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DAELIM NS125III Service Manual

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SERVICE MANUAL
HEAD OFFICE (FACTORY)
#58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA
TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524
OVERSEAS SALES OFFICE
#13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA
TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997
SM37-0211-01E

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Summary of Contents for DAELIM NS125III

  • Page 1 SERVICE MANUAL HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997 SM37-0211-01E...

  • Page 4: 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 Starter System...

  • Page 6: Service Information

    8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. Service Rules 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
  • Page 7 Service Information 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
  • Page 8 Service Information 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
  • Page 9 Service Information 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
  • Page 10 Service Information Caution when Wiring Each cord must be connected depending on its color. When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
  • Page 11 Service Information Turn off the main switch before connecting/dis- When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
  • Page 12 Service Information Insert the connector until the vinyl cover is fully inserted When removing T-start, broaden the groove of T-start into the terminal. using the wiring driver and release the torque. The opening of the vinyl cover must face at the ground Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
  • Page 13 Service Information In case that the wire harness is contacted with the end or The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness is not pressed by the parts.
  • Page 14 Service Information Identification Numbers Frame serial number Engine serial number FARME SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION The frame serial number is stamped on the front The engine serial number is stamped on the central central part of the frame. part of the left crankcase.
  • Page 15 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 16 Service Information Item Specifications Type/Venturi bore CV type(vacuum)24.2mm Model mark BDS 26 -112 Choke type Autoby-starter Carburetor Main jet Pilot screw initial setting 1 and 1/2 trust out Float level 13 mm Idle speed 1,800 100(rpm) Clutch type Automatic Transmission Drive Train Primary reduction 3.231(42/14)
  • Page 17 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 18 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 19 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. CAUTION accident may result if instructions are not followed.
  • Page 20 Service Information Wiring Diagram Winker relay Front brake master cylinder Rear brake cable Speedometer Cable Stop switch connector Front winker connector Front winker connector Main switch Resister(excepted some countries) Front brake hose Packing lever Horn Radiator Front brake hose Throttle cable Radiator hose Rear brake cable Speedometer cable...
  • Page 21 Service Information CDI unit Ignition coil Radiator hose CDI unit Ignition coil Fuel filter Throttle cable Fuel pump Rear brake cable 1-16...

  • Page 22: 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 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 23 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 Oil level now Pressure relief valve stuck open Plugged oil pick-up screen Oil pump worn...
  • Page 24 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 If the oil level is between the lower and higher sight-glass oil level line, oil level is satisfactory.
  • Page 25 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 26 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 rotor Outer rotor Inspection Assemble the inner and outer rotors to the oil pump Measure the pump body clearance.
  • Page 27 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 Outer rotor rotor...
  • Page 28 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 29 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 30 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 31 MEMO...

  • Page 32: Inspections/Adjustments

    Inspections/Adjustments 3. Inspections/Adjustments Service Information Brake Pad/Shoe 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 3-10 Carburetor Idling Steering Head Bearing...
  • Page 33 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 34 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 35 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 Check if the throttle grip operates smoothly in any steering position.
  • Page 36 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. Squeeze Squeeze out oil...
  • Page 37 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 38 Inspecitions/Adjustments Brake Fluid Brake hose bolt Master cylinder Remove the brake fluid cover. Check the oil level inside the front brake reservoir. If the oil level 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 39 Inspections/Adjustments Brake Lever Free Play Check the free play after pulling the lever. Front:10-20mm Rear:10-20mm Rear Brake Free Play Adjustment Turn the adjuster nut to adjust the free play. After initial adjustment, check the operation of the rear brake light switch. Make additional adjustments, if necessary.
  • Page 40 Inspections/Adjustments Check the side stand ignition cut-off switch ; Put the side stand up. Start the engine. Lower the side stand. The engine should stop as you put the side stand down. If there is a problem with the system, check the side stand swich.
  • Page 41 Inspections/Adjustments Wheels/Tires NOTE Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, Tire pressure gauge cracks or damage. Replace damaged tires. Standard Pressure (kPa) Item Front wheel...

  • Page 42: 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. A muffler is hot. Do not service it immediately after the engine is stopped.
  • Page 43 External Parts Maintenance Procedure Names of frame covers This chart shows arrows connected in the order of disassembling covers. Front cover Floor side cover Luggage box Front handle cover Rear carrier Inner box Rear handle cover Center cover Maintenance cover Front side cover Rear under cover Body cover...
  • Page 44 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 Remove the front fender. ( 4-10) Remove the front wheel.
  • Page 45 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. Front inner box Remove the 6 front side cover screws.
  • Page 46 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 47 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 48 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. Screw Bolt Withdraw the battery wiring, and...
  • Page 49 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 50 External Parts Muffler Setting Bolt Removal Loosen the 3 flange nuts securing the EX. pipe comp. Loosen the flange bolt securing the rear wheel mud guard. Loosen the 2 flange bolts securing the R. crank- case. Remove the EX. muffler comp. WARNING Never perform the maintenance of the muffler right after stopping the vehicle because the...
  • Page 51 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 Loosen 1 setting screw of the front fender B. Remove the speedometer cable guide.
  • Page 52 MEMO...
  • Page 53 Fuel System Fuel tank Fuel strainer Fuel pump Carburetor...

  • Page 54: 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 55: 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. Mixture too lean or rich Air cleaner clogged.

  • Page 56: 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 ( 4-5) - Rear carrier (...

  • Page 57: 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. Install in the reverse order of removal.
  • Page 58 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. Inspection Jet needle Jet needle holder...
  • Page 59 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. Check the float valve operation. Seat Remove the main jet, needle jet holder, and needle jet, and remove the slow jet.
  • Page 60 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 61 Fuel System Float Level Main jet Install the float valves, and float pins. Check the float valve level. Float level: 13mm Assemble the float chamber. Float level gauge Vacuum Chamber Assembly Insert the jet needle and spring to the piston, and install the holder.

  • Page 62: 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 starter cable Adjust the throttle operation.
  • Page 63 MEMO...

  • Page 64: 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 65 Engine Removal Engine Removal Drain the engine oil. A.C.G connector Remove the following parts. - Luggage box ( 4-5) - Frame body cover ( 4-6) - Air cleaner ( 5-4) Remove A.C. generator, and starter motor cable. Remove the high-tension cord. Remove the carburetor.
  • Page 66 Engine Removal Remove the engine. (with the muffler and rear wheel attached) Remove the muffler. ( 4-9) Remove the rear wheel. ( 13-3) Installation Install in the reverse order of removal. NOTE Take precautions not to damage wiring and cable. Take precautions not to damage the threaded part of bolts.
  • Page 67 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission L. crank case cover...
  • Page 68 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 Clutch/Disassembly 7-12 L. Crank Case Cover 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 69: 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 70: 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 71: 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. Remove the kick driven gear.
  • Page 72 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. Check the kick starter spindle bushing and the idle gearshaft assembly for damage.
  • Page 73 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 74: 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. As shown in the figure, match the kick driven gear friction spring with the L.
  • Page 75 Replace the defective drive belt. 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 76: 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 77 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 78 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 79: 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 80 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. Remove the oil seal from the movable driven Movable driven face face.
  • Page 81 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. Measure the inner diameter of the clutch outer.
  • Page 82 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 83 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 84 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 85 Generator/Starter Clutch...

  • Page 86: Generator/Starter Clutch

    Generator/Starter Clutch 8. Generator/Starter Clutch R.Crank Case Cover Service Information Starter Clutch Shroud 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. The charging system can be maintained without removing the engine.
  • Page 87 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. shroud Loosen the shroud L setting screw.
  • Page 88 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 Loosen the pulse generator screw, and remove the pulse generator.
  • Page 89 Generator/Starter Clutch Assembly 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. Assemble the woodruff key to the crankshaft.
  • Page 90 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 Remove the starter reduction gear and shaft. Inspection Check the reduction gear for wear or damage.
  • Page 91 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. Assemble the A.C.
  • Page 92 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. Measure the inner diameter of the starter driven gear.
  • Page 93 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) Assemble the A.C.

  • Page 94: 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 95 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 Cylinder head operation problem can be diagnosed, in general, by a compression test, or by checking noises on the top of the engine.
  • Page 96 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 97 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. Remove the rocker arm.
  • Page 98 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. Remove the cylinder head from the cylinder. Remove the gasket, dowel pin and cam chain Cam chain guide guide from the cylinder.
  • Page 99 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 100 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 Measure, and record, the inner diameter of the valve guide.
  • Page 101 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. Install new O-ring and new valve guide. Insert the valve guide from the top of the cylinder head.
  • Page 102 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 103 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. Gently strike the valve with a valve guide reamer to check the status of contact, Too high without turning the valve.
  • Page 104 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 105 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 Tighten the carburetor insulator with mounting insulator...
  • Page 106 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 107 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. Install the dowel pins on the cylinder head.
  • Page 108 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 109 Cylinder/Piston Piston top ring Piston 2ND ring Piston Oil ring Piston pin clip Piston pin clip 10-0...

  • Page 110: 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. Take precautions not to damage the inside of the cylinder or the exterior part of the piston.
  • Page 111 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. Inspection Cylinder gauge Measure, and record, the cylinder inner diameter...
  • Page 112 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. Check the piston ring.
  • Page 113 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) Measure the piston outer diameter at a point 10mm from the piston bottom in the direction of...
  • Page 114 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 115 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.
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  • Page 117 Transmission/Crankshaft/Crank Case R.Crank Case L.Crank Case Crankshaft 11-0...

  • Page 118: 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. Service transmission without removing the engine from the vehicle.

  • Page 119: 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. Crank pin bearing loose.

  • Page 120: 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. Remove the transmission cover.
  • Page 121 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 122 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 Use special tools to push in the bearing into the case.

  • Page 123: Crank Case Disassembly

    Transmission/Crankshaft/Crank Case Install a new gasket and dowel pin. 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) Fill transmission oil.

  • Page 124: 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 Be careful not to distort the mating surface of the crank case during disassembly.

  • Page 125: 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 Check the vertical shaft play of the connecting...

  • Page 126: 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. Remove the countergear bearing. Apply clean engine oil to a new bearing, and assemble it to the crank case.

  • Page 127: 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 128: 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 Handle Bar 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 129 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 Bent front forks Bent front axle: wheel installed incorrectly Front wheel wobbling Bent rim...
  • Page 130 Front Wheel/Front Fork/Steering Handle Bar Screw Removal Remove the following parts. - Headlight ( 18-2) - Main switch connector ( 18-4) - Front cover ( 4-3) - Front handle cover - Headlight, and winker wiring - Disassemble the speedometer cable from the speedometer.
  • Page 131 NOTE Check that the throttle grip moves smoothly. Adjust the throttle grip free play. ( 3-4 ) Apply DAELIM Bond A to the inside surface of the grip and to the clean surface of the left handle bar. Wait Bond 3~6 minutes and install the grip.
  • Page 132 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. Lift the front handle cover, and connect the winker wiring.
  • Page 133 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 134 Front Wheel/Front Fork/Steering Remove the right side collar. Right side collar Remove the dust seal and brake disc. Dust Seal Brake disc Check the disc for defects. ( 14-5) Wheel bearing replacement Install the bearing remover head and the remover Bearing shaft on the wheel, and remove the bearing and distance collar.
  • Page 135 Front Wheel/Front Fork/Steering Speedometer gear replacement Speedometer gear box Speedometer 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 136 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. Install the dust seal, and align the tangs of the Retainer speedometer gear retainer with the gear groove to assemble the speedometer gear box.
  • Page 137 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 Loosen the fork tube cap bolt, but do not remove Fork tube cap...
  • Page 138 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 Remove the dust seal.
  • Page 139 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. If the free length deviates from the service limit, replace the spring with a new one.
  • Page 140 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 When a vise is used to hold the bottom case, do not insert the case itself but insert the bracket.
  • Page 141 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) Assemble the front fork to the steering stem. Bolt Assemble the front fork setting bolt.
  • Page 142 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) Loosen the 2 headlight stay bolts, and remove the stay.
  • Page 143 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 144 Front Wheel/Front Fork/Steering Insert the dust seal washer and the dust seal into Top ball race Top thread nut the steering stem. Top cone race 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 145 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 Headlight - Main switch stay - Handle bar - Front cover 12-18...

  • Page 146: Rear Wheel/Brake/Suspension

    Rear Wheel/Brake/Suspension 13. Rear Wheel/Brake/Suspension Service Information 13-1 Rear Brake 13-4 Troubleshooting 13-2 Rear Cushion 13-6 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 147 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 Shock absorber improperly adjusted Bent shock absorber rod Suspension noise Loose fasteners...
  • Page 148 Rear Wheel/Brake/Suspension Rear Wheel Removal Support the motorcycle on the main stand. Loosen the rear brake adjuster, and remove the brake cable. Loosen the brake arm setting bolts, and remove the spring. Adjuster Remove the muffler. ( 4-9) Loosen the rear wheel axle nut. Remove the lock washer.
  • Page 149 Rear Wheel/Brake/Suspension Insert the lock washer, and tighten with the axle nuts. Torque value: 6.0-8.0kg-m (60-80N.m, 43-58ft-lb) Rear wheel Axle nut Assemble the brake cable cable and adjust nuts. Install the spring on the brake arm, and tighten with setting bolts. Adjuster Rear Brake Drum...
  • Page 150 Rear Wheel/Brake/Suspension Disassembly Manually open the brake shoe and remove it. Shoe spring Remove the shoe spring from the brake shoe. Brake shoe Brake cam Remove the brake cam. Brake cam Assembly Apply small amount of grease to the brake cam and anchor pin.
  • Page 151 Rear Wheel/Brake/Suspension Rear Cushion Removal - Remove the body cover( 4-6) Setting bolt - Remove the luggage box ( 4-5) Loosen the top and bottom rear cushion setting bolts. NOTE Support the frame firmly prior to working. Disassembly Cushion compressor Install the compressor attachment as shown in the figure.
  • Page 152 Rear Wheel/Brake/Suspension Assembly Cushion compressor Assemble the spring, spring guide, and stopper rubber. NOTE Install the spring with its narrow pitch side facing upward Apply thread locking agent to the lock nut, and Compressor install the rear cushion compressor attachment on attachment the damper rod.
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  • Page 154: Brake System

    Brake System 14. Brake System Service Information 14-1 Brake Disk 14-5 Troubleshooting 14-1 Brake Caliper 14-6 Brake Fluid/Bleeding 14-2 Master Cylinder 14-8 Brake Pad 14-3 Service Information General Safety Do not allow foreign material to enter the system when replenishing brake fluid. To prevent chemical changes, do not mix different types of brake fluid.
  • Page 155 Brake System Brake Fluid/Bleeding Brake hose bolt Master cylinder Brake fluid change 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 156 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. Squeeze the brake lever completely loosen the bleeder valve 1/2 turn, and tighten it again.
  • Page 157 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 158 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 value: 2.7kg m(27N.m, 19ft-lb) Brake caliper Install pad pin bolt. Torque value: 1.8kg m(18N.m, 13ft-lb) Bend the lock plate tangs, and fix the pad pin bolt.
  • Page 159 Brake System Brake Disk Removal Slide pin Remove the brake oil bolt and the brake hose from the brake caliper. Remove the caliper from the R. front fork and remove the pad spring, hanger pin and brake pad. Brake CAUTION Brake caliper hose Pay attention not to let the brake fluid adhere to...
  • Page 160 Brake System Caliper piston Check the caliper piston O.D. part for scratches or other damage. Installation Clean the piston seal and the dust seal with the brake fouid and install them in the caliper. Install the piston in the caliper with the groove side of Tongued the piston facing the pad.
  • Page 161 Brake System Master Cylinder 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. Remove the front brake hose from the master cylinder.
  • Page 162 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. Chack the master cylinder for scores, scratches or nicks and replace if necessary.
  • Page 163 Brake System Inatall the brake hose to the master cylinder with Master cylinder 2 new sealing washers and the hose bolt. Torque value: 3.5kgf m(35N m, 25ft-1b Connect the front brake stop switch wire. Fill the brake fluid, and bleed air. Install the rear handle cover.( 4-8) Install the front handle cover.( 4-8) Install the back mirror.

  • Page 164: 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 165 Charging System/Battery Troubleshooting Low power - engine running Battery undercharged No power - key turned on -Low fluid level Dead battery - One or more dead cells - Low fluid level Charging system failure - Low specific gravity - Charging system failure Intermittent power Disconnected battery cable Loose battery connection...
  • Page 166 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 Use a PVA multi-tester to check the status of...
  • Page 167 Charging System/Battery Charging Status Inspection NOTE Ampere meter Battery (-) Current level changes according to the status of 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 168 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 169 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 to the engine.

  • Page 170: Ignition System

    Ignition System 16. Ignition system Service Information 16-1 Pulse Generator Inspection 16-5 Troubleshooting 16-2 Ignition Timing Check 16-6 CDI Unit Inspection 16-3 Side Stand Ignition Cut-off Switch 16-6 Ignition Coil Inspection 16-4 Service Information General Safety Carry out inspection in sequence based on the troubleshooting table. If the CDI unit is dropped, or if strong shock is applied thereto, CDI unit malfunction may result.

  • Page 171: Troubleshooting

    Ignition System TROUBLESHOOTING No spark at plug. UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. Battery is undercharged (or operating force of the kick starter is weak). 3.

  • Page 172: 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 173: 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. Measure the primary resistance between the ignition coil terminal and earth.

  • Page 174: 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 CDI tester NOTE Read the tester manual carefully prior to using...

  • Page 175: 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. Connect the timing light to the high-tension cord.
  • Page 176 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.
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  • Page 178: Starter System

    Starter System 17. Starter System Service Information 17-1 Starter Motor 17-3 Troubleshooting 17-2 Starter Magnetic Switch 17-6 Service Information General Safety Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. The starter motor can be maintained without removing the engine from the vehicle.
  • Page 179 Starter System Troubleshooting Starter motor will not turn. Check for a blown main fuse before servicing. Check that the stop light is correctly adjusted. Check that the side stand is positioned in the condition under which the engine can be started. Connect the starter motor (+) terminal to the With the ignition switch ON and squeeze...
  • Page 180 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. NOTE Bolt Always turn the ignition switch OFF before servicing the starter motor.
  • Page 181 Starter System Remove the brush spring, and then remove the brush. Measure the brush length. Replace the brush if it is worn beyond the service limit. Brush Service Limit : 5 mm Tool : Vernier Caliper NOTE If replacement, replace with a brush holder set. Check the commutator for : -Damage or abnormal wear.
  • Page 182 Starter System Starter Motor Assembly Install the brush and brush spring to the brush hold set. Insert the brush terminal into the rear bracket, and install the terminal set and flange nut. Align the brush holder set with the rear bracket groove, and install the brush holder set.
  • Page 183 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 184: Light/Switch/Horn

    Light/Switch/Horn Services 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 Switch 18-7 Main Switch 18-4...

  • Page 185: 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. Install in the reverse order of removal.

  • Page 186: 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 Remove the speedometer cable from the meter, cable...

  • Page 187: 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 LOCK...

  • Page 188: Front Stop Light Switch

    Light/Switch/Horn Horn switch Hazard switch Dimmer swithc COLOR LIGHT GREEN BLACK COLOR SKY BLUE GRAY ORANGE Terminal TERMINAL FREE FREE PUSH PUSH Winker switch Horn swiitch Front Stop Light Switch Remove the front handle cover. ( 4-8) Remove the black wire and green/yellow wire terminals inside the headlight case, and check the following.

  • Page 189: 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 Horn...

  • Page 190: Trunk Lamp Switch

    Light/Switch/Horn Trunk Lamp Switch INSPECTION Trunk Lamp Switch Release the seat lock with the main key, open the seat. Disconnect the trunk lamp switch, check for continuity between the terminals. COLOR BLACK TERMINAL PUSH FREE 18-7...
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  • Page 194: Wiring Diagram

    Wiring Diagram 19. Wiring Diagram 19-1...

  • Page 195: 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 196 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 197 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 198 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 199 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 200 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 201 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...
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  • Page 203 SERVICE MANUAL 2002. 11. PRINTED NO COPY 1999. 11. PUBLICATION...

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