Daelim s2 125 Service Manual

HOW TO USE THIS MANUAL
This manual describes effective maintenance procedure for the S2-125 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; section 3, assembly and disassembly procedures for external components, and section 4 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.
CONTENTS
GENERAL
SERVICE INFORMATION INSPECTIONS/ADJUSTMENTS EXTERNAL PARTS LUBRICATION SYSTEM FUEL SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
ENGINE ELECTRICAL SYSTEM FRAME
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 Co., Ltd.,
ENGINE REMOVAL/INSTALLATION LH.CRANK CASE COVER/TRANSMISSION A.C. GENERATOR/STARTING CLUTCH CYLINDER HEAD/VALVE CYLINDER/PISTON TRANSMISSION / CRANK SHAFT / CRANK CASE FRONT WHEEL / FRONT FORK / STEERING / BRAKE REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM LIGHTS / SWITCHES / HORN WIRING DIAGRAM
1. SERVICE INFORMATION
GENERAL SAFETY SERVICE RULES CAUTION WHEN WIRING SERIAL NUMBER LOCATION SPECIFICATIONS 1-1 1-1 1-5 1-9 1-10 TORQUE VALUES STANDARD TORQUE VALUES SYMBOLS LUBRICATION OIL WIRING DIAGRAM 1-12 1-13 1-13 1-14 1-15
GENERAL SAFETY
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 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 alway 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 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 chassis.
1-1
SERVICE 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
SERVICE 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.
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.
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
SERVICE 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.
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.
1-4
SERVICE 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.
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.
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
SERVICE 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
SERVICE 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.
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
SERVICE 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 expended 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
SERVICE INFORMATION
SERIAL NUMBER LOCATION
FRAME SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
FRAME SERIAL NUMBER LOCATION
1-9
SERVICE INFORMATION
SPECIFICATIONS
ITEM
OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE / TYPE REAR TIRE SIZE / TYPE TIRE PRESSURE 1 PERSON 2 PERSON FRONT BRAKE REAR BRAKE FUEL TANK CAPACITY 2,110 mm 745 mm 1,356 mm 1,481 mm 760 mm 121 mm 150 kg 294 kg Underbone Telescopic Swing arm 120 / 70 - 12 / Tubeless 130 / 70 - 12 / Tubeless 2.00 Kgf / 2.00 Kgf / 2.00 Kgf / 2.25 Kgf / Hydraulic disk Hydraulic disk 11 2.8 27 87.1 mm 135/65 Oil cooled / air cooled 4 cycle SOHC engine 1(Single cylinder), front angle 80 5650.7 mm 124.9 10.8 : 1 SOHC chain drive 1.1After disassembly 0.75After Oil change 0.8After Oil filter change 0.9After Oil change with Oil in the Oil hose removed Forced pressure splash type Paper Filter 14.0 kgf / (550 rpm) 5 BTDC 14 ABDC 18 BBDC 1 BTDC 0.120.12 mm 0.120.12 mm
SPECIFICATIONS
DIMENSIONS
FRAME
FRONT REAR FRONT REAR
FULL CAPACITY RESERVE CAPACITY
CASTER ANGLE TRAIL FRONT FORK /REAR FORK OIL CAPACITY TYPE CYLINDERS / ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY
ENGINE
LUBRICATION SYSTEM AIR CLEANER TYPE CYLINDER COMPRESSION INTAKE VALVE
OPEN CLOSED EXHAUST VALVE CLOSED CLOSED VALVE CLEARANCE (COOLING-OFF PERIOD) INTAKE EXHAUST
1-10
SERVICE INFORMATION
ITEM
TYPE / VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING AC GENERATOR CAPACITY BATTERY TYPE / CAPACITY SPARK PLUG SPARK PLUG GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT ( HIGH / LOW ) POSITION LIGHT WINKER LIGHTS ( FR / RR ) TAIL / STOP LIGHT HIGH-BEAM PILOT WINKER PILOT METER LIGHTS TRUNK LAMP LICENSE LAMP
SPECIFICATIONS
CV type ( vacuum ) 25 mm CVK 116 A Auto-bystarter # 102 2 and trust out 20.5 mm 1.700100 ( rpm ) Automatic Transmission 3.231 (42/13) 2.786 (39/14) C.D.I Ignition 15 BTDC / 1.800 ( rpm ) 12V 10A / 5,000 ( rpm ) Closed type (MF) 12V 10AH CR8EH - 9 (NGK) 0.8 - 0.9 mm 15A Starter motor 12V 55W /12V 55W 12V 5W 12V 10W4 12V 21 / 5W 14V 3W 14V 3W2 12V 2W2 14V 1.4W 12V 5W
CARBURETOR
DRIVE TRAIN
F MARK
ELECTRICAL SYSTEM
1-11
SERVICE INFORMATION
TORQUE VALUES
ENGINE
ITEM
OIL FILTER CAP OIL DRAIN PLUG BOLT VALVE ADJUST SCREW LOCK NUT CYLINDER HEAD BOLT FLYWHEEL BOLT DRIVE FACE NUT CLUTCH OUTER BOLT CAM CHAIN TENSIONER PIVOT BOLT SPARK PLUG DRIVE PLATE CAM SHAFT HOLDER NUT CAM CHAIN TENSIONER FLANGE BOLT CAM CHAIN TENSIONER PAN SCREW CYLINDER HEAD COVER BOLT MISSION COVER BOLT MISSION COVER DRAIN BOLT MISSION COVER CHECK BOLT COOLING FAN BOLT STARTING CLUTCH NUT STARTER MOTOR FLANGE BOLT RADIATOR OIL BOLT OIL PUMP FLAT SCREW OIL PUMP DRIVEN GEAR NUT
QTY
1 1 4 2 1 1 1 1 1 1 4 2 1 4 8 1 1 3 1 2 4 3 1
THREAD DIA (mm)

20 12 5 6 12 12 12 8 12 30 8 6 6 6 6 8 8 6 22 6 12 6 6
TORQUE VALUE
1.1 kgfm 2.5 kgfm 0.8 kgfm 1.0 kgfm 5.5 kgfm 7.5 kgfm 5.5 kgfm 1.0 kgfm 1.2 kgfm 5.5 kgfm 2.0 kgfm 1.0 kgfm 0.4 kgfm 0.9 kgfm 1.2 kgfm 1.0 kgfm 0.9 kgfm 1.0 kgfm 9.5 kgfm 0.9 kgfm 3.2 kgfm 1.0 kgfm 1.0 kgfm
REFERENCE
Apply engine oil
FRAME
ITEM
STEERING STEM NUT STEERING TOP THREAD NUT FORK PIPE BOTTOM BRIDGE HANDLE POST FRONT AXLE NUT FRONT CALIPER BRACKET BOLT FRONT MASTER CYLINDER HOLDER BOLT FRIBT DISK PLATE BOLT REAR AXLE NUT REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER BOLT REAR DISK PLATE BOLT SPEEDOMETER GEARBOX SCREW FRONT FORK BOLT REAR CUSHION UPPER BOLT REAR CUSHION UNDER BOLT REAR CUSHION LOCK NUT ENGINE HANGER UPPER BOLT ENGINE HANGER LOWER BOLT MAINSTAND BOLT SIDESTAND PIVET SEREW SIDESTAND PIVET NUT
QTY
1 1 1 2 1 2 2 3 1 2 2 3 1 2 2 2 2 2 1 2 1 1
THREAD DIA (mm)

26 26 10 10 12 8 6 8 16 8 6 8 5 22 10 10 10 12 10 10 10 10
TORQUE VALUE
7.0 kgfm 0.25 kgfm 7.5 kgfm 6.0 kgfm 6.0 kgfm 3.1 kgfm 1.2 kgfm 4.25 kgfm 12.5 kgfm 3.1 kgfm 1.2 kgfm 4.25 kgfm 0.43 kgfm 2.25 kgfm 4.0 kgfm 4.0 kgfm 3.5 kgfm 5.25 kgfm 4.5 kgfm 4.0 kgfm 1.5 kgfm 4.5 kgfm
REFERENCE
Initial torque
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.
1-12
SERVICE INFORMATION
STANDARD TORQUE VALUES

ITEM
5mm BOLT, NUT 6mm BOLT, NUT 8mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT
TORQUE VALUE
0.5 kgfm 1.0 kgfm 2.2 kgfm 3.5 kgfm 5.5 kgfm
ITEM
5mm SCREW 6mm SCREW 6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT
TORQUE VALUE
0.4 kgfm 0.9 kgfm 1.2 kgfm 2.7 kgfm 4.0 kgfm
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 oil adding, oil change, or parts.

SYMBOL MEANING
OIL GREASE (3-1)
Add oil. If there is no specific oil indicated, use the designated or recommended engine oil. Apply grease Indicates reference page. (example : Refer to page 3-1)
The following abbreviations are used in this manual.

ASSY ASSEMBLY
LH. RH.
Left Right
1-13
SERVICE INFORMATION
WIRING DIAGRAM
LIGHTING CORD (EXPORT USE ONLY) WINKER SW. CORD FR. BRAKE HOSE RR. BRAKE HOSE THROTTLE CABLE HORN WIRE WIRE CLIP HORN CABLE GUIDE WINKER SW. CORD LIGHTING SW. CORD (EXPORT USE ONLY) HAZARD SW. WIRE (DOMESTIC USE ONLY) FUEL NECK EARTH WIER AUTO CHOKE WIRE WIRE CLIP LH. SEAT LOCK CABLE THROTTLE CABLE SIDE STAND SW. COUPLER WIRE CLAMP NOISE SUPPRESSOR CAP THROTTLE CABLE SEAT LOCK CABLE TRUNK LAMP WIRE THROTTLE CABLE SEAT LOCK CABLE MAIN WIRE HARNESS CORD PROTECTOR SEAT LOCK JUNCTION CLAMP SEAT LOCK JUNCTION RH. SEAT LOCK CABLE LH. SEAT LOCK CABLE BATTERY BOX BATTERY (12V 10AH) C.D.I UNIT COMP. WIRE CLIP WIRE CLIP
WIRE CLIP FR. BRAKE HOSE COMBI. METER WIRE HOSE CLIP FUEL BREATHER TUBE FUEL SUPPLY TUBE TUBE CLAMP FR. BRAKE HOSE
WIRE CLAMP EARTH WIRE C.D.I UNIT WIRE
OIL EL LEV
BRAKE HOSE CLAMP SPEEDOMETER CABLE
WIRE CLIP LH. SEAT LOCK CABLE FUEL UNIT WIRE RADIATOR ASS'Y LH. RADIATOR HOSE SIDE STAND SW. CORD WIRE CLIP THROTTLE CABLE
FUEL UNIT CORD WIRE CLIP DRAIN TUBE(AIR CLEANER) AUTO CHOKE CORD BREATHER TUBE DRAIN TUBE(CARB.) FUEL TUBE(CARB.)
FUEL UNIT COUPLER TUBE CLAMP
EARTH CABLE BATTERY + CABLE START-MAG. SW. WIRE BATTERY + CABLE START-MAGNETIC SW. START -MOTOR CABLE THROTTLE CABLE LIGHTING SW. CORD CABLE GUIDE
FR. BRAKE HOSE SEAT LOCK CABLE HORN WIRE WIRE CLIP HORN COMP. HOSE GUIDE SPEEDOMETER CABLE FR. BRAKE HOSE CABLE GUIDE
LICENSE LAMP WIRE RR. COMBI. LIGHT WIRE WIRE CLIP MAIN WIRE HARNESS A.I.C.V ASSY START-MAG. SW. CORD EARTH CABLE ACG. WIRE TUBE D, A.I.C.V TUBE E, A.I.C.V TUBE C, A.I.C.V
FUEL PUMP FUEL TUBE(TO. CARB.) RH. SEAT LOCK CABLE FUEL TUBE(TO. FUEL TANK) FUEL TUBE(TO. INSULATOR) COMB. SW. CORD TUBE A, A.I.C.V RR. BRAKE HOSE (TO REED VALVE) FUEL TUBE(TO. FUEL TANK) FUEL STRAINER BRAKE HOSE CLIP RADIATOR ASSY RR. BRAKE HOSE PIPE
ACG. CORD RR. BRAKE HOSE CLAMP RR. BRAKE HOSE WIRE CLIP RR. BRAKE HOSE GUIDE EARTH CABLE START-MOTOR CABLE
WIRE CLIP RH. RADIATOR HOSE WIRE GROMMET SPEEDOMETER CABLE
1-14
SERVICE INFORMATION
RR. BRAKE HOSE CABLE GUIDE WINKER SW. CORD HORN WIRE FR. BRAKE HOSE LIGHTING SW. CORD (EXPORT USE ONLY) THROTTLE CABLE
THROTTLE CABLE SEAT LOCK CABLE HAZARD SW. WIER (DOMESTIC USE ONLY) COMBI. METER COUPLER FUEL SUPPLY TUBE FUEL BREATHER TUBE TUBE CLAMP HEAD LIGHT WIRE CABLE GUIDE COMB. SW. WIRE WIRE CLAMP SEAT LOCK CABLE
RR. BRAKE HOSE
SPEEDOMETER CABLE
RADIATOR ASSY WIRE CLIP SEAT LOCK JUNCTION SEAT LOCK JUNCTION CLAMP LH. RADIATOR HOSE BRAKE HOSE CLIP RR. BRAKE HOSE PIPE LH. SEAT LOCK CABLE RH. SEAT LOCK CABLE RH. RADIATOR HOSE
WIRE CLIP TUBE CLAMP TUBE CLIP FUEL TUBE (TO. INSULATOR) FUEL TUBE (TO. CARB.) FUEL TUBE (TO. FUEL TANK) FUEL PUMP HOSE CLAMP START-MOTOR CABLE EARTH CABLE ACG. CORD HOSE CLAMP
FUEL STRAINER RH. SEAT LOCK CABLE RR. BRAKE HOSE PIPE
WIRE CLIP TUBE C, A.I.C.V HIGHTENSION CORD BAND B 45, AIR CLEANER CONNECTING TUBE AIR CLEANER CONNECTING TUBE
WIRE HARNESS SIDE STAND SW. COUPLER
IGN. COIL AUTO CHOKE COUPLER
WIRE CLIP LH. SEAT LOCK COUPLER
1-15
SERVICE INFORMATION
HEAD LIGHT RELAY WINKER RELAY
EARTH CABLE BATTERY BOX COUPLER *NOTE - WHITE COLOR : EXPORT USE ONLY - BLACK COLOR : DOMESTIC USE ONLY
REG. RECTIFIER REG. RECTIFIER CORD BATTERY + CABLE
WIER CLIP ACG. CORD WIER CLIP START-MAGNETIC SW. CORD START-MAGNETIC SW. START-MOTOR CABLE EARTH CABLE
1-16
SERVICE INFORMATION
FRAME BODY COMP. BATTERY + CABLE SPARE FUSE(15A) FUSE WIRE
12V 10AH BATTERY (MF) EARTH CORD (TO. FRAME) EARTH CABLE
BATTERY + CABLE START-MAGNET SW. ASSY. START MOTOR CABLE TO. CARBULATOR TUBE CLIP FUEL PUMP TUBE CLIP TUBE CLIP TO. FUEL TANK TO. INSULATOR
WIRE CLIP BATTERY EARTH CABLE ACG. WIRE START-MAG. SW. CORD
ACG. CORD
1-17
MEMO
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1 MAINTENANCE SCHEDULE 2-3 FUEL LINE (FUEL TUBE) 2-4 THROTTLE GRIP OPERATION 2-4 AIR CLEANER 2-4 SPARK PLUG 2-5 VALVE CLEARANCE 2-5 CYLINDER COMPRESSION PRESSURE 2-6 CARBURETOR IDLE SPEED 2-6 BRAKE FLUID2-7 BRAKE PAD/SHOE BRAKE SYSTEM BRAKE LEVER FREE PLAY HEADLIGHT AIM SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING 2-7 2-7 2-8 2-8 2-8 2-9 2-9 2-10 2-10
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 2-3 and 2-4 Stand the main stand prior to beginning work.
SPECIFICATIONS
THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE IN EX 2- 6mm CR8EH-9 0.8-0.9mm 0.120.02mm 0.120.02mm 1,700100rpm 142kgf/ ( 550rpm )
CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE
TIRES
COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 2.00kgf/ 2.00kgf/ 2.00kgf/ 2.25kgf/ 120/70 - 12 58S(Tubeless) 130/70 - 12 62S(Tubeless) 0.5mm 0.5mm
2-1
TIRE SIZE MIN, TREAD DEPTH
INSPECTIONS / ADJUSTMENTS
TORQUE VALUES
SPARK PLUG CYLINDER HEAD COVER BOLTS VALVE ADJUSTING NUTS TIMING HOLE CAP 1.1kgfm 1.0kgfm 1.1kgfm 0.6kgfm
TOOLS
WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE
2-2
MAINTENANCE SCHEDULE
Carry out pre-operation check at each scheduled maintenance period based on the information described in the owners manual.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN
These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart.
FREQUENCY ITEM ODOMETER READING(NOTE 1) x 1000Km 1 1 4 6 8 12 12 18 16 24 REMARK
MONTH
FUEL LINE FUEL FILTER THROTTLE OPERATION AIR CLEANER ELEMENT SPARK PLUG
I R I I I I R R C I I I I I I I I
I R I R I I R R C I I I I I I I I I I I I I L
I R I R I I R R C R I I I I I I I I I I I I I L
CARBURETOR IDLE ENGINE OIL ENGINE OIL FILTER OIL FILTER SCREEN
TRANSMISSION OIL BRAKE FLUID VALVE CLEARANCE
BRAKE SHOE / PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT ADJUSTMENT SUSPENSION BOLTS, NUTS, FASTENERS WHEELS / TIRES STEERING
DRIVE VALTE WEIGHT ROLLER SLIDE PIECE MOVABLE DRIVE FACE GREASE
If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections. To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops, dealers or other designated repair shops.
NOTE
1. After the odometer reading exceeds 12,000km, repeat maintenance service at intervals indicated in the table. 2. After riding in areas with high humidity or pollution, carry out maintenance service more frequently. 3. Replace every 2 years. Proper technology is required for this job.
2-3
FUEL LINE(FUEL TUBE)

Remove the luggage box. Check the fuel tube of the fuel auto cock connected to the fuel tank and carburetor. If the fuel tube is cranked, damaged or leaks, replace it.
THROTTLE GRIP OPERATION

Check if the throttle grip operates smoothly in any steering position. If the throttle grip does not operate properly, lubricate the throttle cable. If the throttle grip does not operate properly, check the throttle cable for aging, damage or kinking. Check the throttle grip free play.
FREE PLAY : 2~6mm
LOCK NUTS LOCK NUTS LOCK NUTS
ADJUSTRING NUTS ADJUSTRING NUTS ADJUSTRING NUTS
For main adjustment, loosen the lock nut and turn adjuster. After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play.
For simple adjustment, use the adjuster under the throttle grip. RH. Remove the Rubber. Loosen the lock nut and turn the adjuster.
2-4
AIR CLEANER
Loosen the 6 screws securing the air cleaner case cover, remove it. Loosen the 2 screws securing the air cleaner element holder, remove it.
Remove the air cleaner element. Wash away any accumulated dust or dirt, by gently squeezing it in non flammable or high flash point solvent.
Using gasoline or low flash point solvents for cleaning parts may result in a fire or explosion.
VALVE CLEARANCE
Remove the following parts. -Luggage box. (4-4) -Center cover. (4-5) Loosen the 4 cylinder head bolts.
CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER
Inspect and adjust the valve clearance when the engine is cool. (under 35 / 95 C F) Remove the cylinder head cover. Turn the flywheel counterclockwise, and align the T mark on the flywheel with the index mark on the RH. crank case cover. The piston at this time must be at the top dead center of the compression stroke. Measure valve clearance with a feeler gauge.
RH. SHROUD
VALVE CLEARANCE : Intake : 0.120.02mm Exhaust : 0.120.02mm
TIMING CHECKING
2-5
CHECK GAP, DEPOSITS
SPARK PLUG
0.8 ~ 0.9mm
CHECK WASHER FOR DAMAGE CHECK FOR CRACKS
Remove the plug maintenance cover. Remove the spark plug cap and disassemble the plug. 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.
GENUINE PLUG : CR8EH-9 SPARK PLUG : 0.8~0.9mm TORQUE VALUE : 1.2kgfm
ADJUSTER WRENCH
FEELER GAUGE
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. Loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut.
TORQUE VALUES : 0.8kgfm TOOLS : WRENCH 8X9mm ADJUSTING WRENCH B FEELER GAUGE
Measure the valve clearance again. Install the cylinder head cover and tighten the bolts.
TORQUE VALUES : 0.9 kgfm
CYLINDER COMPRESSION PRESSURE

Start and warm up the engine. Remove the plug maintenance cover. Stop engine, and remove the spark plug cap and spark plug. Install a compression gauge. Open the throttle completely, and crank the engine with the starter motor until the gauge reading rising.
TOOL : COMPRESSION GAUGE
SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG
The maximum reading is usually reached within 4~7 seconds.

COMPRESSION PRESSURE : 14.0 kg/cm2
COMPRESSION GAUGE
If the pressure is low, check the following: -Inadequate valve clearance adjustment -Valve leakage -Leakage from the cylinder head gasket -Piston/cylinder worn If pressure is high, check the following: -Carbon deposits on the piston head, and cylinder head.
2-6
CARBURETOR IDLE SPEED

Remove the plug maintenance cover. (4-5) Check the idle speed and adjust if necessary by turning the throttle stop screw.
Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. Heat the engine to make accurate idling inspection and adjustment. Stand the vehicle on the main stand. Turn the throttle stop screw and make adjustments to prescribed idling speed.
FINAL REDUCTION GEAR OIL

OIL CHECK BOLT
Erect the main stand prior to beginning work. Erect the main stand prior to beginning work. Stop the engine and remove the oil check bolt. Check the oil level through the oil check hole. If the oil level is below, fill the oil (SAE90#). Install and tighten the oil check bolt.
Make sure that the sealing washer is good condition.
GEAR OIL REPLACEMENT

Remove the oil check bolt. Remove oil drain bolt and drain oil completely. Install and tighten the oil drain bolt.
TORQUE VALUE : 0.98kgfm
Make sure that the sealing washer is good condition.

DRAIN BOLT
OIL DRAIN BOLT OIL DRAIN BOLT OIL DRAIN BOLT OIL DRAIN BOLT
Fill the recommended oil(SAE90#).

GEAR OIL CAPACITY At disassembling: 200cc At replacing: 180cc
DRIVE BELT
Remove the L.crankcase cover. Check the drive belt for wear or damage. Check scheduled maintenance period, replace the new drive belt if possible.
2-7
BRAKE FLUID
Remove the brake fluid cover. Check the oil level inside the front brake reservoir. If the oil level is near the lower limit line, remove the reservoir diaphragm and fill DOT 3 and DOT 4 brake fluid to the top limit line. If the brake fluid reaches the lower limit line, check the entire brake system for leaks.
Brake fluid will damage painted, plastic or rubber parts. Mixing incompatible fluids can impair braking efficiency. A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability.
BRAKE PAD/SHOE
BRAKE PAD REPLACEMENT
Check the brake pads for wear. If the red mark on the pad reaches the brake disc, replace the pads.
Replace the brake pads in sets.

RR. CALIPER RR. CALIPER RR. CALIPER
BRAKE SYSTEM
Check the front brake hose for cracks or damage. If any leaks are found, replace immediately. Check the brake rod for looseness or damage, and replace it if necessary.
FR. CALIPER FR. CALIPER FR. CALIPER
BRAKE LEVER FREE PLAY

Check the free play after pulling the lever.
FRONT : 10~20mm REAR : 10~20mm
2-8
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.
Check the side stand ignition cut-off switch : -Put the side stand up. -Start the engine. -Lower the side stand. The engine should stop as you put the side stand down. If there is a problem with the system, check the side stand switch.
SIDE STAND SWITCH
SUSPENSION
Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicles safety and operation efficiency.
FRONT WHEEL
Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions. Check the front fork for oil leakage, parts damage or looseness.
REAR WHEEL
Compress the near cushion up and down several times to check the operating conditions. Check the rear fork for oil leakage, parts damage or looseness.
2-9
BOLTS, NUTS, FASTENERS

F
Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value. Check all pins, clips, hose clamps and cable stays.
WHEELS/TIRES
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) DRIVER AND A PASSENGER 2.00(200) 2.25(225)
Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tire.
SERVICE LIMIT : 0.5mm
STEERING HEAD BEARING

Check the cable if it interferes with the handle operation. Lift the front wheel and check if the handle moves right and left smoothly. If the handles move heavily, check if the cable or electric cord interferes with the handle. If the hadle moves satisfactorily, adjust the steering head bearing.
2-10
3. EXTERNAL PARTS
SERVICE INFORMATION 3-1 SEAT 3-2 PILLION SEAT 3-2 LUGGAGE BOX TOP COVER 3-2 REAR GRIP 3-2 LUGGAGE BOX 3-3 CENTER COVER 3-3 BODY SIDE COVER 3-3 BODY COVER 3-4 REAR FENDER 3-4 FLOOR SIDE COVER 3-4 FLOOR PANEL 3-4 UNDER COVER 3-5 HANDLE COVER 3-5 FRONT COVER 3-5 WINDSCREEN 3-6 FRONT UNDER COVER A 3-6 FRONT UNDER COVER B 3-6 INNER COVER 3-7 SPEEDOMETER COVER 3-7 FRONT FENDER 3-8 REAR WHEEL MUDGUARD 3-8 MUFFLER 3-8 EX. PIPE 3-8
SERVICE INFORMATION
This section describes external parts removal/installation. Do not apply unreasonable force when disassembling covers, to prevent possible damage. A muffler is hot. Do not service it immediately after the engine is stopped.
3-1
EXTERNAL PARTS
SEAT
Release the seat lock by turning the main switch key to open the seat. Loosen the flange nuts and remove the seat. Install in the reverse order of removal.
FLANGE NUTS FLANGE NUTS FLANGE NUTS
PILLION SEAT
Release the seat lock by turning the main switch key to open seat. Pull the pillion seat forward and remove it. Install in the reverse order of removal.
LUGGAGE BOX TOP COVER

Loosen the 5 Tapping screws and remove the top cover. Install in the reverse order of removal.
REAR GRIP
Remove the rear grip cap (R.L) Loosen the 4 special bolts. Install in the reverse order of removal.
REAR GRIP CAP REAR GRIP CAP REAR GRIP CAP
3-2
EXTERNAL PARTS
LUGGAGE BOX
Remove the seat. Remove the pillion seat. Remove the luggage box top cover. Loosen the screws on the seat catch. Loosen the open stay nuts. Loosen the washer bolts. Remove the wire for the trunk lamp. Install in the reverse order of removal.
SEAT CATCH SEAT CATCH SEAT CATCH
CARBURETOR MAINTENANCE COVER CARBURETOR MAINTENANCE COVER CARBURETOR MAINTENANCE COVER
CENTER COVER
Remove the floor mat. Loosen the 2 washer screws and 1 special screw. Install in the reverse order of removal.
BODY SIDE COVER

Remove the center cover. Loosen the 2 washer screws. Loosen the 2 tapping screws securing the body side cover on the inside of the body cover. Install in the reverse order of removal.
Remove the air duct cover in dissembling LH. body side cover.
3-3
EXTERNAL PARTS
BODY COVER
Remove the Rr. Grip R/L Remove the following parts - Seat - Luggage box - Center cover - Body side cover Loosen the special screw Loosen the body cover clip (R/L) Remove the wire for the tail light and pull the body cover backward. Install in the reverse order of removal
REAR FENDER
Remove the body cover Loosen the 4 washer bolts and remove the Rr. fender Install in the reverse order of removal
FLOOR SIDE COVER

Remove the center cover Loosen the 3 body cover clips, 2 washer screws and 1 tapping screw in back side of left Remove the floor mat Install in the reverse order of removal
FLOOR PANEL
Remove the floor side cover Loosen the 6 washer bolts Pull the floor panel backward to remove it Install in the reverse order of removal
3-4
EXTERNAL PARTS
UNDER COVER
Loosen the 4 special screws (R/L, 2Ea for each) to remove the under cover Install in the reverse order of removal
HANDLE COVER
Loosen the washer screw and tapping screw securing the under handle cover Loosen the screw in the top of the upper handle cover Remove the under handle cover Loosen the 2 screws (R/L) in the upper handle cover securing the steering handle Install in the reverse order of removal
FRONT COVER
Loosen the 2 tapping screws securing the fornt cover Loosen the 2 tapping screws securing the inner cover Install in the reverse order of removal
3-5
EXTERNAL PARTS
WINDSCREEN
Remove the front cover Loosen the 4 washer bolts and remove the windscreen Install in the reverse order of removal
FRONT UNDER COVER A

Remove the front cover and windscreen Loosen the 7 tapping screws securing the inner cover Install in the reverse order of removal
Loosen the 2 washer bolts in the top of the front under cover Loosen the 2 tapping screws
FRONT UNDER COVER B

Loosen the 2 flange bolts Loosen the 4 tapping screws securing the inner cover
3-6
EXTERNAL PARTS
Loosen the 4 tapping screws securing the inner cover
INNER COVER
Remove the front cover and windscreen Remove the coolant reserve tank Remove the fuel tube clip Remove the breather tube Loosen the 3 screws securing the inner cover Remove the bag holder Loosen the 2 tapping screws securing the speedometer cover Install in the reverse order of removal
SPEEDOMETER COVER
Remove the speedometer cable Remove the coupler and wire Loosen the 2 tapping screws secring the speedometer cover Install in the reverse order of removal
3-7
EXTERNAL PARTS
FRONT FENDER
Loosen the 4 screws (R/L, 2Ea for each) Install in the reverse order of removal
REAL WHEEL MUDGUARD

Loosen the 2 flange bolts of RH. Loosen the flange bolt securing the air cleaner and mudguard Remove the air cleaner Loosen the washer bolt securing the mudguard Install in the reverse order of removal
MUFFLER
Loosen the muffler flange bolt securing Ex. pipe comp. Loosen the 3 bolts securing the Rr. Fork Remove the Ex. muffler comp.
Never performing the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot.
EX. PIPE
Loosen the 2 cap nuts securing the cylinder comp. Pull the Ex. Pipe comp. downward to remove it Install in the reverse order of removal
Replace the packing when assemblying the muffler and Ex. pipe comp.
3-8
LUBRICATION SYSTEM
4. LUBRICATION SYSTEM
SERVICE INFORMATION 2-1 TROUBLESHOOTING 2-2 ENGINE OIL LEVEL INSPECTION 2-3 ENGINE OIL CHANGE 2-3 OIL FILTER ELEMENT CHANGE 2-4 OIL PUMP RADIATOR TRANSMISSION OIL INSPECTION LUBRICATION POINTS 2-4 2-7 2-8 2-9
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 contect 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
1.1 (After disassembly) 0.9 (After Oil change with Oil in the Oil hose removed) OIL CAPACITY 0.8 (After Oil filter change) 0.75 (After Oil change) API service classification : SE, SF, SH grade Viscosity : SAE10W-30 RECOMMENDED (Use appropriate type of oil with viscosity satisfying OIL the atmospheric temperature In your riding area based on the table shown on the right side.)
-10
10
20
30
40
TRANSMISSION OIL
OIL CAPACITY RECOMMENDED OIL 0.15 (Full capacity) 0.14 (After oil change) DMC Pure mission oil or SAE 80W/90
TORQUE VALUES
OIL FILTER SCREEN CAP OIL FILTER COVER BOLT OIL PUMP MOUNTING BOLT OIL DRAIN PLUG BOLT 1.5fm 1.1fm 1.1fm 2.5fm
4-1
LUBRICATION SYSTEM
TROUBLESHOOTING
Oil level low
Oil consumption. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal.
Oil contamination
Oil or filter not changed often enough. Faulty head gasket. Worn piston rings.
Low or no oil pressure

Clogged oil orifice. Incorrect oil being used.
4-2
LUBRICATION SYSTEM
ENGINE OIL LEVEL INSPECTION

UPPER LINE PROPER LINE LOWER LINE
Erect the motorcycle on the main stand. Warm up the engine to heat the engine oil to an appropriate level. Stop the engine, and check the oil level line on the sight-glass installed on the LH. crank case cover. If the oil level is between the lower and higher sightglass oil level line, oil level is satisfactory. If the oil level is below or near the lower level mark, add the recommended engine oil.
SIGHT GLASS
ENGINE OIL CHANGE

To completely and rapidly drain engine oil, warm up engine and erect the motorcycle on its side stand. Loosen the oil drain plug bolt and drain engine oil. Operate the kick starter arm several times to remove the remaining oil from the engine. Tighten the oil drain plug bolt.
OIL DRAIN PLUG TORQUE VALUE : 2.0-3.0 kgfm
TAPPET ADJUSTING HOLE CAP
OIL PICK UP COLLAR OIL FILTER SCREEN
It is extremely important to replace oil filter or clean the oil filter screen at the first maintenance interval (after 1,000Km). Clean the oil filter screen every 4,000Km. Clean the filter screen with fresh cleaning oil. Check the hole cap O-ring for satisfactory condition. Tighten the hole cap with specified tightening torque.
TORQUE VALUE : 1.5 kgfm
Loosen the special screw, remove the plug maintenance cover. Fill the recommended oil after opening oil filter cap of cylinder head cover.
OIL CAPACITY : 1.1(After disassembly) 0.9(After Oil change with Oil in the Oil hose removed) 0.8(After Oil filter change) 0.75(After Oil change)
API service classification : SE, SF, SH grade. Start the engine and keep it idle for a few minutes. Stop the engine and check the oil level. If the oil level is low, add the recommended engine oil. Check on oil leaks.
OIL FILTER CAP OIL FILTER CAP OIL FILTER CAP
4-3
LUBRICATION SYSTEM
OIL FILTER ELEMENT CHANGE

Drain engine oil. (4-3) Loosen the 3 flange bolts securing the oil filter cover, remove the oil filter cover. Remove the oil filter element and oil filter spring.
OIL FILTER COVER
ELEMENT
Change the oil filter element with a new one. Check if the oil filter seal is in good condition. Assemble the filter element spring and filter cover, and tighten bolts.
TORQUE VALUE : OIL FILTER COVER 1.1kgfm
OIL FILTER SEAL
Always use a genuine oil filter element. Be sure to replace the oil filter seal when removing oil filter element. Be careful not to lose the oil filter spring when assembling the oil filter element.
OIL PUMP
REMOVAL
Remove the following parts : -Rear cushion lower bolt (13-7) -Muffler (3-8) -Rear swing arm (13-7) -Rear caliper (13-3) -Shroud (8-2) -Cooling fan (8-2) -A.C. generator (8-2) -RH. crankcase cover (8-4) -Starter driven gear (8-7) -Reduction gear (8-5) -Starting clutch assembly (8-8) Loosen the oil pump driven gear setting nut. Remove the oil pump driven gear. Remove the oil pump drive gear. Loosen the 3 flat screws securing the oil pump. Remove the oil pump.
DRIVE GEAR
DRIVEN GEAR
NUT
FLAT SCREW
4-4
LUBRICATION SYSTEM
OIL PUMP DISASSEMBLY
PUMP PLATE PUMP BODY INNER ROTOR PUMP SHAFT
Loosen the screw securing the oil pump plate. Remove the oil pump body and the oil pump plate. Clean the oil pump body, inner and outer rotors with fresh cleaning oil.
OUTER ROTOR
ROLLER2.5x11.8
OIL PUMP INSPECTION

Assemble the inner and outer rotors to the oil pump body. Measure the pump body clearance.
SERVICE LIMIT : 0.23mm TOOL : FEELER GAUGE
FEELER GAUGE
Measure the rotor tip clearance.

SERVICE LIMIT : 0.18mm INNER ROTOR OUTER ROTOR
Measure the pump side clearance

4-5
LUBRICATION SYSTEM
OIL PUMP ASSEMBLY
PUMP PLATE PUMP BODY INNER ROTOR PUMP SHAFT
Clean all parts with fresh cleaning oil.
OUTER ROTOR
ROLLER2.5x11.8
Install the inner and outer rotors to the pump body. Assemble the pump shaft with setting pin.
INNER ROTOR
OUTER ROTOR
Install the oil pump plate to the pump body. Tighten the pan screw.
PUMP PLATE
After installing, check the oil pump to operate smoothly.
PAN SCREW
OIL PUMP INSTALLATION

FLAT SCREW
Install the oil pump to the RH. crankcase. Install the following parts. -Oil pump drive gear and driven gear. -Starting clutch assembly. (8-8) -Starter driven gear and reduction gear (8-5, 8-7) -A.C. generator (8-2) -RH. crank case cover (8-4) -Shroud and cooling fan (8-2) -Rear swing arm (13-7) -Rear caliper (13-3) -Muffler (3-8)
4-6
LUBRICATION SYSTEM
RADIATOR RADIATOR RADIATOR
RADIATOR
REMOVAL
Remove the front cover. (3-5) Remove the front wheel. (12-4) Loosen the 2 oil bolts and the 4 drain cock packings from the main pipe bracket. Loosen the 3 flange bolts securing the radiator. Remove the radiator.
FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS
Be careful not to damage the radiator when removing it. Pay attention not to turn over the vehicle.
FIN
INSPECTION
Check the oil line connections for leaks. Check the oil cooler for bent or collapsed fins. Straighten the bent or collapsed fins with a suitable, small, blade-type screw driver if necessary. Check the air passages for clogging or restriction. Blow dirt out from between core fins with compressed air or wash off dirt with water. After installing, start the engine and check for leak. Stop the engine and check the oil level.
OIL RADIATOR
RADIATOR RUBBER RADIATOR COLLAR
FLANGE BOLT
4-7
LUBRICATION SYSTEM
RADIATOR INSTALLATION
RADIATOR RADIATOR RADIATOR
Tighten the 3 radiator setting flange bolts to the main pipe bracket.
FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS
Tighten the drain cock packings and oil bolts.

Install the front wheel. (12-4) Install the front cover. (3-5)
OIL BOLTS OIL BOLTS OIL BOLTS
Pay attention not to turn over the vehicle. When installing the radiator, tighten the oil bolts with specified tightening torque.
TRANSMISSION OIL INSPECTION

OIL CHECK BOLT
Remove the LH. crankcase cover. (7-2) Check the body and the connection of each engine component for any leak. Remove the oil check bolt and check to see if the oil overflows from the oil check hole. If only the small amount of oil overflows. fill the recommended transmission oil through the oil filler hole gradually.
Oil level inspection must be performed in the flat ground with the vehicle being straight by raising the main stand.
RECOMMENDED OIL : SAE 80W/90 A.C.GENERATOR CAP
Tighten the oil check bolt.

BREATHER TUBE
Start the engine and check for leak. Install the LH. crankcase cover. (7-2)
4-8
LUBRICATION SYSTEM
LUBRICATION POINTS
Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease.
CONTROL CABLE LUBRICATION

Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it.
FRONT BRAKE LEVER PIVOT THROTTLE GRIP STEERING HEAD BEARING
FRONT FORK DUST SEAL
WHEEL BEARING SIDE/MAIN STAND PIVOT
BRAKE CALIPER BRACKET WHEEL BEARING/SPEEDOMETER GEAR
4-9
MEMO
FUEL SYSTEM
5. FUEL SYSTEM
SERVICE INFORMATION 5-1 TROUBLESHOOTING 5-2 FUEL TANK 5-3 AIR CLEANER 5-4 CARBURETOR 5-4 PILOT SCREW ADJUSTMENT 5-10
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.
Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions. Pay particular attention to the position of O-ring. Replace with new ones when disassembled. If it is desired to store a vehicle for a period longer than 1 month, drain gasoline out of the carburetor float chamber. Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits, and idling may become unstable.
SPECIFICATIONS
FUEL TANK CAPACITY : 11 RESERVE FUEL CAPACITY: 2.8
CARBURETOR
ITEM STANDARD CV TYPE (VACUUM)/25mm CVK 116 A #102 2 RETURNS 20.5mm 1,700100rpm 2-6mm
TYPE/THROTTLE BORE MODEL MARK MAIN JET No. PILOT SCREW OPENING FLOAT LEVEL IDLING SPEED THROTTLE GRIP FREE PLAY
TOOL
FLOAT LEVEL GAUGE
5-1
FUEL SYSTEM
TROUBLESHOOTING
The vehicle does not start. No gasoline in fuel tank. Fuel is not coming out of carburetor. Too much fuel is flowing into cylinder. No spark emitted from spark plug. Air cleaner is blocked. Suction system is experiencing secondary intake of air. Using low quality gasoline. Starter is damaged. Throttle cable is working improperly. Fuel tank is functioning improperly. Back firing Ignition system is damaged. Mixture is too lean.
Insufficient power and high fuel consumption. Air cleaner is blocked. Ignition system is damaged. Mixture is too rich.
Idle is unstable and engine turns off after starting. Starter is damaged. Ignition system is damaged. Using low qualty gasoline. Suction system is experiencing secondary intake of air. Idle is adjusted improperly. Air screw is adjusted improperly. Compression pressure is low. Air/Fuel mixture is either too lean or rich. Carburetor is blocked.
Air/Fuel mixture is extremely lean Fuel jet is blocked. Float valve is damaged. Oil level is low. Bad ventilation of air in tank cap. Fuel strainer screen is blocked. Fuel tube is bent, creased or blocked. Suction system is receiving secondary suction of air.
Air/Fuel mixture is extremely rich. Mis-firing occurs when driving at high speeds. Ignition system is damaged. Mixture is too lean. Air jet is blocked. Float valve is damaged. Oil level is too high. Starter is damaged. Air cleaner is blocked.
5-2
FUEL SYSTEM
FUEL TANK
REMOVAL
Gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthemore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Release the seat lock by turning the main switch key to open the seat. Remove the following parts. - Luggage box. (3-2) - Floor panel leg. - Center cover. - Rear center cover. - Rear carrier/Back rest. - Body cover. Remove the fuel tube from the fuel tank. Remove the tube between the fuel tank and the fuel filter. Remove the fuel vapor tub. Remove the fuel tank. Install in the revers order of removal
FUEL TANK FUEL TANK FUEL TANK
After removing the fuel tank, be sure to close the fuel tank cap.
AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER
CARBURETOR
REMOVAL
Remove the luggage box. (3-2) Remove the center cover. (3-3) Remove the air cleaner. (2-5) Loosen the throttle cable lock nut, and remove the throttle cable from the carburetor. Remove the fuel tube from the carburetor.
Remove the wiring coupler of the auto bystarter. Loosen the set plate setting screw. Loosen the screw of the carburetor insulator band 46. Remove the carburetor.
5-3
FUEL SYSTEM
CARBURETOR DISASSEMBLY
Remove the drain tube and air band hose. Loosen the 4 diaphragm cover setting screws.
Remove the diaphragm cover. Remove the diaphragm spring, diaphragm assembly.
Turn the jet needle with a screwdriver, and remove the needle spring, spring holder, and jet needle from the vacuum piston.
DIAPHRAGM DIAPHRAGM DIAPHRAGM
CARBURETOR INSPECTION
Check the jet needle for stepped wear and replace if necessary. Check the vacuum piston for damage and replace if necessary. Check the diaphragm for damage, pin holes, wrinkles and bends and replace if necessary.
JET NEEDLE JET NEEDLE JET NEEDLE
NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER
Air leaks out of the vacuum chamber if the diaphragm is damaged in any way-even a pin hole.
5-4
FUEL SYSTEM
FLOAT CHAMBER/FLOAT/JET DISASSEMBLY
Loosen the 4 screws securing the float body.
Remove the float pin, float, and float value.
Check the float valve and valve seat for scores, scratches, clogging and damage. Replace if necessary. Check the float valve operation.
Remove the main jet, main jet holder, holder washer, jet screw, jet washer, needle jet, slow jet, pilot jet, washer and O-ring.
Turn in the pilot jet and record the number of turns it takes before it seats lightly. Do not force the pilot screw against its seat ; the seat will be damaged.
5-5
FUEL SYSTEM
CARBURETOR BODY
CARBURETOR CLEANING
After removing all parts, blow open air and fuel passages in the carburetor body with compressed air.
Cleaning the air and fuel passages with a piece of wire will damage the carburetor body or fuel pump.
MAIN JET
SLOW JET
PLUNGER ASS'Y
DIAPHRAGM NEEDLE JET JET NEEDLE SPRING DIAPHRAGM COVER
PILOT JET
FLOAT BODY
FLOAT
FLOAT VALVE
FLOAT CHAMBER/FLOAT/JET ASSEMBLY

Install the needle jet, needle jet holder, main jet and slow jet. Tighten the pilot jet until it seats lightly, then turn it out as much as the number recorded during removal. Install the pilot jet rubber.
5-6
FUEL SYSTEM
FLOAT LEVEL INSPECTION
Install the float valve, float, float pin. Measure the float level with the float level gauge.
FLOAT LEVEL : 13 mm TOOL : FLOAT LEVEL GAUGE
If the level is out of specification and the float arm lip can be bent, adjust the float level by bending the lip. Non-adjustable floats must be replaced.
Be sure to keep the float level at the specified height. If the float level is low / high, fuel mixture becomes lean / rich. Install the float body assembly, install the bracket and 4 pan screws.
Be sure to replace the float chamber body O-ring with the new one.
Insert the jet needle, needle spring holder, needle spring, diaphragm assembly, and install the needle screw.
Install the jet needle aligned with the grooves in the diaphragm. Install the diaphragm assembly on the carburetor body. Install the diaphragm spring. Install the diaphragm cover with its cutout aligned with the hole in the tab of diaphragm.
COMPRESS STRAIGHT
Be careful not to pinch the diaphragm, and to keep the spring straight. Install the auto bystarter wiring plate to the diaphragm, and tighten the 4 pan screws. Install the drain tube and air-hose.
ALIGN 5-7
FUEL SYSTEM
CABURETOR INSTALLATION
Install the carburetor to the carburetor insulator. Tighten the carburetor insulator band screw. Tighten the setting screw securing the carburetor and set plate. Install the fuel tube to the carburetor. Install the wiring coupler of the auto bystarter. Install the throttle cable to the carburetor. Install the air cleaner.(2-5) Install the center cover.(3-3) Install the luggage box.(3-2)
After adjusting the carburetor, check the throttle grip free play.
CABURETOR INSULATOR REMOVAL

Remove the luggage box. (3-2) Remove the center cover. (3-3) Remove the air cleaner. (2-5) Remove the carburetor. (5-3) Remove the fuel pump negative pressure tube. Loosen the carburetor insulator RH. socket bolt, and remove the carburetor setting plate and socket bolt. Loosen the carburetor insulator LH. socket bolt, and remove the carburetor insulator. Remove the carburetor insulator band. Install in the reverse order of removal.
INSPECTION
Check the carburetor insulator O-ring for wear or damage.
5-8
FUEL SYSTEM
PILOT SCREW ADJUSTMENT

Remove the carburetor maintenance cover. (3-3) Turn the pilot screw clockwise until it seats lightly, then back it out to the specification given (1). Warm up the engine to operating temperature (60). Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100 rpm
THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW
The pilot screw is factory pre-set. Adjustment is not necessary unless the caburetor is overhauled or a new pilot screw is installed. Before adjusting the pilot screw, check the following items. -Fuel system, electrical system for troubling. -Spark plug for cleaning and gap adjusting. -Valve clearance for adjusting.
PILOT SCREW PILOT SCREW PILOT SCREW
Tightening the pilot screw against its seat will damage the seat. Rev the engine up slightly from the idle speed and make sure that engine speed rises and returns smoothly. When turning the throttle stop screw in gradually until the engine speed drops 1,000rpm, make sure that the engine does not run. Adjust by turning the pilot screw with a turn and repeat steps and
If the engine cannot be adjusted by turning the pilot screw within a turn, check for other engine problems. Readjust the idle speed with the throttle stop screw. Install the carburetor maintenance cover.
5-9
MEMO
6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 6-1 ENGINE REMOVAL 6-2
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 can be carried out without removing the engine from the vehicle body. -TRANSMISSION (SECTION 11) -STARTING CLUTCH (SECTION 8) -OIL PUMP (SECTION 4) -A.C. GENERATOR (SECTION 8) -STARTER MOTOR (SECTION 16) -CONTINUOUSLY VARIABLE TRANSMISSION (SECTION 7) -CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 9,10) -EX. MUFFLER (SECTION 3) -CARBURETOR (SECTION 5) -REAR SWING ARM (SECTION 13) Items to be worked after removing engine. -CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING Engine oil capacity : 1.1- when disassembled.
TORQUE VALUES :
ENGINE HANGER BOLT (FRONT) : 2.7fm (REAR) : 3.5fm
6-1
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil. Release the seat lock by turning the main switch key to open the seat. Remove the following parts. -Luggage box (3-2) -Center cover (3-3) -Air cleaner (2-5) -Carburetor (5-3) Disconnect the A.C generator coupler and connector wiring connected to the A.C generator, disconnect the starter motor wiring cable. Remove the battery earth cable from the RH. shroud groove. Disconnect the high-tension cord from the engine. Remove the bleeder tube from the cylinder head cover. Loosen the parking brake rod adjuster nut B, remove the parking brake cable. Remove the negative pressure tube from the carburetor insulator.
ACG WIRING COUPLER BATTERY EARTH CABLE STARTER MOTOR CABLE
ADJUSTER NUT B
Remove the EX. muffler. (3-8) Remove the rear brake caliper. (13-3)
REAR BRAKE CALIPER
Remove the RH./LH. floor side cover. (3-4) Remove the under cover (3-5)
UNDER COVER
6-2
ENGINE REMOVAL/INSTALLATION
Remove the RH./LH. radiator hose, remove the RH./LH. radiator hose from the frame setting clamp.
RADIATOR HOSE
Loosen the U-nut securing the engine hanger. Loosen the rear cushion lower bolt.
U-NUT
Remove the engine. (with the rear swing arm and rear wheel attached) Remove the rear swing arm. (13-7) Remove the rear wheel. (13-5) Remove the rear wheel mud guard. (3-8)
ENGINE INSTALLATION
Install in the reverse order of removal.
Take precautions not to damage wiring and cable. Take precautions not to damage the threaded part of bolts. Arrange the cable, tubes and wiring in the right positions.
LOWER BOLT LOWER BOLT LOWER BOLT
TORQUE VALUE ENGINE HANGER BOLT (FRONT) : 4.5fm (REAR) : 4.5fm
Check the following after the engine is installed. -Engine oil -Electric systems. -Adjust of the parking brake free play. -Inspection of the throttle cable operation.
6-3
LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION
LH. CRANKCASE COVER
7-0
7. LH. CRANKCASE COVER /CONTINUOUSLY VARIABLE TRANSMISSION

SERVICE INFORMATION 7-1 TROUBLESHOOTING 7-1 LH. CRANKCASE COVER 7-2 DRIVE BELT 7-6 MOVABLE DRIVE FACE 7-8 CLUTCH/DRIVEN PULLEY7-11
SERVICE INFORMATION
GENERAL SAFETY
Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil contact. Do not operate starter motor while the LH. crank case cover is removed.
7
Take precautions not to apply the grease oil to the movable drive face or weight roller.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER DRIVE FACE BOSS OUTER DIAMETER DRIVE BELT WIDTH WEIGHT ROLLER OUTER DIAMETER CLUTCH OUTER INNER DIAMETER DRIVEN FACE SPRING PLAY DRIVEN FACE OUTER DIAMETER DRIVEN FACE INNER DIAMETER
24.000-24.013mm 23.980-23.993mm 22mm 19.95-20.02mm 120.0-120.2mm 97.85mm 37.965-37.985mm 38.000-38.025mm
24.05mm 23.96mm 20.50mm 19.50mm 120.50mm 90.00mm 37.94mm 38.06mm
TROUBLESHOOTING
Engine starts but motorcycle does not work.
Drive belt worn. Ramp plate damaged. Clutch shoe worn or damaged. Movable driven face spring cut.
Vehicle unable to run at the maximum speed, or lack of output

Drive belt worn. Defective movable driven face spring. Weight roller worn. Pulley face contaminated.
Engine stops, or the vehicle runs suddenly, after starting.

Clutch shoe spring cut.
7-1
LH. CRANKCASE COVER

REMOVAL
Remove the 12 flange bolts securing LH. crankcase.
Remove the LH. crankcase cover. Remove the gasket and dowel pin.
INSTALLATION
Install the new gasket and dowel pin after removing the gasket of the crankcase surface.
Align the bolts to uniform the tightening location before tightening then when you dont know the bolt length. Tighten the bolts diagonally with specified tightening torque. Be sure to replace a new gasket and dowel pin Tighten the LH. crankcase cover bolts.
7-2
DRIVE BELT
REMOVAL
Remove the LH. crankcase cover. (7-2 ) Hold the clutch outer using the universal holder and remove the nut. Remove the clutch outer.
TOOL: UNIVERSAL HOLDER
UNIVERSAL HOLDER DRIVE BELT
Use the special tool when loosening the lock nut. Holding the rear wheel or rear brake will damage the final reduction system. Squeeze the drive belt into the pulley groove as shown so that it slackens enough to remove the driven pulley from the drive shaft.
DRIVEN PULLEY SUB ASS'Y
Loosen the drive face setting nut 12mm with the clutch center holder. Remove the kick starter ratchet and drive face.
TOOL : DRIVE FACE HOLDER
Remove the driven pulley sub assembly with the drive belt in place. Remove the drive belt from the driven pulley groove and drive pulley groove.
7-3

DRIVE BELT INSPECTION
COG WIDTH
Check the drive belt for cracks, pry separation and wear; replace as necessary. Measure the width of the drive belt as shown. Replace the belt if the service limit is exceeded.
Use only a genuine DAELIM replacement drive belt. Do not get oil or grease on the drive belt or pulley faces. Clean off any grease or oil before reinstalling.
DRIVE BELT INSTALLATION

Temporarily install the driven pulley sub assembly on the drive shaft.
Turn the pulley clockwise and spread the faces apart while installing the drive belt. Remove the pulley assembly once with the drive belt installed.
MOVABLE DRIVE FACE
Put the drive belt over the movable drive face. Install the drive face to the LH. crank shaft, and install the kick starter ratchet. Hold the drive face using the drive face holder and tighten the nut to the specified torque.
TORQUE VALUE : 7.0-8.0 kgfm TOOL : DRIVE FACE HOLDER
DRIVE BELT
Hold the faces apart preventing them from closing.
7-4

Reinstall the driven pulley on the drive shaft with the drive belt attached. Hold the clutch outer using the universal holder. Tighten the nut to the specified torque.
TORQUE VALUE : 5.0-6.0 kgfm TOOL : UNIVERSAL HOLDER
Reinstall the LH. crankcase cover. ( 7-2 )

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MOVABLE DRIVE FACE

REMOVAL
Remove the LH. crankcase cover. ( 7-2 ) Hold the drive face using the drive face holder and remove the nut.
TOOL : DRIVE FACE HOLDER
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Remove the kick starter ratchet and drive face. If the drive face holder cannot be used, remove the cooling fan at the right side of the crankshaft, and hold the flywheel with the universal holder.
TOOL : UNIVERSAL HOLDER
Remove the drive belt. ( 7-3 ) Remove the movable drive face and drive face boss.
FACE BOSS
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MOVABLE DRIVE FACE
SLIDE PIECE
DRIVE FACE BOSS
Remove the ramp plate, weight rollers and oil seal from the movable drive face.
RAMP PLATE
MOVABLE DRIVE FACE COMP
WEIGHT ROLLER
7-5

MOVABLE DRIVE FACE INSPECTION
WEIGHT ROLLER
The weight rollers push on the movable drive face (by centrifugal force); worn or damaged weight rollers will interfere with this force. Check the rollers for wear or damage and replace as necessary. Measure the O.D. of each roller, replace if the service limit is exceeded.
MOVABLE DRIVE FACE
BOSS
Check the drive face boss for wear or damage and replace as necessary. Measure the O.D of the drive face boss. Replace the boss if the service limit is exceeded. Measure the I.D. of the drive face. Replace it if the service limit is exceeded. Movable drive face boss outer diameter.
Movable drive face inner diameter.

MOVABLE DRIVE FACE INSTALLATION

RAMP PLATE
Install the weight roller on the movable drive face. Install the ramp plate.
WEIGHT ROLLER
Apply the inside of the movable drive face with the specified amount of grease.
SPECIFIED GREASE : ALVANIA EP2 GREASE APPLICATION : 0.5-1.5 g
Install the movable drive face boss.
MOVABLE DRIVE FACE
Do not get the grease on the drive face. Remove any misplaced grease with a degreasing agent. Use only the specified grease in the specified amount.
7-6

Install the movable drive face on the crank shaft.
BOSS
MOVABLE DRIVE FACE
Squeeze the drive belt into the drive face groove and pull the drive belt over the drive face shaft.
DRIVE BELT
Hold the drive face using the drive face holder and tighten the nut to the specified torque.
TORQUE VALUE : 7.0-8.0 kgfm TOOL : DRIVE FACE HOLDER
Tighten the drive face nut to the specified torque. Correctly match the drive face and crank shaft serration when assembling. If the drive face holder cannot be used, remove the cooling fan and hold the flywheel with the universal holder. Install the LH. crankcase cover. ( 7-2 )
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7-7
CLUTCH/DRIVEN PULLEY
REMOVAL
Remove the LH. crankcase cover. ( 7-2) Remove the drive face. ( 7-5) Hold the clutch outer using the universal holder and remove the flange nut, then remove the clutch outer.
TOOLS : UNIVERSAL HOLDER DRIVE FACE HOLDER DRIVEN PULLEY ASS'Y UNIVERSAL HOLDER DRIVE BELT
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Remove the driven pulley sub assembly from the drive shaft. Remove the drive belt.
LOCK NUT WRENCH LOCK NUT
DISASSEMBLY
Install a clutch spring compressor on the pulley assembly and tighten the tool to gain access to the nut.
Do not overtighten the compressor. Hold the clutch spring compressor in a vise as shown and remove the lock nut using the lock nut wrench. Loosen the clutch spring compressor and disassembly the clutch and spring from the driven pulley.
TOOLS : CLUTCH SPRING COMPRESSOR LOCK NUT WRENCH DRIVEN FACE SPRING
CLUTCH SPRING COMPRESSOR
Remove the drive plate, driven face spring and driven face spring guide.
SPRING GUIDE DRIVE PLATE
7-8

Remove the seal collar from the driven pulley.
SEAL COLLAR
MOVABLE DRIVEN FACE
GUIDE PINS
Remove the guide pins and guide pin rollers and the movable driven face.
GUIDE PIN ROLLER
DRIVEN FACE
GUIDE PIN
MOVABLE DRIVEN FACE
OIL SEAL
Remove the O-ring and oil seals from the movable driven face
O-RINGS GUIDE PIN
Remove the movable driven face.

OIL SEAL
O-RINGS
7-9

CLUTCH / DRIVEN PULLEY INSPECTION
Driven Face Bearing Inspection
Check the inner bearing oil seal (if installed) for damage; replace as necessary. Check the needle bearing for damage or excessive play and replace as necessary. Turn the inner race of the outer bearing with your finger. Check that the bearing turns smoothly and quietly, and that the bearing outer race fits securely. Replace the bearing if necessary.
OUTER BALL BEARING MOVABLE DRIVEN FACE SPRING
NEEDLE BEARING
Movable Driven Face Spring Inspection

Measure the free length of the driven pulley spring and replace if the service limit is exceeded.
SERVICE LIMIT : 97.23mm TOOL : VERNIER CALIPER
FREE LENGTH
Clutch Outer
VERNIER CALIPER
Measure the I.D. at shoe contact surface of the clutch outer. Replace the outer if the service limit is exceeded.
CLUTCH OUTER
Clutch Shoe Inspection

Measure the thickness of each shoe ; replace if the service limit is exceeded.
CLUTCH SHOE
7-10

Check the following; -Movable driven face for damage or excessive wear. -Guide pin groove for damage or deformation. Replace damaged or worn parts as necessary. Measure the I.D. of the movable driven face; replace if the service limit is exceeded.
SERVICE LIMIT : 38.060 mm
MOVABLE DRIVEN FACE
GUIDE GROOVE
DRIVEN FACE
Check the driven face for damage or excessive wear; replace as necessary Measure the O.D. of the driven face; replace if the service limit is exceeded.
DRIVEN FACE BEARING REPLACEMENT

Remove the inner bearing.
CIRCLIP OUTER BEARING
If the driven face has an oil seal at inner bearing side, remove the oil seal first. If a ball bearing is used on the inside, remove the snap ring first then remove the bearing. Remove the snap ring then drive out the outer bearing toward the inner bearing side. Drive a new outer bearing into place with the sealed end toward the outside. Install the snap ring securely.
INNER BALL BEARING SNAP RING INNER NEEDLE BEARING
Apply the specified amount of specified grease as shown.

GREASE APPLICATION : 9.0-9.5 g
Install in a new inner bearing.

SEALED SIDE
SPECIFIED GREASE SNAP RING
Install the bearing with the sealed side facing out. Install the needle bearing using a hydraulic press. Install the ball bearing by driving it in or using a hydraulic press. Install the snap ring into the groove in the driven face. Install a new oil seal with the lip toward the bearing (if required).
TOOLS : BEARING DRIVER ATTACHMENT DRIVE PILOT
7-11
INNER NEEDLE OUTER BEARING BEARING SEALED END

OIL SEAL
CLUTCH / DRIVEN PULLEY ASSEMBLY

Install new oil seals and O-rings on the movable driven pulley face.
O-RING
MOVABLE DRIVEN FACE
GUIDE PINS
Install the movable face on the driven pulley face. Install the guide pins, or guide pins and guide pin rollers.
GUIDE PIN ROLLER
GUIDE PIN DRIVEN FACE
SEAL COLLAR
Install the seal collar.
LOCK NUT WRENCH
Assemble the driven pulley, spring and clutch in the clutch spring compressor. Compress the assembly by turning the tool handle until the lock nut can be installed. Clamp the clutch spring compressor in a vise and tighten the lock nut to the specified torque using the lock nut wrench.
Remove the spring compressor.

TOOLS : CLUTCH SPRING COMPRESSOR LOCK NUT WRENCH
CLUTCH SPRING COMPRESSOR
7-12
Install the clutch / driven pulley and drive belt onto the drive shaft. Install the drive belt. ( 7-3)
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MOVABLE DRIVE FACE
CLUTCH/DRIVEN PULLEY INSTALLATION
Install the drive face. ( 7-5) Install the LH. crankcase cover. ( 7-2)
7-13
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A.C GENERATOR/STARTER CLUTCH
STATOR COMP FLYWHEEL COOLING FAN
RH. SHROUD
8-0
8. A.C GENERATOR / STARTER CLUTCH

SERVICE INFORMATION 8-1 SHROUD 8-2 A.C GENERATOR 8-2 RH. CRANKCASE COVER 8-4 STARTER REDUCTION GEAR 8-5 STARTER CLUTCH 8-6
SERVICE INFORMATION
GENERAL SAFETY
This section describes the removal and assembling of the A.C generator. For information on A.C generator inspection, refer to the section 15. The charging system can be maintained without removing the engine.
SPECIFICATIONS
ITEM STANDARD VALUE
Unit : mm
SERVICE LIMIT
STARTER DRIVEN GEAR REDUCTION GEAR REDUCTION GEAR SHAFT
O.D I.D I.D O.D
39.622 - 39.635 32.000 - 32.025 12.016 - 12.034 11.966 - 11.984
39.53 32.10 12.10 11.97
TORQUE VALUES
FLY WHEEL BOLT STARTER CLUTCH LOCK NUT RH. CRANKCASE COVER BOLT 5.5 kgfm 9.5 kgfm 1.1 kgfm
TOOLS
SPECIAL SOCKET (12.7 x 28 x 120) A.C.G ROTOR PULLER
8-1
SHROUD
REMOVAL
Remove the following parts. -Luggage box (3-2 ) -Center cover (3-3 ) -Engine (6-2 )
LH. SHROUD
Loosen the RH. shroud 4 flange bolts and 4 tapping screws. Remove the RH. shroud. Loosen the LH. shroud setting screw. Remove the LH. shroud. Install in the reverse order of removal.
SETTING SCREW
Before removing the RH. shroud, be sure to remove the RH. floor side cover and rear cushion upper bolt.
A.C GENERATOR
A.C.G WIRING COUPLER
REMOVAL
Loosen the rear cushion under bolt. Remove the following parts. -Luggage box (3-2) -Body cover (3-4 ) -Center cover (3-3 ) -Engine (6-2 ) -RH. shroud comp (8-2 )
Remove the A.C.G wiring coupler and connector connected to the wire harness. Remove the A.C.G wiring from the A.C.G wiring setting clamp securing the engine and frame. Loosen the 3 cooling fan bolts.
COOLING FAN
8-2

Install the universal holder on the flywheel. If the universal holder connot be used, remove the LH. crankcase cover at the left side of the crankshaft, and hold the drive face with the drive face holder. Loosen the flange nut securing the fly wheel, and remove the flywheel using the A.C.G rotor puller.
FLANGE NUT
Insert the puller shaft and remove the flywheel after inserting the A.C.G rotor puller and securing it with spanner. The flywheel may easily removed if you rotate the puller while tapping the roller shaft with metal hammer. Always use a holder and a puller to remove the flywheel. Do not try to remove the flywheel by hammering directly on it. The crankshaft or components could be damaged. After removing the flywheel, check the woodruff key for damage and wear.
TOOLS : A.C.G ROTOR PULLER UNIVERSAL HOLDER DRIVE FACE HOLDER
UNIVERSAL HOLDER
FLYWHEEL
Loosen the 2 pan screws securing the pulse generator, and remove it.
A,C,G. ROTOR PULLER
Loosen the 3 starter setting pan screws, remove the stator.

PAN SCREWS
PAN SCREWS
8-3

A.C GENERATOR INSTALLTION
PAN SCREW
Install the stator to the RH. crankcase cover. Clean the tapered portion of the crankshaft. Clean the inside part of the flywheel. Check the woodruff key, install the flywheel by aligning the groove with the woodruff key.
PAN SCREW
Temporarily install the flywheel nut, hold the flywheel with the universal holder, and tighten the flywheel nut with the specified torque.
TORQUE VALUE : 5.0 - 6.0 kgfm TOOL : UNIVERSAL HOLDER
If the universal holder cannot be used, remove the LH. crankcase cover and hold the drive face with the drive face holder.
UNIVERSAL HOLDER DRIVE FACE HOLDER COOLING FAN TORQUE VALUE : 0.8 - 1.2 kgfm TOOL : DRIVE FACE HOLDER
Install the RH. shroud. (8-2 ) Connect the A.C.G wiring coupler and connector to the wire harness, and install the wiring with the clamp. Insert the battery earth cable to the shroud groove. Install the rear cushion under bolt. Install the RH. floor side cover. (4-7 ) Install the center cover. (4-5 ) Install the luggage box. (4-4 )
RH. CRANKCASE COVER

RH. CRANKCASE COVER
REMOVAL
Loosen the rear cushion under bolt. Remove the following parts. -Luggage box (3-2 ) -Center cover (3-3 ) -RH. floor side cover (3-4 ) -RH. shroud (8-2 ) -EX. muffler (3-8 ) -Rear caliper (13-3 ) -Rear swing arm (13-7 ) -Cooling fan (8-2 ) -A.C Generator (8-2 )
8-4

Loosen the 9 RH. crankcase cover setting bolts. Remove the RH. crankcase cover. Remove the gasket and dowel pin.
DOWEL PIN
RH. CRANKCASE COVER
Remove the RH. crankcase cover oil seal. Check the oil seal for wear or damage and replace with a new one as necessary.
OIL SEAL
REDUCTION GEAR
SHAFT
STARTER REDUCTION GEAR

REMOVAL
Remove the starter reduction gear and shaft.
INSPECTION
Check the reduction gear for wear or damage. Measure the inner diameter of the gear.
Measure the outer diameter of the gear shaft.

STARTER REDUCTION GEAR
SHAFT
8-5

REDUCTION GEAR SHAFT
STARTER REDUCTION GEAR INSTALLATION

Install the starter reduction gear and shaft.
Remove the gasket residues from the RH. crankcase. Install a new gasket and dowel pin. Tighten the RH. crankcase cover with setting bolts. Install the following parts. -A.C.Generator (8-2 ) -Cooling fan (8-2 ) -RH. shroud (8-2 ) -Rear swing arm (13-7 ) -Rear caliper (13-3) -EX. muffler (3-8 ) -RH. floor side cover (4-7 ) -Luggage box (3-2 ) Tighten the rear cushion under bolt.
RH. CRANKCASE COVER
STARTER CLUTCH
REMOVAL
Loosen the rear cushion under bolt. Remove the following parts. -RH. floor side cover (3-4 ) -RH. shroud (8-2 ) -Cooling fan (8-2 ) -A.C Generator (8-2 ) -EX. muffler (3-8 ) -Rear caliper (13-3 ) -Rear swing arm (13-7 ) -RH. crankcase cover (8-4 ) Remove the LH. crankcase cover and hold the drive face with the drive face holder. Loosen the starter clutch lock nut with a special socket.
TORQUE VALUE : 9.5 kgfm TOOLS : SPECIAL SOCKET (12.7x28x120) DRIVE FACE HOLDER
STARTER CLUTCH
SPECIAL SOCKET (12.7X28X120)
8-6

WASHER STARTER CLUTCH
Remove the washer. Remove the starter driven gear and starter clutch.
STARTER CLUTCH
Check the starter driven gear and starter clutch for proper operation. Remove the starter clutch.
STARTER CLUTCH INSPECTION

Remove the starter driven gear, needle bearing and starter oneway clutch set from the starter clutch assembly.
STARTER DRIVEN GEAR
STARTER ONEWAY CLUTCH SET
Check the starter driven gear for wear or damage. Measure the inner diameter of the starter driven gear.
SERVICE LIMIT : A : 32.10 mm B : 39.53 mm
8-7

STARTER CLUTCH INSTALLATION
Install the starter oneway clutch set, starter driven gear and needle bearing to the starter clutch assembly. Install the starter clutch to the RH. crankshaft.
When installing the starter clutch, match it with the groove accurately
STARTER ONEWAY CLUTCH SET
Install the thrust washer. Temporarily install the starter clutch lock nut.
LOCK NUT
SPECIAL SOCKET
Hold the drive face with the drive face holder. Tighten the starter clutch lock nut with a special socket.
Tighten the lock nut with specified torque.

TORQUE VALUE : 9.5 kgfm TOOLS : SPECIAL SOCKET (12.7x28x120) DRIVE FACE HOLDER
RH. CRANKCASE COVER
Install the following parts. -RH. crankcase cover (8-2 ) -A.C Generator (8-2 ) -Cooling fan (8-2 ) -RH. shroud (8-2 ) -Rear swing arm (13-7 ) -Rear caliper (13-3 ) -EX. muffler (3-8 ) -RH. floor side cover (3-4 ) -LH. crankcase cover (7-2 ) Tighten the rear cushion upper bolt.
8-8
MEMO
CYLINDER HEAD / VALVE
INLET VALVE ROCKER ARM
CAM SHAFT HOLDER EXHAVST VALVE ROCKER ARM
CAM SHAFT COMP
INLET VALVE
EXHAVST VALVE
CARBURETOR INSULATOR
CYLINDER HEAD COMP
CYLINDER HEAD GASKET
9-0
9. CYLINDER HEAD / VALVES

SERVICE INFORMATION 9-1 TROUBLESHOOTING 9-2 CAMSHAFT 9-3 CYLINDER HEAD 9-5 VALVE SPRINGS 9-6 VALVES 9-6 VALVE GUIDES 9-7 VALVE SEATS 9-8 CYLINDER HEAD ASSEMBLY9-11 CAMSHAFT ASSEMBLY9-13
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 oil 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
ROCKER ARM
ROCKER ARM INNER DIAMETER ROCKER ARM SHAFT OUTER DIAMETER CAM HEIGHT IN EX
12.016 - 12.034 11.982 - 12.000 33.835 - 33.995 33.984 - 34.144 15.005 - 15.018 IN,EX IN EX IN,EX IN EX 37.21 4.972 - 4.984 4.952 - 4.964 5.000 - 5.012 0.016 - 0.040 0.036 - 0.060 0.8 - 1.0
39.05 11.950 33.625 33.765 15.040 36.90 4.920 4.900 5.030 0.090 0.120 1.4
CAMSHAFT
CAMSHAFT OUTER DIAMETER CYLINDER HEAD WARPAGE VALVE SPRING FREE LENGTH VALVE STEM OUTER DIAMETER VALVE VALVE GUIDE VALVE GUIDE INNER DIAMETER CLEARANCE BETWEEN STEM AND GUIDE VALVE SEAT WIDTH
TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT SPARK PLUG CAMSHAFT HOLDER 8mm NUT CAM CHAIN TENSIONER MOUNTING BOLT CAM CHAIN TENSIONER SEALING SCREW CYLINDER HEAD COVER BOLT CYLINDER HEAD BOLT TAPPET ADJUST NUT 1.0 kgfm 1.2 kgfm 2.0 kgfm 1.2 kgfm 0.4 kgfm 0.9 kgfm 1.1 kgfm 0.8 kgfm
9-1

TOOLS
VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 37 (21.5mm) EX 37 (18.5mm) IN 45 (22.0mm) EX 45 (22.0mm) IN 55 (20.0mm) EX 55 (20.0mm)
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) -Burned or bent valves -Incorrect valve timing -Broken valve spring -Uneven valve seating Cylinder head -Leaking or damage head gasket -Warped or cracked cylinder head Cylinder, piston (see section 10)
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 Worn rocker arm and / or shaft Loose or worn cam chain Worn or damaged cam chain tensioner Damaged cylinder head gasket Incorrect spark plug installation
Excessive white smoke

Worn valve guide or valve stem Damaged valve stem seal Worn or damaged piston ring
9-2
CAMSHAFT
REMOVAL
Remove the luggage box. (3-2 ) Remove the center cover. (3-3 ) Loosen the cylinder head cover bolts, remove the cover. Remove the shroud grommet B of the fan cover.
The camshaft can be maintained without removing the engine.
Turn the crankshaft to the left, and align the T mark of the flywheel with the index mark of the RH. 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 (360 and align the ), T mark with the index mark once again.
"T" MARK
PAN SCREW CAM CHAIN TENSIONER LIFTER
Loosen the pan screw of the cam chain, remove the tensioner flange bolts and tensioner lifter.
FLANGE BOLT
Loosen the 4 camshaft holder 8mm nuts. Remove the cam cover plate. Remove the camshaft holder from the cylinder head.
9-3

Remove the cam chain from the camshaft.
CAM CHAIN
Take precautions not to allow the cam chain to drop into the crankcase.
Insert the 6mm bolt into the rocker arm shaft, and pulling bolts to remove the rocker arm shaft. Remove the rocker arm. Remove the other side rocker arm shaft and rocker arm in the same sequence. ROCKER ARM
CAM SHAFT HOLDER
CAMSHAFT INSPECTION
Check the rocker arm and rocker arm shaft for wear or damage. Measure the inner diameter of the rocker arm.
Measure the outer diameter of the rocker arm shaft.

ROCKER ARM SHAFT
Check the cam lobes of the camshaft for wear or damage. Measure the height of the cam lobe.
SERVICE LIMIT : IN : 33.625 mm EX: 33.765 mm
CAM SHAFT
9-4

Manually turn the camshaft bearing outer race, and check if it turns smoothly. Check the bearing for wear or damage.
Be sure to check the valve clearance.
CAMSHAFT BEARING
CYLINDER HEAD
REMOVAL
Remove the engine from the frame. (6-2 ) Remove the cylinder head cover. Remove the RH. LH. shroud. (8-2 ) Remove the camshaft. (9-3 ) Remove the EX. pipe. (3-8 ) Remove the cylinder head.
CYLINDER HEAD
Remove the cylinder head gasket, dowel pin and cam chain guide from the cylinder.
CAM CHAIN GUIDE
DISASSEMBLY
Remove the carburetor insulator. Remove the spark plug from the cylinder head.
9-5

Remove the valve spring, valve 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 spring more than necessary. Mark the disassembled parts so that they can be reassembled into the original position later.
VALVE SPRING VALVE SPRING VALVE SPRING SPRING COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR
Remove the valve spring seat and valve stem seal. Remove carbon deposits from the inside of the combustion chamber.
CYLINDER HEAD INSPECTION

Remove gasket marks from the cylinder head gasket.
Take precautions not to damage the cylinder head gasket attachment. Check the spark plug assembling hole and the valve seat for cracks. Using a square and a feeler gauge, check the cylinder head distortion.
VALVE SPRINGS
Measure the free length of the inner and outer valve springs.
Replace the valve spring with new one if the length of any one is less than the service limit.
VALVES
Inspect each valve for bending, burning, scratches or abnormal wear. Insert the valves in their original positions in the cylinder head. Check that each valve moves up and down smothly, without binding. Measure and record the valve stem outer diameter in three places along the valve guide sliding area.
Replace the valve with a new one if the service limit is exceeded.
9-6

VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER
VALVE GUIDES
INSPECTION
Insert the valve guide reamer from the combustion chamber side and ream the guide to remove any carbon build-up before measuring the guide.
DIAL INDICATOR DIAL INDICATOR DIAL INDICATOR
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. Rotate the reamer clockwise, never counterclockwise when inserting and removing.
TOOL : VALVE GUIDE REAMER
Measure and record each valve guide inner diameter.

Measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust.
Measure the inner diameter of the new valve guide. If the clearance is not within the service limit, replace the valve.
VALVE GUIDE DRIVER
VALVE GUIDE
REPLACEMENT
Refinish the valve seats whenever the valve guides are replaced to prevent uneven seating. Heat the cylinder head to 130 - 140 (275 - 290 C C F F). Do not heat the cylinder head beyond 150 (300 C F). Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper temperature.
Using a torch to heat the cylinder head may cause warping.
Wear insulated gloves to avoid burns when handling the heated cylinder head.
9-7

Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER
VALVE GUIDE DRIVER
Avoid damaging the head when driving the valve guide out. Apply oil to a new O-ring and install it onto a new valve guide. Drive the new guide in from the camshaft side of the cylinder head while the cylinder head is still heated.
VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER
When reaming new valve guides, insert the valve guide reamer from the combustion chamber side.
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 Rotate the reamer clockwise, never counterclockwise when inserting and removing.
Reface the valve seats and clean the cylinder head thoroughly to remove any metal particles.
VALVE SEATS
INSPECTION
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.
9-8

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.
37
Valve faces and stem tips cannot be ground. If a valve face or stem tip is rough, worn unevenly, or contacts the seat improperly, the valve must be replaced. Measure the valve seat width.
VALVE SEAT
STANDARD VALUE : 0.8 -1.0 mm SERVICE LIMIT : 1.4 mm
VALVE SEAT REFACING

Reface the worn valve seat by using valve seat cutters and grinders.
45
55 37
Follow the refacer manufactuers operating instructions. Reface the valve seat whenever the valve guide has been replaced. Be careful not to grind the seat more than necessary.
Using a 45 degree cutter, remove any roughness or irregularities from the seat.
ROUGHNESS
Using a 37 degree cutter, remove of the existing valve seat material.
37
9-9

Using a 55 degree cutter, remove the bottom the old seat. of
55
Using a 45 degree cutter, cut the seat to the proper width.

SEAT WIDTH
45
If the contact area is too high on the valve, the seat must be lowered using a 37 degree flat cutter. Refinish the seat to specifications, using a 45 degree finish cutter.
CONTACT TOO HIGH OLD SEAT WIDTH
37
If the contact area is too low on the valve, the seat must be raised using a 55 degree inner cutter. Refinish the seat to specifications, using a 45 degree finish cutter.
CONTACT TOO LOW OLD SEAT WIDTH
55
9-10

After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer.
Do not excessively press and turn the valve to set it as it may cause damage. Gently strike and set the valve. The seat surface may become worn on one side if the valve is set in the same position. Turn the valve slightly when setting it. Take precautions not to allow compound to get into the clearance between the stem and guide while the valve is being set.
CYLINDER HEAD ASSEMBLY

Install new stem seals.
STEM SEAL VALVE SPRING RETAINER COTTER
Replace the stem seals with new ones whenever a stem seal is removed. Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide.
Turning a valve too fast can damage the stem seals. Install the spring seats, valve springs and retainers.
For valve spring with varying pitch, install the valve springs with the narrow pitch end facing down.
NARROW PITCH
Compress the valve springs with the valve spring compressor and install the valve cotters.
Compressing the valve spring more than necessary when installing the valve cotters may cause loss of valve spring tension.
TOOL : VALVE SPRING COMPRESSOR
VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING COMPRESSOR COMPRESSOR COMPRESSOR 9-11

Tap the valve stems gently with a soft hammer to firmly seat the cotters.
Take necessary precautions not to damage the valve.
Apply engine oil to the new O-ring, and assemble it to the carburetor insulator groove. Tighten the carburetor insulator with mounting bolts. Install the cam chain tensioner, and assemble pivot bolts.
TORQUE : 1.0 kgf m
Install the spark plug.

TORQUE : 1.2 kgf m
Clean any gasket material from the cylinder mating surface. Install the cam chain guide to the cylinder. Install the dowel pins and new gasket.
CAM CHAIN GUIDE
Install the cylinder head.
CYLINDER HEAD
9-12
CAMSHAFT ASSEMBLY
EX. VALVE ROCKER ARM IN. VALVE ROCKER ARM
Apply engine oil to the rocker arm shaft, and assemble the rocker arm to the camshaft holder.
EX. ROCKER ARM SHAFT
CAM SHAFT HOLDER
IN. ROCKER ARM SHAFT
Tighten the rocker arm shaft with 6mm bolts, and align the bolt hole of the camshaft holder with the fitting side of the rocker arm shaft.
CAM CHAIN CYLINDER HEAD CAM SHAFT
Check the camshaft assembly for abnormal condition, and place it on the cylinder head. Put the cam chain on the cam sprocket.
Slowly rotate the crankshaft counterclockwise, and align theTmark of the flywheel with the index mark of the RH. crank case cover.
Take precautions not to allow the cam chain to come off the camshaft timing gear while turning the camshaft.
"T" MARK
9-13

Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. Assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head.
Install the dowel pins on the cylinder head. Install the camshaft holder.
CAM SHAFT HOLDER
The hole of the camshaft holder and the fitting section of the rocker arm shaft fit section must be in alignment. Of IN and EX, the shorter rocker arm should be installed on the IN side.
Install the cam cover plate. Apply engine oil to the threaded part; install the camshaft holder nut and bolts, and tighten them driving with 2 - 3 times.
TORQUE VALUE : 2.0 kgf m
Remove the pan screws and seals from the cam chain tensioner lifter. Rotate the tensioner shaft clockwise with a small driver, and insert the shaft into the body completely.
If the cam chain tensioner lifter is dropped, the shaft will advance by the spring force.
9-14

CAM CHAIN TENSIONER LIFTER
Fix the tensioner shaft with a hard clip. Assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. Tighten the tensioner mounting bolts.
CLIP
Remove the tensioner shaft clip from the tensioner lifter. Assemble the O-ring and pan screws to the tensioner lifter.
Fill clean engine oil into the operating parts of the cylinder head. Adjust the valve clearance. (2-5 ) Remove oil from the cylinder head cover grooves, and accurately assemble the gasket to the cover.
CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER
Install the cylinder head cover. Tighten the cylinder head cover bolts.
Install the carburetor insulator. Install the EX. pipe. (3-8 ) Install the RH. / LH. shroud. (8-12 ) Install the engine to the frame. (6-2 )
9-15
CYLINDER/PISTON
CYLINDER
TOP RING SECOND RING OIL RING CYLINDER GASKET
PISTON
10-0
10. CYLINDER / PISTON

SERVICE INFORMATION 10-1 TROUBLESHOOTING 10-1 CYLINDER 10-2 PISTON / PISTON RING 10-3 CYLINDER INSTALLATION 10-5
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. Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
INNER DIAMETER CYLINDER TAPER OUT-OF-ROUND 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 PISTON RING-TOGROOVE CLEARANCE PISTON RING JOINT GAP TOP SECOND TOP / SECOND OIL RING (SIDE RAIL)
56.000-56.010 mm 55.925-55.945 mm 15.002-15.008 mm 14.994-15.000 mm 0.002-0.014 mm 0.040-0.067 mm 0.025-0.052 mm 0.10-0.25 mm 0.20-0.70 mm 0.055-0.090 mm 15.010-15.028 mm 0.010-0.034 mm
56.100 mm 0.050 mm 0.005 mm 0.020 mm 58.825 mm 15.040 mm 14.960 mm 0.020 mm 0.110 mm 0.080 mm 0.50 mm 1.10 mm 0.200 mm 15.060 mm 0.040 mm
10
CYLINDER-TO-PISTON CLEARANCE CONNECTING ROD SMALL END INNER DIAMETER GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN
TROUBLESHOOTING
Comperssion 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 wall Worn cylinder and piston Worn connecting rod small end bearing or piston pin Damaged piston ring Excessive carbon build-up on top of piston
10-1
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the engine from the frame. (6-2 ) Remove the EX. pipe. (3-8 ) Remove the camshaft. (9-3 ) Remove the cylinder head. (9-5 ) Remove the cam chain guide from the cylinder. Remove the cylinder. Remove the gasket and dowel pin. Carefully remove any adhering gasket material from the cylinder / head mating surface. Do not scratch the surface.
CYLINDER COMP
CAM CHAIN GUIDE
DOWEL PIN
Take care not to damage the cylinder mating surface.
PISTON
WEAR INSPECTION
CYLINDER GAUGE
Inspect the cylinder wall for scratches and wear. Measure and record the cylinder inner diameter at three levels in both an X and Y axis. Take the maximum reading to determine the cylinder wear.
Measure the piston outer diameter. Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance.
TOP
MIDDLE
Calculate the cylinder for out-of-round at three levels in an X and Y axis. Take the maximum reading to determine the out-of-round. Calculate the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. If any of the cylinder measurements exceed the service limits, replace the cylinder.
SERVICE LIMIT : OUT-OF-ROUND : 0.005 mm TAPER : 0.05 mm
BOTTOM
10-2
CYLINDER/PISTON
WARPAGE INSPECTION
FEELER GAUGE
Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded.
SERVICE LIMIT : 0.02 mm STRAIGHT EDGE
Any clearance between the cylinder and head due to damage or warpage will result in compression leaks and reduced performance.
PISTON / PISTON RING

REMOVAL
Place a clean shop towel over the crankcase to prevent the possibility of the clip falling into the crankcase. Remove the piston pin clip using a pair of pliers. Press the piston pin out of the piston.
PISTON
Do not damage or scratch the piston. Do not apply side force to the connecting rod. Do not let the clip fall into the crankcase.
INSPECTION
Clean carbon deposits from the piston. Inspect the piston rings for movement by pressing the rings. The rings should be able to move in its groove without catching. Spread each piston ring and remove it by lifting it up at a point just opposite the gap.
PISTON RING
Do not damage the piston ring by spreading the ends too far. Measure the clearance between the piston ring and piston grooves.
SERVICE LIMIT : TOP : 0.110 mm SECOND : 0.080 mm OIL RING : 0.280 mm
Inspect the piston for wear or damage.
10-3
CYLINDER/PISTON
Insert the piston ring into the bottom of the cylinder squarely, using the piston. Measure the end gap using a feeler gauge. Replace the ring if the service limit is exceeded.
Always replace piston ring as a set.

FEELER GAUGE SERVICE LIMIT : TOP / SECOND : 0.50 mm OIL RING (SIDE RAIL) : 1.10 mm TOOL : FEELER GAUGE
SPECIFIED DISTANCE 90
Measure and record the piston outer diameter 90 the to piston pin bore and at the point specified (10mm), near the bottom of the piston skirt. Replace the piston if the service limit is exceeded.
PISTON PIN INSPECTION

Measure the piston pin bore inner diameter in an X and Y axis. Take the maximum reading to determine the inner diameter. Replace the piston if the inner diameter is over the service limit.
1 2 3
Measure the piston pin outer diameter at three points. Replace the piston pin if the service limit is exceeded.
Calculate the piston pin-to-pin bore clearance by subtracting the piston pin outer diameter from the pin bore inner diameter.
SMALL END BEARING SURFACE INSPECTION

Measure the inner dismeter of the connecting rod small end.
Calculate the connecting rod small end-to-piston pin clearance.

10-4
CYLINDER/PISTON
PISTON / PISTON RING INSTALLATION
MARK R
Clean the piston heads, ring lands and skirts. Carefully install the piston rings onto the piston with the markings facing up.
TOP RING 120 120 SECOND RING SIDE RAIL 20mm SPACER SIDE RAIL OIL 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. Space the side rail gaps 40mm or more apart as shown.
20mm
PISTON
After installing the rings they should rotate freely, without sticking.
PISTON INSTALLATION
Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. Install the piston and insert the piston pin.
CRANK SHAFT
The mark that is stamped on the piston head should be facing the correct direction.
IN MARK : TO INTAKE SIDE EX MARK : TO EXHAUST SIDE
10-5
CYLINDER/PISTON
Install new piston pin clips.
PISTON PIN CLIP
Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage.
Take care not to drop the piston pin clip into the crankcase. Set the piston pin clip in the groove properly. Do not align the clips end gap with the piston cutout.
CYLINDER INSTALLATION
DOWEL PIN
Make sure that the piston ring end gap is correct. Carefully remove any adhering gasket material from the cylinder / head mating surface. Do not scratch the surface. Install a new cylinder gasket and dowel pins.
Take care not to damage the cylinder mating surface.

GASKET
CYLINDER
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.
CAM CHAIN
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. (9-11 ) Install the camshaft. (9-13 ) Install the cylinder head cover. Install the EX. pipe. (3-8 ) Install the engine to the frame. (6-2 )
CAM CHAIN GUIDE
10-6
MEMO
TRANSMISSION/CRANKSHAFT/CRANKCASE
RH. CRANKCASE
LH. CRANKCASE CRANKSHAFT
11-0
11. TRANSMISSION/CRANKSHAFT/CRANKCASE
SERVICE INFORMATION11-1 TROUBLESHOOTING 11-2 TRANSMISSION 11-3 CRANK CASE REMOVAL11-6 CRANKSHAFT REMOVAL11-7 TRANSMISSION BEARING 11-8 CRANKSHAFT INSTALLATION11-9 CRANK CASE INSTALLATION 11-10
SERVICE INFORMATION
GENERAL SAFETY
This section describes how to remove the crank case and to maintain the transmission and the crankshaft. Service transmission without removing the engine from the vehicle. However, to prevent damage to the LH. crank case, remove the engine and disassemble the rear brake prior to changing the LH. crank case bearing. Always use special tools to change the drive shaft. Fix the bearing inner race, and install the shaft. The following parts must be removed prior to removing the crank case. Follow the removal procedure specified in each section. -OIL PUMP (SECTION 2 ) -CARBURETOR (SECTION 5 ) -ENGINE (SECTION 6 ) -CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 9 AND 10 ) -AC GENERATOR (SECTION 8 ) -DRIVE PULLEY (SECTION 7 ) -CLUTCH/DRIVEN PULLEY (SECTION 7 ) The following parts must be removed prior to changing the LH. crank case. Follow the removal procedure specified in each section. -TRANSMISSION (SECTION 11 ) -PARKING BRAKE (SECTION 14 ) To assemble the crank case and crankshaft, set the special tool to the inner race of the crankshaft bearing, and push and assemble. Remove the bearing from the crankshaft during disassembling work, and insert a new bearing in the case. Install the oil seal after the case is assembled.
11
SPECIFICATIONS
ITEM STANDARD VALUE SERVICE LIMIT
CONNECTING ROD LARGE END SIDE CLEARANCE CRANK SHAFT CONNECTING ROD BIG END CRANKSHAFT SHAKING RIGHT LEFT
0.15 ~ 0.60 mm 0.1 ~ 0.35 mm 0 ~ 0.008 mm -
0.60 mm 0.05 mm 0.1 mm 0.1 mm
TRANSMISSION OIL
OIL CAPACITY RECOMMENDED OIL 0.15(Full capacity) 0.14(After oil change) DMC Pure mission oil or SAE 80W/90
11-1
TORQUE VALUE
CRANK CASE BOLT 1.0kg-m
TOOLS
-UNIVERSAL BEARING PULLER -BEARING REMOVER SET -REMOVER ASSEMBLY -REMOVER SHAFT -REMOVER HEAD -SLIDING WEIGHT -ASSEMBLY SHAFT
TROUBLESHOOTING
Engine Noise
Connecting rod big and small ends loose. Crank pin bearing loose.
Engine started but unable to move out

Transmission damage. Transmission seized.
Noise during operation

Gear worn, overheated, or cranked. Bearing worn.
Oil leaks
Excessive oil level. Oil seal worn or damaged.
11-2
TRANSMISSION
DISASSEMBLY
Loosen the drain bolt, drain the mission oil. Remove the LH. crankcase cover. (7-2 ) Remove the continuously variable transmission. (SECTION 7 ) Remove the EX. muffler. (3-8 ) Remove the rear swing arm. (13-8 ) Remove the rear brake caliper. (13-3 ) Remove the rear wheel. (13-5) Loosen the rear cushion upper bolt. Remove the transmission bleeder tube from the mission cover groove. Loosen the 8 transmission cover bolts. Remove the transmission cover. Remove the gasket and dowel pin.
TRANSMISSION COVER
DRAIN BOLT
Remove the drive shaft from the transmission cover by using a hydraulic press.
DRIVE SHAFT
Take precautions not to damage the cover joints.
Remove the oil seal of the drive shaft.
OIL SEAL
11-3
Remove the final shaft and the counter shaft comp.
FINAL SHAFT
COUNTER SHAFT
TRANSMISSION INSPECTION
Check the drive shaft for wear or damage.
DRIVE SHAFT
Check the final shaft for wear or damage.
FINAL SHAFT
Check the counter shaft for wear or damage.

COUNTER SHAFT
11-4
TRANSMISSION BEARING INSPECTION
Check that the bearing outer race fits the case tightly without play. Turn the inner race and check that the bearing turns smoothly and quietly. Replace the bearings if necessary.
BEARING
Install the bearing to the case with special tools.

OUTER DRIVER OUTER HANDLE TOOLS : DRIVE HANDLE A OUTER DRIVER DRIVER PILOT
Check the LH. crankcase oil seal for wear or damage.
DRIVER PILOT
TRANSMISSION ASSEMBLY
CRANK ASSEMBLY COLLAR
Install the drive shaft on the transmission cover. Install a new drive shaft oil seal.
TOOLS : CRANK ASSEMBLY SHAFT CRANK ASSEMBLY COLLAR
CRANK ASSEMBLY SHAFT
FINAL SHAFT
Inatall the final shaft and counter shaft on the LH. crank case.
COUNTER SHAFT
11-5
Install a new gasket and dowel pin.
OIL CHECK BOLT
Tighten the transmission cover with the setting bolts. Install the following parts. -Rear wheel (13-5 ) -Rear swing arm (13-8 ) -Rear brake caliper (13-3 ) -EX. muffler ( 3-8 ) -Continuously variable transmission (SECTION 7 ) -RH. crank case cover (8-4 ) Install the rear cushion upper bolt. Install the transmission bleeder tube. Remove the oil check bolt, release the transmission oil filler ACG cap or the LH. crankcase until the oil overflow through oil hole and fill the recommended oil slowly. Install the oil check bolt and the cap.
RECOMMENDED OIL : SAE 80W- 90 TRANSMISSION OIL AMOUNT : 0.15
TRANSMISSION COVER
CRANK CASE REMOVAL

Remove the engine from the frame. (6-2 ) Remove the RH./LH. crankcase cover.(8-4,7-2) Remove the transmission cover. (11-3 ) Remove the parts to disassemble crankcase.
Loosen the 8 RH./LH. crankcase setting bolts.
SETTING BOLTS
SETTING BOLTS
11-6
Remove the transmission bleeder tube. Remove the RH./LH. radiator hose from the RH. crankcase. Face the LH. crankcase downward, and remove the RH. crankcase from the LH. crankcase while tapping a few places on the LH. crankcase with a plastic hammer.
RH. CRANKCASE
LH. CRANKCASE
Be careful not to distort the mating surface of the crank case during removal.
Remove the dowel pin and gasket.
CRANKSHAFT
DOWEL PIN
CRANK BEARING
CRANKSHAFT REMOVAL
Remove the crankshaft from the RH. crankcase by using a crankshaft remover. If the bearing is left on the RH. crankcase, use the driver handle and the outer driver to remove it.
TOOLS : DRIVER ATTACHMENT, 42 X 47 mm
If the bearing is left on the crankshaft, use a bearing puller to remove it.
RH. CRANKCASE TOOL : UNIVERSAL BEARING PULLER
After removing the crankshaft from the RH. crankcase, replace the RH. crankshaft bearing with a new one.
UNIVERSAL BEARING PULLER
11-7
CRANKSHAFT INSPECTION
MEASURING POINT DIAL GAUGE
Place the crankshaft on a stand or V-block, and measure the crankshaft runout using dial gauge.
SERVICE LIMIT : RIGHT : 0.1 mm LEFT : 0.1 mm
FEELER GAUGE
Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end as shown.
TOOL : FEELER GAUGE
DIAL GAUGE
Measure the connecting rod radial clearance in both X and Y directions. Replace the crankshaft if the service limit is exceeded.
TRANSMISSION BEARING
OIL SEAL BEARINGS
Remove the transmission and crankshaft.
INSPECTION
Check that the bearing outer race fits the case tightly without play. Turn the inner race and check that the bearing turns smoothly and quietly. Replace the bearing if necessary.
11-8
BEARING REMOVER SET
TRANSMISSION BEARING REPLACEMENT

LH. crankcase
Use special tools to remove the drive shaft bearing.
TOOLS : BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD
Remove the final shaft bearing and oil seal. Remove the countergear bearing. Apply clean engine oil to a new bearing, and assemble it to the crankcase.
TOOLS : DRIVER HANDLE A DRIVER PILOT OUTER DRIVER
DRIVER HANDLE A
Install a new final shaft oil seal.

OUTER DRIVER
DRIVER PILOT
CRANKSHAFT INSTALLATION
DRIVER HANDLE A
Apply clean engine oil to the new RH. crankshaft bearing, and press in the bearing into the RH. crankcase.
TOOLS : DRIVER HANDLE A OUTER DRIVER DRIVER PILOT
Use special tools to assemble the crankshaft bearing to the RH. crankcase.
TOOLS : DRIVER HANDLE A OUTER DRIVER DRIVER PILOT
CRANKSHAFT ASSEMBLER
11-9
CRANKCASE INSTALLATION
DOWEL PIN
Install the dowel pins and a new gasket. Install the cam chain to the LH. crankcase.
LH. CRANKCASE
Install the RH. crankcase to the LH. crankcase.

RH. CRANKCASE
Make sure that the gasket is completely attached without any clearance.
LH. CRANKCASE
LH. CRANKCASE
Install the RH./LH. radiator hose. Install the bleeder tube to the LH. crankcase. Install the removed parts. Install the engine on the frame.(6-2 )
RH. CRANKCASE
SETTING BOLTS SETTING BOLTS
11-10
MEMO
FRONT WHEEL/FRONT FORK/STEERING/BRAKE
STEERING HANDLE
STEERING STEM
FRONT FORK
FRONT DISK
FRONT TIRE FRONT CASTING WHEEL
12-0
12. FRONT WHEEL/FRONT FORK/STEERING/BRAKE

SERVICE INFORMATION 12-1 TROUBLESHOOTING 12-2 STEERING HANDLE 12-3 FRONT WHEEL 12-4 FRONT WHEEL BEARING 12-5 SPEEDOMETER 12-6 FRONT WHEEL INSTALLATION 12-7 FRONT BRAKE 12-7 BRAKE FLUID 12-10 BRAKE CALIPER 12-12 FRONT FORK 12-14 STEERING STEM 12-19
SERVICE INFORMATION
GENERAL SAFETY
Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance. If contaminated, replace the pad with a new one, and clean the disk. Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged. Place a jack underneath the engine to support the 2-wheeled vehicle.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT (mm)
AXLE SHAFT RUNOUT FRONT WHEEL RIM RUNOUT RADICAL AXIAL
240.6mm 3.8~4.2mm 26.94~26.97mm 27.00~27.05mm 33.90~33.93mm 33.96~34.01mm
0.2mm 2.0mm 2.0mm 233mm 3.0mm 0.30mm 26.91mm 27.00mm 33.87mm 34.01mm
12
FRONT SHOCK ABSORBER SPRING FREE LENGTH BRAKE DISK THICKNESS BRAKE DISK RUNOUT TOP BRAKE CALIPER PISTON O.D. TOP BRAKE CALIPER CYLINDER I.D. UNDER BRAKE CALIPER PISTON O.D. UNDER BRAKE CALIPER CYLINDER I.D.
TORQUE VALUES
STEERING STEM LOCK NUT STEERING TOP CONE RACE FRONT SHOCK ABSORBER BOLT FRONT AXLE NUT BRAKE CALIPER BOLT 7.84~11.76m 0.49~1.27fm 1.98~2.45fm 4.41~4.9fm 2.45~3.43fm
12-1
TROUBLESHOOTING
Hard steering
Steering bearing adjustment nut too tight. Faulty steering stem bearings. Damaged steering stem bearings. Insufficient tire pressure.
Brake lever hard

Clogged brake system Sticking caliper piston Caliper not sliding properly Clogged fluid passage Worn caliper piston seal Sticking or worn master cylinder piston Bent brake lever
Steers to one side or does not track straight

Unevenly adjusted right and left shock absorbers. Bent front forks. Bent front axle : wheel installed incorrectly.
Brake drags
Contaminated brake pad or disk Misaligned wheel Worn brake pad or disk Warped or deformed disk Caliper not sliding properly Hydraulic system contaminated with dust
Front wheel wobbling

Bent rim. Worn front wheel bearings. Faulty tire. Axle nut not tightened properly. Wheel out of balance.
Soft suspension
Weak fork springs. Insufficient fluid in front forks.
Hard suspension
Incorrect fluid weight in front forks. Front fork air pressure incorrect. Bent fork tubes. Clogged fluid passage. Clogged anti-dive orifice.
Front suspension noise

Worn slider or guide bushings. Insufficient fluid in forks. Loose front fork fasteners. Lack of grease in speedometer gear box.
Brake lever soft or spongy

Air in hydraulic system Mixed brake fluid and wet Contaminated brake pad or disk Worn caliper piston seal Worn master cylinder piston seal Worn brake pad Contaminated caliper inside Caliper not sliding properly Worn brake pad or disk Low brake fluid level Clogged fluid passage Warped or deformed brake disk Sticking or worn caliper piston Sticking or worn master cylinder piston Contaminated master cylinder inside Bent brake lever
12-2
STEERING HANDLE
REMOVAL
Remove the upper handle cover and the under handle cover from the handle bar. Loosen the bolts securing the front and rear break master cylinder. Remove the front cover, front under cover and speedometer cover.
Loosen the 4 screws securing the housing. Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar.
SCREWS SCREWS SCREWS
Remove the handlebar lock nut and take out the bolt. Remove the handlebar.
LOCK NUT LOCK NUT LOCK NUT
INSTALLATION
Install the handlebar onto the steering stem and install the handlebar collar, lock nut and bolt. Tighten the bolt, to the specified torque.
TORQUE VALUE : 3.92~4.9kgfm
12-3

Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
Adjust the throttle grip free play to the specified range of 2~6mm.
Install the front and rear brake master cylinders.
Install the brake master cylinders by aligning the index marks. Install in the reverse order of removal.
BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER
FRONT WHEEL
REMOVAL
Jack the motorcycle front wheel off the ground. Remove the front axle nut to pull out the axle. Remove the front wheel and the speedometer gear unit.
AXLE NUT AXLE NUT AXLE NUT
INSPECTION
DIAL GAUGE
AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge. The actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT : 0.2mm replace if over
AXLE
12-4

WHEEL RIM Check the wheel rim runout.
SERVICE LIMIT : RADIAL : 2.0mm replace if over AXIAL : 2.0mm replace if over
DIAL GAUGE DIAL GAUGE DIAL GAUGE
BEARING
FRONT WHEEL BEARING

INSPECTION
Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.
WHEEL BEARING REPLACEMENT

Install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance collar.
Always replace bearings in pairs, and never use old bearings.

TOOLS : BEARING REMOVER HEAD BEARING REMOVER
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.
TOOLS : DRIVER HANDLE A DRIVER PILOT OUTER DRIVER
The bearing inserted in the last must be inserted until it contacts with the distance collar. Excessively inserted bearing can cause damage the opposite side bearing.
12-5

SPEEDOMETER GEAR REPLACEMENT
Remove the speedometer gear and washer from the speedometer gear box. Check the gear for wear or damage. Install the washer. Apply grease to the speedometer gear prior to assembling. Install the washer. Apply grease to the speedometer gear unit and install.
SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX
SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR
FRONT WHEEL ASSEMBLY

Apply grease to the left side dust seal rim. Install the left side dust seal. Install the brake disk. Install disk bolts.
DUST SEAL DUST SEAL DUST SEAL
Install the left side collar.
RH. SIDE COLLAR RH. SIDE COLLAR RH. SIDE COLLAR
Install the speedometer gear unit by aligning its retaining pawl with the hub cutout.
GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER
12-6
FRONT WHEEL/FRONT FORK/STEERING

Apply grease to the dust seal rim. Install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box.
SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX
FRONT WHEEL INSTALLATION

Insert the front wheel between the front forks. Insert the disk, taking precautions not to damage the pad, and assemble the wheel. Align the slots of the speedometer gear with the tangs of the left fork slider. Insert the front axle into the speedometer gear box and the wheel hub.
FRONT AXLE FRONT AXLE FRONT AXLE
Install the axle nut. Install the speedometer cable, and tighten with screws. Place the front wheel on the ground, and tighten the axle nut to the specified torque.
TORQUE VALUE : 5.0-7.0 kgfm
AXLE NUT AXLE NUT AXLE NUT
FRONT WHEEL
BRAKE MASTER CYLINDER REMOVAL
Remove the handlebar covers. First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector. Remove the brake fluid tube bolt. Remove the two bolts securing the brake master cylinder. Remove the brake master cylinder.
12-7
When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid. When removing the brake fluid tube bolt, be sure to plug the tube end to avoid brake fluid leakage.
DISASSEMBLY
Remove the Fr/Rr stop switch. Take out the boot and circlip from the master cylinder.
TOOLS : SNAP RING PLIERS
CIR CLIP CIR CLIP CIR CLIP MASTER MASTER MASTER MASTER CYLINDER SET CYLINDER SET CYLINDER SET
STOP STOP STOP SWITCH SWITCH SWITCH
Remove the washer, piston, spring from the master cylinder. Clean the master cylinder, reserve, master piston with the recommended brake fluid.
LEVER LEVER LEVER
BOOT BOOT BOOT CIR CLIP CIR CLIP CIR CLIP
MASTER MASTER MASTER MASTER CYLINDER BODY CYLINDER BODY CYLINDER BODY
INSPECTION
PISTON PISTON PISTON
Check the piston periphery for scores, scratches or nicks and replace if necessary. Check the primary and secondary cups for wear.
SECONDARY CUP SECONDARY CUP SECONDARY CUP SECONDARY CUP
PRIMARY CUP PRIMARY CUP PRIMARY CUP PRIMARY CUP
12-8
If there is any leak of fluid when installing new piston, it may indicate the side wear of the cylinder by the direction of the piston contacting face. In this case, the master cylinder must be replaced also. Check the master cylinder for scores, scratches or nicks and replace if necessary.
OIL CUP CAP BOOT DIAPHRAGM PLATE CIR CLIP DIAPHRAGM SPRING
ASSEMBLY
WASHER
MASTER CYLINDER BODY
Replace the piston, spring, cups and snap ring as a set. Be sure that each part is free from dust or dirt before reassembly. When cleaning with the brake fluid, use the specified brake fluid. Coat the piston, cup with the fresh brake fluid and install it on the piston. Install the spring with its larger diameter end toward the master cylinder.
LEVEL
STOP SWITCH
When installing the cups, do not allow the lips to turn inside out. Note the installation direction of the snap ring. Be certain that the snap ring is seated firmly in the groove. Install the primary cup with its concaved side toward the inner side of the master cylinder. Install the snap ring. Install the rubber boot in the groove properly.
BOOT BOOT BOOT
TOOL : SNAP RING PLIERS
INSTALLATION
SETTING BOLTS SETTING BOLTS SETTING BOLTS
Install the front / rear master cylinder to the handle bar.
Install the holder with its UP mark facing upwards, and align the holder joint with the punch mark on the handle bar. Tighten the holder upper bolt first.
12-9

Install the brake hose to the master cylinder with 2 new sealing washers and the hose bolt.
TORQUE VALUE : 2.5~3.5 kgfm
Loosen the 2 flat screws, remove the oil cup cap, diaphragm plate and diaphragm. Fill the brake fluid, and bleed air. Install the diaphragm, diaphragm plate and the oil cup cap, tighten the 2 flat screws.
OIL BOLT OIL BOLT OIL BOLT
BRAKE FLUID
A contaminate disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. Replace contaminated pads, and remove pollutants from the disk completely. Check the brake fluid level often, and replenish new fluid as required. Do not spill fluid on painted, plastic or rubber parts.
Remove the wind screen. Remove the oil cup cap, diaphragm plate and diaphragm from the master cylinder. Connect the bleeder hose to the bleeder valve. Loosen the bleeder valve, and pump the brake lever repeatedly. When there is no more fluid flowing out of the bleeder valve, stop pumping the brake lever.
AIR BLEEDING <When the brake bleeder is available>

BRAKE BLEEDER
Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level.
To prevent chemical changed, do not use different types of brake fluid. Connect the recommended brake bleeder to the bleeder valve. Loosen the bleeder valve while pumping the brake lever. Repeat this operation until the brake fluid flows out of the brake bleeder. Add brake fluid.
12-10
Check the fluid level often, and replenish fluid if the amount of fluid is reduced to the lower level. Read the users manual carefully prior to disassembling or using the brake bleeder. Protect the bleeder valve with tape to prevent air from entering the bleeder valve. Repeat the above procedures until no air bubbles appear in the bleeder hose. Squeeze the bleeder valve and operate the brake lever to check the ingress of air.
BLEEDER VALVE
<When the brake bleeder is not available>

Fill the brake fluid up to the upper limit line. Connect the transparent bleeder hose to the bleeder valve and place the other end of the hose in a container. Squeeze the brake lever, then open the bleeder valve 1/2 turn, and close the valve.
BLEEDER HOSE NO REUSE
Do not release the brake lever until the bleeder valve has been closed. Check the brake fluid level often while bleeding the system to prevent air from being pumped into the system. Release the brake lever slowly and wait several seconds after it reaches the end of its travel. Repeat the above steps and until bubbles cease to appear in the fluid at the end of the hose. 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.
Be sure that the brake fluid is up to the upper level of the master cylinder and refill if necessary Reinstall the diaphragm, diaphragm plate and oil cup cap.
12-11
BRAKE CALIPER
REMOVAL
First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts securing the brake master cylinder. Remove the brake caliper.
Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface. Wind the hose joint with cloth to prevent the brake fluid from leaking. Clean the removed parts with the brake fluid and make sure that the each port isnt clogged with the compressed air. Keep the removed parts in order to avoid dust from adhering.
DISASSEMBLY
Remove the slide pin, the LH. bracket, the pin bush, the boot and the pin boot, and the pin bolt from the caliper. If there is any wear or damage in the boot, replace it with a new one. Wind the caliper with cloth to prevent the piston or brake fluid from leaking. Remove the piston from the caliper while blowing the low-pressure air in the opening of the brake hose.
Never use the high-pressure air or bring the air gun too close. Never touch the inside of the caliper Disassemble the piston seal and the dust seal
Pay attention not to damage the inner surface of the caliper. Clean the piston and the inside of the caliper and remove the oil from the seal groove.
12-12

INSPECTION
Check the caliper cylinder bore for scoring, scratches or other damage. Measure the caliper I.D.
Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge.
Clean the piston seal and the dust seal with the brake fluid and install them in the caliper. Install the piston in the caliper with the groove side of the piston facing the pad.
PISTON PISTON PISTON
CALIPER CALIPER CALIPER DUST SEAL DUST SEAL DUST SEAL PISTON SEAL PISTON SEAL PISTON SEAL
12-13

Apply the silicone grease to the boot. Connect the boot to the portion of the caliper. Install the pad spring in the caliper. Install the caliper pin bolt and the slide pin in the caliper. Install the brake pad and the hanger pin in the caliper.
Install the front caliper to the front fork Tighten the bolt to the specified torque.
Connect the brake hose to the caliper and install 2 sealing washers and oil bolt. Tighten the oil bolt to the specified torque
Fill the brake fluid to the upper limit line and bleed air.
FRONT FORK
REMOVAL
Remove the following parts. -Front under cover -Front brake caliper -Front fender -Front wheel
When removing the front fork, loosen the fork pipe bolt lightly.
Support the vehicle securely under the engine not to turn over it. Loosen the fork pipe bolt, but do not remove it. Loosen the 4 setting bolts securing the RH./LH. front fork, remove the RH./LH. front fork. After removal of RH. front fork, loosen the flange bolt and remove the front brake hose clamp A.
12-14

DISASSEMBLY
Remove the fork pipe bolt.
SPRING
If the screw is completely loosened, the fork tube cap bolt may spring out by the force of the spring. Take due precautions. 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.
SOCKET BOLT SOCKET BOLT SOCKET BOLT
VISE
If the socket bolt turns idle but cannot be removed, temporarily assemble the spring and the fork tube cap bolt first. Hold the bottom case firmly with a vise, taking precautions not to distort or damage it.
BRACKET
Remove the dust seal.
DUST SEAL DUST SEAL DUST SEAL
12-15

Remove the oil seal stop ring.
OIL SEAL OIL SEAL OIL SEAL STOPPER RING STOPPER RING STOPPER RING
Remove the oil seal.
Take precautions not to damage the interior and exterior rim of the bottom case.
OIL SEAL OIL SEAL OIL SEAL
Remove the fork tube from the bottom case. Remove the piston and rebound spring from the fork tube.
BOTTOM CASE
FORK TUBE
FRONT FORK 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 spring with a new one. Check components for damage or abnormal wear. Replace defective parts with new ones.
SERVICE LIMIT : FORK SPRING 235mm
TOP
BOTTOM
Set the fork pipe on a V-blocks, and measure fork pipe deflection by rotating with a dial gauge.
SERVICE LIMIT : Replace if the deflection is greater than 0.2mm
12-16

Check the slider bush contact face. If the slider bush is extensively damaged, replace the bottom case.
FORK TUBE
FRONT FORK ASSEMBLY

BOTTOM CASE
Wash parts with clean oil prior to assembling. Assemble the rebound spring and thd fork piston to the fork tube. Assemble the fork tube to the bottom case.
FORK TUBE
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 fork piston.
When a vise is used to hold the bottom case, do not insert the case itself but insert the bracket.
FORK SEAL DRIVER
Apply ATF to a new oil seal. Assemble the oil seal to the bottom case. Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed.
TOOLS : FORK SEAL DRIVER FORK SEAL DRIVER BODY
FORK SEAL DRIVER ATTACHMENT
12-17

OIL SEAL OIL SEAL OIL SEAL OIL SEAL STOPPER RING STOPPER RING STOPPER RING
Install the oil seal stopper ring Accurately assemble the oil seal stop ring to the bottom case.
FORK OIL
Install the dust seal. Fill a prescribed amount of automatic transmission fluid(ATF) into the fork tube.
CAPACITY : 90cm3
OIL LEVEL
Slowly press the fork tube 2-3 times to discharge air.
FORK OIL
Assemble the spring to the fork pipe.
Install the spring with the smaller pitch side facing downward.
FORK PIPE CAP BOLT FORK PIPE CAP BOLT FORK PIPE CAP BOLT
Assemble the fork bolt to the fork pipe.
12-18

Install the front fork to the steering stem. Install the front fork setting bolts.
Install the brake hose clip A to the RH. front fork.
STEERING STEM
REMOVAL
Remove the following parts. -Handle cover -Handle bar -Front cover -Front under cover -Inner cover -Front wheel -Front fork
Be careful not to turn over the vehicle. Remove the steering stem nut using the steering stem nut socket.
TOOL : STEERING STEM NUT SOCKET
Remove the steering top thread nut using the steering stem socket.
TOOL : STEERING STEM SOCKET
Remove the top cone race. Check the upper ball assembly, top cone race and ball race for damage or abnormal and replace as necessary. Check the bottom cone race for wear and damage.
12-19

Remove the steering top ball race from the head pipe. Remove the steering bottom race.
Check all of the races and balls for damage or abnormal wear and replace as necessary. If the vehicle has been involved in an accident, examine the area around the steering head for crack.
INSTALLATION
Install the steering head dust seal washer and dust seal onto the steering stem. Press in the steering bottom cone race using the steering stem driver. Install the under ball assy into the steering stem.
TOOL : STEERING STEM DRIVER
Install the steering stem into the head pipe. Install the steering upper ball assy into the steering stem. Install the top cone race and steering top thread onto the steering head. Tighten the top thread to specified torque, then loosen the top thread 1/8 turn
Recheck that the steering stem moves smoothly without play or binding. Tighten the steering stem lock nut temporarily.
TOOLS : STEERING STEM LOCK NUT SOCKET STEERING STEM SOCKET
Install the following parts. - Front fork - Front wheel - Inner cover - Front under cover - Front cover - Handle bar - Handle cover
12-20
MEMO
REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM
13-0
13. REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM

SERVICE INFORMATION 13-1 TROUBLESHOOTING 13-2 REAR BRAKE 13-3 PARKING WHEEL 13-5 REAR CUSHION 13-7 REAR SWING ARM 13-7
SERVICE INFORMATION
GENERAL SAFETY
If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use a brake cleaner, designed to minimize the hazard caused by airborne asbestos fibers.
SPECIFICATIONS
ITEM STANDARD VALUE SERVICE LIMIT
AXLE SHAFT DEFLECTION REAR WHEEL RIM WOBBLES RADICAL AXIAL
110.0 mm 4.0 mm 250.8 mm
0.2 mm 2.0 mm 2.0 mm 111.0 mm 2.0 mm 243.3 mm
REAR BRAKE DRUM INNER DIAMETER REAR BRAKE LINING THICKNESS REAR CUSHION SPRING FREE LENGTH
TORQUE VALUES :
REAR CUSHION UPPER BOLT REAR CUSHION LOWER BOLT REAR CUSHION ROD LOCK NUT REAR AXLE NUT 3.5~4.5fm 3.5~4.5fm 3.0~4.5fm 6.0~8.0fm
13
13-1
REAR WHEEL / BRAKE / SUSPENSION / SWING ARM
TROUBLESHOOTING
Wobble or vibration in motorcycle
Tire pressure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance
Soft suspension
Weak springs Rear damper improperly adjusted, oil leakage
Hard suspension
Rear damper improperly adjusted Bent shock absorber rod
Suspension noise
Loose fasteners Worn shock
13-2
REAR BRAKE
REMOVAL
Remove the muffler. Loosen the rear break tube bolt and remove the break tube. Loosen 2 bolts and remove rear break caliper.
SETTING BOLTS
INSPECTION
Inspect break pad and disk. Measure the break disk thickness.
SERVICE LIMIT : 3mm
DISASSEMBLY
Remove the rear break caliper. Inspect caliper assembly. Remove the pad spring, slide pin, caliper bracket, and boot from the caliper body. Check the boot for wearand damage and replace if necessany.
PISTON
Wind the caliper facing down with cloth to prevent the piston or break fluid from leaking. Remove the piston from the caliper while blowing the low-pressure air in the opening of the break hose.
Never use the high-pressure air or bring the air gun too close. Never touch the inside of the caliper
PISTON SEAL DUST SEAL
13-3

Disassemble the piston seal and the dust seal. Clean the piston and inside of caliper with break fluid.
INSPECTION
PISTON
Check the caliper cylinder bore for scoring, scratches or other damage. Measure the caliper I.D.
Inspect piston surface for scratch or damage. Measure the piston O.D.
DUST PLUG LOCK PLATE PIN BOOT
CALIPER BRACKET
BRAKE CALIPER ASSEMBLY

Clean the piston seal and the dust seal with the brake fluid and install them in the caliper. Install the piston in the caliper with the groove side of the piston facing the pad.
HANGER PINS PAD SPRING PADS
SLIDE PIN
PIN BUSH DUST SEAL
PISTON SEAL PISTON
CALIPER COMP.
Apply the silicone grease to the pin bush. Connect the pin bush to the portion of the caliper. Install the pad spring in the caliper. Install the caliper pin bolt and the caliper bracket in the caliper. Install the break pad in the caliper.
DUST PLUG
13-4
REAR WHEEL
REAR CALIPER
REMOVAL
Support the motorcycle on the main stand. Loosen the parking brake rod adjust nut B, and remove the parking brake cable. Remove the brake arm joint B from the rear parking brake arm. Remove the muffler. (3-8 ) Remove the rear brake caliper assembly from the rear swing arm.
REAR SWING ARM
Loosen the rear axle nut.
REAR AXLE NUT
Remove the rear swing arm. (13-7 ) Remove the rear wheel inside collar. Remove the rear wheel mudguard. (3-8 ) Remove the rear wheel.
INSIDE COLLAR
Loosen the 3 rear brake disk bolts, remove the rear brake disk from the rear wheel.
DISK BOLTS
13-5

REAR WHEEL INSPECTION
Check the rim for wobbles by rotating the wheel.
DIAL GAUGE SERVICE LIMIT : Radical 2.0mm Axial 2.0mm TOOL : DIAL GAUGE
REAR WHEEL INSTALLATION

FINAL SHAFT
Install the rear brake disk. Insert the rear wheel over the final shaft.
INSIDE COLLAR
Install the rear wheel inside collar. Install the rear swing arm. (13-8 ) Tighten the rear axle U-nut to the specified torque.
Install the rear brake caliper assembly to the rear swing arm. Install the EX. muffler. (3-8 ) Install the rear wheel mudguard. (3-8 )
Insert the brake arm joint B into the rear parking brake arm, and connect the brake arm joint B to the parking brake cable and tighten the adjust nut B.
REAR PARKING BRAKE ARM ADJUST NUT B
After installing the parking brake, be sure to adjust the parking brake free play.
13-6
REAR CUSHION ADJUST

Adjust the cushion spring according to the load condition. The rear cushion can be adjusted as below. 1 - 2 - 3 - 4 - 5 soft medium hard
REAR CUSHION
REMOVAL
Remove the luggage box. Remove the air cleaner. Remove the upper bolt. Remove the lower bolt. Remove the rear cushion.
INSTALLATION
REAR SWING ARM

REMOVAL
Remove the EX. muffler. (3-8 ) Remove the rear brake caliper. (13-3 ) Loosen the flange bolt securing the RH. crank case cover. Loosen the rear axle U-nut. Remove the rear swing arm.
13-7

REAR SWING ARM
DISASSEMBLY
Disassemble the rear wheel outside collar from the rear swing arm. Disassemble the oil seal (28427) and radial ball bearing (6302UU). Install in the reverse order of removal.
AXLE U-NUT
TORQUE VALUE - REAR WHEEL AXLE NUT : 6.0~8.0 kgfm
13-8
MEMO
CHARGING SYSTEM
REGULATOR RECTIFIER
MAIN SWITCH
A.C. GENERATOR
YELLOW YELLOW YELLOW RED MAIN SWITCH
GREEN BLACK (CABLE) FUSE

(15A)
RED BLACK
ENGINE EARTH GREEN
REGULATOR RECTIFIER AC.GENERATOR
_ FRAME EARTH
BATTERY (12V 10AH)
14-0
14. CHARGING SYSTEM

SERVICE INFORMATION 14-1 TROUBLESHOOTING 14-2 BATTERY 14-2 CHARGING SYSTEM INSPECTION 14-3 A.C. GENERATOR INSPECTION 14-4 REGULATOR RECTIFIER INSPECTION 14-5
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 and do not open stopper. 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 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.
14
SPECIFICATIONS
ITEM STANDARD VALUES
BATTERY A.C.GENERATOR REGULATOR /RECTIFIER
Capacity Terminal-to-terminal voltage (When fully charged) Charging coil resistance value ( 20 ) C rpm at charging start Regulator voltage
12V - 10AH (MF) 13.0 - 13.2V 0.6 - 1.6 1,500rpm 14.50.5V
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER
14-1
CHARGING SYSTEM
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.
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.
Low power (Key turned on)

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

Loose, broken or shorted wire or connection. Faulty regulator rectifier. Faulty A.C generator.
CHARGING SYSTEM
Measure battery current leakage.
CORRECT INCORRECT
Check the regulator rectifier.

CORRECT INCORRECT
Shorted harness wire. Faulty ignition switch. Faulty regulator rectifier.
Inspect the charging voltage.

UNDER 14V
OVER 15V
14~15V
Battery is failing
Check the voltage between the battery line and ground wire of regulator rectifier.
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.
CORRECT
INCORRECT
Check the charging coil of theA.C generator.

NORMAL
Poorly connected A.C generator coupler.

ABNORMAL
Faulty charging coil.

ABNORMAL
Check the regulator rectifier.

NORMAL
Faulty regulator rectifier.
Faulty battery.
14-2
CHARGING SYSTEM
BATTERY
Remove the seat and luggage box. Loosen the screws secuning the battery cover and remove the battery cover.
Remove the battery. First disconnect the negative battery cable, and then disconnect the positive cable.
When disconnecting the battery positive cable, do not touch the frame with tool ; otherwise it will cause short circuit and sparks to fire the fuel. The installation sequence is the reverse of removal.
First connect the positive cable and then negative cable to avoid short circuit.
BATTERY (OPEN-CIRCUIT VOLTAGE) INSPECTION

Remove the battery cover. Disconnect the battery terminals from the battery. Measure the voltage between the battery terminals.
- FULLY CHARGED : 13.2V - INSUFFICIENTLY CHARGED : UNDER 12.3V TOOL : DIGITAL TESTER
Use a voltmeter that will accurately indicate 0.1V difference. When measuring the battery volate after charging, leave it for at least 30 minutes, or the accurate results cannot be obtained because the battery voltage fluctuates just after charging. Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal.
BATTERY CHARGER
Keep flames and sparks away from a charging battery. Turn power ON/OFF at the charger, not at the battery terminals to prevent sparks near the battery. Charge the battery according to the current specified on the battery. During quick charging, the battery temperature should not exeeed 45 C
14-3
CHARGING SYSTEM
CHARGING SYSTEM INSPECTION

LEAK TEST
Trun off the ignition switch, and disconnect the ground (-) cable from the battery. Connect an ampere meter between negative (-) terminal and ground cable. With the ignition switch off, measure the leakage current.
LEAK CURRENT : Not to exceed 0.5A(max) TOOL : DIGITAL TESTER
AMPERE METER
BATTERY
TERMINAL
When measuring current using a tester, set it to a large range, and then bring it down the range to an appropriate level. Current flow larger 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.
EARTH CABLE
A.C. GENERATOR INSPECTION

This test can be made without removing the stator from the engine. Disconnect the yellow wire from the auto bystarter. Remove the frame center cover. Disconnect the A.C. generator connector.
Measure the resistance between the yellow wires. Replece the stator if resistance value is high or there is continuity between each yellow wire and ground. Resistance : yellow~yellow 0.6~1.6
14-4
CHARGING SYSTEM
REGULATOR RECTIFIER INSPECTION

Remove the luggage box. Remove the regulator rectifier coupler. Measure each terminal.
RESISTANCE VALUE
Tester Tester
Unit : , (20)
B 0-5 1-4 1-4 1-4 25-40K
Y 1-3
Y 1-3
Y 1-3
G 1-4 25-40K 1-4 1-4 1-4
R B Y Y Y G
Replace the regulator rectifier unit if the resistance value between the terminals is abnormal.
14-5
IGNITION SYSTEM
BATTERY REGULATOR RECTIFIER
IGNITION UNIT MAIN SWITCH
A.C. GENERATOR
SIDE STAND SWITCH IGNITION COIL SPARK PLUG
MAIN SWITCH
BLUE/YELLOW BLACK/WHITE GREEN/RED BLACK/YELLOW
GREEN
BLACK
GREEN RED
+
PULSE GENERATOR
BATTERY (12V 10AH)
PINK
AC.GENERATOR
CDI UNIT
15-0
GREEN
(15A)
TO.LIGHT RELAY
FUSE
BLUE/YELLOW
GREEN
15. IGNITION SYSTEM

SERVICE INFORMATION 15-1 TROUBLESHOOTING 15-3 CDI UNIT INSPECTION 15-7 PULSE GENERATOR INSPECTION 15-4 IGNITION COIL INSPECTION 15-5 IGNITION TIMING INSPECTION 15-6 SIDE STAND IGNITION CUT-OFF SWITCH 15-6
SERVICE INFORMATION
GENERAL SAFETY
Follow the steps described in the troubleshooting flow chart when servicing the ignition system. The CDI unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the unit. Always turn off the ignition switch before servicing. The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing. Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color couplers. 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 18 )
SPECIFICATIONS
ITEM STANDARD VALUE
SPARK PLUG SPARK PLUG GAP PRIMARY COIL IGNITION COIL RESISTANCE VALUE 20 WITH PLUG CAP SECONDARY COIL WITHOUT PLUG CAP PULSE GENERATOR COIL RESISTANCE VALUE 20
NGK CR8EH-9 0.8~0.9mm 0.1 ~ 0.2 7.3 ~ 11 3.6 ~ 4.6 90 ~ 150
15
TOOLS
DIGITAL TESTER PVA MULTI-TESTER CDI TESTER
15-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug.
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 (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. Poorly connected connectors or an open circuit in ignition system. 5. Faulty ignition system control circuit such as side stand switch. 6. Faulty ignition coil. 7. Faulty CDI unit (in case when above No. 1~6 are normal). 1. Incorrect peak voltage adaptor connections. 2. Faulty ignition switch. 3. Loose or poorly connected CDI unit connector. 4. Open circuit or poor connection in ground cord of the CDI unit. 5. Faulty ignition system control circuit such as side stand switch. 6. Faulty peak voltage adaptor. 7. Faulty CDI unit (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 pulse generator.
15-2
IGNITION COIL PRIMARY VOLTAGE PULSE GENERATOR
No peak voltage.
Peak voltage is normal, but no spark jumps at plug.
Low peak voltage.
No peak voltage.
IGNITION SYSTEM
CDI UNIT INSPECTION

CDI IGNITION CIRCUIT INSPECTION
Follow the steps described in the troubleshooting flow chart when servicing the ignition system. Release the seat lock with the main key. Remove the luggage box. (3-3) Disconnect the coupler from the CDI unit, and check the ignition system circuits from the wiring coupler side. Inspection Items
ITEM INSPECTION
MAIN SWITCH
Check that there is battery voltage between main switch wire (black) and ground wire when the ignition is ON
Check that the resistance of coil (between blue / PULSE yellow and green) is within the specified range. GENERATOR ( 90~150, 20) Check that the resistance of coil (between black IGNITION COIL (PRIMARY COIL) / yellow and green) is within the specified range. ( 0.1~0.2, 20) GROUND WIRE Check continuity between ground and frame.
CDI UNIT
If there are a normality in the diagonosis above, and if there is no spark at plug, check the CDI unit and ignition coil by using a CDI tester.
TOOLS : CDI TESTER DIGITAL TESTER
Read tester manual carefully prior to using the tester. Replace the CDI unit if faulty. Install in the reverse order of removal.
PULSE GENERATOR INSPECTION

RESISTANCE MEASUREMENT
Release the seat lock with the main key. Remove the luggage box. (3-3) Disconnect the A.C generator 4P coupler and the blue / yellow wire connector. Measure the resistance between the green and blue / yellow.
STANDARD VALUE : 90~150 (20)
PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire connector. Connect the peak voltage adaptor probes to the pulse generator wire terminal of the wire harness side connector and ground. Crank the engine with the kick starter or starter motor and measure the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V TOOL : PVA MULTI TESTER

15-3
IGNITION SYSTEM
IGNITION COIL INSPECTION

Remove the seat lock with the main key. Remove the luggage box. Remove the center cover. Remove the primary wire.
Since the resistance value of the primary coil is inherently very small, it is difficult to distinguish it from a shorted wire.
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 : 1.5~3.5
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.
STANDARD VALUE : 17~21
Measure resistance between the primary coil terminal and high-tension cord. If the resistance value is within the specified range, then the coil is good. If the resistance is (open wire), replace the coil with a new one.
STANDARD VALUE : 12~16
REPLACEMENT
Remove the high-tension cord from the plug, remove the plug cap. Remove the wire from the ignition coil. Remove the primary wire from the ignition coil. Loosen the ignition coil fixing bolt securing the frame, Remove the ignition coil. Install in the reverse order of removal.
15-4
IGNITION SYSTEM
IGNITION TIMING INSPECTION

As the system uses the CDI unit, the ignition timing need not be adjusted. Check the ignition system if the ignition timing is incorrect.
TIMING CHECK
Start and warm up the engine. Remove the plug maintenance cover. Connect the timing light to the high-tension cord.
Read the timing light manual prior to using it. Remove the timing hole cap from the RH. shroud, and start the engine. If the F mark on the rotor is aligned with the index mark on the case at the correct idling speed, then the timing is correct.
IDLING SPEED : 15 BTDC 1, 800 rpm
TIMING LIGHT
Increase engine speed by rotating the stop screw on the carburetor. At the engine speed greater than 4,000rpm, the ignition timing is correct if the index mark is set within the advance mark. Install in the reverse order of removal.
SIDE STAND IGNITION CUT-OFF SWITCH

INSPECTION
Remove the floor mat. Remove the RH. floor side cover. (3-4) Remove the coupler of the side stand switch.
Check for continuity between the terminal as shown below ;

ITEM TERMINAL SPECIFICATION
ON (Side stand is lowered) OFF (Side stand is retracted)
BLACK AND BLACK/BLUE BLACK AND BLACK/BLUE
NO CONTINUITY CONTINUITY
15-5
IGNITION SYSTEM
REMOVAL
Remove the floor mat. Remove the center cover. (3-3) Remove the RH. floor side cover. (3-4) Remove the coupler of the side stand switch. Remove the LH. floor side cover. (3-4) Loosen the side stand switch mounting 2 bolts. Release the wire clamps and remove the side stand switch.
INSTALLATION
Install in the reverse order of removal. Check the side stand ignition cut-off switch. - Put the side stand up. - Start the engine. - Lower the side stand. The engine should stop as you put the side stand down.
SIDE STAND SWITCH
15-6
MEMO
STARTER SYSTEM
STOP SWITCH
BATTERY
MAIN SWITCH
STARTER MOTOR
STARTER CABLE RELAY CABLE
GREEM/YELLOW GREEM/YELLOW STOP LAMP YELLOW/RED GREEN FR.STOP SWITCH RR.STOP SWITCH GREEN MAIN SWITCH BLACK FUSE (15A) STARTER SWITCH
STARTER MOTOR
BATTERY (12V 10AH)
16-0
16. STARTER SYSTEM

SERVICE INFORMATION 16-1 STARTER DEVICES LOCATION 16-2 TROUBLESHOOTING 16-3 STARTER MOTOR 16-4 STARTER MAGNETIC SWITCH 16-7
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. The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over. The engine may not be turned over if the stop switch is faulty.
SPECIFICATION
ITEM STARTER MOTOR BRUSH LENGTH STANDARD VALUE 10.2 mm SERVICE LIMIT 5 mm
TOOLS
DIGITAL TESTER VERNIER CALIPER
16
16-1
STARTER SYSTEM
TROUBLESHOOTING
Starter motor will not turn.
Check for a blown main fuse before servicing. Check that the stop light is correctly adjusted. Check that the side stand is positioned in the condition under which the engine can be started.
With the ignition switchONand squeeze the brake lever, check for click sound a from starter magnetic switch. (16-6)
CLICKS
Connect the starter motor (+) terminal to the battery positive terminal. (Because a large amount of current flows, do not use thin wires). (16-3) Starter motor does not turn.
NO CLICK. Starter motor turns. Faulty starter motor. Disconnect starter magnetic switch coupler, and check the starter magnetic switch coil ground wire. (17-7) Loose or disconnected wire or cable. NO CONTINUITY. Faulty starter switch. Faulty side stand switch. Loose or poor contact at connector. Open circuit in wire harness.
CONTINUITY. Connect the starter magnetic switch coupler. Measure the starter magnetic voltage at the starter magnetic switch coupler. (16-6) VOLTAGE MEASURED. Check the starter magnetic switch operation. (17-8) ABNORMAL NORMAL
NO VOLTAGE.
Faulty ignition switch or starter switch. Loose or poor contact at connector. Open circuit in wire harness. Faulty brake stop switch. Loose or poor contact at starter magnetic switch coupler. Faulty starter magnetic switch.
Starter motor turns slowly.

Low specific gravity in battery. (or dead battery) Poorly connected battery terminal cable. Poorly connected starter motor cable. Faulty starter motor. Poorly connected battery ground cable. Damaged or worn brush.
Starter motor and engine turns, but engine does not start.
Faulty ignition system. Engine problems.
Starter motor turns, but engine does not turn over.

Starter motor is running backwards. -Brushes assembled improperly. -Case assembled improperly. -Terminals connected improperly. Faulty starter clutch. Damaged starter gear.
16-2
STARTER SYSTEM
STARTER MOTOR
REMOVAL
Release the seat lock with the main key. Remove the luggage box. (3-3) Remove the starter motor cable from the starter magnetic switch. Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor. Install in the reverse order of removal.
FLANGE BOLTS
STARTER MOTOR
STARTER MOTOR INDEX MARK
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. Accurately tighten the battery earth cable.
DISASSEMBLY
Remove the starter motor cable. Before disassembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later. Loosen the starter motor case bolts and remove the motor cover.
SETTING BOLTS
INSPECTION
REAR BRACKET BRUSH
Check for continuity of the starter motor case. -Between cord terminal and bracket: normal if no continuity. -Between cord terminal and brush : normal if there is continuity. If abnormal, replace with a new one.
CORD TERMINAL
TERMINAL
Loosen the brush terminal setting nut, remove the brush holder set. Check for continuity between and terminals of the brush holder. If there is continuity, replace with a new one.
BRUSH HOLDER SET TERMINAL
16-3
STARTER SYSTEM
Remove the brush spring, and then remove the brush. Measure the brush length. Replace the brush if it is worn beyond the service limit.
BRUSH SERVICE LIMIT : 5 mm TOOL : VERNIER CALIPER
If replacement, replace with a brush holder set.
Check the commutator for : -Damage or abnormal wear. Replace with a new one. -Discoloration of the commutator bar. Replace with a new one. -Metallic debris between commutator bars. Clean it off.
COMMUTATOR
COMMUTATOR BARS
Check for continuity between pairs of commutator bars. Make a continuity check between individual commutator bars and the armature shaft. There should be no continuity.
ARMATURE SHAFT
NEEDLE BEARING
Check the needle bearing and oil seal. -Do not rotate smoothly. Replace with a new one. -Damage oil seal. Replace with a new one.
OIL SEAL
16-4
STARTER SYSTEM
STARTER MOTOR ASSEMBLY
Install the brush and brush spring to the brush hold set. Insert the brush terminal into the rear bracket, and install the terminal set and flange nut. Align the brush holder set with the rear bracket groove, and install the brush holder set. Apply grease to both ends of the armature shaft, and install the 2 washers.
BRUSH HOLDER SET REAR BRACKET
Push and hold the brush inside the rear bracket, and insert the armature into the rear bracket groove. Align the case mark with the rear bracket mark, and install the case. Insert the thrust washer (0.5t), thrust washer (0.2t), slip washer and thrust support.
REAR BRACKET
The sliding surfaces of the brushes can be damaged if they are not installed properly. When inserting the armature into the case, hold the armature tightly to keep the magnet from pulling the armature against the case. Align the front bracket with the case mark, and install the front bracket.
FRONT BRACKET
CASE REAR BRACKET
Tighten the motor cover bolts.
When installing the cover, take care to prevent damaging the oil seal lip with the shaft. Overtightening the starter motor cable terminal nuts may cause the inside the starter motor, resulting in serious damage to the inner connectors.
SETTING BOLTS
16-5
STARTER SYSTEM
STARTER MOTOR CABLE
STARTER MAGNETIC SWITCH

REMOVAL
Release the seat lock with the main key. Remove the luggage box. (3-3) Remove the center cover. (3-3) Remove the battery (+) cable from the starter magnetic switch terminal. Remove the starter motor cable from the starter magnetic switch terminal. Disconnect the yellow / red connector and green / yellow connector from the wire harness. Remove the starter magnetic switch from the switch setting bracket securing the frame. Install in the reverse order of removal.
BATTERY CABLE
INSPECTION
Check if the starter magnetic switch clicks when it is turned ON. -Clicks Poorly connected battery terminal and motor terminal of the switch. (Check the starter magnetic switch) -No clicks No starter magnetic switch input voltage. (Faulty relay ground line and starter magnetic switch)
Starter magnetic switch voltage

Measure the voltage between the yellow / red wire (+) and ground at the starter magnetic switch connector. If battery voltage appears only when the starter switch is pressed, it is normal.
Starter magnetic switch ground line

WIRE CONNECTOR
Disconnect the wire connector from the starter magnetic switch and check for continuity between the ground wire (green / yellow) and ground.
16-6
STARTER SYSTEM
OPERATION CHECK
Disconnect the magnetic switch wire connector. Apply battery voltage between terminals, when the yellow / red wire is connected to the positive (+) battery terminal and the green / yellow wire to the negative (-) battery terminal. If there is continuity between battery and motor terminal, it is normal.
16-7
MEMO
17. LIGHTS/SWITCHS/HORN
SERVICE INFORMATION 17-1 TROUBLESHOOTING 17-1 MAIN SWITCH 17-2 HANDLE SWITCH 17-2 HORN 17-3 FUEL UNIT 17-3 THERMOSTATIC SWITCH 17-4 HEATER CONTROLLER UNIT 17-4 HEADLIGHT CONTROLLER 17-4 COOLANT TEMPERATURE GAUGE 17-5 THROTTLE POSITION SENSOR 17-5 HEADLIGHT BULB REPLACEMENT 17-6 FRONT WINKER REPLACEMENT 17-6 TAI LIGHT/REAR WINKER BULB REPLACEMENT 17-6 FUSE CAPACITY 17-7
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.
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
17
Headlight Hi-Low bean cannot be charged

Faulty light bulb Faulty dimmer switch
17-1
LIGHTS/SWITCH/HORN
MAIN SWITCH
Remove the front covers. Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. RED
OFF ON
BLACK
HANDLE SWITCH
Remove the headlight. Disconnect the connector of handle switch. Check for continuity between teminals. Remove the Fr. cover. Remove the coupler wire. Test each teminal of handle switch.
HEADLIGHT SWITCH
LIGHTING BAT3 OFF P H COLOR Br/L Br Br/W TL HL
WINKER SWITCH
W R N L COLOR GREY SKY BLUE ORANGE R L
HORN SWITCH
HO FREE PUSH COLOR
17-2
BAT2
LIGHT GREEN
BLACK
LIGHTS/SWITCH/HORN
PASSING SWITCH
BAT2
HI COLOR
HI BLUE
BLACK
DIMMER SWITCH
BAT4 HI (N) LO COLOR BROWN/WHITE BLUE WHITE BLACK HI LO BAT2
HORN
Remove the horn from the wire connector. Connect the horn terminal with 12V battery. Normal if it sounds.
FUEL UNIT
Remove the foor panel. Be cover full not to be damaged for the wire. Check the base packing for damage. Measure the resistance between the fuel unit upper and lower.
COLOR Y/W~L/W
UPPER 1.8~1.2
LOWER 70~130
17-3
LIGHTS/SWITCH/HORN
HEADLIGHT BULB REPLACEMENT

Remove the front cover. Remove the headlight coupler and winker coupler. Remove the bulb socket of rubber boots. Remove the rubber boots. Replace the headlight bulb.
When replacing the bulb, be sure not to put finger and contaminated gloves prints on the headlight bulb, as they may create hot spots on the bulb and cause is to fail. Note the following when replacing the bulb. - Do not replace while the headlight is ON. After it is turned OFF, be sure to let it cool down before servicing. - Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb. - If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol and clean it with a clean cloth again. - Be sure to install the rubber cover after replacing the bulb.
FRONT WINKER BULB REPLACEMENT

Loosen the 2 screws, remove the winker lens. Replace the winker bulb.
TAILLIGHT/REAR WINKER BULB REPLACEMENT

Loosen the 2 screws of taillight. Remove the taillight lens and winker lens. Replace the taillight bulb and winker bulb.
17-4
18
FR. STOP SW.
LIGHT/START SW.
COMB. SW. 12V 1.4W

BAT 2 BAT 1 BAT 1
BAT3
TRUNK LAMP SWITCH
CHARGE SOCKET CHARGE SOCKET
FUEL UNIT
ST. HL TL
Br/L
Y/R
G/Y
Br
R R Y/W
BATTERY
Br Br/L
3P MINI
G/Y
Y/R
G R
2P MINI
Y/R
G/Y
G R
L/W
6P MINI
Y/W
6P MINI 2P
(ENGINE)
B
Y/R
G/Y
L/W
12V 10AH
G/Y
2P MINI
Sb
Gr
P/W
G/Y
Sb
Br Br/L
Y/R
G G Sb B
G R
FUSE 15A
R
RH. FR. WINKER 12V 10W
Y/R
ENGINE EARTH
FRAME EARTH
Br
METER ILLUM. 12V 2WX2
G
Br
G
Sb G
COMBINATION METER ASSY.
RH. RR. WINKER 12V 10W
FUEL METER
Y/W L/W
Br/L
G G
Sb
Sb
6P MINI
G/Y
G/Y
G/Y
Br
O Sb 6P MINI Sb B O
Br
Br
Br
Br
STOP & TAIL LIGHT
Br/L
Y/W Y/W L/W L L/W
12V 21/5W
HIGH BEAM 14V 3W

G Sb G
TURN RH. 14V 3W

Br/W
2P MINI
Gr
TURN LH. 14V 3W

O
Br/L
LH. RR. WINKER 12V 10W
Br
Br
G
2P MINI
Br/W
2P MINI
Br P/W
SIDE STAND SWITCH
WINKER RELAY
O G
O G
Br/W
LICENSE LIGHT 12V 5W
G
P/W
4P
18. WIRING DIAGRAM
LH. FR. WINKER 12V 10W

L
Br
W L
Br
9P MINI
Sb
Gr Lg
B G/Y
G B/W
Br/W W L Sb O Gr Lg B G/Y
HEAD LIGHT(LOW) 12V 55W
L/Y
2P MINI
G /
B G/Y Br/W W L Sb O Gr Lg B
4P
G W
R G B/W
2P MINI
R Y
Y Y
Y Y
G Y Y
L/Y
Br/W
Br
B/W
Lg
POSITION LIGHT 12V 5W
WINKER,DIMMER,PASSING,HORN S/W.
RR. STOP SW.
HL HL LO(BAT4) HI (BAT2) R
W HO BAT2
B G L / / G / R Y Y
6P REG.RECTI
B/Y G
AUTO B/S
FILLER CAP
G L
DC CDI UNIT
LIGHT RELAY(CDI)
HEAD LIGHT(HIGH) 12V 55W
HORN
IGNITION COIL
PULSE GEN.
A.C.G
COMB. SW.
BAT1 BAT2
START
ST E
LIGHTING
BAT3 TL HL
WINKER
W R L
HORN
Ho BAT2
DIMMER
BAT 4
PASSING
HI LO BAT 2 BAT2 Hi
SIDE STAND SW. TRUNK LAMP

E CDI BAT1 BAT1
ON OFF LOCK
COLOR R B
FREE PUSH
COLOR Y/R G
OFF P H
COLOR Br/L Br P
R N L
COLOR Gr Sb O
FREE PUSH
COLOR Lg B
Hi (N) Lo
COLOR Br/W L W B
FREE PUSH
COLOR B L
FREE PUSH
COLOR G B/W
FREE PUSH
COLOR R R
V B Y L G R W
VIOLET BLACK YELLOW BLUE GREEN RED WHITE
Br O Sb Lg P Gr
BROWN ORANGE SKY BLUE LIGHT GREEN PINK GRAY COLOR COMB. : GROUND/MARKING
18-1
2P MINI
SERVICE MANUAL
2004. 11. PRINTED 2004. 11. PUBLICATION
NO COPY
HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997
SM51-0411-01E

Daelim s2 125 Service Manual

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What are the main sections covered in the manual?

What are the main sections covered in the manual?

What safety precautions should be followed when working with the battery?

What safety precautions should be followed when working with the battery?

HOW TO USE THIS MANUAL

SERVICE INFORMATION INSPECTIONS/ADJUSTMENTS EXTERNAL PARTS LUBRICATION SYSTEM FUEL SYSTEM

ENGINE ELECTRICAL SYSTEM FRAME

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

CAUTION WHEN WIRING

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.

SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

FRONT REAR FRONT REAR

FULL CAPACITY RESERVE CAPACITY

THREAD DIA (mm)

Apply engine oil

THREAD DIA (mm)

STANDARD TORQUE VALUES

The following symbols indicate oil adding, oil change, or parts.

OIL GREASE (3-1)

The following abbreviations are used in this manual.

WIRE CLAMP EARTH WIRE C.D.I UNIT WIRE

BRAKE HOSE CLAMP SPEEDOMETER CABLE

FUEL UNIT COUPLER TUBE CLAMP

WIRE CLIP RH. RADIATOR HOSE WIRE GROMMET SPEEDOMETER CABLE

RR. BRAKE HOSE

WIRE HARNESS SIDE STAND SW. COUPLER

IGN. COIL AUTO CHOKE COUPLER

WIRE CLIP LH. SEAT LOCK COUPLER

HEAD LIGHT RELAY WINKER RELAY

REG. RECTIFIER REG. RECTIFIER CORD BATTERY + CABLE

FRAME BODY COMP. BATTERY + CABLE SPARE FUSE(15A) FUSE WIRE

CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE

TIRE SIZE MIN, TREAD DEPTH

TRANSMISSION OIL BRAKE FLUID VALVE CLEARANCE

FUEL LINE(FUEL TUBE)

THROTTLE GRIP OPERATION

LOCK NUTS LOCK NUTS LOCK NUTS

ADJUSTRING NUTS ADJUSTRING NUTS ADJUSTRING NUTS

CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER

VALVE CLEARANCE : Intake : 0.120.02mm Exhaust : 0.120.02mm

CHECK WASHER FOR DAMAGE CHECK FOR CRACKS

CYLINDER COMPRESSION PRESSURE

SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG

The maximum reading is usually reached within 4~7 seconds.

CARBURETOR IDLE SPEED

FINAL REDUCTION GEAR OIL

Make sure that the sealing washer is good condition.

GEAR OIL REPLACEMENT

Make sure that the sealing washer is good condition.