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HYOSUNG COMET 125 Service Manual

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SERVICE MANUAL

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  • Page 1 SERVICE MANUAL...
  • Page 2 HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer. HYOSUNG MOTORS & MACHINERY INC. COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2002.
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where you are look- ing for.
  • Page 4 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Apply THREAD LOCK 1324 . Data beside it indicates specified torque. Apply oil.
  • Page 5 NOTE Difference between photographs and actual motorcycles depends on the markets.
  • Page 6: Table Of Contents

    GENERAL INFORMATION CONTENTS INFORMATION LABELS 1 - 1 GENERAL PRECAUTIONS 1 - 1 1 - 3 SERIAL NUMBER LOCATION 1 - 4 FUEL AND OIL RECOMMENDATIONS 1 - 5 BREAK-IN PROCEDURES 1 - 5 CYLINDER CLASSIFICATION 1 - 6 EXTERIOR ILLUSTRATION 1 - 8 SPECIFICATIONS...
  • Page 7: General Precautions

    1-1 GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. WARNING Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION 1-2 WARNING If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  • Page 9: Serial Number Location

    1-3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine seri- al number is located on the left upside of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER...
  • Page 10: Fuel And Oil Recommendations

    GENERAL INFORMATION 1-4 FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85~95 octane (Research Method) or higher. An unleaded gasoline type is recommended. ENGINE OIL ENGINE OIL SPECIFICATION Classification system Grade Over SG 10W/30 or 10W/40 If an SAE 10W/30 or 10W/40 motor oil is not available, select an alternative according to the following chart.
  • Page 11: Break-In Procedures

    1-5 GENERAL INFORMATION BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK-IN before subjecting the engine to maximum stresses.
  • Page 12: Exterior Illustration

    GENERAL INFORMATION 1-6 EXTERIOR ILLUSTRATION 1,455 2,080...
  • Page 13 1-7 GENERAL INFORMATION EXTERIOR ILLUSTRATION...
  • Page 14: Specifications

    GENERAL INFORMATION 1-8 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2,080 mm (81.9 in) Overall width 760 mm (29.9 in) Overall height 1,120 mm (44.1 in) Wheelbase 1,455 mm (53.7 in) Ground clearance 180 mm (7.1 in) Unladen mass 170 kg (375 lbs) 167 kg (368 lbs) ENGINE Type...
  • Page 15 1-9 GENERAL INFORMATION CHASSIS Front suspension Telescopic type Rear suspension Swingarm type Steering angle 33 (right & left) Caster 25.5 Trail 85 mm (3.35 in) 76 mm (2.29 in) Front brake Disk brake Rear brake Disk brake Front tire size 110/70 - 17 54H Rear tire size 150/70 - 17 69H...
  • Page 16 PERIODIC MAINTENANCE CONTENTS 2 - 1 PERIODIC MAINTENANCE SCHEDULE 2 - 1 PERIODIC MAINTENANCE CHART 2 - 2 LUBRICATION POINTS MAINTENANCE PROCEDURES 2 - 3 2 - 3 VALVE CLEARANCE 2 - 5 SPARK PLUG 2 - 5 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2 - 6 AIR CLEANER 2 - 7...
  • Page 17: 2-1 Periodic Maintenance

    2-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. CAUTION More frequent servicing should be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART ENGINE Interval...
  • Page 18: Lubrication Points

    PERIODIC MAINTENANCE 2-2 LUBRICATION POINT Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Clutch lever holder Front brake lever holder Drive chain Throttle cable Side stand pivot and spring hook Rear brake pedal pivot Speedometer gear box - Motor oil,...
  • Page 19: Maintenance Procedures

    2-3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURE This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE Inspect Interval Inspect Initial 1,000 km and Every 4,000 km. CAUTION The clearance specification is for COLD state. The valve clearance specification is different for intake and exhause valves.
  • Page 20 PERIODIC MAINTENANCE 2-4 If the clearance is out of specification, first remove the cam chain tensioner, camshaft housing, camshaft. To install the tappet shim at original position, record the shim NO. and clearance with A , B , C , D mark on the cylinder head as the illustration.
  • Page 21: Spark Plug

    2-5 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 4,000 km, Replace Every 8,000 km. Disconnect the spark plug caps. Remove the spark plugs. TYPE SPARK PLUG SPECIFICATION Hot type CR7E Standard type CR8E Cold type CR9E Remove the carbon deposite with wire or pin and adjust the spark plug gap to 0.7 0.8 mm, measuring with a...
  • Page 22: Air Cleaner

    PERIODIC MAINTENANCE 2-6 [ Rear Cylinder ] AIR CLEANER Inspect Interval Clean Every 3,000 km, Replace Every 12,000 km. The air cleaner is located under the fuel tank. Remove the fuel tank. Remove the four screw Pull up the air cleaner cover and the air cleaner ele- ment...
  • Page 23: Carburetor

    2-7 PERIODIC MAINTENANCE Clean the air cleaner element for the following: CAUTION When the air cleaner element clean with the air gun, necessarily blow at the inside by compressed air. More frequent servicing may be performed on mo- Carefully examine the air cleaner element for tears during torcycles that are used under severe condi- tions, also clean the air cleaner element when cleaning.
  • Page 24: Fuel Hose

    PERIODIC MAINTENANCE 2-8 FUEL HOSE Inspect Interval Inspect Initial 1,000 km and Every 4,000 km, Replace every 4 years. Remove the front and rear seat. (Refer to page 6-1) Inspect the fuel hoses for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. CLUTCH Inspect Interval Inspect Initial 1,000 km and Every 4,000 km.
  • Page 25: Engine Oil

    2-9 PERIODIC MAINTENANCE GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the lock nut With the link rod turned, adjust the gearshift lever height. ENGINE OIL Inspect Interval Replace Initial 1,000 km and Every 4,000 km. Necessary amount of engine oil Oil change 1,450 1,450 Filter change...
  • Page 26: Engine Oil Filter

    PERIODIC MAINTENANCE 2-10 CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark(L) in the inspec- tion window. Never fill the engine oil above the Upper line mark(F) . Engine oil level being most suitable about 1mm under the Upper line mark(F) of the engine oil lens.
  • Page 27: Drive Chain

    TER only, since the other make s genuine filters and after-market parts may differ filtering perfor- mance and durability, which could cause engine damage or oil leaks. Hyosung motors genuine oil filter is also not usable for the motocycles. DRIVE CHAIN Inspect Interval Clean and Lubricate Every 1,000 km.
  • Page 28 PERIODIC MAINTENANCE 2-12 NOTE When replacing the drive chain, replace the drive chain and sprocket as a set. Loose the axle nut Tense the drive chain fully by turning both chain adjusters Count out 21 pins (20 pitches) on the chain and mea- sure the distance between the two points.
  • Page 29: Brake System

    2-13 PERIODIC MAINTENANCE Place the motorcycle on jack or block for accurate adjustment. After adjusting the drive chain, tighten the axle nut to the specified torque. Tighten both chain adjusters securely. Rear axle nut : 90~140 N m (9.0~14.0 kg m) Recheck the drive chain slack after tightening the axle nut.
  • Page 30 PERIODIC MAINTENANCE 2-14 BRAKE FLUID LEVEL CHECK Keep the motorcycle upright and place the handle- LOWER LIMIT LINE bars straight. Check the brake fluid level by observing the lower limit line (LOWER) on the front brake fluid reservoir. When the level is below the lower limit line (LOWER), replenish with brake fluid that meets the following specification.
  • Page 31 2-15 PERIODIC MAINTENANCE FRONT AND REAR BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Specification and Classification : DOT 3 or DOT 4 Connect a clear hose...
  • Page 32 PERIODIC MAINTENANCE 2-16 AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak- ing performance of the brake caliper.
  • Page 33: Steering

    2-17 PERIODIC MAINTENANCE FRONT BRAKE LAMP SWITCH The front brake lamp switch is located beneath the front brake lever. Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward. REAR BRAKE LAMP SWITCH Adjust the rear brake lamp switch so that the brake lamp will come on just before pressure is felt when the brake pedal is depressed.
  • Page 34: Tire

    150/70-17 69H for rear. as follows. The use of tires other than those specified may cause instability. It is highly recommended to SOLD RIDING DUAL RIDING COLD INFLATION use a HYOSUNG Genuine Tire. TIRE PRESSURE kgf/cm KPa kgf/cm Front 2.00 29.0 2.00...
  • Page 35: Compression Pressure

    2-19 PERIODIC MAINTENANCE COMPRESSION PRESSURE The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compres- sion reading for each maintenance service.
  • Page 36: Oil Pressure

    PERIODIC MAINTENANCE 2-20 OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Standard Oil pressure Oil pressure 0.9 1.1 (at 65 3,000 rpm) (at 65 3,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE Oil leakage from the oil passage Damaged O-ring...
  • Page 37 ENGINE CONTENTS ENGINE REMOVAL AND REINSTALLATION 3 - 1 ENGINE REMOVAL 3 - 1 3 - 5 ENGINE REINSTALLATION 3 - 7 ENGINE DISASSEMBLY 3 - 7 STARTER MOTER 3 - 8 CYLINDER HEAD COVER 3 - 12 PISTON 3 - 13 MAGNETO COVER MAGNETO ROTOR 3 - 13...
  • Page 38: Engine Removal And Reinstallation

    3-1 ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL NOTE If the engine is dirtied, wash the machine with a suitable cleaner before removing the engine. Remove the front seat.(Refer to page 6-1) Remove the fuel tank.(Refer to page 4-1) Drain the engine oil.(Refer to page 2-9) Disconnect the battery lead wire CAUTION...
  • Page 39 ENGINE 3-2 CLUTCH CABLE Disconnect the clutch cable end out of clutch lever. Disconnect the clutch cable end out of clutch release arm. EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts and muffler mounting bolts removed, remove the exhaust pipes and muf- flers.
  • Page 40 3-3 ENGINE ELECTRIC PARTS With take out the spark plug caps, remove the spark plug. [ Front Cylinder ] [ Rear Cylinder ] Remove the starter motor lead wire. Remove the engine ground lead wire Disconnect the magneto coupler...
  • Page 41 ENGINE 3-4 ENGINE SPROCKET Remove the engine sprocket cover. Remove the breather hose. Loosen the bolt and remove the link rod. Flatten the lock washer. Remove the engine sprocket nut and washer. NOTE When loosening the engine sprocket nut, depress the brake pedal. Remove the engine sprocket.
  • Page 42: Engine Reinstallation

    3-5 ENGINE Remove the oil cooler. Support the engine using an engine jack. Remove the engine mounting nuts and bolts. Remove the engine from the frame. CAUTION Remove the carburetor when removing or installing the engine necessarily. When removing the carburetor , loosen the intake pipe mounting bolts at the same time.
  • Page 43 ENGINE 3-6 ENGINE SPOCKET Loosen the rear axle nut and chain adjusters, left and right. Install the engine sprocket. Tighten the engine sprocket nut to the specified torque. Engine sprocket nut : 80~100 N m (8.0~10.0 kg m) NOTE When tightening the engine sprocket nut, depress the rear brake pedal.
  • Page 44: Engine Disassembly

    3-7 ENGINE ENGINE DISASSEMBLY STARTER MOTOR Remove the starter motor. Remove the gear position switch. Remove the contacts and springs Remove the three union bolts.
  • Page 45: Cylinder Head Cover

    ENGINE 3-8 CYLINDER HEAD COVER Remove the cylinder head cover. To set the piston at TDC(Top Dead Center). CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter-clockwise. To set piston at TDC(Top Dead Center) of the compression stroke as align the F mark for...
  • Page 46 3-9 ENGINE With the three bolts removed, remove the cam chain guide NO.2. Remove the camshaft housing. Remove the camshaft (IN. EX.). Remove the C-ring.
  • Page 47 ENGINE 3-10 Loosen the two cylinder head base cover nuts. Loosen the three cylinder head base nuts. Loosen the four cylinder head stud bolts. Remove the chain guide NO.1 and cylinder head.
  • Page 48 3-11 ENGINE Remove the tappet and the shim. CAUTION Draw out the tappet and shim with the strong magnet not to be scratched. CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly.
  • Page 49: Piston

    ENGINE 3-12 Remove the two cylinder base nuts and cylinder. CAUTION If tapping with the plastic hammer is necessary, pay attention to break the fins. Remove the rear cylinder head and cylinder with the Rear Cylinder same manner of the front cylinder head and cylinder removal.
  • Page 50: Magneto Cover

    3-13 ENGINE MAGNETO COVER Remove the magneto cover. Remove in the order of spacer , shaft , starter idle gear MAGNETO ROTOR With the magneto rotor held immovable using the special tool, loosen the rotor nut. Conrod holder : 09910-20115 Remove the magneto rotor by using the special tool.
  • Page 51: Clutch Cover

    ENGINE 3-14 Remove the key Remove the starter driven gear Remove the cam chain tensioner and cam chain CLUTCH COVER Remove the clutch release arm . Remove the clutch cover bolts. Remove the clutch cover.
  • Page 52: Clutch

    3-15 ENGINE CLUTCH With the primary drive gear held immovable, remove the clutch spring mounting bolts diagonally. Remove the disk pressure Remove the clutch drive and driven plates. Flatten the lock washer With the clutch sleeve hub held immovable using special tool, remove the clutch sleeve hub nut.
  • Page 53: Primary Drive Gear

    ENGINE 3-16 Remove the clutch sleeve hub and primary driven gear assembly PRIMARY DRIVE GEAR With the magneto rotor held immovable using special tool, remove the primary drive gear nut. Conrod holder : 09910-20115 CAUTION This bolt has left-hand thread. If turning it counter-clockwise( ), it may cause damage.
  • Page 54: Gearshift Shaft

    3-17 ENGINE Remove the pin With the three screws loosened, remove the oil pump GEARSHIFT SHAFT Draw out the gearshift shaft With the cam guide screws loosened, draw out the guide and lifter. Remove the cam driven gear. CAUTION Pay attention to not lost the gearshift pawl, pin, spring with the cam driven gear removal.
  • Page 55 ENGINE 3-18 Remove the crankcase securing bolts. Separate the crankcase into 2 parts, right and left, with a special tool. Crankcase separator : 09920-13120 CAUTION When separating the crankcase , necessarily, remove it after installed the special tool (Crankcase separator) on the side of clutch. In case separate oppositely, the gearshift cam stop- per will be damaged in the side of magneto.
  • Page 56: Engine Component Inspection And Service

    3-19 ENGINE ENGINE COMPONENT INSPEC- TION AND SERVICE CAUTION Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as Front cylinder , Rear cylinder , Exhaust , Intake , so that each will be restored to the origi- nal location during assembly.
  • Page 57 ENGINE 3-20 CAMSHAFT (T.D.C) (B.T.D.C) The camshaft should be checked for runout and also for (A.T.D.C) Intake open wear of cams and journals if the engine has been noted Exhaust close to produce abnormal noise or vibration or a lack of out- 17 45 put power.
  • Page 58 3-21 ENGINE VALVE HEAD RADIAL RUNOUT Place a dial gauge as shown and measure valve head radial runout. If the service limit is exceeded, replace the valve. Service limit Valve head radial runout 0.03 mm (0.0012 in) Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304 VALVE GUIDE-VALVE STEM CLEAR-...
  • Page 59 ENGINE 3-22 Service limit Valve spring free length(IN. & EX.) 37.64 mm 37.80 mm (1.482 in) (1.488 in) Venier calipers : 09900-20101 Standard Valve spring tension 12.0~13.9 kgf 30.0 kgf (IN. & EX.) (26.7~30.6 lbs) (66.1 lbs) at length 33.7 mm (1.33 in) at length 27.95 mm (1.10 in) CYLINDER DISTORTION Check the gasketed surface of the cylinder for distor-...
  • Page 60 3-23 ENGINE CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new one. CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear, damage and kinked or bind- ing links.
  • Page 61 ENGINE 3-24 PISTON PIN HOLE BORE Using a dial calipers, measure the piston pin hole bore both in the vertical and horizontal directions. If the measurement exceeds the service limit, replace the piston. Service limit Piston pin hole bore 15.030 mm (0.5917 in) 13.030 mm (0.513 in) Dial calipers : 09900-20605 PISTON PIN DIAMETER INSPECTION Using a micrometer, measure the piston pin outside...
  • Page 62 3-25 ENGINE Piston ring end gap(Assembly condition) Service limit 0.5 mm (0.02 in) 0.5 mm (0.02 in) Thickness gauge : 0990-20806 PISTON RING-TO-GROOVE CLEAR- ANCE INSPECTION Remove carbon deposit both from the piston ring and its groove. Fit the piston ring into the groove. With the ring com- pressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.
  • Page 63 ENGINE 3-26 CONROD SMALL END INSIDE DIAM- ETER INSPECTION Using a dial calipers, measure the conrod small end inside diameter both in vertical and horizontal directions. If any of the measurements exceeds the service limit, replace the conrod. Service limit Standard Conrod small 15.006~15.014 mm...
  • Page 64 3-27 ENGINE Service limit Crankshaft runout 0.05 mm (0.002 in) Magnetic stand : 09900-20701 Dial gauge : 09900-20606 V-block : 09900-21304 CRANKSHAFT REASSEBLY Measure the width between the webs referring to the fi- gure below when rebuilding the crankshaft. (2.84 0.004 in) Standard Width between webs 72 0.1 mm...
  • Page 65 ENGINE 3-28 REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tighten them to the spec- ified torque while holding the rotor with the rotor holder. Thread Lock 1324 Rotor holder : 09930-44510 Starter clutch bolt : 15~20 N m(1.5~2.0 kg m) STARTER DRIVEN GEAR STARTER DRIVEN GEAR BUSHING...
  • Page 66 3-29 ENGINE REASSEMBLY Drive in the oil seal using the special tool. Bearing installer : 09913-75820 Install the circlip. CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set.
  • Page 67 ENGINE 3-30 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring. Service limit Clutch spring free length 36.2 mm (1.43 in) 29.5 mm (1.16 in) Vernier calipers : 09900-20101 CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality,...
  • Page 68 3-31 ENGINE GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture. TRANSMISSION INSPECTION GEAR-SHIFTING FORK Using a thickness gauge, check the clearance between in the groove of its gear and shifting fork. The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.
  • Page 69 ENGINE 3-32 CAUTION Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded Thrust and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft.
  • Page 70 3-33 ENGINE Thickness for washers, circlips and spacers 1.2mm 6.0mm 0.5mm 1.0mm 1.0mm CRANKCASE play play BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase. Replace the bearing in the following procedure if there is anything unusual.
  • Page 71 ENGINE 3-34 DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer. Remove the bearings Bearing remover(17 mm) : 09923-73210 Bearing remover(20~35 mm) : 09923-74510 Remove the bearing Bearing installer : 09913-76010 CAUTION The removed bearing should be replace with a new one. LEFT CRANKCASE BEARING Remove the oil seals Oil seal remover : 09913-50121...
  • Page 72 3-35 ENGINE Remove the bearing retainer. Remove the bearings Bearing remover(17 mm) : 09923-73210 Bearing remover(20~35 mm) : 09923-74510 REASSEMBLY RIGHT CRANKCASE BEARING Drive in the bearings Bearing installer : 09913-70122 Bearing installer : 09913-76010 LEFT CRANKCASE BEARING Drive in the bearings Bearing installer : 09913-70122 Bearing installer : 09913-76010...
  • Page 73: Engine Reassembly

    ENGINE 3-36 Install the oil seals Apply SUPER GREASE A on the lip of oil seal. SUPER GREASE A ENGINE REASSEMBLY The engine reassembly can be performed in the reverse order of disassembly procedures. However, the follow- ing points must be observed in the reassembly opera- tion.
  • Page 74 3-37 ENGINE GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift fork NO.1 , NO.2 , and NO.3 Install the gearshift cam , and gearshift fork shaft Install the oil pump idle gear shaft Install the dowel pins Before assembling the crankcase, apply the engine oil to each gear and bearing.
  • Page 75 ENGINE 3-38 NOTE After the crankcase bolts have been tight- ened, make sure that the crankshaft, counter- shaft and driveshaft rotate smoothly. If these shafts do not rotate smoothly, try to free it by tapping with a plastic hammer. Apply the SUPER GREASE A to the driveshaft O- ring and oil seal lip.
  • Page 76 3-39 ENGINE GEARSHIFT SHAFT Install the gear shifting shaft. Match the center teeth of the gear on the shifting shaft with the center teeth on the shifting driven gear as shown. CAUTION After the cam driven gear, cam guide, gear shift shaft and neutral cam stopper have been fitted, confirm that gear change is normal while turning, the countshaft and driveshaft.
  • Page 77 ENGINE 3-40 CAUTION When installing the oil pump to the crankcase, turn the pump gear and check that rotation is smooth by the hand. CAM CHAIN TENSIONER Install the washer and cam chain tensioner tighten the cam chain tensioner bolt. Cam chain tensioner bolt : 6~8 N m(0.6~0.8 kg m) Install the cam chain...
  • Page 78 3-41 ENGINE CAUTION Pay attention to the two washer to lower end of the primary drive gear nut in times of assemblage. With the magneto rotor held immovable using special tool, tighten the primary drive gear nut. Conrod holder : 09910-20115 Primary drive gear nut : 40~60 N m(4.0~6.0 kg m) PRIMARY DIRVEN GEAR...
  • Page 79 ENGINE 3-42 Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool. Clutch sleeve hub holder : 09920-53710 Clutch sleeve hub nut : 30~50 N m(3.0~5.0 kg m) Bend the lock washer securely. Install the clutch drive plates and driven plates.
  • Page 80 3-43 ENGINE Install the clutch pressure plate clutch springs and clutch spring mounting bolts. Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern. NOTE Make sure that the clutch pressure plate is installed correctly.
  • Page 81 ENGINE 3-44 NEUTRAL CAM STOPPER Put in the neutral cam stopper, spring and washer, tighten the cam stopper plug to the specified torque. Neutral cam stopper plug : 20~25 N m(2.0~2.5 kg m) OIL DRAIN PLUG Tighten the oil drain plug to the specified torque. Engine oil drain plug : 18~20 N m(1.8~2.0 kg m) STATOR...
  • Page 82 3-45 ENGINE Tighten the magneto rotor nut to the specified torque. Conrod holder : 09910-20115 Magneto rotor nut : 50~60 N m(5.0~6.0 kg m) STARTER IDLE GEAR AND MOTOR Install the starter idle gear, shaft and spacer. Install the starter motor. MAGNETO COVER Install the new gasket and dowel pin.
  • Page 83 ENGINE 3-46 Install the magneto cover and tighten the magneto cover bolts. Magneto cover bolt : 8~12 N m (0.8~1.2 kg m) PISTON RING Install the piston ring in order of oil ring, 2nd ring and 1st ring at first at the front cylinder. CAUTION Be careful not to cause scratch on the piston when inserting the piston ring to the piston.
  • Page 84 3-47 ENGINE CYLINDER Apply BOND 1215 to the parting line of crankcase. BOND 1215 Place the dowel pin and new gasket on the crankcase. CAUTION Make sure to replace the gasket with a new one. Apply the engine oil to the conrod big end, piston and the piston rings.
  • Page 85 ENGINE 3-48 Tighten the cylinder head base nuts. Cylinder head base nut : 7~11 N m (0.7~1.1 kg m) Cylinder head base nut : 15~20 N m (1.5~2.0 kg m) Tighten the two cylinder base cover nuts. Tappet Install the tappet and shim. CAUTION Shim With fit the tappet, it should be replaced if turn...
  • Page 86 3-49 ENGINE CAMSHAFT ASSEMBLY Distinguish the EX mark for the exhaust camshaft, the IN mark for the intake camshaft. Be distinguished always each camshaft what has notch at the rightside end and leftside end of it. When installing the camshaft and cam sprocket, apply a small quantity THREAD LOCK 1324 to the bolts and tighten with the specified torque.
  • Page 87 ENGINE 3-50 The notch mark of exhaust camshaft should be aligned with the plane of cylinder head. At that time, the 2 arrow of exhaust camshaft sprock- et should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into camchain.
  • Page 88 3-51 ENGINE CAUTION The cam chain is installed to the all of three sprocket. Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely. 16 Pin Notch mark Exhaust Intake [Front cylinder] 16 Pin Notch mark Exhaust...
  • Page 89 ENGINE 3-52 Each camshaft housing is punched with A B C D . Put on the housing A to the A of head surface, the housing B to the B , the housing C to the C and the housing D to the D as that A C D is punched also to the cylinder head upper surface.
  • Page 90 3-53 ENGINE Get out the pushrod for the front to turn the lock shaft handle in counter-clockwise ( ). Turn the crankshaft about 10 times counter-clock- wise ( ) on the basis of the magneto rotor. If the valve clearance is within standard after measured the valve clearance, begin the next operation.
  • Page 91 ENGINE 3-54 SPARK PLUG Install the spark plug.(Refer to page 2-5) Install the rear cylinder head and cylinder with the same manner which installed the front cylinder head and cylinder. Front Cylinder Rear Cylinder GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE A to the O-ring and install the gear postion switch.
  • Page 92 FUEL SYSTEM CONTENTS 4 - 1 FUEL TANK / FUEL COCK 4 - 2 FUEL PUMP 4 - 4 CARBURETOR CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
  • Page 93 4-1 FUEL SYSTEM FUEL TANK / FUEL COCK REMOVAL WARNING Gasoline is very explosive. Extreme care must be taken. Remove the front seat. (Refer to page 6-1) Remove the fuel tank mounting bolt, and take off the hooks. Disconnect the fuel hose and remove the fuel tank.
  • Page 94 FUEL SYSTEM 4-2 FUEL PUMP ( REMOVAL Remove the front seat and fuel tank. Turn the fuel cock to OFF . Disconnect the fuel hoses Remove the fuel pump mounting bolts. Remove the fuel pump lead wire coupler . INSPECTION WARNING Gasolin is very explosive.
  • Page 95 4-3 FUEL SYSTEM FUEL PUMP ( REMOVAL Remove the front seat and fuel tank. Turn the fuel cock to OFF . Disconnect the fuel hoses and vacuum hose INSPECTION WARNING Gasolin is very explosive. Extreme care must be taken. Disconnect the fuel hose , connect the suitable hose and insert the free end of the hose into a recep- tacle.
  • Page 96 FUEL SYSTEM 4-4 CARBURETOR...
  • Page 97 4-5 FUEL SYSTEM LOCATION OF CARBURETOR I.D. The carburetor I.D. is stamped on the location on the carburetor as shown in the right photo. REMOVAL Remove the fuel tank. (Refer to page 4-1) Remove the fuel hose. Remove the throttle cables and choke cable Loosen the clamp screw and remove the carburetor.
  • Page 98 FUEL SYSTEM 4-6 Remove the jet needle cap spring retainer and jet needle Remove the float chamber body Remove the float assembly along with the needle valve by removing the pin. Remove the valve seat Remove the main jet jet holder and pilot jet...
  • Page 99 4-7 FUEL SYSTEM Remove the throttle cable bracket Remove the pilot screw with count and tighten the number of turn. NOTE Record the number of turn for the pilot screw when install to confer. INSPECTION Check the following parts for damage and clogging. Pilot jet Piston valve Check for...
  • Page 100 FUEL SYSTEM 4-8 FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Measure the float height while the float arm is just contacting the needle valve using vernier calipers. Float height 17mm (0.67 in) Vernier calipers : 09900 - 20101 Bend the float arm as necessary to bring the height...
  • Page 101 4-9 FUEL SYSTEM Install the jet needle with the pin on the spacer securely engaged with the hole on the piston valve. Align the hole of the diaphragm with passage way on the carburetor body. Install the eight screw CAUTION Never adjust CO adjust screw of the carbure- tor.
  • Page 102 ELECTRICAL SYSTEM CONTENTS 5 - 1 LOCATION OF ELECTRICAL COMPONENTS 5 - 3 IGNITION SYSTEM 5 - 7 CHARGING SYSTEM STARTER SYSTEM AND 5 - 11 SIDE STAND IGNITION INTERLOCK SYSTEM 5 - 15 SWITCHES 5 - 16 LAMP 5 - 18 BATTERY 5 - 21 FUEL SYSTEM(...
  • Page 103: Location Of Electrical Components

    5-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Front brake lamp switch Turn signal relay Head lamp relay C.D.I Unit Rear brake lamp switch Side stand switch Starter motor...
  • Page 104 ELECTRICAL SYSTEM 5-2 Ignition coil (NO.1 & NO.2) Regulator / Rectifier Magneto Gear position switch Fuse Fuel pump relay...
  • Page 105: Ignition System

    5-3 ELECTRICAL SYSTEM IGNITION SYSTEM is started as the battery discharged ignition system without a contact point. The battery igni- tion system is composed a rotor with five rotor tip, the D.C CDI, the ignition coil and battery. This system ignites after get signal from ignition timing of pick-up with the electric energy of this battery and occur the 1st electric current.
  • Page 106 ELECTRICAL SYSTEM 5-4 INSPECTION MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. Pick-up coil G - L Approx 90 110 Charging coil Y - Y Approx 0.6 0.9 Pocket Tester : 09900 - 25002 CAUTION When mounting the stator on the magneto cover, apply a small quantity of THREAD LOCK 1324...
  • Page 107 5-5 ELECTRICAL SYSTEM CAUTION Numberical value may differ a little according to the tester. Please remind that there may be a defect which can not be identified even though the measurement by using the tester indicates a low voltage. The range of measurement adjust a [ unit.
  • Page 108 ELECTRICAL SYSTEM 5-6 SPARK PLUG Clean the plug with a wire brush and pin. Use the pin to remove carbon, taking care not to damage the porce- lain. Check the gap with a thickness gauge. Thickness gauge : 09900 - 20806 0.8 mm Spark plug gap (0.028...
  • Page 109: Charging System

    5-7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator / rec- tifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current, then it charges the battery.
  • Page 110 ELECTRICAL SYSTEM 5-8 When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the voltage between points of the regulator according becomes high, and when it reaches the adjusted voltage of the control unit, consequently the control unit becomes ON condition. On the ON condition of the control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become ON condition.
  • Page 111 5-9 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal If the tester reads under 14.0 V or over 15.0 V, check the magneto no-load performance and regulator / rectifier.
  • Page 112 ELECTRICAL SYSTEM 5-10 REGULATOR / RECTIFIER Disconnect the coupler. Using the multi-tester ( range), measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the regu lator / rectifier. Unit : Probe of tester 30 55 0.8 2 0.8 2...
  • Page 113: Starter System And Side Stand Ignition Interlock System

    5-11 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever position switch, C.D.I unit, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery. Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
  • Page 114 ELECTRICAL SYSTEM 5-12 TRANSMISSION : Neutral - ON Side stand - Down ( OFF ) IGNITION SWITCH IGNITION COIL BATTERY Unit NEUTRAL INDICATOR LIGHT SIDE STAND SWITCH GEAR POSITION DOWN POSITION SWITCH ON TRANSMISSION : Neutral - OFF Side stand - Up ( ON ) IGNITION SWITCH IGNITION COIL BATTERY...
  • Page 115 5-13 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire With loosen the bolt , remove the starter motor. Disassemble the starter motor. STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, crack or smoothness in the brush holder. If the brush has failed, replace the brush sub assy.
  • Page 116 ELECTRICAL SYSTEM 5-14 STARTER MOTOR REASSEMBLY Reassemble the starter motor. Pay attention to the following points : Reassembly the starter motor as shown in the illustration. Align the mark on the housing with the line on the housing end. Apply SUPER GREASE A to the O-ring and remount the starter motor.
  • Page 117: Switches

    5-15 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Pocket tester : 09900 - 25002 IGNITION SWITCH ENGINE STOP SWITCH LOCK LIGHT SWITCH STARTER SWITCH DIMMER SWITCH HORN SWITCH TURN SIGNAL SWITCH...
  • Page 118: Lamp

    ELECTRICAL SYSTEM 5-16 LAMP HEADLAMP TURN SIGNAL LAMP Front Rear TAIL / BRAKE LAMP...
  • Page 119 5-17 ELECTRICAL SYSTEM COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. INSPECTION Using the pocket tester, check the continuity between lead wires in the following illustration. If the continuity measured incorrect, replace the respec- tive part.
  • Page 120: Battery

    ELECTRICAL SYSTEM 5-18 BATTERY CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas. If you don t follow the instruction in the below, there may be a explosion and severe accident. Therefore, please pay attention to the following points. Prohibit positively battery from contacting to short, spark or firearms.
  • Page 121 5-19 ELECTRICAL SYSTEM Seal Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any fluid to spill. CAUTION The pouring of electrolyte may not be done if the electrolyte container is pushed slopely.
  • Page 122 ELECTRICAL SYSTEM 5-20 Separation of electrolyte container After confirming that you entered the electrolyte into bat- tery completely, remove the electrolyte containers from the battery. CAUTION Draw the empty receptacle out slowly because there may be a chance which remaining elec- trolyte vaporize.
  • Page 123: Fuel System

    5-21 ELECTRICAL SYSTEM FUEL SYSTEM FUEL PUMP Remove the front seat and fuel tank. Remove the fuel pump lead wire coupler Using the pocket tester (X 1 range), measure the resistance between the terminals in the following table. If the resistance checked is incorrect, replace the fuel pump.
  • Page 124 CHASSIS CONTENTS EXTERIOR PARTS 6- 1 6 - 2 FRONT WHEEL FRONT BRAKE 6- 6 6 - 12 HANDLEBARS 6 - 14 FRONT FORK ( FRONT FORK ( 6- 20 6 - 27 STEERING REAR WHEEL 6- 30 REAR BRAKE 6- 34 REAR SHOCK ABSORBER 6- 36...
  • Page 125: Exterior Parts

    6-1 CHASSIS EXTERIOR PARTS FRONT FENDER With the bolts removed, remove the front fender. REAR SEAT Remove the rear seat with the ignition key. FRONT SEAT To remove the front seat, pull the knob located under the rear seat.
  • Page 126: Front Wheel

    CHASSIS 6-2 FRONT WHEEL REMOVAL Loosen the axle pinch bolt , right and left. Loosen the front axle Raise the front wheel off the ground with a block or jack. CAUTION When using a jack, take care not to cause scratches on the chassis.
  • Page 127 6-3 CHASSIS Remove the brake disc. INSPECTION AND DISASSEMBLY TIRE For inspection of the tire : Refer to page 2-18. FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle. Service limit Axle shaft runout 0.25 mm (0.01 in)
  • Page 128 CHASSIS 6-4 WHEEL BEARING REMOVAL Remove the wheel bearing by using the special tool. Wheel bearing remover : 09941 - 50111 CAUTION The removed bearing should be replaced with new ones. REASSEMBLY Reassemble the front wheel in the reverse order of removal and disassembly.
  • Page 129 6-5 CHASSIS Tighten the front axle bolt and axle pinch bolt the specified torque. Front axle bolt : 50~80 N m (5.0 ~8.0 kg m) Front axle pinch bolt : 15~25 N m (1.5 ~2.5 kg m)
  • Page 130: Front Brake

    CHASSIS 6-6 FRONT BRAKE WARNING Do not mix with brake fluid of different brand. Do not use a brake fluid kept in an open container or stored for long period of time. To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.
  • Page 131 6-7 CHASSIS CAUTION Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause discoloration or crack. BRAKE FLUID REPLACEMENT For replacing procedure of brake fluid : Refer to page 2-15 BRAKE PAD REPLACEMENT For replacing procedure of brake pad : Refer to page 2-14 CALIPER DISASSEMBLY...
  • Page 132 CHASSIS 6-8 Remove the dust seal and piston seal CAUTION Care not to cause scratch on the cylinder bore. Do not reuse the piston seal and dust seal that have been removed. CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages.
  • Page 133 6-9 CHASSIS Apply SILICONE GREASE to the brake caliper hold- SILICONE GREASE Install the brake pads. (Refer to page 2-14) Tighten the caliper mounting bolts With the hose end seated to the stopper, tighten the union bolt Front brake caliper mounting bolts :18~28 N m (1.8~2.8 kg m) Front brake hose union bolts :20~25 N m (2.0~2.5 kg m)
  • Page 134 CHASSIS 6-10 MASTER CYLINDER DISASSEMBLY Drain brake fluid the master cylinder. Disconnect the brake lamp switch lead wire coupler. Remove the union bolt CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts. Remove the two clamp bolts and take off the master cylinder.
  • Page 135 6-11 CHASSIS MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage. MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disassembly. Pay attention to the following points : CAUTION Wash the master cylider components with new brake fluid before reassembly.
  • Page 136: Handlebars

    CHASSIS 6-12 HANDLEBARS HANDLEBARS RIGHT SIDE PARTS REMOVAL Remove the right handlebar switches. Disconnect the brake lamp switch lead wires and remove the master cylinder. (Refer to page 6-10) Remove the handlebar balancer and grip HANDLEBARS LEFT SIDE PARTS REMOVAL Remove the left handlebar switches.
  • Page 137 6-13 CHASSIS NOTE The gap between the handlebar clamp and holder should be even. Align the mating face of clutch lever holders with the respective punch marks and tighten the bolt. Install the brake master cylinder. (Refer to page 6- 11).
  • Page 138: Front Fork

    CHASSIS 6-14 FRONT FORK...
  • Page 139 6-15 CHASSIS REMOVAL AND DISASSEMBLY Take off the front wheel. (See page 6-2) Loosen the front fork upper and lower clamp bolts. Remove the front brake hose clamp. Pull down right and left front forks. Remove the front fork cap, O-ring , and seat lever.
  • Page 140 CHASSIS 6-16 Remove the damper rod bolt by using the special tool. T Handle : 09940-34520 D Attachment : 09940-34561 T Type hexagon wrench (6mm) : 09914-25811 Separate the inner tube from outer tube. Remove oil lock piece and damper rod with rebound spring.
  • Page 141 6-17 CHASSIS INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear and damage. INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws. FORK SPRING Measure the fork spring free length If it is shorter than the service limit, replace it.
  • Page 142 CHASSIS 6-18 DAMPER ROD BOLT Apply Bond 1215 and Thread Lock 1324 to the damper rod bolt and tighten the bolt with specified torque by the Special tool Bond 1215 Thread Lock 1324 T Handle : 09940-34520 D Attachment : 09940-34561 T Type hexagon wrench (6mm) : 09914-25811 Front fork damper rod bolt : 30 40 N m (3.0 4.0...
  • Page 143 6-19 CHASSIS FORK SPRING The narrow pitch side of spring face to the upper side when installing the front fork spring. Up side STOPPER RING To install a new stopper ring, it will be necessary to push the spring seat inward. CAUTION Always use a new stopper ring.
  • Page 144: Front Fork

    CHASSIS 6-20 FRONT FORK...
  • Page 145 6-21 CHASSIS DISASSEMBLY Remove the front wheel. (Refer to page 6-2) Remove the brake caliper. (Refer to page 6-7) CAUTION Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose. Remove the front fender. (Refer to page 6-1) Remove the front fork after loosening the front fork upper and lower...
  • Page 146 CHASSIS 6-22 With the damper rod held immovable, remove the damper rod bolt. Remove the damper rod and rebound spring from the inner tube. Remove the dust seal and oil seal stopper ring Separate the inner tube from the outer tube. Remove the following parts.
  • Page 147 6-23 CHASSIS INSPECTION FRONT FORK SPRING Measure the free length of the front fork spring If the length is found shorter than the service limit, replace the spring. Service limit Fork spring free length 354 mm (13.9 in) INNER TUBE AND OUTER TUBE Check the sliding surface of the inner tube, outer tube and damper rod ring for scratch, wear, bend- ing, or other abnormal condition.
  • Page 148 CHASSIS 6-24 With the oil lock piece fitted to the inner tube, assem- ble the inner tube to the outer tube. Apply SUPER GREASE A to the lip of the oil seal and install it into the outer tube using the front fork oil seal installer.
  • Page 149 6-25 CHASSIS Apply THREAD LOCK 1324 to the damper rod bolt With the damper rod held immovable, with the gasket fitted, tighten the damper rod bolt Front fork damper rod bolt : 30~40 N m (3.0~4.0 kg m) THREAD LOCK 1324 CAUTION Replace the gasket with a new one.
  • Page 150 CHASSIS 6-26 Fit the O-ring to the front fork upper bolt and apply SUPER GREASE A . SUPER GREASE A CAUTION Use a new O-ring to prevent oil lieakage. Install the front fork to the motocycle. Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket.
  • Page 151: Steering

    6-27 CHASSIS STEERING REMOVAL AND DISASSEMBLY Take off the front wheel. (See page 6-2) Remove the four bolts and front fender. Take off the front fork. (See page 6-15, 6-21)
  • Page 152 CHASSIS 6-28 Remove the handlebar clamp bolts. Remove the steering stem head nut and take off the steering stem upper bracket Remove the steering stem nut and draw out the steering stem. Clamp wrench : 09940-10122 Take off the steering stem lower bracket CAUTION Hold the steering stem lower bracket by hand to prevent from falling.
  • Page 153 6-29 CHASSIS INSPECTION Inspect and check the removed parts for the following abnormalities. Handlebar distortion. Handlebar clamp wear. Abnormality operation of bearing. Worn or damaged races. Distortion of steering stem. REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps : Apply SUPER GREASE A to the upper bearing and lower bearing...
  • Page 154: Rear Wheel

    CHASSIS 6-30 REAR WHEEL REMOVAL Raise the rear wheel off the ground with a jack or block. Loosen the drive chain adjuster right and left. Disengage the drive chain from the rear sprocket.
  • Page 155 6-31 CHASSIS Remove the rear wheel by removing the rear axle Remove the brake disc. Remove the spacer Remove the rear sprocket with mounting drum from the rear wheel. NOTE Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts. Remove the rear wheel shock absorber Remove the rear sprocket from the rear sprock-...
  • Page 156 CHASSIS 6-32 INSPECTION WHEEL AXLE : Refer to page 6-3 WHEEL : Refer to page 6-3 WHEEL BEARING : Refer to page 6-3 TIRE : Refer to page 2-18 REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and damage. Replace the rear wheel shock absorber if there is any- thing unusual.
  • Page 157 6-33 CHASSIS Install the rear wheel. After installing the drive chain to the rear sprocket, adjust the drive chain. Tighten both chain adjusting nuts securely. Tighten the rear axle nut to the specified torque. Rear axle nut : 90~140 N m (9.0~14.0 kg m)
  • Page 158: Rear Brake

    CHASSIS 6-34 REAR BRAKE WARNING Do not mix with brake fluid of different brand. Do not use a brake fluid kept in an open container or stored for long period of time. To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.
  • Page 159 6-35 CHASSIS Brake fluid replacement : Refer to page 2-15 Brake pad replacement : Refer to page 2-14 Disassembly of caliper : Refer to page 6-7 Inspection of caliper : Refer to page 6-8 Reassembly of caliper : Refer to page 6-8 Inspection of brake disc : Refer to page 6-9...
  • Page 160: Rear Shock Absorber

    CHASSIS 6-36 REAR SHOCK ABSORBER REMOVAL Remove the rear shock absorbers by removing their nuts. INSPECTION Inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one. CAUTION Do not attempt to disassemble the rear shock absorber.
  • Page 161: Swingarm

    6-37 CHASSIS SWINGARM REMOVAL AND DISASSEMBLY Remove the rear wheel. (See page 6-30) Remove the rear shock absorber fitting nut and bolt. (See page 6-36) Remove the swing arm pivot nut. Draw out the pivot shaft and take off the swing arm.
  • Page 162 CHASSIS 6-38 Remove the chain case. Remove the two spacers. Remove the bearing by using the special tools. Bearing remover (17 mm) : 09923-73210 Rotor remover sliding shaft : 09930-30102 INSPECTION SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one.
  • Page 163 6-39 CHASSIS REASSEMBLY Reassemble the swingarm and rear shock absorber in the reverse order of disassembly. Pay attention to the following points : Press the needle bearings into the swingarm pivot using the special tool. Steering race installer : 09941 - 34513 Apply SUPER GREASE A to the needle bearing and spacers.
  • Page 164 SERVICING INFORMATION CONTENTS 7 - 1 TROUBLESHOOTING 7 - 8 SPECIAL TOOLS 7 - 11 TIGHTENING TORQUE 7 - 13 SERVICE DATA 7 - 23 WIRE AND CABLE ROUTING WIRE AND CABLE ROUTING 7 - 27 WIRING DIAGRAM 7 - 31 7 - 32 WIRING DIAGRAM...
  • Page 165: Troubleshooting

    7-1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard 1. Valve clearance out of adjustment. Adjust. to start. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
  • Page 166 SERVICING INFORMATION 7-2 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from transmission 1. Gears worn or rubbing. Replace. 2. Badly worn splines. Replace. 3. Primary gears worn or rubbing. Replace. 3. Badly worn bearings. Replace. Slipping clutch.
  • Page 167 7-3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. 1. Loosen of valve clearance. Adjust. 2. Weakened valve springs. Replace. 3. Valve timing out of adjustment. Adjust. 4. Worn piston ring or cylinder. Replace. 5. Poor seating of valves. Repair or replace.
  • Page 168 SERVICING INFORMATION 7-4 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective CDI unit. Replace. Spark plug soon 1. Mixture too rich. Adjust carburetor. become fouled with 2.
  • Page 169 7-5 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation acidic 1. Not enough electrolyte. Add distilled water, if the battery white powdery has not been damaged and substance or spots sulfation has not advanced on surfaces of too far, and recharge. cell plates.
  • Page 170 SERVICING INFORMATION 7-6 CHASSIS Complaint Symptom and possible causes Remedy Steering feels too 1. Steering stem nut overtightened. Adjust. heavy or stiff. 2. Worn bearing or race in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust.
  • Page 171 7-7 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking 1. Not enough brake fluid in the reservoir. Refill to level mark. (FRONT and REAR) 2. Air trapped in brake fluid circuit. Bleed air out. 3. Pads worn down. Replace.
  • Page 172: Special Tools

    SERVICING INFORMATION 7-8 SPECIAL TOOLS Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09900-20101 09900-21109 Vernier Caliper Torque wrench Used to conveniently measure various dimensions. Measure torque of tightening. 09900-20201 09900-21304 Micrometer(0~25mm) V-block Used for precise measurement (00~25mm measure ranges). With using magnetic stand.
  • Page 173 7-9 SERVICING INFORMATION Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09913-80112 09910-32812 Bearing installer Crankshaft installer Used to install the crankshaft in the crankcase. Used to drive bearing in. 09910-34510 09915-63310 Piston pin puller Compression gauge adapter Use to remove the piston pin.
  • Page 174 SERVICING INFORMATION 7-10 Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09921-20200 09930-44510 Bearing remover(10mm) Rotor holder Used to remove oil seal or bearing. Widely used to lock rotary parts such as a flywheel magneto. 09921-20210 09940-10122 Bearing remover(12mm)
  • Page 175: Tightening Torque

    7-11 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM kg m Magneto rotor nut 50 ~ 60 5.0 ~ 6.0 Magneto cover bolt 8 ~ 12 0.8 ~ 1.2 Muffler mounting bolt 20 ~ 30 2.0 ~ 3.0 Exhaust pipe nut 18 ~ 28 1.8 ~ 2.8 Starter clutch bolt 15 ~ 20...
  • Page 176 SERVICING INFORMATION 7-12 CHASSIS ITEM kg m Rear shock absorber mounting nut (Upper) 40 ~ 60 4.0 ~ 6.0 Rear shock absorber mounting nut (Lower) 40 ~ 60 4.0 ~ 6.0 Rear sprocket nut 20 ~ 30 2.0 ~ 3.0 Rear axle nut 90 ~ 140 9.0 ~ 14.0...
  • Page 177: Service Data

    7-13 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT Valve diam. 22.0 (0.87) 19.0 (0.75) Valve clearance (When cold) 0.1 ~ 0.2 (0.004 ~ 0.008) 0.2 ~ 0.3 (0.008 ~ 0.012) Valve guide to valve stem clearance 0.010 ~ 0.037 (0.0004 ~ 0.0015) 0.030 ~ 0.057 (0.0012 ~ 0.0022) Valve stem deflection...
  • Page 178 SERVICING INFORMATION 7-14 VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT Valve diam. 18.0 (0.71) 14.5 (0.57) Valve clearance (When cold) 0.1 ~ 0.2 (0.004 ~ 0.008) 0.2 ~ 0.3 (0.008 ~ 0.012) Valve guide to valve stem clearance 0.010 ~ 0.037 (0.0004 ~ 0.0015) 0.030 ~ 0.057 (0.0012 ~ 0.0022) Valve stem deflection...
  • Page 179 7-15 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT Compression pressure 14~16 kg/cm (at 500 rpm) 12 kg/cm Piston to cylinder clearance 0.050 ~ 0.060 (0.0020 ~ 0.0024) 0.120 (0.0047) Cylinder bore 57.000 ~ 57.015 (2.2441 ~ 2.2447) 57.080 (2.2473) Piston diam.
  • Page 180 SERVICING INFORMATION 7-16 CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT Compression pressure 11~13 kg/cm (at 500 rpm) 10 kg/cm Piston to cylinder clearance 0.03 ~ 0.04 (0.0012 ~ 0.0016) 0.1 (0.0040) Cylinder bore 44.000 ~ 44.015 (1.7323 ~ 1.7329) 44.080 (1.7354) Piston diam.
  • Page 181 7-17 SERVICING INFORMATION OIL PUMP ITEM STANDARD NOTE Oil pressure 0.5 kg/cm (at 65 , 3,000 rpm) 58/19 14/20 = 2.137 Oil pump reduction ratio OIL PUMP ITEM STANDARD NOTE Oil pressure 0.9 ~ 1.1 kg/cm (at 65 , 3,000 rpm) Oil pump reduction ratio 70/20 14/20 = 2.45 CLUTCH...
  • Page 182 SERVICING INFORMATION 7-18 TRANSMISSION + DRIVE CHAIN Unit : mm (in) ITEM STANDARD LIMIT Primary reduction ratio 3.053 (58/19) Secondary reduction ratio 3.286 (46/14) Gear ratio 2.462 (32/13) 1.556 (28/18) 1.190 (25/21) 0.957 (22/23) 0.840 (21/25) Shift fork to groove clearance 0.10 ~ 0.30 (0.004 ~ 0.012) 0.5 (0.020) Shift fork groove width...
  • Page 183 7-19 SERVICING INFORMATION CARBURETOR Unit : mm (in) ITEM SPECIFICATION Carburetor type MIKUNI BDS26 TYPE(DOUBLE) Bore size 1,450~1,550 r.p.m. Idle r.p.m. 17 (0.67) Float height Throttle cable play 0.5~1.0 (0.02 ~ 0.04) FRONT REAR Main jet (M.J.) 92.5 Main air jet (M.A.J.) Jet needle (J.N.)
  • Page 184 SERVICING INFORMATION 7-20 ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE Ignition timing 15 /2,000rpm ~ 30 /6,000rpm Type CR8E 0.7~0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E Spark performance Over 8mm (0.32) Ignition coil resistance 0.19 ~ 0.24 Primary...
  • Page 185 7-21 SERVICING INFORMATION SUSPENSION Unit : mm (in) ITEM STANDARD LIMIT Front fork stroke 120 (4.27) Front fork spring free length 433.3 (17.1) Front fork oil type TELLUS #22 Front fork oil level 146 (5.8) Front fork oil capacity (each leg) 2.5cc Rear wheel travel 110 (4.33)
  • Page 186 SERVICING INFORMATION 7-22 BRAKE+WHEEL Unit : mm (in) ITEM STANDARD LIMIT Rear brake pedal height 290 (11.4) [when one person riding from the ground] Brake disc thickness Front 4.0 (0.16) 3.0 (0.12) Rear 4.3 (0.17) 3.0 (0.12) Brake disc runout Front Rear 0.3 (0.012) Master cylinder bore...
  • Page 187: Wire And Cable Routing

    7-23 SERVICING INFORMATION WIRE AND CABLE ROUTING HEAD LAMP RELAY TURN SIGLAL RELAY FUSE BOX 09407-22402 HARNESS STARTER RELAY 45280-35000 09407-22402 CABLE COMP. SEAT LOCK BATTERY PLUS HARNESS 09407-22402 HARNESS REAR BRAKE S/W C.D.I UNIT WELDING CLAMP L/WIRE STARTER MOTOR REGULATOR BATTERY MINUS BATTERY MINUS...
  • Page 188 SERVICING INFORMATION 7-24...
  • Page 189 7-25 SERVICING INFORMATION...
  • Page 190 SERVICING INFORMATION 7-26...
  • Page 191: Wire And Cable Routing

    7-27 SERVICING INFORMATION WIRE AND CABLE ROUTING FUSE BOX TURN SIGLAL REALY 09407-14408 BATTERY PLUS STARTER RELAY HARNESS 45280-35000 09407-14408 CABLE COMP. SEAT LOCK 09407-14408 HARNESS HARNESS REAR BRAKE S/W WELDING CLAMP L/WIRE STARTER MOTOR C.D.I UNIT BATTERY MINUS FUEL GAUGE REGULATOR Rr.
  • Page 192 SERVICING INFORMATION 7-28...
  • Page 193 7-29 SERVICING INFORMATION...
  • Page 194 SERVICING INFORMATION 7-30...
  • Page 195: Wiring Diagram

    7-31 SERVICING INFORMATION WIRING DIAGRAM...
  • Page 196: Wiring Diagram

    SERVICING INFORMATION 7-32 WIRING DIAGRAM...
  • Page 199 Prepared by HYOSUNG MOTORS & MACHINERY INC. Overseas Technical Department 1st Ed. NOV. 2002. Manual No. 99000-94710 Printed in Korea...