Daelim VJF250 - Service Manual

HOW TO USE THIS MANUAL
This manual describes effective maintenance procedure for the VJF125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 2). Sections 1 through 2 provide information on overall vehicle; and section 3 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 21: Troubleshooting.
CONTENTS
GENERAL INFORMATION INSPECTIONS / ADJUSTMENTS LUBRICATION FUEL SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
EMS (Engine Management System)

COOLING SYSTEM ENGINE FRAME ELECTRICAL SYSTEM ENGINE REMOVAL CLUTCH / GEARSHIFT A.C.GENERATOR / STARTER CLUTCH CYLINDER HEAD / VALVES CYLINDER / PISTON
CRANKCASE / TRANSMISSION / CRANKSHAFT
Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM MOTOR.
EXTERNAL PARTS
FRONT WHEEL/FRONT FORK/STEERING
REAR WHEEL /REAR SUSPENSION HYDRAULIC BRAKE BATTERY / CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES TROUBLESHOOTING WIRING DIAGRAM
1. GENERAL INFORMATION
1
SERVICE INFORMATION SERVICE RULES CAUTION WHEN WIRING MODEL IDENTIFICATION SPECIFICATIONS 1-1 1-1 1-5 1-9 1-10 TORQUE VALUES SYMBOLS / ABBREVIATIONS TOOLS WIRING DIAGRAM 1-12 1-14 1-15 1-16
SERVICE INFORMATION
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children) 3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops. 4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark. 5. When more than two person are working, always pay attention to other workers action and always have safety in mind. 6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash carefully with soap and water after handling. 7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc. 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 recommended parts. 2. Before maintenance, remove deposit or dust from the chasis.
1-1
GENERAL INFORMATION
3. Store the parts of each system discriminatively to install each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation.
6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing.
7. Align the bolts to uniform the tightening points before tightening them when you dont know the bolt length.
8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque.
9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils.
10. Recommended grease must be applied to or filled in the specified place.
1-2
GENERAL INFORMATION
11. Maintenance needed to use the specialized tools must be performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing.
13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually. Replace the ball bearing having excessive axial/ longitudinal hanging. Wipe the ball bearing likely to have hanging with cleaning oil.(except double-sided sealed type ball bearing) Replace the ball bearing of which press-fitted part is slacked at the case or shaft.
14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle.
SINGLE-SEALED TYPE DOUBLE-SEALED TYPE
OPEN TYPE
MANUFACTURERS NAME, BEARING No.
15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing.
16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring.
SNAP RING
CHAMFERED EDGE
17. Check each part for proper tightening and operation after installation.
18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact.
1-3
GENERAL INFORMATION
19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil) Pay attention not to bend or damage the lip. Apply the grease to the lip. 20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end.
CAVITY MANUFACTURERS NAME CLIP FITTING
21. Keep the pneumatic system interior or the engine interior from the infiltration of dust.
22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage.
24. Install the boots with the installing groove by inserting the boots into the groove.
BOOTS
1-4
GENERAL INFORMATION
CAUTION WHEN WIRING

Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. Identify the two-colored cord by main color first and then spriped color . When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler.
TESTER PLUG RED STRIPE
BLACK TUBE
WHITE TUBE
WHITE COUPLER. WHITE
BLACK CORD
RED STRIPE
Recheck the condition of contact, securing and continuity of each part after maintenance. When connecting the battery, the plus terminal must be connected first. After connecting the terminal, apply the grease to the terminal.
WHITE / RED CORD
When disconnecting the battery, the minus terminal must be disconnected first. Make sure that the tool such as spanner do not contact with the frame.
Connect covers to the terminal after maintenance.
If the fuse is short-circuited, find out the cause and repair. Replace with the fuse having the specified capacity.
If there is rust in the terminal, remove the rust with sand paper prior to connecting.
VALIDATION OF CAPACITY!
REMOVE THE RUST!
1-5
GENERAL INFORMATION
Turn off the main switch before connecting/disconnecting. Release the lock to disconnect the lock of the coupler. 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. - Typical releasing method of the coupler is illustrated in the following. When disconnecting the coupler, disconnect it while holding the coupler body. Pull while holding the wire harness cord and do not remove the coupler connection.
Insert the lock of the coupler until the lock is fully secured.
Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler.
Pay attention not to damage the vinyl cover of the coupler.
Check to see if there is bended terminal and secure it to avoid disconnecting.
If the wire harness coating is damaged, repair by winding vinyl tape or replace it. Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened.
1-6
GENERAL INFORMATION
Insert the connector until the vinyl cover is fully inserted into the terminal. The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction. When removing T-start, broaden the groove of T-start using the wiring driver and release the torque. Connect the harness and the hose to T-start and then insert until the groove is locked. When removing T-start from the frame, replace it with the new one.
DRAINING HOLE
WIRING DRIVER
GROOVE SIDE
Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part.
Secure the wire harness firmly using the clamp.
In case of the weld clamp, do not clamp in the welded part.
When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part.
When clamping the wire, pay attention not to contact with hot part.
The wire harness must be routed without contacting with the end of the lamp or any sharp edge. The wire harness must be routed without contacting with the end of the bolt or the piece.
1-7
GENERAL INFORMATION
In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. The wire must not hang down or be pulled excessively.
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.
Do not twist the wire harness.
Wire the wire harness not to be pulled or expanded when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine.
Prior to using the tester, please read the manual carefully and understand the contents. When testing the resistance of the tester, the zero adjustment must be performed before testing.
Is this measurement range or configuration in accord with the manual?
Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop.
1-8
GENERAL INFORMATION
MODEL IDENTIFICATION
TOOL BOX REAR CUSHION RADIATOR HELMET HOLDER CALIPER
BRAKE DISK GEAR SHIFT PEDAL MAIN STAND SIDE STAND
PILLION STEP BAR MAIN STEP BAR
ENGINE ENGINE ENGINE SERIAL SERIAL SERIAL NUMBER NUMBER NUMBER
FRAME SERIAL SERIAL NUMBER NUMBER FRAME
ENGINE SERIAL NUMBER LOCATION

The engine serial number is stamped on left crankcase.
FRAME SERIAL NUMBER LOCATION

The frame serial number is stamped on the left side of steering head.
1-9
GENERAL INFORMATION
SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS
OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT CURB WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE (TYPE) REAR TIRE SIZE (TYPE) TIRE PRESSURE 1 PERSON FRONT REAR 2 PERSON FRONT REAR FRONT BRAKE REAR BRAKE FUEL CAPACITY FUEL RESERVE CAPACITY CASTER ANGLE TRAIL FRONT FORK OIL CAPACITY TYPE CYLINDER NUMBER, ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY
2,025mm 778mm 1,180mm 1,380mm 780mm 139mm 173kgf 292kgf Double Cradle Telescopic / 130mm Swingarm / 28mm 110/70-17 54P (Tubeless) 140/60-17 69P (Tubeless) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.25kgf/cm2(225kPa) Hydraulic Disk Hydraulic Disk 14.85 4.0 25.2 93.5mm 2652.5cc Liquid 4-stroke DOHC(4 Valve) 1 Cylinder, 20 Inclined from vertical 56.5 X 49.5mm 124.1cm3 11.8:1 DOHC Chain Drive 1.5 After Disassembly 1.35After Draining and Oil Filter Change 1.3 After Draining Wet Pressing and Spray Paper Filter 13.0kgf/cm2 (600rpm) 23 BTDC 55 ABDC (1.12mm Lift) 66.3 BBDC 23.6 ATDC (1.12mm Lift) 0.150.02mm 0.200.02mm 32.0kgf
FRAME
ENGINE
LUBRICATION SYSTEM AIR FILTRATION TYPE CYLINDER COMPRESSION INTAKE VALVE OPEN CLOSED EXHAUST VALVE OPEN CLOSED VALVE CLEARANCE INTAKE (A COOLING-OFF PERIOD) EXHAUST ENGINE DRY WEIGHT
1-10
GENERAL INFORMATION
ITEM
SPECIFICATIONS
DRIVE TRAIN
CLUTCH TYPE TRANSMISSION TYPE GEAR RATIO 1st GEAR RATIO 2nd GEAR RATIO 3rd GEAR RATIO 4th GEAR RATIO 5th GEARSHIFT PATTERN
Multiplate Wet Clutch / 5 Constant Mesh 3.200(37/12 T) 2.143(32/17 T) 1.438(29/21 T) 1.095(23/21 T) 0.923(24/26 T) Left foot operated return system Down 1-N-2-3-4-5 Up Full Transisterized 18 BTDC / 1,600(rpm) 30 BTDC / 8,500(rpm) 12V-17A/5,000(rpm) 12V 10AH CR9EH - 9 0.8 - 0.9mm 30A Starter Motor 55W/55W 5W 10W4 21W/5W 3W LED1 LED LED 5W LED1 LED
ELECTRICAL
IGNITION TYPE IGNITION TIMING F MARK FULL ADVANCE AC GENERATOR BATTERY CAPACITY SPARK PLUG SPARK PLUG GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT (HIGH/LOW BEAM) POSITION LAMP TURN SIGNAL LAMP STOP/TAIL LIGHTS SPEEDOMETER LAMP NEUTRAL INDICATOR LAMP HIGH BEAM INDICATOR LAMP WINKER INDICATOR LAMP LICENCE PLATE LAMP TACHOMETER LAMP MALFUNCTION INDICATOR LAMP
1-11
GENERAL INFORMATION
TORQUE VALUES
ENGINE
ITEM QTY THREAD DIA (mm) TORQUE kgf.m,(N.m) REFERENCE
CAM HOLDER BOLT(SHBOLT) CYLINDER HEAD SPECIAL SOCKET NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARING SET PLATE BOLT OIL FILTER COVER SOCKET BOLT SHIFT DRUM STOPPER ARM BOLT DRIVE SPROCKET BOLT R.CRANKCASE COVER BOLT OIL FILTER COVER BOLT L.CRANKCASE COVER BOLT A.C GENERATOR CAP CRANKSHAFT HOLE CAP CRANKCASE BOLT SPARK PLUG START MOTOR NUT TAPPET ADJUST HOLE CAP ENGIN TEMPERATURE SENSOR
8 4 4 1 2 1 1 1 1 3 2 3 1 2 12 1 7 1 1 10 1 1 1 1
M61.0 M101.25 M61.0 M61.0 M61.0 M61.0 M161.0 M161.0 M121.25 M81.25 M61.0 M101.25 M61.0 M61.0 M61.0 M61.0 M61.0 M141.5 M301.5 M61.0 M101.25 M61.0 M361.5 M121.25
1.0~1.2 3.5~4.5 0.8~1.2 0.8~1.2 1.0~1.4 0.35~0.5 6.0~7.0 6.0~7.0 5.0~6.0 3.0~3.4 1.0~1.4 1.0~1.4 1.0~1.4 1.0~1.4 1.0~1.2 1.0~1.2 1.0~1.2 0.4~0.8 1.0~2.0 1.0~1.2 1.0~1.2 1.0~1.4 1.0~2.0 1.0~2.0
Apply Engine Oil Apply Engine Oil
Apply Engine Oil Apply Engine Oil Apply Engine Oil Remove negative screw Remove negative screw
FRAME
ITEM QTY THREAD DIA (mm) TORQUE kgf.m,(N.m) REFERENCE
REAR ENGIN HANGER BOLT(UPPER) REAR ENGIN HANGER BOLT(UNDER) FRONT ENGIN HANGER BOLT(UPPER/UNDER) FRONT ENGIN HANGER PLATE BOLT STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROKET NUT REAR BRAKE OIL BOLT
1 1 2 4 2 1 1 1 1 4 2
M101.25 M101.25 M101.25 M81.25 M81.25 M101.25 M101.25 M 50.8 M141.5 M101.25 M101.25
4.5~5.5 5.0~6.0 4.5~5.5 2.4~3.0 2.4~3.0 1.0~2.0 4.0~5.0 0.35~0.5 8.0~10.0 5.5~6.5 3.4~4.0
HEX NUT U- NUT U- NUT
1-12
GENERAL INFORMATION
FRAME
ITEM QTY THREAD DIA (mm) TORQUE kgf.m,(N,m) REFERENCE
REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER SOCKET BOLT FRONT AXLE NUT FRONT BRAKE DISK BOLT BRAKE OIL BOLT (FRONT/REAR) CALIPER BRACKET BOLT (FRONT/REAR) FRONT MASTER CYLINDER HOLDER BOLT STEERING STEM NUT STEERING TOP THREAD FORK TOP BRIDGE PINCH BOLT BOTTOM BRIDGE PINCH BOLT FORK HANDLE PIPE MOUNTING BOLT SWINGARM PIVOT NUT REAR CUSHION UPPER/UNDER BOLT CHAIN SLIDER SCREW L. DOWNTUBE COMP B HANDLE WEIGHT SOCKET BOLT REAR BRAKE DISK SOCKET BOLT
2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5
M81.25 M61.0 M141.5 M81.25 M101.25 M81.25 M61.0 M221.0 M221.0 M81.25 M81.25 M81.25 M141.25 M101.25 6mm Tapping M81.25 M81.25 M81.25
2.8~3.4 1.0~1.4 5.5~6.5 4.0~4.5 3.0~4.0 2.8~3.4 1.0~1.4 6.0~9.0 0.25~0.35 2.4~3.0 3.0~4.0 2.4~3.0 8.0~10.0 3.5~4.5 0.5~0.7 4.0~4.5 1.8~2.5 4.0~4.5
U- NUT
U- NUT
*Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.
TYPE
TORQUE kgfm Nm
TYPE
TORQUE kgfm Nm
15mm BOLT, NUT 16mm BOLT, NUT 18mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT
4.0~6.0 8~12 18~25 29~39 49~59
0.45~0.6 0.8~1.2 1.8~2.5 3.0~4.0 5.0~6.0
5mm SCREW 6mm SCREW, FLANGE BOLT

(Include SH type)
3.4~5.0 7~11 9.8~14 24~29 34~44
0.35~0.5 0.7~1.1 1.0~1.4 2.4~3.0 3.5~4.5
6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT
*SH(Small Head) : It describe 6mm bolt of 8mm flange bolt.
1-13
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 accident may result if instructions are not followed. vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures.
The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance.
SYMBOL CAUTION
Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1) Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) Use silicone grease Apply a locking agent. Use the agent of the middle strength, unless otherwise specified Apply sealant Replace the parts with new ones before assembly
Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified Use Fork or Suspension Fluid Use special tool Use option tool. These tools are obtained as you order parts. ( 3-1) Indicates reference page. (Example : Refer to page 3-1)
Special grease, etc. that do not correspond to the above are indicated without using symbols.
1-14
GENERAL INFORMATION
TOOLS
SPECIAL DESCRIPTION CLUTCH CENTER HOLDER ACG ROTOR PULLER VALVE GUIDE DRIVER VALVE GUIDE REAMER UNIVERSAL BEARING PULLER BEARING REMOVER SET THREAD ADAPTER ASSEMBLY SHAFT CRANK CASE ASSEMBLY COLOR BALL RACE DRIVER STEERING STEM DRIVER FORK SEAL DRIVER STEERING STEM SOCKET SNAP RING PLIERS COMMON REF. SEC. DESCRIPTION 8 WRENCH, 89mm 9 ADJUSTING WRENCH, B 10 LOCK NUT WRENCH, 2024mm 10 EXTENSION BAR 12 FLY WHEEL HOLDER 12 VALVE SPRING COMPRESSOR 12 DRIVER 12 ATTACHMENT 12 PILOT 14 FORK SEAL DRIVER BODY 14 BEARING REMOVER HEAD 14 BEARING REMOVER SHAFT 14 LOCK NUT(M8) 16 REF. SEC. 2 2 6 8, 14 8, 9 10 12, 14, 15 12, 14, 15 12, 14, 15 14 15 15 10
TESTER, GAUGE
DESCRIPTION COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER TESTER RECORDER REFERENCE SECTION 2 17, 18 17, 18 18 5 REMARK
VALVE SEAT CUTTER

DESCRIPTION VALVE SEAT CUTTER 45 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 60 CUTTER HOLDER 5mm REFERENCE SECTION 10 10 10 10 10 REMARK 24.5mm IN, EX 23mm IN 20mm EX 22mm IN, EX Use with Valve Seat
1-15
GENERAL INFORMATION
WIRING DIAGRAM
1-16
GENERAL INFORMATION
1-17
GENERAL INFORMATION
1-18
GENERAL INFORMATION
1-19
MEMO
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1 2-3 MAINTENANCE SCHEDULE FUEL LINE (FUEL TUBE) 2-4 THROTTLE GRIP OPERATION 2-4 AIR CLEANER 2-5 SPARK PLUG 2-5 VALVE CLEARANCE 2-6 CYLINDER COMPRESSION PRESSURE 2-7 DRIVE CHAIN 2-8 DRIVE CHAIN SLIDER 2-9 BRAKE FLUID 2-9 BRAKE PAD WEAR 2-9 BRAKE SYSTEM 2-10 BRAKE STOP SWITCH 2-11 HEADLIGHT AIM 2-11 CLUTCH SYSTEM 2-11 SIDE STAND 2-12 SUSPENSION 2-13 BOLTS, NUTS, FASTENERS 2-13 WHEEL/TIRE 2-14 STEERING STEM 2-14 COOLANT LEVEL INSPECTION 2-15 COOLANT REPLACEMENT 2-15
SERVICE INFORMATION
The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.
For information on engine oil and oil filter, refer to sections 3-3 and 3-4. Stand the main stand prior to beginning work.
SPECIFICATIONS
THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE CARBURETOR IDLE SPEED CYLINDER COMPRESSION DRIVE CHAIN SLACK REAR BRAKE PEDAL FREE PLAY CLUTCH LEVER FREE PLAY IN. EX. 2~6mm CR9EH-9 0.8~0.9mm 0.15mm 0.20mm 1,600rpm100rpm 13.0kgf/ ( 600rpm ) 10~20mm 10~20mm 10~20mm
TIRES
COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT REAR FRONT REAR FRONT REAR FRONT REAR 2.00kgf/ (200kPa, 29psi 2.00kgf/ (200kPa, 29psi 2.00kgf/ (200kPa, 29psi 2.25kgf/ (225kPa, 32psi 110/70-17 54S 140/60-17 69S 5.5mm 7.0mm ) ) ) )
TIRE SIZE TIRE PART MINIMUM-DEPTH
2-1
INSPECTIONS / ADJUSTMENTS
TORQUE VALUES
SPARK PLUG CYLINDER HEAD COVER BOLT AC GENERATOR CAP HOLE CAP 30mm AIR CLEANER CASE COVER SCREW REAR AXLE NUT DRIVE SPROCKET BOLT DRIVEN SPROCKET NUT 1.0~1.2kgf-m 0.8~1.2kgf-m 0.4~0.8kgf-m 0.6~1.0kgf-m 0.4~0.8kgf-m 8.0~10.0kgf-m 1.0~1.4kgf-m 5.6~6.5kgf-m
TOOLS
WRENCH, 89mm COMPRESSION GAUGE
2-2
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) x 1000Km 1/2 4 6 8 12 12 18 REMARK
FREQUENCY ITEM
MONTH I
FUEL LINE FUEL FILTER THROTTLE GRIP OPERATION AIR CLEANER ELEMENT SPARK PLUG
I R I R I
I R I R R I R R C
I R I R I I R R C NOTE (3) NOTE (2)
VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER ELEMENT OIL FILTER SCREEN DRIVE CHAIN BRAKE FLUID BRAKE /PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND
I R R C
I R R C
Every 1,000 : I and L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R I I I I I I I I I I I I I
SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING RADIATOR COOLANT RADIATOR CORE RADIATOR CAP
If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs. To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers.
NOTES : (1) After the odometer reading exceeds 1,200Km, repeat maintenance service at intervals indicated in the table.
(2) Service more frequently when riding in unusually wet or dusty areas. (3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.
2-3
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.
INJECTOR INJECTOR INJECTOR
FUEL TUBE FUEL FUEL TUBE TUBE FUEL TUBE
THROTTLE THROTTLE GRIP THROTTLE GRIP GRIP
THROTTLE GRIP OPERATION

Check if the throttle grip operates smoothly in all steering positions. If not operating smoothly, check the deterioration, damage and kink of the throttle cable. Measure the free play at the throttle grip.
FREE PLAY : 2~6mm
FREEPLAY FREEPLAY FREEPLAY FREEPLAY
For simple adjustment, use the adjuster under the throttle grip. Adjust the free play by loosening the lock nut and turning the adjuster. After adjusting, tighten the lock nut.
THROTTLE THROTTLE CABLE THROTTLE CABLE CABLE
ADJUSTER ADJUSTER ADJUSTER
LOCK NUT LOCK LOCK NUT NUT LOCK NUT
Major adjustments are made with the lower adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary.
LOCK LOCK NUT LOCK NUT NUT
THROTTLE THROTTLE CABLE CABLE THROTTLE CABLE
2-4
SCREWS SCREWS SCREWS
AIR CLEANER
Remove the seat. (13-2) Loosen the 4 screws, remove the air cleaner cover.
AIR AIR CLEANER AIR CLEANER CLEANER HOUSING COVER COVER HOUSING COVER HOUSING
Remove the air cleaner element. Also replace the filter any time it is excessively dirty or damage. Install in the reverse order of removal.
CLEANER AIR AIR AIR CLEANER CLEANER ELEMENT ELEMENT ELEMENT
Do not reuse the filter element to clean by compressed air.
SPARK PLUG
Remove the spark plug cap. Check the plug for damage, contamination or deposits. If the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug. Always use a feeler gauge to check the gap.
SPARK SPARK PLUG WRENCH SPARK PLUG PLUG WRENCH WRENCH
GENUINE PLUG : CR9EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgfm
CHECK GAP, DEPOSITS
0.8~0.9mm
CHECK WASHER FOR DAMAGE CHECK FOR CRACKS
Make sure there is no dirt or debris on the seat of the spark plug hole before inserting the spark plug. To prevent damage to the cylinder head, handtighten the spark plug before using a wrench to tighten to the specified torque. Do not overtighten the spark plug. Assemble the spark plug.
2-5
T MARK T T MARK MARK T MARK
VALVE CLEARANCE
Inspect and adjust valve clearance while the engine is cold. (below 35 C/95F) Remove the cylinder head cover. Remove the A.C generator cap and crankcase hole cap. Rotate the flywheel counterclockwise to align the "T" mark with the index mark on the left crankcase cover. Make sure the piston is at TDC(Top Dead Center) on the compression stroke. Measure the valve clearance with a feeler gauge.
VALVE CLEARANCE : INTAKE : 0.15mm EXHAUST : 0.20mm
CAM CAM SHAFT CAM SHAFT SHAFT
SHIM SHIM SHIM
FEELER FEELER GAUGE GAUGE FEELER GAUGE
SHIM ADJUSTMENT
If the valve clearance is out of standard, adjust the shim as below. - Remove the camshaft. - Remove the valve lifter and shim.
VALVE LIFTER LIFTER VALVE VALVE LIFTER
If the valve lifter is to be removed, use the special tool. Be careful not to drop the shim into the cylinder when remove the shim with valve lifter. If it is too difficult to remove the shim, use a tweezer or magnet. Valve lifter, and shim should be preserved on the assembly position distinguishably. Remove the valve lifter and clean by compressed air. Mop the oil from the attached area of shim, and measure and record the thinkness with a micrometer.
SHIM SHIM SHIM SHIM
VALVE VALVE LIFTER LIFTER VALVE LIFTER
2-6
SHIM SHIM SHIM SHIM
The type of shim is 33 The clearance of shim is 1,500mm to 2,300mm with 0.025mm clearance. Demanded thickness of shim :A Recorded clearance of the valve lifter : B Specified clearance of the valve lifter : C (In :0.15mm / Ex : 0.20mm) Removed thickness of the shim : D how to calculate : A = (B-C)+D Example) B : 0.06mm D : 1.875mm C : 0.15mm(IN) A = (0.06-0.15)+1.875mm New thickness of the shim : 1.775mm
18 80 0 1 1.800mm
18 82 2 1 1.825mm
18 85 5 1 1.850mm
18 88 8 1 1.875mm
Meaure the thickness of new shim and removed shim, using a micrometer accurately. If the demanded thickness of shim is over 2,300mm, check the valve seat and remove the carbon deposit and modify the valve seat. Install the chosen shim into the valve spring retainer. Apply the molybdenum to wet side of valve lifter and install the lifter. Install the cam shaft and rotate the crank shaft for many timed and recheck the valve clearance after setting the shim. Apply the engine oil to O-ring of pulse generator cover cap and install the cap.
TORQUE : 0.6kgf-m
CYLINDER COMPRESSION PRESSURE

Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and spark plug. install the compression gauge. open the throttle completely and crank the engine with the starter motor until the gauge reading stops rising.
COMPRESSION PRESSURE GAUGE COMPRESSION COMPRESSION PRESSURE PRESSURE GAUGE GAUGE COMPRESSION PRESSURE GAUGE
Tool:compression gauge.
The maximum reading is usually reached within 4~7seconds compression 13.0kg f/ If compression is low, check the following -Incorrect valve clearance adjustment. -Valve leakage. -Leak the gasket from the cylinder head. -Worn piston/cylinder. If compression is high, check the following -Carbon deposits on the piston head, cylinder head.
2-7
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

CHAIN CHAIN SLACK SLACK 10~20mm 10~20mm CHAIN SLACK 10~20mm
Turn off the ignition switch, support the motorcycle on its main stand, and shift the transmission into neutral. Check slack in the lower chain with a hand midway between the sprockets.
CHAIN SLACK : 25~35mm
ADJUSTER SCALE ADJUSTER ADJUSTER SCALE SCALE WHEEL AXLE AXLE WHEEL WHEEL AXLE
Adjust the slack of drive chain if necessary. Adjust it by loosening the axle nut, loosening both lock nuts of adjust, and turning the adjusting nut.
Make sure that the chain adjuster scale are aligned with the corresponding scale graduations on both sides of the swing arm.
ADJUSTING NUT ADJUSTING ADJUSTING NUT NUT
Tighten the axle nut with the specified torque.

TORQUE : 8.8kgfm
DRIVE SPROCKET SPROCKET DRIVE
DRIVE CHAIN INSPECTION

Lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying fully. Because an extremely lubricated oil splash while the chain moves round, clean it with a piece of cloth. After checking a wear and damage of the drive chain, replace it if necessary.
DRIVE DRIVE CHAIN DRIVE CHAIN CHAIN
After inspecting an excessive wear and damage of the drive sprocket, replace it if necessary.
DAMAGE WEAR
Always replace the chain and sprocket as a set. Because using the stretched chain and new sprocket or similar case, the parts will damage quickly cause by the pictch is not engage each other. Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, tighten them to the specified torque.
TORQUE : DRIVE SPROCKET BOLT : 1.2kgfm DRIVE SPROCKET NUT : 5.9kgfm
2-8
NORMAL DRIVE SPROCKET DRIVE SPROCKET DRIVE SPROCKET
DRIVE CHAIN SLIDER

CHAIN CHAIN SLIDER CHAIN SLIDER SLIDER
WEAR WEAR WEAR INDICATOR INDICATOR INDICATOR
Inspect the drive chain slider for excessive wear or damage. If it is worn to the wear indicator, replace the drive chain slider.
BRAKE FLUID
BRAKE BRAKE FLUID CHECKING SCREEN BRAKE FLUID FLUID CHECKING CHECKING SCREEN SCREEN
LOWER LEVEL LINE LOWER LOWER LEVEL LEVEL LINE LINE
Do not mix a dust or different types of fluid when filling the brake fluid. Mind that the reservoir is level in checking and filling it. Avoid spilling the fluid on painted, plastic, or rubber parts. When the fluid level is low, check the brake pads for wear. If the brake pads are not worn and the fluid level is low, check entire system for leaks.
REAR REAR BRAKE RESERVER VESSEL REAR BRAKE BRAKE RESERVER RESERVER VESSEL VESSEL
FRONT BRAKE
Turn the handlebar so that the reservoir is level and check the front brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear.
UPPER LOWER
REAR BRAKE
Place the motorcycle on a level surface, and support it upright position. Check the rear brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear.
BRAKE PAD WEAR

FRONT 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 16-6 for brake pad replacement.
FRONT CALLIPER FRONT FRONT CALLIPER CALLIPER FRONT CALLIPER
WEAR WEAR INDICATOR WEAR INDICATOR INDICATOR
2-9
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 WEAR INDICATOR WEAR INDICATOR INDICATOR
REAR REAR CALLIPER REAR CALLIPER CALLIPER
BRAKE SYSTEM
Check to see if there is a crack and damage in the front and rear brake hose. If leak, replace it with new one.
BRAKE BRAKE HOSE HOSE BRAKE HOSE
FRONT BRAKE LEVER FREE PLAY

Check the free play after pulling the lever.
BRAKE LEVER FREE PLAY : 10~20mm
10~20mm 10~20mm 10~20mm
REAR BRAKE PEDAL FREE PLAY

REAR REAR BRAKE PEDAL REAR BRAKE BRAKE PEDAL PEDAL
Adjust the brake pedal free play at the end part of pedal.
BRAKE PEDAL FREE PLAY : 10~20mm
10~20mm 10~20mm 10~20mm
2-10
BRAKE PEDAL HEIGHT ADJUSTMENT
BRAKE BRAKE HOSE JOINT BRAKE HOSE HOSE JOINT JOINT
Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. After adjustment, tighten the lock nut securely.
The adjustment faulty of height may caused that the brake runs in state of operation. After adjusting the brake pedal height, inspect the operation of rear brake light switch and brake pedal, and adjust them if necessary.
REAR REAR STOP SWITCH REAR STOP STOP SWITCH SWITCH
ADJUST ADJUST NUT ADJUST NUT NUT
BRAKE STOP SWITCH
Adjust the brake stop switch by turning the adjust nut, pressing the switch so that the brake light will come on just before the brake pedal is depressed and brake engagement begins.
ADJUST ADJUST NUT ADJUST NUT NUT
HEADLIGHT AIM
Adjust the headlight beam vertically by turning the headlight case adjustment bolts. It can be adjusted up/down and left/right by adjustment bolt.
Adjust the headlight beam as specified by local laws and regulations.
An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance.
CLUTCH LEVER LEVER CLUTCH CLUTCH LEVER 10~20mm 10~20mm 10~20mm 10~20mm
CLUTCH SYSTEM
FREE PLAY : 10~20mm
Measure the clutch lever free play at the end of the clutch lever.
2-11
Minor adjustments are made using the upper adjuster at the clutch lever. Loosen the lock nut and turn the adjuster.
LOCK NUT NUT LOCK LOCK NUT
CLUTCH CLUTCH CABLE CLUTCH CABLE CABLE
Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjuster nut to adjust free play. Hold the adjuster nut securely while tightening the lock nut. If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch.
CLUTCH CLUTCH REVER CLUTCH REVER REVER
CLUTCH WIRE HOLDER CLUTCH CLUTCH WIRE WIRE HOLDER HOLDER CLUTCH WIRE HOLDER
SIDE STAND
Erect the main stand.
Pull the lower end of the side stand, and see if it moves freely. If the side stand does not move smoothly, apply grease to the pivot area. If the side stand moves too freely, check the side stand spring. Check the axial movement of the side stand.
SIDE STAND SIDE SIDE STAND STAND SIDE STAND
2-12
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. Check the front fork for oil leakage, parts damage or looseness.
REAR CUSHION
Compress the rear cushion up and down several times to check the operating conditions. Check the rear cushion for oil leakage, parts damage or looseness.
WHEEL INSPECTION
Erect the motorcycle with the main stand. Check a wear of the rear fork bush by moving the rear wheel aside. If there is a free play, replace the rear fork bush. Tighten all nuts and bolts of the rear suspension.
BOLTS, NUTS, FASTENERS

Check that all frame nuts and bolts are tightened to their correct torque values. (2-3) Check that all safety clips, hose clamps and cable stays are in place and properly secured.
2-13
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
f/ (kpa)
ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 2.00(200) 2.00(200) 2.00(200) 2.25(225) DRIVER AND A PASSENGER
Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tires.
SERVICE LIMIT : FRONT : 5.5 0.5 mm REAR : 7.0 0.5mm
STEERING STEM
Check that the cables do not interfere with handlebar rotation. Erect the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds or has vertical movement, inspect the steering stem.
2-14
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).
Unless the coolant is refilled or replaced, the engine temperature too high or low. Fill to the F(UPPER LEVEL) line.
COOLANT REPLACEMENT
Remove the radiator cap.
Remove the drain bolt and drain the coolant. (Tilt the vehicle to the right in order to assure complete and rapid draining.) Install the drain bolt.
Fill the radiator with new coolant.

COOLANT CAPACITY : 1,10020cc RADIATOR CAPACITY : 1,00020cc RESERVE TANK CAPACITY: 28020cc
Start the engine. Bleed air from the coolant and check the level of coolant. Install the radiator cap. Fill the coolant with the reserve tank up to the upper level.
2-15
MEMO
3. LUBRICATION
SERVICE INFORMATION 3-1 3-2 TROUBLESHOOTING ENGINE OIL LEVEL INSPECTION 3-3 ENGINE OIL CHANGE 3-3 OIL FILTER ELEMENT CHANGE 3-4 OIL PUMP 3-4 LUBRICATION POINTS 3-7
SERVICE INFORMATION
GENERAL SAFETY
1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. 2. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after handling the used oil. 3. The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
1.5 (After disassembly) OIL CAPACITY 1.35 (After Oil filter change) 1.3 (After Oil change) Daelim pure oil (4cycle motics 4) API service classification : SL grade RECOMMENDED Viscosity : SAE10W-40 OIL (Use appropriate type of oil with viscosity satisfying the atmospheric temperature in your riding area based on the table shown on the right side.)
-10
10
20
30
40
OIL PUMP
ITEM PUMP BODY CLEARANCE ROTOR END CLEARANCE STANDARD VALUE 0.15~0.20 0.15
Unit : mm
SERVICE LIMIT 0.25 0.20
TORQUE VALUES
OIL DRAIN CAP OIL FILTER COVER BOLT 1.5fm 1.1fm
3-1
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. Incorrect oil being used.
3-2
LUBRICATION
ENGINE OIL LEVEL INSPECTION

OIL LEVEL LEVEL GAUGE GAUGE OIL OIL LEVEL GAUGE
Erect the motorcycle by main stand. Start the engine and let it be warm fully. Stop the engine, remove the oil level gauge and wipe it clean. Check the oil level with the level gauge by inserting it in engine screwing level gauge. It is good if the oil surface is between the lower level mark and upper that of the level gauge. If the oil level is near the lower level mark on the dipstick or below that, full to the upper level mark with the recommended oil.
ENGINE OIL CHANGE

Loosen the drain plug bolt on the LH. crank case and drain the oil. Loosen the oil drain cap on the RH. crank case. Clean filter screen with a clean wash. Check if the oil filter screen seal rubber and O-ring of the tappet adjust hole are in good condition. Unscrew the spark plug from the spark plug cap and operate the starter motor for a second to remove the remaining oil from the engine. Install the filter screen, spring and tappet adjust hole cap.
Make the engine warm and erect the motorcycle with side stand in order to assure complete and rapid draining.
TORQUE : 1.5 kgfm
Fill the crankcase with recommened engine oil.

OIL CAPACITY: 1.5 (After disassembly) 1.35 (After oil filter change) 1.3 (After oil change)
OIL OIL FILTER SCREEN OIL FILTER FILTER SCREEN SCREEN OIL OIL DRAIN CAP OIL DRAIN DRAIN CAP CAP
DRAIN PLUG BOLT DRAIN DRAIN PLUG PLUG BOLT BOLT DRAIN PLUG BOLT
RECOMMENDED ENGINE OIL : Genuine oil API classification : SL grade viscosity : 10W-40
Install the oil level gauge. Start the engine and let it idle for a few minutes. Stop the engine and recheck the oil level,if necessary, supply the recommended oil. Check to see if the oil is leak.
TAPPET ADJUST HOLE CAP TAPPET TAPPET ADJUST ADJUST HOLE HOLE CAP CAP
3-3
LUBRICATION
OIL FILTER ELEMENT CHANGE

OIL FILTER OIL FILTER FILTER OIL MAINTENANCE MAINTENANCE MAINTENANCE COVER COVER COVER OIL OIL FILTER COVER OIL FILTER FILTER COVER COVER
Remove the oilfilter maintenance cover on RH. side cowl. Drain the engine oil. (3-3)
RH. RH. SIDE COWL RH. SIDE SIDE COWL COWL
OIL OIL FILTER ELEMENT OIL FILTER FILTER ELEMENT ELEMENT
Remove the oilfilter cover bolt, filter cover, filter element and spring. Change the oilfilter element with a new one.
OIL OIL SEAL OIL SEAL SEAL
If the valve is turned on completely when it pushed, or the valve is turned off automatically when it relocated again, it is fine. Check the oil filtercover seal is in good condition. Change the oil filter cover seal with a new one. Install the filter element, spring and oil filter cover and tighten the bolts to the specified torque.
TORQUE : 1.1 kgfm (11 Nm)
Fill the genuine engine oil to the crankcase. (3-1)

RELIEF RELIEF VALVE VALVE SOCKET SOCKET BOLT BOLT RELIEF VALVE SOCKET BOLT
OIL OIL PUMP GEAR OIL PUMP PUMP GEAR GEAR
OIL PUMP
REMOVAL
Drain the engine oil. (3-3) Remove the oil filter. (3-4)
3-4
LUBRICATION
Clean the oil pump body (inner and outer) and rotors with fresh cleaning oil.
OUTER OUTER ROTOR OUTER ROTOR ROTOR
INNER INNER ROTOR INNER ROTOR ROTOR
INNER INNER ROTOR INNER ROTOR ROTOR
INSPECTION
Install the inner and outer rotors into the oil pump body. Measure the pump body clearance.
SERVICE LIMIT : 0.25mm
OUTER ROTOR ROTOR OUTER OUTER ROTOR
FEELER GAUGE FEELER FEELER GAUGE GAUGE FEELER GAUGE
Measure the rotor end clearance.

ASSEMBLY
Clean all parts with fresh cleaning oil. Install the lnner and outer rotor to the pump body.
After installing, check the oil pump to operate smoothly
INSTALLATION
Install the oil filter cover to the RH.crank case. Fill the recommended oil into the crankcase. (3-3)
3-5
LUBRICATION
LUBRICATION POINTS
Use general grease
SECTION ROTATE SLIDING PART EDGE PART SLIDING PART INSIDE PART OF MASTER CYLINDER CUP SLIDING PART EDGE PART SLIDING PART EDGE PART GEAR COUPLING INSIDE EDGE PART SLIDING PART CONCORDANT PART SLIDING PART CASTING AND CONTACT INSIDE PART CASTING INSIDE PART SLIDING PART Apply oil or grease to the other sliding surfaces not shown here. SHEEL ALVANIA EP2 or SUITABLENESS WIDTH DOT3 or DOT 4 ASSEMBLY OIL CCI No.20 or SUITABLENESS WIDTH BRAKE GREASE SPECIAL ASSEMBLY OIL CCI No.20 or SUITABLENESS WIDTH MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH DAPHNE EPONEX EP2 or SUITABLENESS WIDTH ULTRA CUSH OIL NO.10 SUITABLENESS WIDTH LIQUID O-RING #400 GREASE CEMEDINE #540 or SUITABLENESS WIDTH MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH SILICON GREASE MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH
3-6
MEMO
FUEL SYSTEM
4-0
4. FUEL SYSTEM
SERVICE INFORMATION 4-1 TROUBLESHOOTING 4-2 FUEL TANK 4-3 AIR CLEANER CASE 4-4
SERVICE INFORMATION
GENERAL SAFETY
Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly ventilated area.
STANDARD OF MAINTENANCE
Fuel tank capacity : 14.85 Reserve fuel capacity: 4.0 Fuel pump specification : KGF38 Flow quantity : Mimnim 20/hr Flow pressure : 380kpa Injector specification Injector angle : 15 Operation pressure : 380kpa
TORQUE VALUE
Air cleaner case cover screw 0.43kgfm (4.3Nm)
TOOL
Float level gauge
TROUBLESHOOTING
Engine cranks but wont start
No fule in tank No fule to carburetor Cylinder flooded with fuel Clogged air cleaner No spark at plug
4-1
FUEL SYSTEM
FUEL TANK FUEL FUEL TANK TANK FUEL TANK
FULE TANK
REMOVAL
Do not smoke or allow flames or sparks in the work area because gasoline is extremely flammable. Immediately wipe off a leaked gasoline. Remove the seat. Remove the fuel tank cover by looseing the 2 special screws and washer bolt. Disconnect the fuel serve cord.
FUEL FUEL TANK SERVE CORD FUEL TANK TANK SERVE SERVE CORD CORD
FUEL FUEL TUBE FUEL TUBE TUBE CLIP CLIP CLIP
After lift a section of the fuel tank, seperate a clip of the fuel tank and the hose. Remove the fuel tank.
INSTALLATION
Install the fuel tank in the reverse order of removal. After installation, check if there is a gasoline leak.
FUEL FILLER CAP
FUEL TANK SEALING RUBBER FUEL PUMP FUEL TANK COVER
FUEL CAP NECK
FUEL TANK
4-2
FUEL SYSTEM
AIR CLEANER CASE

AIR CLEANER CLEANER CASE CASE AIR AIR CLEANER CASE
REMOVAL
Remove the main seat. Remove the fuel tank. Remove the RH. LH. side covers. Remove the fuel tank rear stay.
FUEL FUEL TANK REAR STAY FUEL TANK TANK REAR REAR STAY STAY
Remove the battery. Remove the battery box by loosening the washer bolt. Remove the air cleaner connecting tube band. Remove the air cleaner case mounting bolts, then remove the air cleaner case.
INSTALLATION
Install in the reverse order of removal.
Insert the hook area of battery box into the front hole of rear fender accurately when assemble the air cleaner case.
AIR CLEANER ELEMENT
AIR CLEANER CASE COVER
AIR CLEANER CASE
4-3
MEMO
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. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - SELF DIAGNOSTIC FUNCTION - FAIL SAFE FUNCTION - HOW TO CHECK THE FAULT CODE - HOW TO SHOW THE FAULT CODE - HOW TO READ THE FAULT CODE - FAULT CODE TABLE - HOW TO REMOVE THE FAULT CODE - EMS TROUBLE SHOOTING 7. ECU (Electronic control unit) 8. THROTTLE BODY 9. INJECTOR 10. MAPAT 11. TPS (Throttle Position Sensor) 12. ETS (Engine Temperature Sensor) 13. ISA (Idle Speed Actuator) 14. O2 (Oxgen Sensor) 15. CHECKING OF ESS CIRCUIT 16. CHECKING OF MIL CIRCUIT 17. CKP (Crank Position Sensor) 18. FUEL PUMP 19. HOW TO USE SCAN - ECU INITIALIZING - ISA PWM ADJUSTING - IGNITION TIMING CHECK - ENGINE RPM CHECK 5-2 5-3 5-4 5-5 5-5 5-5 5-5 5-6 5-8 5-9 5-9 5-10 5-11 5-11 5-12 5-13 5-17 5-20 5-24 5-27 5-30 5-33 5-36 5-37 5-38 5-42 5-45 5-45 5-47 5-48 5-49
5-1
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. Do not drop or throw the EMS parts, because these parts may be damaged by the impact of the drop.
Do not touch the ECU terminal, because it may be damaged by the static.
The ignition key off before assembly and disassembly of the ECU coupler.
Otherwise, it might be damage to ECU.
Do not connect adversely the polarity of battery, otherwise, it might be broken the EMS parts
While engine operating, do not disassemble the battery terminal.
Otherwise, it might cause damaged the EMS parts.
Use the specified voltmeter and resistance meter.
5-2
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. In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means that idle speed control system is installed in order to control small of quantity of air being necessary for combustion.
2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division pipe and injector. The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter. Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of intake system. Injector sprays fuel into the intake system by injection signals of ECU.
3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to control proper spark time in cylinder, high-voltage system, and so forth.
4) CONTROL SYSTEM
Various sensors to move electric signals converted by checking the current engine status Input interface which works various processes like regulating voltage levels, removal of noise, A/D conversion, amplifying of inputted signals from above sensors. Micro-computer which decides output value through various calculating, arithmetic and logic processing. Output interface to amplify the above output signals. Actuator being mechanically worked by receiving the amplified output signals.
(Intake pressure sensor+Intake temperature)
5-3
3. TERMINAL ARRANGEMENT OF THE ECU

ECU PIN NO. VS FUNCTION
PIN NO.
FUNCTION ECU Earth Oxygen sensor Earth Intake pressure sensor Earth TPS. ETS Earth Engine KILL ECU Earth After main key turn on, Battery power Oxygen sensor Signal Side stand Signal Battery Power supply TPS Power (5V) supply Throttle Position Sensor Signal Engine Temperature Sensor Signal
PIN NO.
FUNCTION Third Gear Crank Position Signal B Communication LOW MIL Battery Power Intake pressure sensor power(5V) Intake pressure sensor Signal Intake temperature sensor Signal Neutral Gear Crank Position Signal A Communication HIGH Engine Speed Signal Idle Speed Actuator Oxygen sensor Heat Ignition coil Earth Ignition Signal HEad lamp relay Signal Fuel pump relay Signal Injector Signal
Remarks
ECU PIN NO. 6,7,8,11,14,15,16,36 were not connected. Terminal arrangement is based on the ECU.
5-4
4. WIRING DIAGRAM OF THE ECU
5. AN ERROR CHECKLIST FOR EACH TERMINAL OF ECU

ERROR Checklist PIN NO. ECU 01 ECU 02 ECU 03 ECU 04 ECU 05 6, 7, 8 ECU 09 ECU 10 ECU 11 ECU 12 ECU 13 14,15,16 ECU 17 ECU 18 ECU 19 ECU 20 ECU 21 ECU 22
Starting Idle RPM Stability Driving Durability SCAN tool
communication
ERROR Checklist
MIL
PIN NO. ECU 23 ECU 24 ECU 25 ECU 26 ECU 27 ECU 28 ECU 29 ECU 30 ECU 31 ECU 32 ECU 33 ECU 34 ECU 35 ECU 36 ECU 37 ECU 38 ECU 39 ECU 40
Starting
Idle RPM Stability
Driving
Durability SCAN tool

communication
MIL
O O O O X O X O X X O O O O X
O X X X O X X X X O -
O O O O X O X O X X O O O O X
X X X X X X X X X O -
O O O O O O X O O X O O O O O
X O O O X X X O X X O O O X X
O X O O O X X O O O O X X O X X
O X X X O O X X O -
O X O O O X X O O O O X X O X X
O X X X O O O X O -
X O X O O O O O X O O O O O O O O
X X X O O O X X X O O O X X O O O
5-5
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). It gives the rider that malfunction has occurred in the system. However, the ECU takes fail-safe function, it enables to drive only temporary when that happen. Normally, the MIL illuminates for 3 seconds, when the main key is turned on.
MIL(Malfuction Indicator Lamp)
when the ignition key ON.
MIL OFF ON
Unable to engine start Able to engine start Starting and driving are temporary
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen. - Crankposition sensor - Injector - Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON Blink
MIL on continuously, when the engine operating MIL blinks, when the main key is turn on (engine is stop)
5-6

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.
MIL on
INTAKE INTAKE
MILoff on/off :: MIL
: MIL on on : MIL
If there is something wrong in the EMS, it has fail safe function in order for engine to work and to cover a minimum driving of vehicle.
INTAKE
The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order.
INTAKE
valve of ofintake intaketemperature temperature fixed The value isis fixed asto a 20.25 when the intakewhen pressure temperature just before thesensor intakeis out of order. sensor is out of order. pressure
! CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case. In this case, safe repairing of vehicle shall be required.
5-7

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 The MIL blinks continuously Find the defects by checking the number of lighting, the fault code can be verified (refer to the fault code table) Second) The diagnostic tool (refer to scan users manual for checking.) Turn off the ignition key Aassemble the coupler of diagnostic tool with the coupler to check the malfunction of vehicle. Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool.
Coupler to check the malfunction diagnosis

Wire color to check the malfunction diagnosis -P/W : PINK/WHITE : CAN_L -P/Y : PINK/YELLOW : CAN_H -B : BLACK : IGNITION KEY -G : GREEN : GROUND
Third) Use the wireharness for checking Coupler for checking (ECU 1 - ECU 20 PIN)
Coupler for checking (ECU 21 - ECU 40 PIN)
Measure the wire harness for checking by connecting the ECU with main wire harness to check the ECU. It has two coupler to check the terminal. The wireharness to check the ECU arrangement Coupler for checking : ECU PIN no. 1,2,3,4,5,9,10,12,17,18,19,20 were connected. ECU PIN no. 6,7,8,11,13,14,15,16 is not connected. Coupler for checking : ECU PIN no. 21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,37,39,40 were connected. ECU PIN no. 36 is not connected.
5-8

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. This time, so for checking the fault code, stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be verified.(refer to the fault code table) Second) The ways of indication only turn on the ignition key. When only ignition key is on and if the defect of each part brings out, the MIL keeps showing the Fault code of defect part repeatedly in order to give defect information to driver.
! CAUTION
If the MIL on when engine is working, engine is able to be operated by fail safe. However, in the event that Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started.
HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS. Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed. E.g. ) The Fault code of ISA
ON
OFF 1.5 sec 3 sec
1 flashing cycle : 0.5 sec

If many problems will happened in the EMS parts at the same time, only one fault code is displayed by the priority, however, the ECU remembers all the fault codes. After revise the code, remove the memorized fault code by the method of warm up.(5-10) (Refer to remove the fault codes) When the vehicle is checked using the diagnosis tool. - If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.
5-9

FAULT CODES TABLE
MIL INDICATION (The number of blinks)
Fault code no.
Priority order No failure
Description
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)
Lambda signal failure (VLS) Engine temperature signal failure (TENG) Breathing air temperature signal failure (TBA) Engine speed signal output failure (ESS)
Headlamp relay failure Malfunction indicate lamp failure (MIL)
5-10

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. Turn off the ignition key after full warm up the engine 4. Turn on the ignition key again, and check whether the fault code is disappeared or not. After full warm up, it is possible to check the fault code is removed with the ignition key on/off. If many problems happened in the EMS parts at the same time, only one defect code will is displayed by the priority order. Even thought repair a fault and remove the memorized fault code, another fault code blinks. at this time, revise the fault and remove the memorized fault code by the warm up. Second) Malfunction diagnosis tool (refer to the scan users manual)
EMS TROUBLE SHOOTING Inspection before diagnosis

Inspection the following before malfunction diagnosis. Quantity of engine oil and leakage Quantity of fuel and leakage Blocked of air cleaner Condition of battery Free play of throttle cable Cutting of fuse Leakage of emission gas Connection of each coupler Cylinder press pressure Condition of spark plug
5-11
7.ECU(ELECTRONIC CONTROL UNIT)

It is located inside a pillion seat
SEAT SEAT
SEAT SEAT LOCK LOCK SEAT LOCK ! CAUTION
The key is off before disassembly.
Remove the setting grommet and center cover.
CENTER COVER COVER CENTER CENTER COVER
COVER COVER SETTING GROMMET COVER SETTING SETTING GROMMET GROMMET
Remove
ECU ECU GROUND WIRE ECU GROUND GROUND WIRE WIRE
- ECU coupler - Remove the coupler in sequence - Remove the 4 flange bolts securing ECU
FLANGE FLANGE BOLTS FLANGE BOLTS BOLTS
Install
- Install in the reverse order of removal
! CAUTION
Be sure to assemble the ECU ground wire. (The color is green)
5-12
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 AIR CLEANER CLEANER AIR CLEANER
MAPAT SENSOR MAPAT MAPAT SENSOR SENSOR MAPAT SENSOR
Remove the gasoline in fuel tube. Disconnect fuel tube securing inject or cap. Disconnect injector, MAPAT, throttle sensor, ISA coupler. Disconnect throttle cable.
INSULATOR INSULATOR INSULATOR INSULATOR
Loosen the 2 flange bolts securing insulator and remove the throttle body assy.
5-13
DISCONNECT THE THROTTLE BODY

Remove the each component parts securing throttle body and check.
THROTTLE THROTTLE BODY THROTTLE BODY BODY
INSULATOR INSULATOR INSULATOR
! CAUTION
MAPAT MAPAT SENSOR MAPAT SENSOR SENSOR
Do not disconnect both the throttle adjust screw and adjust nut.
REMOVE
Loosen the throttle body 2 bolts securing the insulator. Disconnect the TPS (Throttle position sensor). Disconnect the ISA(Idle speed actuator). Disconnect the MAPAT.
! CAUTION IDLE SPEED ACTUATOR IDLE IDLE SPEED SPEED ACTUATOR ACTUATOR IDLE
Do not disconnect the throttle valve.
CHECKING THE THROTTLE BODY

THROTTLE SHAFT THROTTLE THROTTLE SHAFT SHAFT
Checking the O-ring. Checking the Throttle shaft. Checking the Throttle valve.
O-RING O-RING O-RING
Checking the ISA. Checking the TPS.

! CAUTION
Replace the O-ring with new one.
5-14
DISASSEMBLE THE INSULATOR

Disconnect injector cap bolt.
MAPAT MAPAT SENSOR MAPAT SENSOR SENSOR
Disconnect injector and injector cap at the same time from the insulator. Disconnect injector and injector cap.
MAPAT SENSOR MAPAT MAPAT SENSOR SENSOR MAPAT SENSOR
INSULATOR INSULATOR INSULATOR
CHECKING THE INSULATOR

CAP CAP CAP
Check the O-ring. Check the insulator inside. Check the MAPAT sensor. Check the injector Assemble is the reverse order of removal.
! CAUTION
Replace the o-ring with new one.

MAPAT SENSOR SENSOR MAPAT MAPAT SENSOR INJECTOR INJECTOR INJECTOR INJECTOR
INSTALLATION OF INSULATOR AND THROTTLE BODY

Installation of insulator and throttle body in the reverse order of removal. Check the o-ring when the insulator assembly. Torque : 1.0 kgf m
! CAUTION
Replace the gasket with new one.

THROTTLE THROTTLE BODY BODY THROTTLE BODY INSULATOR INSULATOR INSULATOR
Install the assembled insulator and throttle body to the cylinder head. Torque : 1.2 kgf m
5-15
THROTTLE THROTTLE CABLE CABLE THROTTLE CABLE
ASSEMBLY
Assemble the throttle cable. Adjust the free play of throttle grip.
INSPECTION OF SENSOR AND ACTUATOR

Connect each sensor and the actuator coupler. Check the ISA. Check the TPS. Check the MAPAT sensor.
! CAUTION
Be sure to the valve of TPS is whether the standard valve after it became assembly.
ADJUSTMENT OF IDLE SPEED ACTUATOR (ISA)

! CAUTION
The ECU is always initilized, before the engine is starting.
ADJUST ADJUST SCREW ADJUST SCREW SCREW
The vehicle is warms up enough to adjust the idling speed. Disconnect the RH. side cover. Connect the coupler of scanner to the coupler of diagnostic tool. Press the POWER button on the scanner and check the ISA value. If the ISA value is not around 20% adjust it using the adjust screw to around 20% in 80~90 of engine temperature.
ADJUST ADJUST SCREW ADJUST SCREW SCREW
5-16
9.INJECTOR
Remove
Remove the fuel tank.
! CAUTION
After push the injector coupler, pulling it
upward.
Remove the injector cap bolt.
! CAUTION
Be sure to check the engine is cooling because
a little gasoline remains. it could be still hot and it could be cause fire.
Be sure to injector the gasoline, after remove
the coupler from the ignition coil. It could be damaged for the fire, sparked on the spark plug.
Remove the injector.
Assemble
Install in reverse order of removal.
5-17

CHECKING METHODS BY FAULT CODES Checking of the Injector circuit
The fault code is displayed by MIL
Checking Circuit
ECU
40 : INJECTOR control 39 : FUEL PUMP control
INJECTOR
FUEL PUMP RELAY

Coupler terminal is based on wire harness.
5-18
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 : 14.50.7[ ], 20 Remarks : measuring unit for resistance : resistance R [ ] 4)If there is no problem, check the continuity between each terminal and ground. The resistance between each terminal and ground : [ ] If resistance value is not normal, replace injector with the new one. 5)If the resistance is normal, turns on the ignition key - If the fuel pump operated for 3 seconds, the power supply relay of injector is normal. 6) Measure between the voltage of coupler. Measuring terminal : BLACK/RED electric wire ~ ground Measuring voltage : battery voltage 1.0[V]over Remarks : Measuring unit of voltage : voltage [V] 7) If the measured voltage is normal, Check the Blue/Yellow electric wire to see if they have been broken or have short-circuited or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40) If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks 8) If the measured voltage is not normal, Check the Black/Red electric wire to see if they have been broken or have short-circuited. Check the fuel pump relay. 9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-19
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 MAPAT SENSOR MAPAT SENSOR SENSOR
The key is off before disassembly. Loosen the MAPAT sensor screw 2EA.
MAPAT sensor.
Assemble
5-20

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
ECU
33: Intake pressure sensor ground : Inhalation pressure 26 : 5V voltage sensor GROUND 27 : 26 :IMP 5V voltage 28 27::TBA IMP 28 : TBA
Coupler terminal is based on the side of wire-harness
CHECKING PROCEDURE
1) Turn off the ignition key . 2) Check to see if the MAPAT coupler has come loose or the wire is peeling off. If there is normal, measured the input 5 voltage of MAPATs coupler. 3) Disassemble the coupler of MAPAT and turn on the ignition key 4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)s coupler. Input voltage : 4.5 ~ 5.5[V] Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal Remarks : Measuring unit of voltage : voltage [V] 5) If voltage value is not normal, Check to see if the ECU coupler is loose or if there is a bad contact. Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited Remark : refer to (5-16) if the intake pressure sensor is broken refer to (5-16) if the intake temperature sensor is broken After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-21
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. Start engine and operate idle. 4) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor. Measuring terminal : ECU No. 27(P/L:PINK/BLUE) ~ ECU No.3(P/G : PINK/GREEN) Measuring voltage : 0.1[V] ~ 4.8[V] Remarks : Measuring unit of voltage : Voltage [V] The voltage of air pressure; 20[kPa]: 0.719 ~ 0.859[V] 107[kPa]: 4.154 ~ 4.294[V] 5) If the measured voltage is not normal, Check the P electric wire, P/G electric wire, P /L electric wire to see if they have been broken or have short- circuited. Replace the MAPAT sensor with the new one and it rechecks. If measuring voltage is normal, Check the P electric wire, P/G electric wire, P/L electric wire to see if they have been broken or have short- circuited if there is a bad contact. badness of terminal No. 3, No. 26, No.27 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks. 6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.
Connecting the wire harness for checking
5-22
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 : 2000100[], 251 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; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ] 3) If measuring resistance is not normal, Replace the MAPAT sensor with new one and it rechecks. If the measured voltage is normal, Check the P electric wire, P/G electric wire, P/L electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 3, No. 26, No. 27 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks. 4) Turn on the ignition key. Start the engine and idling. 5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No.28(TBA) ~ ECU No.3(IMP ground) - Measuring voltage: 0.1[V] ~ 4.9[V] Remarks : Measuring unit of voltage : Voltage [V] 6) If the measured voltage is not normal, Check the P electric wire, P/G electric wire, P /L electric wire to see if they have been broken or have short- circuited. Replace the MAPAT sensor with new one and it rechecks. If the measured voltage is normal, Check the P electric wire, P/G electric wire, P/L electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 3, No. 26, No.28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace ECU with the new one, it rechecks. 7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-23
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
Remove the TPS screw 2EA
MAPAT MAPAT SENSOR SENSOR MAPAT SENSOR
SCREWS SCREWS SCREWS
Remove the TPS
Assemble
5-24

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. 3) Disassemble the TPS coupler 4) Turn on the ignition key. Input voltage : 4.5 ~ 5.5[V] Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED) Measure the terminal voltage of TPSs coupler. Measuring voltage : 4.5[V] ~ 5.5[V] Remarks : Measuring unit of voltage : Voltage [V] If voltage value is not normal, Check to see if the ECU coupler is loose if there is bad contact. Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been broken or have short- circuited. 5) If the value of voltage is normal, turn off the ignition key.
5-25

Checking Procedure
6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0~1.0[ ],201 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. By turning round throttle Lever, measure the resistance. The resistance of TPS If the throttle is totally closed : 0.9~1.6[k ],201 If the throttle is totally opened : 2.3~2.6[k ],201 Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED) Remarks : Measuring value of resistance : Resistance[k ] 8) If resistance and the continuty are not abnormal. Adjust correctly the position of TPS Replace the TPS with the new one and re-check. 9) If resistance and continuty are normal, connect the coupler of TPS. 10) Turn on the ignition key. 11) Measure the TPS voltage of the wire-harness to check the ECU. Rotate the throttle lever, measure the voltage Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED) Output voltage of TPS -If the throttle is totally closed : 0.1~0.6[V] -If the throttle is totally opened : 4.0~5.5 [V] Remarks : Measuring unit for voltage : Voltage [V] 12) If the measured voltage is abnormal, Replace the TPS with the new one, and re-check. If the measured voltage is normal, Check the GR/B electric wire, GR/L electric wire, W/R electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler. If there is no problem in wires, ECU has broken down. Replace ECU with the new one, and recheck. 13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
5-26
THERMO THERMO STAT THERMO STAT STAT
12.ETS(ENGINE TEMPERATURE SENSOR)

It is located on the left-hand side of cylinder head.
Remove
After pressing the ETS coupler and pull it..
! CAUTION ENG. ENG. TEMP. ENG. TEMP. TEMP. SENSOR SENSOR SENSOR
The key is off, before disassembly.
Remove the ETS coupler.
ENG. ENG. TEMP. ENG. TEMP. TEMP. SENSOR SENSOR SENSOR
Remove the ETS.
Assemble
5-27

1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)
CHECKING CIRCUIT
ETS
ECU
4 : SENSOR GROUND 20 : ETS 50V SUPPLY VOLTAGE
Coupler terminal is based on the side of wire-harness

ETS ETS
Checking Procedure
1) Turn off the ignition key . 2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ETS. 3) Disassemble the coupler of ETS 4) Turn on ignition key. Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE) ~ ECU No.4 (W/R : WHITE/RED) Measure the terminal voltage of ETSs coupler. Measuring voltage : 4.5[V] ~ 5.5[V] Remarks : Measuring unit for voltage : voltage [V] If the voltage value is not normal, Check to see if the ECU coupler is loose, or bad contact. Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been broken or have short- circuited. 5) If the voltage value is normal, turn off the ignition key. 6) Disassemble the coupler of ETS, and measure the resistance of ETS. Resistance of ETS :1.6[k ]~10.6[k ],20 ~80 Measuring terminal : Each terminal of ETS Remarks : Measuring unit for resistance : Resistance R [k ]
5-28

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. 20.) If the electric wire is no problem, ECU is broken. Replace ECU with the new one, recheck. 6-2) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
Checking Procedure
1) Disassembly Disassemble the ETS(Engine Temperature Sensor) : (Refer to 5-27) 2) Check the ETS(Engine Temperature Sensor) Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil. Read the temperature of thermometer depending upon oil temperatures change and testers value. Characters of ETS
Temperature 20 80 110
Resistance value 10.6[k ]~14.4[k ] 1.35[k ]~1.65[k ] 0.57[k ]~0.69[k ]
Measuring unit of resistance : Resistance R [k ] If the value of resistance is high or out of the standard value, replace the ETS with the new one.
! CAUTION
1)Be careful do not fell down the ETS, because its weakness. 2)Be careful the ETS and the Thermometer do not to touched to oil bowl. 3)Be careful oil temperature will not raised more than measurement temperature.
3) Install Install in the reverse order of removal with standard torque.
ETS torque : 3.0[kgf m]
5-29
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
5-30

1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.
Showing of defects codes by MIL
CHECKING CIRCUIT ECU
40
39
39::ISA FUEL PUMP CONTROL 33 CONTROL 40 : INJECTOR 39:FUEL PUMP CONTROL
ISA
FUEL PUMP RELAY
Coupler terminal is based on the side of the wire-harness
CHECK PROCEDURE
1) Turn off ignition key . 2) Check to see if the ISA(Throttle Position Sensor) coupler is loose, or bad.If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of ISA, measure the resistance between ISA terminals. ISA resistance : 31.5~ 38.5[ ],20 remarks : Measuring unit of resistance : Resistance R[ ]
4) If there is no problem, check about the level of electricity flow between each terminal, and between each ground. Resistance between each terminal , and between each ground : [ ] If measure resistance value is not normal, replace with the new one Disassembly and Assembly : refer to ( 5-28 ) remarks : Measuring unit for resistance : Resistance R[ ]
5-31

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] Remarks : Voltage measuring unit : Voltage [V] If the measured voltage is normal, Check the B/R electric wire, L/G electric wire, W/R electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler. If there is no problem in wires, ECU has broken down. Replace ECU with the new one, recheck. If the measured voltage is abnormal, Check the B/R electric wire, L/G electric wire, W/B electric wire to see if they have been broken or have short- circuited. 9) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
5-32
14.O2(Oxygen) SENSOR
It is located on the exhaust pipe
! CAUTION

O2 O2 SENSOR COUPLER O2 SENSOR SENSOR COUPLER COUPLER
O2 SENSOR O2 O2 SENSOR SENSOR
Remove
Center cowl O2 sensor coupler
O2 O2 SENSOR COUPLER O2 SENSOR SENSOR COUPLER COUPLER
Check the O2 sensor.
Handle with care or fraglile.
Assemble
5-33

1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT
Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.
CHECKING CIRCUIT
OXYGEN SENSOR
ECU
2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER
Coupler terminal is based on the side of Wire-Harness.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

1) Turn off the ignition key. 2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen) 3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key 4) Measure input voltage of oxygen(O2)sensor coupler Input voltage : Battery voltage[V] Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler (B/BR : BLACK/BROWN) ~ EARTH Remarks : Measuring unit of voltage : Voltage[V]
5-34

CHECKING FOR A FAULT CODE BY OXYGEN(O2)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. 5) If the voltage value is normal, turn off the ignition key. Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22 Measuring terminal (side of wire-harness) : oxygen(O2)4 terminal of sensor coupler (B/BR : BLACK/BROWN) ~ ECU No.34(G/W :GREEN/WHITE) Remarks : Measuring unit of Resistance : Resistance R[ ] 6) If the measured resistance is abnormal, Replace the oxygen(O2)sensor with new one and recheck it. If the measured resistance is normal, Check the B/B electric wire, G/W electric wire to see if they have been broken or have short- circuited. If the electric wire is no problem, the ECU is broken. Replace the ECU with new one, and recheck it.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key 2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen) 3) The wire-harness to checck the ECU is connected to the ECU with a coupler. refer to the ECU assembly/disassembly. 4) Turn on the ignition key 5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU. Measuring terminal: ECU No.12(V :VIOLET)~ ECU No.2(V/B:VIOLET/BLACK) Output voltage of oxygen(O2) sensor : 0.1~0.8[V] Remark : Measuring unit of voltage : Voltage[V] Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf If the measured voltage is normal, Check the B/R electric wire, V electric wire, V/B electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 2, No. 12 of ECU coupler. If there is no problem in wires, ECU is broken. Replace the ECU with new one, and recheck it. If the measured voltage is abnormal, Check the V electric wire, V/B electric wire, W/B electric wire to see if they have been broken or have short- circuited. 6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
5-35
15.CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT

CHECKING CIRCUIT
TACHOMETER
ECU 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. If there is no problem, check the resistance of tachometer. 3) Check the resistance between each terminals and ground. Measuring terminal: B electric wire ~ EARTH, ECU NO. 32 (B/Y:BLACK/YELLOW) ~ EARTH The resistance between each terminals and ground : [ ] If the measured resistance value is abnormal, replace the part with new one. Refer to ( ) for assembly and disassembly Remark : Measuring unit of voltage : Resistance [ ] 4) If the measured resistance and continuity are abnormal, Replace the tachometer with new one, and it rechecks. 5) If the resistance and continuity are normal, contact the tachometer coupler. 6)Turn on the ignition key. 7) Measure the voltage or tachometer of wire harness for ECU check. Measuring terminal: B electric wire ~ G electric wire => Output Voltage: battery voltage Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G electric wire =>Output voltage: 9[V]~15[V] Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G Measuring the output voltage of electric wire, using the PVA(peak voltage adapter) multi-tester tool. Remark : Measuring unit of voltage : Voltage[V]
If the measured voltage is normal, Check the B/Y electric wire, B electric wire, G electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 32 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and recheck it. If the measured voltage is abnormal, Check the B/Y electric wire, B electric wire, G electric wire to see if they have been broken or have short- circuited. 8) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
5-36
16.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT

CHECKING CIRCUIT
ECU 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. 3) Turn on the ignition key. 4) Check the MIL on for 3 seconds when turn on the ignition key at the same time. If there is no lighting, check the Lamp. But If the Lamp is working for 3 second, 5) Measure the MIL voltage of wire harness to check ECU. Measuring terminal : B electric wire ~ EARTH => Output Voltage: battery voltage Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~ EARTH => Output voltage: battery voltage Remarks : Measuring unit of voltage : Voltage[V] If the measured voltage is normal, Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and rechecks it. If the measured voltage is abnormal, Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been broken or have short- circuited. 6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
5-37
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.
LH.REAR LH.REAR COVER LH.REAR COVER COVER
- Remove the LH. RR. cover. - Remove the LH. crank case cover.
LH.CRANK LH.CRANK CASE COVER LH.CRANK CASE CASE COVER COVER
- Remove the 3 screws securing ACG stator. - Remove the 2 screws securing CKP.
AC. GENERATOR AC. AC. GENERATOR GENERATOR
Check the ACG stator and position sensor. Take precaution not to use the stator comp (18 terminal) like the carburetor type stator.
5-38
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
SPOT SPOT SPOT
When replace the fly wheel, check the 10 spots of protrusion part.
ASSEMBLY
Assembly is the reverse order of removal.
CHECKING OF CKP(Crank Position Sensor)

MEASUREMENT RESISTANCE
Remove the LH. side cover. Disconnect the ACG coupler and (L/G) connector. Measure the resistance between G and L. STANDARD : 80~150(20)
MEASUREMENT PVA
Disconnect the ACG (L/G) connector. Connect the (+)cord of PVA tester to the green terminal or ground wire. Connect the (-)cord of PVA tester to the blue terminal. Crank the engine with the starter motor and measure the peak voltage of crank position sensor coil. HIGHEST VOLTAGE : 1.5V Over. TOOL : PVA Multy tester. Assembly is the reverse order of removal.
5-39
CHECK THE CIRCUIT OF CKP

CHECKING CIRCUIT
GREEN
BLUE
BLUE
RED
ECU PIN NUMBER ECU 30 : CRANK SIGNAL-A 30 : _ A 22 : _ B 22 : CRANK SIGNAL-B
22
30
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 to ON, its okay. Check if ENGINE SINK ON is OFF while start up. - Remove the A.C. generator. - If there are over 10 spots on the flywheel protrusion, replace it. - Check the CKP is working or NOT (metal residue) 3) Turn OFF ignition key, check the breaking of A.C GEN CKP. Check the A.C. GEN CKP resistance. - measuring resistance : 80 ~ 150[]
5-40

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. - Measuring resistance : 0 ~ 1[]
Check the wiring of crank signal B - Measure terminal : No. 22 pin of wire harness for inspection Blue wire of coupler of CKP. - Measuring resistance : 0 ~ 1[]
RED
5) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code.(5-11)
BLUE
5-41
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
Remove
Loosen the 2 special screws. Remove the tank cover.
Remove the fuel tube. Remove the fuel pump coupler. Loosen the 4 special screws and remove the fuel pump setting plate.
Remove the fuel pump.
5-42
18.FUEL PUMP
The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump)
5-43

Check the fuel pump. Remove the fuel pump. Measure the resistance between terminals.
The FLOAT position F : 192[mm] 1/2 : 138[mm] E : 74[mm]
Terminals resistance [] 30 5[] 300 5[] 566 3[]
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 Remark : measuring unit of resistance : resistance[] If the measured resistance value is out of standard at float position, replace the fuel unit.
CHECK THE BLOW PRESSURE OF FUEL PUMP

- Blow pressure : 3.8 Bar - After remove fuel tube from the injector, turn the ignition key ON/OFF 3 times, when the fuel come out about 130cc over, its Okay. If under 130cc, check the fuel pump. Replace it if necessary. (Be sure to the resistance of battery is over 12.6V)
ASSEMBLY
Assembly is the reverse order of removal.
5-44
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.
Press the enter button on the resetting ECU values.
If the enter-key is press than the ECU will reset.
Press the rest button on the following screen.
5-45

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
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.
Press the enter button on the current data.
By looking the displayed figure on the idle speed actuator PWM, adjust the throttle adjust screw. (Refer to 5-41)
5-47
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.
To check the ignition angle
5-48
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.
Check the engine rpm on the engine speed
5-49
COOLING SYSTEM
6-0
6. COOLING SYSTEM
SERVICE INFORMATION6-1 STROUBLESHOOTING6-2 COOLANT 6-3 COOLING SYSTEM INSPECTION 6-3 COOLING SYSTEM TEST6-4 RADIATOR6-4 RADIATOR DISASSEMBLY 6-5 CHECK THERMOSTATIC SWITCH 6-6 RADIATOR INSTALLATION 6-6 WATER PUMP 6-7 TERMOSENSOR6-10 THERMOSTATIC6-10
SERVICE INFORMATION
Do not remove the radiator cap if the coolant temperature is over 100C. It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. When the temperature is below, carefully remove the cap with a cloth. Cooling system service should be done while the engine is cool. Radiator coolant is toxic. Keep it away from skin, eyes and clothes. - If any coolant gets on your skin or clothes, rinse thoroughly with soap and water. - If any coolant gets in your eyes, rinse them with water and consults a doctor immediately. - If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. - Especially pay attention to reserve the coolant. Keep out of reach of children. Do not remove the radiator cap, except to refill or drain the cooling system after servicing the cooling system. Avoid spilling coolant on painted surfaces, if contaminated, do wash in water immediately. After disassembling or servicing the cooling system, check for leaks with a radiator cap tester.(sale at a market)
SPECIFICATIONS
RADIATOR CAP RELIEF PRESSURE BEGIN TO OPEN THERMOSTAT FULLY OPEN TEMPERATURE VALVE LIFT COOLANT CAPACITY 0.90.1kg/cm2 802 C 903 C 3.5~4.5mm Full : 1,100cc Exchange : 1,000cc
RESERVE TANK : 28020cc
TORQUE VALUE
WATER PUMP IMPELLER WATER PUMP COVER BOLT 1.0~1.4kgfm 0.8~1.2kgfm
6-1
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
Coolant leaks
Faulty water pump mechanical seal Damaged or deteriorated O-rings Faulty radiator cap Damaged or deteriorated gasket Loose hose connection or clamp
6-2
COOLING SYSTEM
COOLANT
COOLANT INSPECTION
Radiator coolant mixes the distilled water. Standard consistenly : 30~50%
RADIATOR WATER
Coolant mixes the light water and radiator liquid about 5C of tolerance inrespect to the minimum temperature.
COOLANT
RADIATOR COOLANT MIXTURE CHART (ANTICORROSIVE AND ANTIFREEZE)

Radiator coolant is toxic. Keep it away from skin, eyes and clothes. - If any coolant gets on your skin or clothes, rinse thoroughly with soap and water. - If any coolant gets in your eyes, rinse them with water and consults a doctor immediately. - If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. - Especially pay attention to reserve the coolant. Keep out of reach of children. When the whole capacity of coolant is 2000cc
Minimum temperature Mixture Ratio
(Unit:cc)
-9 C -16 C -25 C -37 C -44.5 C
20% 30% 40% 50% 60%
400 600 800 1,000 1,100
Distilled water 1,600 1,400 1,200 1,000 900
COOLING SYSTEM INSPECTION

SPECIFIC GRAVITY TEST OF COOLANT
HYDROMETER (Sale at a market)
Follow the hydrometer manufacturers instructions. Check the coolant specific gravity using a hydrometer. Check the contamination of the coolant.
COOLANT GRAVITY CHART
5 10 15 20 25 30 35 40 45 50 55 60
1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100
1.009 1.017 1.027 1.035 1.044 1.052 1.062 1.070 1.078 1.084 1.093 1.098
1.008 1.017 1.026 1.034 1.043 1.051 1.060 1.068 1.076 1.082 1.091 1.095
1.009 1.016 1.025 1.033 1.042 1.049 1.058 1.066 1.074 1.080 1.088 1.092
1.007 1.015 1.024 1.031 1.040 0.047 1.056 1.064 1.072 1.077 1.085 1.089
1.006 1.014 1.022 1.029 1.038 1.045 1.054 1.062 1.069 1.074 1.082 1.086
1.005 1.013 1.020 1.027 1.036 1.043 1.052 1.059 1.066 1.071 1.079 1.083
1.003 1.011 1.018 1.025 1.034 1.041 1.049 1.056 1.063 1.068 1.076 1.080
1.001 1.009 1.016 1.023 1.031 1.038 1.046 1.053 1.060 1.065 1.073 1.077
0.999 1.007 1.014 1.021 1.028 1.035 1.043 1.050 1.057 1.062 1.070 1.074
0.997 1.005 1.012 1.019 1.025 1.032 1.040 1.047 1.054 1.059 1.067 1.071
6-3
COOLING SYSTEM
COOLING SYSTEM TEST

RADIATOR CAP RADIATOR TESTER (SALE AT A MARKET)
Install the redicator cap onto the radiator tester. Press it with specified pressure and it must keep the pressure for at least six seconds.
Apply water to the cap sealing surface before the test. Radiator Cap Relief Pressure : 0.90.15kg/cm2
SCREWS SCREWS SCREWS SCREWS BOLT BOLT BOLT BOLT
RADIATOR
INSPECTION
Remove the center cowl and side cowl. Remove the RH. side cowl.
RADIATOR CAP RADIATOR RADIATOR CAP CAP RESERVE RESERVE TANK RESERVE TANK TANK
Inspect the radiator soldered joints and shims for leaks. Blow dirt out from between core fins with compressed air.
RADIATOR RADIATOR RADIATOR RADIATOR
WATER WATER PUMP WATER PUMP PUMP
REMOVAL
Remove the radiator cap. Drain the coolant. Disconnect the air vent tube from the radiator filler. Remove the overflow tube clamp and disconnect the overflow tube.
DRAIN BOLT BOLT DRAIN DRAIN BOLT
6-4
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 UPPER HOSE UPPER HOSE HOSE LOWER HOSE LOWER LOWER HOSE HOSE
Remove 2 bolts and 1 nut on the radiator.

FLANGE FLANGE NUT FLANGE NUT NUT
FLANGE FLANGE BOLT FLANGE BOLT BOLT RADIATOR RADIATOR RADIATOR
REMOVAL
Remove 3 bolts and then remove the fan/shroud from the radiator.
FAN SHROUD FAN FAN SHROUD SHROUD
Connect the fan motor wire to battery. Check the fan rotate well.
6-5
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 the thermostatic switch ON.
COOLING COOLING FAN SWITCH COOLING FAN FAN SWITCH SWITCH
Install the fan shroud on the radiator with the 2 bolts.
RADIATOR INSTALLATION
Intall the radiator on the radiator bracket with the 2 bolts and 1 nut.
PASS TUBE PASS PASS TUBE TUBE PASS TUBE
Connect the upper and lower hoses and tighten securely them with hose bands. Assemble the pass tube. Connect the thermoseatic switch wire and fan motor wire coupler.
6-6
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. Idling the engine for a few minutes, deflate air in cooling system with a snap slightly, then refill the coolant. After checking the amount of coolant in reserve tank, if it is not enough, fill up it to the upper level. Install the RH/LH side cowl and center cowl.
WATER PUMP
CHECKING CHECKING HOLE CHECKING HOLE HOLE
MECHANICAL SEAL (WATER SEAL) INSPECTION

At the checking hole, inspect the mechanical seal for damage and leakage. If the coolant leaks, disassemble the water pump, check the mechanical seal and replace it.
INLET INLET HOSE INLET HOSE HOSE
WATER PUMP / IMPELLER REMOVAL

Remove the coolant inlet hose.
WATER WATER PUMP PUMP COVER COVER WATER PUMP COVER
6-7
COOLING SYSTEM
Loosen the 3 bolts and remove the water pump cover.
WATER PUMP COVER WATER WATER PUMP PUMP COVER COVER WATER PUMP COVER
DRAIN BOLT DRAIN DRAIN BOLT BOLT DRAIN BOLT
FLANGE FLANGE BOLT FLANGE BOLT BOLT
WATER WATER PUMP IMPELLER WATER PUMP PUMP IMPELLER IMPELLER
Remove the water pump impeller.
The impeller has left hand threads.
WATER PUMP PUMP BODY BODY WATER WATER PUMP BODY
Inspect the mechanical (water) seal and seal washer for wear or damage.
The mechanical seal and seal washer change with a set.
WATER PUMP BODY REMOVAL

REMOVE
Water pump body.
6-8
COOLING SYSTEM
Check the coolant checking hole. Check the water pump body and O-ring for damage and wear.
O-RING O-RING O-RING O-RING
CHECKING HOLE CHECKING CHECKING HOLE HOLE
MECHANICAL SEAL REPLACEMENT

MECHANICAL MECHANICAL SEAL MECHANICAL SEAL SEAL
Remove water pump assembly from the inside by tool. Replace the mechanical seal with new one.
The mechanical seal and the seal washer change with a set.
WATER PUMP / IMPELLER INSTALLATION

When the mechanical seal in replaced, a new seal washer must be installed to the impeller. Install in the reverse order of removal
Install the water pump cover. Install in the reverse order of removal.
6-9
COOLING SYSTEM
THERMOSENSOR THERMOSENSOR THERMOSENSOR
ENGINE COOLANT TEMPERATURE GAUGE

REMOVAL
Remove RH.side cowl. Drain the coolant. Disconnect the engine coolant temperature gauge wire.
Remove the engine coolant temperature gauge.
ENGINE COOLANT TEMPERATURE GAUGE
INSPECTION
Soak the engine coolant temperature gauge in the beaker(fill the beaker with water) Heats up the beaker. Measure the resistance. Temperature() Resistance() 50 154 80 52 100 27 120 16
TEMPERATURE
INSTALLATION
Apply a sealant to the threads and install the thermostat cover. Connect the engine coolant temperature gauge coupler.
6-10
COOLING SYSTEM
THERMOSTAT
THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT
REMOVAL
Disconnect the water hose from the thermostat cover. Remove the 2 bolts and separate the thermostat cover. Remove the thermostat from thermostat cover.
INSPECTION
Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation. Technical data Begins to open Full-open Valve lift 802 903 3.5~4.5mm
THERMOSTAT
THERMOMETER
Do not let the thermostat touch the pan as it will give a false reading. Replace the thermostat if the valve stays open at room temperature. Test the thermostat after it is opened for about 5 minutes and hold the temperature at 70
INSTALLATION
When assembling, the location of air vent hole must be upward.
6-11
ENGINE REMOVAL/INSTALLATION
7-0
7. ENGINE REMOVAL/INSTALLATION
7-1 SERVICE INFORMATION 7-2 ENGINE REMOVAL 7-3 ENGINE INSTALLATION
SERVICE INFORMATION
GENERAL SAFETY
Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. Attach tape to the frame to protect it during the engine removal or installation. The following works require engine removal for service. - Cylinder head/valve - Cylinder/piston - Transmission - Crank shaft
SPECIFICATION
ITEM ENGINE OIL CAPACITY(AT DISASSEMBLY) SPECIFICATIONS 1.5
TORQUE VALUES :
ENGINE HANGER BOLT (FRONT ) : (REAR ) : GEAR CHANGE ARM BOLT : DRIVE SPROCKET BOLT : LH. DOWNTUBE MOUNTING BOLT (SPECIAL BOLT) : 4.9fm 4.9fm 1.2fm 1.2fm 4.2fm
7-1
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.
RADIATOR CAP CAP RADIATOR RADIATOR CAP
Remove the RH. side cowl and LH.side cowl. Drain the coolant. -Remove the radiator cap -Loosen the drain bolt from the water pump and drain the coolant.
Loosen the hose band and remove the radiator hose from the engine.
LH. LH. DOWN DOWN TUBE TUBE COMP. COMP. B B LH. DOWN TUBE COMP. B
Disconnect the AC generator wire coupler and gear position switch wire coupler. Disconnect the starter motor cable. Remove the gear change arm. Remove the LH. rear cover. Loosen the rear axle nut and drive chain adjuster nut then remove the drive sprocket after pushing the rear wheel forward.
GEAR GEAR CHANGE GEAR CHANGE CHANGE
DRIVE DRIVE SPROCKET SPROCKET DRIVE SPROCKET
7-2
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 BOLTS FLANGE FLANGE BOLTS
ENGINE INSTALLATION
Engine installation is essentially the reverse order of removal.
Carefully align mounting points with the jack to prevent damage from mounting bolt threads and wire harness and cables. Be careful not to damage any part of the frame and bolt nuts. Be sure to install the cables, tubes, and wires to their correct positions( 1~8).
TORQUE : ENGINE HANGER BOLTS : (FRONT ) (REAR ) GEAR CHANGE ARM BOLT DRIVE SPROCKET BOLT
4.9kgfm(49Nm) 4.9kgfm(49Nm) 1.2kgfm(12Nm) 1.2kgfm(12Nm)
Inspect the following after installing the engine. - Engine oil level - Throttle grip operation and free play. - Clutch lever operation and free play. - Drive chain slack
7-3
CLUTCH/GEARSHIFT
8-0
8. CLUTCH / GEARSHIFT
SERVICE INFORMATION 8-1 TROUBLESHOOTING 8-2 RH. CRANK 8-3 CLUTCH REMOVAL 8-4 GEARSHIFT SPINDLE 8-7 CLUTCH INSTALLATION 8-9 PRIMARY DRIVE GEAR 8-10 RH. CRANKCASE COVER INSTALLATION 8-12
SERVICE INFORMATION
GENERAL SAFETY
The clutch, gearshift spindle can be serviced with the engine in the frame. If the shift fork, drum and transmission require service, remove the engine and separate the crankcase. The quality and level of fluid affect clutch operation. If the clutch slips, check the fluid level before servicing the clutch system.
8
SPECIFICATIONS
ITEM CLUTCH SPRING FREE LENGTH CLUTCH DISK THICKNESS CLUTCH PLATE WARPAGE CLUTCH OUTER I.D CLUTCH OUTER GUIDE O.D. STANDARD VALUE 35.5 2.9~3.0 28.000~28.013 28-0.020~0.033 Unit : mm SERVICE LIMIT 34.2 2.6 0.2 28.030 28.50.1
TORQUE VALUES
CLUTCH LOCK NUT DRUM STOPPER ARM BOLT PRIMARY DRIVE GEAR NUT RH. CRANKCASE COVER BOLT GEAR SHIFT PEDAL BOLT 6.5kgfm - Apply engine oil 1.2kgfm 6.5kgfm - Apply engine oil 1.1kgfm 1.2kgfm
TOOLS
CLUTCH CENTER HOLDER LOCK NUT WRENCH EXTENSION BAR FLYWHEEL HOLDER
8-1
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 High fluid level or high fluid weight
Clutch slippage
Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play
Difficult to engage the gear

Incorrect clutch adjustment(too big free play) Bent shift fork Bent shift fork shaft Damaged gear shift spindle Damaged shift drum guide groove Damaged shift drum guide pin
Gear disengages
Worn the protrusion of a gear Bent shift fork shaft Damaged shift drum stopper Worn shift drum guide groove Worn gear shift fork groove
8-2
CLUTCH/GEARSHIFT
CABLE CABLE HOLDER CABLE HOLDER HOLDER
RH. CRANKCASE COVER

REMOVAL
Drain the engine oil and coolant. Remove the clutch adjustor locknut and the adjusting nut, then disconnect the clutch cable end from the clutch lever. Remove the right crankcase cover bolts and remove the right crankcase cover.
RH. RH. CRANK CASE COVER RH. CRANK CRANK CASE CASE COVER COVER
Remove the two dowel pins and gasket.
CLUTCH LEVER/LIFTER ROD REMOVAL

Remove the clutch lifter rod. Remove the clutch lever and spring from the RH. crankcase cover simultaneously.
LIFTER LIFTER ROD LIFTER ROD ROD
CLUTCH LEVER SPRING CLUTCH CLUTCH LEVER LEVER SPRING SPRING
Remove the clutch lever spring and O-ring from the clutch lever. Check the wear and damage of the lifter rod and clutch lever and clutch lever spring.
CLUTCH LEVER CLUTCH CLUTCH LEVER LEVER
8-3
CLUTCH/GEARSHIFT
HOLE HOLE HOLE
CLUTCH LEVER INSTALLATION

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.
SPRING SPRING ENDS SPRING ENDS ENDS
After installing the clutch lever into the RH. crankcase cover, turn the clutch lever to the clockwise and install the lifter rod aligning the clutch lever with the RH. crankcase cover hole.
BEARING BEARING BEARING
CLUTCH CLUTCH CLUTCH PRIMARY DRIVE DRIVE GEAR GEAR PRIMARY PRIMARY DRIVE GEAR
CLUTCH REMOVAL
Remove the bearing.
WATER WATER PUMP DRIVE GEAR WATER PUMP PUMP DRIVE DRIVE GEAR GEAR
Remove the clutch lock nut.
8-4
CLUTCH/GEARSHIFT
Remove the lock washer. Remove the clutch inner assy.
SPLINE SPLINE WASHER SPLINE WASHER WASHER
CLUTCH CLUTCH OUTER CLUTCH OUTER OUTER
Remove the spline washer.
CLUTCH OUTER GUIDE CLUTCH CLUTCH OUTER OUTER GUIDE GUIDE
Remove the clutch outer guide and thrust washer.
LIFTER LIFTER PLATE LIFTER PLATE PLATE
BEARING BEARING BEARING
INSPECTION
Remove the clutch center, disk plate, clutch spring and check the other part each. Inspect the lifter plate bearing for damage. (It rotates by hand, if the free play is big, replace them) Inspect the lifter plate for damage. If necessary, replace them.
Remove the clutch spring to diagonal direction.
8-5
CLUTCH/GEARSHIFT
Measure the clutch spring free length; replace the springs if the measurement is not within the service limit.
Replace the clutch disks and plates as a set.(4EA)

CLUTCH CLUTCH SPRING CLUTCH SPRING SPRING
Measure the disk thickness and replace the disks if the service limit is exceeded.
CLUTCH DISK DISK CLUTCH CLUTCH DISK
Check for plate warpage on a surface plate using a feeler gauge; replace if the service limit is exceeded.
CLUTCH PLATE CLUTCH CLUTCH PLATE PLATE
Warped clutch plates prevent the clutch from disengaging properly. Check the slots ( ) in the clutch outer for nicks or indentations made by the clutch discs. If necessary replace them. Measure the inside diameter of clutch outer.
CAUGE FEELER FEELER GAUGE FEELER CAUGE CAUGE CAUGE CLUTCH CENTER FRICTION DISK
Measure the outside diameter of clutch outer guide.

INSTALLATION
Apply the clean engine oil to the clutch friction disk and pressure plate. Install the 7pcs disks and 6pcs plates into the clutch center by turns. Install the spring, lifter plate and clutch spring bolts to diagonal direction.
PRESSURE PLATE
CLUTCH OUTER
Check the condition that the pressure plate is depressed the friction disk and disk plate correctly.
8-6
CLUTCH/GEARSHIFT
GEAR SHIFT SPINDLE

GEAR CHANGE ARM GEAR GEAR CHANGE CHANGE ARM ARM
REMOVAL
Loosen the hex bolt at LH. side and remove the gear change arm.
GEAR GEAR SHIFT SPINDLE GEAR SHIFT SHIFT SPINDLE SPINDLE
Remove the RH. crankcase cover.( 8-3) Remove clutch assembly.( 8-4) Remove the gear shift spindle and thrust washer.
GEAR GEAR SHIFT ARM GEAR SHIFT SHIFT ARM ARM
Remove the gear shift cam bolt, cam and roller. Remove the drum stopper bolt, drum stopper, collar and spring. Remove the pivot securing gear shift and remove the spring and washer pivot.
INSPECTION
Check the gear shift spindle for wear or damage. Inspect the gear shift plate for deformation, wear, or other damage. Check the return spring and gear shift plate spring for wear or damage.
8-7
CLUTCH/GEARSHIFT
INSTALLATION
Install the collar, spring, drum stopper and bolt. Tighten the bolt.
TORQUE : 1.2kgfm
COLLAR COLLAR COLLAR
SPRING COLLAR STOPPER ARM GEAR GEAR SHIFT CAM GEAR SHIFT SHIFT CAM CAM SPRING SPRING SPRING STOPPER STOPPER ARM ARM STOPPER ARM
Press the drum stopper and install the gear shift cam, aligning the roller with the gear shift cam hole.
Install the thrust washer into the gear shift spindle. Install the gear shift spindle into the crank case, aligning the teeth of the return spring with the tappet of the right crank case as shown.
Install the following: - Clutch assembly. - RH. crank case cover Install the gear shift arm aligning its slit with the punch mark on the gear shift spindle. Install and tighten the pinch bolt to the specified torque.
GEAR GEAR CHANGE CHANGE ARM ARM GEAR CHANGE ARM
8-8
CLUTCH/GEARSHIFT
CLUTCH INSTALLATION
OUTER GUIDE GUIDE OUTER OUTER GUIDE
Coat the clutch outer guide with clean engine oil.
Install the trust washer and outer guide into the main shaft.
CLUTCH INNER ASSY CLUTCH CLUTCH INNER INNER ASSY ASSY CLUTCH INNER ASSY CLUTCH CLUTCH OUTER COMP. CLUTCH OUTER OUTER COMP. COMP.
Install the clutch outer into the main shaft. Install the spline washer.
Install the clutch inner assy to clutch outer. Install the lockwasher. Apply the clean engine oil to the washer and install the lock nut temporarily
8-9
CLUTCH/GEARSHIFT
Install the lock nut by pressing clutch center into the clutch center holder.
TORQUE : 6.5kgfm
Install the bearing.
PRIMARY DRIVE GEAR

LOCK NUT LOCK LOCK NUT NUT
REMOVAL
Remove the LH. crankcase cover. Loosen the locknut.
PRIMARY DRIVE GEAR PRIMARY PRIMARY DRIVE DRIVE GEAR GEAR
WATER WATER PUMP DRIVE GEAR WATER PUMP PUMP DRIVE DRIVE GEAR GEAR
Remove the water drive gear. Remove the primary drive gear and sub gear. Check the wear or damage and if have the problem replace it.
SUB GEAR GEAR SUB SUB GEAR
8-10
CLUTCH/GEARSHIFT
INSTALLATION
Insert the woodruff key into the key groove of the crankshaft. Align the primary drive gear key groove with the crankshaft key. Align the sub gear and clutch outer groove and install the gear.
OUTER OUTER GEAR OUTER GEAR GEAR PD PD GEAR PD GEAR GEAR
WATER WATER PUMP PUMP DRIVE DRIVE GEAR GEAR WATER PUMP DRIVE GEAR
Install the water pump drive gear.
Install the lock washer. Coat the nut with clean engine oil, and temporarily tighten the lock nut.
Tighten the primary drive gear lock nut.

TORQUE : 6.5kgfm
8-11
CLUTCH/GEARSHIFT
WATER WATER PUMP PUMP DRIVE DRIVE GEAR GEAR WATER PUMP DRIVE GEAR
RH. CRANKCASE COVER INSTALLATION

Remove the gasket from the crankcase surface. Install the two dowel pins and a new gasket.
Install the crankcase cover bolts and clutch cable holder.

TORQUE : 1.1kgfm
Connect the clutch cable end to the clutch lever, then install the clutch wire holder with the two bolts. Adjust the clutch lever free play. ( 2-12) Remove the oil level gauge, then fill the crankcase with the recommended oil.( 3-3)
RADIATOR RADIATOR HOSE RADIATOR HOSE HOSE
Connect the radiator hose Pour the coolant.
Install the side cowls and center cowl. Install in the reverse order of removal.
8-12
MEMO
A.C GENERATOR / STARTER CLUTCH
9-0
9. A.C GENERATOR / FLY WHEEL

SERVICE INFORMATION 9-1 A.C GENERATOR 9-2 STARTER CLUTCH 9-5 STARTOR 9-6
SERVICE INFORMATION
GENERAL SAFETY
This section covers removal and installation of the A.C. generator. Refer to section 17 for inspection of the A.C. generator. The A.C. generator/starter clutch service can be done with the engine installed in the frame.
SPECIFICATIONS
ITEM STARTER DRIVEN GEAR STARTER IDLE GEAR STARTER IDLE GEAR SHAFT REDUCTION GEAR REDUCTION GEAR SHAFT O.D. I.D I.D O.D I.D O.D STANDARD VALUE 39.622~39.635 22.010~22.022 10.013~10.045 9.991~10.000 10.013~10.045 9.991~10.000
Unit:mm SERVICE LIMIT 39.607 22.100 10.100 9.970 10.100 9.970
TORQUE VALUES
FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT LEFT CRANK CASE COVER BOLT 5.5kgfm(55Nm) 3.2kgfm(32Nm) 1.1kgfm(11Nm)
TOOLS
ACG ROTOR PULLER FLYWHEEL HOLDER
9-1
LH. LH. REAR REAR COVER COVER LH. REAR COVER
A.C GENERATOR REMOVAL

Remove the LH. rear cover.
Remove the AC. generator coupler connecting of gear change switch.
Remove the starter reduction gear cover.

STARTER REDUCTION GEAR COVER STARTER STARTER REDUCTION REDUCTION GEAR GEAR COVER COVER STARTER REDUCTION GEAR COVER
Remove the starter reduction gear shaft and starter reduction gear.
9-2

Remove the left crankcase cover bolts and left crankcase cover.
LH. LH. CRANK CASE COVER LH. CRANK CRANK CASE CASE COVER COVER
FLY FLY WHEEL FLY WHEEL WHEEL
Remove the gasket and the dowel pins.
STARTER STARTER IDLE GEAR STARTER IDLE IDLE GEAR GEAR
GEAR GEAR SHAFT GEAR SHAFT SHAFT
Remove the starter idle gear shaft.
FLYWHEEL HOLDER FLYWHEEL FLYWHEEL HOLDER HOLDER
Hold the flywheel rotor with a flywheel holder, and remove the rotor bolt.
TOOL : LOCKNUT WRENCH FRY WHEEL HOLDER
9-3

After installing the ACG rotor puller on the rotor, remove the rotor.
TOOL : ACG ROTOR PULLER
ACG ROTOR PULLER ACG ACG ROTOR ROTOR PULLER PULLER ACG
GEAR GEAR CHANGE SWITCH GEAR CHANGE CHANGE SWITCH SWITCH
Remove the fly wheel and starter driven gear collar.
STARTER STARTER DRIVEN GEAR COLLAR STARTER DRIVEN DRIVEN GEAR GEAR COLLAR COLLAR
STARTER IDLE GEAR INSPECTION

Inspect the wear and damage of starter ldle gear. Measure the gear inside diameter.
STARTER STARTER IDLE GEAR STARTER IDLE IDLE GEAR GEAR
Measure the gear shaft outside diameter.

REDUCTION GEAR INSPECTION

Inspect the wear and damage of reduction gear. Measure the gear inside diameter.
REDUCTION REDUCTION GEAR REDUCTION GEAR GEAR
Measure the gear shaft outside diameter.

9-4
SOCKET SOCKET BOLTS SOCKET BOLTS BOLTS
STARTER CLUTCH
DISASSEMBLY
Remove the flywheel. Remove the three socket bolts, and remove the starter clutch (one way clutch) from the flywheel.
STARTER STARTER DRIVEN GEAR STARTER DRIVEN DRIVEN GEAR GEAR FLY FLY WHEEL COMP FLY WHEEL WHEEL COMP COMP
Check the starter driven gear for damage or wear. Measure the starter driven gear I.D. and O.D.
SERVICE LIMIT : O.D. : 39.607mm I.D. : 22.100mm
STARTER DRIVEN GEAR STARTER STARTER DRIVEN DRIVEN GEAR GEAR STARTER DRIVEN GEAR STARTER STARTER ONE-WAY CLUTCH ASSY STARTER ONE-WAY ONE-WAY CLUTCH CLUTCH ASSY ASSY
INSTALLTION
Check the one-way clutch for wear or damage. Install the one-way clutch flange into the clutch outer. Apply the screw locking bond to the socket bolt and install it.
TORQUE : 3.2kgf-m
Grip the flywheel. Check the operation of the one-way clutch by turning the driven gear. You should be able to turn the driven gear counterclockwise smoothly, but the gear should not turn clockwise.(as like photo)
9-5

STATOR REMOVAL / INSTALLATION
Remove the crank position sensor screw, then remove crank position sensor. Remove the wire guide using a long nose plier and screwdriver.
WIRE WIRE GUIDE GUIDE WIRE GUIDE
Loosen the stator screw and remove the stator.
CRANK CRANK POSITION SENSOR CRANK POSITION POSITION SENSOR SENSOR STATOR STATOR STATOR
Fix the grommet to groove part correctly.
INSTALLTION
STARTER STARTER DRIVEN GEAR COLLAR STARTER DRIVEN DRIVEN GEAR GEAR COLLAR COLLAR
Install the starter driven gear collar. Clean the taper part of crank shaft and remove the dust. If installing the rotor with dust in taper part, the key will be damaged. Because the contacted area of taper will be small and it will occur the stress in the woodruff key.
After checking whether inside magnet of rotor is attached by the bolts and nuts, install them. If installing the rotor with the foreign material, the starter coil is damaged.
9-6

Install the woodruff key into the crank shaft key groove.
FLY WHEEL FLY FLY WHEEL WHEEL
Install the rotor bolt temporarily. After fixing the flywheel with holder, tighten the fly wheel nut.
TORQUE : 5.5kgf-m TOOLS : FLYWHEEL HOLDER LOCKNUT WRENCH
IDLE GEAR IDLE IDLE GEAR GEAR
Install starter idle gear and shaft. Install new gasket and dowel pins.
ACG. CHANGE SWITCH WIRE ACG. ACG. CHANGE CHANGE SWITCH SWITCH WIRE WIRE
Install the LH. crank shaft cover at this time be careful not to catch the wires in between the cover and case.
9-7

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.
LH. LH. REAR COVER LH. REAR REAR COVER COVER
Install the LH. rear cover.

TORQUE : 1.2kgf-m
9-8
MEMO
CYLINDER HEAD / VALVES
10-0
10. CYLINDER HEAD / VALVES

10-1 SERVICE INFORMATION TROUBLESHOOTING 10-2 CAMSHAFT 10-3 CYLINDER HEAD 10-4 VALVE SPRINGS 10-6 VALVE GUIDES 10-7 VALVE SEATS 10-8 CYLINDER HEAD ASSEMBLY10-8
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. The oil of camshaft is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder head.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
CAMSHAFT
CAM HEIGHT VALVE SPRING FREE LENGTH VALVE STEM OUTER DIAMETER
IN EX IN,EX IN EX IN,EX IN EX
32.02~32.18 31.72~31.88 41.40 4.975~4.990 4.995~4.970 5.000~5.012 0.010~0.037 0.030~0.057 0.7~0.9
31.90 31.60 40.00 4.925 4.905 5.030 0.080 0.100 1.3
VALVE, VALVE GUIDE
VALVE GUIDE INNER DIAMETER CLEARANCE BETWEEN STEM AND GUIDE VALVE SEAT WIDTH
TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT SPARK PLUG CYLINDER HEADSPECIAL SOCKET BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW CYLINDER HEAD COVER BOLT CRANK SHAFT HOLE CAP A.C.GENERATOR CAP 1.0 kgfm (10Nm) 1.1 kgfm (11Nm) 4.0 kgfm (40Nm) 1.2 kgfm (12Nm) 0.4 kgfm ( 4Nm) 1.0 kgfm (10Nm) 0.8 kgfm ( 8Nm) 0.6 kgfm ( 6Nm)
10-1

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.
Low comperssion
Valves - Incorrect valve adjustment (see section 3) - Valve springs damage - Incorrect valve timing - Uneven valve seating Cylinder head - Leaking or damage head gasket - Warped or cracked cylinder head Cylinder, piston (see section 10,11)
Rough idle
Low cylinder compression
Compression too high

Excessive carbon build-up on piston or combustion chamber
Excessive noise
Incorrect valve adjustment Sticking valve or broken valve spring Damaged or worn camshaft Loose or worn cam chain Worn or damaged cam chain tensioner
Excessive white smoke

Worn valve guide or valve stem Damaged valve stem seal Worn or damaged piston ring
10-2
CAMSHAFT
SPARK SPARK PLUG SPARK PLUG PLUG
REMOVAL
Remove the side cowl. Remove the noise suppressor cap assembly from the spark plug.
TENSIONER TENSIONER TENSIONER TENSIONER
Loosen the screw of the cam chain tensioner and remove the tensioner mounting bolt. Remove the AC generator cap and crank shaft hole cap out of the left crankcase cover. Turn the crankshaft to the left, and align the T mark of the flywheel with the index mark of the LH. crankcase cover. Verify that the piston is located at the top dead center. (Make all camshaft lobes face downward.) If all camshaft lobes face upward, rotate the crankshaft to the left for 1 turn (180 ), and align theTmark with the index mark once again.
Remove the fuel tank. Loosen the 4 cylinder head cover special bolts and remove the cover.
CYLINDER CYLINDER HEAD COVER CYLINDER HEAD HEAD COVER COVER
CAM CAM SHAFT HOLDER CAM SHAFT SHAFT HOLDER HOLDER
Remove the 8 flange bolts of the camshaft holder and remove the camshaft holder from the cylinderhead. Remove the cam chain from the camshaft.
10-3

Remove the cam chain from the cam shaft. Take precautions not to allow the cam chain to drop into crankcase. Remove the cam shaft.
CAM CAM CHAIN CAM CHAIN CHAIN
Take precautions not to allow the cam chain to drop into the crankcase.
Check the cam lobes of the camshaft for wear or damage. Measure the height of the cam lobe.
SERVICE LIMIT : IN : 31.9 mm EX: 31.6 mm
Manually turn the camshaft bearing outer race, and check if it turns smoothly. Check the bearing for wear or damage.
BEARING BEARING
CYLINDER HEAD SOCKET NUT (M8X 4) CYLINDER CYLINDER HEAD HEAD SOCKET SOCKET NUT NUT (M8X (M8X 4) 4) CYLINDER HEAD SOCKET NUT (M8X 4)
CYLINDER HEAD
REMOVAL
Remove the cylinder head cover Remove the camshaft. Remove the cylinder head special socket nut(M8) Remove the throttle body insulator.
10-4
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.
IN IN VALVE IN VALVE VALVE
NOTE
Mark all parts during disassembly so they can be placed back in their original locations. Remove the valve stem seals and valve spring seals, remove the carbon deposits from the combustion chamber.
OUT OUT VALVE OUT VALVE VALVE
INSPECTION
CYLINDER HEAD
Clean off the head gasket surface. Inspect the spark plug assembly hole and the crack of near valve seat. Check for the warp of the cylinder head with a square and filler gauge. Service Limit : 0.1mm
Avoid damaging the gasket surfaces.

10-5

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. Check the operating condition using the valve guide. Measure and record external diameter of valve stem.
Insert the valve guide reamer from the combustion chamber side and ream the guide to remove any carbon build-up before measuring the guide.
Rotate the reamer clockwise during the installation and removal of reamer. Otherwise, it may cause the damage to the inside of the guide.
TOOL : VALVE GUIDE REAMER
Measure and record each valve guide inner diameter.

SERVICE LIMIT : 5.030 mm
Measure the gap between valve stem and guide.

Measure the inner diameter of the new valve guide. If the clearance is not within the service limit, replace the valve.
10-6

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. Do not heat the cylinder head partly using the torch that may cause the cylinder head warping. Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER
Avoid damaging the head when driving the valve guide out. Install the new O-ring to new valve guide. Insert the valve guide from the upper part of cylinder head.
TOOL : VALVE GUIDE DRIVER
After insert the valve guide, complete the valve guide reamer by putting the valve guide reamer on the cylinder heads conbustion chamber.
TOOL : VALVE GUIDE REAMER
Take care not to tilt or lean the reamer in the guide while reaming. Otherwise, the valve is installed slanted, that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed. Use cutting oil on the reamer during this operation.
Reface and clean the cylinder head. Inspect and correct around the valve seat.
10-7
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. Remove the valve and inspect the valve seat face. The valve seat contact should be within the specified width and evenly all around the circumference. If the valve seat width is not within specification, reface the valve seat.
Valve faces cannot be ground. If a valve face is rough, worn unevenly, or contacts the seat improperly, the valve must be replaced. Measure the valve seat width.
STANDARD VALUE : 0.7~0.9 mm SERVICE LIMIT : 1.3 mm
VALVE SEAT CUTTER

70 20 IN : 22mm EX : 22mm IN : 23mm
Reface the worn valve seat by using valve seat cutters and grinders.
45 IN : 24.5mm EX : 24.5mm EX : 20mm
30
Follow the refacer manufactuers operating instructions. Be careful not to grind the seat more than necessary.
CYLINDER HEAD ASSEMBLY

Install new stem seals and valve spring seat. Lubricate each valve stem with molybdenum grease and insert the valve into the valve guide turning it slowly to avoid damage the stem seals. Check to see if the valve move up and down smoothly.
10-8

Install the valve springs with the narrow pitch forward to cylinder head.
FOR FOR CYLINDER CYLINDER HEAD HEAD FOR CYLINDER HEAD
Install the spring retainer. Using the valve spring compressor. Install the valve cotters.
Do not compress the valve spring more than necessary.

TOOL : VALVE SPRING COMPRESSOR
VALV E E SPRING SPRING COMPRESSOR COMPRESSOR VALV VALV E SPRING COMPRESSOR
Tap the valve stems gently 2~3times with a soft hammer to firmly seat the cotters.
Take necessary precautions not to damage the valve.
Install the cam chain tensioner, and assemble pivot bolts.

TORQUE : 1.0 kgf m
Install the spark plug.

TORQUE : 1.1 kgf m
10-9
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 (M8 1.25), tighten them for 2times as shown picture. half installation Complete installation Complete installation Complete installation Complete installation
TORQUE : 4.0 kgf m
Assemble the shim in place. After checking the comshaft for damage, put it to the cylinder head.
Slowly rotate the crankshaft counterclockwise, and align theTmark of the flywheel with the index mark of the LH. crankcase cover.
Take precautions not to allow the cam chain to drop into the camshaft timing gear while turning the camshaft.
LOCATION OF OF TIMING TIMING MARK MARK LOCATION LOCATION OF TIMING MARK
Apply engine oil to the camshaft then assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head.
10-10

Install the dowel pins on the cylinder head. Install the camshaft holder. Install the cam chain guide.
CAM CAM CHAIN CHAIN GUIDE GUIDE CAM CHAIN GUIDE
CAM CAM SHAFT HOLDER CAM SHAFT SHAFT HOLDER HOLDER
Remove the sealing screws and o-ring from the cam chain tensioner. Rotate the tensioner shaft clockwise with a small screwdriver, and insert the shaft into the body completely. Assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. Install tensioner lifter bolt.
TORQUE : 1.2 kgf m
Install the O-ring and sealing screw to the tensioner lifer.

TORQUE : 0.4 kgf m
If the cam chain tensioner lifter is dropped, the shaft will advance by the spring force. Fill clean engine oil into the operating parts of the cylinder head. Adjust the valve clearance. If the valve clearance is unfit, adjust the shim. Install the 30mm cap and A.C generator cap.
TORQUE : 30mm CAP : 0.8kgfm A.C.GENERATOR CAP : 0.6kgfm
Remove oil from the cylinder head cover grooves, and accurately assemble the gasket to the cylinder head cover. Install the cylinder head cover. Tighten the cylinder head cover bolt.
TORQUE : 1.0 kgf m
10-11
CYLINDER / PISTON
11-0
11. CYLINDER / PISTON

11-1 SERVICE INFORMATION TROUBLESHOOTING 11-1 CYLINDER REMOVAL 11-2 PISTON / PISTON RING 11-3 CYLINDER INSTALLATION 11-6
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. Take care not to damage the cylinder wall and piston.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
INNER DIAMETER CYLINDER CYLINDERICAL ROUNDLESS HEAD CONTACT WARPAGE PISTON SKIRT OUTER DIAMETER PISTON PIN HOLE INNER DIAMETER PISTON PIN OUTER DIAMETER PISTON, PISTON PIN, PISTON RING PISTON-TO-PISTON PIN CLEARANCE TOP PISTON RING-TOGROOVE CLEARANCE SECOND PISTON RING JOINT GAP CYLINDER-TO-PISTON CLEARANCE CONNECTING ROD SMALL END INNER DIAMETER GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN TOP / SECOND OIL RING (SIDE RAIL)
73.005~73.015 72.985~72.965 17.002~17.008 16.994~17.000 0.002~0.014 0.015~0.045 0.015~0.045 0.35~0.45 0.20~0.70 0.020~0.050 17.010~17.028 0.010~0.034
73.10 0.10 0.05 0.10 72.60 17.04 16.96 0.02 0.09 0.09 0.50 1.10 0.30 17.06 0.04
TROUBLESHOOTING
Compression too low
Worn piston Worn, damaged piston ring Worn cylinder
Overheating
Excessive carbon build-up on top of piston
Abnormal noise Excessive smoke

Worn cylinder, piston or piston rings Improper installation of piston ring Scored or scratched piston or cylinder Worn cylinder and piston Worn connecting rod small end bearing or piston pin Damaged piston ring Excessive carbon build-up on top of piston
11-1
CYLINDER / PISTON
CYLINDER CYLINDER HEAD GASKET CYLINDER HEAD HEAD GASKET GASKET
CYLINDER CYLINDER REMOVAL REMOVAL

Remove 10-5 Remove the the cylinder cylinder head. head. ( ( 10-4 10-4 ) ) Remove Remove the the cylinder cylinder head head gasket. gasket. Remove Remove the the cam cam chain chain guide guide from from the the cylinder. cylinder. Remove Remove the the cylinder. cylinder.
PISTON PISTON PISTON PISTON
CYLINDER CYLINDER CYLINDER
Remove Remove the the gasket gasket and and dowel dowel pin. pin. Carefully Carefully remove remove from any the cylinder // head from the any adhering adhering gasket gasket material the cylinder cylindermating head material from mating surface. mating surface. surface. Do Do not not scratch scratch the the surface. surface.
Take care not to damage the cylinder interface.
INSPECTION INSPECTION INSPECTION

Inspect the cylinder wall for scratches and wear. Inspect Measure and cylinder record wall the for cylinder scratches inner and diameter at Inspect the the cylinder wall for scratches and wear. wear. Measure and record cylinder three levels in both an the X and Y axis.inner Measure and record the cylinder inner diameter diameter at at Take the maximum reading toaxis. determine the cylinder three in X three levels levels in both both an an X and and Y Y axis. Take wear. Take the the maximum maximum reading reading to to determine determine the the cylinder cylinder SERVICE LIMIT : 73.005~73.015 mm wear. wear.
LIMIT : 56.60 mm SERVICE SERVICE SERVICELIMIT LIMIT: :56.60 56.60mm mm LIMIT : 56.60 mm
CYLINDER CYLINDER GAUGE CYLINDER GAUGE GAUGE
Measure the piston outer diameter. Measure Calculate the piston piston-to-cylinder outer Measure the the piston outer diameter. diameter.clearance. Take the Calculate piston-to-cylinder clearance. maximum reading to determine the clearance.Take Calculate the the piston-to-cylinder clearance. Take the the SERVICE : 0.30 mm maximum reading to the maximumLIMIT reading to determine determine the clearance. clearance.
LIMIT : 0.30 mm SERVICE SERVICE SERVICELIMIT LIMIT: :0.30 0.30mm mm LIMIT : 0.30 mm
TOP
MIDDLE
Calculate the cylinder roundness and cylinderical at the cylinder forY out-of-round Calculate the cylinder for out-of-round levels three levels in an X and axis. Take at the maximum Calculate at three three levels in and Y Take the reading reading determine the roundness and cylinderical. in an an X Xto and Y axis. axis. Take the maximum maximum reading to to SERVICE : ROUNDNESS : 0.05 mm determine the determineLIMIT the out-of-round. out-of-round. Calculate CYLINDERICAL for 0.1 mm levels Calculate the the cylinder cylinder for taper taper at at :three three levels in in an an X X and and Y Y axis. axis. Take Take the the maximum maximum reading reading to to determine determine If any of the cylinder measurements exceed the service the taper. the taper. If the measurements limits, replace the cylinder. If any any of of the cylinder cylinder measurements exceed exceed the the service service SERVICE LIMIT : OUT-OF-ROUND : 0.2 mm , 0.50mm limits, the cylinder. limits, replace replace the cylinder.
LIMIT : OUT-OF-ROUND : 0.05 mm SERVICE SERVICE SERVICELIMIT LIMIT: :OUT-OF-ROUND OUT-OF-ROUND: :0.05 0.75mm 0.05mm mm, 1.0mm LIMIT : OUT-OF-ROUND : 0.05 mm TAPER : 0.1 mm STANDARD LIMIT TAPER TAPER : 0.020~0.050 : :0.1 0.1mm mm mm TAPER : 0.1 mm
BOTTOM
If the piston outer diameter is oversize, boring the cylinder to fit.
11-2
CYLINDER / PISTON
WARPAGE INSPECTION
Check the torsion of contact surface in gasket cylinder.
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. Remove the second ring.
Do not damage or scratch the piston.
PISON PISON RING RING PISON RING
Measure the clearance between the piston ring and piston grooves.
SERVICE LIMIT : TOP : 0.090 mm SECOND : 0.090 mm OIL RING : 0.090 mm
RING RING RING
C C C Y Y Y L L L III N N N D D D E E E E R R R R
Inspect the piston for wear or damage.
PISTON PISTON PISTON PISTON ABNORMAL ABNORMAL WEAR ABNORMAL WEAR WEAR
11-3
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.
PISTON RING RING PISTON PISTON RING
Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder.
90 90 90
Measure the outer diameter of the piston at 10mm from the bottom and 90 to the piston pin. Replace the piston if the service limit is exceeded.
SERVICE LIMIT : 72.965 - 72.985 mm
MICROMETER MICROMETER MICROMETER
PISTON PIN INSPECTION

Measure the piston pin hole inside diameter.
SERVICE LIMIT : 17.002 - 17.008 mm
Measure the piston pin outer diameter.

SERVICE LIMIT : 16.994 ~ 17.000 mm
Calculate the clearance between the piston and the piston pin.
Measure the inner dismeter of the connecting rod small end.

Calculate the clearance between the inner diameter of the connecting rod small end and pisto pin.
CYLINDER GAUGE
11-4
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
TOP RING SECOND RING
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. Install the ring forward to the marking facing up. Do not accord the side rail of oil ring
SIDE RAIL SPACER SIDE RAIL

OIL RING
After installation, the rings should rotate freely in the ring grooves.
PISTON / CYLINDER INSTALLATION

Remove gasket on the crank case surface.
Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. Do not damage the contact place of gasket
GASKET GASKET GASKET
PISTON PISTON PIN CLIP PISTON PIN PIN CLIP CLIP
Insert the piston and piston into the conrod Install new piston pin clips.
INMARK, it does toward to intake side. Take care not to drop the piston pin clip into the crankcase. Do not align the clips end gap with the piston cutout.
11-5
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.
Install the lower part of the cam chain guide to the part of the crankcase, and install the cam chain guide by aligning the projection part with the part of cylinder. Install the cylinder head. ( 10-10 ) Install in reverse order of removal.
11-6
MEMO
CRANKCASE/TRANSMISSION/CRANKSHAFT
12-0
12. CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION TROUBLESHOOTING 12-1 12-2 CRANKCASE BEARING 12-7 CRANKSHAFT INSTALLATION 12-8 TRANSMISSION ASSEMBLY 12-9 CRANKCASE ASSEMBLY 12-11
CRANKCASE DISASSEMBLY 12-3 TRANSMISSION DISASSEMBLY12-4 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. - CLUTCH, GEAR SHIFT SPINDLE ( SECTION 8) - A.C. GENERATOR, STARTER CLUTCH ( SECTION 9) - CYLINDER HEAD ( SECTION 10) - CYLINDER, PISTON ( SECTION 11) - STARTER MOTOR ( SECTION 19)
SPECIFICATIONS
ITEM STANDARD VALUE
Unit: mm
SERVICE LIMIT
SHIFT FORK/SHAFT
FORK SHAFT O.D. MAIN SHAFT O.D. COUNTER SHAFT O.D.
I.D. CLAW THICKNESS M3, M5 C1 C2 C4 M5 M3, C2 C4 C1 M5 M3, C2 C1 M3, C2 C1 M3, M5 C1, C2 C4 M3 C1 C2
GEAR I.D. TRANSMISSION GEAR BUSHING O.D.
GEAR-TO-BUSHING I.D. GEAR-TO-BUSHING CLEARANCE GEAR-TO-SHAFT CLEARANCE BUSH-TO-SHAFT CLEARANCE
12.000~12.018 4.930~5.000 11.976~11.994 19.967~19.980 16.466~16.484 19.974~19.987 19.959~19.980 23.000~23.021 23.020~23.041 20.020~20.041 20.000~20.021 22.959~22.980 22.979~23.000 19.959~19.980 20.000~20.021 16.500~16.518 0.020~0.062 0.040~0.082 0.200~0.062 0.016~0.052 0.013~0.047
12.050 4.500 11.960 19.930 16.440 19.940 19.930 23.050 23.070 20.070 20.050 22.930 22.950 19.930 20.050 16.550 0.100 0.120 0.100 0.090 0.090
12-1
Unit: mm
ITEM STANDARD VALUE SERVICE LIMIT
CONNECTING ROD BIG END SIDE CLEARANCE CRANKSHAFT CONNECTING ROD BID END VERTICAL DIRECTION CLEARANCE CRANKSHAFT RUNOUT RIGHT LEFT
0.050~0.300 0~0.008
0.600 0.050 0.100 0.100
TORQUE VALUES
BEARING SETTING PLATE CRANKCASE BOLT 1.2kgf m(12N m) 1.1kgf m(11N m)
TOOLS
UNIVERSAL BEARING PULLER BEARING REMOVER SET DRIVER ATTACHMENT PIROT THREAD ADAPTER ASSEMBLY SHAFT CRANKCASE ASSEMBLY COLLAR
TROUBLESHOOTING
Hard to shift
Incorrect clutch system adjustment (Free play is too big) Shift fork bent Shift fork shaft bent Gear shift spindle claw bent Shift drum guide grooves damaged Shift fork guide spot damaged
Engine noise
Connecting rod big end bearing worn Connecting rod bent Crank shaft main bearing worn or breakage Transmission gear worn or breakage
Transmission jumps out of gear

Gear dogs worn Shift fork shaft bent Shift drum stopper damaged Shift drum guide grooves worn Shift fork grooves worn
12-2
RH. CRANK CRANK CASE CASE RH. RH. CRANK CASE
CRANKCASE DISASSEMBLY
Drain the coolant. The engine must be seperated from the frame. ( section 7) Refer to the service information for removal of necessary parts before disassembling the crankcase. Remove the LH. cover / Fly wheel. Remove the RH. cover / Clutch. Remove the Cylinder head / Cylinder / Piston.
LH. LH. CRANK CASE LH. CRANK CRANK CASE CASE
Remove the 4pcs bolts from the RH. crankcase. Loosen the ten 11pcs bolts from the LH. crankcase in a crisscross pattern, remove the bolts.
Place the crank case down, and separate the LH. crankcase from the RH. crankcase by tapping the crankcase with a soft hammer.
Be careful not to distort the mating surface of the crankcase during removal.
BALANCE GEAR BALANCE BALANCE GEAR GEAR
MAIN MAIN SHAFT MAIN SHAFT SHAFT
GASKET GASKET GASKET
Remove the dowel pins and gasket.
COUNT SHAFT COUNT COUNT SHAFT SHAFT COUNT
GEAR GEAR SHIFT DRUM GEAR SHIFT SHIFT DRUM DRUM
12-3
SHIFT SHIFT FORK SHAFT SHIFT FORK FORK SHAFT SHAFT
TRANSMISSION DISASSEMBLY
Remove the shift fork shaft. Remove the shift fork and the shift drum.
COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT MAIN MAIN SHAFT SHAFT MAIN SHAFT
Remove the main shaft and the counter shaft as an assembly.
CRANK CRANK BALANCER GEAR CRANK BALANCER BALANCER GEAR GEAR
Remove the crank balancer gear.
INSPECTION
Check the shift fork for wear or damage. Measure the shift fork inside diameter and the shift fork claw thickness.
SERVICE LIMIT : INSIDE DIAMETER : 12.050mm CLAW THICKNESS : 4.500mm
Check the shift fork shaft for wear or damage. Measure the shift fork shaft outside diameter in shift fork operation part.
12-4
Check the shift drum for wear or damage. Check the shift drum guide groove for partial wear or damage.
MAIN SHAFT MAIN MAIN SHAFT SHAFT
Measure the main shaft and counter shaft outside diameter.

SERVICE LIMIT : M3, M5 : 19.930mm C1 : 16.440mm C2 : 19.940mm C4 : 19.930mm
COUNTER SHAFT COUNTER COUNTER SHAFT SHAFT
MAIN GEAR MAIN MAIN GEAR GEAR MAIN GEAR
Check the gear holes teeth and threads for wear and damage. Measure the gear inside diameter.
SERVICE LIMIT : M5 : 23.050mm M3, C2 : 23.070mm C4 : 20.070mm C1 : 20.050mm
M3 M3 M3
M4 M4 M4
M5 M5 M5
M2 M2 M2
Measure the gear bush inside diameter and outside diameter.

SERVICE LIMIT : M5 : OUTSIDE DIAMETER : 22.930mm M3, M2 OUTSIDE DIAMETER : 22.950mm C1 OUTSIDE DIAMETER : 19.930mm M3, C2 INSIDE DIAMETER : 20.050mm C1 INSIDE DIAMETER : 16.550mm
COUNTER COUNTER GEAR COUNTER GEAR GEAR
Measure out the gear-to-bush clearance.

SERVICE LIMIT : M3, M5, C1, C2 : 0.100mm
Measure out the gear-to-shaft clearance.

SERVICE LIMIT : C4 :0.120mm
Measure out the bush-to-shaft clearance.

M1 M1 M1 M3 M3 M3 M4 M4 M4 M5 M5 M5 M5 M2 M2 M2 M2
SERVICE LIMIT : M3 : 0.100mm C1 : 0.090mm C2 : 0.090mm
12-5
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.
TOOLS : DRIVER ATTACHMENT
RH. RH. CRANK CRANK CASE CASE RH. CRANK CASE
UNIVERSAL UNIVERSAL BEARING PULLER UNIVERSAL BEARING BEARING PULLER PULLER
If the bearing is left on the crankshaft, use a universal bearing puller to remove it.
TOOL : UNIVERSAL BEARING PULLER
After removing the crankshaft from the RH. crankcase, replace the RH. crankshaft bearing with a new one.
RIGHT RIGHT RIGHT
LEFT LEFT LEFT
INSPECTION
Place the crankshaft on a stand or V-block, and measure the crankshaft runout using dial gauge.
SERVICE LIMIT : RIGHT : 0.100 mm LEFT : 0.100 mm
90mm 90mm 90mm 90mm
75mm 75mm 75mm 75mm
FEELER FEELER GAUGE FEELER GAUGE GAUGE
Measure the side clearance between the crankshaft and connecting rod big end by the feeler gauge.
SERVICE LIMIT : 0.600mm TOOL : FEELER GAUGE
12-6
Measure the connecting rod radial clearance in both X and Y directions. Replace the crankshaft if the service limit is exceeded.
REMOVER REMOVER 15mm REMOVER 15mm 15mm
CRANKCASE BEARING
MAIN MAIN SHAFT SHAFT BEARING BEARING MAIN SHAFT BEARING CRANK CRANK BALANCE CRANK BALANCE BALANCE SHAFT SHAFT BEARING SHAFT BEARING BEARING
Remove the transmission and crank shaft.
INSPECTION
Turn the Inner race of bearing with fingers and inspect for smooth turning. Also inspect that the outer race is driven into the case exactly. If the clearance is excessive, or the driving for the case is loose, remove and replace them.
COUNTER COUNTER COUNTER COUNTER SHAFT SHAFT SHAFT SHAFT BEARING BEARING BEARING BEARING
CRANK SHAFT BEARING CRANK CRANK SHAFT SHAFT BEARING BEARING
Replace the transmission bearing with the right and left sets.
DRIVER DRIVER DRIVER DRIVER
REPLACEMENT
LH. Crankcase
Remove the cranke balance shaft bearing, main shaft bearing, crank shaft bearing with the tools.
TOOL : BEARING REMOVER SET
Remove the counter shaft bearing and oil seal. Coat the new bearing with clean engine oil, and install it into the crank case.
TOOLS : MAIN SHAFT BEARING : - DRIVER - ATTACHMENT COUNTER SHAFT BEARING: - DRIVER - ATTACHMENT - PILOT
COUNTER COUNTER SHAFT OIL SEAL COUNTER SHAFT SHAFT OIL OIL SEAL SEAL
Pressing the new counter shaft oil seal. Inspect the gear shift spindle oil seal for wear and damage, it must be replaced if necessary.
GEAR GEAR SHIFT SPINDLE OIL SEAL GEAR SHIFT SHIFT SPINDLE SPINDLE OIL OIL SEAL SEAL
12-7
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 2

TOOLS : MAIN SHAFT / COUNTER SHAFT / CRANK BALANCER SHAFT BEARING - DRIVER - ATTACHMENT - PILOT
Coat the socket bolt screw part with oil and install the main shaft bearing set plate.
TORQUE : 1.2kgfm (12Nm)
CRANKSHAFT INSTALLATION
Coat a new left crankshaft bearing with clean engine oil and install new bearings into the right crankcase.
CRANK ASSEMBLY CRANK SHAFT
TOOLS : DRIVER ATTACHMENT PILOT
Install the crankshaft into the RH. crankcase with the following tools:
TOOLS : ASSEMBLY SHAFT CRANKSHAFT ASSEMBLY COLLAR
12-8
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
COUNTER COUNTER SHAFT COUNTER SHAFT SHAFT
Apply the gear and gear bush with clean engine oil and install the main shaft and counter shaft. Check the gears for freedom of movement or rotation on the shaft.
Note the installation direction of each snap ring. Do not use the worn snap ring again. Check the snap rings are seated in the grooves spinning the rings. Align the end gaps of the snap ring with the grooves of spline. Install the balancer gear.
BALANCE DRIVE DRIVE GEAR GEAR BALANCE BALANCE DRIVE GEAR BALANCE DRIVEN GEAR BALANCE BALANCE DRIVEN DRIVEN GEAR GEAR
Align the balancer drive gear and balancer driven gear with the marking location.
ALIGN THE THE GEAR GEAR WITH WITH THE THE MARKING MARKING LOCATION LOCATION ALIGN ALIGN THE GEAR WITH THE MARKING LOCATION
12-9
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 RIGHT FORK RIGHT FORK FORK CENTER CENTER FORK CENTER FORK FORK LEFT LEFT FORK LEFT FORK FORK
COUNTER COUNTER SHAFT COUNTER SHAFT SHAFT
DRUM SHIFT SHIFT SHIFT DRUM DRUM
Install the L. fork mark and center fork and then install R. fork. Install the shift drum. Install the shift fork guide pin into the guide groove of the drum.
SHIFT SHIFT FORK SHAFT SHIFT FORK FORK SHAFT SHAFT
Install the shift fork into the shift fork shaft, then install the shift fork shaft into the RH. crankcase assembling hole.
12-10
CRANKCASE ASSEMBLY
Install the dowel pins and a new gasket.
RH. CRANK CASE RH. RH. CRANK CRANK CASE CASE RH. CRANK CASE
Install the LH. crank case.
Make sure that there is no gap between the mating surfaces of the right and left crankcase.
Tighten the LH. crankcase bolts in a crisscross pattern in 2-3 steps.

TORQUE : 1.1kgfm(11Nm)
After replacing the o-ring of the gear change switch to a new one, coat the new o-ring with engine oil, then install the switch pin into the groove of the shift drum.
GEAR GEAR CHANGE SWITCH GEAR CHANGE CHANGE SWITCH SWITCH
Tighten the 4pcs of RH. crankcase bolt.

TORQUE : 1.1kgfm(11Nm)
12-11
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
MEMO
EXTERNAL PARTS
13-0
13. SEAT / EXHAUST MUFFLER

13-1 SERVICE INFORMATION 13-2 SEAT/SIDE COVER 13-2 REAR SEAT (PILLION SEAT) 13-3 REAR COWL 13-3 REAR FENDER 13-3 REAR WHEEL MUDGUARD 13-4 MUFFLER/EXHAUST PIPE 13-5 FRONT FENDER
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
EXTERNAL PARTS
SIDE SIDE COVER SIDE COVER COVER
SIDE COVER / SEAT

SIDE COVER REMOVAL
Remove the seat. Remove the RH/LH. side cover special bolts, then remove the RH/HL. side covers. Remove the side cover hook from the grommet of the frame, by pulling the side cover forward.
SEAT REMOVAL
MAIN MAIN SEAT MAIN SEAT SEAT PILLION PILLION SEAT PILLION SEAT SEAT
Turn the helmet holder left to unlock the seat and then pull the seat back and up. Installation is in the reverse order of removal.
CENTER CENTER COVER CENTER COVER COVER
REAR SEAT(PILLION SEAT)

Remove the seat. Remove the center cover setting grommet and center cover.
Remove a flange bolt, and then pull the seat front and up. Installation is in the reverse order of removal.
FRONT FRONT BOLT FRONT BOLT BOLT
13-2
EXTERNAL PARTS
REAR COWL REAR REAR COWL COWL REAR COWL
REAR COWL
Remove the below parts. The seat. The R/L. side cover. The center cover. The pillion seat. The two flange bolts and 4 special bolts.(RH./LH.) The rear fender mounting 4 body cover clips.(RH./LH.) Carefully spread the bottom of both sides of the rear cowl, then remove it. Installation is in the reverse order of removal.
FAN FAN MOTOR RELAY FAN MOTOR MOTOR RELAY RELAY
TAIL TAIL LIGHT TAIL LIGHT LIGHT
REAR FENDER
Remove the seat. Remove the RH. / LH. side cover. Remove the center cover. Remove the pillion seat. Remove the rear cowl. Remove the head light relay, winker relay from the rear fender. Remove the tail light, winker connector.
WINKER RELAY WINKER WINKER RELAY RELAY WINKER RELAY
FUSE BOX FUSE FUEL PUMP FUEL PUMP RELAY FUSE BOX BOX FUEL PUMP RELAY RELAY
REAR REAR FENDER REAR FENDER FENDER
Remove the R/L special screws. Remove 4 pcs flange bolts on bottom of rear fender. Remove the rear fender from the frame. Installation is in the reverse order of removal.
REAR REAR WHEEL MUDGUARD REAR WHEEL WHEEL MUDGUARD MUDGUARD
REAR WHEEL MUDGUARD

Remove the 4 rear wheel mudguard mounting bolts and rear wheel mudguard. Installation is in the reverse order of removal.
13-3
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
BOLT FLANGE BOLT BOLT FLANGE FLANGE BOLT
MUFFLER MUFFLER MUFFLER
Remove the muffler mounting bolt/nut securing pillion step bracket and remove the muffler.
Remove the exhaust pipe flange gasket.
FLANGE GASKET GASKET FLANGE FLANGE GASKET
Remove the oxygen sensor. Remove the 2pcs exhaust pipe joint cap nuts.
CAP NUT CAP CAP NUT NUT CAP O2 SENSOR O2 O2 SENSOR SENSOR O2
13-4
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.
FRONT FRONT FENDER FENDER FRONT FENDER
FRONT FENDER
Remove the front fender mounting 6pcs special screws. (RH/LH.) Remove the front fender forward. Install in the reverse order of removal.
13-5
14-0
14. FRONT WHEEL/FRONT FORK/STEERING

SERVICE INFORMATION14-1 TROUBLESHOOTING 14-2 HANDLEBARS 14-3 FRONT WHEEL 14-7 FRONT FORK 14-12 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. Because inhaled asbestos fibers have been found to cause respiratory disease and cancer, work so that the fibers near the brake pad can't spread to the brake cleaner. When removing or installing tires from the rim, use the special tire lever and rim protector so that the rim can't be damaged. This section covers maintenance of the front wheel, front fork and steering stem. Refer to section 15 for front brake service. Use a jack or a hoist under the engine to support the motorcycle.
SPECIFICATIONS
ITEM STANDARD VALUE
Unit : mm
SERVICE LIMIT
FRONT AXLE DEFLELTION FRONT WHEEL RIM VIBRATION FRONT FORK PIPE DEFLECTION FRONT FORK FLUID CAPACITY FORK SPRING FREE LENGTH RADICAL AXIAL
2452.5cc 528.0
0.2 2.0 2.0 0.2 480.0
TORQUE VALUES
STEERING HANDLE PIPE BOLT FRONT BRAKE DISK BOLT FRONT AXLE NUT FORK TOP BRIDGE PINCH BOLT FORK BOTTOM BRIDGE PINCH BOLT FORK TUBE CAP BOLT FORK SOCKET BOLT CALIPER BRACKET BOLT STEERING STEM NUT STEERING TOP THREAD NUT HANDLE WEIGHT SOCKET BOLT 2.6kgf 4.2kgf 5.9kgf 2.6kgf 3.4kgf 2.3kgf 2.0kgf 3.0kgf 7.4kgf 2.5kgf 0.3kgf 2.0kgf m(26N m(42N m(59N m(26N m(34N m(23N m(20N m(30N m(74N m(25N m(3N m(20N m) m) m) m) m) m) m) (Apply locking agent) m) m) m) (Initial torque) m) (Last torque) m)
14-1

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
Bearing adjustment nut too tight Damaged, worn steering head bearing Damaged, worn inner and outer race Insufficient tire pressure Worn tire
Soft suspension
Weak springs Oil level too low Inferiorization of oil Oil viscosity too low
Steers to one side

Damaged, incorrectly tightened steering head bearing Unbalance of left, right cushion Bent front fork Bent front axle shaft and inclind tire Worn tire Worn wheel bearing Worn swing arm pivot
Hard suspension
Bend fork tube Oil level too high Oil viscosity too high Too much air in tire
Strange noise of front cushion

Defective bottom case Loose fork leg fasteners Insufficient fork oil
Front wheel wobbling

Deformed rim Worn wheel bearings
14-2
HANDLE WEIGHT HANDLE WEIGHT CAP HANDLE WEIGHT CAP CAP
HANDLE BARS
REMOVAL
Loosen the socket bolt from the end of the RH. handle grib.
Loosen the 2 screws.

STARTER STARTER SWITCH STARTER SWITCH SWITCH
Remove the starter switch from RH. steering handle.
MASTER MASTER CYLINDER MASTER CYLINDER CYLINDER
Remove the front stop switch wire from the switch. Loosen the 2 master cylinder holder bolts, remove the holder and master cylinder.
14-3

Remove the 2pcs screws on the left handlebar switch.
SCREW SCREW SCREW
Remove the winker switch.
CLUTCH CLUTCH LEVER BRACKET CLUTCH LEVER LEVER BRACKET BRACKET
Loosen the 2pcs clutch lever bracket holder bolts. Loosen the socket bolts on LH. handle grip end and remove the handle weight cap. Remove the LH. handle grip and choke lever from the handle bar.
HOLDER HOLDER HOLDER HOLDER
HANDLE PIPE ASSEMBLY HANDLE HANDLE PIPE PIPE ASSEMBLY ASSEMBLY SOCKET BOLT BOLT SOCKET BOLT SOCKET
Loosen the handle pipe pinch RH/LH bolt. Remove the handlebars from the front forks.
RH. RH. HANDLE PIPE RH. HANDLE HANDLE PIPE PIPE
LH. LH. HANDLE PIPE LH. HANDLE HANDLE PIPE PIPE
14-4

INSTALLATION
Install the handlebars onto the front forks. Install the handle pipe while aligning its grooves with the fork top bridge holes. Tighten the handle pipe pinch bolts to the specified torque.
TORQUE : 2.6kgfm
RH. RH. HANDLE HANDLE PIPE PIPE RH. HANDLE PIPE
LH. LH. HANDLE HANDLE PIPE PIPE LH. HANDLE PIPE
HOLE HOLE HOLE HOLE HOLE HOLE
RH. RH. FRONT FORK RH. FRONT FRONT FORK FORK
RH. RH. FRONT FORK RH. FRONT FRONT FORK FORK
Install the clutch lever bracket with the UP mark of the holder facing up.
THROTTLE CABLE THROTTLE THROTTLE CABLE CABLE THROTTLE CABLE
Connect the throttle cable to the throttle pipe. Install the winker switch housing aligning its locating pin with the hole in the handlebar. Install the handle weight cap, tighten the socket bolts.
TORQUE : 2.0kgfm
Install the master cylinder by aligning the end of the master cylinder with the punch mark on the handle bar, tighten the upper bolts firstly, then tighten the lower bolts. Connect the front stop switch wires.
14-5

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.

LH. GRIP
CLUTCH CLUTCH CASE CLUTCH CASE CASE
Install the master cylinder with the UP mark of the holder facing up. Install the master cylinder by aligning the end of the master cylinder with the punch mark on the handlebar. Tighten the upper bolt first, the lower bolt.
LH. LH. HANDLE PIPE LH. HANDLE HANDLE PIPE PIPE
PUNCH MARK PUNCH PUNCH MARK MARK
PUNCH PUNCH MARK MARK PUNCH MARK
Install the winker switch housing aligning it is locating pin with the hole on the handle bar.
WINKER WINKER SWITCH ASSY WINKER SWITCH SWITCH ASSY ASSY
Insall the screws.
14-6
FRONT WHEEL
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.
BRAKE BRAKE HOSE BRAKE HOSE HOSE
FRONT FRONT BRAKE CALLIPER FRONT BRAKE BRAKE CALLIPER CALLIPER
SPEEDOMETER SPEEDOMETER CABLE SPEEDOMETER CABLE CABLE
SPEEDOMETER SPEEDOMETER CABLE SPEEDOMETER CABLE CABLE
Remove the speedometer gear box screws and remove the cable.
Loosen the axle screw and pull the speedometer cable out of the speedometer gear box. Remove the axle nut, front axle the front wheel and R. side collar.
Don't operate the brake lever after removing the front wheel.
INSPECTION
Axle Measure the runout of the front axle. Install the front axle in v-block and measure the runout with dial gauge.
Wheel rim runout Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator.
SERVICE LIMIT : RADIAL : 2.0mm SERVICE LIMIT : AXIAL : 2.0mm
14-7

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.
OIL SEAL OIL OIL SEAL SEAL
DISASSEMBLY
Remove and speedometer gear box, oil seal and gar box retainer.
SPEEDOMETER GEAR BOX SPEEDOMETER SPEEDOMETER GEAR GEAR BOX BOX
GEAR GEAR BOX RETAINER GEAR BOX BOX RETAINER RETAINER
Loosen the 6 LH. brake disk bolts on front rim and remove the brake disk.
Loosen the 6 RH. brake disk bolts on front rim and remove the brake disk.
Check the disk for defects. ( 16-9)
14-8

WHEEL BEARING REPLACEMENT
BEARING REMOVER BEARING BEARING REMOVER REMOVER HEAD HEAD HEAD
Install the bearing remover head into the bearing. Remove the distance collar and drive out the other bearing.
TOOLS : BEARING REMOVER HEAD BEARING REMOVER SHAFT
Always replace bearings as a sets, and never use old bearings. Apply sufficient amount of grease to the bearing. Insert the right bearing with its seal surface facing outside. Do not tilt the bearing. Insert accurately. Upon assembling the distance collar, insert the left bearing with its seal surface facing outside.
SPEEDOMETER GEAR REPLACEMENT

Remove the speedometer gear and washer from the speedometer gear box.
SPEEDOMETER SPEEDOMETER GEAR GEAR SPEEDOMETER GEAR
Check the gear for wear or damage. Install the washers. Apply grease to the speedometer gear and install it.
WASHERS WASHERS WASHERS WASHERS
PINION PINION GEAR PINION GEAR GEAR
14-9

ASSEMBLY
FR. WHEEL SIDE COLLAR FR. CASTING WHEEL
FR. WHEEL AXLE
RADIAL BALL BEARING
RH. FR. BRAKE DISK
GEAR BOX RETAINER
OIL SEAL DUST SEAL SPEEDOMETER GEAR RADIAL BALL BEARING
FR. DISTANCE COLLAR
FR. TIRE LH. FR. BRAKE DISK SPEEDOMETER GEAR BOX ASSEMBLY
Install the brake disk on LH. front rim. Install and tighten the new mounting bolts to the specified torque.
TORQUE : 4.2 kgfm (42Nm)
Inatall the gear box retainer to wheel projection. Apply grease to the rim part of LH. oil deal and pressing to front rim.
GEAR RETAINER GEAR GEAR RETAINER RETAINER GEAR
14-10

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. Insert the front axle into the speedometer gear box and the wheel hub. Install the axle nut.
TORQUE : 5.9 kgfm
COLLAR COLLAR COLLAR
Install the speedometer cable and tighten it correctly with the screw.
SCREW SCREW SCREW
14-11

Install the RH/LH caliper and tighten the new mounting bolts to the specified torque.
TORQUE : 3.0kgfm (30Nm)
CALLIPER CALLIPER CALLIPER
FRONT FORK
REMOVE
Remove the front fender. ( 13-5) Remove the RH/LH front caliper. Remove the front wheel. ( 14-7)
STEERING STEERING HANDLE PIPE STEERING HANDLE HANDLE PIPE PIPE
When the front fork will be disassembled, loosen the fork pipe bolt, but do not remove it yet.
Support the motorcycle securely under the engine not to turn over it. Loosen the handle pipe pinch bolt. Loosen the fork top bridge pinch bolt.
FORK FORK TOP BRIDGE FORK TOP TOP BRIDGE BRIDGE SOCKET BOLT BOLT SOCKET SOCKET BOLT
Loosen the fork bottom pinch bolt and remove the fork pipe from the handle pipe, fork top bridge and steering stem.
STEERING STEM BOLT STEERING STEERING STEM STEM BOLT BOLT
14-12

DESASSEMBLY
Remove the front fork bolt.
FRONT FRONT FORK BOLT FRONT FORK FORK BOLT BOLT
If the bolt is completely loosened, the fork pipe bolt may spring out by the force for the spring. Remove the fork spring, and expand and release the fork pipe several times to drain fork oil.
Wrap the bottom case with a piece of cloth, and remove the socket bolt.
If the socket bolt turns idle cannot be removed, temporarily assemble the spring and the fork tube cap blot first. Hold the bottom case firmly with a vise, taking precautions not to distort or damage it.
SEAT SEAT PIPE SEAT PIPE PIPE
Remove the piston ring, seat pipe and rebound spring from the fork pipe.
DUST SEAL DUST DUST SEAL SEAL DUST SEAL
Remove the dust seal.
BOTTOM BOTTOM CASE BOTTOM CASE CASE
14-13

Remove the oil seal stopper ring.
STOPPER RING STOPPER STOPPER RING RING
Pull the fork pipe out until you feel resistance from the slider bushing. Then move it in and out, tapping the bushing lightly until the fork pipe separates from the bottom case.
OIL SEAL OIL OIL SEAL SEAL BACK-UP RING BACK-UP BACK-UP RING RING
SLIDER SLIDER SLIDER BUSHING BUSHING BUSHING
Remove the slider bushing, guide bushing, back-up ring, oil seal, stopper ring and dust seal from the fork pipe.
DUST SEAL DUST DUST SEAL SEAL GUIDE GUIDE BUSHING GUIDE BUSHING BUSHING STOPPER RING STOPPER STOPPER RING RING
INSPECTION
Place the fork spring on a level place, and measure the free length. If the free length deviates from the service limit, replace the springs with new ones.
FORK FORK SPRING FORK SPRING SPRING REBOUND SPRING REBOUND REBOUND SPRING SPRING REBOUND
SERVICE LIMIT : FORK SPRING : 480mm REBOUND SPRING : 21.6mm
14-14

BOTTOM CASE BOTTOM BOTTOM CASE CASE
Check components for damage or abnormal wear. Replace defective parts with new ones.
SEAT PIPE SEAT SEAT PIPE PIPE FORK PIPE FORK FORK PIPE PIPE OIL LOCK PIECE OIL LOCK OIL LOCK PIECE PIECE OIL LOCK PIECE DIAL GAUGE DIAL DIAL GAUGE GAUGE DIAL
FORK FORK PIPE FORK PIPE PIPE
Place the fork pipe in V-block and measure the runout. Actual runout is 1/2 the total indicator reading.
SLIDER BUSHING BACK-UP RING
Visually inspect the slider and fork pipe bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire surface.
CHECK POINTS
14-15

ASSEMBLY
DUST SEAL FORK PIPE OIL SEAL STOPPER RING OIL SEAL BACK UP RING GUIDE BUSH RH. BOTTOM CASE FR. FORK BOLT FR. FORK SPRING
SEAT PIPE LH. BOTTOM CASE OIL LOCK PIECE REBOUND SPRING
Before assembly, wash all parts with a non-flammable solvent and wip them dry. Install the oil lock piece onto the end of the seat pipe. Install the seat pipe into the fork pipe. Install the fork pipe into the bottom case.
SEAT SEAT PIPE PIPE SEAT PIPE OIL LOCK PIECE OIL OIL LOCK LOCK PIECE PIECE OIL
Install the guide bush and slider bush. Install the fork pipe into the bottom case.
14-16

Wrap the bottom case with a piece of cloth, and fix it to the vise. Apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the seat pipe.
STOPPER RING STOPPER STOPPER RING RING
VISE
When a vise is used to hole the bottom case, do not insert the case itself but insert the bracket.
BRACKET
FORK SEAL DRIVER
Apply ATF(Automatic Transmission Filuid) to a new oil seal. Assemble the oil seal to the bottom case. Install the oil seal with special tools until the attachment groove of thebottom case set ring is exposed.
TOOLS : OIL SEAL DRIVER OIL SEAL DRIVER BODY
ATTACHMENT
STOPPER STOPPER RING STOPPER RING RING
Install the oil seal stopper ring. Install the oil seal stopper ring into the bottom case correctly.
DUST SEAL DUST DUST SEAL SEAL DUST
Install the dust seal.
14-17

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.
UP UP WARD UP WARD WARD DOWN DOWN WARD WARD DOWN WARD FORK SPRING FORK SPRING FORK SPRING
Install the new O-ring to the fork cap bolt.

FORK FORK CAP CAP BOLT BOLT
Install the fork cap bolt to the fork pipe.
14-18

INSTALLATION
Install the fork pipe through the bottom bridge, fork top bridge and handle pipe. Position the marking line of the fork pipe with the upper surface of the top bridge as shown.
FORK FORK TOP TOP BRIDGE BRIDGE
MARKING LINE LINE MARKING MARKING LINE
Tighten the fork top bridge pinch bolt to the specified torque.
TORQUE : 2.6 kgfm
Tighten the handle pipe pinch bolt to the specified torque.

TORQUE : 2.6 kgfm
Tighten the steering stem to the specified torque.

TORQUE : 7.4 kgfm
Tighten the fork cap bolt to the specified torque.

TORQUE : 2.3 kgfm
FRONT FRONT COWL FRONT COWL COWL
Install the following. - Front wheel. - Front fender. - Front cowl - Side cowls
14-19
STEERING STEM
REMOVAL
Remove the following : - Front wheel - Kandle bars - Front fork Remove the 2 flange bolts and front brake hose stay.
JUNCTION JUNCTION VALVE JUNCTION VALVE VALVE
BRAKE BRAKE OIL HOSE BRAKE OIL OIL HOSE HOSE
Remove the steering stem nut.

STEERING STEM STEM NUT NUT STEERING STEERING STEM NUT
STEERING STEM STEERING STEM SOCKET STEERING STEM SOCKET SOCKET
Remove the steering head top thread nut using the special tool.
TOOL : STEERING STEM SOCKET
STEERING STEERING STEM STEM STEERING STEM
Remove the following : - Steering top cone race - Steering steel ball - Steering stem
Place a shop towel under the steering stem to catch the steel balls.
BEARING BEARING BEARING BEARING
Check the steel ball, cone race, ball race for damage or abnormal wear and replace as necessary.
14-20

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
DRIVER
Install the new ball races of the frame using the driver and attachment.
ATTACHMENT
STEERING STEM STEERING STEERING STEM STEM STEERING STEM
Temporarily install the steering stem nut onto the stem to prevent the threads from being damaged when removing the bottom cone race from the stem. Inspect the followings. - Steering head top threads - Steering cone top race - Steering steel ball assy - Steering ball race
TOP TOP CONE RACE TOP CONE CONE RACE RACE
BALL BALL RACE BALL RACE RACE
STEERING HEAD STEERING STEERING HEAD HEAD TOP TOP THREAD THREAD TOP THREAD
STEEL STEEL BALL ASSY STEEL BALL BALL ASSY ASSY STEERING STEM DRIVER STEERING STEERING STEM STEM DRIVER DRIVER
Install the new dust seal and washer into the steering stem. Install a new bottom cone race into the steering stem using a special tool and a hydraulic press.
TOOL : STEERING STEM DRIVER
BOTTOM CONE RACE/DUST SEAL BOTTOM BOTTOM CONE CONE RACE/DUST RACE/DUST SEAL SEAL BOTTOM CONE RACE/DUST SEAL
14-21

INSTALLATION
STEERING HEAD TOP THREAD STEEL BALLS STEEL BALL RACE STEEL BALL RACE STEEL BALLS BOTTOM CONE RACE DUST SEAL WASHER TOP CONE RACE
STEERING STEM
STEERING STEM STEM STEERING 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. Insall the steel ball and top cone race.
Tighten the steering head top thread.

TORQUE : 2.5 kgfm (INITIAL TORQUE) TOOL : STEERING STEM SOCKET
Move the steering stem right and left, five times to seat the steel balls. Retighten the steering head top thread to the specified torque.
TORQUE : 0.3 kgfm (FINAL TORQUE)
14-22

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. Install the following: - Front wheel - Front fender - Front cowl - Side cowls
JUNCTION JUNCTION VALVE JUNCTION VALVE VALVE
14-23
REAR WHEEL/REAR SUSPENSION
15-0
15. REAR WHEEL/REAR SUSPENSION

15-1 SERVICE INFORMATION TROUBLESHOOTING 15-2 REAR WHEEL 15-3 REAR CUSHION 15-7 SWINGARM 15-9
SERVICE INFORMATION
SPECIFICATIONS
ITEM STANDARD VALUE
Unit : mm
SERVICE LIMIT
AXLE RUNOUT REAR WHEEL RIM RUNOUT RADICAL AXIAL
131
0.2 2.0 2.0 -
REAR CUSHION SPRING FREE LENGTH
TORQUE VALUES
REAR BRAKE DISK BLOT REAR AXLE NUT REAR CUSHION UPPER / DOWN BOLT REAR CUSHION UNDER BOLT SWINGARM PIVOT NUT FINAL DRIVEN SPROCKET NUT 4.2fm 8.8fm 5.4fm 4.0fm 8.8fm 5.9fm
TOOLS
ATTACHMENT PILOT DRIVER BEARING REMOVER SHAFT BEARING REMOVER HEAD
15
15-1
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
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 CHAIN ADJUST CHAIN ADJUST ADJUST
REAR REAR AXLE NUT REAR AXLE AXLE NUT NUT
Push the rear wheel forward. Remove the drive chain from the driven sprocket. Remove the axle from the left side and remove the rear wheel. Remove the side collars.(2EA)
INSPECTION
AXLE SHAFT AXLE AXLE SHAFT SHAFT
Inspect the bending of axle shaft.

Spin the wheel slowly and read the runout.

GAUGE DIAL DIAL DIAL GAUGE GAUGE GAUGE
SERVICE LIMIT : RADIAL : 2.0mm SERVICE LIMIT : AXIAL : 2.0mm
15-3

REMOVAL
Remove the side collar. Loosen the 5 disk bolts, remove the disk brake. Remove the oil-seal.
SIDE COLLAR SIDE SIDE COLLAR COLLAR SIDE COLLAR
FINAL FINAL DRIVEN SPROCKET FINAL DRIVEN DRIVEN SPROCKET SPROCKET
Remove the final driven sprocket.
Check the teeth of the final driven sprocket. Replace the sprocket if worn or damaged.
GOOD ( O )
REPLACE ( X )
Check the drive chain and driven sprocket at the same time.
REAR REAR WHEEL DAMPER REAR WHEEL WHEEL DAMPER DAMPER
Check the rear wheel damper. Replace the damper, if it damaged.
15-4

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.
TOOLS : BEARING REMOVER SHAFT REMOVER HEAD
If the wheel bearing was replaced, Be sure to replace it with new one. Apply the grease to the bearing. Insert the new bearing in parallel with the seal side facing outside. After inserting the distance collar, insert the bearing of the right side with the seal facing outside.
ASSEMBLY
15-5

Install the dust seal after applying the grease. Install the final driven sprocket.
Install the rear wheel sleeve.

TORQUE : 5.9 kgfm
REAR REAR WHEEL SLEEVE REAR WHEEL WHEEL SLEEVE SLEEVE
Install the brake disk with literal mark facing out. Install and tighten the bolts to the specified torque.
TORQUE : 4.2 kgfm
INSTALLATION
Install the side collar on RH. side rear wheel. Place the rear wheel into the swingarm. Install the drive chain over the driven sprocket. Install the axle from the left side.
AXLE SHAFT SHAFT AXLE AXLE SHAFT
REAR WHEEL SLEEVE REAR REAR WHEEL WHEEL SLEEVE SLEEVE REAR WHEEL SLEEVE
15-6

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 kgfm
AXLE SHAFT AXLE AXLE SHAFT SHAFT
REAR CUSHION
REMOVAL
Raise and support the motorcycle with main stand.
SIDE COVER SIDE SIDE COVER COVER MUD MUD GUARD MUD GUARD GUARD
Remove the rear wheel mudguard. Remove the rear cushion lower flange bolt.
Remove the LH. side cover. Loosen the rear cushion upper flange bolt, and remove the rear cushion.
The damper unit is filled with high pressure nitrogen gas. Do not disassemble gas damper unit.
Heating a gas-filled damper can lead to an explosive release of pressure which can cause a serious injury.
INSPECTION
Visually inspect the rear cushion for damage. Check for the : - Damper rod for bend or damage - Damper unit for deformation or oil leaks - Cushion rubber for wear or damage Check all the other parts for wear or damage. If necessary, replace the rear cushion as an assembly.
REAR REAR CUSHION ASSY REAR CUSHION CUSHION ASSY ASSY
15-7

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. Install the pivot collar.
PIVOT COLLAR PIVOT PIVOT COLLAR COLLAR DUST SEAL DUST DUST SEAL SEAL DUST SEAL DUST DUST SEAL SEAL
DRILLING PONT
REAR CUSHION DISPOSAL PROCEDURE

Punch the damper case center to mark drilling. Wrap the rear cushion inside a plastic bag. Support the rear cushion upright in a vise. Though the open end of the bag, insert a drill motor with a sharp 2~3mm drill bit. Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start.
DRILL PLASTIC BAG
Always wear eyes protection to avoid getting metal shavings in your eyes when gas pressure is released. Drilling farther into the damper case than specified can puncture the oil chamber.
INSTALLATION
Install the rear cushion into the frame and install the rear cushion upper flange bolt to the specified torque.
TORQUE : 3.4 kgfm
Install the LH. side cover.

UPPER FLANGE BOLT UPPER UPPER FLANGE FLANGE BOLT BOLT
15-8

Install the rear cushion lower mounting bolt. Tighten the bolt to the specified torque.
TORQUE : 4.0 kgfm
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.
MUD MUD GUARD MUD GUARD GUARD SWING SWING ARM SWING ARM ARM
REAR REAR CUSHION REAR CUSHION CUSHION
Remove the brake hose from the swingarm clamp. Remove the rear cushion and swing arm securing bolts lower flange bolt.
BRAKE HOSE HOSE BRAKE BRAKE HOSE
Remove the U-nut and swingarm pivot bolt and then remove the swingarm from the frame.
U-NUT U-NUT
15-9

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.
ASSEMBLY
RR. FORK END CAP ADJUSTER NUT CHAIN ADJUSTER LOCK NUT RR. SWING ARM DUST SEAL CAP BUSH
O-RING CHAIN
PIVOT DISTANCE CENTER COLLAR SWING ARM PIVOT BOLT
CHAIN SLIDER
Apply grease to the center collar, bearing and bushes. Install the center collar, bearings and bushes to the swingarm.
15-10

Install the dust seal caps into the swingarm. Install the drive chain slider on the swingarm, then tighten the screws.
TORQUE : 0.6 kgfm ( 6 Nm)
SLIDER SLIDER SLIDER
SCREWS SCREWS SCREWS SCREWS
INSTALLATION
Apply thin coat of grease to the swingarm pivot bolt surface. Align the drive chain installed swingarm to drive slider and install the frame. Install the pivot bolt from the left side and tighten the u-nut to the specified torque.
TORQUE : 8.8 kgfm
U-NUT U-NUT U-NUT U-NUT
Install the swingarm-to-rear cushion lower flange bolt, then tighten the bolt to the specified torque.
TORQUE : 4.0 kgfm
Install the brake hose to swingarm clamp correctly. Install the rear caliper bracket into the groove of the swingarm.
Install the rear wheel mudguard and tighten the mudguard 4 mounting bolts. Install the rear wheel. (15-3) Install the removed parts in the reverse order of removal.
15-11
HYDRAULIC BRAKE
FRONT :
REAR :
16-0
16. HYDRAULIC BRAKE

16-1 SERVICE INFORMATION 16-2 TROUBLESHOOTING BRAKE FLUID REPLACEMENT/ 16-3 AIR BLEEDING 16-6 BRAKE PAD/DISK 16-9 FRONT MASTER CYLINEDR 16-13 REAR MASTER CYLINDER 16-18 FRONT BRAKE CALIPER 16-20 REAR BRAKE CALIPER 16-23 BRAKE PEDAL
SERVICE INFORMATION
GENERAL SAFETY
Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies use and OSHA-approved vacuum cleaner. Don't put in dust or water when filling the reservoir. Don't mix different types of fluid to prevent from changing chemically. Don't use the removed brake fluid. Avoid spilling brake fluid or painted plastic and rubber parts because of damaging them. Cover the joint part of the hose to prevent the leak the brake fluid from leaked. Clean the removed parts with brake fluid and check the airing of each part with a compressed air. Arrange the removed parts not to be soiled with dust or dirt. After checking if dust or dirt soils each part, install them. Always replace the specified parts. Brake pad can be removed without disconnecting the hose. Bleed the air in case of removing the brake hose.
SPECIFICATIONS
ITEM STANDARD VALUE
Unti : mm
SERVICE LIMIT
SPECIFIED BRAKE FLUID BRAKE DISK THICKNESS BRAKE DISK VIBRATION FRONT MASTER CYLINDER I. D. MASTER PISTON O. D. CALIPER CYLINDER I. D. CALIPER PISTON O. D. SPECIFIED BRAKE FLUID BRAKE DISK THICKNESS BRAKE DISK VIBRATION REAR MASTER CYLINDER I. D. MASTER PISTON O. D. CALIPER CYLINDER I. D. CALIPER PISTON O. D.
DOT4 4.0 0.1 14.000~14.043 13.878~13.905 25.000~25.033 24.914~24.935 DOT4 4.0 0.1 12.700~12.743 12.657~12.684 25.000~25.033 24.914~24.935
3.5 0.3 14.055 13.866 25.07 24.87 3.0 0.3 12.755 12.645 25.070 24.870
16-1
16
HYDRAULIC BRAKE
TORQUE VALUES
BRAKE CALIPER BRACKET BOLT (FRONT/REAR) BRAKE CALIPER BLEEDER VALVE (FRONT/REAR) BRAKE CALIPER HANGER PIN (FRONT/REAR) BRAKE PAD PIN BOLT (FRONT/REAR) BRAKE OIL BOLT (FRONT/REAR) MASTER CYLINDER RESERVE CAP SCREW BRAKE LEVER PIVOT BOLT BRAKE LEVER PIVOT LOCK NUT REAR MASTER CYLINDER HOLDER SOCKET BOLT 3.0fm 0.6fm 2.3fm 1.8fm 3.4fm 1.0fm 1.0fm 1.0fm 1.2fm
TOOL
SNAP RING PLIERS
TROUBLESHOOTING
Brake lever/pedal soft or spongy
Air bubbles in the hydraulic system. Leaking hydraulic system. Contaminated brake pad / disk . Worn caliper piston seal. Worn master cylinder piston seal. Worn brake pad/disk. Contaminated caliper. Caliper not sliding properly. Low brake fluid level. Clogged fluid passage. Warped / deformed brake disk. Sticking / worn caliper piston. Sticking / worn master cylinder piston. Contaminated master cylinder. Bent brake lever/pedal.
Brake drags
Contaminated brake pad / disk. Misaligned wheel. Clogged / restricted brake hose joint. Warped / deformed brake disk. Caliper not sliding properly. Clogged/restricted brake hydraulic system Sticking/worn caliper piston Clogged master cylinder port
Brake lever/pedal hard

Clogged / restricted brake system. Sticking / worn caliper piston. Caliper not sliding properly. Clogged / restricted fluid passage. Worn caliper piston seal. Sticking / worn master cylinder piston. Bent brake lever/pedal.
16-2
HYDRAULIC BRAKE
MASTER MASTER CYLINDER CAP MASTER CYLINDER CYLINDER CAP CAP
BRAKE FLUID REPLACEMENT/ AIR BLEEDING

Do not allow foreign material to enter the system when filling the reservoir. Avoid spilling fluid on painted, plastic, or rubber parts.
DIAPHRAGM DIAPHRAGM PLATE PLATE DIAPHRAGM PLATE
BRAKE FLUID DRAINING

<Front brake> Turn the handlebar until the reservoir is parallel to the ground, before removing the reservoir cap. Remove the 2 screws and master cylinder. Remove the diaphragm plate and diaphragm from the master cylinder.
Connect the bleeder hose to caliper bleeder valve.
Loosen the bleeder valve and pump the brake lever or pedal. Stop pumping the lever or pedal when no more fluid frows cut of the bleeder valve.
16-3
HYDRAULIC BRAKE
<Rear brake> Remove the RH. side cover. Remove the reservoir cap.
RESERVOIR CAP RESERVOIR RESERVOIR CAP CAP
RESERVOIR RESERVOIR TANK TANK RESERVOIR TANK
Remove the reservoir cap plate and diaphragm. Drain the brake fluid as same way when the front brake fluid drainning.
BRAKE FLUID FILLING

BLEEDER
Fill the reservoir with DOT4 brake fluid up to the upper level.
Do not mix different types of fluid. There are not compatible. Connect a recommended brake bleeder to the bleeder valve. Pump the brake bleeder and loosen the bleeder valve, adding fluid when the fluid level in the master cylinder reservoir is low. Repeat the previous step procedures until air bubbles do not appear in the plastic hose.
If a brake bleeder is not available, fill the master cylinder and operate the brake lever or pedal to fill the system. Tighten the bleeder valve.
16-4
HYDRAULIC BRAKE
BRAKE BLEEDING
<When the brake bleeder is not available> Connect a clear bleeder hose to the bleeder valve. Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the master cylinder and lever or pedal resistance is felt. 1. Squeeze the brke lever or push the brake pedal, open the bleeder valve 1/2 turn and then close the valve.
FRONT FRONT CALLIPER FRONT CALLIPER CALLIPER
MASTER CYLINDER CYLINDER MASTER MASTER CYLINDER
Do not release the brake lever or pedal until the bleeder valve has been closed.
REAR CALLIPER REAR REAR CALLIPER CALLIPER REAR PEDAL PEDAL REAR REAR PEDAL
2. Release the brake lever or pedal until the bleeder valve has been closed. 3. Repeat steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleeder valve.
BRAKE BRAKE OIL BRAKE OIL OIL
Check the fluid level often, and add fluid if the fluid level is near the lower level. If no air leaks out of the bleeder hose, operate the brake lever to check the presence of air. Tighten the bleeder valve.
TORQUE : 0.6 kgfm (6Nm)
Fill the fluid reservoir to the upper level. Reinstall the diaphragm and diaphragm plate.
<Front brake> Install the master cylinder cap, and tighten the screws. <Rear brake> Install the reservoir cap securely. Install the RH. side cover. Install the seat.
16-5
HYDRAULIC BRAKE
BRAKE BRAKE HOSE CLAMP BRAKE HOSE HOSE CLAMP CLAMP
BRAKE PAD/DISK
FRONT BRAKE PAD REPLACEMENT
When replacing brake pads, replace whole set. Do not remove the brake hose when replacing brake pads. Remove the brake hose clamp from the front fork. Remove the pin plug using the L. wrench. Loosen the hanger pin. Remove the caliper bracket 2 bolts and remove the brake capliper. Press the caliper pistons all the way in to allow installation of new brake pads.
FRONT FRONT CALIPER FRONT CALIPER CALIPER
BRAKE PADS BRAKE BRAKE PADS PADS BRAKE PADS
Remove the pin plug. Remove the hanger pin and replace the brake pads.
PIN PIN PLUG PIN PLUG PLUG CALIPER CALIPER PISTON PISTON CALIPER PISTON
Clean the inside of the caliper especially around the caliper pistons.
16-6
HYDRAULIC BRAKE
Make sure the brake pad spring is in place. Install the new brake pads. Install the hanger pin.
PAD PAD SPRING PAD SPRING SPRING BRAKE PAD BRAKE BRAKE PAD PAD BRAKE PAD
Install the brake caliper to the fork so the disk is positioned between the pads. Install and tighten the new brake caliper mounting bolts to the specified torque.
Tighten the hanger pin and pin bolt.

REAR BRAKE PAD REPLACEMENT

Remove the rear wheel mudguard. (13-3) Remove the rear brake hose clamp. Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads.
REAR REAR BRAKE CALIPER REAR BRAKE BRAKE CALIPER CALIPER
Loosen the dust plug. Loosen the hanger pins. Remove the rear caliper bracket bolts secured rear caliper bracket and bracket caliper.
16-7
HYDRAULIC BRAKE
Remove the hanger pins and brake pads.
BRAKE BRAKE PAD BRAKE PAD PAD
Make sure the brake pad spring is in place. Install the new brake pads.
PAD SPRING PAD PAD SPRING SPRING PAD SPRING
Install the hanger pins.

TORQUE : 2.3 kgfm
Install the brake caliper to the caliper bracket so the disk is positioned between the pads. Tighten the brake caliper mounting bolts.
TORQUE : 3.0 kgfm
Tighten the pin plugs.

TORQUE : 1.8 kgfm
Install the rear brake hose clamp. Install the rear wheel mudguard.
16-8
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.

Check the wheel bearing for excessive play, if the warpage exceeds the service limit. Replace the brake disk if the wheel bearings are normal.
BRAKE BRAKE STOP STOP SWITCH SWITCH BRAKE STOP SWITCH
FRONT MASTER CYLINDER

REMOVAL
Drain the brake fluid. (16-3) Disconnect the the front brake stop switch wire. Remove the brake hose oil bolt and washers.
Brake fluid causes damage to the painted, plastic or rubber parts. Do not spill fluid on these parts. If contaminated, gently wipe off the fluid with a piece of cloth or wash in water. Close hose joints properly to prevent leakage of brake fluid. Remove the bolts from the master cylinder holder and remove the master cylinder assembly.
16-9
HYDRAULIC BRAKE
DISASSEMBLY
Remove the handle lever bolt/nut and RH. handle lever assembly.
STOP STOP SWITCH STOP SWITCH SWITCH
Loosen the screw and remove the front brake stop switch.
Remove the boot.
BOOT BOOT BOOT
Remove the circlip from the master cylinder.

TOOL : SNAP RING PLIERS
Remove the master piston and spring. Clean the inside of the cylinder and reservoir with brake fluid.
16-10
HYDRAULIC BRAKE
INSPECTION
MASTER MASTER CYLINDER PISTON MASTER CYLINDER CYLINDER PISTON PISTON
Check the piston for abnormal scratches. Check the primary cup and secondary cup for fatigue or damage. Measure the master cylinder piston O. D.
Check the master cylinder for abnormal scratches. Measure the master cylinder I.D.
ASSEMBLY
MASTER CYLINDER PISTON SET MASTER CYLINDER CAP DIAPHRAGM PLATE DIAPHRAGM
HANDLE LEVER BOLT
MASTER CYLINDER HOLDER
RH. HANDLE LEVER FR. STOP SWITCH
16-11
HYDRAULIC BRAKE
Coat all parts with clean brake fluid before assembly. Dip the piston in brake fluid. Install the spring into the piston. Install the piston assembly into the master cylinder.
MASTER CYLINDER MASTER MASTER CYLINDER CYLINDER
SPRING SPRING SPRING SPRING
PISTON PISTON PISTON
Install the circlip.

CIRCLIP CIRCLIP CIRCLIP CIRCLIP
Install the boot.
BOOT BOOT BOOT
Install the front stop switch and tighten the screw. Install the RH. handle lever, tighten the bolt and nut.
FRONT FRONT BRAKE STOP SWITCH FRONT BRAKE BRAKE STOP STOP SWITCH SWITCH
16-12
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.
TORQUE : 3.4 kgfm
Connect the front brake switch wire. Fill the reservoir to the upper level and bleed the brake system. (16-5)
REAR MASTER CYLINDER

REMOVAL
Drain the brake fluid. (16-3) Remove the rear reservoir mounting bolt. Remove the rear brake hose oil bolt and washers.
Brake fluid causes damage to the painted, plastic or rubber parts. Do not spill fluid on these parts. If contaminated, gently wipe off the fluid with a piece of cloth or wash in water. Close hose joints properly to prevent leakage of brake fluid.
16-13
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.
JOINT JOINT PIN JOINT PIN PIN
Remove the 2 master cylinder bolts. Remove the joint pin C. Remove the master cylinder mounting socket bolts and master cylinder assembly.
TUBE TUBE JOINT JOINT PIPE PIPE TUBE JOINT PIPE
DISASSEMBLY
Remove the screw and tube joint pipe from the master cylinder.
SCREW SCREW SCREW
SNAP RING PLIERS SNAP SNAP RING RING PLIERS PLIERS BOOT BOOT BOOT BOOT
Remove the boot. Remove the internal circlip using the tool from the master cylinder body.
SNAP RING SNAP RING SNAP RING
16-14
HYDRAULIC BRAKE
Remove the brake rod joint, rear piston and spring. Clean the inside of the cylinder with brake fluid.
MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SPRING SPRING SPRING
BRAKE ROD JOINT BRAKE BRAKE ROD ROD JOINT JOINT
REAR REAR PISTON REAR PISTON PISTON
REAR PISTON REAR REAR PISTON PISTON REAR
INSPECTION
Check the piston for abnormal scratches. Check the primary cup and secondary cup for fatigue or damage. Measure the master rear piston O.D.
Check the master cylinder for abnormal scratches. Measure the master cylinder I.D.
ASSEMBLY
16-15
HYDRAULIC BRAKE
Coat all parts with clean brake fluid before assembly.
SPRING SPRING SPRING
MASTER MASTER CYLINDER CYLINDER MASTER CYLINDER
BRAKE ROD JOINT BRAKE BRAKE ROD ROD JOINT JOINT
Dip the piston in brkae fluid. Install the spring to the secondary cup. Install the spring/secondary cup and master piston assembly.
SNAP RING PLIERS SNAP SNAP RING RING PLIERS PLIERS BOOT BOOT BOOT BOOT
Install the rear brake rod into the master cylinder. Install the internal circlip.
Install the boot.
SNAP RING SNAP SNAP RING RING TUBE TUBE JOINT JOINT PIPE PIPE TUBE JOINT PIPE
Apply brake fluid to a new O-ring and install it into the tube joint pipe. Install the tube joint pipe into the master cylinder.
TUBE JOINT PIPE TUBE TUBE JOINT JOINT PIPE PIPE
Tighten the screw to the specified torque.
SCREW SCREW SCREW
16-16
HYDRAULIC BRAKE
INSTALLATION
JOINT JOINT PIN C JOINT PIN PIN C C
Place the master cylinder into the main step holder, install the master cylinder mounting socket bolts. Connect the brake pedal to the brake rod joint. Install the joint pin C and secure it with a new cotter pin.
Hook the stop switch spring to the brake pedal spring. Install the main step bar assembly to the frame, tighten the socket bolts to the specified torque.
TORQUE : 3.5kgfm
Tighten the master cylinder mounting socket bolts.
Install the brake hose with the oil bolt and new washers. Tighten the oil bolt to the specified torque.
TORQUE : 3.4 kgfm
Tighten the rear reserve mounting bolt. Fill the brake fluid to the upper level and bleed the brake system. (16-5) Adjust the brake pedal free-play. (2-11)
FRONT FRONT RH. BRAKE CALIPER FRONT RH. RH. BRAKE BRAKE CALIPER CALIPER BRAKE FRONT LH. CALIPER FRONT FRONT LH. LH. BRAKE BRAKE CALIPER CALIPER BRAKE
FRONT BRAKE CALIPER

REMOVAL
Drain the brake fluid from RH/LH brake caliper. (16-3) Remove the oil bolt and oil bolt washer. Remove the speedometer cable clamp. Remove the caliper mounting bolts, caliper and the brake pads. (16-6)
OIL OIL BOLT OIL BOLT BOLT
16-17
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. If there is any wear or damage in the boot, replace it with a new one. Install corrugated cardboard or soft wood sheet between the pistons. Apply small squirts of air pressure to the brake hose assembly part to remove the pistons from the caliper.
PISTON SEAL PISTON PISTON SEAL SEAL
Do not use high pressure air or bring the air gun too close. Do not touch the inside of caliper. Remove the piston seal and dust seal.
Be careful not to damage the caliper inside. Clean the caliper inside and piston with brake fluid.
DUST SEAL DUST SEAL DUST SEAL
INSPECTION
Check the caliper friction surface for damage or scratches. Measure the caliper I. D.
16-18
HYDRAULIC BRAKE
Check the appearance of piston for damage or scratches. Measure the piston O. D.
ASSEMBLY
Clean the piston seal and dust seal with brake fluid, install it into caliper groove.
PISTION SEAL PISTION PISTION SEAL SEAL
When install the piston to the caliper the groove side of piston have to toward pad.
CALIPER CALIPER PISTON PISTON CALIPER PISTON
DUST SEAL DUST DUST SEAL SEAL
Coat the sillicon grease on the boot. Install the boot to the caliper groove. Install the pad spring to the caliper. Install the caliper pin bolt then install the caliper bracket to caliper. Install the brake pad to brake caliper.
16-19
HYDRAULIC BRAKE
INSTALLATION
Install the front caliper to front fork. Tighten the caliper mounting bolts to the specified torque.
TORQUE : 3.0kgfm
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.
TORQUE : 3.4kgfm (34 Nm)
Fill the brake fluid to upper level, bleed the brake system. (16-5)
REAR BRAKE CALIPER

REMOVAL
Drain the brake fluid. (16-3) Remove the oil bolt and oil washer.
OIL OIL BOLTS OIL BOLTS BOLTS
Remove the rear caliper bracket bolts, caliper and the brake pads. (16-7)
DISASSEMBLY
Remove the spring, slide pin, caliper bracket and boot from the caliper body. If there is any wear or damage in the boot, replace it with a new one.
16-20
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. Do not touch the inside of caliper.
AIR AIR GUN AIR GUN GUN
DUST DUST SEAL SEAL DUST SEAL
Remove the piston seal and dust seal. Clean the caliper inside and piston with brake fluid.
PISTON SEAL PISTON PISTON SEAL SEAL
INSPECTION
Check the appreance of caliper for damage or scratches.. Measure the caliper I. D.
Check the appreance of pistons for damage or scratches. Measure the piston O. D.
ASSEMBLY
Clean the piston seal, dust seal with brake fluid install it into caliper groove.
16-21
HYDRAULIC BRAKE
Install the piston in the caliper with groove side of the piston facing the pad.
CALIPER CALIPER CALIPER CALIPER
PISTON PISTON SEAL SEAL PISTON SEAL
DUST SEAL DUST DUST SEAL SEAL
BOOT BOOT BOOT BOOT
Coat the silicone grease on the boot. Install the boot to the caliper groove. Install the pad spring to the caliper. Install the caliper pin bolt and the caliper bracket to caliper. Install the brake pad to brake caliper.
PAD SPRING PAD PAD SPRING SPRING PAD SPRING
CALIPER BRACKET CALIPER CALIPER BRACKET BRACKET
INSTALLATION
Install the rear caliper to rear caliper bracket. Tighten the caliper mounting bolts to the specified torque.
TORQUE : 3.0kgfm
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.
TORQUE : 3.4kgfm (34 Nm)
Fill the brake fluid to upper level, bleed the brake system. (16-5)
BRAKE BRAKE PEDAL BRAKE PEDAL PEDAL
BRAKE PEDAL
REMOVAL
Remove the main step holder mounting socket bolts and main stepbar assembly. Unhook the stop switch spring from the brake pedal spring.
16-22
HYDRAULIC BRAKE
Strech and pull out the brake pedal joint cotter pin and remove the joint pin C. Remove the brake pedal spring from the brake pedal. Remove the external cir-clip, washer and brake pedal.
COTTER PIN COTTER PIN COTTER PIN
INSTALLATION
Install the brake pedal to main step holder and assemble the washer and external cir-clip. Connect the brake pedal to the brake rod joint. Install the joint pin C and secure it with a new cotter pin.
Hook the stop switch spring to the brake pedal spring. Install and tighten the main step bar socket bolts into the frame to specified torque.
REAR BRAKE BRAKE PEDAL PEDAL REAR REAR BRAKE PEDAL
16-23
BATTERY/CHARGING SYSTEM
BATTERY
ECU FUSE BOX
REGULATOR/RECTIFIER
IGNITION COIL
AC GENERATOR
Y Y Y R/W /
MAIN SWITCH
FUSE
( 30A) (30A)
AC GENERATOR
REGULATOR RECTIFIER FUSE (15A) ( 15A)
B (CABLE)
BATTERY
LOAD
ECU
B......Black Y.......Yellow G......Green R......Red W..... White Lg.....Light green
17-0
17. BATTERY/CHARGING SYSTEM

CHARGING DIAGRAM 17-0 SERVICE INFORMATION 17-1 TROUBLESHOOTING 17-2 BATTERY 17-3 17-4 CHARGING SYSTEM INSPECTION REGULATOR/RECTIFIER 17-5 A.C. GENERATOR CHARGING COIL INSPECTION 17-6
SERVICE INFORMATION
Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery. Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor. If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin, make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.
This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special care when performing maintenance and especially when replacing parts. Not all regular battery equipment is compatible with MF batteries. When charging the battery, remove the battery from the frame. There is the possibility of damaging the regulator/rectifier, etc. If the terminal or coupler is separated/connected when electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing maintenance to the charging equipment. If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state, the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that the battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss in battery strength. It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive voltage will develop in the battery and normal cell electrolytes will decrease. If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery ability to store electricity is reduced. For information on generator disassembly, refer to section 8.
SPECIFICATIONS
ITEM STANDARD VALUES
17
Capacity 12V - 10AH (MF) 13.0-13.2V Not to exceed 1mA 0.1-1.5(20 C) 1,350 rpm (Headlight ON) Thyristor system 14.51.0V / 5,000(rpm)
BATTERY
Terminal-to-terminal voltage (When fully charged) Current leakage Charging Coil resistance value ( 20 C) rpm at Charging Start Type Regulated Voltage
A.C.GENERATOR REGULATOR / RECTIFIER
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, BATTERY TESTER, SCANNER
17-1
TROUBLESHOOTING
No power (Key turned on)
Dead battery. - Low fluid level. - Low specific gravity. - Charging system failure. Disconnected battery cable. Main fuse burned out. Faulty ignition switch. Loose connection on short circuit in wire harness.
Low power (Engine running)

Battery undercharged. Battery is failing. Charging system failure.
Intermittent power
Loose battery connection. Loose charging system connection. Loose starting system connection. Loose connection or short circuit in ignition system. Loose connection or short circuit in lighting system. Loose connection or short circuit in wire harness.
Low power (Key turned on)

Battery undercharged. - Low fluid level. - Low specific gravity. Charging system failure. Loose battery connection.
Charging System faulty

Loose broken or shorted wire or connection. Faulty regulator rectifier. Faulty A.C generator..
Charging System faulty

Check the battery current leakage.(16-4)
CORRECT INCORRECT
Check the regulator rectifier.(16-5)

CORRECT INCORRECT
Shorted harness wire. Faulty ignition switch. Faulty regulator rectifier.
Measure the charging voltage.(16-4)

NOT CHARGING (14V)
OVERCHARGED (15V) 14 ~ 15V
Battery is failing
Check the voltage between the battery line and ground wire of regulator rectifier.(16-5)
NORMAL
ABNORMAL
Open circuit in wire harness. Poorly connected coupler.
Check the resistance of the charging coil at the charging coil line of regulator rectifier coupler.(16-6)
CORRECT
INCORRECT
Check the charging coil of theA.C generator.(16-6)

NORMAL
Poorly connected A.C generator coupler.

ABNORMAL
Faulty charging coil.

ABNORMAL
Check the regulator rectifier.(16-5)

NORMAL
Faulty regulator rectifier.
Faulty battery.
17-2
BATTERY
BATTERY BAND BAND BATTERY BATTERY BAND
REMOVAL/INSTALLATION
Remove the seat. (13-2) Remove the battery band. Disconnect the negative (-) cable and then the positive (+) cable and remove the battery. Install the battery in the reverse order of removal with the proper wiring.
Connect the positive terminal first and then the negative cable.
VOLTAGE INSPECTION
Measure the battery voltage using a multi tester.
VOLTAGE: - Fully charged : 13.0~13.2V - Under charged : Below 12.3V TOOL : MULTI-TESTER
Use a voltmeter that will accurately indicate 0.1V difference. Never open the sealed filler cap. When measuring the battery voltage after charging, leave it for at least 30 minutes, or the accurate results cannot be obtained because the battery voltage fluctuates just after charging.
BATTERY CHARGING
Remove the battery. Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative(-) cable to the battery negative(-) terminal.
Quick-charging should only be done in an emergency ; slow charging is preferred. For battery charging ; do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery.
17-3
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
AMPERE METER
BATTERY TERMINAL
When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester. If current leakage exceeds the standard value, a shorted circuit is likely to exist.
CHARGING VOLTAGE INSPECTION
GROUND CABLE
Be sure that the battery is fully charged before performing this test. The amount of current flow may change abruptly if not sufficiently charged. Use a battery whose specific gravity is 13.0 ~ 13.2V. When the engine is started using the starter motor, a large amount of current may flow from the battery temporarily. After warming up the engine, replace the battery with a fully charged battery. Connect a tester between the battery terminals. Connect an ampere meter between the terminals of the main fuse.
DIGITAL TESTER AMPERE METER
If the probes are connected in reverse order, the registered current flow direction when charging and discharging the battery will be reversed as well. Turn the headlight ON and start the engine. Gradually increase the engine speed and measure the charging voltage at the specified rpm.
CONTROL VOLTAGE : 14.51.0V / 5,000rpm TOOL : DIGITAL TESTER, AMPERE METER, SCANNER
MAIN FUSE TERMINALS
MAIN FUSE
Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.
17-4
REGULATOR RECTIFIER REGULATOR REGULATOR RECTIFIER RECTIFIER
REGULATOR/RECTIFIER
HARNESS SIDE CIRCUIT INSPECTION
Remove the seat. (13-2) Remove the LH. side cover. (13-2) Disconnect the regulator/rectifier coupler. Inspect the wiring circuits at each terminal of the wire harness side.
Inspection Items
ITEM INSPECTION
BATTERY WIRE(RED)
Check that there is voltage between battery line (+) and ground line.
Check continuity between ground and GROUND WIRE(GREEN) frame. CHARGING COIL WIRE (YELLOW) Check that the resistance of the coil is within the specified range. (0.1~1.5)
Check not continuity between coil and frame. Check that there is battery voltage VOLTAGE DETECTION between voltage detection line (+) and LINE (BLACK) ground wire the ignition is ON.
REGULATOR / RECTIFIER UNIT INSPECTION

If all inspections on the wire harness side are normal and there are no loose connections at the regulator rectifier coupler, inspect the regulator rectifier unit by measuring the resistance between the terminals.
Resistance value will not be accurate if the probes touch your fingers. Use the following recommended tester. Using another manufacturers equipment may not allow you to obtain the specified values.
B
28~36 28~36
Replace the regulator rectifier unit if the resistance value between the terminals is abnormal.
TOOL : MULTI TESTER
indicate more than 1[M]

17-5
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. Measure the resistance between the yellow leads.
RESISTANCE VALUE : 0.1~1.5 (20 )
If the resistance values are much larger than the specified value, or if there is continuity between terminals and earth terminals, replace the stator with a new one. Install in the reverse order of removal.
This test is done with the starter mounted to the engine.
17-6
MEMO
IGNITION SYSTEM
BATTERY
ECU FUSE BOX
REGULATOR/RECTIFIER
IGNITION COIL
AC GENERATOR
18-0
18. IGNITION SYSTEM

IGNITION DIAGRAM18-0 SERVICE INFORMATION 18-1 TROUBLESHOOTING 18-2 CRANKPOSITIONSENSORINSPECTION 18-3 IGNITION COIL INSPECTION 18-4 SIDE STAND SWITCH 18-5
SERVICE INFORMATION
GENERAL SAFETY
Inspect the ignition system in proper sequence based on the troubleshooting. Dropping or giving a shock to the ECU unit causes a trouble. There should be battery voltage with the ignition and engine stop switched ON. Turn the main switch OFF while serving. TRANSISTOR ignition system is used and it can not be adjusted. Couplers are connected to other couplers which have same colour. Coil standard resistance may not be obtained due to the different measuring circumatances. A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding. This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also included, it may be difficult to make a correct determination. Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (chapter 21-1 )
SPECIFICATIONS
Item Primary Coil Ignition coil resistance 20(68) Secondary Coil Without the spark plug cap Standard 0.730.08, 235
(15K)
Crank position sensor resistance 20(68) Ignition timing 100RPM) IDLE (1,6001
80-150,20 BTDC 18
18
TOOLS
DIGITAL TESTER PVA MULTI-TESTER
18-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug. (TOOL : PVA MUITI TESTER)
UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)
Low peak voltage.
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 synchronized. (System is normal if measured voltage is over the standard voltage at least once.) 4. Poorly connected connectors or an open circuit in ignition system. 5. Faulty ignition coil. 6. Faulty ECU unit (in case when above No. 1~5 are normal).
18-2
IGNITION COIL PRIMARY VOLTAGE CRANK POSITION SENSOR
No peak voltage.
1. Incorrect peak voltage adaptor connections. 2. Faulty ignition switch. 3. Loose or poorly connected ECU unit connector. 4. Open circuit or poor connection in ground cord of the ECU unit. 5. Faulty peak voltage adaptor. 6. Faulty ECUunit (in case when above No. 1~6 are normal). 1. Faulty spark plug or leaking ignition coil secondary current ampere. 2. Faulty ignition coil. 1. The multitester impedance is too low. 2. Cranking speed is too slow. - Battery is undercharged (or operating force of the kick starter is weak). 3. The sample timing of the tester and measured pulse were not synchronized.(System is normal if measured voltage is over the standard voltage at least once.) 4. Faulty pulse generator (in case when above No. 1~3 are normal). 1. Faulty peak voltage adaptor. 2. Faulty crank position sensor
Peak voltage is normal, but no spark jumps at plug.
Low peak voltage.
No peak voltage.
IGNITION SYSTEM Inspection Items

ITEM INSPECTION
MAIN SWITCH CRANK POSITION SENSOR
Check the battery voltage between main switch wire (black) and ground wire when the ignition is ON Check the resistance of coil (between blue / yellow and green) is within the specified range. ( 80~150, 20)
IGNITION COIL (PRIMARY COIL) Check the resistance of coil (between black / yellow and green) is within the specified range. ( 0.73~0.08, 235) GROUND WIRE
TOOL : DIGITAL TESTER
Check continuity between ground and frame.
If measured data is out of standard, and there is no spark at plug, check the ignition coil by using a tester.
CRANK POSITION SENSOR INSPECTION

A.C. GENERATOR GENERATOR COUPLER COUPLER A.C.
RESISTANCE MEASUREMENT
Remove the seat. (13-2) Remove the LH. side cover (13-2) Disconnect the A.C generator 4P coupler and blue/yellow wire connector. Measure the resistance between the green and blue/yellow.
STANDARD VALUE : 80-150 (20)
PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire connector. Connect the blue/yellow wire terminal to the PVA tester (+) terminal. Connect the PVA tester (-) terminal to the green wire terminal or no painting area (ground) Crank the engine with the starter motor and measure the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V TOOL : PVA MULTI TESTER
18-3
IGNITION SYSTEM
IGNITION COIL IGNITION IGNITION COIL COIL
IGNITION COIL INSPECTION

Disconnect the ignition coil coupler.
PULL PULL PULL
PUSH PUSH PUSH PUSH
Since the resistance value of the primary coil is small, it is too diffcult to judgment even if the problem happen from the short circuit.
PRIMARY COIL Measure the resistance between the two terminals of the ignition primary coil. If the resistance value is within the specified range the coil is good. If resistance is (infinite), replace the coil with a new one.
STANDARD VALUE : (Resistance) 0.730.08, 230.5(Voltage) over 100V
SECONDARY COIL With the spark plug cap on, measure the resistance between the primary coil terminal and the spark plug cap. If the resistance value is within the specified range, then the coil is good. If the resistance is (open wire), disconnect the spark plug cap and measure the secondary coil resistance.
REFERENCE VALUE : 15K
Dontt measure the secondary coil voltage of ignition coil
18-4
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. Remove the side stand switch couper connected with main wire harness
Remove the side stand switch mounting screws and remove the cord clamp and side stand switch.
INSPECTION
Check the following terminals.
ITEM
SIDE STAND SWITCH
TERMINALS COLOR
STANDARD NORMAL IF THERE IS CONTINUITY
SHAFT
ON PUSH BLACK/WHITE AND (Side stand THE erected) SHAFT GREEN TERMINAL
PUSH THE SHAFT
OFF RELEASE BLACK/WHITE AND NORMAL IF THERE (Side stand THE GREEN TERMINAL pull back) SHAFT RELEASE THE SHAFT IS NO CONTINUITY Install in the reverse order of removal.
18-5
ELECTRIC STARTER
STARTER SWITCH Y/R /Y G O FUSE
B(CABLE)
STARTER MAGNETIC SWITCH
HQUaI
B/ G/Y B/W
STARTER MOTOR G/W B/W Lg/R B/W
MAIN SWITCH R/W O FUSE R
B(CABLE)
SIDE STAND SWITCH
HSPaI
G
GEAR POSITION SWITCH B......Black Y.......Yellow G......Green R......Red W..... White Lg.....Light green
NEUTRAL LAMP
BATTERY (12A 10AH) Lg/R
19-0
19. ELECTRIC STARTER

STARTING DIAGRAM 19-0 STARTER MOTOR 19-3 STARTER MAGNETIC SWITCH 19-6
SERVICE INFORMATION 19-1 TROUBLESHOOTING 19-2
SERVICE INFORMATION
GENERAL SAFETY
Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing serious injury. The starter motor can be maintained without removing the engine from the vehicle. A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.
SPECIFICATION
ITEM STARTER MOTOR BRUSH LENGTH STANDARD VALUE 10.2mm 5.0mm
Unit : mm SERVICE LIMIT
TOOLS
MULTI TESTER VERNIER CALIPER SCANNER
19
19-1
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.
With the ignition switchON , check for a CLICK sound from starter magnetic switch. (19-6) Connect the starter motor (+) terminal to the battery positive terminal. (Because a large amount of current flows, do not use thin wires). Starter motor does not turn. CLICK not heard Starter motor turns. Faulty starter motor. Disconnect starter magnetic switch coupler, and check the starter magnetic switch coil ground wire. (19-6) Loose or disconnected wire or cable. Faulty starter magnetic switch. NO CONTINUITY. Faulty neutral switch. Faulty clutch switch. Loose or poor contact at connector. Open circuit in wire harness.
CLICK heard
CONTINUITY. Connect the starter magnetic switch coupler. Measure the starter magnetic voltage at the starter magnetic switch coupler. (19-6) VOLTAGE MEASURED Check the starter magnetic switch operation. (19-6) ABNORMAL NORMAL
NO VOLTAGE.
Faulty ignition switch. Loose or poor contact at connector. Open circuit in wire harness. Loose or poor contact at starter magnetic switch coupler. Faulty starter magnetic switch.
Starter motor turns engine slowly.

Low battery voltage. Poorly connected battery terminal cable. Poorly connected starter motor cable. Faulty starter motor. Poorly connected battery ground cable. Damaged or worn brush.
Starter motor turns, but engine does not turn

Starter motor is running backwards. - Brushes assembled improperly. - Case assembled improperly. - Terminals connected improperly. Faulty starter clutch. Damaged or faulty starter drive gear
Starter motor and engine turns, but engine does not start.
Faulty ignition system. Engine problems. Excessive reduction gear friction.
Starter magnetic switch "Clicks", but engine does not turn over
Crankshaft does not turn due to engine problems.
19-2
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.
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
DISASSEMBLY
FLANGE FLANGE BOLTS BOLTS FLANGE BOLTS
Remove the following. - O-ring - Starter motor case bolts / spring washers - Front cover - Seal ring - Lock washer - Washer - Cir-clip - Rear cover assy - 2 pcs washer - Amature
INSPECTION
Check the bushing in the rear cover for wear or damage. Check the oil seal and bushing in the front cover for wear or damage.
19-3
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. There should be no continuity.
Check for continuity between the insulated brush and cable terminal. There should be continuity.
19-4
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. Install the brush holder into the motor case, aligning the holder tab with the motor case groove. Install the armature in the motor case, while pushing in the brushes into the brush holder.
When installing the armature into the motor case, hold the armature tightly to keep the magnet of the case from pulling the armature against it.
The coil may be damaged if the magnet pulls the armature against the case. Install the two washers. Install a new seal ring onto the motor case. Apply thin coat of grease to the armature shaft end. Install the rear cover, aligning its mark with the motor case mark.
19-5
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. Install the rubber cap securely.
STARTER MAGNETIC SWITCH

MAGNETIC MAGNETIC SWITCH MAGNETIC SWITCH SWITCH
REMOVAL
Remove the seat. (13-2) Remove the RH. side cover. (13-2) Disconnect the battery wire cable from the starter magnetic switch terminal. Disconnect the starter motor cable from the starter magnetic switch terrminal. Disconnect the Yellow/Red and Green/Yellow connector from the wire harness. Remove the starter magnetic switch from the bracket of the frame.
OPERATION INSPECTION
Shift the transmission into neutral. Turn the ignition switch to "ON", and push the starter switch button. The coil is normal if the starter magnetic switch clicks. If you dont hear the switch "CLICK", inspect the magnetic switch using the procedure below.
19-6
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.
CONTINUITY INSPECTION
Disconnect the wire connector of the magnetic switch. Connect the positive wire to the yellow/red wire terminal and the negative wire to the green/yellow wire terminal. There should be continuity.
INSTALLATION
19-7
LIGHTS/METER/SWITCHES
WINKER RELAY HEADLIGHT RELAY FUSE BOX
ECU
HORN
SPEEDOMETER
HEADLIGHT
BATTERY
HORN
20-0
20. LIGHTS/SWITCHES/HORN
20-0 SYSTEM LOCATION 20-1 SERVICE INFORMATION 20-1 TROUBLESHOOTING 20-2 HEADLIGHT 20-3 FRONT/REAR WINKER 20-3 STOP/TAIL LIGHT 20-4 COMBINATION METER 20-5 MAIN SWITCH 20-6 HANDLEBAR SWITCHES FRONT/REAR STOP SWITCH 20-7 20-8 GEAR CHANGE SWITCH 20-8 HORN 20-8 WINKER RELAY
SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together. All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these tabs all the way until locked when assembling. Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or an ohmmeter to the coupler terminals or connectors. The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check the circuit resistance value. The following color codes are used throughout this section. B = Black Y = Yellow L = Blue G = Green R = Red W = White Br = Brown O = Orange Sb = Sky Blue Lg = Light Green P = Pink V = Violet Gr = Gray
TROUBLESHOOTING
Light not turned on when the main switch is ON
Faulty light bulb Faulty switch Faulty or disconnected wiring Fuse cut Battery discharged
Fuel meter indicator malfunctioning

Coupler separated. Harness disconnected. Float operation malfuction. Fuel unit damaged.
Fuel meter needle unstable

Coupler loose. Fuel unit damaged. Meter damaged.
Dim headlight
Battery discharged Wiring and switch resistance high
20
Headlight Hi-Low bean cannot be charged

Faulty light bulb Faulty dimmer switch
20-1
LIGHTS/SWITCHES/HORN
HEADLIGHT
BULB REPLACEMENT
Loosen the flange bolt secured front cowl stay. Remove the headlight, winker, speedometer coupler.
FLANGE BOLT BOLT FLANGE FLANGE BOLT
Remove the headlight dust cover.
HEAD HEAD LIGHT DUST COVER HEAD LIGHT LIGHT DUST DUST COVER COVER
Push the headlight retainer and remove the bulb.
If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent early bulb failure. Avoid touching Halogen headlight bulb. Finger prints can create hot sport that cause a bulb to break. Install in the reverse order of removal
HEADLIGHT HEADLIGHT CASE HEADLIGHT CASE CASE
HEADLIGHT CASE REMOVAL/INSTALLATION

Remove - Center cowl - Side cowl RH/CH - Front cowl stay - Inner panal Remove the headlight case mounting bolts and headlight case from the headlight stay. Disconnect the all cords from the wiring. Remove the headlight case. Install in the reverse order of removal.
20-2
FRONT/REAR WINKER
BULB RREPLACEMENT
Remove the screw and winker lens.
FRONT WINKER WINKER FRONT FRONT WINKER
FRONT WINKER FRONT FRONT WINKER WINKER FRONT WINKER
REAR REAR WINKER REAR WINKER WINKER
While pushing the bulb, turn the bulb counterclockwise to remove it and replace with a new one. Install the winker lens in the reverse order of removal.
STOP/TAIL LIGHT
REAR WINKER REAR REAR WINKER WINKER REAR
INSPECTION
Turn the ignition switch to "ON", and check the tail light operation. Check that the stop/tail light unit light on with the front brake lever and/or rear brake pedal applied. When ever any one does not turn on, replace the stop/tail light bulb.
STOP/TAIL LIGHT STOP/TAIL STOP/TAIL LIGHT LIGHT
BULB REPLACEMENT
Remove the screws and tail light lens. Slightly press down on the bulb and turn it counterclockwise. Replace with a new bulb. Install in the reverse order of removal.
20-3
COMBINATION METER
REMOVAL
Remove the side RH/LH cowl. Rempve the front cowl.
SUB PANNEL SUB SUB PANNEL PANNEL COMBINATION COMBINATION METER COMBINATION METER METER
Remove the inner pannel. Loosen the speedometer cable nut and remove the cable from the meter. Disconnect combination meter connect.
PANNEL INNER INNER INNER PANNEL PANNEL
SPEEDOMETER SPEEDOMETER SPEEDOMETER
Loosen the combination meter mounting screws, remove the combination meter.
INSTALLATION
20-4
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 HAZARD STARTER SWITCH COUPLER HAZARD STARTER STARTER SWITCH SWITCH COUPLER COUPLER WINKER. WINKER. DIMMER DIMMER SWITCH SWITCH COUPLER SWITCH COUPLER COUPLER
MAIN SWITCH COUPLER MAIN MAIN SWITCH SWITCH COUPLER COUPLER
INSPECTION
MAIN MAIN SWITCH COUPLER MAIN SWITCH SWITCH COUPLER COUPLER
Check for continuity between the wire terminals of the main switch connector in each switch position. Continuity should exist between the color coded wires as follows: MAIN SWITCH
BAT1
ON OFF LOCK COLOR R/W B
BAT2
KEY
KEY ON KEY OFF KEY OFF/LOCK 20-5
HAZARD STARTER SWITCH COUPLER HAZARD HAZARD STARTER STARTER SWITCH SWITCH COUPLER COUPLER
HANDLEBAR SWITCHES
Check for continuity between the wire terminals of the handlebar switch connector. Continuity should exist between the color coded wire terminals as follows:
STARTER SWITCH
HEADLIGHT HEADLIGHT SWITCH HEADLIGHT SWITCH SWITCH
ST 1
FREE PUSH COLOR Y/R
BAT 2
HEADLIGHT SWITCH
W
OFF
STARTER STARTER SWITCH SWITCH STARTER SWITCH
P H
WINKER.DIMMER WINKER.DIMMER SWITCH COUPLER WINKER.DIMMER SWITCH SWITCH COUPLER COUPLER
COLOR
Br
Br/L
WINKER SWITCH
W
R N L COLOR Gr SB O
WINKER WINKER SWITCH WINKER SWITCH SWITCH
HORN SWITCH
HO
FREE PUSH COLOR LG B
BAT 2
HORN SWITCH HORN HORN SWITCH SWITCH HORN SWITCH
20-6
DIMMER SWITCH
BAT3
Hi (N) Lo COLOR B/W L W
PASSING PASSING SWITCH SWITCH PASSING SWITCH
HI
LO
PASSING SWITCH
BAT2
DIMMER DIMMER SWITCH DIMMER SWITCH SWITCH
HI
Hi COLOR B L
ASSEMBLY
FRONT/REAR STOP SWITCH

FRONT
Disconnect the front stop switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released.
BRAKE BRAKE LEVER BRAKE LEVER LEVER
STOP SWITCH STOP STOP SWITCH SWITCH
STOP STOP SWITCH COUPLER STOP SWITCH SWITCH COUPLER COUPLER
REAR
Remove the seat (13-2) Remove the RH. side cover. (13-2) Disconnect the rear stop switch connector and check for continuity between the terminals. There should be continuity with the brake pedal applied, and there should be no continuity with the brake pedal is released.
REAR REAR BRAKE PEDAL REAR BRAKE BRAKE PEDAL PEDAL
20-7
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.
HORN
Disconnect the wire connectors from the horn. Connect the 12V battery to the horn terminal directly. The horn is normal if it sounds when the 12V battery is connected acress the horn terminals.
WINKER RELAY
Remove the rear seat. (13-2) Check the following: - Battery condition - Burned bulbs - Burned fuse - Main switch and winker switch function - Loose connectors If the above items are all normal, check the following: 1. Short the Black and Gray terminals of the winker relay connector with a jumper wire. Start the engine and check the winker light by turning the switch to ON. Light comes on Light does not come on Broken wire harness Faulty winker relay Poor connection of the connector
20-8
21. TROUBLESHOOTING
ENGINE WONT START OR IS HARD TO START 21-1 ENGINE LACKS POWER 21-2 POOR PERFORMANCE (AT LOW AND IDLE SPEED) 21-3 POOR PERFORMANCE (AT HIGH SPEED) 21-4 POOR HANDLING 21-4 POOR FRONT/REAR SUSPENSION PERFORMANCE 21-5 FUEL GAUGE 21-5
ENGINE WONT START OR IS HARD TO START

INSPECTION
1. Check fuel flow to carburetor. Fuel is supplied Fuel not supplied to the carburetor
CAUSE OF TROUBLE
Fuel tank empty. Clogged fuel tube or fuel filter. Sticking float valve. Clogged fuel tank cap hole. Faulty spark plug. Contaminated spark plug. Disconnected or shorted high tension wires. Faulty pulse generator. Faulty main switch.
2. Check the spark plug. Good spark
Weak or no spark
3. Test cylinder compression. Compression normal
Low compression
Low speed of starter crank. Incorrect valve clearance. Faulty valve seat. Worn cylinder and piston rings. Seized valve. Improper valve timing. Improper chock valve operation. Improper chock cable free play. Carburetor incorrectly adjusted. Improper ignition timing. Fuel contaminated. Lean fuel mixture.
4. Start by following normal procedure. Engine does not start.
Engine starts but stops.
5. Remove and inspect spark plug. Dry plug
Wet plug
6. Close the choke and start engine again.
Carburetor flooded. Throttle valve open. Choke closed. Air cleaner dirty. Rich fuel mixture.
21
21-1
TROUBLESHOOTING
ENGINE LACKS POWER

INSPECTION
1. Check tire pressure. Pressure normal 2. Raise wheels off ground and rotate by hands. Wheel rotate freely. Pressure low
CAUSE OF TROUBLE
Punctured tire. Faulty tire valve.
Wheel dont rotate freely
Dragged brake. Worn or damaged wheel bearings. Lacked wheel bearings lubrication. D Axle nut tightened excessively. Clutch slipping. Worn clutch disk and plate. Damaged clutch disk and plate.
3. Accelerate suddenly. Engine speed increased.
Engine speed not changed.
4. Accelerate lightly. Engine speed increased.
Engine speed doesnt increase.
Closed carburetor choke. Clogged fuel aisle. Clogged air cleaner. Clogged fuel tank breather. Clogged muffler. Faulty ECU unit. Faulty pulse generator.
5. Check ignition timing by using scan. Correct
Incorrect
6. Check valve clearance Correct
Incorrect
Improper valve adjustment. Worn valve seat.
7. Measure the cylinder compression. Compression normal 8. Check the carburetor for clogging. Not clogged
Low
Improper valve operation. Worn cylinder and piston ring. Worn cylinder head gasket. Incorrect valve timing.
Clogged
Damaged fuel strainer or screen. Poor carburetor maintenance.
21-2
TROUBLESHOOTING
INSPECTION
9. Check the spark plug. Not contaminated or not discolored. 10. Check oil level. Level normal 11. Remove cylinder head 30mm hole cap, and inspect lubrication. Valve train lubricated properly. 12. Check for engine overheating. Not overheated. Overheated Contaminated or discolored
CAUSE OF TROUBLE
Lean fuel mixture. Using spark plug with on incorrect heat range. Oil level too high. Oil level too low. Contaminated oil. Oil level too low. Contaminated oil. Faulty oil pump. Clogged oil passage. Excessive carbon build-up in combustion chamber. Poor quality fuel being used. Lean fuel mixture. Clutch slipping. Worn piston ring and cylinder. Lean fuel mixture. Excessive carbon build-up in cambustion chamber. Incorrect ignition timing.
Level low or high
Valve train lubricated improperly.
13. Accelerate or run at high speed. Engine does not knocking.
Engine knocking
POOR PERFORMANCE (AT LOW AND IDLE SPEED)

INSPECTION
1. Check ignition timing and valve clearance. Correct 2. Check inlet pipe for leakage. No leak 3. Check sparks. Sparks normal. Weak or intermittent sparks Carbon depasited on spark plug or spark plug contaminated. Incorrect
CAUSE OF TROUBLE
Incorrect valve clearance. Faulty ECU unit. Faulty pulse generator.
Leaking
Faulty insulator O-ring. Loose throttlebody.
21-3
TROUBLESHOOTING
POOR PERFORMANCE(AT HIGH SPEED)

INSPECTION
1. Check the ignition timing and valve clearance. Correct. Incorrect.
CAUSE OF TROUBLE
Faulty valve clearance adjustment. Faulty ECU unit. Faulty pulse generator.
2. Disconnect fuel tube at carburetor. Fuel flows freely.
Fuel flows restricted.
No fuel to fuel tank. Carburetor choke closed. Clogged fuel tube. Clogged fuel tank cap hole. Clogged fuel strainer or screen.
3. Remove the carburetor and check for clogged jets. No clogged. 4. Check valve timing Correct.
Clogged.
Damaged fuel strainer or screen.
Incorrect.
Cam sprocket not installed properly.
5. Check valve spring tension.
Weak.
Faulty valve spring.
POOR HANDLING
INSPECTION
1. If steering is heavy.
CAUSE OF TROUBLE
Too tight steering top thread. Damaged steering bearings.
2. If either wheel is wobbling
Excessive wheel bearing play. Bent rim. Improperly installed wheel hub. Worn rear fork pivot bush. Bent frame. Rear fork pivot adjusting bolt is too tight. Front and rear wheels are not aligned. Bent front fork. Bent rear fork.
3. If the motorcycle pulled to one side.
21-4
TROUBLESHOOTING
POOR FRONT/REAR SUSPENSION PERFORMANCE

INSPECTION
1. Suspension excessively soft.
CAUSE OF TROUBLE
Cushion spring weak. Overloaded. Damper oil leaks. Fork pipe or cushion rod bent. Sliders stuck. Cushion stopper rubber damaged.
2. Suspension excessively hard. 3. Noise from the suspension.
FUEL GAUGE
GAUGE READING INACCURATE (IGNITION SWTICH ON) INSPECTION
1. Operate the turn signal to check the battery circuit.
Signal operates satisfactorily.
CAUSE OF TROUBLE
Signal continuously operates dim or does not operate at all. Fuse cut. Battery weak or totally discharged. Faulty ignition swtich. Faulty terminal connection. Wire harness damaged. Faulty float.
2. Remove the fuel level sensor, and move float to check the status of operation.
Float up : Full position Float down : Empty position Needle not moving.
Needle moves.
3. Short-circuit the tank unit terminal on the wire harness side.

Needle not moving.
Needle not moving.
Balance coil damaged or shorted.
4. Terminal joints loose or faulty connection.
Unsatisfactory
Terminal loose. Faulty terminal connection.
Check
Balance coil/lead shorted or damaged.
21-5
TROUBLESHOOTING
GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON) INSPECTION
1. Operate the turn signal to check the battery circuit.
Signal operates satisfactorily.
CAUSE OF TROUBLE
Signal continuously operates dim or does not operate at all. Fuse cut. Battery weak or totally discharged. Ignition switch damaged or shorted. Terminal loose of faulty connection. Wire harness damaged. Faulty fuel level sensor connection.
2. Remove the tank and operate the float.

Needle moving.
Needle not moving.
3. Move the float rapidly. One up/down motion per second.

Needle moving.
Needle not moving.
Damper oil inside the meter insufficient.
4. Start the engine, and measure the fuel level sensor resistance.
Resistance not changed.
Resistance changed significantly.
Faulty connection between the sliding arm and the resistance.
5. Check each joint.

Satisfactory
Unsatisfactory
Terminal connection loose or faulty connection. Balance coil/lead shorted or damaged.
21-6
MEMO
MEMO
MEMO
MEMO
22. WIRING DIAGRAM
WIRING DIAGRAM
22
22-1
22. WIRING DIAGRAM
33 01 09 17 25 08 16 24 32 36
34
35
37
38
39
40
1 2
1 2
1 2
1 2
SERVICE MANUAL
2009. 10 PRINTED 2009. 10 PUBLICATION
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What safety precautions should be followed when working with the battery?

HOW TO USE THIS MANUAL

EMS (Engine Management System)

10. Recommended grease must be applied to or filled in the specified place.

MANUFACTURERS NAME, BEARING No.

CAVITY MANUFACTURERS NAME CLIP FITTING

CAUTION WHEN WIRING

WHITE COUPLER. WHITE

WHITE / RED CORD

Connect covers to the terminal after maintenance.

REMOVE THE RUST!

Pay attention not to damage the vinyl cover of the coupler.

Check to see if there is bended terminal and secure it to avoid disconnecting.

Secure the wire harness firmly using the clamp.

In case of the weld clamp, do not clamp in the welded part.

If necessary, lock the wire harness properly.

Do not twist the wire harness.

TOOL BOX REAR CUSHION RADIATOR HELMET HOLDER CALIPER

BRAKE DISK GEAR SHIFT PEDAL MAIN STAND SIDE STAND

PILLION STEP BAR MAIN STEP BAR

ENGINE ENGINE ENGINE SERIAL SERIAL SERIAL NUMBER NUMBER NUMBER

FRAME SERIAL SERIAL NUMBER NUMBER FRAME

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

Apply Engine Oil Apply Engine Oil

HEX NUT U- NUT U- NUT

4.0~6.0 8~12 18~25 29~39 49~59

0.45~0.6 0.8~1.2 1.8~2.5 3.0~4.0 5.0~6.0

5mm SCREW 6mm SCREW, FLANGE BOLT

3.4~5.0 7~11 9.8~14 24~29 34~44

0.35~0.5 0.7~1.1 1.0~1.4 2.4~3.0 3.5~4.5

*SH(Small Head) : It describe 6mm bolt of 8mm flange bolt.

VALVE SEAT CUTTER

TIRE SIZE TIRE PART MINIMUM-DEPTH

I R I R I I R R C NOTE (3) NOTE (2)

Every 1,000 : I and L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R I I I I I I I I I I I I I

FUEL LINE (FUEL TUBE)

INJECTOR INJECTOR INJECTOR

FUEL TUBE FUEL FUEL TUBE TUBE FUEL TUBE

THROTTLE THROTTLE GRIP THROTTLE GRIP GRIP

THROTTLE GRIP OPERATION

FREEPLAY FREEPLAY FREEPLAY FREEPLAY

THROTTLE THROTTLE CABLE THROTTLE CABLE CABLE

ADJUSTER ADJUSTER ADJUSTER

LOCK NUT LOCK LOCK NUT NUT LOCK NUT

ADJUSTER ADJUSTER ADJUSTER

LOCK LOCK NUT LOCK NUT NUT

THROTTLE THROTTLE CABLE CABLE THROTTLE CABLE

SCREWS SCREWS SCREWS

CLEANER AIR AIR AIR CLEANER CLEANER ELEMENT ELEMENT ELEMENT

Do not reuse the filter element to clean by compressed air.

GENUINE PLUG : CR9EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgfm

CHECK GAP, DEPOSITS

CHECK WASHER FOR DAMAGE CHECK FOR CRACKS

T MARK T T MARK MARK T MARK