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Sym HD 125 Service Manual

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Table of Contents
FORWARD
CONTENTS
HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATIONS
HD125 / 200
SERVICE MANUAL

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  • Page 1 FORWARD CONTENTS HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS HD125 / 200 SERVICE MANUAL...
  • Page 2 “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, HD 125 / 200, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
  • Page 3 HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG HD 125/200 motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 Homepage CONTENTS Page Content Index 1-1 ~ 1-18 GENERAL INFORMATION 2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 3-1 ~ 3-8 LUBRICATION SYSTEM 4-1 ~ 4-12 FUEL SYSTEM 5-1 ~ 5-8 ENGINE REMOVAL 6-1 ~ 6-14 CYLINDER HEAD/VALVE 7-1 ~ 7-8 CYLINDER/PISTON 8-1 ~ 8-14 “V”...
  • Page 5 Home page Contents MECHANISM ILLUSTRATIONS LH12W / LH18W Battery/CDI Front brake lever Oil lever / Oil filter Water pump AC. Generator Winker relay Horn Fuel unit Radiator Ignition coil Rear brake lever Luggage box Spark plug Fuel tank cap Front winker light Tail light/ Rear winker light Headlight...
  • Page 6: Table Of Contents

    Homepage Contents 1. GENERAL INFORMATION Symbols and Marks....... 1-1 Specifications........1-10 General safety........1-2 Torque Values ........1-11 Service Precautions ......1-3 Troubles Diagnosis ......1-13 Specifications ........1-9 Parts to Be Greased ......1-17 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
  • Page 7: General Safety

    To this chapter contents 1. GENERAL INFORMATION General safety Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you ¡...
  • Page 8: Service Precautions

    To this chapter contents 1. GENERAL INFORMATION Service Precautions Always use with Sanyang genuine parts and Never bend or twist a control cable to prevent recommended oils. Using non-designed parts unsmooth control and premature worn out. for Sanyang motorcycle may damage the motorcycle.
  • Page 9 To this chapter contents 1. GENERAL INFORMATION The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant cover plates or boxes is different from one before reinstallation, grind with a grindstone if another, be sure they are correctly installed. In the contact surface has any damage.
  • Page 10 To this chapter contents 1. GENERAL INFORMATION Lubricate the rotation face with specified After service completed, make sure all lubricant on the lubrication points before connection points is secured. assembling. Battery positive (+) cable should be connected firstly. And the two posts of battery have to be greased after connected the cables.
  • Page 11 To this chapter contents 1. GENERAL INFORMATION When separating a connector, it locker has to Insert the terminal completely. be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot. operation. Do not let boot open facing up. Secure wires and wire harnesses to the frame Do not pull the wires as removing a connector with respective wire bands at the designated...
  • Page 12 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness contact with rotating, Protect wires or wire harnesses with electrical moving or vibrating components as routing the tape or tube if they contact a sharp edge or harness.
  • Page 13 To this chapter contents 1. GENERAL INFORMATION Do not let the wire harness been twisted as With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering...
  • Page 14: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL LH18W-6 Overall Length 2064 mm Front Telescopic Fork Suspension System Overall Width 760 mm Rear Unit Swing Overall Height 1165 mm Front 100 / 80 – 16 50P/TL Tire Specifications...
  • Page 15: Specifications

    To this chapter contents 1. GENERAL INFORMATION Specifications MAKER SANYANG MODEL LH12W-6 Overall Length 2064 mm Front Telescopic Fork Suspension System Overall Width 706 mm Rear Unit Swing Overall Height 1165 mm Front 100 / 80 -16 50P/TL Tire Specifications...
  • Page 16: Torque Values

    To this chapter contents 1. GENERAL INFORMATION Torque Values The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference Type Type Tighten Torque Tighten Torque 5 mm bolt¡...
  • Page 17 To this chapter contents 1. GENERAL INFORMATION Frame Torque Values Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks Stopper nut for engine hanger 1.8~2.2 rubber Engine hanger nut 4.0~5.0 Engine hanger bolt 4.0~5.0 Engine connection bolt 3.5~4.5 Front wheel axle nut 5.0~7.0 Rear wheel shaft nut 10.0~12.0...
  • Page 18: Troubles Diagnosis

    To this chapter contents 1. GENERAL INFORMATION Troubles Diagnosis A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes Loosen carburetor drain bolt to check if there is gasoline inside the carburetor 1. No fuel in fuel tank 2.
  • Page 19 To this chapter contents 1. GENERAL INFORMATION B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed Air cleaner clogged Poor fuel supply Engine speed can be Engine speed can not be Lines in fuel tank evaporation system increased.
  • Page 20 To this chapter contents 1. GENERAL INFORMATION C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Abnormal Normal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor...
  • Page 21 To this chapter contents 1. GENERAL INFORMATION E. Clutch, driving and driving pulley PROBABLE CAUSES FAULT CONDITIONS Drive belt worn out or deformation Ramp plate of movable drive face damaged Engine can be started but Driving pulley spring broken motorcycle can not be moved. Clutch weights broken Drive slide-shaft gear groove broken Transmission gear damaged...
  • Page 22: Parts To Be Greased

    To this chapter contents 1. GENERAL INFORMATION Parts to Be Greased Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Seat catch Main stand pivot Speedometer gear/ Side stand pivot Rear wheel bearing front wheel bearing 1-17...
  • Page 23 To this chapter contents 1. GENERAL INFORMATION Note: 1-18...
  • Page 24 Home page Contents 2. MAINTENANCE INFORMATION Precautions in Operation ······················ 2-1 Brake Light Switch/Starting Inhibitor Switch ················································· 2-10 Periodical Maintenance Schedule ········ 2-2 Headlight Beam Distance ·················· 2-10 Fuel Lines / Cable ·································· 2-3 Clutch Disc Wear································ 2-10 Air Cleaner·············································· 2-4 Side Stand···········································...
  • Page 25: Periodical Maintenance Schedule

    To this chapter contents 2. MAINTENANCE INFORMATION Periodical Maintenance Schedule 1 Month 3 month 6 month 1 year 15 month Maintenance Every Item every every every every every Code 300KM 1,000KM 3,000KM 6000KM 12,000KM 14,500KM ¡ ¸ Air cleaner ¡ ¸ 2nd air jet leaner ¡...
  • Page 26: Fuel Lines / Cable

    To this chapter contents 2. MAINTENANCE INFORMATION Fuel Lines / Cable Fuel tank Vacuum hose Remove luggage box. Remove rear carrier. Remove body covers. Check all lines, and replace it when they are deterioration, damage or leaking. Warning Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
  • Page 27: Air Cleaner

    To this chapter contents 2. MAINTENANCE INFORMATION Air Cleaner 6 screws Air Cleaner Element Remove 6 screws from the air cleaner cover and then remove the cover. Remove 4 screws, and then remove the air 4 screws cleaner element. Caution The air cleaner element is made of paper so do not soap it into water or wash it with water.
  • Page 28: Valve Clearance

    To this chapter contents 2. MAINTENANCE INFORMATION Valve Clearance Timing mark Caution Checks and adjustment must be performed when the engine temperature is below 35¢ J . Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W.
  • Page 29: Carburetor Idle Speed Adjustment

    To this chapter contents 2. MAINTENANCE INFORMATION Carburetor Idle Speed Adjustment Ignition cable Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up.
  • Page 30: Ignition System

    To this chapter contents 2. MAINTENANCE INFORMATION Ignition System Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for checking whether CDI function is in normal or not. Remove right side cover. Remove ignition timing hole cap located in front upper side of engine right cover.
  • Page 31: Drive Belt

    To this chapter contents 2. MAINTENANCE INFORMATION Drive Belt Remove mounting bolt located under air cleaner. Remove 7 bolts of the engine left side cover and the cover. Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.
  • Page 32 To this chapter contents 2. MAINTENANCE INFORMATION Filling Out Brake Fluid Tighten the drain valve, and add brake fluid. Screws Operate the brake lever so that brake fluid Master cylinder cap contents inside the brake system hoses. Diaphragm plate Air Bleed Operation Upper Diaphragm Connect a transparent hose to draining valve.
  • Page 33: Brake Light Switch/Starting Inhibitor

    To this chapter contents 2. MAINTENANCE INFORMATION Make sure the brake lining condition. Replace Brake lining wear Lining limitation groove the lining if the brake lining wear limitation groove close to the brake disc. Brake Lining Replacement Compress the caliper and let the brake lining out of the caliper mounting plate.
  • Page 34: Side Stand

    To this chapter contents 2. MAINTENANCE INFORMATION Side Stand Check side stand spring for damage or looseness. Press down side stand and pull it with spring gauge. If gauge reading is over 2 kg, it means that the spring capacity is in normal. Check if side stand set is operated smoothly.
  • Page 35: Wheel/Tire

    To this chapter contents 2. MAINTENANCE INFORMATION Wheel/Tire Caution Tire pressure check should be done as cold engine. Check if tire surface is ticked with nails, stones or other materials. Appointed tire pressure Tire size Front tire Rear tire Load for Tire 1.75 2.25...
  • Page 36: Special Tools List

    To this chapter contents 2. MAINTENANCE INFORMATION Special Tools List NAME NAME NAME R/L. CRANK DISASS. TOOL CRANK SHAFT PULLER L. CRANK SHAFT BRG. DRIVER SYM-1120000-H9A SYM-1130000-H9A SYM-9100200-H9A (£ r 22mm) (£ r 30mm) CRANK SHAFT BRG. FIXING NAME NAME NAME CRANK CASE BUSH PULLER CRANK CASE BUSH PULLER...
  • Page 37 To this chapter contents 2. MAINTENANCE INFORMATION NAME NAME NAME INNER BEARING PULLER OUTER BEARING PULLER AC.G. FLYWHEEL PULLER SYM-6204002 SYM-6204001 SYM-3110A00 (12*20*5) (6901) WATER PUMP OIL SEAL WATER PUMP BEARING WATER PUMP MECHANICL NAME NAME NAME DRIVER DRIVER SEAL DRIVER SYM-9120500-H9A SYM-9100100 SYM-1721700-H9A...
  • Page 38 To this chapter contents 2. MAINTENANCE INFORMATION NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush (long) SYM-1130000-L SYM-1130010 SYM-1130031 NAME Extension bush (short) NAME NAME SYM-1130032 NAME NAME NAME NAME NAME NAME 2-15...
  • Page 39 To this chapter contents 2. MAINTENANCE INFORMATION Note: 2-16...
  • Page 40: Lubrication System

    Home page Contents 3. LUBRICATION SYSTEM Precautions in Operation ···················· 3-2 Engine Oil Strainer Clean ···················· 3-3 Troubleshooting ·································· 3-2 Oil Pump ··············································· 3-4 Engine Oil ············································· 3-3 Gear Oil ················································· 3-7 Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Spray Lubrication...
  • Page 41: Precautions In Operation

    To this chapter contents 3. LUBRICATION SYSTEM Precautions in Operation General Information: This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 1000 c.c. Change: 800 c.c. Oil viscosity SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly:...
  • Page 42: Engine Oil

    To this chapter contents 3. LUBRICATION SYSTEM Engine Oil Turn off engine, and park the motorcycle in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 43: Oil Pump

    To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) ¡ C Remove snap ring and take out oil pump driving chain and sprocket. Clip Make sure that pump shaft can be rotated freely. Remove 2 bolts on the oil pump, and then remove oil pump.
  • Page 44 To this chapter contents 3. LUBRICATION SYSTEM Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor.
  • Page 45 To this chapter contents 3. LUBRICATION SYSTEM Oil Pump Installation Install the oil pump, and then tighten bolts. Torque value¡ G 0.8~1.2kgf-m Make sure that oil pump shaft can be rotated freely. Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft.
  • Page 46: Gear Oil

    To this chapter contents 3. LUBRICATION SYSTEM Gear Oil Oil level inspection Park the motorcycle on flat surface with main stand. Turn off engine and remove oil inspection bolt. Gear oil Inspection Bolt Gear lubrication oil quantity has to be measured with measure device.
  • Page 47 To this chapter contents 3. LUBRICATION SYSTEM Notes:...
  • Page 48: Fuel System

    Home page Contents 4. FUEL SYSTEM Precautions in Operation....4-2 Auto By-Starter ........4-7 Trouble Diagnosis.......4-3 Float Chamber........4-8 Carburetor removal......4-4 Fuel Tank ..........4-10 Vacuum chamber ........4-4 Air Cleaner.......... 4-11 Air Cut-Off Valve .........4-6 To fuel vapor separator...
  • Page 49: Precautions In Operation

    To this chapter contents 4. FUEL SYSTEM Precautions in Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.
  • Page 50: Trouble Diagnosis

    To this chapter contents 4. FUEL SYSTEM Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system )
  • Page 51: Carburetor Removal

    To this chapter contents 4. FUEL SYSTEM Carburetor removal Throttle cable Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Disconnect automatic by-starter connector. Release the clamp strip of air cleaner. Air cleaner clamp Auto by-starter Air cleaner clamp...
  • Page 52 To this chapter contents 4. FUEL SYSTEM Check if the vacuum piston for wear out, crack or other damage. Check if the diaphragm for damage or crack. Installation Install needle, spring and needle seat to vacuum Needle seat Spring piston. Piston Needle Install vacuum piston to carburetor body and align...
  • Page 53: Air Cut-Off Valve

    To this chapter contents 4. FUEL SYSTEM Air Cut-Off Valve Inspection Disconnect vacuum hose and air vent hose from the air cut-off valve. Connect a hose from vacuum hose connector to vacuum pump. Connect air pump to air vent hose. Apply with specified vacuum to air cut-off valve.
  • Page 54: Auto By-Starter

    To this chapter contents 4. FUEL SYSTEM Auto By-Starter Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter. Resistance value: Max. 10£ [ (Measured after engine stopped for more than 10 minutes) Replace the auto starter with a new one if resistance value exceeds standard.
  • Page 55: Float Chamber

    To this chapter contents 4. FUEL SYSTEM Float Chamber 3 Screws Float Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the float pin and float. Checking Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
  • Page 56 To this chapter contents 4. FUEL SYSTEM Assembly Install main jet, fuel needle jet holder, fuel needle jet slow jet and pilot screw. Caution Set the pilot screw in according to number of turns noted before it was removed. Install the float valve, float, and float pin. Checking fuel level Caution Pilot screw...
  • Page 57: Fuel Tank

    To this chapter contents 4. FUEL SYSTEM Fuel Tank Fuel unit removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts).) Remove body cover. Disconnect fuel unit connector. Remove fuel unit (4 screws). Caution £...
  • Page 58: Air Cleaner

    To this chapter contents 4. FUEL SYSTEM Air Cleaner Clamp strip of air cleaner Removal Open the seat. Remove the luggage box (6 bolts and 1 screw). Loosen the clamp strip of air cleaner. Remove the Vapor hose. Remove the Air cleaner (2 bolts). Installation Install the tank in the reverse order of removal.
  • Page 59 To this chapter contents 4. FUEL SYSTEM Notes: 4-12...
  • Page 60: Engine Removal

    Home page Contents 5. ENGINE REMOVAL Precautions in Operation ....5-1 Removal of Engine Hanger Bush ..5-6 Removal of Engine ......5-2 Engine Hanger Installation ....5-7 Engine Hanger removal.......5-5 Engine Installation.........5-7 Precautions in Operation General Information The engine has to be supported with special service tools that can be lifted or adjustable. The following parts can be serviced as engine mounted on frame.
  • Page 61: Removal Of Engine

    To this chapter contents 5. ENGINE REMOVAL Removal of Engine Auto by-starter & AC. G. coupler Open seat and remove the luggage box (6 bolts and 1 screw). Remove rear carrier (4 bolts). Remove battery cover (2 screws). Remove battery negative (-) post. Remove battery positive (+) post.
  • Page 62 To this chapter contents 5. ENGINE REMOVAL Remove water hoses from water pump. Water hoses Water pump Remove the thermo-sensor wire. Thermo-sensor wire Remove the muffler (3 bolts, 2 nuts). 3 bolts 2 nuts Remove rear inner fender Right side Left side 2 Bolts 1 Bolt...
  • Page 63 To this chapter contents 5. ENGINE REMOVAL Remove the mounting bolt of right-rear cushion. 2 Bolts Remove the rear fork mounting bolt. (2 bolts) Remove rear wheel mounting nut. Rear wheel axle nut Remove rear fork and collars. Remove rear wheel. Remove the mounting bolt of left-rear cushion.
  • Page 64: Engine Hanger Removal

    To this chapter contents 5. ENGINE REMOVAL Remove the right and left side engine hanger Left side mounting bolts and nuts, then remove engine. Caution £ » Support engine and frame separately with special supporters to prevent from engine or frame falling down.
  • Page 65: Removal Of Engine Hanger Bush

    To this chapter contents 5. ENGINE REMOVAL Removal of Engine Hanger Bush Bush Check if engine hanger bush and cushion rubber bush for damage. Pressing out If engine hanger and the rear cushion rubber bush damaged. Then, with the bush remover / presser, Ø...
  • Page 66: Engine Hanger Installation

    To this chapter contents 5. ENGINE REMOVAL Engine Hanger Installation Install engine hanger onto engine. Install engine mounting bolts & nuts and then tighten the nuts. Torque value: 4.0~5.0kgf-m Engine Installation Check if the bush of engine hanger parts and cushion for damage.
  • Page 67 To this chapter contents 5. ENGINE REMOVAL Note:...
  • Page 68: Cylinder Head/Valve

    Home page Contents 6. CYLINDER HEAD/VALVE Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-8 Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-9 Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-11 Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-12 Cylinder Head Disassembly···············...
  • Page 69: Precautions In Operation

    To this chapter contents 6. CYLINDER HEAD/VALVE Precautions in Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. Specification Item Standard...
  • Page 70: Troubleshooting

    To this chapter contents 6. CYLINDER HEAD/VALVE Troubleshooting Engine performance will be effected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1.
  • Page 71: Cylinder Head Removal

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Removal Vacuum tube Clamp strip Remove seat, luggage box and body cover. Remove engine. (Refer to chapter 5) Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator.
  • Page 72 To this chapter contents 6. CYLINDER HEAD/VALVE Remove the 2 cylinder head mounting bolts from 4 Nuts 2 Insulator bolts cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Cylinder head mounting Remove the cylinder head. Remove 2 bolts of carburetor insulator and then take the insulator out.
  • Page 73: Cylinder Head Disassembly

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Disassembly Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts. Then, remove the cap. Remove the rocker arm pin stopper plate, and then screw a 5mm bolt into the rocker arm pin. Finally, remove the pin and the rocker arm.
  • Page 74: Cylinder Head Inspection

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge. Service limit: 0.5 mm Valve spring free length Measure the free length of intake and exhaust valve springs.
  • Page 75: Valve Stem Replacement

    To this chapter contents 6. CYLINDER HEAD/VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide.
  • Page 76: Valve Seat Inspection And Service

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Seat Inspection and Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 77 To this chapter contents 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width.
  • Page 78: Cylinder Head Reassembly

    To this chapter contents 6. CYLINDER HEAD/VALVE After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. Cylinder Head Reassembly Intake valve Lubricate valve stem with engine oil, and then insert the valve into valve guide.
  • Page 79: Cylinder Head Installation

    To this chapter contents 6. CYLINDER HEAD/VALVE Cylinder Head Installation Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts. Carburetor insulator Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole.
  • Page 80 To this chapter contents 6. CYLINDER HEAD/VALVE Tighten 4 nuts and washers on the cylinder head 4 Nuts 2 Insulator bolts upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover. Torque value: 2.0~2.4kgf-m Install and tighten spark plug Torque value: 2.0~2.4kgf-m Caution This model is equipped with more precision...
  • Page 81: Valve Clearance Adjustment

    To this chapter contents 6. CYLINDER HEAD/VALVE Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
  • Page 82: Cylinder/Piston

    Home page Contents 7. CYLINDER/PISTON Mechanism Diagram ······························ 7-1 Piston Removal ··································7-4 Precautions in Operation ······················ 7-2 Piston Ring Installation ·····················7-6 Trouble Diagnosis·································· 7-2 Piston Installation ······························7-7 Cylinder Removal··································· 7-3 Cylinder Installation ···························7-7 Mechanism Diagram...
  • Page 83: Precautions In Operation

    To this chapter contents 7. CYLINDER/PISTON Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification Unit¡ G mm LH12W & LH18W Item Standard Limit ID ( LA18W not included) 56.995~57.015 57.016 Cylinder...
  • Page 84: Cylinder Removal

    To this chapter contents 7. CYLINDER/PISTON Cylinder Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
  • Page 85: Piston Removal

    To this chapter contents 7. CYLINDER/PISTON Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 86 To this chapter contents 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 15.040 mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06 mm Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.
  • Page 87: Piston Ring Installation

    To this chapter contents 7. CYLINDER/PISTON Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
  • Page 88: Piston Installation

    To this chapter contents 7. CYLINDER/PISTON Piston Installation Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring. Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 89 To this chapter contents 7. CYLINDER/PISTON Notes:...
  • Page 90 Home page Contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Mechanism Diagram ··························· 8-1 Driving Belt···········································8-4 Maintenance Description ···················· 8-2 Drive Face·············································8-6 Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley··················8-9 Left Crankcase Cover ························· 8-3 Mechanism Diagram 3.5~4.5kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m...
  • Page 91: Maintenance Description

    To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Maintenance Description Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Driving belt and driving pulley must be free of grease. Specification Unit¡...
  • Page 92: Left Crankcase Cover

    To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Left Crankcase Cover Left crankcase cover removal Remove body cover. Remove air cleaner. (2 bolts) Remove L crankcase cover. (7 bolts) Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
  • Page 93: Driving Belt

    To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Driving Belt Removal Remove left crankcase cover Hold drive face with universal holder, and remove nut and drive face. Universal holder Hold clutch outer with universal holder, and remove nut and clutch outer. Caution Using special service tools for tightening or loosening the nut.
  • Page 94 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Installation Caution Pull out driven face to avoid it closing. Driven face Install driving belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.
  • Page 95: Drive Face

    To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Drive Face Removal Remove left crankcase cover. Hold generator flywheel with universal holder, and then remove drive face nut. Remove drive face. Universal holder Remove driving belt and movable drive face comp Movable drive face from crankshaft.
  • Page 96 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be effected. Check if rollers are worn or damaged.
  • Page 97 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Install movable drive face comp.
  • Page 98: Clutch Outer/Driven Pulley

    To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt and clutch outer/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much.
  • Page 99 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit.
  • Page 100 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Clutch weight Replacement Spring Driving plate Remove snap ring and washer, and then remove clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
  • Page 101 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 102 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Movable driven face Install the movable driven face onto driven face.
  • Page 103 To this chapter contents 8. V-BELT DRIVING SYSTEM/KICK STARTER Notes: 8-14...
  • Page 104: Final Driving Mechanism

    Home page Contents 9. FINAL DRIVING MECHANISM Mechanism Diagram ··························· 9-1 Inspection of Final Driving Mechanism ······························································· 9-4 Precautions in operation ···················· 9-2 Bearing Replacement ·························· 9-5 Trouble Diagnosis ······························· 9-2 Re-assembly of Final Driving Mechanism Disassembly of Final Driving Mechanism ·······························································...
  • Page 105 To this chapter contents 9. FINAL DRIVING MECHANISM Precautions in operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 110 c.c. (100 c.c. when replacing) Torque value Gear box cover 1.0~1.4kgf-m Tools Special tools Bearing (6203/6004UZ) driver: SYM-9620000 Bearing (6204) driver:...
  • Page 106 To this chapter contents 9. FINAL DRIVING MECHANISM Disassembly of Final Driving Mechanism Remove driven pulley. Drain gear oil out from gear box. Remove gear box cover bolts and then remove the cover and drive shaft. 7 bolts Counter shaft & gear Remove final gear and shaft.
  • Page 107 To this chapter contents 9. FINAL DRIVING MECHANISM Inspection of Final Driving Mechanism Check if the countershaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box. Bearing Oil seal Rotate each bearing’s inner ring with fingers.
  • Page 108: Bearing Replacement

    To this chapter contents 9. FINAL DRIVING MECHANISM Bearing Replacement Caution Never install used bearings. Once bearing removed, it has to be replaced with new one. Remove driving shaft bearing and counter shaft bearing from left crankcase using following tools: Special tool: Inner bearing puller Install new drive shaft bearing and counter shaft...
  • Page 109 To this chapter contents 9. FINAL DRIVING MECHANISM Install new final shaft seal. Oil seal driver Special tool: Oil seal driver (27*42*7) Install new final shaft bearing. Special tool: Bearing driver Bearing driver (6203/6004UZ) Press out the drive shaft from gear box cover. Inner bearing puller Using shaft protector as operation.
  • Page 110 To this chapter contents 9. FINAL DRIVING MECHANISM Install a new drive shaft bearing onto gear box cover. Special tool: Bearing driver (6204) Bearing driver Install a new final shaft bearing and counter shaft Bearing driver bearing onto gear box cover. Special tool: Bearing driver (6203/6004UZ) Bearing driver (6301)
  • Page 111 To this chapter contents 9. FINAL DRIVING MECHANISM Re-assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft. Final shaft Install countershaft, counter gear, final shaft and final driving gear. Final drive gear Countershaft Install dowel pin and new gasket.
  • Page 112 To this chapter contents 9. FINAL DRIVING MECHANISM Apply with grease onto new oil seal lip, and then Oil seal driver install the oil seal. Special tool: Oil seal driver (20*32*6) Install driven pulley/clutch outer/belt. Install movable drive face, drive face and left crankcase.
  • Page 113 To this chapter contents 9. FINAL DRIVING MECHANISM Notes: 9-10...
  • Page 114: Alternator

    Home page Contents 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram ··························10-1 Starting Clutch ··································· 10-4 Precautions in Operation···················10-2 Flywheel Installation·························· 10-7 Right Crankcase Cover Removal ······10-3 A.C.G. Set Installation························ 10-7 A.C.G. Set Removal····························10-3 Right Crankcase Cover Installation·· 10-7 Flywheel Removal ······························10-3 Mechanism Diagram 1.0~1.4kgf-m 5.0~6.0kgf-m 0.8~1.2kgf-m...
  • Page 115: Precautions In Operation

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Precautions in Operation General information Refer to chapter 5: Engine removal and installation Refer to chapter 16: The troubleshooting and inspection of alternator Refer to chapter 16: The service procedures and precaution items of starter motor Specification Item Standard value (mm)
  • Page 116: Right Crankcase Cover Removal

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Right Crankcase Cover Removal 9 bolts Remove 9 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. 2 bolts A.C.G. Set Removal Remove 2 mounted bolts from pulse generator and then remove it.
  • Page 117: Starting Clutch

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Remove the oil through guide pin from crankshaft. Pull out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Flywheel puller Starting Clutch Removal Remove starting driven gear. Remove mounting plate, starter reduction gear, and the shaft.
  • Page 118 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Starting Clutch Inspection Check the starting clutch gear for wear or damage. Measure the ID and OD of the starting clutch gear. Service Limit: ID: 20.1 mm OD: 42.10 mm Check the starting reduction gear and shaft for wear or damage.
  • Page 119 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Remove 3 hexagon bolts with air and hex socket wrenches. Disassembly Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Installation Install reduction gear shaft and reduction gear.
  • Page 120: Flywheel Installation

    To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Flywheel Installation Align the key on crankshaft with the flywheel groove, and then install the flywheel. Insert the oil through guide pin onto crankshaft. Make sure that there is no other material stock on it.
  • Page 121 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Install the water pump cover onto crankcase cover. Connect water hose to the right crankcase cover and water pump cover. 10-8...
  • Page 122 Home page Contents 11. CRANKCASE / CRANK Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3 General information ···························11-2 Crankshaft Inspection ······················· 11-5 Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6 Mechanism Diagram 1.2~1.6kgf-m 1.0~1.5kgf-m 0.8~1.2kgf-m 1.5~3.0kgf-m 11-1...
  • Page 123: General Information

    To this chapter contents 11. CRANKCASE / CRANK General information Operational precautions This Section concerns disassembly of the crankcase for repair purpose. Remove following components before disassembling crankcase. ¡ Ð Engine Section 5 ¡ Ð Cylinder head Section 6 ¡ Ð Cylinder and piston Section 7 ¡...
  • Page 124: Disassembly Of Crankcase

    To this chapter contents 11. CRANKCASE / CRANK Disassembly of crankcase Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the bolt and remove the tensioner. Cam chain setting plate 2 bolts Loosen 2 bolts on the right crankcase. 4 bolts Loosen 4 bolts on the left crankcase.
  • Page 125 To this chapter contents 11. CRANKCASE / CRANK Remove crank by left crank shaft. Refer to chapter 2: Special tools Special tool: R/L. crank case disassemble/install tool (SYM-1120000-H9A) Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface.
  • Page 126: Crankshaft Inspection

    To this chapter contents 11. CRANKCASE / CRANK Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.
  • Page 127: Assembly Of Crankcase

    To this chapter contents 11. CRANKCASE / CRANK Assembly of crankcase Special tool: R/L. crank case disassemble/install tool L. crank shaft bearing driver Crank shaft bearing fixing socket Crank shaft puller Clutch nut wrench The new bearing and bearing driver, puts on the left crank case.
  • Page 128 To this chapter contents 11. CRANKCASE / CRANK Install R/L. crank case disassemble/install tool on Crank shaft the left crank case. puller Again turns on crank shaft puller on the crankshaft spiral tooth. Caution Crank shaft puller lock into on as far as possible the crank spiral tooth, prevented pulls the bad crank spiral tooth.
  • Page 129 To this chapter contents 11. CRANKCASE / CRANK Tighten 4 bolts on the crankcase. 4 bolts Torque value: 0.8~1.2kgf-m Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal.
  • Page 130: Cooling System

    Home page Contents 12. COOLING SYSTEM Mechanism Diagram ··························12-1 System Test········································ 12-5 General Information ···························12-2 Radiator ·············································· 12-6 Trouble Diagnosis ······························12-2 Water Pump ········································ 12-8 Trouble Diagnosis for Cooling System Thermostat ········································· 12-12 ·····························································12-3 Thermo switch (fan) Mechanism Diagram Cooling fan Radiator filler cap Reserve tank Radiator filler cap...
  • Page 131: General Information

    To this chapter contents 12. COOLING SYSTEM General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.
  • Page 132 To this chapter contents 12. COOLING SYSTEM Trouble Diagnosis for Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any cooled down, open cap to Water leaking problem leakage? check the capacity of...
  • Page 133 To this chapter contents 12. COOLING SYSTEM Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was confirm voltage be Replace thermal switch operating after the changed (12¡ ÷ 0V)? temperature gauge over 3 checks? E-2.
  • Page 134: System Test

    To this chapter contents 12. COOLING SYSTEM System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low.
  • Page 135: Radiator

    To this chapter contents 12. COOLING SYSTEM Check reserve tank Remove the front cover, and then remove reserve tank filler cap. Check the liquid level in the reservoir. Add coolant to proper level if too low. Reinstall the reserve tank filler cap. Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in...
  • Page 136 To this chapter contents 12. COOLING SYSTEM Remove coolant outlet pipe and reserve tank pipe, Reserve tank pipe and then remove radiator and cooling fan. Coolant outlet pipe Disassembly Loosen the 4 bolts from the fan duct, and then remove the fan duct and radiator plate. Cooling fan Loosen the 4 bolts from the fan and remove the bolts x3...
  • Page 137: Water Pump

    To this chapter contents 12. COOLING SYSTEM Water Pump Check water pump seal / cooling system divulges inspection Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 138 To this chapter contents 12. COOLING SYSTEM Check any wear and damage of the mechanical Mechanical seal seal and inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Replacement of Mechanical Seal Water pump bearing Remove the inside bearing by inner bearing puller.
  • Page 139 To this chapter contents 12. COOLING SYSTEM Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Install a new outside bearing to the right Water pump bearing crankcase cover.
  • Page 140 To this chapter contents 12. COOLING SYSTEM Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and Water pump rotor tighten. Torque Value: 1.0~1.4kgf-m Caution The rotor is left thread.
  • Page 141: Thermostat

    To this chapter contents 12. COOLING SYSTEM Thermostat By-pass pipe Temperature sensor Please refer to chapter 17 for inspection of temperature sensor. Removal Remove the luggage box and body cover. Drain out the coolant. Disconnect the cable of temperature sensor. Disconnect the by-pass pipe.
  • Page 142 To this chapter contents 12. COOLING SYSTEM Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation. Caution Whenever the thermostat and the thermometer are in contact to the wall of heated water container, the reading displayed is incorrect.
  • Page 143 To this chapter contents 12. COOLING SYSTEM Notes: 12-14...
  • Page 144 Home page Contents 13. BODY COVER Mechanism Diagram ····················· 13-1 Rear carrier·····································13-9 Maintenance··································· 13-2 Body cover ·····································13-10 Front cover····································· 13-3 Inner box·········································13-11 Handle front cover························· 13-4 Floor panel ·····································13-12 Handle rear cover ·························· 13-5 Front fender····································13-13 Side cover ······································ 13-6 Rear fender·····································13-15 Front under spoiler ·······················...
  • Page 145: Maintenance

    To this chapter contents 13. BODY COVER Maintenance Body covers disassemble sequence: Handle front cover Front cover Seat & Luggage box Handle rear cover Front under spoiler Rear carrier Inner box Body cover Right front fender B Left front fender B Rear fender Front fender Center cover...
  • Page 146: Front Cover

    To this chapter contents 13. BODY COVER Front cover Remove Loosen 8 screw frome the front cover. 8 screws Loosen 2 screw bottom of front handle cover. 2 screws Remove headlight coupler, and then remove front cover. electric cord coupling Installation Install in reverse order of removal procedures.
  • Page 147: Handle Front Cover

    To this chapter contents 13. BODY COVER Handle front cover Disassembly Loosen 2 screws from handle rear cover rear side. 2 Screws Loosen 1 screw from front handle cover. Screw×1 Coupler Remove front winker light cord coupler. Remove the handle front cover. 13-4...
  • Page 148: Handle Rear Cover

    To this chapter contents 13. BODY COVER Handle rear cover Speedometer cable Remover Remove front cover. Remove speedometer cable. Disconnect each switch connectors. Each switch connectors Remove electric line coupler from the radiator. Coupler 2 Screws Loosen 2 screws from the handle rear cover. Loosen 1 screw from backside of the handle rear cover.
  • Page 149: Side Cover

    To this chapter contents 13. BODY COVER Side cover Remove Loosen 2 screws from the lift side cover. 2 screws Loosen 2 screws from the right side cover. 2 screws Remove the right & left side cover. Installation Install in reverse order of removal procedures. 13-6...
  • Page 150: Front Under Spoiler

    To this chapter contents 13. BODY COVER Front under spoiler Remove Remove front cover. Loosen 4 screw of the inner box side. 4 screws Loosen 2 screws from front side of the front under spoiler. 2 bolts Remove the front under spoiler. Installation Install in reverse order of removal procedures.
  • Page 151: Luggage Box

    To this chapter contents 13. BODY COVER Luggage box 4 nuts Remove Open seat. Loosen 4 nuts & 2 bolt of the luggage box. 2 bolts Loosen 1 screw from front side of the body cover. 1 screw Remove the luggage box. Installation Install in reverse order of removal procedures.
  • Page 152: Rear Carrier

    To this chapter contents 13. BODY COVER Rear carrier Remove Loosen 4 bolts from the rear carrier. 4 bolts Remove the rear carrier. Installation Install in reverse order of removal procedures. 13-9...
  • Page 153: 13. Body Cover

    To this chapter contents 13. BODY COVER Body cover Rubber Remove Remove luggage box and rear carrier. Remove the fuel tank cap and rubber. Fuel tank cap Loosen 2 bolts from the taillight underneath. 2 bolts Loosen 1 screw from the center cover. 1 screw Remove electric line coupler from the taillight and seat look cable.
  • Page 154: Inner Box

    To this chapter contents 13. BODY COVER Inner box Main switch cover Remove Remove the front cover. Loosen 1 bolt from the setting at hook and remove the hook. Remove main switch cover. 1 bolt Loosen 2 screws from the under spoiler. 2 bolts Remove the inner box.
  • Page 155: Floor Panel

    To this chapter contents 13. BODY COVER Floor panel Remove Loosen 4 screws from the right & left step bar. Remove the right & left step bar covers. 4 screws 2 bolts Loosen 2 screws from the right & left step bar, and then remove step bars.
  • Page 156: Front Fender

    To this chapter contents 13. BODY COVER Front fender Remove Remove right & left front fender B. (4 bolts) 4 bolts Upward pushes, after causes the tenon to fall off front, again takes out the front fender B. Caution When disassemble age must pay attention, whether the tenon is separated from.
  • Page 157 To this chapter contents 13. BODY COVER Use T flex socket wrench, remove front fender in upside bolt. (3 bolts) 3 bolts Downward presses the front fender, will cause it to be separated from the front cushion, and then take down to front.
  • Page 158: Rear Fender

    To this chapter contents 13. BODY COVER Rear fender Remove luggage box and seat. Remove rear carrier. Remove body cover. Remove fuel tank. Remove rear fender upper side bolts. (2 bolts) 2 bolts Remove rear fender. Installation Install in reverse order of removal procedures. Center fender Remove air cleaner.
  • Page 159 To this chapter contents 13. BODY COVER Note: 13-16...
  • Page 160 Home page Contents 14. BRAKE Mechanism Diagram-Front Disk Brake 14-1 Brake fluid replacement / Air-bleed···· 14-7 Mechanism Diagram-Rear Drum Brake 14-2 Disk Brake-Caliper ······························· 14-8 Maintenance Description ······················ 14-3 Brake Disk ············································ 14-9 Trouble Diagnosis ································· 14-4 Disk Brake - Master Cylinder ·············· 14-9 Disk Brake System Inspection ·············...
  • Page 161: Mechanism Diagram-Rear Drum Brake

    To this chapter contents 14. BRAKE Mechanism Diagram-Rear Drum Brake 14-2...
  • Page 162: Maintenance Description

    To this chapter contents 14. BRAKE Maintenance Description Operational precautions Caution Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake caliper can be removed without removing the hydraulic system.
  • Page 163: Trouble Diagnosis

    To this chapter contents 14. BRAKE Trouble Diagnosis Disk Brake Soft brake lever Uneven brake 1. Air inside the hydraulic system 1. Dirty brake lining/disk 2. Hydraulic system leaking 2. Poor wheel alignment 3. Worn master piston 3. Clogged brake hose 4.
  • Page 164: Disk Brake System Inspection

    To this chapter contents 14. BRAKE Disk Brake System Inspection Inspection By visual examination whether divulges or the damage, with spanner inspection brake tube seam whether becomes less crowded, and the inspection handle bar turn right or turn left, or pressure the cushion, whether besides the pipeline protection department, whether there is interferes, contacts other parts of.
  • Page 165: Adding Brake Fluid

    To this chapter contents 14. BRAKE Adding Brake Fluid Master cylinder Before the brake fluid reservoir is removed, turn the handle so that the brake fluid reservoir becomes horizontal, and then remove the brake fluid reservoir. When maintenance brake system, will be supposed to paint the surface or the rubber parts catches up by the rags.
  • Page 166: Brake Fluid Replacement / Air-Bleed

    To this chapter contents 14. BRAKE Brake fluid replacement / Air-bleed Air-bleed valve Connect drain hose to air-bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out. Close the drain valve and add specified brake fluid into the brake master cylinder.
  • Page 167: Disk Brake-Caliper

    To this chapter contents 14. BRAKE Disk Brake - Caliper Removal Place a container under the brake caliper, and loosen the brake hose bolt and finally remove the brake hose. Caution Do not spill brake fluid on painted surfaces. Brake hose bolt Remove two caliper bolts and the caliper.
  • Page 168: Brake Disk

    To this chapter contents 14. BRAKE Brake Disk Brake disk Inspection Visually check the brake disk for wear or break. Measure the thickness of the disk at several places. Replace the disk if it has exceeded the service limit. Allowable limit: 2.0 mm Micrometer Remove the brake disk from wheel.
  • Page 169 To this chapter contents 14. BRAKE Master Cylinder Inspection Check the master cylinder for damage or scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
  • Page 170 To this chapter contents 14. BRAKE Master Cylinder Install Install the rubber pad into the groove correctly. Place the master cylinder onto handlebar, and install the bolts. Install the brake lever, and connect leads to brake light switch. 2 bolts Connect brake hoses with 2 new washers.
  • Page 171: Rear Drum Brake

    To this chapter contents 14. BRAKE Rear Drum Brake Remove brake drum Remove wheel and brake drum. To use vacuum cleaner or other alternatives to avoid danger caused from dusts. Caution Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use compressed air or dry brush to clean brake parts.
  • Page 172 To this chapter contents 14. BRAKE Install brake lining Apply with a thin coat of grease to the brake cam Brake cam and the anchor pin. Install brake cam. Never allow brake linings to be contaminated by oil or grease. Wipe off the excessive grease from brake cam Lock pin and the anchor pin.
  • Page 173 To this chapter contents 14. BRAKE Notes: 14-14...
  • Page 174 Home page Contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Mechanism Diagram ··························15-1 Front Wheel ········································ 15-5 Operational Precautions ····················15-2 Front Cushion ···································· 15-8 Trouble Diagnosis ······························15-2 Steering Stem····································· 15-9 Steering Handle ··································15-3 Mechanism Diagram 4.0~5.0kgf-m 1.0~2.0kgf-m 0.2~0.3kgf-m 2.4~3.0kgf-m 4.0~4.5kgf-m 5.0~7.0kgf-m 15-1...
  • Page 175: Operational Precautions

    To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Operational Precautions General Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of the tire. Torque Values Nut for the front wheel axle 5.0 ~ 7.0kgf-m Nut for the steering handle 4.0 ~ 5.0kgf-m...
  • Page 176: Steering Handle

    To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Steering Handle Holder Removal Remove the handle front cover, handle rear cover and front cover. (Refer to chapter 13) Loosen the lock bolts for the master cylinder of the front brake.
  • Page 177 To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Installation Install handle and align with bolt hole. Install bolt and nut and then tighten it. Bolt Torque value: 4.5kgf-m Apply with grease onto throttle cable and the sliding surface of handle.
  • Page 178: Front Wheel

    To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Front Wheel Remove First by the bracket strut frame base, causes the front wheel to float off. Remove the speedometer cable. Turn loose the axle nut. Speedometer cable Shaft nut Pull out the front wheel axle.
  • Page 179 To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Wheel Place the wheel on to a rotation seat to check its rim wobbling. Turn the wheel with hand and measure its rim wobbling value with a dial gauge. Service limit: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
  • Page 180 To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Installation Open out brake lining with brake caliper. Place the front wheel between the front cushion. Wheel axle Caution Gear box groove Align the gear box groove with the stopper flange.
  • Page 181: Front Cushion

    To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Front Cushion Remove Remove front cover, front under spoiler and front fender. Remove front brake caliper. Remove front wheel. Remove front cushion upper mounting bolts, and then remove front cushion. 4 bolts Installation Align the cover flange with upper level of the...
  • Page 182: Steering Stem

    To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Steering Stem Remove Steering lock nut Remove handle, front wheel and front cushion. Remove the steering stem mounting nut. Remove top cone race and front fork. Caution Place the steel ball onto a parts container to prevent from missing.
  • Page 183 To this chapter contents 15. STEERING / FRONT WHEEL / FRONT CUSHION Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body. Torque value: 1.0~2.0kgf-m Steering lock nut Install in reverse order of removal procedures. Top cone-race Shake steering handle up &...
  • Page 184 Home page Contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Mechanism Diagram ··························· 16-1 Muffler ················································· 16-3 Operational Precaution ······················· 16-2 Rear Wheel ········································· 16-3 Trouble Diagnosis ······························· 16-2 Rear Cushion······································ 16-5 Mechanism Diagram 3.5~4.5kgf-m 2.4~3.0kgf-m 1.0~1.2kgf-m 4.0~5.0kgf-m 10.0~12.0kgf-m 3.2~3.8kgf-m 16-1...
  • Page 185: Operational Precaution

    To this chapter contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Operational Precaution General Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation of the tires. Service data Unit: mm Item Standard Allowable Limit...
  • Page 186: Muffler

    To this chapter contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Muffler Removal Loosen the 2 nuts from exhaust muffler front side. 2 nuts Loosen the 3 mounting bolts by exhaust muffler right side. Remove the exhaust muffler. Installation Install in reverse order of removal procedures.
  • Page 187 To this chapter contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Inspection Rear wheel rim Place the wheel rim on a rotational support. Rotate it by hand and measure the run-out with a dial indicator. Run-out limit: 2.0 mm Rear fork bearing Free play Rotate the inner ring of the bearing with a finger.
  • Page 188: Rear Cushion

    To this chapter contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Installation Install the rear wheel. Install the inside collar on the rear fork. Install the rear fork onto the rear wheel shaft. Mount the outside collar on the rear fork. Tighten the rear wheel shaft nut.
  • Page 189 To this chapter contents 16. REAR WHEEL / REAR FORK / REAR CUSHION Notes: 16-6...
  • Page 190: Electrical System

    Home page Contents 17. ELECTRICAL SYSTEM Mechanism Diagram ··························17-1 Meters················································17-11 Maintenance Data·······························17-2 Light / Bulb········································17-12 Technical Specification······················17-2 Switch / Horn·····································17-14 Trouble Diagnosis ······························17-3 Fuel Unit ············································17-17 Battery ·················································17-4 Cooling Fan Thermo Switch ············17-18 Charging System ································17-5 Thermo Unit ······································17-19 Ignition System···································17-8 Water Temperature Meter ················17-19 Starting System ··································17-10 Mechanism Diagram...
  • Page 191: Maintenance Data

    To this chapter contents 17. ELECTRICAL SYSTEM Maintenance Data Operational precaution When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) The model of the spark plug and the tightening torque. The ignition timing.
  • Page 192: Trouble Diagnosis

    To this chapter contents 17. ELECTRICAL SYSTEM Trouble Diagnosis No voltage Charging system does not operate Battery discharged properly The cable disconnected Burnt fuse The fuse is blown Poor contact, open or short circuit Improper operation of the main switch Poor regulator Poor ACG Low voltage...
  • Page 193: Battery

    To this chapter contents 17. ELECTRICAL SYSTEM Battery Removal Loosen 5 screws and remove the battery cover. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery from the motorcycle. 5 screws Voltage Check Use the digital voltmeter to check the voltage of the battery.
  • Page 194: Charging System

    To this chapter contents 17. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Green Black Yellow Yellow Fuse 20A Yellow Battery Yellow Regulator rectifier Auto by-starter AC. Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery.
  • Page 195 To this chapter contents 17. ELECTRICAL SYSTEM Connect a tachometer. Inspection on Charging Voltage Turn on the headlight to high beam and start the engine. Voltmeter Accelerate the engine to the specified revolution per minute and measure the charging voltage. Ammeter Specified Charging Current: 1.2 A / 6000 rpm...
  • Page 196 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the luggage box, rear carrier and body covers. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch...
  • Page 197: Ignition System

    To this chapter contents 17. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram CDI. Unit Green/white Green Black/yellow Black/white Black/red Ignition coil Blue/Yellow Main switch Spark plug Green Pulse generator Exciting coil C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result...
  • Page 198 To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Ignition Coil Remove the luggage box. Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Ω ± 10% Standard resistance: 0.17 Remove the cap from the spark plug and measure the resistance between the spark plug and the...
  • Page 199: Starting System

    To this chapter contents 17. ELECTRICAL SYSTEM Starting System Starting circuit diagram Main switch Battery Main fuse 20A Fuse 10A Starter relay Starter motor Brake switch Green/yellow Yellow/red Starter switch Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch.
  • Page 200: Meters

    To this chapter contents 17. ELECTRICAL SYSTEM Removal of Starter motor Remove the battery cover (5 screws). Disconnect the cable negative terminal (-), then the cable positive terminal (+). Remove the luggage box. Remove the air cleaner. Loosen the lock bolts and remove the starter 2 Bolts motor.
  • Page 201: Light / Bulb

    To this chapter contents 17. ELECTRICAL SYSTEM Light / Bulb Replacing bulb for headlight Remove the front cover. Headlight adjustment screw Disconnect the terminal coupler and the rubber Headlight Position light sleeve from the headlight. Headlight Position light Remove the bulb spring holder and the bulb. Replace with new bulb if necessary.
  • Page 202 To this chapter contents 17. ELECTRICAL SYSTEM Replacing the Front winker light Bulb Loosen fixing screws and remove the handle front cover (screw x 3). Replace with new front winker light bulb. Replacing Bulb of taillight Remove the taillight lens (2 screws). 2 Screws Replace taillight or winker light bulb.
  • Page 203: Switch / Horn

    To this chapter contents 17. ELECTRICAL SYSTEM Switch / Horn Main Switch Inspection Remove the front cover. Disconnect the main switch coupler. Check the continuity between two points as indicted below: BAT1 BAT2 Position LOCK Main switch Black / Wire Color Black Green White...
  • Page 204 To this chapter contents 17. ELECTRICAL SYSTEM Dimmer and Passing switch Dimmer and passing switch PASS Position PASSING Winker switch Horn switch Wire color Brown White / White Blue Dimmer and passing switch / White Green Winker switch Position FROM R Winker switch PUSH OFF Horn switch...
  • Page 205 To this chapter contents 17. ELECTRICAL SYSTEM Brake Switch While grasp the brake lever firmly, the terminals of white/green and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake switch Horn Remove the front cover. ³ â ¥ z Apply 12 V power source to two terminals of the horn, the horn should sound.
  • Page 206: Fuel Unit

    To this chapter contents 17. ELECTRICAL SYSTEM Fuel Unit Fuel unit Open the seat. Remove the luggage box. Remove the rear carrier. Remove the body cover. Disconnect the coupler of the fuel unit. Fuel unit coupler Remove the fuel unit (screw x 4). Caution Great care shall be taken not to damage or bend the float arm of the gauge.
  • Page 207: Cooling Fan Thermo Switch

    To this chapter contents 17. ELECTRICAL SYSTEM Cooling Fan Thermo Switch The thermo switch mounted on the radiator controls the operation of the cooling fan motor. In case that the fan motor fails to work, disconnect the green and black/blue leads and connect jump wires to the terminals, then, turn on the main switch, the fan motor should operate.
  • Page 208: Thermo Unit

    To this chapter contents 17. ELECTRICAL SYSTEM Thermo unit Remove the thermo unit. Hang the thermo unit in an oil heater, heat the oil and measure the resistance at each temperature. Temperature 50°C 80°C 100°C 120°C Standard (£ [ ) 134~149 47.5~57.0 26~29 14.8~17.2 Thermo unit Caution...
  • Page 209 To this chapter contents 17. ELECTRICAL SYSTEM Notes: 17-20...
  • Page 210: Electrical Diagram

    Home page Contents 18. ELECTRICAL DIAGRAM 18-1...
  • Page 211 Home page Contents 18. ELECTRICAL DIAGRAM Notes: 18-2...

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