Page 1: Table Of Contents
Crankshaft on the latest product information avaliable at the time of approval for printing. Cooling System DAELIM reserves the right to make changes at any time without notice and without incurring any Seat / Exhaust Muffler obligation whatever. Front Wheel / Front Fork...
Page 2: General Information
Service Rules 1. Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents. 2. Use the special tools designed for this product. 3. Install new gaskets, o-ring, piston pins, clips, cotter pins, etc. When reassembling.
Page 3 General Information Model Identification Frame No Frame No Frame No Engine No Engine No Engine No Frame No Frame No Engine No Engine No Engine No Engine No Frame No Frame No Frame No Frame No Engine No Engine No Frame No Frame No Frame No...
Page 4: Specifications
General Information Specifications Item Specifications Overall Length 2,240mm Overall Width 860mm Overall Height 1,140mm Dimensions Wheel Base 1,505mm Seat Height 720mm Ground clearance 135mm Dry Weight 147.5kgf Curb Weight 344.9kgf Type Double Cradle Front Suspension Stroke Telescopic fork 140mm Rear Suspension Stroke Swingarm 35mm Front Tire Size 90/90 - 18 (Tubeless)
Page 5 General Information Item Specifications Clutch Hydraulic, Multi-plate Transmission Type Constant Mesh Transmission Primary Reduction 3.650(73/20) Secondary Reduction 3.214(45/14) Gear Ratio 1st 3.083(37/12) Drive Train Gear Ratio 1.882(32/17) Gear Ratio 1.380(29/21) Gear Ratio 1.095(23/21) Gear Ratio 0.923(24/26) Gearshift Pattern Left foot operated return system 1-N-2-3-4-5 Ignition TRANSISTER...
Page 6: Torque Values
General Information Torque Values Engine Thread dia Torque Item Q’ty Remark (mm) kgf.m,(N.m) Oil Filter Screen Cap 1.5(15) Oil Filter Relief Valve Oval Screw 1.2(12) Oil Filter Cover Socket Bolt 1.1(11) Oil Pump Mounting Bolt 1.1(11) Valve Adjusting Screw Lock Nut 1.1(11) Drive Sprocket 1.2(12)
Page 7 General Information Thread dia Torque Item Q’ty Remark (mm) kgf.m,(N,m) Brake Caliper Bracket Bolt 3.0(30) Brake Caliper Bleed Valve 0.6(6) Brake Pad pin Bolt (1.8, 13) Master Cylinder Reservoir Cap Screw 0.13(1.3) Brake Hose Bolt 3.4(34) Brake Lever Pivot Bolt 1.0(10, 7) Brake Lever Pivot Lock Nut 1.0(10, 7)
Page 8: Safety Notices
General Information Safety Notices Following marks indicate some warnings and caution against some specific service methods. Mark Meaning Mark Meaning Indicates a possibility of Indicates a strong possibility of WARNING personal injury or equipment severe personal injury or loss of CAUTION damage if instructions are not life if instructions are not...
Page 9 General Information Tools Special Common Description Reference section Description Reference section Clutch Center Holder Wrench, 8 9mm Flywheel Puller Adjusting Wrench, B Lock Pin Puller Set Float Level Gauge Sliding shaft Lock Nut Wrench, 20 24mm Sliding Weight Extension Bar 6, 13 Valve Guide Reamer Fly Wheel Holder...
Page 10 General Information Tester, Gauge Description Reference section Remark Compression Gauge Digital Circuit Tester 16, 17 Circuit Tester 16, 17 Inspecion Adapter Spark Adapter Valve Seat Cut Description Reference section Remark 24.5mm IN, EX Valve Seat Cutter 45 23mm IN Valve Seat Cutter 35 20mm EX Valve Seat Cutter 35 22mm IN, EX...
Page 11 General Information Cable & Harness Routing Note the following when routing cables and wire harnesses: A loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. Do not squeeze wires against the weld or its clamp.
Page 12 General Information 1-11...
Page 13 General Information 1-12...
Page 14 General Information 1-13...
Page 15 MEMO...
Page 16: Lubrication
Lubrication 2. Lubrication Service Information Engine Oil Change Specifications Engine Oil Filter Element Change Troubleshooting Oil Pump Engine Oil Level Check Lubrication Points Service Information WARNING If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
Page 17 Lubrication Troubleshooting Low oil pressure Oil level low Pressure relief valve stuck open Plugged oil pick-up screen Oil pump worm External oil leaks High oil pressure Pressure relief valve stuck closed Plugged oil filter, gallery, or metering orifice In correct oil being used No oil pressure Oil level low Oil pump drive gear broken...
Page 18: Engine Oil Level Check
Fill the crankcase with recommended engine oil. Oil Capacity : (After disassembly) 1.15 (After Oil filter change) (After oil change) Oil Recommendation : DAELIM genuine oil Filter Screen Filter Screen Filter Screen Filter Screen Filter Screen Filter Screen Filter Screen...
Page 19 Lubrication Engine 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 Remove the drain plug and drain the oil.
Page 20 Lubrication Measure the rotor end clearance. Service Limit : 0.20mm(0.008 in) Measure the pump side clearance. Service Limit : 0.12mm(0.005 in) Disassembly / Assembly Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring...
Page 21 Lubrication Remove the oval screw, sealing washer, spring and relief valve from oil filter cover. Remove the oil filter element from R. crank case cover. Blow the oil path way of crank case cover with compressed air, and clean. Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw: 1.2kgf-m(12N.m) Install the dowel pins and oil pump plate into...
Page 22 Lubrication Lubrication points if there is no specific indication of oil, use general grease to lubricate the lubrication parts. Lubricate the other operation parts which are not shown below with oil or grease. Control Cable Lubrication Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil.
Page 23 MEMO...
Page 24: Maintenance
Maintenance 3. Maintenance Service Information Maintenance Schedule Brake System 3-11 Fuel Line Brake Stop Switch 3-12 Throttle Grip Operation Headlight Adjustment 3-12 Air Cleaner Clutch 3-12 Spark Plug Side Stand 3-13 Valve Clearance Suspension 3-13 Cylinder Compression Pressure Bolts, Nuts Fasteners 3-14 Drive Chain Wheels / Tires...
Page 25 Maintenance 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) Timing Hole Cap 0.6 kgf-m( 6N.m) Crankshaft Hole Cap 0.8 kgf-m( 8N.m) Rear Axle Nut 8.8kgf-m(88N.m) Tools Common Tool Wrench, 8 9 mm Adjuster Wrench Compression Gauge...
Page 26: Maintenance Schedule
Steering Head Bearing 3-15 Should serviced by an authorized DAELIM dealer, unless the owner has proper tools and service date and is mechanically qualified. In the interest of safety, we recommended these items be serviced only by an authorized DAELIM dealer.
Page 27: Fuel Line
Maintenance Fuel Line Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Cock Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock...
Page 28: Air Cleaner
Maintenance Air Cleaner Loosen the four screw, and remove the air cleaner case cover. Loosen the three screw, and remove the air cleaner element.
Page 29: Note
Maintenance Make sure if there is no deterioration and Element Element Element Element Element Element Element Element Element Element Element Element Element damage in the air cleaner element. Replace damaged parts. NOTE The element is a viscous type which contains oil.
Page 30: Valve Clearance
Maintenance Measure the valve clearance with filler gauge. Valve Clearance: Intake: 0.12 0.02mm(0.05 0.001in) Exhaust: 0.12 0.02mm(0.05 0.001in) Loosen the lock nut with a valve wrench, and adjust the adjuster screw to the standard clearance using a valve adjusting wrench. When the standard clearance is done, hold the adjuster screw with a valve adjusting wrench.
Page 31: Drive Chain
Maintenance Drive Chain NOTE Stop the engine to inspect the drive chain, otherwise fingers can be caught in the drive chain while the drive chain is operating. Chain Free Play Adjustment Stop the engine and shaft the gear into neutral, support the motorcycle on a level surfase.
Page 32: Note
Maintenance Inspect the drive chain for adherence and damaging. Remove the contamination with a cleaner. After drying completely, coat the chain with #80-90 gear oil. Wipe any excessive oil off Gear Oil(#80-90) the chain, check the drive chain for wear and damage, replace it if necessary.
Page 33: Brake Shoe/Pad I I I
Maintenance Battery Remove the right side cover. CAUTION The battery contains sulfuric acid(electrolyte). Contact with skin or eyes may cause severe burns. If electrolyte gets on your eyes, flush with water for at least 15 minutes and call a physician. Brake Fluid Check the fluid level of the front brake reservoir.
Page 34: Brake System
Maintenance Brake Shoe Replacement Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Replace the brake shoes if the arrow on the brake arm aligns with the reference mark on full application of the rear brake pedal. Arrow Arrow Arrow...
Page 35: Brake Stop Switch
Maintenance Height Adjustment Adjust the brake pedal height to 10-20mm. CAUTION The adjustment faulty of height may caused that the brake runs in state of operation. Loosen the lock nut, and then adjust the height by turning the brake pedal stoper bolt. After adjusting, tighten the lock nut securely.
Page 36: Side Stand
Maintenance Perform the light adjustment by loosening the Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster lock nut from the handle and turning the adjuster. Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut...
Page 37: Wheels/Tires
Maintenance Rear Check the action of the rear cushion by compressing them several times. Check the rear cushion for leaks, damage, or looseness. Support the motorcycle with a main stand. Check for worn rear fork bush by attempting to move the wheel side to side. Replace the bearings if any looseness is noted.
Page 38: Steering Head Bearing I I
Maintenance Measure the tread depth at the center of the tire. Replace the tire when the tread depth reaches the following limits: Minimum Tread Depth: 4mm (0.16 in) 8.5mm (0.3 in) Steering Head Bearings NOTE Check that the control cables do not interfere with handle bar rotation.
Page 39 Fuel System...
Page 40: Fuel System
Fuel System 4. FUEL SYSTEM Service Information Fuel Tank Troubleshooting Air Cleaner Case Service Information General WARNING Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refuelled.
Page 41: Float Level Gauge
Fuel System Torque Air cleaner case cover screw 0.43kg-m (4.3N.m, 3.1ft-lb) Tools Float level gauge Troubleshooting Engine cranks but won t start No fuel in tank Engine flooded with fuel Clogged air cleaner No spark at plug(Ignition system faulty) Rough idle, hard starting or stalling starting Incorrect idle ring adjustment Lean mixture, rich mixture Clogged air cleaner...
Page 42 Fuel System Fuel Tank Removal WARNING Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled.
Page 43 Fuel System Air Cleaner Case Removal Remove the L. side cover. Remove the air cleaner connecting tube band out of the air cleaner side. Remove the battery. Remove the air cleaner mounting bolt. Remove the air cleaner case. Installation Installation is essentially the reverse order of removal.
Page 44: Ems(Engine Management System)
EMS(Engine Management System) 5. EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS 2. THE COMPONENT PARTS OF THE EMS 3.TERMINAL ARRANGEMENT OF THE ECU 4. WIRING DIAGRAM OF THE ECU 5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - Self diagnostic function - Fail safe function - How to check the fault code - How to show the fault code...
Page 45: Caution When Repairing The Ems Parts
EMS(Engine Management System) 1.CAUTION WHEN REPAIRING THE EMS PARTS. If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop. Do not touch the ECU terminal, because it may be damaged by the static.
Page 46: The Component Parts Of The Ems
EMS(Engine Management System) 2.THE COMPONENT PARTS OF THE EMS EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM. 1) INTAKE SYSTEM As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc.
Page 47: Terminal Arrangement Of The Ecu
EMS(Engine Management System) 3. TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO. 6,7,8,11,13,14,15,16,36,38 were not connected. 4. WIRING DIAGRAM OF THE ECU...
Page 48: Self-Diagnostic Function By Mil(Malfunction Indicator Lamp)
EMS(Engine Management System) 5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp) SELF-DIAGNOSTIC FUNCTION The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL (malfunction indicator lamp).
Page 49: Fail Safe Function
EMS(Engine Management System) FAIL-SAFE FUNCTION If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible. INTAKE : MIL on/off INTAKE...
Page 50: How To Check The Fault Code
EMS(Engine Management System) HOW TO CHECK THE FAULT CODE There are two methods of checking the Fault codes. 1) Use the MIL in the Speedometer. 2) The diagnostic Tool. First) Use the MIL in the Speedometer(refer to how to read the fault codes and Fault codes table and diagnostic methods for each part) Second) The diagnostic tool (refer to scan user’s manual.) Turn off the ignition key...
Page 51: How To Show The Fault Code
EMS(Engine Management System) HOW TO SHOW THE FAULT CODE There are two methods to show the Fault codes. First, the methods to show in engine operation In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the light on/off function of MIL in order for driver to acknowledge defect.
Page 52: Fault Code Table
EMS(Engine Management System) FAULT CODES TABLE No failure Injection valve failure(IV) Idle speed actuator failure (ISA) Electrical fuel pump failure (EFP) Intake Manifold absolute pressure signal failure (IMP) Throttle position signal failure (TPS) O2 sensor heater output failure (LSH) Lambda signal failure (VLS) Engine temperature signal failure (TENG) Breathing air temperature signal failure (TBA)
Page 53: How To Remove The Fault Code
EMS(Engine Management System) HOW TO REMOVE THE FAULT CODE Remove the fault codes in two ways; First) Full warm up 1. Starting the engine. - The MIL blinks continuously because the ECU memorized the fault code yet. 2. Full warm up the engine (keep idling five minutes) 3.
Page 54: Injector
EMS(Engine Management System) 6.INJECTOR Remove connector connector bolt Injector and Injector cap. Replace the Injector CAUTION Before disassemble, the key is off. CAUTION Be sure to check the engine is cooling because a little gasoline remains. it could be still hot. 5-11...
Page 55 EMS(Engine Management System) CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit 40 : INJECTOR control 39 : FUEL PUMP control INJECTOR FUEL PUMP RELAY Coupler terminal is based on wire harness. Checking Procedure 1) Turn off the ignition key.
Page 56 EMS(Engine Management System) 7) If the measured voltage is normal, Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40) If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks 8) If the measured voltage is not normal,...
Page 57: Mapat
EMS(Engine Management System) 7. MAPAT(Manifold Air pressure sensor, Temperature sensor) It is Located on the left side of the throttle body MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT CAUTION Before disassembly, the key is off. Remove MAPAT connector (Push by hand and pull to the front-side)
Page 58 EMS(Engine Management System) Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit Fault code number is displayed by MIL The Fault code of intake pressure sensor The Fault code of intake temperature sensor Checking circuit MAPAT 3 : Intake pressure sensor ground 3 : Inhalation pressure 26 : 5V voltage sensor GROUND...
Page 59 EMS(Engine Management System) Checking of the intake pressure sensor 1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler 2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 ) 3) Turn on the ignition key.
Page 60: Tps
EMS(Engine Management System) Checking of intake temperature sensor 4) Turn on the ignition key. Start the engine and idling. 5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No.28(TBA) ECU No.3(IMP ground) - Measuring voltage: 0.1[V] ~ 4.9[V]...
Page 61 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number is displayed by MIL Checking circuit 4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key .
Page 62 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ 7) If not problem, measure the resistance of TPS.
Page 63: Ets
EMS(Engine Management System) 9.ETS(ENGINE TEMPERATURE SENSOR) It is located on the left-hand side of cylinder head CAUTION Before disassembly, the key is off. Remove Rh.shroud comp Connector by hand Replace the ETS Install in reverse order of removal CAUTION ETS torque:3±0.3[kgf m] 5-20...
Page 64 EMS(Engine Management System) 1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) Fault code number is displayed by MIL CHECKING CIRCUIT 4 : SENSOR GROUND 20 : ETS Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key . 2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad.
Page 65 EMS(Engine Management System) 6-1) If the measured value is not normal, Replace the ETS with the new one, recheck. If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if the ECU coupler is a bad contact ( No.4, No.
Page 66: Isa
EMS(Engine Management System) 10.ISA(IDLE SPEED ACTUATOR) It is located upwards on the throttle body CAUTION Before disassembly, the key is off. Remove LH.side cover Air cleaner ISA connector TPS connector Throttle cable Throttle body (loosen the throttle body bolt) Loosen the ISA screw Replace the ISA 5-23...
Page 67 EMS(Engine Management System) 1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT. Showing of defects codes by MIL CHECKING CIRCUIT 33 : ISA CONTROL 39:FUEL PUMP FUEL PUMP RELAY Coupler terminal is based on the side of the wire-harness CHECK PROCEDURE 1) Turn off ignition key . 2) Check to see if the ISA(Throttle Position Sensor) coupler is loose, or bad.If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of ISA, measure the resistance...
Page 68 EMS(Engine Management System) CHECK PROCEDURE 5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck. 6) If resistance and continuty is normal, connect the coupler of ISA. 7) Turn on ignition key 8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : 10~14[V]...
Page 69: O2(Oxygen) Sensor
EMS(Engine Management System) 11.O2(Oxygen) SENSOR Located on the exhaust pipe RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover CAUTION...
Page 70 EMS(Engine Management System) 1) CHECKING OF OXYGEN(O ) SENSOR CIRCUIT Fault code number is displayed by MIL Fault code number is displayed by MIL of the oxygen(O )sensor lambda signal. CHECKING CIRCUIT OXYGEN SENSOR 2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER Coupler terminal is based on the side of Wire-Harness.
Page 71 EMS(Engine Management System) CHECKING FOR A FAULT CODE BY OXYGEN(O )SENSOR HEATER If the voltage value is abnormal, Check to see if the ECU coupler is loose or if there is bad contact. Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been broken or have short- circuited.
Page 72: Checking Of Ess Circuit
EMS(Engine Management System) 12.CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT Fault code number is displayed by MIL CHECKING CIRCUIT TACHOMETER 32 : ESS(ENGINE SPEED SIGNAL) Coupler terminal is based on the side of Wire-Harness. CHECK PROCEDURE 1) Turn off the ignition key . 2) Check the ESS coupler is loose, or bad.
Page 73 EMS(Engine Management System) 6)Turn on the ignition key. 7) Measure the voltage or tachometer of wire harness for ECU check. Measuring terminal: B electric wire ~ G electric wire => Output Voltage: battery voltage Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G electric wire =>Output voltage: 9[V]~15[V] Measuring terminal: ECU No.
Page 74 EMS(Engine Management System) 12.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT Fault code number is displayed by MIL CHECKING CIRCUIT 24 : MALFUNCTION INDICATOR LAMP OUTPUT MALFUNCTION INDICATOR LAMP(MIL) CHECK PROCEDURE 1) Turn off ignition key. 2) Check the ESS coupler is loose, or bad. If there is no problem.
Page 75: Ecu(Electronic Control Unit)
EMS(Engine Management System) 14.ECU(ELECTRONIC CONTROL UNIT) It is located inside of the LH. side cover CAUTION Before disassembly, the key is off. Remove LH.side cover Connector (A display portion is pulled behind) Flange bolt 4 EA Replace the ECU Install in the reverse order of removal. Replace the ECU CAUTION Be sure to assemble the ECU ground wire.
Page 76: Ignition Coil/Spark Plug
EMS(Engine Management System) 15.IGNITION COIL / SPARK PLUG Locate on bottom of the fuel tank CAUTION Be sure to check the engine is cooling. because a little gasoline remains, it is still hot. Remove SEAT Head light unit ass’y Fuel unit coupler Fuel pump connector Ignition coil -Connector...
Page 77 EMS(Engine Management System) 16.CRANK POSITION SENSOR :CPS Located on LH.crank case cover CAUTION Before disassembly, the key is off. Remove LH. side cover LH. lower cover Gear shift drum Drive chain cuide Connector - CPS connector(BLUE, LIGHT GREEN) - ACG connector(YELLOW) - Neutral S/W (Black coupler) ENG.
Page 78: Fuel Pump
EMS(Engine Management System) 17.FUEL PUMP It is Located inside the fuel tank CAUTION Before disassembly, the key is off. Remove Fuel pump nut 4EA Replace the fuel pump NOTICE Do not push the fuel pump base under the fuel tank when the fuel tank is stored. Always replace the packing when the fuel pump is removed.
Page 79 EMS(Engine Management System) 17.FUEL PUMP The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump) 5-36...
Page 80 EMS(Engine Management System) CHECKING OF THE FUEL LEVEL GAUGE. Remove the fuel level gauge (19-10) Measure the resistance between terminals. The FLOAT position Terminals resistance [ ] F : 140.5[mm] 3[ ] 1/2 : 83.5[mm] 5[ ] E : 28.5[mm] 3[ ] The float position is based on the tank bottom plate after assemble.
Page 81: Throttle Body
EMS(Engine Management System) 18.THROTTLE BODY INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY...
Page 82 EMS(Engine Management System) DISCONNECT THE THROTTLE BODY DISCONNECT: - Fuel tank and air cleaner - Gasoline in the fuel tube. - Fuel tube connected to the injector cap. - TPS, ISA, MAPAT, injector coupler. - Throttle cable CAUTION Do not disconnect both the throttle adjust screw and adjusting nut Disconnect the Insulator mounting two bolts DISASSEMBLE THE THROTTLE BODY...
Page 83 EMS(Engine Management System) DISCONNECT THE THROTTLE BODY MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP...
Page 84 EMS(Engine Management System) ASSEMBLY OF THE THROTTLE BODY AND INSULATOR Assemble the insulator into the throttle body. Torque: 1.0 kgf m INSTALLATION OF INSULATOR AND THROTTLE BODY Installation of insulator and throttle body is the reverse order of removal Check the o-ring when the insulator become assembly. Assemble the insulator gasket.
Page 85 EMS(Engine Management System) SUPPLEMENT ADJUSTMENT OF THROTTLE ADJUST SCREW A vehicle is assembled in the state which engine operation is possible. Loosen the fuel tank, and the adjust-screw is makes possible to adjust.. Disconnect the RH. Side cover. The couper to check the malfunction of vehicle is connected to the coupler of diagnostic tool Press the power-button of diagnostic tool.
Page 86: The Usage Of Scan When The Ecu Is Initialized
EMS(Engine Management System) 19.THE USAGE OF SCAN WHEN THE ECU IS INITIALIZED The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnostic tool. Press the enter button in the initial screen.
Page 87 EMS(Engine Management System) Press the enter button when it is ready When the ECU was initialized. turn off the lgnition key and then turn on the ignition key. 5-44...
Page 88: The Usage Of Scan When The Isa Pwm Adjusting
EMS(Engine Management System) 20.THE USAGE OF SCAN WHEN THE ISA PWM IS ADJUSTING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
Page 89: The Usage Of Scan When The Ignition Timing Is Check
EMS(Engine Management System) 21.THE USAGE OF SCAN WHEN THE IGNITION TIMING IS CHECK The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
Page 90: The Usage Of Scan When The Engine Revolution Is Check
EMS(Engine Management System) 22.THE USAGE OF SCAN WHEN THE ENGINE REVOLUTION IS CHECK The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
Page 91 MEMO...
Page 92: Engine Removal/Installation
SERVICE INFOR Engine Removal/Installation 6. Engine Removal/Installation Service Information Engine Installation Engine Removal...
Page 93 Engine Removal / Installation Service Information General A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the frame, engine body, cables, wire system. The following parts or components can not be served with the engine installed in the frame. Cylinder head, valve( Chapter 8) Cylinder, piston(...
Page 94: Engine Removal
Engine Removal / Installation Engine Removal Drain the engine oil.( 2-3) Remove the following - Side cover( 12-2) - Seat( 12-2) - Fuel tank( 4-3) - Mufflers( 12-3) Disconnect the connector of the starter motor cable, AC generator wire, gear change switch Screw Screw Screw...
Page 95: Engine Installation
Engine Removal / Installation Engine Installation Engine installation is essentially the reverse order of removal. NOTE Carefully align mounting points with the jack to prevent damage from mounting bolt threads and wire harness and cables. Be careful not to damage any part of the frame and bolt nuts.
Page 96 MEMO...
Page 97 Clutch, Gearshift...
Page 98: Clutch / Gearshift
Clutch, Gearshift 7. Clutch / Gearshift Service Information Gearshift Linkage 7- 7 Troubleshooting Clutch Installation 7- 9 R. Crankcase Cover Dissembly Primary Drive Gear 7-10 Clutch Disassembly R. Crank Case Cover 7-11 Service Information The clutch, gearshift linkage can be serviced with the engine in the frame. If the shift fork, drum and transmission require service, remove the engine and separate the crank case.
Page 99 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 100 Clutch, Gearshift R. Crankcase Cover Disassembly Drain the engine oil( 2-3) Remove the clutch adjusting lock nut and adjusting nut. Separate the clutch cable from the clutch arm. Remove the cable out of the cable holder. Remove the right crank case cover bolt and remove the cover.
Page 101 Clutch, Gearshift Separate the clutch arm spring and o-ring from O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring O-ring the clutch arm/lift shaft. Inspect the wear and damage of the lifter rod and clutch arm/lift shaft. Inspect the wear and damage of the clutch arm spring.
Page 102 Clutch, Gearshift Press the clutch center using the clutch center Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar Extension Bar...
Page 103 Clutch, Gearshift Inspection Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Inspect the lifter plate bearing for scoring and other damage. Inspect the lifter plate for damage. If necessary, replace them.
Page 104 Clutch, Gearshift Check the slots in the clutch outer for nicks or indentations made by the clutch discs. If necessary replace them. Measure the clutch outer inside diameter. Service Limit:28.030mm(1.1035in) Measure the clutch outer guide outsider diameter. Service Limit:27.950mm(1.1004in) Installation Installation is essentially the reverse order of removal.
Page 105 Clutch, Gearshift Inspection Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Check the gear shift spindle for wear or damage.
Page 106 Clutch, Gearshift Install the following: - Clutch assy. - R. crank case cover Install the gear shift arm into the gear shift spindle Clutch Assembly Thrust Washer Thrust Washer Clutch Outer Guide Clutch Outer Guide Thrust Washer Thrust Washer Clutch Outer Guide Clutch Outer Guide Thrust Washer Thrust Washer...
Page 107 Clutch, Gearshift Install the pressure plate, disk, plate and clutch center into the clutch outer. Coat the nut parts with clean engine oil, and tighten the lock nut. Install the lock nut by pressing clutch center Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench...
Page 108 Clutch, Gearshift Remove the lock nut, primary drive gear, and woodruff key Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key...
Page 109 Clutch, Gearshift R. Crankcase Cover Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Installation Remove the gasket from the crank case surface. Install the dowel pins and a new gasket.
Page 110 MEMO...
Page 111 A.C Generator / Starter Clutch...
Page 112: Generator / Starter Clutch
A.C Generator / Starter Clutch 8. A.C Generator / Starter Clutch Service Information Starter Clutch A.C Generator Service Information General 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 113 A.C Generator / Starter Clutch A.C Generator Removal Remove the gear change pedal. Remove the L. lower cover. L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L.
Page 114 A.C Generator / Starter Clutch Remove the starter reduction gear shaft and 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 Starter Reduction Gear...
Page 115 A.C Generator / Starter Clutch After installing the flywheel puller on the rotor, remove the rotor. Tool: Flywheel puller Flywheel Puller Remove the woodruff key from the crank 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 116 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(0.393in) Measure the gear shaft inside diameter. Service Limit : 9.97mm(0.393in) Starter Idle Gear Reduction Gear Reduction Gear Inspection Inspect the wear and damage of reduction gear.
Page 117 A.C Generator / Starter Clutch Install the starter idle gear and shaft. Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear...
Page 118 A.C Generator / Starter Clutch Connect the AC generator wire and gear position light switch wire coupler, and install the wire clamp. Install the L. Lower cover and gear change Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal...
Page 119 A.C Generator / Starter Clutch Check the starter driven gear for damage and wear. Measure the driven gear I.D. and O.D. Service Limit: O.D. : 39.607mm(1.5566in) I.D. : 22.100mm(0.870in) Assembly Clutch Outer Flange Part Inspect the one way clutch for wear and damage.
Page 120 MEMO...
Page 121: Cylinder Head / Valve
Cylinder Head / Valve...
Page 122 Cylinder Head / Valve 9. Cylinder Head / Valve Service Information Valve Guide Replacement Troubleshooting Valve Seat Inspection Camshaft Removal Cylinder Head Assembly 9-11 Cylinder head Removal Cylinder Head Assembly 9-13 Cylinder Head Disassembly Cylinder Heand Installation 9-13 Service Information General Rocker arm and cam shaft can be serviced with the engine installed in the frame.
Page 123: Cylinder Head / Valve
Cylinder Head / Valve Torque Values Cam Chain Tensioner Pivot Bolt 1.1kgf-m(11N.m) Spark Plug 1.1kgf-m(11N.m)-Apply engine oil Camshaft Holder 8mm nut 2.0kgf-m(20N.m)-Apply engine oil Cam Chain Tensioner Mounting Bolt 1.2kgf-m(12N.m) Cam Chain Tensioner Sealing Screw 0.4kgf-m(4N.m) Cylinder Head Cover Bolt 1.0kgf-m(10N.m) Crank Shaft Hole Cap 0.8kgf-m(8N.m)
Page 124: Camshaft Removal
Cylinder Head / Valve Camshaft Removal Remove the fuel tank( 4-3) Remove the cylinder head cover bolts and cover. Remove the timing hole cap and crank shaft Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap...
Page 125 Cylinder Head / Valve Remove the cam chain from 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 Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins...
Page 126: Cylinder Head Removal
Cylinder Head / Valve Inspection Inspect the rocker arm and rocker arm shaft for wear and damage. Measure the rocker arm I.D. Service Limit : 12.060mm(0.4748in) Measure the rocker arm O.D. Service Limit : 11.950mm(0.4505in) Inspect the cam lobe of the camshaft for wear and damage.
Page 127: Cylinder Head Disassembly
Cylinder Head / Valve Remove the gasket, dowel pins, and cam chain Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide...
Page 128 Cylinder Head / Valve Inspect the spark plug assembly hole and the crack of near valve seat. Check for the warp of the cylinder head with a square and filler gauge. Service Limit : 0.1mm(0.004in) Valve Spring Measure the free field of valve spring. Service Limit : 40.0mm(1.57in) CAUTION If any valve spring is shorter than the service...
Page 129: Valve Guide Replacement
Cylinder Head / Valve Valve Guide Replacement CAUTION When replacing the valve guide, valve seat must be amended. Heat the cylinder head equally to 130-140 . Avoid heating over 150 CAUTION Avoid performing the unskilled work. It is caused a burn. When heating the cylinder Head, do not heat it sectionally using a gas burner.
Page 130: Valve Seat Inspection
Cylinder Head / Valve CAUTION Trim the reamer not to lean. If cutting the reamer by leaning, the valve hole is inclined, the step seal is leaked, and the around of valve seat is enlarged. So the around of seat is not amended.
Page 131 Cylinder Head / Valve Valve Seat Amendment Damaged or Rough If the Seat part is damaged or rough, cut them using 45 cutter. CAUTION After replacing the valve guide, cut the seat Valve part. Seat Amend the flat using a 35 cutter side by side. Cut The Seat Part Amend the inside using a 60 cutter side by side.
Page 132: Cylinder Head Assembly
Cylinder Head / Valve Coat the valve seat with the compound. Use the valve guide reamer without turning the Contact Part is Hight Valve, check the attached state by hitting against lightly. Seat Width Before If the position of contacting side is high, cut it Cutting using a 35 cutter, and then cut it using a 45 cutter according to the standard width.
Page 133 Cylinder Head / Valve Install the valve springs. The springs tightly would coils should face toward the cylinder head. For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head...
Page 134 Cylinder Head / Valve Cylinder Head Installation Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede...
Page 135 Cylinder Head / Valve Insert the dowel pins into the camshaft holder thoroughly. Align the teeth of the rocker arm spring with the dowel pins as shown. Check the camshaft ass y for wear or damage, and Install the Cylinder head Install the cam chain on the cam sprocket.
Page 136 Cylinder Head / Valve Install the dowel pin into the cylinder Head. Install the camshaft holder. Apply engine oil to the nut part, install and tighten the cam shaft holder nut and bolt in two or three steps as shown Torque : 2.0kgf-m(29N.m) Remove the screw and O-RING from the cam Mount Bolt...
Page 137 Cylinder Head / Valve Hold the tensioner shaft with the light clip as shown Install a new gasket into the tensioner lifter, then install the tensioner lifter into the cylinder. Tensioner Lifter Install the tensioner mounting bolt. Torque:1.2kgf-m(12N.m) From the tensioner lifter, remove the clip Screw Screw Screw...
Page 138 MEMO...
Page 139 Cylinder / Piston 10-0...
Page 140: Cylinder / Piston
Cylinder / Piston 10. Cylinder / Piston Service Information 10-1 Piston 10-3 Trouble shootint 10-1 Piston/Cylinder Installation 10-5 Cylinder 10-2 Service Information Geaneral When removing the cylinder, avoid damaging the cylinder joint part with a driver or cooling pin by hitting the cylinder strongly.
Page 141 Cylinder / Piston Cylinder Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Removal Remove the cylinder head(Section 8).
Page 142 Cylinder / Piston nspect the twist of cylinder. Ruller Service Limit:0.1mm(0.004in) Filter Gauge Piston Piston Pin Clip Piston Removal Remove the piston pin clips. NOTE Do not let the clips fall into the crankcase. Push the piston pin out and remove the piston. Check the piston ring for damage or deterioration.
Page 143 Cylinder / Piston Insert the piston ring into the cylinder inside, Filter Gauge and inspect the piston ring clearance. NOTE Insert the piston ring horizontally using a piston head. Service Limit: Top/Second:0.5mm(0.02in) Oil(Side rail):1.1mm(0.04in) Piston Ring Measure the piston outside diameter at 10mm position in piston end part facing 90 direction.
Page 144 Cylinder / Piston Piston/Cylinder Installation Piston Ring Installation Clean the piston domes, ring lands and skirts and install the piston ring. NOTE Be careful not to damage the piston and piston rings during assembly. Carefully install the piston rings onto the piston with the markings facing up.
Page 145 Cylinder / Piston Install the piston, piston pin on the connecting Piston Pin Clip Piston rod. Install new piston pin clips. NOTE Install the piston with the IN mark facing towards the intake side. Place a shop towel over the opening to prevent piston pin clips from falling into the crankcase.
Page 146 Cylinder / Piston Install the lower part of the cam chain into the Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide...
Page 147: Crankcase / Transmission / Crankshaft
Crank Case / Transmission / Crankshaft 1.2kgf-m(12N-m) 1.1kgf-m(11N-m) 11-0...
Page 148 Crank Case / Transmission / Crankshaft 11. Crank Case/Transmission/Crankshaft Service Information 11-1 Crank Case Bearing 11-7 Troubleshooting 11-2 Crankshaft Installation 11-8 Crank Case Disassembly 11-3 Transmission Assembly 11-9 Transmission Disassembly 11-4 Crank Case Assembly 11-10 Crankshaft Disassembly 11-6 Crank Case Assembly 10-12 Service Information General...
Page 149: Bearing Remover Set, 15Mm
Crank Case / Transmission / Crankshaft Item Standard Service Limit 0.20-0.062(0.0008-0.0024) 0.10(0.004) Transmissin Bush-to-shaft clearance 0.016-0.052(0.0006-0.0020) 0.09(0.004) 0.013-0.047(0.0005-0.0019) 0.09(0.004) Connecting rod big end side 0.05-0.3(0.002-0.012) 0.6(0.02) clearance Connecting rod bid end Crankshaft 0-0.008(0-0.0003) 0.05(0.002) vertical direction clearance Right 0.1(0.004) Crankshaft runout Left 0.1(0.004) Torque Values...
Page 150 Crank Case / 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 The engine must be separated from the frame section 5) Refer to the service information for removal of necessary parts before disassembling the...
Page 151 Crank Case / 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...
Page 152 Crank Case / Transmission / Crankshaft Inspect the shift drum for wear and damaging. Inspect the shift drum guide groove for partial wear and damaging. Measure the main shaft and counter shaft outside diameter. Service Limit: M3, M5:19.930mm(0.7486in) C1:16.440mm(0.6472in) C2:19.940mm(0.7850in) C4:19.930mm(0.7846in) Inspect the gear for hole, projection part in gear, shift groove, gear wear, and damaging.
Page 153 Crank Case / Transmission / Crankshaft Crankshaft Disassembly Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Disassemble the transmission. 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 154 Crank Case / Transmission / Crankshaft Measure the state of vertical flux of the Connecting Rod end by X and Y direction. Service Limit:0.05mm(0.002in) Crankcase Bearing Remove the transmission and crank shaft. Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing...
Page 155: Attachment, 72 78Mm
Crank Case / Transmission / Crankshaft R. Crank Case Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Remove the main shaft bearing set plate. Separate the main shaft bearing, counter shaft bearing and crank shaft bearing form crank case.
Page 156 Crank Case / Transmission / Crankshaft Transmission Assembly Coat the gear and gear bush with clean engine Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft oil and install the mainshaft and counter shaft.
Page 157 Crank Case / Transmission / Crankshaft Check the marks on the shift forks. - Left fork: L. mark - Center fork: C. mark - Right fork: R. mark Center Fork Center Fork Left Fork Left Fork Center Fork Center Fork Right Fork Right Fork Right Fork...
Page 158 Crank Case / Transmission / Crankshaft Tighten the left crankcase bolt in crisscross Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube pattern in 2-3 steps. Torque: 1.1kgf-m(11N.m) Tighten the right crankcase bolt.
Page 159 MEMO 12-0...
Page 160: Cooling System
Cooling System 12. Cooling System Service Information 12-1 Radiator 12-2 Service Information General The engine must be cool before servicing the cooling system. 12-1...
Page 161 Cooling System Radiator Removal Remove the radiator grill Remove the radiator from the frame. Loosen the oil through bolt from the cylinder, and remove the radiator hose R.L Loosen the oil through bolt from the radiator, and remove the radiator hose R.L Radiator Grill Radiator Grill Radiator Grill...
Page 162: Seat/Exhaust Muffler
Seat/Exhaust Muffler 13. Seat/Exhaust Muffler Service Information 13-1 Rear Fender 13-3 Side Cover, Seat 13-2 Muffler 13-3 Grab Rail 13-2 Tool Box 13-4 Service Information CAUTION Muffler is very hot after engine stops. Avoid inspection right after engine stop. 13-1...
Page 163 Seat/Exhaust Muffler Side Cover/Seat Side Cover Removal Remove the R.side cover. (Removing with a lock key) Loosen the screw with a “+” driver Separate the side cover hook from grommet of frame. (When removing, remove the side cover with pushing toward the down.) Screw Screw Screw...
Page 164 Seat/Exhaust Muffler Rear Fender R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R.
Page 165 Seat/Exhaust Muffler Muffler Removal/Assembly Loosen the 3 pan screw of muffler protector and remove the protector. Loosen the upper/low muffler band. Loosen the 2 flange nut of upper muffler stay and remove the muffler comp Pan Screw Pan Screw Pan Screw Pan Screw Pan Screw Pan Screw...
Page 166 MEMO 13-5...
Page 167 Front Wheel/Front Fork/Steering 14-0...
Page 168: Front Wheel/Front Fork/Steering
Front Wheel/Front Fork/Steering 14. Front Wheel/Front Fork/Steering Front Wheel 14-6 Service Information 14-1 Front Fork 14-11 Troubleshooting 14-2 Handle Bar 14-3 Steering Stem 14-18 Service Information General CAUTION Contaminated brake disk and pad reduce stopping power. keep grease off the brake disk and pad. Wipe any excess grease off the disk.
Page 169: Steering Stem Driver
Front Wheel/Front Fork/Steering Tools Special Ball Race Driver Steering Stem Driver Fork Seal Driver Steering Stem Socket Common Extension Bar Driver Fork Seal Driver Body Lock Nut Wrench 30 32mm Bearing Remover shaft Remover Head Attachment 42 47mm Attachment 37 40mm Pilot 12mm Troubleshooting Hard steering...
Page 170 Front Wheel/Front Fork/Steering handle Bar Removal Loosen the cable guide bolt and remove the guide. Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Remove the starter switch, Throttle cable and Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder...
Page 171 Front Wheel/Front Fork/Steering Assembly Install the handle into the top bridge connecting hole. Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole...
Page 172 Front Wheel/Front Fork/Steering Apply grease to the ends of the 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 Install the throttle cable into the throttle pipe. Install the lighting start switch housing mounting holder pin onto the handlebar hole and tighten the mounting holder pin.
Page 173 Front Wheel/Front Fork/Steering Tighten the forward screws first, then tighten the rear screws. Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw After installing the brake hose, kill switch cable, winker switch code into the cable guide, tighten the guide.
Page 174 Front Wheel/Front Fork/Steering Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Service Limit: Radial Runout: 2.0mm(0.08in) Axial Runout: 2.0mm(0.08in) Wheel Bearing Inspection Turn the inner race of each bearing with your finger.
Page 175 Front Wheel/Front Fork/Steering Remove the bust seal of R. side. Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Remove the brake disc of L. side. NOTE Inspection for the problems of disk.
Page 176 Front Wheel/Front Fork/Steering Assembly Apply grease to the dust seal rim. Install the dust seal, brake disk. Install the brake disk. Torque: 4.2kgf-m(42N.m) Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal...
Page 177 Front Wheel/Front Fork/Steering Loosen the brake disc by the disk bolt. Align the speedometer gear retainer hole with the slot of the wheel hub. Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer...
Page 178 Front Wheel/Front Fork/Steering Front Fork Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Removal Remove the following - Front wheel ( 13-6) - Brake caliper - Front fender Loosen the fork tube cap bolt when disassem-...
Page 179 Front Wheel/Front Fork/Steering Cover the bottom case with cloth, and remove the socket bolt. CAUTION If nto removing the socket bolt with turning, assemble temporarily the spring and fork tube cap bolt. Support the bottom case by vise strongly, preventing it from transformation or damaging. Remove the fork tube from the bottom case.
Page 180 Front Wheel/Front Fork/Steering Remove the set ring. Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Remove the oil seal. CAUTION Prevent the around of bottom case inside and outside from damaging.
Page 181 Front Wheel/Front Fork/Steering Install the fork tube into V-block, and measure the bent with a dial gauge. Service Limit: replacement if over 0.2mm Inspect the contacted part of slider bush. Bottom case must be replaced if the copper Slider Bush portion is shown over three of quarter in teflon coating part or remarkably damaging.
Page 182 Front Wheel/Front Fork/Steering Connect the rebound spring and fork piston Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube into the fork tube. Connect the oil lock piece into the piston top end part, and install the fork tube into the bottom case.
Page 183 Front Wheel/Front Fork/Steering Install the set ring. Set Ring Install the set ring to bottom case exactly. Install the dust seal. Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal...
Page 184 Front Wheel/Front Fork/Steering Install the new O-ring to frok tube cap bolt. Fork Tube Cap Bolt Fork Tube Cap Bolt O-Ring O-Ring O-Ring O-Ring Fork Tube Cap Bolt Fork Tube Cap Bolt O-Ring O-Ring O-Ring O-Ring Fork Tube Cap Bolt Fork Tube Cap Bolt Fork Tube Cap Bolt Fork Tube Cap Bolt...
Page 185 Front Wheel/Front Fork/Steering Install the following: Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender - Brake Caliper Torque: 3.0kgf-m - Front fender - Front wheel ( 13-6) Steering Stem Removal...
Page 186 Front Wheel/Front Fork/Steering Remove the steering head top thread. Tools: Steering stem socket Extension bar Steering Stem Socket Remove the steering upper bearing. NOTE Bearing Replacement NOTE Always replace the bearing and races as a set. Tool: Ball race driver To protect the nuts, install the stem nut into the steering stem and remove the steering under bearing with a drill or equivalent tool.
Page 187 Front Wheel/Front Fork/Steering NOTE If the motorcycle had caused an accident, check the steering head pipe for crack of damage. Tighten the top thread. Torque: 1.8kgf Tools: Steering stem socket Steering Extension bar Stem Socket Move the steering stem from side to side 4-5 times, and allow the steel ball to operate.
Page 188 Front Wheel/Front Fork/Steering After arranging the cable, install the cable guide. Install the front fork. ( 13-11) Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Install the parts as the below.
Page 189 Rear Wheel/Rear Brake/Suspension 15-0...
Page 190: Rear Wheel/Rear Brake/Suspension
Rear Wheel/Rear Brake/Suspension 15. Rear Wheel/Rear Brake/Suspension Service Information 15-1 Rear Brake Pedal 15-8 Troubleshooting 15-2 Rear Cushion 15-8 Rear Wheel 15-3 Rear Fork 15-10 Rear Brake 15-6 Service Information General Note the assembling direction of the bolts. Specifications Unit: mm(in) Item Standard Service Limit...
Page 191 Rear Wheel/Rear Brake/Suspension Tools Common Rear Cushion Compressor Rear Cushion Compressor Attachment Attachment, 32 35mm Attatchment, 42 47mm Pilot, 15mm Driver Bearing Remover Shaft Remover Head, 15mm Troubleshooting Wobble or vibration in motorcycle Rear cushion noise Bent rim Binding shock case Worn rear wheel bearings Loose fasteners Faulty tire...
Page 192 Rear Wheel/Rear Brake/Suspension Rear Wheel Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Removal Raise and support the motorcycle with main stand. Loosen the rear brake adjuster, remove the brake rod.
Page 193 Rear Wheel/Rear Brake/Suspension Check the teeth of the final driven sprocket. Replace the worn, damaged final driven sprocket. Good WARNING Check the drive chain and drive sprocket at the same time. Disassembly Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket...
Page 194 Rear Wheel/Rear Brake/Suspension Coat the bearing with the grease. Insert the new bearing in parallel with the seal side facing outside. After inserting the distance collar, insert the bearing of the right side with the seal side facing outside. Tools: Driver Attachment Pilot, 15mm...
Page 195 Rear Wheel/Rear Brake/Suspension Install the chain adjuster, insert the axle shaft Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut...
Page 196 Rear Wheel/Rear Brake/Suspension Assembly Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Apply Grease a little to the anchor pins and brake cam. Assemble the brake cam.
Page 197 Rear Wheel/Rear Brake/Suspension Rear Brake Pedal 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 Disassembly Remove the bolts and brake pedal. Loosen the rear brake adjusting nut and remove the brake rod from the brake arm.
Page 198 Rear Wheel/Rear Brake/Suspension Disassembly Attachment Install the rear cushion compressor and attachment. Tools: Rear cushion compressor Rear cushion attachment CAUTION Avoid the upper joint from damage. Rear Cushion Compressor Fix the upper joint, and remove the upper joint Attachment by loosening the lock nut. Remove the case, spring, lock nut, damper rubber, and spring adjuster.
Page 199 Rear Wheel/Rear Brake/Suspension Coat the lock nut with oil to the thread, and install the rear cushion compressor attachment into the damper rod. Coat the upper joint with oil to the thread and install it into the damper rod. Fix the upper joint and tighten the lock nut. Torque: 3.8kgf-m (38N.m) Tools: Rear cushion compressor...
Page 200 Rear Wheel/Rear Brake/Suspension Disassembly Disassemble the rear sub fender. Disassemble the chain slider. Disassemble the rear fork pivot bearing. Disassemble the dust seal and center collar. Disassemble the pivot bush. Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider...
Page 201 Hydraulic Brake 16-0...
Page 202: Hydraulic Brake
Hydraulic Brake 16. Hydraulic Brake Service Information 16-1 Brake Disk 16-6 Troubleshooting 16-2 Brake Caliper 16-7 Brake Fluid/Bleeding 16-3 Master Cylinder 16-9 Brake Pad 16-4 Service Information General Do not allow foreign material to enter the system when filling the reservoir. Do not mix different types of brake fluid.
Page 203: Snap Ring Pliers
Hydraulic Brake Tools Special Snap Ring Pliers Troubleshooting Brake lever soft or too hard Air bubbles in hydraulic system. Moisture in brake fluid. Brake pad and disk contaminated. Caliper piston worn. Master cylinder piston worn. Brake pad worn. Contaminated caliper inner part. Incorrectly installed caliper.
Page 204 Hydraulic Brake Brake Fluid / Bleeding Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Master Cylinder Master Cylinder...
Page 205 Hydraulic Brake If the brake bleeder is not available, use the following procedure. Fill the master cylinder reservoir to the upper level mark. Connect the bleeder hose to the bleed valve and bleed the system as follows. 1. Squeeze the brake lever, open the bleed valve 1/2 turn and then close the bleed valve.
Page 206 Hydraulic Brake Remove the brake caliper from the left front Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper fork. Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...
Page 207 Hydraulic Brake Install the brake caliper into the left front fork. 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 NOTE Be careful not to damage the brake pad. Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...
Page 208 Hydraulic Brake Brake Caliper 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 Removal Remove the brake hose bolt and brake hose from the brake caliper. Remove the caliper from the front fork, then remove the pad pin bolt, brake pad.
Page 209 Hydraulic Brake Inspection Caliper Inspect the caliper friction surface for damaging or crack. Measure the caliper inside diameter. Service Limit: 34.02mm (1.339in) Inspect the piston outside for damaging or Caliper Piston crack. Measure the piston outside diameter. Service Limit: 33.87mm (1.333in) Micro Meter Assembly Bush...
Page 210: Master Cylinder
Hydraulic Brake Installation 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 Connect the brake hose to the caliper, and install the 2 sheets of sealing washer and brake hose bolt.
Page 211 Hydraulic Brake Remove the washer, piston, spring from the Master Piston Master Piston Spring Spring Secondary Cope Secondary Cope Secondary Cope Secondary Cope Master Piston Master Piston Master Piston Master Piston Spring Spring Secondary Cope Secondary Cope Secondary Cope Secondary Cope Master Piston Master Piston Master Piston...
Page 212 Hydraulic Brake Install the boot into master cylinder. Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Install the rear mirror, brake lever and stop switch.
Page 213 Charging System/Battery Regulator Rectifier Fuse AC Generator Battery 17-0...
Page 214: Charging System / Battery
Charging System/Battery 17. Charging System / Battery Service Information 17-1 Charging System Inspection 17-5 Troubleshooting 17-2 Regulator/Rectifier 17-6 Battery 17-3 A.C Generator Inspection 17-7 Service Information General CAUTION The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. - If Electrolyte gets on your skin, flush with water.
Page 215 Charging System/Battery Troubleshooting No power (Main switch turned “ON”) Dead battery - Charging system failure Disconnected battery cable Main fuse burned out Faulty ignition switch Low power (Main switch turned “ON”) Weak battery - Charging system failure Charging system failure Loose battery connection Low power (Engine running) Battery undercharged...
Page 216 Charging System/Battery Battery Removal Remove the right side cover. Disassemble the battery holder. Remove the battery cable from the battery terminal. CAUTION + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal...
Page 217 Charging System/Battery Charging Connect the charger positive cable to the battery positive terminal. Connect the charger negative cable to the battery negative terminal. CAUTION Turn power ON/OFF at the charger, not at the Battery Charger battery terminals to prevent spark. CAUTION Discontinue charging if the electrolyte temperature exceeds 45...
Page 218 Charging System/Battery Charging System Inspection Amperetmeter Leakage Inspection Turn the ignition switch OFF. Remove the negative cable from the battery. Connect the voltmeters between the negative cable and battery negative terminal. Measure the leakage current with the main switch OFF. CAUTION Battery Earth Cable...
Page 219 Must inspect using the defined tester as the below. If being inspected by different tester, can not be inspected exactly because strange resistance value is indicated. Measure the resistance using the DAELIM PVA multi-tester. - PVA multi-tester 17-6...
Page 220 Charging System/Battery 28~36 28~36 Replace the regulator / rectifier if the resistance is out of specification. ‘ epresent more than 1[MG] Replacement Remove the Seat. Disconnect the wire coupler of the regulator/rectifier connectors. Remove the voltage regulator/rectifier by removing the two flange bolts Installation is the reverse order of removal.
Page 221 Ignition System Ignition Coil Spark Plug A.C Generator 18-0...
Page 222: Ignition System
Ignition System 18. Ignition System Service Information 18-1 Ignition Coil Inspection 18-3 Troubleshooting 18-2 Pulse Generator 18-4 Service Information General Inspect the ignition system in proper sequence based on the troubleshooting. Dropping or giving a shock to the ECU unit causes a trouble. There should be battery voltage with the ignition and engine stop switched ON.
Page 223 Ignition System TROUBLESHOOTING NO SPARK AT PLUG Poorly connected, broken or shorted wires - Between A.C. generator and ECU unit - Between ECU unit and ignition coil - Between ignition coil and plug Faulty main switch Faulty ignition coil Faulty ECU unit Faulty A.C.
Page 224 Ignition System IGNITION COIL INSPECTION 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 seat Remove the Fuel Tank Disconnect the primary circuit. Measure the ignition coil primary coil resistance between the ignition coil terminal and ground.
Page 225 Ignition System Performance Test Measure it using the DAELIM PVA multi- PVA Adapter tester. - PVA multi-tester CAUTION Well read the instruction manual of tester and handle it. Crank Position Sensor Disconnect the AC generator 2P coupler blue/green wire connector.
Page 226 Ignition System 18-5...
Page 227 MEMO 18-6...
Page 228 Electric Starter Starter Magnetic Switch Starter Motor Battery 19-0...
Page 229: Electric Starter
Electric Starter 19. Electric Starter Service Information 19-1 Starter Motor 19-2 Troubleshooting 19-1 Starter Magnetic Switch 19-5 Service Information General The Starter motor can be serviced with the engine in the frame. Specification Unit: mm(in) Item Standard Service Limit Starter Motor Brush Length 12.5-13.0(0.49-0.51) 8.5(0.33) Starter Motor Brush Spring Tension...
Page 230 Electric Starter Starter Motor Removal CAUTION Turn the main switch OFF before servicing the starter motor. The main switch ON brings about an injury. Remove the starter motor cable from the motor. Remove the starter motor mounting bolt, and starter motor. Disassembly Remove the following parts - Motor case...
Page 231 Electric Starter Inspect the continuity between cable terminal and case. Inspect the continuity between the terminal and brush. If it doesn’t have continuity between cable terminal and case, it is OK. If it doesn’t have continuity between the cable terminal and Brush (Case side), it is OK. Replace or repair them if necessary.
Page 232 Electric Starter Assembly Rear Cover Armature Brush Brush Holder Shim Front Cover Shim O-Ring Motor Case Brush Spring Lock Washer Insert the armature into the brush holder center with driving each brush into the brush holder inside. Install the holder into the case aligning the projecting part of brush holder with the part of case.
Page 233 Electric Starter Align the rear cover with the case mark and Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover install the 2 setting bolts. Tighten the setting bolts exactly.
Page 234 Electric Starter Voltage Inspection Measure the voltage between the yellow/red wire of the starter magnetic switch and Yellow/Red Wire ground. Turn the main switch “ON”. There should be battery voltage while the starter switch is depressed. Ground Circuit Inspection Disconnect the green/red wire connector of the Green/Red Wire starter magnetic switch.
Page 235 MEMO...
Page 236 Lights/Switches/Horn SERVICE 20-0...
Page 237 Lights/Switches/Horn 20. Lights/Switches/Horn Service Information 20-1 Main Switch 20-7 Troubleshooting 20-1 Handle Switch 20-8 Headlight 20-2 Gear Change Switch 20-9 Speedometer/Tachometer/Fuel Meter 20-2 Brake Light Switch 20-9 Tail/Brake Light 20-4 Horn 20-9 Winker Bulb 20-5 Fuel Unit 20-10 Winker Ass y Removal 20-6 Service Information General...
Page 238: Lights/Switches/Horn
Lights/Switches/Horn Headlight Removal Remove the two headlight mounting bolts and remove the headlight from the bracket. Remove the individual code from the wire. Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Bulb Replacement Remove the headlight rim and unit. Headlight Socket Headlight Socket Headlight Socket...
Page 239 Lights/Switches/Horn Remove the combination switch upper/ Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover...
Page 240: Tail/Brake Light
Lights/Switches/Horn Fuel Meter Bulb Replacement Remove the hax socket bolt(3) of fuel meter. Take off the bulb socket, and replace the bulb Fuel Mete Removal Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Remove the headlight and remove the individual code from the case.
Page 241: Winker Bulb
Lights/Switches/Horn Take off the bulb by turning toward anti- clockwise, and replace it. Assembly is done in the reverse order of disassembly. Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Winker Bulb Loosen the screw and remove the winker unit. Remove the bulb in bulb socket by turning toward anti-clockwise Screw...
Page 242: Winker Ass Y Removal
Lights/Switches/Horn Winker Ass’y Removal Front Loosen the head light case screw (2 screws) Remove the winker connector connection in state of inclining for ward the head light lens. Remove the winker. NOTE Place the wiring and cables exactly according to a wiring diagram. Installation is done in the reverse order of removal.
Page 243: Main Switch
Lights/Switches/Horn Main Switch Inspection Remove the fuel tank. Disconnect the main switch code coupler connection. Check for continuity between terminals in each switch position. There should be a continuity between the colour coded wire. ( Color Code Black Cable Guide Cable Guide Cable Guide Cable Guide...
Page 244: Handle Switch
Lights/Switches/Horn Handle Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Light Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch...
Page 245: Brake Light Switch
Lights/Switches/Horn Gear Chain Switch Disconnect the gear change switch wire coupler. Check for the continuity between the terminal and engine ground. Gear Position Terminal Neutral Light green/Red 3Position gear White/Blue Brake Light Switch Front Remove the headlight case. Disconnect the front brake light switch wire connectors and check for continuity between the connector terminals.
Page 246: Fuel Unit
Lights/Switches/Horn The horn should sound when a fully charge 12V battery is connected across he horn terminals. Fuel Unit Remove the fuel tank. Drain fuel out of tank at clean container. Loosen the 4 nuts and remove the fuel unit from tank.
Page 247 MEMO...
Page 248: Wiring Diagram
Wiring Diagram 21. Wiring Diagram 21-1...
Page 249 21-2...
Page 250: Troubleshooting
Troubleshooting 22. Troubleshooting Engine Does Not Starter is Hard to Start 22-1 Engine Lacks Power 22-2 Poor Performance(At Low and Idle Speeds) 22-3 Poor Performance (At High speed) 22-4 Poor Handling 22-4 Engine Doesn’t Start or is Hard to Start 1.
Page 251 Troubleshooting Engine Lacks Power 1. Raise wheels off ground Wheel don’t Brake dragging and spin by hands. spin freely. Worn or damaged wheel bearings Wheel bearings need lubrication Wheels spin freely. Wheels spin freely. 2. Check tire pressure. Pressure low. Punctured tire Faulty tire valve Pressure normal.
Page 252 SERVICE INFOR Troubleshooting 10. Check oil level. Incorrect. Oil level too high. Oil level too low. Correct. Contaminated oil. 11. Remove cylinder head cover Valve train Clogged oil passage. and inspect lubrication. lubricated Clogged oil filter element. properly. Valve train lubricated properly.
Page 253 Troubleshooting SERVICE Poor Performance(At High Speed) 1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment. valve clearance. Faulty ECU. Faulty crank position sensor. Correct. Flywheel not installed properly. 2. Disconnect fuel tube at Fuel flows Clogged fuel tube. Fule pump.

DAELIM Daystar VL125E Service Manual

Table of Contents

Table of Contents

Maintenance Schedule

5. Ems(Engine Management System)

9. Cylinder Head / Valve

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Troubleshooting

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Summary of Contents for DAELIM Daystar VL125E

Table of Contents