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DAELIM ROADWIN VJ125 Service Manual

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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

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  • Page 1 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...
  • Page 2 HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure GENERAL INFORMATION for the VJ125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the INSPECTIONS / ADJUSTMENTS vehicle, carry out regular inspections according to the maintenance schedule (Section 2).
  • Page 4 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 5 GENERAL 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 6 GENERAL INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball be 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 7 GENERAL 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 8 GENERAL 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 9 GENERAL 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 10 GENERAL INFORMATION Insert the connector until the vinyl cover is fully When removing T-start, broaden the groove of T-start inserted 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 11 GENERAL 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 12 GENERAL INFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION The engine serial number is stamped on left crankcase. The frame serial number is stamped on the left side of steering head.
  • Page 13 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 2,010mm OVERALL WIDTH 740mm OVERALL HEIGHT 1,040mm DIMENSIONS WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 150mm DRY WEIGHT 130kgf CURB WEIGHT 147kgf TYPE Double Cradle FRONT SUSPENSION / STROKE Telescopic / 130mm REAR SUSPENSION / STROKE Swingarm / 28mm FRONT TIRE SIZE (TYPE)
  • Page 14 GENERAL INFORMATION ITEM SPECIFICATIONS TYPE PD 24 VENTURI BORE 24mm SETTING SERIES MARK VJ 125 C MAIN JET #100 CARBURETOR SLOW JET PILOT SCREW INITIAL SETTING 2 1/8 FLOAT LEVEL 12.5mm IDLE SPEED 1,600 100(rpm) CLUTCH TYPE Multiplate Wet Clutch TRANSMISSION TYPE Constant Mesh Transmission GEAR RATIO 1st...
  • Page 15 GENERAL INFORMATION TORQUE VALUES ENGINE TORQUE THREAD DIA Q’TY REFERENCE ITEM (mm) kgf.m,(N.m) CAM SHAFT HOLDER NUT 2.0 (20) Apply Engine Oil 1.25 CYLINDER HEAD COVER BOLT 1.0 (10) M6 1.0 CAM CHAIN TENSIONER PIVOT BOLT 1.0 (10) M8 1.25 CAM CHAIN TENSIONER LIFTER BOLT 1.2 (12) M6 1.0...
  • Page 16 GENERAL INFORMATION FRAME THREAD DIA TORQUE Q’TY ITEM REFERENCE (mm) kgf.m,(N,m) REAR CALIPER BRACKET BOLT 3.0(30) M8 1.25 REAR MASTER CYLINDER HOLDER SOCKET BOLT 1.2(12) M6 1.0 FRONT AXLE NUT 5.9(59) M14 1.5 U- NUT FRONT BRAKE DISK BOLT 4.2(42) M8 1.25 BRAKE OIL BOLT (FRONT/REAR) 3.4(34)
  • Page 17 GENERAL 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 injury or Indicates dangerous area. Serious vehicle part damage may result if instruction accident may result if instructions are not are not followed.
  • Page 18 GENERAL INFORMATION TOOLS SPECIAL COMMON DESCRIPTION REF. SEC. DESCRIPTION REF. SEC. CLUTCH CENTER HOLDER WRENCH, 8 9mm ACG ROTOR PULLER ADJUSTING WRENCH, B VALVE GUIDE DRIVER FLOAT LEVEL GAUGE VALVE GUIDE REAMER LOCK NUT WRENCH, 20 24mm UNIVERSAL BEARING PULLER EXTENSION BAR 7, 13 BEARING REMOVER SET...
  • Page 19 GENERAL INFORMATION WIRING DIAGRAM BATTERY EARTH CABLE THROTTLE CABLE ST.-MOTOR CABLE ST.-HAZ. SW. CORD SIDE STAND SW. CORD FR. BRAKE HOSE RR. STOP SW. CORD HORN COMP. CABLE GUIDE ST.-MAG SW. CORD CLUTCH CABLE LH. RADIATOR HOSE ST.-MAG. BATTERY CABLE(+) CHOKE CABLE BATTERY EARTH CABLE RH.
  • Page 20 GENERAL INFORMATION CHOKE CABLE WIRE HARNESS CLUTCH CABLE IGN. COIL LH. RADIATOR HOSE WIRE CLIP RH. RADIATOR HOSE THROTTLE JUNCTION THROTTLE CABLE JUNCTION CLAMP CABLE GUIDE IGN. COIL CORD CHOKE CABLE THROTTLE CABLE (TO. ACCELERATION PUMP) FUEL COCK THROTTLE CABLE(TO. CARB.) WIRE CLAMP(WIRE PIVOT) FUEL COCK(RES) FUEL COCK(ON)
  • Page 21 GENERAL INFORMATION ST.-MAG. BATTERY CABLE(+) ST.-MAG. SW. WIRE WIRE CLIP BATTERY EARTH CABLE HARNESS COVER ST.-MAG. BATTERY CABLE(+) ST.-MAG. SW. ASS'Y. ST.-MOTOR CABLE BATTERY EARTH CABLE SIDE STAND SW. CORD RR. STOP SW. CORD RESERVE TANK RR. BRAKE HOSE RR. BRAKE HOSE GUIDE RR.
  • Page 22 GENERAL INFORMATION DRAIN TUBE FUEL DRAIN TUBE ENG. DREATHER TUBE DRAIN TUBE CLUTCH CABLE TUBE GUIDE BRAKE HOSE CLAMP SPDMT. CABLE BRAKE HOSE HORN COMP. SPDMT. CABLE GUIDE RH. RADIATOR HOSE BRAKE HOSE CLAMPER DETAIL OF VIEW A DETAIL OF VIEW D RH.
  • Page 23 MEMO...
  • Page 24 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION BRAKE FLUID 2-10 MAINTENANCE SCHEDULE BRAKE PAD WEAR 2-10 FUEL LINE (FUEL TUBE) BRAKE SYSTEM 2-11 THROTTLE GRIP OPERATION BRAKE STOP SWITCH 2-12 CARBURETOR CHOKE HEADLIGHT AIM 2-12 AIR CLEANER CLUTCH SYSTEM 2-12 SPARK PLUG SIDE STAND 2-13 VALVE CLEARANCE SUSPENSION...
  • Page 25 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG 1.1 kgf-m( 11N.m) CYLINDER HEAD COVER BOLT 1.0 kgf-m( 10N.m) VALVE ADJUSTING NUT 1.1 kgf-m( 11N.m) AC GENERATOR CAP 0.6 kgf-m( 6N.m) CRANKSHAFT HOLE CAP 0.8 kgf-m( 8N.m) AIR CLEANER CASE COVER SCREW 0.43kgf-m( 4.3N.m) REAR AXLE NUT 8.8kgf-m(88N.m)
  • Page 26 INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Perform the Self Inspections Before Operation at each scheduled maintenance period. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart.
  • Page 27 INSPECTIONS / ADJUSTMENTS FUEL LINE (FUEL TUBE) FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE Check the fuel tube for deterioration, damage or leakage.
  • Page 28 INSPECTIONS / ADJUSTMENTS CARBURETOR CHOKE CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER Check the deterioration, damage and kink of the choke cable.

  • Page 29: Spark Plug

    INSPECTIONS / ADJUSTMENTS SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits.
  • Page 30 INSPECTIONS / ADJUSTMENTS Measure the vlave clearance again. ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B ADJUSTING WRENCH B...
  • Page 31 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN Because there is a danger which fingers get jammed in the drive chain, never inspect or adjust it while the engine is running. DRIVE CHAIN SLACK ADJUSTMENT Turn off the ignition switch, support the motorcycle 10~20mm 10~20mm 10~20mm...
  • Page 32 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN INSPECTION Lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying WIPE AND DRY fully. Because an extremely lubricated oil splash while GEAR OIL(#80-90) the chain moves round, clean it with a piece of cloth.
  • Page 33 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN SLIDER WEAR Inspect the drive chain slider for excessive wear or INDICATOR damage. If it is worn to the wear indicator, replace the drive chain slider. BRAKE FLUID Do not mix a dust or different types of fluid when filling the brake fluid.
  • Page 34 INSPECTIONS / ADJUSTMENTS REAR BRAKE PADS WEAR INDICATOR Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 15-6 for brake pad replacement. BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system.
  • Page 35 INSPECTIONS / ADJUSTMENTS BRAKE PEDAL HEIGHT ADJUSTMENT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained.
  • Page 36 INSPECTIONS / ADJUSTMENTS Minor adjustments are made using the upper adjuster at the clutch lever. ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...
  • Page 37 INSPECTIONS / ADJUSTMENTS SUSPENSION Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle's safety and operation efficiency. FRONT SUSPENSION INSPECTION Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.
  • Page 38 INSPECTIONS / ADJUSTMENTS WHEELS/TIRES 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, cracks or damage. Replace damaged tires. STANDARD PRESSURE (kpa) ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY...
  • Page 39 MEMO...
  • Page 40 3. LUBRICATION SERVICE INFORMATION OIL FILTER ELEMENT CHANGE TROUBLESHOOTING OIL PUMP ENGINE OIL LEVEL INSPECTION LUBRICATION POINTS ENGINE OIL CHANGE SERVICE INFORMATION GENERAL SAFETY 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 41 LUBRICATION TROUBLESHOOTING Engine oil level too low Oil consumption. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal. Oil contamination Oil or filter not changed often enough. Faulty head gasket. Worn piston rings. Low or no oil pressure Clogged oil orifice.
  • Page 42 LUBRICATION ENGINE OIL LEVEL INSPECTION OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE...
  • Page 43 LUBRICATION OIL FILTER ELEMENT CHANGE OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER OIL FILTER COVER...
  • Page 44 LUBRICATION INSPECTION OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR Install the inner and outer rotors into the oil pump body.
  • Page 45 LUBRICATION Install the pump shaft, oil seal and spacer, then assemble into the setting ring. SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING...
  • Page 46 LUBRICATION LUBRICATION POINTS Use general grease unless specified here. Apply oil or grease to the other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning. Change it when the cable lengthened.
  • Page 47 FUEL SYSTEM...

  • Page 48: Fuel System

    4. FUEL SYSTEM SERVICE INFORMATION THROTTLE VALVE TROUBLESHOOTING CARBURETOR FUEL TANK PILOT SCREW ADJUSTMENT 4-12 AIR CLEANER CASE SERVICE INFORMATION GENERAL SAFETY Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Exhaust gas contains poisonous substance.
  • Page 49 FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start No fuel in tank No fuel to carburetor Cylinder flooded with fuel Clogged air cleaner No spark at plug Rough idle, incorrect idle speed Faulty idle adjustment Excessively lean or rich mixture Clogged fuel system Intake air leak Clogged fuel system...
  • Page 50 FUEL SYSTEM FULE TANK SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS REMOVAL Do not smoke or allow flames or sparks in the work area because gasoline is extremely flammable.
  • Page 51 FUEL SYSTEM AIR CLEANER CASE AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER REMOVAL Remove the fuel tank. ( 4-3) Remove the RH.
  • Page 52 FUEL SYSTEM THROTTLE VALVE CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP CARBURETOR TOP REMOVAL Remove the fuel tank.
  • Page 53 FUEL SYSTEM INSTALLATION (Rich mixture) RETAINER Install the clip on the jet needle. 1st LEVEL STANDARD CLIP POSITION : 2nd LEVEL jet needle into the throttle valve and Install the 2nd LEVEL secure with the retainer. Install the carburetor top into the throttle cable. CLIP 3th LEVEL (Lean mixture)
  • Page 54 FUEL SYSTEM Remove the throttle cable. Loosen the carburetor mounting nut, and remove the carburetor. THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE...
  • Page 55 FUEL SYSTEM Align the diaphragm projecting part with float GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE chamber groove. Install the spring to diaphragm GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE GROOVE cover, and install the cover to the float chamber preventing the diaphragm form damaging.
  • Page 56 FUEL SYSTEM NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER NEEDLE JET HOLDER...
  • Page 57 FUEL SYSTEM Blow open air and fuel passages in the carburetor body with compressed air. Install the needle jet, needle jet holder, main jet and slow jet. MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET MAIN JET...
  • Page 58 FUEL SYSTEM Install the new o-ring to the float chamber groove. FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER FLOAT CHAMBER Install the float chamber and screws.
  • Page 59 FUEL SYSTEM PILOT SCREW ADJUSTMENT THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW...
  • Page 60 MEMO...
  • Page 61 COOLING SYSTEM...
  • Page 62 5. COOLING SYSTEM SERVICE INFORMATION RADIATOR SERVICE INFORMATION GENERAL SAFETY Wait until the engine is cool before servicing the cooling system. TORQUE VALUE OIL THROUGH BOLT 3.2kgf m (32N m)
  • Page 63 COOLING SYSTEM RADIATOR REMOVAL Loosen the horn mounting bolt and remove the horn. Loosen the 4 radiator cover mounting screws and remove the radiator cover. SCREWS SCREWS SCREWS SCREWS SCREWS BOLT BOLT BOLT BOLT BOLT SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS BOLT BOLT...
  • Page 64 MEMO...
  • Page 65 ENGINE REMOVAL/INSTALLATION...
  • Page 66 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL SERVICE INFORMATION GENERAL SAFETY 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 67 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP NOISE SUPPRESSOR CAP...
  • Page 68 ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS...
  • Page 69 CLUTCH/GEARSHIFT...
  • Page 70 7. CLUTCH / GEARSHIFT SERVICE INFORMATION GEARSHIFT SPINDLE TROUBLESHOOTING CLUTCH INSTALLATION R. CRANKCASE COVER PRIMARY DRIVE GEAR 7-10 CLUTCH R. CRANKCASE COVER INSTALLATION 7-11 SERVICE INFORMATION GENERAL SAFETY The clutch, gearshift spindle can be serviced with the engine in the frame. If the shift fork, drum and transmission require service, remove the engine and separate the crankcase.
  • Page 71 CLUTCH/GEARSHIFT TROUBLESHOOTING Clutch operation problem can be corrected by adjusting a cable free play. Clutch lever pull too hard Damaged, clogged or sticking clutch cable Damaged lifter mechanism Damaged clutch lifter plate bearing Incorrect wiring of clutch cable Clutch slips Too big clutch lever free play Clutch plate warpage Clutch lock nut loose...
  • Page 72 CLUTCH/GEARSHIFT R. CRANKCASE COVER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER...
  • Page 73 CLUTCH/GEARSHIFT Coat the new o-ring with grease, and install it to HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE the clutch lever. HOLE Install the clutch lever spring to the clutch lever. Install the spring ends into the hole of the clutch lever.
  • Page 74 CLUTCH/GEARSHIFT Remove the lock washer. Remove the clutch center, disk, plate and pressure LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER plate.
  • Page 75 CLUTCH/GEARSHIFT Measure the clutch spring free length; replace the springs if the measurement is not within the service limit. SERVICE LIMIT : 34.2mm If the motorcycle has been used for a long time, the clutch springs free lingth will be shorten, because the clutch springs are compressed while the clutch is disengaged.
  • Page 76 CLUTCH/GEARSHIFT GEAR SHIFT SPINDLE HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT REMOVAL Loosen the hex bolt and remove the gear change arm.
  • Page 77 CLUTCH/GEARSHIFT INSTALLATION COLLAR Install the collar, spring, drum stopper and bolt. Tighten the bolt. TORQUE : 1.2kgf m(12N m) SPRING DRUM STOPPER Press the drum stopper, and install the gear shift cam, aligning the roller with the gear shift cam BOLT BOLT BOLT...
  • Page 78 CLUTCH/GEARSHIFT CLUTCH INSTALLATION CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE...
  • Page 79 CLUTCH/GEARSHIFT Install the lock nut by pressing clutch center into the clutch center holder. CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER CLUTCH CENTER HOLDER...
  • Page 80 CLUTCH/GEARSHIFT INSTALLATION WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY Install the woodruff key into the key groove of the crankshaft.
  • Page 81 CLUTCH/GEARSHIFT Install the right crankcase cover, aligning the spline of the crank shaft and with the spline of the oil pump shaft. If any difficulty is encountered in joining the crank shaft spline to the oil pump shaft spline, remove the crankshaft hole cap, then install the right crank case cover while turning the crankshaft to the right slowly.
  • Page 82 MEMO...
  • Page 83 A.C GENERATOR / STARTER CLUTCH...
  • Page 84 8. A.C GENERATOR / STARTER CLUTCH SERVICE INFORMATION STARTER CLUTCH TROUBLESHOOTING A.C GENERATOR INSTALLATION A.C GENERATOR REMOVAL SERVICE INFORMATION GENERAL SAFETY This section covers removal and installation of the A.C. generator. Refer to section 16 for inspection of the A.C. generator. The A.C.
  • Page 85 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR REMOVAL BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L.
  • Page 86 A.C GENERATOR / STARTER CLUTCH Remove the starter reduction gear shaft and starter STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR...
  • Page 87 A.C GENERATOR / STARTER CLUTCH After installing the ACG rotor puller on the rotor, remove the rotor. TOOL : ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER...
  • Page 88 A.C GENERATOR / STARTER CLUTCH STARTER IDLE GEAR INSPECTION GEAR SHAFT Inspect the wear and damage of starter ldle gear. Measure the gear inside diameter. SERVICE LIMIT : 10.100mm Measure the gear shaft outside diameter. SERVICE LIMIT : 9.970mm STARTER IDLE GEAR REDUCTION GEAR INSPECTION REDUCTION GEAR Inspect the wear and damage of reduction gear.
  • Page 89 A.C GENERATOR / STARTER CLUTCH Check the starter driven gear for damage or wear. Measure the starter driven gear I.D. and O.D. SERVICE LIMIT : O.D. : 39.607mm I.D. : 22.100mm INSTALLATION CLUTCH OUTER FLANGE PART Check the one-way clutch for wear or damage. Install the one-way clutch flange onto the clutch outer.
  • Page 90 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR INSTALLATION STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR...
  • Page 91 A.C GENERATOR / STARTER CLUTCH Install the L. crankcase cover. L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L. CLANK CASE COVER L.
  • Page 92 A.C GENERATOR / STARTER CLUTCH Install the L. rear cover. BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L.
  • Page 93 CYLINDER HEAD / VALVES...
  • Page 94 9. CYLINDER HEAD / VALVES SERVICE INFORMATION VALVES TROUBLESHOOTING VALVE GUIDES CAMSHAFT VALVE SEATS CYLINDER HEAD CYLINDER HEAD ASSEMBLY 9-11 VALVE SPRINGS 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 / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 35 (23mm) EX 35 (20mm) IN 45 (24.5mm) EX 45 (24.5mm) IN 60 (22mm) EX 60 (22mm) CUTTER HOLDER 5mm TROUBLESHOOTING Enging top-end problems useally affect engine performance.
  • Page 96 CYLINDER HEAD / VALVES CAMSHAFT BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS REMOVAL Remove the noise suppressor cap assembly from the spark plug. Remove the cylinder head cover bolts and cover. The camshaft can be maintained without removing the engine.
  • Page 97 CYLINDER HEAD / VALVES Remove the cam chain from the camshaft. CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT...
  • Page 98 CYLINDER HEAD / VALVES Check the cam lobes of the camshaft for wear or damage. Measure the height of the cam lobe. SERVICE LIMIT : IN : 37.110 mm EX: 36.870 mm Manually turn the camshaft bearing outer race, and CAMSHAFT BEARINGS check if it turns smoothly.
  • Page 99 CYLINDER HEAD / VALVES DISASSEMBLY PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT Loosen the pivot bolt and remove the cam chain tensioner.
  • Page 100 CYLINDER HEAD / VALVES VALVES Inspect each valve for bending, burning, scratches or abnormal wear. Insert the valves in their original positions in the cylinder head. Check that each valve moves up and down smothly, without binding. Measure and record the valve stem outer diameter in three places along the valve guide sliding area.
  • Page 101 CYLINDER HEAD / VALVES VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER...
  • Page 102 CYLINDER HEAD / VALVES Remove the valve and inspect the valve seat face. The valve seat contact should be within the specified width and evenly all around the circumference. If the valve seat width is not within specification, reface the valve seat. Valve faces and stem tips cannot be ground.
  • Page 103 CYLINDER HEAD / VALVES Using a 60 degree cutter, remove the bottom of the old seat. OLD SEAT WIDTH Using a 45 degree cutter, cut the seat to the proper width. VALVE SEAT WIDTH : 0.9~1.1mm SEAT WIDTH If the contact area is too high on the valve, the seat must be lowered using a 35 degree flat cutter.
  • Page 104 CYLINDER HEAD / VALVES After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. 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 / VALVES Tap the valve stems gently with a soft hammer to firmly seat the cotters. Take necessary precautions not to damage the valve. Install the cam chain tensioner, and assemble pivot PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT...
  • Page 106 CYLINDER HEAD / VALVES CAMSHAFT ASSEMBLY CAM SHAFT HOLDER ROCK ARMS ROCK ARMS ROCK ARMS CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER ROCK ARMS ROCK ARMS ROCK ARMS ROCK ARMS CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER...
  • Page 107 CYLINDER HEAD / VALVES Slowly rotate the crankshaft counterclockwise, and align the T mark of the flywheel with the index CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT...
  • Page 108 CYLINDER HEAD / VALVES Assemble a new gasket to the tensioner lifter, and MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS install the tensioner lifter on the cylinder. MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS...
  • Page 109 CYLINDER / PISTON 10-0...
  • Page 110 10. CYLINDER / PISTON SERVICE INFORMATION 10-1 PISTON / PISTON RING 10-3 TROUBLESHOOTING 10-1 CYLINDER INSTALLATION 10-6 CYLINDER REMOVAL 10-2 SERVICE INFORMATION GENERAL SAFETY Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins.
  • Page 111 CYLINDER / PISTON CYLINDER REMOVAL CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER 9-5 ) Remove the cylinder head. ( Remove the cylinder head gasket. Remove the cam chain guide from the cylinder. Remove the cylinder.
  • Page 112 CYLINDER / PISTON WARPAGE INSPECTION RULLER Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT : 0.100 mm Any clearance between the cylinder and head due to damage or warpage will result in compression leaks and reduced performance.
  • Page 113 CYLINDER / PISTON Insert the piston ring squarely into the bottom of the cylinder, using the piston. FEELER GAUGE Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder. Measure the end gap using a feeler gauge.
  • Page 114 CYLINDER / PISTON PISTON ASSEMBLY TOP RIDNG Clean the piston heads, ring lands and skirts. SECOND RING Carefully install the piston rings onto the piston with the markings facing up. MARK Be careful not to damage the piston and rings during assembly.
  • Page 115 CYLINDER / PISTON CYLINDER INSTALLATION Make sure that the piston ring end gap is correct. Carefully remove any adhering gasket material from the cylinder / head mating surface. Do not scratch the surface. Install a new cylinder gasket and dowel pins. Take care not to damage the cylinder mating surface.
  • Page 116 MEMO...
  • Page 117 CRANKCASE/TRANSMISSION/CRANKSHAFT 11-0...
  • Page 118 11. CRANKCASE/TRANSMISSION/CRANKSHAFT SERVICE INFORMATION 11-1 CRANKCASE BEARING 11-7 TROUBLESHOOTING 11-2 CRANKSHAFT INSTALLATION 11-8 CRANKCASE DISASSEMBLY 11-3 TRANSMISSION ASSEMBLY 11-9 TRANSMISSION DISASSEMBLY 11-4 CRANKCASE ASSEMBLY 11-10 CRANKSHAFT 11-6 SERVICE INFORMATION GENERAL SAFETY To service the transmission, crank shaft and kick starter, the crankcase should be disassembled. Before disassembling the crankcase, the following parts must be removed.
  • Page 119 CRANKCASE/TRANSMISSION/CRANKSHAFT Unit: mm ITEM STANDARD VALUE SERVICE LIMIT CONNECTING ROD BIG END SIDE 0.050~0.300 0.600 CLEARANCE CONNECTING ROD BID END CRANKSHAFT 0~0.008 0.050 VERTICAL DIRECTION CLEARANCE RIGHT 0.100 CRANKSHAFT RUNOUT LEFT 0.100 TORQUE VALUES MAIN SHAFT BEARING SETTING PLATE 1.2kgf m(12N m) CRANKCASE BOLT 1.1kgf m(11N m) TOOLS...
  • Page 120 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE DISASSEMBLY CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN The engine must be separated from the frame. section 6) Refer to the service information for removal of necessary parts before disassembling the...
  • Page 121 CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION DISASSEMBLY SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT...
  • Page 122 CRANKCASE/TRANSMISSION/CRANKSHAFT Check the shift drum for wear or damage. Check the shift drum guide groove for partial wear or damage. Measure the main shaft and counter shaft outside diameter. SERVICE LIMIT : M3, M5 : 19.930mm C1 : 16.440mm C2 : 19.940mm C4 : 19.930mm Check the gear for hole, projection part in gear, shift groove, gear wear, and damage.
  • Page 123 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT REMOVAL Remove the transmission. ( 11-4) Remove the crankshaft from the left crankcase using a crankshaft separating tool. Remove the remaining bearings in the left crankcase with a driver handle and outer driver.
  • Page 124 CRANKCASE/TRANSMISSION/CRANKSHAFT Measure the connecting rod radial clearance in both X and Y directions. Replace the crankshaft if the service limit is exceeded. SERVICE LIMIT : 0.050 mm CRANKCASE BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING...
  • Page 125 CRANKCASE/TRANSMISSION/CRANKSHAFT RH. Crank Case Remove the main shaft bearing set plate. BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE...
  • Page 126 CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION ASSEMBLY C-1 GEAR COUNTER TRANSMISSION SHAFT C-3 GEAR C-4 GEAR C-5 GEAR C-2 GEAR DRIVE SPROCKET MAIN SHAFT M-3 GEAR M-4 GEAR M-5 GEAR M-2 GEAR Coat the gear and gear bush with clean engine oil and install the main shaft and counter shaft. COUNTER SHAFT Check the gears for freedom of movement or rotation on the shaft.
  • Page 127 CRANKCASE/TRANSMISSION/CRANKSHAFT Check the marks on the shift forks. - L. fork : “L” mark - Center fork : “C” mark - R. fork : “R” mark RIGHT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK RIGHT FORK RIGHT FORK RIGHT FORK RIGHT FORK...
  • Page 128 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the right crankcase into the left crankcase . Make sure that there is no gap between the mating surfaces of the right and left crankcase. Tighten the left crankcase bolts in a crisscross pattern in 2-3 steps. TORQUE : 1.1kgf m(11N m) BOLTS BOLTS BOLTS...
  • Page 129 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the cam chain. CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN Install the disassembled parts.
  • Page 130 MEMO...
  • Page 131 EXTERNAL PARTS 12-0...
  • Page 132 12. EXTERNAL PARTS SERVICE INFORMATION 12-1 REAR FENDER 12-3 TROUBLESHOOTING 12-1 REAR WHEEL MUDGUARD 12-3 SEAT/SIDE COVER 12-2 MUFFLER/EXHAUST PIPE 12-4 REAR SEAT (PILLION SEAT) 12-2 FRONT FENDER 12-5 REAR COWL 12-3 SERVICE INFORMATION GENERAL SAFETY Because of the hat muffler, avoid the check immediately after the engine stop. This section covers removal and installation of the seat and exhaust muffler.
  • Page 133 EXTERNAL PARTS SEAT / SIDE COVER SEAT REMOVAL Insert the ignition key into the seat lock. Turn the ignition key counterclockwise, and then pull the seat back and up. Installation is in the reverse order of removal. SIDE COVER REMOVAL Remove the seat (see above).
  • Page 134 EXTERNAL PARTS REAR COWL FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS FLANGE BOLT FLANGE BOLT FLANGE BOLT...
  • Page 135 EXTERNAL PARTS MUFFLER/EXHAUST PIPE BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT BOLT/NUT Do not service the exhaust system while it is hot. REMOVAL Remove the exhaust pipe to muffler mounting bolts. Remove the muffler mounting bolt/nut and washer, then remove the muffler.
  • Page 136 EXTERNAL PARTS INSTALLATION Install the removed parts in the reverse order of removal. Check the protrusion of the exhaust pipe stud bolt. Install the new exhaust pipe gasket onto the exhaust ports of the cylinder head. Install the new gasket onto the exhaust pipe. FRONT FENDER FRONT FENDER FRONT FENDER...
  • Page 137 FRONT WHEEL/FRONT FORK/STEERING 13-0...
  • Page 138 13. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION 13-1 FRONT WHEEL 13-7 TROUBLESHOOTING 13-2 FRONT FORK 13-12 HANDLEBARS 13-3 STEERING STEM 13-20 SERVICE INFORMATION GENERAL SAFETY A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk with a brake degreasing agent.
  • Page 139 FRONT WHEEL/FRONT FORK/STEERING TOOLS BALL RACE DRIVER STEERING STEM DRIVER FORK SEAL DRIVER STEERING STEM SOCKET EXTENSION BAR DRIVER FORK SEAL DRIVER BODY LOCK NUT WRENCH BEARING REMOVER SHAFT REMOVER HEAD ATTACHMENT PILOT TROUBLESHOOTING Hard steering Soft suspension Steering bearing adjustment nut too tight Weak springs Damaged, worn steering head bearing Oil level too low...
  • Page 140 FRONT WHEEL/FRONT FORK/STEERING HANDLEBARS REMOVAL Remove the back mirrors. Remove the socket bolt and right handle weight cap. HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP...
  • Page 141 FRONT WHEEL/FRONT FORK/STEERING Remove the screws and left handlebar switch housing. SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SCREWS SCREWS...
  • Page 142 Install the winker switch housing aligning its locating pin with the hole in the handlebar. Tighten the forward screw first, then the rear screw. Apply DAELIM Bond A to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip.
  • Page 143 FRONT WHEEL/FRONT FORK/STEERING Apply grease to the sliding surface of the throttle pipe. THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE Connect the throttle cable to the throttle pipe.
  • Page 144 FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS...
  • Page 145 FRONT WHEEL/FRONT FORK/STEERING Wheel bearing Turn the inner race of each bearing with your finger. Bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub.
  • Page 146 FRONT WHEEL/FRONT FORK/STEERING WHEEL BEARING REPLACEMENT Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.
  • Page 147 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. WHEEL SIDE COLLAR FR. CASTING WHEEL RADIAL BALL BEARING FR. WHEEL AXLE GEAR BOX RETAINER OIL SEAL DUST SEAL SPEEDOMETER GEAR RADIAL BALL BEARING FR. DISTANCE COLLAR FR. TIRE LH. FR. BRAKE DISK SPEEDOMETER GEAR BOX ASSEMBLY Install the brake disk on the wheel hub.
  • Page 148 FRONT WHEEL/FRONT FORK/STEERING Align the wheel hub tangs with the slots of the gear box retainer, and assemble the speedometer gear box seal. Apply grease to the dust seal rim. SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX...
  • Page 149 FRONT WHEEL/FRONT FORK/STEERING Install the brake caliper and tighten the new mounting FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS bolts to the specified torque.
  • Page 150 FRONT WHEEL/FRONT FORK/STEERING DESASSEMBLY Remove the fork pipe bolt from the fork. FORK SPRING If the bolt is completely loosened, the fork pipe bolt may spring out by the force for the spring. Take due precautions. Remove the fork spring, and expand and release the fork pipe several times to drain fork oil.
  • Page 151 FRONT WHEEL/FRONT FORK/STEERING Remove the oil seal stopper ring. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING Pull the fork pipe out until you feel resistance from the slider bushing.
  • Page 152 FRONT WHEEL/FRONT FORK/STEERING Check components for damage or abnormal wear. BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE Replace defective parts with new ones.
  • Page 153 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. FORK BOLT DUST SEAL FORK PIPE FR. FORK SPRING OIL SEAL STOPPER RING SEAT PIPE OIL SEAL BACK UP RING GUIDE BUSH RH. BOTTOM CASE REBOUND SPRING LH. FR. FORK ASSEMBLY OIL LOCK PIECE Before assembly, wash all parts with a clean oil and OIL SEAL OIL SEAL OIL SEAL...
  • Page 154 FRONT WHEEL/FRONT FORK/STEERING Install the oil seal stopper ring into the bottom case groove securely. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING...
  • Page 155 FRONT WHEEL/FRONT FORK/STEERING Pour the specified amount of automatic transmission fluid(ATF) into the fork pipe. CAPACITY : 265 2.5cc Slowly press the fork tube 2-3 times to discharge air. FORK OIL FORK OIL Install the fork spring to the fork pipe. Install the spring with the smaller pitch side facing downward.

  • Page 156: Front Wheel/Front Fork/Steering Installation

    FRONT WHEEL/FRONT FORK/STEERING INSTALLATION MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE MARKING LINE Install the fork pipe through the bottom bridge, fork top bridge and handle pipe.
  • Page 157 FRONT WHEEL/FRONT FORK/STEERING STEERING STEM BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY...
  • Page 158 FRONT WHEEL/FRONT FORK/STEERING RACE REPLACEMENT Replace the cone reces and ball races in pairs. Remove the ball races from the steering head using the ball race dirver. TOOL : BALL RACE DRIVER Install the new ball races into the head pipe using the driver and attachment.
  • Page 159 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION STEERING HEAD TOP THREAD TOP CONE RACE STEEL BALLS STEEL BALL RACE STEEL BALL RACE STEEL BALLS BOTTOM CONE RACE DUST SEAL WASHER STEERING STEM FR. BRAKE HOSE STAY Install the steel ball. STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL...
  • Page 160 FRONT WHEEL/FRONT FORK/STEERING Install the top bridge, washer and steering stem nut. STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT STEM NUT Temporarily install the R/L front forks, then tighten the...
  • Page 161 REAR WHEEL/REAR SUSPENSION 14-0...
  • Page 162 14. REAR WHEEL/REAR SUSPENSION SERVICE INFORMATION 14-1 REAR CUSHION 14-7 TROUBLESHOOTING 14-2 SWINGARM 14-9 REAR WHEEL 14-3 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 163 REAR WHEEL/REAR SUSPENSION TROUBLESHOOTING Wobble or vibration in motorcycle Bent rim Worn rear wheel bearing Damaged tire Axle not tightened properly Insufficient air in tire Worn rear fork bush Soft suspension Weak spring Improper rear cushion adjust Incorrect rear damper Hard suspension Improper rear cushion adjust Bent damper rod...
  • Page 164 REAR WHEEL/REAR SUSPENSION REAR WHEEL LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT REMOVAL Support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground.
  • Page 165 REAR WHEEL/REAR SUSPENSION Wheel bearing Turn the inner race of each bearing with your finger. Bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub.
  • Page 166 REAR WHEEL/REAR SUSPENSION Inspect the damper rubber for deterioration or damage. DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER Replace it if necessary.
  • Page 167 REAR WHEEL/REAR SUSPENSION Wheel Bearing Installation DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER Drive in a new left bearing squarely. Install the distance collar. Drive in a new right bearing. TOOLS : DRIVER ATTACHMENT PILOT 15mm...
  • Page 168 REAR WHEEL/REAR SUSPENSION INSTALLATION Install the side collar. Place the rear wheel into the swingarm. Install the drive chain over the driven sprocket. Install the axle from the left side. AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT...
  • Page 169 REAR WHEEL/REAR SUSPENSION INSPECTION Visually inspect the rear cushion for damage. Check for the : - Damper rod for bend or damage - Damper unit for deformation or oil leaks - Cushion rubber for wear or damage Inspect all the other parts for wear or damage. If necessary, replace the rear cushion as an assembly.
  • Page 170 REAR WHEEL/REAR SUSPENSION INSTALLATION UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT...
  • Page 171 REAR WHEEL/REAR SUSPENSION Remove the U-nut and swingarm pivot bolt and then remove the swingarm from the frame. U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT DISASSEMBLY/INSPECTION DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP...
  • Page 172 REAR WHEEL/REAR SUSPENSION ASSEMBLY RR. FORK END CAP CHAIN ADJUSTER CHAIN ADJUSTER LOCK NUT RR. SWING ARM DUST SEAL CAP BUSH BEARING BEARING O-RING CHAIN CHAIN SLIDER PIVOT DISTANCE CENTER COLLAR SWING ARM PIVOT BOLT Apply grease to the center collar, bearing and bushes. Install the center collar, bearings and bushes to the swingarm.
  • Page 173 REAR WHEEL/REAR SUSPENSION INSTALLATION Apply thin coat of grease to the swingarm pivot bolt surface. Install the swingarm into the frame, then install the pivot bolt from the left side. Install the U-nut. Hold the pivot bolt using a special tool, tighten the U- nut to the specified torque using the same tool.
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  • Page 175 HYDRAULIC BRAKE FRONT : REAR : 15-0...
  • Page 176 15. HYDRAULIC BRAKE FRONT MASTER CYLINEDR 15-9 SERVICE INFORMATION 15-1 REAR MASTER CYLINDER 15-13 TROUBLESHOOTING 15-2 FRONT BRAKE CALIPER 15-18 BRAKE FLUID REPLACEMENT/ AIR BLEEDING 15-3 REAR BRAKE CALIPER 15-20 BRAKE PAD/DISK 15-6 BRAKE PEDAL 15-23 SERVICE INFORMATION GENERAL SAFETY Don't put in dust or water when filling the reservoir.
  • Page 177 HYDRAULIC BRAKE TORQUE VALUES BRAKE CALIPER BRACKET BOLT 3.0 f m ( 30N m) BRAKE CALIPER BLEEDER VALVE 0.6 f m ( 6N m) BRAKE CALIPER HANGER PIN 2.3 f m ( 23N m) BRAKE CALIPER PIN BOLT 1.8 f m ( 18N m) BRAKE PAD PIN BOLT 1.8 f m ( 18N m) BRAKE OIL BOLT...
  • Page 178 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS AIR BLEEDING Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic, or rubber parts.
  • Page 179 HYDRAULIC BRAKE Connect a bleeder hose to the caliper bleeder valve. BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER VALVE BLEEDER VALVE...
  • Page 180 HYDRAULIC BRAKE BRAKE BLEEDING BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE <When the brake bleeder is not available> Connect a clear bleeder hose to the bleeder valve.
  • Page 181 HYDRAULIC BRAKE BRAKE PAD/DISK BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BOLT BOLT BOLT BOLT BOLT BOLT BOLT...
  • Page 182 HYDRAULIC BRAKE Make sure the brake pad spring is in place. BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS HANGER PINS HANGER PINS...
  • Page 183 HYDRAULIC BRAKE Remove the rear caliper bracket bolts and brake caliper. CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS CALIPER BRACKET BOLTS...
  • Page 184 HYDRAULIC BRAKE BRAKE DISK INSPECTION Visually inspect the brake disk for damage or crack. Measure the brake disk thickness with a micrometer. SERVICE LIMIT : FRONT: 3.0mm REAR : 3.0mm Replace the brake disk if the smallest measurement is less than the service limit. Measure the brake disk runout with a dial indicator.
  • Page 185 HYDRAULIC BRAKE DISASSEMBLY BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT Remove the handle lever bolt/nut and RH. handle lever assembly. HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER...
  • Page 186 HYDRAULIC BRAKE INSPECTION Check the piston for abnormal scratches. Check the primary cup and secondary cup for fatigue or damage. Measure the master cylinder piston O. D. SERVICE LIMIT : 12.645mm Check the master cylinder for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT : 12.755mm ASSEMBLY MASTER CYLINDER CAP...
  • Page 187 HYDRAULIC BRAKE Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER Dip the piston in brake fluid.
  • Page 188 HYDRAULIC BRAKE Install the RH. handle lever assembly, tighten the bolt. Hold the bolt and tighten the nut. BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER...
  • Page 189 HYDRAULIC BRAKE Loosen the rear master cylinder mounting socket bolts. MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS MOUNTING SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS...
  • Page 190 HYDRAULIC BRAKE Remove the brake rod joint, master piston and spring. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER Clean the inside of the cylinder with brake fluid.
  • Page 191 HYDRAULIC BRAKE ASSEMBLY TUBE JOINT PIPE O-RING RR. RESERVOIR ASSEMBLY MASTER CYLINDER SPRING SECONDARY CUP RR. PISTON PRIMARY CUP INTERNAL CIR CLIP BOOT BRAKE ROD BRAKE ROD JOINT JOINT PIN C Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
  • Page 192 HYDRAULIC BRAKE Apply brake fluid to a new O-ring and install it onto TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE...
  • Page 193 HYDRAULIC BRAKE Install the brake hose with the oil bolt and new BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT washers. Tighten the oil bolt to the specified torque. TORQUE : 3.4 kgf m (34 N m) Install and tighten the rear reservoir mounting bolt.
  • Page 194 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other damage. Measure the caliper cylinder I. D. SERVICE LIMIT : 25.42mm Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston O. D. SERVICE LIMIT : 25.27mm ASSEMBLY CALIPER BRACKET PISTONS...
  • Page 195 HYDRAULIC BRAKE Coat the new piston seals with clean brake fluid. Coat the new dust seals with silicone grease. PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL...
  • Page 196 HYDRAULIC BRAKE Remove the rear caliper bracket bolts and the brake pads. ( 15-7) CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER Pivot the caliper up and remove it. BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS...
  • Page 197 HYDRAULIC BRAKE INSPECTION Check the caliper cylider for scoring or other damage. Measure the caliper cylinder I. D. SERVICE LIMIT : 25.070mm Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston O. D. SERVICE LIMIT : 24.870mm ASSEMBLY CALIPER BRACKET PIN BOLT...
  • Page 198 HYDRAULIC BRAKE Apply the boot with silicone grease. BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT Install the boot into the groove of the caliper body. Install the pad spring into the caliper body. Install the caliper pin bolt and caliper bracket into the caliper body.
  • Page 199 HYDRAULIC BRAKE INSTALLATION JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C COTTER PIN COTTER PIN COTTER PIN...
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  • Page 201 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER BATTERY FUSE A.C. GENERATOR Br/W MAIN FUSE SWITCH (15A) B(CABLE) A.C. GENERATOR REG. RECTI. BATTERY (12V 10AH) HEADLIGHT RELAY Br/W Br/W LIGHTING CDI UNIT SWITCH Br/W Br/W Br/W Br/W DIMMER SWITCH SPEEDOMETER ILLUM. TAIL LIGHT (HIGH) (LOW) (12V 2W X 2EA, 12V 3W) (12V 5W) B..
  • Page 202 16. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 16-1 REGULATOR/RECTIFIER 16-5 TROUBLESHOOTING 16-2 A.C. GENERATOR CHARGING COIL INSPECTION 16-6 BATTERY 16-3 CHARGING SYSTEM INSPECTION 16-4 SERVICE INFORMATION Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.
  • Page 203 BATTERY/CHARGING SYSTEM TROUBLESHOOTING No power (Key turned on) Low power (Engine running) Dead battery. Battery undercharged. - Low fluid level. Battery is failing. - Low specific gravity. Charging system failure. - Charging system failure. Intermittent power Disconnected battery cable. Main fuse burned out. Loose battery connection.
  • Page 204 BATTERY/CHARGING SYSTEM BATTERY TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL REMOVAL/INSTALLATION Remove the seat. ( 12-2) TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL...
  • Page 205 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL CURRENT LEAKAGE INSPECITION Turn the ignition switch off and disconnect the negative battery cable from the battery. Connect an ampere meter between negative (-) terminal and ground cable.
  • Page 206 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER HARNESS SIDE CIRCUIT INSPECTION Remove the seat. ( 12-2) Remove the LH.
  • Page 207 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER Disconnect the regulator/rectifier 6P coupler. REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER Remove the regulator/rectifier unit mounting bolts and...
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  • Page 209 IGNITION SYSTEM IGNITION SWITCH CDI UNIT BATTERY FUSE IGNITION COIL SPARK PLUG SIDE STAND SWITCH SIDE STAND SWITCH FUSE MAIN SWITCH (15A) GEAR POSITION SPARK SWITCH PLUG A.C. GENERATOR IGNITION BATTERY COIL (12V 10AH) PULSE GENERATOR CDI UNIT B..Black Y..Yellow HEADLIGHT RELAY L..
  • Page 210 17. IGNITION SYSTEM SERVICE INFORMATION 17-1 IGNITION COIL INSPECTION 17-4 TROUBLESHOOTING 17-2 IGNITION TIMING 17-5 CDI UNIT INSPECTION 17-3 SIDE STAND SWITCH 17-5 PULSE GENERATOR INSPECTION 17-3 SERVICE INFORMATION GENERAL SAFETY Follow the steps described in the troubleshooting flow chart when servicing the ignition system. The CDI unit may be damage if dropped.
  • Page 211 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 212 IGNITION SYSTEM CDI UNIT INSPECTION CDI IGNITION CIRCUIT INSPECTION Follow the steps described in the troubleshooting flow chart when servicing the ignition system. Remove the seat. ( 12-2) Remove the rear seat. ( 12-2) Disconnect the CDI unit coupler and check the ignition system circuits from the wire harness side.
  • Page 213 IGNITION SYSTEM PVA MEASUREMENT BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL BLUE/YELLOW TERMINAL Disconnect the A.C generator blue / yellow wire connector. CORD CORD CORD...
  • Page 214 IGNITION SYSTEM REPLACEMENT IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL Remove the high-tension cord from the plug, remove the plug cap.
  • Page 215 IGNITION SYSTEM SIDE STAND SWITCH INSPECTION Remove the RH. side cover. ( 12-2) Remove the side stand switch coupler connected with wire. Check the following terminals. ITEM TERMINALS STANDARD (Side stand retracted) (Side stand lowered) REPLACEMENT Remove the RH. side cover. ( 12-2) Disconnect the side stand coupler from the wire harness.
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  • Page 217 ELECTRIC STARTER STARTER SWITCH IGNITION SWITCH BATTERY STARTER MAGNETIC SWITCH FUSE STARTER MOTOR STARTER IGNITION MAGNETIC STARTER CONTROL UNIT B(CABLE) SWITCH SWITCH Lg/R SIDE STAND MAIN SWITCH B(CABLE) SWITCH FUSE (15A) GEAR POSITION NEUTRAL BATTERY LAMP (12A 10AH) B..Black Y..Yellow G..Green Lg/R R..Red...
  • Page 218 18. ELECTRIC STARTER SERVICE INFORMATION 18-1 STARTER MOTOR 18-3 TROUBLESHOOTING 18-2 STARTER MAGNETIC SWITCH 18-9 SERVICE INFORMATION GENERAL SAFETY Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing serious injury. The starter motor can be maintained without removing the engine from the vehicle. A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
  • Page 219 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn. Check for a blown out main fuse before servicing. Make sure the battery is fully charged and in good condition. Connect the starter motor (+) terminal to the With the ignition switch ON , check for a battery positive terminal.
  • Page 220 ELECTRIC STARTER STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR BOLTS BOLTS BOLTS...
  • Page 221 ELECTRIC STARTER Remove the following : WASHERS WASHERS WASHERS REAR COVER REAR COVER REAR COVER REAR COVER REAR COVER WASHERS WASHERS WASHERS WASHERS REAR COVER REAR COVER REAR COVER REAR COVER WASHERS WASHERS WASHERS WASHERS REAR COVER REAR COVER REAR COVER REAR COVER WASHERS WASHERS...
  • Page 222 ELECTRIC STARTER Check for continuity between pairs of commutator bars. There should be continuity. Check for continuity between each commtator bar and armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and the case.
  • Page 223 ELECTRIC STARTER Remove the following: BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER - Washer nut - Washer - O-ring - Terminal setting bush...
  • Page 224 ELECTRIC STARTER Install the brushes into the brush holder. Install the brush holder into the motor case, aligning the holder tab with the motor case groove. Install the following : - New O-ring - Insulators - Washer - Washer nut Install the armature in the motor case, while pushing in the brushes into the brush holder.
  • Page 225 ELECTRIC STARTER Install the cir-clip and washers onto the armature shaft. Install a new seal ring onto the motor case. FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER...
  • Page 226 ELECTRIC STARTER STARTER MAGNETIC SWITCH BATTERY WIRE CABLE BATTERY BATTERY BATTERY BATTERY WIRE CABLE WIRE CABLE WIRE CABLE WIRE CABLE BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY WIRE CABLE WIRE CABLE WIRE CABLE WIRE CABLE WIRE CABLE WIRE CABLE BATTERY BATTERY WIRE CABLE WIRE CABLE BATTERY...
  • Page 227 ELECTRIC STARTER CONTINUITY INSPECTION Disconnect the wire connector of the magnetic switch. Connect the positive wire to the yellow/red wire terminal and the negative wire to the green/yellow wire terminal. There should be continuity. INSTALLATION Install in the reverse order of removal. STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH...
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  • Page 229 LIGHTS/METER/SWITCHES IGNITION SWITCH RIGHT HANDLEBAR SWITCH FR. STOP SWITCH STARTER RELAY LEFT HANDLEBAR SWITCH WINKER RELAY FUEL UNIT HORN NEUTRAL SWITCH 19-0...
  • Page 230 19. LIGHTS/METER/SWITCHES SERVICE INFORMATION 19-1 MAIN SWITCH 19-7 TROUBLESHOOTING 19-2 HANDLEBAR SWITCHES 19-8 HEADLIGHT 19-3 FRONT/REAR STOP SWITCH 19-9 POSITION LIGHT 19-4 NEUTRAL SWITCH 19-9 FRONT/REAR WINKER 19-4 HORN 19-9 STOP/TAIL LIGHT 19-4 WINKER RELAY 19-10 COMBINATION METER 19-5 FUEL UNIT 19-10 SERVICE INFORMATION GENERAL SAFETY...
  • Page 231 LIGHTS/METER/SWITCHES TROUBLESHOOTING Fuel meter indicator malfunctioning Light not turned on when the main switch is ON Coupler separated. Faulty light bulb Harness disconnected. Faulty switch Float operation malfuction. Faulty or disconnected wiring Fuel unit damaged. Fuse cut Battery discharged Fuel meter needle unstable Coupler loose.
  • Page 232 LIGHTS/METER/SWITCHES HEADLIGHT BULB REPLACEMENT Headlight bulbs become very hot while the headlight is ON, and remain hot for a while after they are turned OFF. Be sure to turn the ignition switch OFF and let the bulb cool down before replacement.
  • Page 233 LIGHTS/METER/SWITCHES POSITION LIGHT BULB REPLACEMENT Pull out the position light bulb socket. Remove the bulb from the socket, replace it with a new one. Install the position light bulb socket and headlight unit in the reverse order of removal. POSITION LIGHT SOCKET BULB FRONT/REAR WINKER WINKER LENS...
  • Page 234 LIGHTS/METER/SWITCHES BULB REPLACEMENT SCREWS Remove the screws and tail light lens. Slightly press down on the bulb and turn it counterclockwise. Replace with a new bulb. BULB Install in the reverse order of removal. TAIL LIGHT LENS COMBINATION METER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER...
  • Page 235 LIGHTS/METER/SWITCHES Remove the meter stay mounting nuts. Remove the meter stay from the combination meter FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS...
  • Page 236 LIGHTS/METER/SWITCHES MAIN SWITCH INSPECTION Remove the headlight. ( 19-3) Disconnect the main switch wire connector. MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR...
  • Page 237 LIGHTS/METER/SWITCHES HANDLEBAR SWITCHES LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH Remove the headlight. (19-3) Disconnect the handlebar switch connectors. Check for continuity between the wire terminals of the handlebar switch connector.
  • Page 238 LIGHTS/METER/SWITCHES FRONT/REAR STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH...
  • Page 239 LIGHTS/METER/SWITCHES WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY WINKER RELAY JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE...
  • Page 240 LIGHTS/METER/SWITCHES INSPECTION FUEL UNIT Move the float upward and downward, and measure the resistance between the terminals. Unit : (20 ) WIRE TERMINAL FLOAT UPPER LINE FLOAT LOWER LINE GREEN AND YELLOW/WHITE 30~36 400~750 GREEN AND BLUE/WHITE 400~700 140~160 BLUE/WHITE AND BLUE/WHITE 450~750 450~750 FLOAT...
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  • Page 242 WIRING DIAGRAM 20. WIRING DIAGRAM LIGHT/START SW. FR.STOP SW. COMB. SW. WINKER RELAY FUEL UNIT HORN RH. FR WINKER 12V 10W BATTERY 12V 10AH START-MAG.S/W ILLUM, LAMP RR STOP SW. Br/W (ENGINE) 12V 2W FUSE 15A B Gr MINI (ENGINE) 2P MINI MINI ILLUM, LAMP...
  • Page 243 21. TROUBLESHOOTING ENGINE WON’T START OR IS HARD TO START 21-1 POOR HANDLING 21-4 ENGINE LACKS POWER 21-2 POOR FRONT/REAR SUSPENSION PERFORMANCE 21-5 POOR PERFORMANCE (AT LOW AND IDLE SPEED) 21-3 FUEL GAUGE 21-5 POOR PERFORMANCE (AT HIGH SPEED) 21-4 ENGINE WON’T START OR IS HARD TO START INSPECTION CAUSE OF TROUBLE...
  • Page 244 TROUBLESHOOTING ENGINE LACKS POWER INSPECTION CAUSE OF TROUBLE Punctured tire. 1. Check tire pressure. Pressure low Faulty tire valve. Pressure normal 2. Raise wheels off ground and Dragged brake. Wheel don’t rotate rotate by hands. Worn or damaged wheel bearings. freely Lacked wheel bearings lubrication.
  • Page 245 TROUBLESHOOTING INSPECTION CAUSE OF TROUBLE 9. Check the spark plug. Lean fuel mixture. Contaminated or Using spark plug with on incorrect heat discolored Not contaminated or not range. discolored. Oil level too high. 10. Check oil level. Level low or high Oil level too low.
  • Page 246 TROUBLESHOOTING POOR PERFORMANCE(AT HIGH SPEED) INSPECTION CAUSE OF TROUBLE 1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment. valve clearance. Faulty CDI unit. Faulty pulse generator. Correct. 2. Disconnect fuel tube at Fuel flows No fuel to fuel tank. carburetor.
  • Page 247 TROUBLESHOOTING POOR FRONT/REAR SUSPENSION PERFORMANCE INSPECTION CAUSE OF TROUBLE Cushion spring weak. 1. Suspension excessively soft. Overloaded. Damper oil leaks. 2. Suspension excessively hard. Fork pipe or cushion rod bent. 3. Noise from the suspension. Sliders stuck. Cushion stopper rubber damaged. FUEL GAUGE GAUGE READING INACCURATE (IGNITION SWTICH ON) INSPECTION...
  • Page 248 TROUBLESHOOTING GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON) INSPECTION CAUSE OF TROUBLE Fuse cut. 1. Operate the turn signal to check the Signal continuously Battery weak or totally discharged. battery circuit. operates dim or does not Ignition switch damaged or shorted. operate at all.
  • Page 249 MEMO...
  • Page 250 MEMO...
  • Page 251 SERVICE MANUAL 2004. 1. PRINTED NO C C OPY 2004. 1. PUBLICATION...

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