (Fuel Tube) ● Remove the luggage box (⇨ 4-5) Fuel tube ● Check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. Fuel pump Throttle Grip Operation ●...
  • Page 27 Inspecitions/Adjustments ● Soak the element in solvent, and dry completely. ● Soak in gear oil (SAE #80-90), and squeeze firmly to remove excessive oil. ● If the element is excessively contaminated or damaged, replace it. ● Assemble in the reverse order of the disassembling.
  • Page 28 Inspections/Adjustments ● Loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the Feeler gauge adjusting screw with a valve adjusting wrench. Adjusting ● After setting clearance to the prescribed level, hold wrench the adjuster screw with a valve adjusting wrench, and tighten the lock nut.
  • Page 29 Inspecitions/Adjustments Brake Fluid Front brake fluid ● Remove the screw rivet and take the front brake fluid maintenance lid off. ● Check the oil level inside the front brake reservoir. If the oil is near the lower limit line, remove the reservoir diaphragm and fill DOT 3 and DOT 4 brake fluid to the top limit line.
  • Page 30 Inspections/Adjustments Brake Lever Free Play REAR BRAKE FRONT BRAKE ● Check the free play after pulling the lever. Front:10-20mm Rear:10-20mm Headlight Adjustment ● Adjust the headlight beam level by operating the adjusting screw located on the upper side of the front fender.
  • Page 31 Inspections/Adjustments Suspension NOTE •Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle’ s safety and operation efficiency. Front wheel ● Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.
  • Page 32 Inspections/Adjustments ● Check the tread depth at the tire center. ● If the tread depth has reached the service limit, replace the tire. Service limit: 4mm (0.16in) 7.5mm (0.3in) Wear indicator position mark Steering Head Bearing NOTE •Check the cable if it interferes with the handle operation.

  • Page 33: External Parts

    External Parts 4. External Parts Service Information Muffler Maintenance Procedure Front Fender 4-10 External Parts Removal/Installation 4-3 Service Information NOTE ● This section describes external parts removal/installation. ● Do not apply unreasonable force when disassembling covers, to prevent possible damage. ●...
  • Page 34 External Parts Maintenance Procedure Names of frame covers ⑭ ⑥ ⑪ ⑤ ⑮ ① ② ⑬ ③ ⑨ ⑦ ⑧ ⑫ ⑩ ④ ● This chart shows arrows connected in the order of disassembling covers. ① Front cover ④ Floor side cover ⑤...
  • Page 35 External Parts Front Cover removal/Installation ● Loosen the 2 upper screws. ● Loosen the 2 lower screws. Screw ● Pull upward and remove the front cover. ● Install in the reverse order of removal. Front cover Screw Front Side Cover Removal/Installation ●...
  • Page 36 External Parts Inner Box ● Loosen the 2 bolts installed on the bag holder. ● Remove the bag holder. ● Open the inner box lid. ● Remove the 1 cap nut. ● Remove the 2 flange bolt installed on the floor panel.
  • Page 37 External Parts Side Cover ● Remove the floor mat. ● Loosen the 2 screws on the side of the R/L side covers. ● Loosen 1 each of the R/L screws assembled to the floor panel. ● Loosen 3 each of the R/L body cover clips assembled to the floor panel.
  • Page 38 External Parts Rear Carrier ● Loosen 1 each of the R/L flange bolt set on the body cover side. ● Loosen the 2 flange bolts set on top of the body cover. Screw ● Remove the rear carrier. ● Install in the reverse order of removal. Rear carrier Body cover clip Rear upper cover...
  • Page 39 External Parts Floor Panel/Battery Cover Floor ● Remove the center cover. (⇨ 4-4) ● Loosen 2 each of the R/L pillion step cover setting screws of the floor mat, and remove the floor mat. Bolt ● Loosen the 2 battery cover setting screws, and remove the battery cover.
  • Page 40 External Parts Handle Cover Bolt Rear view mirror Front Handle Cover ● Loosen the 4 rear handle cover setting screws. (1 each on R/L side, and 2 each on meter side) ● Loosen 1 front handle cover setting screw. ● Remove 1 R/L handle side cover lower screw, and 1 each of the special upper side screws.
  • Page 41 External Parts Muffler Removal ● Loosen the 3 flange nuts securing the EX. pipe comp. ● Loosen the rear brake hose setting bolt. Flange bolts ● Loosen the flange bolt securing the rear wheel mud guard. ● Loosen the 2 flange bolts securing the R. crankcase. ●...
  • Page 42 External Parts Front Fender Bolt ● Loosen the flange bolt connecting the front fender A and B. Fender A Screw ● Loosen the 2 setting screws of the front fender A, and remove the front fender A. Fender B Screw ●...
  • Page 43 MEMO...
  • Page 44 Fuel System Fuel tank Fuel strainer Fuel pump Carburetor...

  • Page 45: Fuel System

    Fuel System 5. Fuel System Service Information Carburetor Troubleshooting Pilot Screw Adjustment Fuel Tank Fuel Pump Inspection Air Cleaner Removal Service Information General Safety WARNING ● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive.

  • Page 46: Troubleshooting

    Fuel System Troubleshooting Unable to start the engine ● No fuel in the tank. ● Fuel cannot be supplied. ● Fuel excessively absorbed into the cylinder. ● Air cleaner clogged. ● No spark from plugs. Unstable idling, unsatisfactory rotation ● Unsatisfactory idling adjustment. ●...

  • Page 47: Fuel Tank

    Fuel System Fuel Tank Fuel Pump Remove WARNING •Gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Fuel Tank ● Remove the following parts. - Luggage box (⇨...

  • Page 48: Air Cleaner Removal

    Fuel System Air Cleaner Removal Air cleaner ● Remove the luggage box. (⇨ 4-5) ● Loosen the 2 R/L bolts attached to the frame body. ● Loosen the band attached to the lower part(carburetor) of the intake coupling and remove the air cleaner. ●...
  • Page 49 Fuel System ● Remove the 4 vacuum chamber screws. Screw ● Remove the compression spring, vacuum piston, and diaphragm. Spring ● Turn the jet needle holder with a ⊖ screwdriver, Jet needle and remove the jet needle holder, spring, and jet holder needle.
  • Page 50 Fuel System Float Chamber/Float/Jet Removal Screw ● Lossen the 4 float chamber screws. Screw Float chamber ● Remove the float pins, float, and valve. Float Float valve ● Check the float valves and seats for cracks or Float valve damage. ●...
  • Page 51 Fuel System ● Clean all jets and holes with an air hose. Carburetor body ● Assemble the needle jet, needle jet holder, main jet, and slow jets. ● Assemble and turn the pilot screw to the number of turns memorized.
  • Page 52 Fuel System Float Level Main jet ● Install the float valves, and float pins. ● Check the float valve level. Float level: 17.5mm ● Assemble the float chamber. Float level gauge Vacuum Chamber Assembly ● Insert the jet needle and spring to the piston, and install the holder.

  • Page 53: Pilot Screw Adjustment

    Fuel System ● Connect the Autoby starter cable to the terminal. ● Assemble the carburetor insulator and connecting tube to the carburetor, and tighten the band screw. ● Connect the throttle cable to the carburetor. ● Rearrange the tube passing positions.(⇨ 1-10) Autoby- Screw ●Adjust the throttle operation.
  • Page 54 MEMO...

  • Page 55: Engine Removal/Installation

    Engine Removal 6. Engine Removal Service Information Engine Removal Service Information General Safety NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation.
  • Page 56 Engine Removal Engine Removal ● Drain the engine oil. A.C.G connector ● Remove the following parts. - Luggage box (⇨ 4-5) - Body cover (⇨ 4-6) - Air cleaner (⇨ 5-4) - Carburetor (⇨ 5-6) ● Disconnect the A.C. generator connector and starter motor cable cord.
  • Page 57 Engine Removal ● Remove the engine. (with the rear swing arm and rear wheel attached) ● Remove the rear swing arm. ● Remove the rear wheel. (⇨ 13-3) Rear swing arm Engine Installation ● Install in the reverse order of removal. NOTE •...
  • Page 58 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission L. crank case cover...
  • Page 59 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission 7. L. Crank Case Cover/Kick Starter/Continuously variable transmission Drive Belt Service Information Movable Drive Face Troubleshooting L. Crank Case Cover Clutch/Disassembly 7-12 Driven Face Disassembly 7-12 Kick Starter Service Information General Safety ● Take precautions not to apply grease or oil to the drive belt and pulley surface. NOTE •Take precautions not to apply the grease oil to the movable drive face or weight roller.

  • Page 60: Crank Case Cover

    L. Crank Case Cover/Kick Starter/Continuously Variable Transmission L. Crank Case Cover Removal ● Loosen the kick starter pedal bolt. ● Remove the kick starter pedal. Kick starter pedal ● Remove the cover side cooling hose. ● Loosen the L. crank case cover bolt, and remove the cover.

  • Page 61: Crank Case Cover/Kick Starter/Continuously Variable Transmission

    ● Tighten the L. crank case cover bolt. ● Assemble the cooling hose to the cover. Crank case cover ● Install the kick starter pedal and tighten bolts. Torque value: 2.2kg-m (22N.m, 16ft-Ib) ● Feed the DAELIM genuine oil to the cylinder head cover. Kick starter pedal...

  • Page 62: Kick Starter

    L. Crank Case Cover/Kick Starter/Continuously Variable Transmission Kick Starter Stopper plate Removal ● Remove the L. crank case cover.(⇨ 7-2) ● Remove the kick starter spring from the kick return stopper plate on the L. crank case cover. ● Remove the kick starter spindle. ●...
  • Page 63 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Disassemble the kick starter driven gear. Driven gear Idle gear ● Disassemble the kick starter idle shaft. Kick Starter Inspection ● Check the kick starter spindle for wear or damage. ● Check the return spring for defects or damage. ●...
  • Page 64 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Check the kick starter driven gear for wear and damage. Check the friction spring for defects and Kick starter driven gear damage. Friction spring...

  • Page 65: Drive Belt

    L. Crank Case Cover/Kick Starter/Continuously Variable Transmission Kick Starter Assembly Driven gear ● Assemble the kick starter idle gear shaft and the kick driven gear comp to the left cover. NOTE •Apply grease to the spring groove, kick driven gear, and idle gear wedge. ●...
  • Page 66 ● Check the drive belt width. Width Service limit: 20.5mm (0.8071in) NOTE • Use Daelim genuine parts. • Be careful not to apply oil to the belt pulley contact. Drive Belt Assembly ● Temporarily assemble the clutch / driven pulley to the drive shaft.

  • Page 67: Movable Drive Face

    L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Assemble the clutch outer to the drive shaft. ● Fix the clutch outer with the universal holder, and fasten with the setting nuts. Torque value: 5.5kg-m (55N.m,40ft-Ib) Tool: Universal holder ● Assemble the L. crank case cover. Setting nut Movable Drive Face Drive face...
  • Page 68 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission Movable Drive Face Inspection ● Check the weight roller for wear or damage. Weight roller ● Check the weight roller outer diameter. Service limit: 19.5mm (0.767in) ● Check the movable drive face boss for wear or Movable drive face damage.
  • Page 69 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Assemble the movable drive face boss and the movable drive face to the crank shaft. ● Assemble the assembly drive belt to the crank shaft. Drive belt ● Tighten the drive pulley nut with a drive holder. Torque value: 5.5kg-m (55N.m,40ft-Ib) Tool: Drive pulley holder Setting nut...

  • Page 70: Clutch/Disassembly

    L. Crank Case Cover/Kick Starter/Continuously Variable Transmission Clutch Disassembly ● Remove the L. crank case cover. (⇨ 7-2) ● Disassemble the movable drive face. (⇨ 7-9) ● Disassemble the drive belt. (⇨ 7-7) ● Use a universal holder to hold the clutch outer, and remove the clutch outer after disassembling the 12mm flange nut.
  • Page 71 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Remove the seal collar. Seal collar ● Remove the guide roller and its pin. Movable ● Remove the movable driven face. driven face Guide roller ● Remove the O-ring from the movable drive face. ●...
  • Page 72 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Disassemble the circlip and remove the outer bearing. Outer bearing Clutch/Driven Face Inspection ● Measure the free length of the driven face spring. Service limit: 97.23mm (3.822in) Free length ● Check the clutch outer for wear or damage. ●...
  • Page 73 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Check the driven face assembly for wear or damage. ● Measure the outer diameter of the driven face. Service limit: 37.94mm(1.491in) Movable face Guide pin globe ● Check the movable driven face for wear or damage.
  • Page 74 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Assemble the movable driven face, guide roller Movable and roller pin driven face Guide roller ● Assemble the seal collar. Seal collar ● Assemble the driven pulley, spring and clutch in Lock nut wrench Lock nut the clutch spring compressor.
  • Page 75 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission ● Assemble the clutch outer. Hold the clutch outer, and tighten nuts with the prescribed torque. Torque value: 5.5kg-m(55N.m, 40ft-lb) Tool: Universal holder ● Assemble the drive face. ● Assemble the L. crank case cover. Setting nut 7-17...
  • Page 76 Generator/Starter Clutch...

  • Page 77: Generator/Starter Clutch

    Generator/Starter Clutch 8. Generator/Starter Clutch R.Crank Case Cover Service Information Shroud Starter Clutch A.C Generator Service Information General Safety ● This section describes the removal and assembling of the A.C. generator. ● For information on A.C generator inspection, refer to the section 15. ●...
  • Page 78 Generator/Starter Clutch Shroud Removal ● Remove the following parts. - Luggage box (⇨ 4-5) - Body cover (⇨ 4-6) - Center cover (⇨ 4-4) ● Loosen the 4 R. shroud setting bolts. R. shroud ● Loosen the 3 shroud R/L setting bolts. L.
  • Page 79 Generator/Starter Clutch ● Remove the A.C generator flange nut. Flange nut ● Install the flywheel puller on the rotor, and Woodruff key remove the flywheel Tool: Fly wheel puller holder ● Remove the woodruff key from the crankshaft. Crankshaft Stator Removal/Installation Pulse generator ●...
  • Page 80 Generator/Starter Clutch Assembly Woodruff key ● Clean, and remove dust from the tapered part of the crankshaft. ● If the flywheel is installed with the tapered part contaminated by foreign matters, stress may be applied to the taper contact surface, causing damage to the key.
  • Page 81 Generator/Starter Clutch ● Remove the gasket and dowel pin. Dowel pin Gasket ● Remove the oil seal ● Check the oil seal for wear or damage, and Oil seal replace with new oil seals, if necessary. Starter Reduction Gear Reduction gear Shaft ●...
  • Page 82 Generator/Starter Clutch Assembly Reduction gear Shaft ● Assemble the starter reduction gear and shaft. ● Remove the gasket residues from the R. crank Dowel pin case. ● Install the new gasket and dowel pin. ● Tighten the R. crank case cover with setting bolts. ●...
  • Page 83 Generator/Starter Clutch ● Remove the washer. Starter driven gear ● Remove the starter driven gear. ● Check the starter driven gear and starter clutch for proper operation. Starter clutch ● Remove the starter clutch. Inspection ● Check the starter driven gear for wear of damage. ●...
  • Page 84 Generator/Starter Clutch ● Use a special socket to tighten the starter driven gear with lock nuts. Starter clutch Torque value: 9.0kg-m(90N.m, 65ft-lb) Tool: Special socket (12.7× × 28× × 120) ● Assemble the washer. Lock nut ● Assemble the R. crank case cover (⇨ 8-4) ●...

  • Page 85: Cylinder Head/Valve

    Cylinder Head/Valve 9. Cylinder Head/Valve Services information Valve guide replacement Troubleshooting Valve seat Inspection/Adjustment 9-8 Camshaft Removal Cylinder head Assembly 9-11 Cylinder Head Removal Cylinder Head Installation 9-12 Cylinder Head Disassembly Camshaft Assembly 9-13 Service Information General Safety ● The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed from the frame to maintain the cylinder head.
  • Page 86 Cylinder Head/Valve Tools Valve guide reamer Valve guide driver Valve spring compressor Valve seat cutter ○ Seat Cutter IN 37 (21.5mm) ○ EX 37 (18.5mm) ○ IN 45 (22mm) ○ EX 45 (22mm) ○ IN 55 (20mm) ○ EX 55 (20mm) Troubleshooting ●...
  • Page 87 Cylinder Head/Valve Camshaft Removal Cylinder head cover ● Remove the luggage box. (⇨ 4-5) ● Remove the center cover. (⇨ 4-4) ● Remove the shroud R/L.(⇨ 8-2) ● Remove the cylinder head cover bolt and cover. ● Remove the fan cover from the R shroud. Turn the crankshaft to the left, and align the “T”...
  • Page 88 Cylinder Head/Valve ● Remove the cam chain from the camshaft. Camshaft NOTE •Take precautions not to allow the cam chain to drop into the crank case. ● Remove the camshaft. chain ● Insert the 6mm bolt into the rocker arm shaft, and pulling bolts to remove the rocker arm shaft.
  • Page 89 Cylinder Head/Valve ● Manually turn the camshaft bearing outer race, Bearing and check if it turns smoothly. ● Check the bearing for wear or damage. Cylinder Head Removal ● Remove the engine from the frame.(⇨ section 5) Cylinder head ● Remove the camshaft. ●...
  • Page 90 Cylinder Head/Valve ● Remove the valve spring, valve cotter, retainer, spring and valve. Tool: Valve spring compressor NOTE •To prevent the loss of tension, do not compress the valve spring more than necessary. Valve spring compressor NOTE •Mark the disassembled parts so that they can be reassembled into the original position later.
  • Page 91 Cylinder Head/Valve ● Insert the valve guide reamer into the combustion chamber, and remove the carbon deposits. NOTE Valve guide reamer • Always insert the reamer while turning it right. If it is inserted without turning, or while turning left, interior part of guide will be damaged. Tool: Valve guide reamer ●...
  • Page 92 Cylinder Head/Valve ● Support the cylinder head, and strike and remove the valve guide from the combustion chamber by Valve guide driver using a valve guide driver. Tool: Valve guide driver NOTE •Take precautions not to damage the cylinder head. ●...
  • Page 93 Cylinder Head/Valve ● Remove the valve, and check the status of the seat contact, with a light coating of prussian blue applied to the valve face. ● If the valve seat is damage, make necessary repair. If the valve is tilted, check the clearance between the valve guide and stem.
  • Page 94 Cylinder Head/Valve ● Use a 55 ◦ cutter to make minor repairs on the inside. ○ ● Use a 45 ◦ cutter to make adjustment within the level of prescribed width. Seat width ○ ● Apply a light coating of prussian blue to the valve seat.
  • Page 95 Cylinder Head/Valve ● After adjustment, apply compound evenly to the valve seat and set the valve with a valve guide reamer. NOTE •Do not excessively press and turn the valve to set it as it may cause damage. Gently strike and set the valve. •The seat surface may become worn on one side if the valve is set in the same position.
  • Page 96 Cylinder Head/Valve ● Lightly strike the valve stem end for about 2-3 times to ensure better installation of the valve and cotter. NOTE •Take necessary precautions not to damage valve. ● Apply engine oil to the new O-ring, and assemble it to the carburetor insulator groove. Carburetor ●...
  • Page 97 Cylinder Head/Valve Cam Shaft Assembly Rocker Rocker Shaft Shaft ● Apply engine oil to the rocker arm shaft, and assemble the rocker arm to the camshaft holder. ● Tighten the rocker arm shaft with 6mm bolts, and align the bolt hole of the camshaft holder with the fitting side of the rocker arm shaft.
  • Page 98 Cylinder Head/Valve ● Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. ● Assemble the cam chain and cam sprocket after Dowel pin matching the cam sprocket timing mark in parallel with the top of the cylinder head.
  • Page 99 Cylinder Head/Valve ● Fix the tensioner shaft with a hard clip. ● assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. ● Tighten the tensioner mounting bolts. Torque values: 1.2kg-m (12N.m, 9ft-lb) ● Remove the tensioner shaft clip from the Sealing screw tensioner lifter.
  • Page 100 Cylinder/Piston Piston top ring Piston 2ND ring Piston Oil ring Piston pin clip Piston pin clip 10-0...

  • Page 101: Cylinder/Piston

    Cylinder/Piston 10. Cylinder/Piston Services information 10-1 Piston 10-3 Troubleshooting 10-1 Piston/Cylinder assembly 10-5 Cylinder 10-2 Service Information General Safety ● Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling pin by striking the cylinder too hard. ●...
  • Page 102 Cylinder/Piston Cylinder Cam chain guide Removal ● Remove the cylinder head. (⇨ 9-5) ● Remove the cam chain guide from the cylinder. ● Remove the cylinder. ● Remove the gasket and dowel pin. Remove the gasket residues attached to the cylinder. NOTE Gasket •Take precautions not to damage the gasket.
  • Page 103 Cylinder/Piston ● Check the cylinder distortion. Service limit: 0.02mm (0.0008in) Piston Piston pin Disassembly ● Remove the piston pin clip NOTE Piston •Take precautions not to drop the piston pin clip into the crank case. ● Remove the piston pin, and separate piston. ●...
  • Page 104 Cylinder/Piston ● Insert the piston ring into the inside of the cylinder, and check the piston ring clearance. Feeler gauge NOTE •Use the piston head to insert the piston ring so that the piston can be level. Service limit: Top/second 0.50mm (0.020in) Oil (side rail) 1.10mm (0.040in) ●...
  • Page 105 Cylinder/Piston Piston/Cylinder Assembly Piston Ring Assembly Mark ● Clean the piston ring groove with oil, and assemble the piston ring. NOTE •The ring is easily broken. Take necessary precautions not to break it, and not to damage the piston during assembly. •Assemble the ring with the marked side facing upward.
  • Page 106 Cylinder/Piston ● Assemble the piston, and piston pin to the Piston pin connecting rod. ● Assemble new piston pin clips. NOTE •Let the “IN” mark face towards the intake valve Piston side. •Place a piece of cloth over the crank case to prevent the piston pin clips from falling into the crank case.
  • Page 107 MEMO...
  • Page 108 Transmission/Crankshaft/Crank Case R.Crank Case L.Crank Case Crankshaft 11-0...

  • Page 109: Transmission/Crankshaft/Crank Case

    Transmission/Crankshaft/Crank Case 11. Transmission/Crankshaft/Crank Case Service Information 11-1 Crankshaft Disassembly 11-7 Troubleshooting 11-2 Crankshaft Bearing 11-8 Transmission 11-3 Crankshaft Assembly 11-9 Crank Case Disassembly 11-6 Crank Case Assembly 11-10 Service Information General Safety ● This section describes how to remove the crank case and to maintain the transmission and the crankshaft. ●...

  • Page 110: Troubleshooting

    Transmission/Crankshaft/Crank Case Torque value Crank case bolt 1.0kg-m(10N.m, 7ft-lb) Tools - Universal bearing puller - Bearing remover set - Remover assembly - Remover shaft - Remover head - Sliding weight - Assembly shaft Troubleshooting Engine noise ● Connecting rod big and small ends loose. ●...

  • Page 111: Transmission

    Transmission/Crankshaft/Crank Case Transmission ● Loosen the drain bolt and remove the transmission oil. ● Remove R. crank case cover. (⇨ section 8) ● Remove the continuously variable transmission. (⇨ section 7) ● Remove the rear wheel. (⇨ section 13) ● Loosen the 8 transmission cover bolts. ●...
  • Page 112 Transmission/Crankshaft/Crank Case ● Remove the final shaft and the countershaft Final shaft comp. Countershaft Inspection ● Check the drive shaft for wear or damage. ● Check the final shaft for wear or damage. ● Check the countershaft for wear or damage. 11-4...
  • Page 113 Transmission/Crankshaft/Crank Case Bearing inspection ● Manually turn the bearing inner race installed inside the transmission cover, and check if the race is turning smoothly. ● Verify the outer race is accurately installed in the case. ● Replace the bearing, if necessary. Bearing ●...

  • Page 114: Crank Case Disassembly

    Transmission/Crankshaft/Crank Case ● Install a new gasket and dowel pin. ● Tighten the transmission cover with setting bolts. - Assemble the rear wheel (⇨ section 13) - Assemble continuously variable transmission (⇨ section 8) - Assemble the R. crank case cover (⇨ section 8) ●...

  • Page 115: Crankshaft Disassembly

    Transmission/Crankshaft/Crank Case ● Remove the crank case bleeder tube. ● Face the L. crank case downward. ● Disassemble the R. crank case from the L. crank case while tapping a few places on the L. crank case with a plastic hammer. NOTE •...

  • Page 116: Crankshaft Bearing

    Transmission/Crankshaft/Crank Case Inspection Checking ● Place the crankshaft on a stand or V-block, and Dial point check the journal vibration. gauge Service limit: Right side 0.1mm (0.004in) Left side 0.1mm(0.004in) ● Measure the side gap between the connecting rod big end and the crank weight. Feeler gauge ●...

  • Page 117: Crankshaft Assembly

    Transmission/Crankshaft/Crank Case Replacement Remove shaft Drive shaft bearing L. crank case ● Use special tools to remove the drive shaft bearing. Tools:Bearing remover set Final shaft bearing Remover shaft Remover head ● Remove the final shaft bearing and oil seal. ●...

  • Page 118: Crank Case Assembly

    Transmission/Crankshaft/Crank Case Crank Case Assembly Gasket ● Install dowel pins and new gaskets. Dowel pin ● Assemble the R. crank case to the L. crank case. NOTE • Make sure that the gasket is completely attached without any clearance. ● Tighten the crank case bolts. Torque value: 1.0kg-m (10N.m,7ft-lb) - Install the R/L crank case cover.

  • Page 119: Front Wheel/Front Fork/Steering

    Front Wheel/Front Fork/Steering 12. Front Wheel/Front Fork/Steering Service Information 12-1 Front Wheel 12-5 Troubleshooting 12-2 Front Fork 12-10 Steering Handle 12-3 Steering Stem 12-15 Service Information General Safety CAUTION ● Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance.
  • Page 120 Front Wheel/Front Fork/Steering Troubleshooting Hard steering ● Steering bearing adjustment nut too tight ● Faulty steering stem bearings ● Damaged steering stem bearings ● Insufficient tire pressure Steers to one side or does not track straight ● Unevenly adjusted right and left shock absorbers ●...
  • Page 121 Front Wheel/Front Fork/Steering Steering Handle Screw Removal ● Remove the following parts. - Back mirror - Front cover (⇨ 4-3) - LH. RH. Front handle side cover - Front handle cover -Remove the speedometer cable from the speedometer. - Rear handle cover ●...
  • Page 122 Front Wheel/Front Fork/Steering ● Clean the area where the throttle grip turns. ● Apply the grease to the operation part of the grip and insert the throttle grip to the RH. handle pipe. ● Apply grease to the throttle cable end, and connect Throttle cable the throttle cable to the throttle pipe.
  • Page 123 Front Wheel/Front Fork/Steering ● Insert the brake cable, speedometer cable, throttle Rear handle cover cable into the handle cable guide. ● Install the rear handle cover to the steering handle. ● Connect the speedometer cable, and tighten cable nut completely. ●...
  • Page 124 Front Wheel/Front Fork/Steering Inspection Didal gauge ● Check the front axle for deflection. Place the front axle on a V-block, and measure deflection with a dial gauge. Service limit: 0.2mm (0.008in) Axle ● Place the front wheel on an inspection stand. Slowly turn the wheel, and check the rim runout with a dial gauge.
  • Page 125 Front Wheel/Front Fork/Steering ● Remove the right side collar. Right side collar ● Remove the dust seal and brake disk. Dust Seal ● Check the disk for defects. (⇨ 14-5) Brake disk Wheel bearing replacement Bearing ● Install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance collar.
  • Page 126 Front Wheel/Front Fork/Steering Speedometer gear replacement Speedometer Speedometer gear box ● Remove the speedometer gear and washer from gear the speedometer gear box. ● Check the gear for wear or damage. ● Install the washer. ● Apply grease to the speedometer gear prior to assembling.
  • Page 127 Front Wheel/Front Fork/Steering ● Align the wheel hub tangs with the slots of the speedometer gear retainer, and assemble. Tang Slot ● Apply grease to the dust seal rim. Retainer ● Install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box.
  • Page 128 Front Wheel/Front Fork/Steering Front Fork Removal ● Remove the following parts. - Front cover (⇨ 4-3) - Front fender (⇨ 11-3) - Front wheel - Brake caliper (⇨ 14-7) ● Loosen the fork tube cap bolt and remove the front fork. Bolt NOTE •...
  • Page 129 Front Wheel/Front Fork/Steering NOTE • If the socket bolt turns idle but cannot be Vise removed, temporarily assemble the spring and the fork tube cap bolt first. • Hold the bottom case firmly with a vise, taking precautions not to distort or damage it. Bracket ●...
  • Page 130 Front Wheel/Front Fork/Steering ● Remove the fork tube from the bottom case. ● Remove the piston and rebound spring from the fork tube. Bottom case Inspection ● Place the fork spring on a level place, and measure the free length. ●...
  • Page 131 Front Wheel/Front Fork/Steering ● Wrap the bottom case with a piece of cloth, and fix it to the vise. ● Apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. Socket bolt Torque value: 2.0kg-m (20N.m, 14ft-lb) NOTE •...
  • Page 132 Front Wheel/Front Fork/Steering ● Assemble the spring to the fork tube. NOTE • Install the spring with the smaller pitch side facing downward. Bottom ● Assemble the fork tube cap bolt to the fork tube. Fork tube cap Assembly (Installation) ●...
  • Page 133 Front Wheel/Front Fork/Steering Steering Stem Removal ● Remove the following parts. - Front cover (⇨ 4-3) - Headlight (⇨ 18-2) - Handle (⇨ 12-3) - Headlight stay (⇨ 18-2) - Main switch (⇨ 18-4) - Front wheel (⇨ 12-5) - Front fork (⇨ 12-10) ●...
  • Page 134 Front Wheel/Front Fork/Steering ● Remove the top cone race, steel ball, and steering stem. NOTE Top cone race •Place steel balls in a pan to prevent from being lost. ● Check the steel ball, cone race, and ball race for Steel ball wear or damage.
  • Page 135 Front Wheel/Front Fork/Steering ● Insert the dust seal washer and the dust seal into Top ball race Top thread nut Top cone race the steering stem. Steel ball ● Using a steering stem driver, insert the steering Steel ball botton cone race into the steering stem. Bottom cone race Dust seal Washer...
  • Page 136 Front Wheel/Front Fork/Steering ● Readjust and clamp the speedometer cable. ● Install the front fork. ● Install the headlight stay. ● Install the following parts. - Front fork - Front wheel - Main switch - Handle bar - Front cover 12-18...

  • Page 137: Rear Wheel/Brake/Suspension

    Rear Wheel/Brake/Suspension 13. Rear Wheel/Brake/Suspension Rear Cushion 13-4 Service Information 13-1 Troubleshooting 13-2 Rear Swing Arm 13-7 Rear Wheel 13-3 Service Information General Safety ● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.
  • Page 138 Rear Wheel/Brake/Suspension Troubleshooting Wobble or vibration in motorcycle ● Tire pressure incorrect ● Faulty tire ● Bent rim ● Loose wheel bearing ● Swing arm bushing worn ● Wheel out of balance Soft suspension ● Weak springs ● Shock absorber improperly adjusted Hard suspension ●...
  • Page 139 Rear Wheel/Brake/Suspension Rear Wheel Removal ● Support the motorcycle on the main stand. ● Remove the muffler. (⇨ 4-9) ● Remove the rear caliper assembly from the rear swing arm. Muffler ● Loosen the rear axle nut, remove the rear swing arm. ●...
  • Page 140 Rear Wheel/Brake/Suspension ● Install the rear wheel inside collar. ● Install the rear swing arm, tighten the rear axle nut. Torque value: 6.0-8.0kgf m (60-80N m, 43-58ft-lb) Rear wheel Axle nut ● Install the rear caliper assembly to the rear swing arm.
  • Page 141 Rear Wheel/Brake/Suspension ● Fix the bottom metal, and loosen the lock nut. ● Remove the bottom metal. ● Remove the lock nut, bottom metal, stopper rubber, spring, and spring guide from the damper component. Lock Bottom metal Inspection Spring ● Measure the rear cushion spring free length. ●...
  • Page 142 Rear Wheel/Brake/Suspension Rear Swing Arm Removal ● Remove the following parts. - EX. muffler.(⇨4-9) - Rear brake caliper. ● Loosen the axle nut, remove the rear swing arm. Muffler ● Disassemble the rear wheel outside collar to the rear swing arm. ●...

  • Page 143: Brake System

    Brake System 14. Brake System Service Information 14-1 Brake Disk 14-6 Troubleshooting 14-1 Brake Caliper 14-6 Brake Fluid/Bleeding 14-2 Master Cylinder 14-9 Brake Pad 14-3 Service Information General Safety ● Do not allow foreign material to enter the system when replenishing brake fluid. ●...
  • Page 144 Brake System Brake Fluid/Bleeding Brake hose bolt Front master cylinder Front brake CAUTION •A contaminated disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. •Replace contaminated pads, and remove pollutants from the disk completely. NOTE •Check the brake fluid level often, and replenish new fluid as required.
  • Page 145 Brake System ●If the brake bleeder is not used, do the following. ●First, fill the brake fluid up to the upper limit line. Connect the hose to the bleeder valve to receive brake fluid. ① Squeeze the brake lever completely loosen the bleeder valve 1/2 turn, and tighten it again.
  • Page 146 Brake System ● Remove the brake caliper from the right front fork. Brake caliper ● To install a new brake pad into the brake, press the piston to return to the original position. Lock plate ● Remove the pad pin bolt, lock plate, and brake pad.
  • Page 147 Brake System ● Install the brake caliper into the right front fork. NOTE •Be careful not to damage the brake pad. ● Tighten the caliper braket bolt. Torque: 2.7kg– – m(27N.m, 19ft-lb) ● Install pad pin bolt. Torque: 1.8kg– – m(18N.m, 13ft-lb) Brake caliper ●...
  • Page 148 Brake System Brake Disk Inspection ● Measure the thickness of the disks. Thickness: 3.0mm(0.1181in) ● Check the brake disks for vibration. Service limit: 0.02mm(0.0008in) Brake Caliper Front brake caliper removal ● Remove the brake oil bolt and the brake hose from the brake caliper.
  • Page 149 Brake System CAUTION •Never use the high-pressure air or bring the air gun too close. •Never touch the inside of the caliper. ● Disassemble the piston seal and the dust seal. Dust seal NOTE Piston seal •Pay attention not to damage the inner surface of the caliper.
  • Page 150 Brake System ● Apply the silicone grease to the pin bush. ● Connect the pin bush to the portion of the caliper. ● Install the pad spring in the caliper. ● Install the caliper pin bolt and the slide pin in the caliper.
  • Page 151 Brake System Master Cylinder Front master cylinder Rear master cylinder Removal ● Remove the back mirror. ● Remove the front handle cover.(⇨ 4–8) ● Remove the the rear handle cover.(⇨ 4–8) ● Disconnect the front brake switch wire. ● Drain the brake fluid. ●...
  • Page 152 Brake System NOTE •If there is any leak of fluid when installing new piston, it may indicate the side wear of the cylinder by the direction of the piston contacting face. In this case, the master cylinder must be replaced also. ●...
  • Page 153 Brake System ● Inatall the brake hose to the master cylinder with 2 new sealing washers and the hose bolt. Rear master cylinder Torque: 3.5kgf· · m ● Connest the brake stop switch wire. ● Fill the brake fluid, and bleed air. Front master cylinder Rear master cylinder ●...
  • Page 154 MEMO...

  • Page 155: Charging System/Battery

    Charging System/Battery 15. Charging System/Battery Service Information 15-1 Charging System Inspection 15-3 Troubleshooting 15-2 Regulator/Rectifier 15-5 Battery 15-3 A.C generator Inspection 15-6 Service Information General Safety ● The maintenance-free (MF) battery does not require battery acid level inspection. Do not replenish distilled water.
  • Page 156 Charging System/Battery Troubleshooting No power - key turned on ● Dead battery - Low fluid level - Low specific gravity - Charging system failure ● Disconnected battery cable ● Main fuse burned out ● Faulty ignition switch Low voltage - key turned on ●...
  • Page 157 Charging System/Battery Battery Battery cover Removal ● Remove the floor panel mat. ● Loosen the 2 battery cover setting bolts. ● Remove the battery cover. Charging Status (Open Voltage) Inspection ● Remove the battery terminal from the battery. Check the battery terminal voltage. Fully charged: 13.0-13.2V Under charged: Not to exceed 12.3V NOTE...
  • Page 158 Charging System/Battery Charging Status Inspection NOTE Ampere meter •Current level changes according to the status of Battery (-) battery charging. Inspect the fully charged battery with its voltage running at 13.0~13.2V between battery terminal. •If the engine is started by a starter motor, large level of current may flow sometimes because the battery power is consumed during starting.
  • Page 159 Charging System/Battery Regulator/Rectifier Harness side circuit inspection ● Remove the regulator / rectifier coupler, and check the wiring circuits at each terminal of the main harness coupler. Inspection Items Item Judgment criteria Battery voltage must be Battery (red) between red(+) and earth(-) Power must be connected Ground wire (green) between the green and the earth.
  • Page 160 Charging System/Battery Replacement ● Remove the front cover. (⇨ 4-3) ● Disconnect the regulator / rectifier wire coupler. Remove the 2 regulator / rectifier setting bolts attached to the headlight stay. ● Install in the reverse order of removal. Rectifier A.C Generator Inspection NOTE •This test is carried out with the stator assembled...

  • Page 161: Ignition System

    Ignition System 16. Ignition system Service Information 16-1 Pulse Generator Inspection 16-5 Troubleshooting 16-2 A.C Generator Inspection 16-5 CDI Unit Inspection 16-3 Ignition Timing Check 16-6 Ignition Coil Inspection 16-4 Side Stand Cut-off Switch 16-6 Service Information General Safety ● Carry out inspection in sequence based on the troubleshooting table. ●...

  • Page 162: Troubleshooting

    Ignition System Troubleshooting No spark at plug ● Poorly connected, broken or shorted wires - Between the A.C. generator and CDI unit - Between the CDI unit and ignition coil - Between the CDI unit and main switch - Between the ignition coil and plug ●...

  • Page 163: Cdi Unit Inspection

    Ignition System CDI Unit Inspection CDI ignition circuit inspection NOTE • Inspect the ignition system in proper sequence based on the troubleshooting table. - Remove the luggage box. (⇨ 4-5) - Remove the body cover. (⇨ 4-6) ● Remove the coupler from the CDI unit, and check the ignition system circuits from the wiring coupler side.

  • Page 164: Ignition Coil Inspection

    Ignition System Ignition Coil Inspection ● Remove the luggage box. (⇨ 4-5) ● Remove the body cover. (⇨ 4-6) ● Remove the center cover. (⇨ 4-4) ● Remove the primary wire. NOTE • This test is inaccurate. Conduct the ignition coil performance test with an ignition coil tester.

  • Page 165: Pulse Generator Inspection

    Ignition System Performance Test CDI Tester ● Remove the ignition coil. ● Use a CDI unit to test spark performance of the ignition coil. If there is no spark from the spark Ignition coil cap of the spark adaptor, replace coil. Tools: Spark adaptor Inspection adaptor NOTE...

  • Page 166: Ignition Timing Check

    Ignition System Ignition Timing Check Hole cap Timing light NOTE •As the system uses the CDI unit, the ignition timing need not be adjusted. Check the ignition system if the ignition timing is incorrect. ● Start and warm up the engine. ●...
  • Page 167 Ignition System Removal ● Remove the front cover.(⇨ 4-3) ● Remove the headlight.(⇨ 18-2) ● Remove the coupler of the side stand switch. ● Remove the L. side cover.(⇨4-5) ● Loosen the side stand switch mounting 2 bolts. ● Release the wire clamps and remove the side stand switch.
  • Page 168 MEMO...

  • Page 169: Starter System

    Starter System 17. Starter System Service Information 17-1 Starter Motor 17-2 Troubleshooting 17-1 Starter Magnetic Switch 17-3 Service Information General Safety ● The starter motor can be maintained without removing the engine from the vehicle. Specifications Unit: mm(in) Item Standard value Service limit Starter motor brush length 6.5mm (0.255)
  • Page 170 Starter System Starter Motor Removal - Remove the luggage box. (⇨ 4-5) - Remove the body cover (⇨ 4-6) ● Remove the starter motor cable from the motor. ● Unfasten the 2 starter motor mounting bolts, and remove the starter motor. Bolt NOTE •...
  • Page 171 Starter System Starter Magnetic Switch Starter magnetic switch Inspection ● Turn on the main switch, and press the starter button. If the starter magnet switch generates operation signal tone at this time, it indicates satisfactory condition. Voltage Check ● Measure the voltage between the yellow/red wire (+) of the starter magnetic switch and the Yellow/red wire vehicle earth.
  • Page 172 MEMO...

  • Page 173: Light/Switch/Horn

    Light/Switch/Horn 18. Light/Switch/Horn Service Information 18-1 Handle Bar Switch 18-4 Troubleshooting 18-1 Front Stop Light Switch 18-5 Headlight 18-2 Fuel Gauge/Fuel Sensor 18-5 Front Winker 18-2 Horn/Clock 18-6 Tail-Stop Light/Rear Winker 18-2 Clock 18-6 Meters(Measuring instruments) 18-3 Trunk Lamp 18-7 Main Switch 18-4 Service Information...

  • Page 174: Headlight

    Light/Switch/Horn Headlight Removal ● Remove the front cover. (⇨ 4-3) ● Loosen the 4 headlight setting bolts. ● Remove the headlight wiring ● Check the headlight wiring for disconnection. (⇨ 15-3) Bulb Replacement Bulb ● Remove the headlight socket and position light socket, and replace the light bulb.

  • Page 175: Meters(Measuring Instruments)

    Light/Switch/Horn Meters (Measuring Instruments) Bulb Replacement ● Remove the front handle cover.(⇨ 4-8) ● Disconnect the winker and headlight wiring. ● Remove the bulb socket, and replace bulbs. Bulb Socket Meter Replacement ● Loosen the speedometer setting screws, and remove the front wheel side speedometer. Speedometer ●...

  • Page 176: Main Switch

    Light/Switch/Horn Main Switch Main switch wire Inspection ● Remove the front cover. (⇨ 4-3) ● Remove the headlight case. ● Remove the main switch terminal. ● Carry out continuity test between the following the same-color wires, as shown on the following table. Color Black/White Green Black Terminal...

  • Page 177: Front Stop Light Switch

    Light/Switch/Horn Winker switch Dimmer switch Color Sky blue Grey Orange Terminal ○ ○ ○ ○ Horn switch Color Light green Black Winker switch Terminal Horn switch Before operation ○ ○ Push Hazard switch Color Sky blue Grey Orange Terminal Before operation ○...

  • Page 178: Clock

    Light/Switch/Horn Fuel Sensor Float ● Remove the fuel sensor terminal, and connect the resistance tester to each terminal. Check the resistance while moving the float up and down. Resistance Ratio Calculation Float position Resistance ratio Fuel amount sufficient 0.02-0.1 Reserve 2.5-4.5 No fuel 13-25.5...

  • Page 179: Trunk Lamp

    Light/Switch/Horn Trunk Lamp ● Replace bulb. ● Remove the luggage box. (⇨ 4-5) ● Replace the trunk lamp bulb socket from the trunk lamp of out side. Color Green Terminal Push ○ ○ Projection 18-7...
  • Page 180 MEMO...

  • Page 181: Wiring Diagram

    Wiring Diagram 19. Wiring Diagram 19-1...
  • Page 182 MEMO...

  • Page 183: Troubleshooting

    Troubleshooting 20. Troubleshooting Engine Does Not Start or Is Hard to Start 20-1 Engine Output Insufficient 20-2 Poor Performance at Low Speed and Idling 20-3 Poor Performance at High Speed 20-3 Unsatisfactory Operation 20-4 Fuel Gauge 20-6 Starter Motor 20-7 Engine Does Not Start or Is Hard to Start Cause of Trouble 1.
  • Page 184 Troubleshooting Engine output Insufficient Cause of Trouble 1. Gently accelerate engine. Engine speed does not (1) Air cleaner clogged increase sufficiently (2) Insufficient fuel supply Engine speed increases. (3) Fuel tank cap air hole clogged (4) Muffler clogged 2. Check ignition timing. Abnormal (1) Faulty CDI unit (2) Faulty A.C.
  • Page 185 Troubleshooting Poor Performance at Low Speed and Idling Cause of Trouble 1. Check ignition timing. Abnormal (1) Faulty CDI unit (2) Faulty A.C. generator Normal 2. Check the carburetor air screw Incorrect (1) Excessive fuel mixture (Loosen screw to correct Correct adjustment level) (2) Lean fuel mixture...
  • Page 186 Troubleshooting Unsatisfactory Operation Cause of Trouble Clutch Drive/Driven Pulley 1. Engine starts but motorcycle does not move. (1) Drive belt worn or slips (2) Ramp plate damaged (3) Drive face spring damaged (4) Clutch lining came off (5) Driven pulley shaft spline damaged (6) Faulty transmission (7) Transmission seized 2.
  • Page 187 Troubleshooting Poor Brake Performance Check brake adjustment Cause of Trouble 1. If the arrow were mark and the brake (1) Brake shoe worn panel mark match with each other (2) Brake cam worn (3) Shoe and cam contact surface worn (4) Brake drum worn 2.
  • Page 188 Troubleshooting Fuel Gauge Gauge Reading Inaccurate (Ignition switch ON) Cause of Trouble 1. Operate the turn signal to check Signal continuously (1) Fuse cut the battery circuit. operates dim or does not (2) Battery weak or totally discharged operate at all (3) Faulty ignition switch Signal operates satisfactorily (4) Faulty terminal connection...
  • Page 189 Troubleshooting Starter Motor Starting motor will not turn Cause of Trouble 1. Apply the brake and check the Light not activated (1) Fuse cut brake stop light for operation (2) Battery weak or totally discharged (3) Faulty stop right switch Light is activated (4) Faulty terminal connection (5) Ignition switch damaged or shorted...
  • Page 190 SERVICE MANUAL 2001. 4. PRINTED NO COPY 2001. 4. PUBLICATION...
  • Page 191 • • HEAD OFFICE (FACTORY) : #58, Sungsan-dong, Changwon, Kyungnam, Korea Tel : (82-55)279-7000 / Fax : (82-55)239-7524 • • OVERSEAS SALES OFFICE : #16-6 Pil-dong 2Ka, Chung-ku, Seoul, Korea Tel : (82-2)2274-3171 / Fax : (82-2)2269-7997 SM41-0104-01E...

This manual is also suitable for:

Ns 125 dlx

Table of Contents