Page 3: Table Of Contents
HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for GENERAL INFORMATION the VJF125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the INSPECTIONS / ADJUSTMENTS vehicle, carry out regular inspections according to the maintenance schedule (Section 2).
Page 4: General Information
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
Page 5 GENERAL INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
Page 6 GENERAL INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball be performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
Page 7 GENERAL INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
Page 8 GENERAL INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
Page 9 GENERAL INFORMATION •Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire •Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
Page 10 GENERAL INFORMATION •Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. •The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
Page 11 GENERAL INFORMATION •In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.
Page 12: Model Identification
GENERAL INFORMATION MODEL IDENTIFICATION TOOL BOX REAR CUSHION RADIATOR HELMET HOLDER CALIPER PILLION STEP BAR BRAKE DISK SIDE STAND MAIN STEP BAR GEAR SHIFT PEDAL MAIN STAND FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER...
Page 13 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 2,025mm OVERALL WIDTH 778mm OVERALL HEIGHT 1,180mm DIMENSIONS WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 139mm DRY WEIGHT 173kgf CURB WEIGHT 292kgf TYPE Double Cradle FRONT SUSPENSION / STROKE Telescopic / 130mm REAR SUSPENSION / STROKE Swingarm / 28mm FRONT TIRE SIZE (TYPE)
Page 14 GENERAL INFORMATION ITEM SPECIFICATIONS CLUTCH TYPE Multiplate Wet Clutch / 5 TRANSMISSION TYPE Constant Mesh GEAR RATIO 1st 3.200(37/12 T) DRIVE TRAIN GEAR RATIO 2.143(32/17 T) GEAR RATIO 1.438(29/21 T) GEAR RATIO 1.095(23/21 T) GEAR RATIO 0.923(24/26 T) GEARSHIFT PATTERN Left foot operated return system Down 1-N-2-3-4-5 Up IGNITION TYPE...
Page 15: Torque Values
GENERAL INFORMATION TORQUE VALUES ENGINE TORQUE THREAD DIA Q’TY REFERENCE ITEM (mm) kgf.m,(N.m) 1.0~1.2 CAM HOLDER BOLT(SHBOLT) Apply Engine Oil M6 1.0 CYLINDER HEAD SPECIAL SOCKET NUT 3.5~4.5 Apply Engine Oil M10 1.25 CYLINDER HEAD COVER BOLT 0.8~1.2 M6 1.0 CAM CHAIN TENSIONER PIVOT BOLT 0.8~1.2 M6 1.0...
Page 16 GENERAL INFORMATION FRAME THREAD DIA TORQUE Q’TY REFERENCE ITEM (mm) kgf.m,(N,m) REAR CALIPER BRACKET BOLT 2.8~3.4 M8×1.25 REAR MASTER CYLINDER HOLDER SOCKET BOLT 1.0~1.4 M6×1.0 FRONT AXLE NUT 5.5~6.5 M14×1.5 U- NUT FRONT BRAKE DISK BOLT 4.0~4.5 M8×1.25 3.0~4.0 BRAKE OIL BOLT (FRONT/REAR) M10×1.25 CALIPER BRACKET BOLT (FRONT/REAR) 2.8~3.4...
Page 17 GENERAL INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious vehicle part damage may result if instruction accident may result if instructions are not are not followed.
Page 18 GENERAL INFORMATION TOOLS SPECIAL COMMON DESCRIPTION REF. SEC. DESCRIPTION REF. SEC. CLUTCH CENTER HOLDER WRENCH, 8 9mm ACG ROTOR PULLER ADJUSTING WRENCH, B VALVE GUIDE DRIVER LOCK NUT WRENCH, 20 24mm VALVE GUIDE REAMER EXTENSION BAR 8, 14 UNIVERSAL BEARING PULLER FLY WHEEL HOLDER 8, 9 BEARING REMOVER SET...
Page 19: Wiring Diagram
GENERAL INFORMATION WIRING DIAGRAM 1-16...
Page 20 GENERAL INFORMATION 1-17...
Page 21 GENERAL INFORMATION 1-18...
Page 22 GENERAL INFORMATION 1-19...
Page 23 MEMO...
Page 24: Inspections/Adjustments
2. INSPECTIONS/ADJUSTMENTS · · · · · · 2-1 BRAKE SYSTEM · · · · · · · · · · · · 2-10 SERVICE INFORMATION MAINTENANCE SCHEDULE · ·· 2-3 BRAKE STOP SWITCH· · · · · · · · 2-11 FUEL LINE (FUEL TUBE) ·...
Page 25 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG 1.0~1.2kgf-m CYLINDER HEAD COVER BOLT 0.8~1.2kgf-m AC GENERATOR CAP 0.4~0.8kgf-m HOLE CAP 30mm 0.6~1.0kgf-m AIR CLEANER CASE COVER SCREW 0.4~0.8kgf-m REAR AXLE NUT 8.0~10.0kgf-m DRIVE SPROCKET BOLT 1.0~1.4kgf-m DRIVEN SPROCKET NUT 5.6~6.5kgf-m TOOLS WRENCH, 8×9mm COMPRESSION GAUGE...
Page 26: Maintenance Schedule
INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE • Perform the Self Inspections Before Operation at each scheduled maintenance period. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN A : ADJUST ODOMETER READING(NOTE 1) FREQUENCY 1000Km...
Page 27: Fuel Line (Fuel Tube)
INSPECTIONS / ADJUSTMENTS FUEL LINE (FUEL TUBE) • Check the connection between injector and fuel tube. • Check the fuel tube for deterioration, damage or leakage. Replace it if necessary. FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE INJECTOR...
Page 28: Air Cleaner
INSPECTIONS / ADJUSTMENTS AIR CLEANER SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS • Remove the seat. (⇨13-2) • Loosen the 4 screws, remove the air cleaner cover. AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER...
Page 29: Valve Clearance
INSPECTIONS / ADJUSTMENTS VALVE CLEARANCE “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK “T” MARK •Inspect and adjust valve clearance while the engine is cold.
Page 30: Cylinder Compression Pressure
INSPECTIONS / ADJUSTMENTS SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM SHIM •The type of shim is 33 •The clearance of shim is 1,500mm to 2,300mm with 0.025mm clearance.
Page 31: Drive Chain
INSPECTIONS / ADJUSTMENTS DRIVE CHAIN •Because there is a danger which fingers get jammed in the drive chain, never inspect or adjust it while the engine is running. DRIVE CHAIN SLACK ADJUSTMENT • Turn off the ignition switch, support the motorcycle CHAIN SLACK 10~20mm CHAIN SLACK 10~20mm CHAIN SLACK 10~20mm...
Page 32: Drive Chain Slider
INSPECTIONS / ADJUSTMENTS DRIVE CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER CHAIN SLIDER...
Page 33: Rear Brake Pads
INSPECTIONS / ADJUSTMENTS REAR BRAKE PADS • Check the brake pads for wear. • Replace the brake pads if either pad is worn to the bottom of wear limit groove. • Refer to page 16-7 for brake pad replacement. WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR...
Page 34: Brake Stop Switch
INSPECTIONS / ADJUSTMENTS BRAKE PEDAL HEIGHT ADJUSTMENT • Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT BRAKE HOSE JOINT...
Page 35: Side Stand
INSPECTIONS / ADJUSTMENTS • Minor adjustments are made using the upper adjuster at the clutch lever. LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...
Page 36: Suspension
INSPECTIONS / ADJUSTMENTS SUSPENSION •Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle's safety and operation efficiency. FRONT FORK • Hold the brake lever, and compress the front fork up and down several times to check the operating conditions.
Page 37: Wheel/Tire
INSPECTIONS / ADJUSTMENTS WHEEL/TIRE •Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE ㎏ /㎠ (kpa) ITEM FRONT WHEEL...
Page 38: Coolant Level Inspection
INSPECTIONS / ADJUSTMENTS COOLANT LEVEL INSPECTION • Erect the main stand prior to beginning work. • Check the coolant level and the reserve tank. • The level should be between the “UPPER” and “LOWER” level lines. • Fill the coolant to the reserve tank up to the “F” (upper level).
Page 39 MEMO...
Page 40: Lubrication
ENGINE OIL 1.5ℓ (After disassembly) 1.35ℓ (After Oil filter change) OIL CAPACITY 1.3ℓ (After Oil change) Daelim pure oil (4cycle motics 4) API service classification : SL grade RECOMMENDED Viscosity : SAE10W-40 (Use appropriate type of oil with viscosity satisfying the atmospheric temperature in your riding area based on the table shown on the right side.)
Page 41: Troubleshooting
LUBRICATION TROUBLESHOOTING Engine oil level too low •Oil consumption naturally. •External oil leaks. •Worn piston ring or incorrect piston ring installation. •Worn valve guide or seal. Oil contamination •Oil or filter not changed regularly. •Faulty head gasket. •Worn piston rings. Low or no oil pressure •Clogged oil orifice.
Page 42: Engine Oil Level Inspection
LUBRICATION ENGINE OIL LEVEL INSPECTION OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE...
Page 43: Oil Pump
LUBRICATION OIL FILTER ELEMENT CHANGE OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER OIL FILTER...
Page 44 LUBRICATION • Clean the oil pump body (inner and outer) and rotors with fresh cleaning oil. OUTER ROTOR OUTER ROTOR OUTER ROTOR INNER ROTOR INNER ROTOR INNER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR INNER ROTOR INNER ROTOR INNER ROTOR...
Page 45: Lubrication Points
LUBRICATION LUBRICATION POINTS Use general grease...
Page 46 MEMO...
Page 47: Fuel System
FUEL SYSTEM...
Page 48: Fuel System
4. FUEL SYSTEM SERVICE INFORMATION · · · · 4-1 FUEL TANK· · · · · · · · · · · · · · · · 4-3 TROUBLESHOOTING · · · · · · · · 4-2 AIR CLEANER CASE· · · · · · · · 4-4 SERVICE INFORMATION GENERAL SAFETY •...
Page 49 FUEL SYSTEM FULE TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK...
Page 50 FUEL SYSTEM AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE...
Page 51 MEMO...
Page 52: 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. AN ERROR CHECK LIST FOR EACH TERMINAL OF ECU 6.
Page 53: Caution When Repairing The Ems Parts
EMS(Engine Management System) 1.CAUTION WHEN REPAIRING THE EMS PARTS. • If the fuse is short-circuited, find out the cause and repair, replace with the fuse having the specified capacity. • Do not use the electlic wires or others instead of the fuse. •...
Page 54: 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 55: Terminal Arrangement Of The Ecu
EMS(Engine Management System) 3. TERMINAL ARRANGEMENT OF THE ECU ECU PIN NO. VS FUNCTION FUNCTION FUNCTION PIN NO. PIN NO. ECU Earth Third Gear Oxygen sensor Earth Crank Position Signal B Communication LOW Intake pressure sensor Earth TPS. ETS Earth Battery Power Engine KILL Intake pressure sensor power(5V)
Page 56: Wiring Diagram Of The Ecu
EMS(Engine Management System) 4. WIRING DIAGRAM OF THE ECU 5. AN ERROR CHECKLIST FOR EACH TERMINAL OF ECU ERROR Checklist ERROR Checklist PIN NO. PIN NO. Idle RPM Durability SCAN tool Idle RPM Durability SCAN tool Starting Driving Starting Driving Stability Stability communication...
Page 57 EMS(Engine Management System) 6. 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 58 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 off : MIL on/off...
Page 59: 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. Use the MIL in the speedometer and the diagnostic tool. First) Use the MIL in the Speedometer for checking. • Turn off the ignition key •...
Page 60: 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 61: Fault Codes Table
EMS(Engine Management System) FAULT CODES TABLE Fault MIL INDICATION Priority Description code no. (The number of blinks) order No failure Crank position sensor failure(CKP) 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)
Page 62: Ems Trouble Shooting
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 63 EMS(Engine Management System) 7.ECU(ELECTRONIC CONTROL UNIT) It is located inside a pillion seat SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK SEAT LOCK...
Page 64: Throttle Body
EMS(Engine Management System) 8. THROTTLE BODY Remove the seat support pipe. Remove the fuel tank. Loosen the screw securing air cleaner connecting tube band. Remove the throttle body and air cleaner. AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER...
Page 65 EMS(Engine Management System) DISCONNECT THE THROTTLE BODY INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR Remove the each component parts securing throttle body and check. THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY...
Page 66 EMS(Engine Management System) DISASSEMBLE THE INSULATOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR Disconnect injector cap bolt. MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR...
Page 67 EMS(Engine Management System) ASSEMBLY THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE...
Page 68 EMS(Engine Management System) 9.INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR Remove • Remove the fuel tank. CAUTION • The key is off before disassembly. • After push the injector coupler, pulling it upward.
Page 69 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. 5-18...
Page 70 EMS(Engine Management System) CHECKING PROCEDURE 1) Turn off the ignition key. 2) Check to see if the injector coupler has come loose or the wire is peeling off. If there is no problem, measured the resistance of injector. 3)Disassemble the injector coupler and measure the resistance between injector terminals. The resistance of injector : 14.5±0.7[ ], 20 Remarks : measuring unit for resistance : resistance ‘...
Page 71 EMS(Engine Management System) 10. MAPAT(Manifold Air pressure sensor, Temperature sensor) It is Located on the left side of the throttle body. Remove Remove the MAPAT sensor coupler. CAUTION MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR...
Page 72 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 73 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 74 EMS(Engine Management System) CHECKING OF INTAKE TEMPERATURE SENSOR 1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND) Remarks : Measuring value for resistance : Resistance[ The Voltage of air pressure;...
Page 75 EMS(Engine Management System) 11.TPS(THROTTLE POSITION SENSOR) It is located on the left side of throttle body. Remove Press the TPS coupler then remove it with pulling. CAUTION The key is off before disassembly. Remove the TPS screw 2EA MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR...
Page 76 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number is displayed by MIL Checking circuit The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key . 2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of TPS.
Page 77 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0~1.0[ ],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 78 EMS(Engine Management System) 12.ETS(ENGINE TEMPERATURE SENSOR) THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT THERMO STAT...
Page 79 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 50V SUPPLY VOLTAGE Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key .
Page 80 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 81 EMS(Engine Management System) 13.ISA(IDLE SPEED ACTUATOR) Remove Remove the ISA coupler CAUTION The key is off, before disassembly. Remove the injector cap firstly for dismantling the ISA. Remove the ISA screws. (2EA) Remove the ISA. Assemble Install in reverse order of removal. 5-30...
Page 82 EMS(Engine Management System) 1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT. Showing of defects codes by MIL CHECKING CIRCUIT 39 : FUEL PUMP CONTROL 33 : ISA CONTROL 40 : INJECTOR 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 .
Page 83 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 : BATTERY VOLTAGE[V]...
Page 84 EMS(Engine Management System) 14.O2(Oxygen) SENSOR It is located on the exhaust pipe CAUTION The key is off before disassembly. O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER...
Page 85 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 86 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 87 EMS(Engine Management System) 15.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 88 EMS(Engine Management System) 16.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 89 EMS(Engine Management System) 17.CKP(CRANK POSITION SENSOR) Remove - Remove the LH. side cover. - Remove the ACG coupler. - Remove the CKP coupler. CAUTION Before disassembly, the key is off. - Remove the LH. RR. cover. LH.REAR COVER - Remove the LH. crank case cover. LH.REAR COVER LH.REAR COVER LH.REAR COVER...
Page 90 EMS(Engine Management System) Check the fly wheel. Fly wheel for the EMS system have 10 spots on the fly wheel protrusion. It is different with carburetor type. Check the mark or contamination on the protrusion. △ CAUTION When replace the fly wheel, check the 10 spots of protrusion part.
Page 91 EMS(Engine Management System) CHECK THE CIRCUIT OF CKP ●Fault code number is displayed by MIL CHECKING CIRCUIT GREEN BLUE BLUE ECU PIN NUMBER 30 : CRANK SIGNAL-A 22 : CRANK SIGNAL-B CHECK PROCEDURE 1) Turn ON ignition key. 2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool. When start up the ENGINE SINK ON change “OFF’...
Page 92 EMS(Engine Management System) 4) Check if crank signal A,B wires is breaks or not. Remove the ECU, connect wire harness for inspection to wire harness of vehicle. Check the wiring of crank signal A - Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP.
Page 93: Fuel Pump
EMS(Engine Management System) 18.FUEL PUMP It is located inside a fuel tank Remove the seat. Loosen the washer bolt, 2 flange bolts securing fuel tank. Loosen the 4 socket bolts and remove the fuel filler cap. CAUTION The key is off before disassembly. Remove Loosen the 2 special screws.
Page 94 EMS(Engine Management System) 18.FUEL PUMP The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump) 5-43...
Page 95 EMS(Engine Management System) Check the fuel pump. Remove the fuel pump. Measure the resistance between terminals. The FLOAT position Terminals resistance [Ω] F : 192[mm] 30 ± 5[Ω] 1/2 : 138[mm] 300 ± 5[Ω] E : 74[mm] 566± 3[Ω] The float position is based on tank bottom plate. Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND) wire of fuel unit terminal ※...
Page 96: How To Use Scan
EMS(Engine Management System) 19.HOW TO USE SCAN ECU INITIALIZING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn on the lgnition key. Press the power button of the diagnostic tool. Press the enter button in the initial screen. Press the enter in the vehicle diagnosis screen.
Page 97 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. 5-46...
Page 98: Isa Pwm Adjusting
EMS(Engine Management System) ISA PWM 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. Press the button at the vehicle diagnostic screen.
Page 99: Ignition Timing Check
EMS(Engine Management System) IGNITION TIMING 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. Press the enter button on the vehicle diagnosis screen.
Page 100: Engine Rpm Check
EMS(Engine Management System) ENGINE RPM 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. Press the enter button on the vehicle diagnosis screen.
Page 101: Cooling System
COOLING SYSTEM...
Page 102: Cooling System
6. COOLING SYSTEM RADIATOR DISASSEMBLY · 6-5 SERVICE INFORMATION····6-1 CHECK THERMOSTATIC SWITCH · 6-6 STROUBLESHOOTING·····6-2 RADIATOR INSTALLATION · 6-6 COOLANT··········6-3 COOLING SYSTEM INSPECTION·6-3 WATER PUMP········6-7 COOLING SYSTEM TEST····6-4 TERMOSENSOR·······6-10 RADIATOR···········6-4 THERMOSTATIC·······6-10 SERVICE INFORMATION •Do not remove the radiator cap if the coolant temperature is over 100°C. •It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding.
Page 103 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high Faulty temperature gauge or thermo sensor Air in cooling system Faulty thermostat stuck (Thermostat stuck closed) Passages blocked in radiator, hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck (Thermostat stuck open) Faulty fan motor switch...
Page 104: Coolant Inspection
COOLING SYSTEM COOLANT COOLANT INSPECTION RADIATOR Radiator coolant mixes the distilled water. WATER Standard consistenly : 30~50% Coolant mixes the light water and radiator liquid COOLANT about 5°C of tolerance inrespect to the minimum temperature. RADIATOR COOLANT MIXTURE CHART (ANTICORROSIVE AND ANTIFREEZE) When the whole capacity of coolant is 2000cc Radiator coolant is toxic.
Page 105 COOLING SYSTEM COOLING SYSTEM TEST RADIATOR CAP Install the redicator cap onto the radiator tester. Press it with specified pressure and it must keep RADIATOR TESTER the pressure for at least six seconds. (SALE AT A MARKET) • Apply water to the cap sealing surface before the test.
Page 106 COOLING SYSTEM Loosen the hose band and disconnect the upper hose and lower hose from the radiator. Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE...
Page 107: Radiator Installation
COOLING SYSTEM CHECK THERMOSTATIC SWITCH REMOVAL When coolant temperature is lower than 83~87 the thermostatic switch OFF. When coolant temperature is over 88~92 thermostatic switch ON. Install the fan shroud on the radiator with the 2 COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH...
Page 108: Water Pump
COOLING SYSTEM Connect the overflow tube and tighten it securely with the tube clamp. Fill the radiator with coolant. Connect the vent tube to the radiator filler. After installation, check for coolant leaks. • The coolant must be filled up to the inlet. Put the transmission gear in neutral and start the engine.
Page 109 COOLING SYSTEM Loosen the 3 bolts and remove the water pump cover. WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER WATER PUMP COVER...
Page 110 COOLING SYSTEM Check the coolant checking hole. 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 O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING Check the water pump body and O-ring for damage and wear. CHECKING HOLE CHECKING HOLE CHECKING HOLE...
Page 111 COOLING SYSTEM ENGINE COOLANT TEMPERATURE GAUGE THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR THERMOSENSOR REMOVAL Remove RH.side cowl. Drain the coolant. Disconnect the engine coolant temperature gauge wire.
Page 112 COOLING SYSTEM THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT REMOVAL Disconnect the water hose from the thermostat cover. Remove the 2 bolts and separate the thermostat cover.
Page 113 ENGINE REMOVAL/INSTALLATION...
Page 114 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION· · · · · · · · · · · · 7-1 ENGINE INSTALLATION· · · · · · · · · · · · 7-3 ENGINE REMOVAL · · · · · · · · · · · · · · · · · · · · 7-2 SERVICE INFORMATION GENERAL SAFETY •Use a jack to remove or install the engine.
Page 115: Engine Removal
ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil. (⇨3-3) Remove the muffler. (⇨13-4) Remove the battery ground cable and clutch cable. Remove the throttlebody from the engine. Remove the RH. side cowl and LH.side cowl. RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP...
Page 116: Engine Installation
ENGINE REMOVAL/INSTALLATION Remove the 2 rear engine hanger bolts, then remove the LH. downtube comp. B. Remove the bolt and flange bolt securing engine hanger plate then remove the engine. FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS...
Page 117: Clutch/Gearshift
CLUTCH/GEARSHIFT...
Page 118 8. CLUTCH / GEARSHIFT SERVICE INFORMATION · · · · · · 8-1 GEARSHIFT SPINDLE· · · · · · · · TROUBLESHOOTING ····· 8-2 CLUTCH INSTALLATION· · · · · · · · 8-9 RH. CRANK· · · · · · · · · · · · · · · · · · 8-3 PRIMARY DRIVE GEAR·...
Page 119 CLUTCH/GEARSHIFT TROUBLESHOOTING Clutch working problem can be solved by adjusting a cable free play. Clutch leverworking is too hard Damaged, clogged or sticking clutch cable Damaged lifter mechanism Damaged clutch lifter plate bearing Incorrect wiring of clutch cable When gripping the clutch tightly, the vehicle moves Too big clutch lever free play Clutch plate warpage Clutch lock nut loose...
Page 120 CLUTCH/GEARSHIFT RH. CRANKCASE COVER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER CABLE HOLDER...
Page 121: Clutch Lever Installation
CLUTCH/GEARSHIFT CLUTCH LEVER INSTALLATION HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE Apply the grease to the new O-ring, and install it to the clutch lever. Install the clutch lever spring into the hole of the clutch lever ends.
Page 122 CLUTCH/GEARSHIFT Remove the lock washer. Remove the clutch inner assy. Remove the spline washer. CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER...
Page 123 CLUTCH/GEARSHIFT Measure the clutch spring free length; replace the springs if the measurement is not within the service limit. SERVICE LIMIT : 34.2mm •Replace the clutch disks and plates as a set.(4EA) CLUTCH SPRING CLUTCH SPRING CLUTCH SPRING CLUTCH SPRING CLUTCH SPRING CLUTCH SPRING CLUTCH SPRING...
Page 124 CLUTCH/GEARSHIFT GEAR SHIFT SPINDLE REMOVAL GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM...
Page 125 CLUTCH/GEARSHIFT INSTALLATION COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR COLLAR Install the collar, spring, drum stopper and bolt. Tighten the bolt. TORQUE : 1.2kgf·m SPRING STOPPER ARM STOPPER ARM STOPPER ARM STOPPER ARM...
Page 126: Clutch Installation
CLUTCH/GEARSHIFT CLUTCH INSTALLATION Coat the clutch outer guide with clean engine oil. OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE OUTER GUIDE...
Page 127: Primary Drive Gear
CLUTCH/GEARSHIFT Install the lock nut by pressing clutch center into the clutch center holder. TORQUE : 6.5kgf·m Install the bearing. PRIMARY DRIVE GEAR REMOVAL LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...
Page 128 CLUTCH/GEARSHIFT INSTALLATION OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR...
Page 129 CLUTCH/GEARSHIFT RH. CRANKCASE COVER WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR...
Page 130 MEMO...
Page 131 A.C GENERATOR / STARTER CLUTCH...
Page 132 9. A.C GENERATOR / FLY WHEEL SERVICE INFORMATION · · · · 9-1 STARTER CLUTCH · · · · · · · · · · 9-5 A.C GENERATOR· · · · · · · · · · · · 9-2 STARTOR·...
Page 133 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR REMOVAL LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH. REAR COVER LH.
Page 134 A.C GENERATOR / STARTER CLUTCH Remove the left crankcase cover bolts and left LH. CRANK CASE COVER LH. CRANK CASE COVER LH. CRANK CASE COVER LH. CRANK CASE COVER LH. CRANK CASE COVER LH. CRANK CASE COVER LH. CRANK CASE COVER LH.
Page 135 A.C GENERATOR / STARTER CLUTCH After installing the ACG rotor puller on the rotor, ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER...
Page 136: A.c.generator / Starter Clutch
A.C GENERATOR / STARTER CLUTCH STARTER CLUTCH SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS...
Page 137 A.C GENERATOR / STARTER CLUTCH STATOR REMOVAL / INSTALLATION WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE WIRE GUIDE...
Page 138 A.C GENERATOR / STARTER CLUTCH Install the woodruff key into the crank shaft key FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL groove.
Page 139 A.C GENERATOR / STARTER CLUTCH Replace the O-ring with new one and install the reduction gear cover. Cover the reduction gear cover and install the two bolts. Install the LH. crank cover bolt. TORQUE : 1.1kgf-m Connect the AC. generator wire coupler and gear change wire coupler.
Page 140 MEMO...
Page 141: Cylinder Head / Valves
CYLINDER HEAD / VALVES 10-0...
Page 142: Cylinder Head / Valves
10. CYLINDER HEAD / VALVES SERVICE INFORMATION 10-1 VALVE SPRINGS 10-6 TROUBLESHOOTING 10-2 VALVE GUIDES 10-7 CAMSHAFT 10-3 VALVE SEATS 10-8 CYLINDER HEAD 10-4 CYLINDER HEAD ASSEMBLY 10-8 SERVICE INFORMATION GENERAL SAFETY The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed from the frame to maintain the cylinder head.
Page 143 CYLINDER HEAD / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER TROUBLESHOOTING Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test, or by tracing noises to the top-end with a sounding rod or stethoscope. Rough idle Low comperssion Low cylinder compression...
Page 144 CYLINDER HEAD / VALVES CAMSHAFT SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG...
Page 145: Cylinder Head
CYLINDER HEAD / VALVES Remove the cam chain from the cam shaft. CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN...
Page 146: Cylinder Head Disassembly
CYLINDER HEAD / VALVES CYLINDER HEAD DISASSEMBLY Remove the cylinder head from cylinder. Remove the cylinder head gasket, dowel pin and cam chain guide. Remove the valve spring cotter, retainer, spring and valve using the valve spring compressor. Tool: Valve spring compressor To prevent the loss of tension, do not compress the valve springs more than necessary to remove the cotters.
Page 147: Valve Spring
CYLINDER HEAD / VALVES VALVE SPRING Measure the free length of valve spring. Service Limit : 40.0mm If any valve spring is shorter than the service limit, it must be replaced as a set. INTERVAL BETWEEN VALVE STEM AND VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal wear.
Page 148 CYLINDER HEAD / VALVES VALVE GUIDES REPLACEMENT Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating. Replace the cylinder head with the temperature of 130 - 140 . Do not heat the cylinder head beyond 150 . Unskillful operation can give the burns.
Page 149: Valve Seat Cutter
CYLINDER HEAD / VALVES VALVE SEATS INSPECTION / REFACE Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat serveral times with the valve guide reamer, without rotating the valve, to check for proper valve seat contact.
Page 150 CYLINDER HEAD / VALVES Install the valve springs with the narrow pitch forward to 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 FOR CYLINDER HEAD...
Page 151: Cylinder Head Installation
CYLINDER HEAD / VALVES CYLINDER HEAD INSTALLATION Clean any gasket material from the cylinder surface. Install the cam chain guide to the cylinder. Install the dowel pins and new gasket. Install the cylinder head. (Install in reverse order of removal) When install the ‘cylinder head special socket nut’...
Page 152 CYLINDER HEAD / VALVES Install the dowel pins on the cylinder head. 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 153: Cylinder / Piston
CYLINDER / PISTON 11-0...
Page 154: Cylinder / Piston
11. CYLINDER / PISTON SERVICE INFORMATION 11-1 PISTON / PISTON RING 11-3 TROUBLESHOOTING 11-1 CYLINDER INSTALLATION 11-6 CYLINDER REMOVAL 11-2 SERVICE INFORMATION GENERAL SAFETY Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins.
Page 155 CYLINDER / PISTON CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL...
Page 156 CYLINDER / PISTON WARPAGE INSPECTION Check the torsion of contact surface in gasket cylinder. SERVICE LIMIT : 0.100 mm PISTON REMOVAL Remove the piston pin clip. Take precautions not to allow the piston pin clip to drop into the crank case. Remove the top ring.
Page 157 CYLINDER / PISTON Insert the piston ring into the inside cylinder, check the piston ring clearance. SERVICE LIMIT TOP/SECOND: 0.5mm OIL RING : 1.10mm. Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder. PISTON RING PISTON RING PISTON RING...
Page 158 CYLINDER / PISTON PISTON / CYLINDER ASSEMBLY TOP RIDNG PISTON RING ASSEMBLY SECOND RING Clean the piston ring grooves and insert the piston rings. MARK WHITE PAINTING Be careful not to damage the piston and rings during assembly. Do not confuse the top and second rings. Space the ring end gaps 120 degrees apart.
Page 159 CYLINDER / PISTON CYLINDER INSTALLATION Install a new cylinder gasket and dowel pins. Coat the cylinder wall with clean engine oil and lubricate the piston rings and install the cylinder. Be careful not to damage the piston rings. Be careful not to drop the cam chain into the crankcase.
Page 160 MEMO...
Page 161: Crankcase / Transmission / Crankshaft
CRANKCASE/TRANSMISSION/CRANKSHAFT 12-0...
Page 162: Crankcase/Transmission/Crankshaft
12. CRANKCASE/TRANSMISSION/CRANKSHAFT SERVICE INFORMATION 12-1 CRANKCASE BEARING 12-7 TROUBLESHOOTING 12-2 CRANKSHAFT INSTALLATION 12-8 CRANKCASE DISASSEMBLY 12-3 TRANSMISSION ASSEMBLY 12-9 TRANSMISSION DISASSEMBLY 12-4 CRANKCASE ASSEMBLY 12-11 CRANKSHAFT 12-6 SERVICE INFORMATION GENERAL SAFETY To service the transmission, crank shaft and kick starter, the crankcase should be disassembled. Before disassembling the crankcase, the following parts must be removed.
Page 163 CRANKCASE/TRANSMISSION/CRANKSHAFT Unit: mm ITEM STANDARD VALUE SERVICE LIMIT CONNECTING ROD BIG END SIDE 0.050~0.300 0.600 CLEARANCE CONNECTING ROD BID END CRANKSHAFT 0~0.008 0.050 VERTICAL DIRECTION CLEARANCE RIGHT 0.100 CRANKSHAFT RUNOUT LEFT 0.100 TORQUE VALUES BEARING SETTING PLATE 1.2kgf m(12N m) CRANKCASE BOLT 1.1kgf m(11N m) TOOLS...
Page 164: Crankcase Disassembly
CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE DISASSEMBLY RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH.
Page 165 CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION DISASSEMBLY SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT...
Page 166 CRANKCASE/TRANSMISSION/CRANKSHAFT Check the shift drum for wear or damage. Check the shift drum guide groove for partial wear or damage. GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM GEAR SHIFT DRUM...
Page 167 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT REMOVAL Remove the transmission. Remove the crankshaft from the RH. crankcase using a hydraulic press. Remove the remaining bearings in the RH.crankcase with a driver handle and outer driver.
Page 168 CRANKCASE/TRANSMISSION/CRANKSHAFT Measure the connecting rod radial clearance in both X and Y directions. Replace the crankshaft if the service limit is exceeded. SERVICE LIMIT : 0.050 mm CRANKCASE BEARING REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm...
Page 169: Crankshaft Installation
CRANKCASE/TRANSMISSION/CRANKSHAFT RH. Crank Case Remove the main shaft bearing set plate. Remove the main shaft bearing, counter shaft bearing and crank shaft bearing from crankcase. Apply the new bearing with clean engine oil and install it into crankcase. Insert closely the cooling jet into crankcase. - Insert angle: 10 TOOLS : MAIN SHAFT / COUNTER SHAFT / CRANK...
Page 170: Transmission Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION ASSEMBLY C-1 GEAR COUNTER TRANSMISSION SHAFT C-3 GEAR C-4 GEAR C-5 GEAR C-2 GEAR DRIVE SPROCKET MAIN SHAFT M-3 GEAR M-4 GEAR M-5 GEAR M-2 GEAR Apply the gear and gear bush with clean engine oil and install the main shaft and counter shaft. COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT...
Page 171 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the main shaft and counter shaft on RH. crank case together. Check the marks on the shift forks. - L. fork : “L” mark - Center fork : “C” mark - R. fork : “R” mark RIGHT FORK RIGHT FORK RIGHT FORK RIGHT FORK...
Page 172: Crankcase Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE ASSEMBLY Install the dowel pins and a new gasket. RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH.
Page 173 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the below parts. - Clutch / RH. cover - Cylinder / Cylinder head - Flywheel / LH. cover Install the engine on the frame. ( Section 7) Pour the engine oil. Pour the coolant. Install of the cowl in the reverse order of removal. 12-12...
Page 174 MEMO...
Page 175: External Parts
EXTERNAL PARTS 13-0...
Page 176 13. SEAT / EXHAUST MUFFLER SERVICE INFORMATION 13-1 REAR WHEEL MUDGUARD 13-3 SEAT/SIDE COVER 13-2 MUFFLER/EXHAUST PIPE 13-4 REAR SEAT (PILLION SEAT) 13-2 FRONT FENDER 13-5 REAR COWL 13-3 REAR FENDER 13-3 SERVICE INFORMATION GENERAL SAFETY Beware of the muffler after driving or engine stop, as it is still hot to be burnt especially never children touch on it. 13-1...
Page 177: Side Cover Removal
EXTERNAL PARTS SIDE COVER / SEAT SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER...
Page 178: Rear Cowl
EXTERNAL PARTS REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL REAR COWL...
Page 179: Muffler/Exhaust Pipe
EXTERNAL PARTS MUFFLER/EXHAUST PIPE Do not service the exhaust system while it is hot. REMOVAL Remove the exhaust pipe and 4 muffler body mounting socket bolts. MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT MUFFLER MUFFLER...
Page 180: Front Fender
EXTERNAL PARTS INSTALLATION Install the removed parts in the reverse order of removal. Check the protrusion of the exhaust pipe stud bolt. Install the new exhaust pipe gasket onto the exhaust ports of the cylinder head. Install the new gasket onto the exhaust pipe. When install the muffler temporarily install the flange bolt to the damper stay and the hex cap nut then tighen the hex cap nut and the flange bolt.
Page 181: Front Wheel/Front Fork/Steering
FRONT WHEEL/FRONT FORK/STEERING 14-0...
Page 182: Front Wheel/Front Fork/Steering
14. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION 14-1 FRONT WHEEL 14-7 TROUBLESHOOTING 14-2 FRONT FORK 14-12 HANDLEBARS 14-3 STEERING STEM 14-20 SERVICE INFORMATION GENERAL SAFETY A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk with a brake degreasing agent.
Page 183: Special Tools
FRONT WHEEL/FRONT FORK/STEERING TOOLS SPECIAL TOOLS BALL RACE DRIVER STEERING STEM DRIVER FORK SEAL DRIVER STEERING STEM SOCKET COMMON TOOLS EXTENSION BAR DRIVER FORK SEAL DRIVER / BODY LOCK NUT WRENCH BEARING REMOVER SHAFT REMOVER HEAD ATTACHMENT PILOT TROUBLESHOOTING Hard steering Soft suspension Bearing adjustment nut too tight Weak springs...
Page 184: Handle Bars
FRONT WHEEL/FRONT FORK/STEERING HANDLE BARS HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP...
Page 185 FRONT WHEEL/FRONT FORK/STEERING Remove the 2pcs screws on the left handlebar switch. SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW Remove the winker switch. Loosen the 2pcs clutch lever bracket holder bolts. CLUTCH LEVER BRACKET CLUTCH LEVER BRACKET CLUTCH LEVER BRACKET...
Page 186 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION RH. HANDLE PIPE RH. HANDLE PIPE RH. HANDLE PIPE RH. HANDLE PIPE RH. HANDLE PIPE RH. HANDLE PIPE RH. HANDLE PIPE LH. HANDLE PIPE LH. HANDLE PIPE LH. HANDLE PIPE LH. HANDLE PIPE LH. HANDLE PIPE RH.
Page 187 FRONT WHEEL/FRONT FORK/STEERING Insert the throttle pipe to the handle bar. Wait 3-5 minutes and install the grip. Rotate the grip for even application of the adhesive. Clean the bonding surface to avoid oil, grease or gasoline from attaching. Leave in for minimum 1 hour until the bond it dried.
Page 188 FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP REMOVAL Loosen the brake hose clamp bolts and remove the clamp. Loosen the 2 flange bolts securing the bottom case and remove the caliper.
Page 189 FRONT WHEEL/FRONT FORK/STEERING Remove the dust seal. BEARING INSPECTION Turn the inner race of each bearing with finger. Bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. If the bearing is worn, replace the new one. Replace the bearing in pairs.
Page 190 FRONT WHEEL/FRONT FORK/STEERING WHEEL BEARING REPLACEMENT BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER Install the bearing remover head into the bearing. BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER BEARING REMOVER...
Page 191 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. WHEEL SIDE COLLAR FR. CASTING WHEEL RADIAL BALL BEARING FR. WHEEL AXLE GEAR BOX RETAINER RH. FR. BRAKE DISK OIL SEAL DUST SEAL SPEEDOMETER GEAR RADIAL BALL BEARING FR. DISTANCE COLLAR FR. TIRE LH. FR. BRAKE DISK SPEEDOMETER GEAR BOX ASSEMBLY Install the brake disk on LH.
Page 192 FRONT WHEEL/FRONT FORK/STEERING Align the wheel hub tangs with the slots of the gear box retainer, and assemble the speedometer gear box seal. Apply grease to the dust seal rim. Install the dust seal. INSTALLATION Place the front wheel between the front forks. Align the slot of the speedometer gear box with the tangs of the left fork slider.
Page 193 FRONT WHEEL/FRONT FORK/STEERING Install the RH/LH caliper and tighten the new mounting bolts to the specified torque. TORQUE : 3.0kgf m (30N m) CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER CALLIPER...
Page 194 FRONT WHEEL/FRONT FORK/STEERING DESASSEMBLY FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT...
Page 195 FRONT WHEEL/FRONT FORK/STEERING Remove the oil seal stopper ring. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING Pull the fork pipe out until you feel resistance from the slider bushing.
Page 196 FRONT WHEEL/FRONT FORK/STEERING Check components for damage or abnormal wear. BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE Replace defective parts with new ones.
Page 197 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. FORK BOLT DUST SEAL FORK PIPE FR. FORK SPRING OIL SEAL STOPPER RING OIL SEAL BACK UP RING GUIDE BUSH RH. BOTTOM CASE SEAT PIPE LH. BOTTOM CASE REBOUND SPRING OIL LOCK PIECE Before assembly, wash all parts with a non-flammable solvent and wip them dry.
Page 198 FRONT WHEEL/FRONT FORK/STEERING Wrap the bottom case with a piece of cloth, and fix it to the vise. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING...
Page 199 FRONT WHEEL/FRONT FORK/STEERING Pour the specified amount of automatic transmission fluid(ATF) into the fork pipe. CAPACITY : 245 2.5cc Slowly press the fork tube 2-3 times to discharge air. FORK OIL FORK OIL Install the fork spring to the fork tube. Install the spring with the smaller pitch side facing downward.
Page 200 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE...
Page 201 FRONT WHEEL/FRONT FORK/STEERING STEERING STEM FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
Page 202 FRONT WHEEL/FRONT FORK/STEERING RACE REPLACEMENT Replace the cone reces and ball races in pairs. Remove the top ball races bottom ball race from the steering head using the ball race dirver. TOOL : BALL RACE DRIVER Install the new ball races of the frame using the driver DRIVER and attachment.
Page 203 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION STEERING HEAD TOP THREAD TOP CONE RACE STEEL BALLS STEEL BALL RACE STEEL BALL RACE STEEL BALLS BOTTOM CONE RACE DUST SEAL WASHER STEERING STEM Apply grease to top and bottom ball races and install the steel ball assy. Instert the steering stem into the steering head pipe.
Page 204 FRONT WHEEL/FRONT FORK/STEERING Install the top bridge, washer and steering stem nut. Temporarily install the R/L front forks, then tighten the steering stem nut to the specified torque. TORQUE : 7.4 kgf m Install the front brake hose junction valve and tighten the flange bolts.
Page 205: Rear Wheel /Rear Suspension
REAR WHEEL/REAR SUSPENSION 15-0...
Page 206: Rear Wheel/Rear Suspension
15. REAR WHEEL/REAR SUSPENSION ···· 15-1 REAR CUSHION ······ 15-7 SERVICE INFORMATION SWINGARM········· 15-9 TROUBLESHOOTING····· 15-2 REAR WHEEL ········ 15-3 SERVICE INFORMATION SPECIFICATIONS Unit : mm ITEM STANDARD VALUE SERVICE LIMIT AXLE RUNOUT RADICAL REAR WHEEL RIM RUNOUT AXIAL REAR CUSHION SPRING FREE LENGTH TORQUE VALUES REAR BRAKE DISK BLOT 4.2㎏f·m...
Page 207 REAR WHEEL/REAR SUSPENSION TROUBLESHOOTING Wobble rear wheel Deformed rim Worn rear wheel bearing Damaged tire Axle not tightened properly Insufficient air in tire Worn rear fork bush Weak rear cushion Weak spring Incorrect rear damper Hard rear cushion Bent damper rod Rear cushion noise Loose fasteners 15-2...
Page 208: Rear Wheel
REAR WHEEL/REAR SUSPENSION REAR WHEEL REMOVAL Erect the motorcycle using a main stand. Loosen the chain adjust nuts and lock nuts. Remove the axle nut (U-nut). CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST CHAIN ADJUST...
Page 209 REAR WHEEL/REAR SUSPENSION REMOVAL Remove the side collar. Loosen the 5 disk bolts, remove the disk brake. Remove the oil-seal. SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR SIDE COLLAR...
Page 210 REAR WHEEL/REAR SUSPENSION Turn the each bearing. Replace it if damaged. REPLACEMENT BEARING Install the bearing remover into the bearing. install the bearing remover shaft at the opposite position, and remove the wheel bearing by heating with a hammer. After removing the distance collar, remove the other bearing.
Page 211 REAR WHEEL/REAR SUSPENSION Install the dust seal after applying the grease. Install the final driven sprocket. Install the rear wheel sleeve. TORQUE : 5.9 kgf·m REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE...
Page 212 REAR WHEEL/REAR SUSPENSION Install the axle nut temporary. By tightening the chain adjust nut, adjust the drive chain slack. (⇨2-8) Tighten the axle nut to the specified torque. TORQUE : 8.8 kgf·m AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT...
Page 213 REAR WHEEL/REAR SUSPENSION BUSHING REPLACEMENT Remove the pivot collar and 2 dust seals. Press out the bushing out of the rear cushion lower mount using the special tools. Install a new bushing into the lower cushion mount . Apply grease to the new dust seal lips, install them into the lower mount.
Page 214 REAR WHEEL/REAR SUSPENSION Install the rear cushion lower mounting bolt. Tighten the bolt to the specified torque. TORQUE : 4.0 kgf·m Install the rear wheel mudguard. SWINGARM REMOVAL Remove the rear wheel. (⇨15-3) Remove the mudguard mounting R/L (2EA) bolts and rear wheel mudguard.
Page 215 REAR WHEEL/REAR SUSPENSION DISASSEMBLY/INSPECTION Remove the upper and lower screws and chain slider. Check the chain slider for wear or damage. Remove the dust seal caps pivot distance center collar and bush. Check the dust seal caps, center collar and bush for wear or damage.
Page 216 REAR WHEEL/REAR SUSPENSION Install the dust seal caps into the swingarm. Install the drive chain slider on the swingarm, then tighten the screws. TORQUE : 0.6 kgf·m ( 6 N·m) SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER SLIDER...
Page 217: Hydraulic Brake
HYDRAULIC BRAKE FRONT : REAR : 16-0...
Page 218: Hydraulic Brake
16. HYDRAULIC BRAKE FRONT MASTER CYLINEDR· · · · 16-9 SERVICE INFORMATION· · · · · · · · 16-1 REAR MASTER CYLINDER· · · · · · 16-13 TROUBLESHOOTING· · · · · · · · · · · · 16-2 FRONT BRAKE CALIPER·...
Page 219 HYDRAULIC BRAKE TORQUE VALUES BRAKE CALIPER BRACKET BOLT (FRONT/REAR) 3.0㎏f·m BRAKE CALIPER BLEEDER VALVE (FRONT/REAR) 0.6㎏f·m BRAKE CALIPER HANGER PIN (FRONT/REAR) 2.3㎏f·m BRAKE PAD PIN BOLT (FRONT/REAR) 1.8㎏f·m BRAKE OIL BOLT (FRONT/REAR) 3.4㎏f·m MASTER CYLINDER RESERVE CAP SCREW 1.0㎏f·m BRAKE LEVER PIVOT BOLT 1.0㎏f·m BRAKE LEVER PIVOT LOCK NUT 1.0㎏f·m...
Page 220: Brake Fluid Replacement
HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP MASTER CYLINDER CAP...
Page 221 HYDRAULIC BRAKE <Rear brake> RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP...
Page 222 HYDRAULIC BRAKE BRAKE BLEEDING MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER MASTER CYLINDER...
Page 223: Brake Pad/Disk
HYDRAULIC BRAKE BRAKE PAD/DISK BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP...
Page 224 HYDRAULIC BRAKE Make sure the brake pad spring is in place. Install the new brake pads. Install the hanger pin. PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING...
Page 225 HYDRAULIC BRAKE Remove the hanger pins and brake pads. BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD...
Page 226: Front Master Cylinder
HYDRAULIC BRAKE BRAKE DISK INSPECTION Visually inspect the brake disk for damage or crack. Measure the brake disk thickness with a micrometer. SERVICE LIMIT : FRONT: 3.5mm REAR : 3.0mm Replace the brake disk if the smallest measurement is less than the service limit. Measure the brake disk runout with a dial indicator.
Page 227 HYDRAULIC BRAKE DISASSEMBLY Remove the handle lever bolt/nut and RH. handle lever assembly. Loosen the screw and remove the front brake stop STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH...
Page 228 HYDRAULIC BRAKE INSPECTION MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON...
Page 229 HYDRAULIC BRAKE Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER Dip the piston in brake fluid.
Page 230: Rear Master Cylinder
HYDRAULIC BRAKE INSTALLATION Place the master cylinder assembly on the handlebar. Install the master cylinder holder with the "UP" mark facing up. Tighten the upper bolt first, then the lower bolt. Install the oil bolt and new washer on brake hose. Tighten the brake hose oil bolt.
Page 231 HYDRAULIC BRAKE Remove the two main step holder socket bolts and main step bar assembly. Unhook the rear brake stop switch spring from the brake pedal spring. Remove the 2 master cylinder bolts. Remove the joint pin C. JOINT PIN JOINT PIN JOINT PIN JOINT PIN...
Page 232 HYDRAULIC BRAKE Remove the brake rod joint, rear piston and spring. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SPRING SPRING...
Page 233 HYDRAULIC BRAKE Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SPRING SPRING...
Page 234: Front Brake Caliper
HYDRAULIC BRAKE INSTALLATION JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C...
Page 235 HYDRAULIC BRAKE Avoid spilling fluid on painted, plastic, or rubber parts. Keep oil off the brake disk or pad, because the contaminated brake disk or pads reduce the braking performance if contaminated. Replace the pad with a new one and clean the disk. DISASSEMBLY Remove the pad spring, slide pin, caliper bracket and boot from the caliper body.
Page 236 HYDRAULIC BRAKE Check the appearance of piston for damage or scratches. Measure the piston O. D. SERVICE LIMIT : 24.87mm ASSEMBLY Clean the piston seal and dust seal with brake fluid, install it into caliper groove. When install the piston to the caliper the groove side of piston have to toward pad.
Page 237: Rear Brake Caliper
HYDRAULIC BRAKE INSTALLATION Install the front caliper to front fork. Tighten the caliper mounting bolts to the specified torque. TORQUE : 3.0kgf·m Install the brake hose to the caliper body with two new 2 oil bolts washers and oil bolts. Tighten the oil bolt to the specified torque.
Page 238 HYDRAULIC BRAKE Wrap the caliper with piece of cloth to avoid piston and brake fluid leakage and facing the piston downward. Remove the piston from the caliper while blowing the low piessure air in the opening of the brake hose. Do not use high perssure air or bring the airgun too close.
Page 239: Brake Pedal
HYDRAULIC BRAKE Install the piston in the caliper with groove side of the CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER PISTON SEAL PISTON SEAL PISTON SEAL CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER PISTON SEAL PISTON SEAL...
Page 240 HYDRAULIC BRAKE Strech and pull out the brake pedal joint cotter pin and COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN remove the joint pin C. COTTER PIN COTTER PIN COTTER PIN...
Page 241: Battery / Charging System
BATTERY/CHARGING SYSTEM BATTERY FUSE BOX REGULATOR/RECTIFIER AC GENERATOR IGNITION COIL ß /„Ø MAIN FUSE SWITCH (30A) ( 30A) B (CABLE) AC GENERATOR REGULATOR FUSE RECTIFIER BATTERY „Ł ¯˝ ‚ﬁ (15A) ( 15A) LOAD ”˛ ˙ˇ B..Black Y..Yellow G..Green R..Red W..White Lg..Light green 17-0...
Page 242: Battery/Charging System
17. BATTERY/CHARGING SYSTEM CHARGING DIAGRAM· · · · · · · · · · · · 17-0 CHARGING SYSTEM INSPECTION · · 17-4 SERVICE INFORMATION· · · · · · · · · · 17-1 REGULATOR/RECTIFIER · · · · · · · · 17-5 TROUBLESHOOTING·...
Page 243 BATTERY/CHARGING SYSTEM TROUBLESHOOTING No power (Key turned on) Low power (Engine running) Dead battery. Battery undercharged. - Low fluid level. Battery is failing. - Low specific gravity. Charging system failure. - Charging system failure. Intermittent power Disconnected battery cable. Main fuse burned out. Loose battery connection.
Page 244: Voltage Inspection
BATTERY/CHARGING SYSTEM BATTERY BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND BATTERY BAND...
Page 245: Charging System Inspection
BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECITION Turn the ignition switch off and disconnect the negative battery cable from the battery. Connect an ampere meter between negative (-) terminal and ground cable. With the ignition switch off, check for current leakage. LEAK CURRENT : Not to exceed 1mA TOOL : DIGITAL TESTER •When measuring current using a tester, set it to a high...
Page 246 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER HARNESS SIDE CIRCUIT INSPECTION Remove the seat. (⇨13-2) Remove the LH.
Page 247 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION Disconnect the regulator/rectifier coupler. Remove the regulator/rectifier unit mounting bolts and regulator/rectifier. Install the reguator/rectifier unit in the reverse order of removal. A.C. GENERATOR CHARGING COIL INSPECTION Remove the seat. (⇨13-2) Remove the LH. side cover. (⇨13-2) Disconnect the A.C generator cord coupler.
Page 248 MEMO...
Page 249 IGNITION SYSTEM BATTERY FUSE BOX REGULATOR/RECTIFIER IGNITION COIL AC GENERATOR 18-0...
Page 250: Ignition System
18. IGNITION SYSTEM IGNITION DIAGRAM· · · · · · · · · · · · 18-0 CRANK POSITION SENSOR INSPECTION· · 18-3 IGNITION COIL INSPECTION· · · · 18-4 SERVICE INFORMATION· · · · · · · · 18-1 SIDE STAND SWITCH ·...
Page 251 IGNITION SYSTEM TROUBLESHOOTING No spark at plug. (TOOL : PVA MUITI TESTER) UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. - Battery is undercharged 3. The sample timing of the tester and measured pulse were not Low peak voltage.
Page 252 IGNITION SYSTEM Inspection Items ITEM INSPECTION Check the battery voltage between main switch wire (black) and ground wire when the ignition is MAIN SWITCH Check the resistance of coil (between blue / yellow and green) is within the specified range. CRANK POSITION SENSOR ( 80~150Ω, 20℃) Check the resistance of coil (between black / yellow and green) is within the specified range.
Page 253: Ignition Coil Inspection
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 IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL...
Page 254 IGNITION SYSTEM REPLACEMENT Remove the high-tension cord from the plug, remove the plug cap. Remove the primary wire from the ignition coil. Loosen the ignition coil mounting bolt securing the frame, remove the ignition coil. Install in the reverse order of removal. SIDE STAND SWITCH REMOVAL Remove the RH side covver.
Page 255: Electric Starter
ELECTRIC STARTER STARTER STARTER MAGNETIC SWITCH B(CABLE) SWITCH STARTER FUSE MOTOR Lg/R SIDE STAND SWITCH B(CABLE) MAIN SWITCH FUSE GEAR POSITION SWITCH B..Black NEUTRAL BATTERY Y..Yellow LAMP (12A 10AH) G..Green R..Red W..White Lg/R Lg..Light green 19-0...
Page 256: Electric Starter
19. ELECTRIC STARTER DIAGRAM· · · · · · · · STARTING 19-0 STARTER MOTOR · · · · · · · · · · · · 19-3 SERVICE INFORMATION· · · · · · · · 19-1 STARTER MAGNETIC SWITCH · · 19-6 TROUBLESHOOTING ·...
Page 257 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn. Check for a blown out main fuse before servicing. Make sure the battery is fully charged and in good condition. Connect the starter motor (+) terminal to the “ON” , check for a With the ignition switch battery positive terminal.
Page 258: Starter Motor
ELECTRIC STARTER STARTER MOTOR REMOVAL With the ignition switch turned to "OFF", remove the negative cable at the battery before servicing the starter motor. Remove the rubber cap. Remove the nut and starter motor cable from the starter motor. Remove the starter motor mounting bolts and ground cable.
Page 259 ELECTRIC STARTER Check the commutator bars of the armature for discoloration. Discoloration of the commutator bars.→ Replace with a new one. Check for continuity between pairs of commutator bars. There should be continuity. Check for continuity between each commtator bar and armature shaft.
Page 260 ELECTRIC STARTER Check for continuity between the cable terminal and the case. There should be no continuity. Inspect the brushes for damage and measure the brush length. SERVICE LIMIT : 5 mm Install the following : - New O-ring - Insulators - Washer - Washer nut Install the brushes into the brush holder.
Page 261: Operation Inspection
ELECTRIC STARTER INSTALLATION Coat a new O-ring with oil and install it into the starter motor groove. Install the starter motor into the crankcase. Install the ground cable and mounting bolts, and tighten the bolts securely. Install the clutch wire holder. Install the starter motor cable, then tighten the terminal nut securely.
Page 262 ELECTRIC STARTER STARTER MAGNETIC SWITCH VOLTAGE INSPECTION Connect the starter magnetic switch connector. Shift the transmission into neutral. Measure the voltage between the Yellow/Red wire terminal(+) and ground (-). If the battery voltage appears only when the starter switch is pushed with the ignition switch to "ON", it is normal.
Page 263: Lights/Meter/Switches
LIGHTS/METER/SWITCHES WINKER RELAY HEADLIGHT RELAY FUSE BOX SPEEDOMETER HEADLIGHT BATTERY HORN 20-0...
Page 264: Troubleshooting
20. LIGHTS/SWITCHES/HORN SYSTEM LOCATION· · · · · · · ·20-0 MAIN SWITCH · · · · · · · · · · · 20-5 SERVICE INFORMATION· · · · ·20-1 HANDLEBAR SWITCHES · · · · 20-6 TROUBLESHOOTING · · · · · · 20-1 FRONT/REAR STOP SWITCH ·...
Page 265: Lights/Switches/Horn
LIGHTS/SWITCHES/HORN HEADLIGHT BULB REPLACEMENT Loosen the flange bolt secured front cowl stay. Remove the headlight, winker, speedometer coupler. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
Page 266: Front/Rear Winker
LIGHTS/SWITCHES/HORN FRONT/REAR WINKER BULB RREPLACEMENT Remove the screw and winker lens. FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER...
Page 267: Combination Meter
LIGHTS/SWITCHES/HORN COMBINATION METER REMOVAL Remove the side RH/LH cowl. Rempve the front cowl. Remove the inner pannel. SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL SUB PANNEL...
Page 268: Main Switch
LIGHTS/SWITCHES/HORN After installing, check to see if the each switch is working properly. connect the wire and cable accurately. MAIN SWITCH REMOVAL Remove the main seat Remove the fuel tank Remove the main switcs coupler HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER...
Page 269: Handlebar Switches
LIGHTS/SWITCHES/HORN HANDLEBAR SWITCHES HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER HAZARD STARTER SWITCH COUPLER...
Page 270: Front/Rear Stop Switch
LIGHTS/SWITCHES/HORN DIMMER SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH PASSING SWITCH...
Page 271: Gear Change Switch
LIGHTS/SWITCHES/HORN GEAR CHANGE SWITCH Remove the seat. (13-2) Remove the LH. side cover. (13-2) Disconnect the neutral switch connector from the switch. Shift the transmission into neutral and check for continuity between the green/white wire terminal and ground. There should be continuity with the transmission is in neutral, and no continuity when the transmission is into gear.
Page 272: Troubleshooting
21. TROUBLESHOOTING ENGINE WON’T START OR IS HARD TO START · · · · · · · · · · 21-1 POOR HANDLING· · · · · · · · · · · · · · · · 21-4 ENGINE LACKS POWER· · · · · · · · · · 21-2 POOR FRONT/REAR SUSPENSION PERFORMANCE·...
Page 273 TROUBLESHOOTING ENGINE LACKS POWER INSPECTION CAUSE OF TROUBLE 1. Check tire pressure. Pressure low Punctured tire. Faulty tire valve. Pressure normal 2. Raise wheels off ground and Wheel don’t rotate Dragged brake. rotate by hands. freely Worn or damaged wheel bearings. Lacked wheel bearings lubrication.
Page 274 TROUBLESHOOTING INSPECTION CAUSE OF TROUBLE 9. Check the spark plug. Lean fuel mixture. Contaminated or discolored Using spark plug with on incorrect heat Not contaminated or not range. discolored. 10. Check oil level. Level low or high Oil level too high. Oil level too low.
Page 275 TROUBLESHOOTING POOR PERFORMANCE(AT HIGH SPEED) INSPECTION CAUSE OF TROUBLE 1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment. valve clearance. Faulty ECU unit. Faulty pulse generator. Correct. 2. Disconnect fuel tube at Fuel flows No fuel to fuel tank. carburetor.
Page 276: Fuel Gauge
TROUBLESHOOTING POOR FRONT/REAR SUSPENSION PERFORMANCE INSPECTION CAUSE OF TROUBLE Cushion spring weak. 1. Suspension excessively soft. Overloaded. Damper oil leaks. 2. Suspension excessively hard. Fork pipe or cushion rod bent. 3. Noise from the suspension. Sliders stuck. Cushion stopper rubber damaged. FUEL GAUGE GAUGE READING INACCURATE (IGNITION SWTICH ON) INSPECTION...
Page 277 TROUBLESHOOTING GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON) INSPECTION CAUSE OF TROUBLE Fuse cut. 1. Operate the turn signal to check the Signal continuously Battery weak or totally discharged. battery circuit. operates dim or does not Ignition switch damaged or shorted. operate at all.
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Page 282: Wiring Diagram
22. WIRING DIAGRAM...
Page 283 WIRING DIAGRAM 22-1...
Page 286 22. WIRING DIAGRAM...
Page 287 SERVICE MANUAL 2009. 10 PRINTED 2009. 10 PUBLICATION...

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Roadwin 250r fi vjf125

DAELIM VJF125 Service Manual

Table of Contents

2. Inspections/Adjustments

Maintenance Schedule

Fuel Line (Fuel Tube)

Throttle Grip Operation

Air Cleaner

Spark Plug

Valve Clearance

Cylinder Compression Pressure

Service Information

2. Inspections/Adjustments

13. Seat / Exhaust Muffler

16. Hydraulic Brake

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Troubleshooting

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