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

SM49-0406-01E
 HOW TO USE THIS MANUAL CONTENTS
This manual describes effective maintenance procedure
for the Cordi manufactured by DAELIM Motor Co., Ltd.
To ensure safety and optimal operating conditions of the
vehicle, carry out regular inspections according to the SERVICE INFORMATION 1

GENERAL
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
INSPECTIONS/ADJUSTMENTS 2
maintenance procedure for the engine, frame and electrical
systems. EXTERNAL PARTS 3
To facilitate use of this manual, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide. If you cannot find the cause of LUBRICATION SYSTEM 4
trouble, refer to Section 18: Troubleshooting.
FUEL SYSTEM 5

ENGINE
Contents of this manual and specifications are ENGINE REMOVAL/INSTALLATION 6
subject to change without prior notice for
improvement of vehicle quality. KICK STARTER/ CONTINUOUSLY
No part of this publication may be reproduced VARIABLE TRANSMISSION 7
without written permission of DAELIM Motor Co.,
Ltd.,
CYLINDER HEAD/CYLINDER/PISTON 8
TRANSMISSION/CRANKSHAFT/CRANK CASE 9
FRONT WHEEL/FRONT FORK/STEERING 10
FRAME

REAR WHEEL/BRAKE/SUSPENSION 11
BRAKE SYSTEM 12
ELECTRICAL SYSTEM

BATTERY/CHARGING SYSTEM 13
IGNITION SYSTEM 14
STARTING SYSTEM 15
LIGHTS/METER/SWITCHES 16
WIRING DIAGRAM 17
TROUBLESHOOTING 18
1. SERVICE INFORMATION

GENERAL SAFETY 1-1 TWIST TORQUE 1-14

SERVICE RULES 1-1 SPECIALIZED TOOLS 1-16
1
CAUTION WHEN WIRING 1-5 LUBRICATION OIL 1-17
SERIAL NUMBER LOCATION 1-9 SYMBOLS 1-18
MAINTENANCE INFORMATION 1-10 WIRING DIAGRAM 1-19

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 worker’s 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 2. Before maintenance, remove deposit or dust from the
recommended parts. chasis.

1-1
SERVICE INFORMATION
3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter
each part in the right place. pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.

5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data
remove the cleaning oil with compressed air. Apply oil during installation. When installing, return to the state
to seal face during installation. before removing.

7. Align the bolts to uniform the tightening points before 8. Bolts, nuts and pieces must be tightened from the bigger
tightening them when you don’t know the bolt length. 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 10. Recommended grease must be applied to or filled in
removing it and replace it if necessary. Some rubber part the specified place.
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.

1-2
 SERVICE INFORMATION
11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
be performed with the right tool. applied pressure when removing press-fitted the
bearing.

13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the
ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open-
Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way
longitudinal hanging. that the face marked with manufacturer and size
Wipe the ball bearing likely to have hanging with should direct to the outer axle.
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.

’
15. When blowing the ball bearing with compressed air 16. Install the snap ring so that chamfered side directs to
after cleaning, keep the race from rotating. High speed the load-applied side. After installation, check the
rotation of the race may damage the bearing. Prior to proper installation by rotating the snap ring.
installation, apply oil or grease to the bearing.

17. Check each part for proper tightening and operation 18. The brake fluid and coolant can damage the painted
after installation. 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 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
Pay attention not to bend or damage the lip.
Apply the grease to the lip.

21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of
interior from the infiltration of dust. 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. 24. Install the boots with the installing groove by inserting
Transformed or damaged cable may cause malfunction the boots into the groove.
or damage.

1-4
 SERVICE INFORMATION

CAUTION WHEN WIRING

Each cord must be connected depending on its color. When measuring voltage or resistance of the cord
When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of
around the connector. Connect the coupler to the the coupler. Pay attention not to open the cord terminal
connector with same color and same pin number. and contact the tester plug from the front of the coupler
Identify the two-colored cord by main color first and in case of water-proof coupler.
then spriped color .

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 Connect covers to the terminal after maintenance.
must be disconnected first.
Make sure that the tool such as spanner do not contact
with the frame.

If the fuse is short-circuited, find out the cause and If there is rust in the terminal, remove the rust with sand
repair. Replace with the fuse having the specified paper prior to connecting.
capacity.

VALIDATION REMOVE
OF CAPACITY! THE
RUST!

1-5
SERVICE INFORMATION
Turn off the main switch before connecting/dis- When disconnecting the coupler, disconnect it while
connecting. holding the coupler body. Pull while holding the wire
Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.

Insert the lock of the coupler until the lock is fully

secured.

Release the lock by inserting the coupler slightly and Pay attention not to damage the vinyl cover of the
then narrowing connection to remove the coupler. coupler.

Check to see if there is bended terminal and secure it to If the wire harness coating is damaged, repair by
avoid disconnecting. 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 When removing T-start, broaden the groove of T-start
inserted into the terminal. using the wiring driver and release the torque.
The opening of the vinyl cover must face at the ground Connect the harness and the hose to T-start and then
direction but in case of the plain connector, the draining insert until the groove is locked.
opening must face at the sky direction. When removing T-start from the frame, replace it with
the new one.

Wire band must be secured firmly in the specified Secure the wire harness firmly using the clamp.
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.

In case of the weld clamp, do not clamp in the welded When clamping the wire harness, make sure that the
part. harness is not contacted with the shaft or rotating part.

When clamping the wire, pay attention not to contact The wire harness must be routed without contacting
with hot part. 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 wire must not hang down or be pulled excessively.
the sharp edge, protect both parts with tube or tape.

NOT TO
PULL!

If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness
is not pressed by the parts.

Do not twist the wire harness. Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.

Prior to using the tester, please read the manual care- Do not drop or throw the parts especially
fully and understand the contents. semiconductor contained parts because these parts may
When testing the resistance of the tester, the zero be damaged by the impact of the drop.
adjustment must be performed before testing.

Is this
measurement range or
configuration in accord
with the manual?

1-8
 SERVICE INFORMATION

SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

1-9
SERVICE INFORMATION

SPECIFICATIONS
ITEM SPECIFICATIONS ITEM SPECIFICATIONS

TYPE OF VEHICLE Cordi BRAKING DISTANCE 8.0m(30km/h )

OVERALL LENGTH 1,715mm MIN. REVOLUTION RADIUS 1,800mm

OVERALL WIDTH 665mm COOLING TYPE AIR-COOLED

OVERALL HEIGHT 1,053mm STARTING STARTER MOTOR, KICK

WHEEL BASE 1,227mm MOTOR TYPE 2-CYCLE

MOTOR TYPE SE50E NO. OF CYLINDERS, MOUNTING 1 CYLINDER, TRANSVERSE

DISPLACEMENT 49.5cc VALVE APPARATUS READ VALVE PISTON VALVE COMBINATION

FUEL TYPE UNLEADED GASOLINE BORE & STROKE 40X39.4mm

FRONT AXLE 28.8kg COMPRESSION RATIO 7.3:1

DRY WEIGHT 5.7PS/7,000rpm
REAR AXLE 47.7kg MAX. OUTPUT (2.95PS/6,000rpm)
0.63kgf·m/6,500rpm
TOTAL 76.5kg MAX. TORQUE (0.35kgf·m/5,500rpm)
PASSENGERS 1(65kg) PRIMARY SPEED REDUCTION RATIO 3.077

GROUND CLEARANCE 105mm SECONDARY SPEED REDUCTION RATIO 3.461

CASTER 27。 TRANSMISSION NON STAGE TRANSMISSION

TRAIL 69mm TRANSMISSION RATIO 1ST GEAR 2.41~0.76

FRAME TYPE UNDER BONE

“( )” MARKED CONTENTS APPLY TO EUROPE ONLY.

1-10
 SERVICE INFORMATION

ITEM STANDARD USE LIMITS

1.2 liters
ENGINE OIL TANK CAPACITY FULL CAPACITY
Motix, 2-Cycle Oil
RECOMMENDED ENGINE OIL
LUBRICATION SYSTEM 0.09 liters
TRANSMISSION OIL CAPACITY FULL CAPACITY
DMC Pure Mission Oil or
RECOMMENDED TRANSMISSION OIL
SAE 80W/90
Separation Lubrication
OIL FILTER TYPE
LUBRICATION TYPE Current Filtration,
OIL PUMP TYPE
Plunger Type
COOLING TYPE COOLING TYPE Air-Cooled

FUEL TANK CAPACITY FULL CAPACITY4.8ℓ

AIR CLEANER TYPE Urethane Foam
CARBURETOR SETTING MARK PA35
VENTURI DIAMETER 14mm
AIR SCREW OPENING 1 1/2 Rotation(1 1/8 Rotation)
FUEL SYSTEM FLOAT LEVEL 12.2
IDLING RPMS 2,000rpm
NO. OF JET NEEDLES 2
MAIN JET #77(#65)
SLOW JET #38(#35)
THROTTLE GRIP CLEARANCE 2-6mm

PORT OPEN/CLOSE PERIODS INHALATION

OPEN Auto Control
CLOSE Auto Control
EXHAUST OPEN 80.5。BBDC
CLOSE 80.5。ABDC
SCAVENGING OPEN 55。BBDC
CLOSE 55。ABDC
CYLINDER HEAD COMPRESSION PRESSURE 12.0kgf/㎠-600rpm
CYLINDER ID MARK LOCATION Top of Cylinder
INSIDE DIAMETER ID MARK(A) 40.005 ~ 40.010mm
NO ID MARK 40.010 ~ 40.015mm
CYLINDRICAL DEGREE - 0.10mm
OUT OF ROUNDNESS - 0.10mm
PISTON OUTSIDE DIAMETER
ID MARK(A) 39.955 ~ 39.960mm
CYLINDER HEAD, ID MARK(B) 39.965 ~ 39.970mm
CYLINDER, NO ID MARK 39.960 ~ 39.965mm
PISTON CYLINDER AND PISTON
CLEARANCE 0.040 ~0.055mm
PISTON PIN HOLE INSIDE
DIAMETER 12.002 ~ 12.008mm
PISTON PIN OUTSIDE
DIAMETER 11.994 ~ 12.000mm
PISTON AND PISTON PIN
CLEARANCE 0.002 ~ 0.014mm
PISTON RING GAP TOP 0.15 ~ 0.3mm
SECOND 0.15 ~ 0.3mm
RING MARK Turning up
CONNECTING ROD SMALL END PORTION
DIAMETER 17.005 ~ 17.017mm 17.03mm

“( )” MARKED CONTENTS APPLY TO EUROPE ONLY.

1-11
SERVICE INFORMATION

ITEM STANDARD USE LIMITS

CLUTCH AUTOMATIC Automatic Centrifugal

TYPE Continuously Variable Transmission
CLUTCH OUTER DIAMETER 107.0~ 107.2mm
CLUTCH LINING THICKNESS 4.0mm

CLUTCH DRIVE BELT WIDTH 15mm

MOVABLE DRIVE FACE
BUSH INSIDE DIAMETER 20.035~ 20.085mm
BOSS OUTSIDE DIAMETER 20.011~ 20.025mm
WEIGHT ROLLER OUTSIDE DIAMETER 15.92~ 16.08mm

DRIVEN PULLEY FACE SPRING FREE LENGTH 98.1mm

FACE OUTSIDE DIAMETER 33.965~ 33.985mm
MOVABLE FACE INSIDE DIAMETER 34.000~ 34.025mm

CRANK SHAFT LARGE END SIDE CLEARANCE 0.15~0.55mm 0.60mm

CRANK SHAFT CONNECTING ROD LARGE END RIGHT
ANGLE DIRECTION CLEARANCE 0.010~0.02mm 0.04mm
CRANK SHAFT SHAKING A 0.05mm(70mm from center) 0.15mm
B 0.03mm(37mm from center) 0.10mm

WHEELS RIM RUNOUT RADICAL - 2.0mm

AXIAL - 2.0mm
AXLE DEFLECTION - 0.2mm
FRONT,
REAR WHEELS TIRES TYPE TUBELESS -
TIRE PRESSURE FRONT 1.25㎏f/㎠ -
REAR 2.00㎏f/㎠ -
TIRE SIZE FRONT 90/90-10-50J -
REAR 90/90-10-50J

1-12
 SERVICE INFORMATION

ITEM STANDARD USE LIMITS

FRONT BRAKE LEVER FREE PLAY 10~20mm -
BRAKE FLUID DOT3 or DOT4 -
BRAKE PAD THICKNESS - to wear line
DISK THICKNESS 3.0mm 2.5mm
DISK SHAKING - 0.3mm
DISK WEAR LINE 2.5mm
MASTER CYLINDER INSIDE DIAMETER 11.000-11.043mm 11.05mm
BRAKES
MASTER PISTON OUTSIDE DIAMETER 10.957-10.984mm 10.91mm
CALIPER CYLINDER INSIDE DIAMETER 30.230-30.280mm 30.29mm
CALIPER PISTON OUTSIDE DIAMETER 30.148-30.198mm 30.14mm
REAR BRAKE LEVER FREE PLAY 10~20mm -
DRUM INSIDE DIAMETER 95mm 95.5mm
LINING THICKNESS 4.0mm 2.0mm

SPARK PLUG STANDARD BP6HS(BPR6HS)

OP (at low speed) B4HSA(BR4HSA)
OP (at high speed) BP7HS(BPR7HS)
PLUG GAP 0.6~0.7mm
IGNITION TIMING F MARK BTDC 15。
/2,000rpm
IGNITION PEAK VOLTAGE IGNITION COIL(PRIMARY VOLTAGE) 300V ±25V
SYSTEM EXCITE COIL over 100V
PULSE GENERATOR over 2.8V
IGNITION COIL RESISTANCE VALUES(20℃)
PRIMARY COIL 0.1~0.5Ω
SECONDARY COIL(PLUG CAP CONNECTION) ㏀
6.3~10.3㏀
SECONDARY COIL(PLUG CAP DISCONNECTION) ㏀
2.8~3.8㏀
EXCITE COIL RESISTANCE VALUE(20℃) 50~200Ω
PLUSE GENERATOR RESISTANCE VALUE(20℃) 400~800Ω

AC GENERATOR TYPE AC
OUTPUT 12V-11A/5,000rpm
CHARGING COIL RESISTANCE VALUE(20℃) 0.4~1.0Ω
LIGHTING COIL RESISTANCE VALUE(20℃) 0.2~0.8Ω
CHARGING REGULATOR/RECTIFIER TYPE Semi-conductor
SYSTEM, AC
CONTROL VOLTAGE LAMP SIDE 12.0~14.0V/5,000rpm
GENERATOR
CHARGING SIDE 13.0~15.0V/5,000rpm
REGISTER RESISTANCE VALUE REGISTER(6.7Ω 5W) 6.3-7.1Ω

“( )” MARKED CONTENTS APPLY TO EUROPE ONLY.

1-13
SERVICE INFORMATION

ITEM STANDARD USE LIMITS

LIGHTS, BULBS HEADLIGHT 12V-35/35W

TAIL/STOP LIGHT 12V-5/21W
WINKER LIGHTS FRONT 12V-10W×2
REAR 12V-10W×2
LIGHTS,
HIGH BEAM LAMP 12V-3W×1
METER,
OIL LEVEL INDICATOR LAMP 12V-3W×1
SWITCHES
WINKER PILOTS 12V-3.0W
FUSE 7A
METER LIGHTS 12V-1.7W×2
LICENCE LAMP 12V-4W×1

TYPE MF BATTERY
CAPACITY 12V-3AH
BATTERY TERMINAL VOLTAGE(20℃) 13.0~13.2V
CHARGING CURRENT/STANDARD 0.4A/5h
CHARGING CURRENT/RAPID 4A/0.5h

TWIST TORQUE
ENGINE
TWIST PART NUMBER SCREW DIAMETER (mm) TWIST TORQUE REFERENCE
FLY WHEEL NUT 1 10 4.0㎏f·m
DRIVE FACE NUT 1 12 5.5㎏f·m
CYLINDER HEAD BOLT 4 6 1.0㎏f·m
SPARK PLUG 1 14 1.4㎏f·m
DRIVEN FACE NUT 1 28 5.5㎏f·m
CLUTCH OUTER NUT 1 10 4.0㎏f·m
OIL LEVEL CHECK BOLT 1 8 1.3㎏f·m
EXHAUST PIPE JOINT NUT 2 6 1.2㎏f·m
MUFFLER BRACKET BOLT 2 8 3.3㎏f·m
CRANK CASE BOLT 6 6 1.0㎏f·m

1-14
 SERVICE INFORMATION

FRAME PARTS

TWIST PART NUMBER SCREW DIAMETER TWIST TORQUE REFERENCE

STEERING STEM LOCK NUT 1 - 7.0㎏f·m
HANDLE POST TWIST NUT 1 10 5.0㎏f·m
FRONT BRAKE LEVER PIVOT BOLT 1 6 1.0㎏f·m
FRONT BRAKE LEVER PIVOT NUT 1 6 1.0㎏f·m
REAR BRAKE LEVER PIVOT SCREW 1 5 0.3㎏f·m
REAR BRAKE LEVER PIVOT NUT 1 5 0.4㎏f·m
MASTER CYLINDER HOLDER BOLT 2 6 1.2㎏f·m
MASTER CYLINDER COVER SCREW 2 4 0.2㎏f·m
BRAKE HOSE BOLT 2 10 3.5㎏f·m
CALIPER MOUNT BOLT 2 8 2.7㎏f·m
CALIPER BREATHER VALVE 1 8 0.6㎏f·m
CALIPER PAD PIN 2 10 1.8㎏f·m
CALIPER SLIDE PIN BOLT 1 8 2.3㎏f·m
BRAKE SWITCH SCREW 1 4 0.12㎏f·m
STEERING STEM BOLT(FRONT FORK SIDE) 4 10 3.5~4.5㎏f·m
FRONT AXLE NUT 1 12 6㎏f·m
REAR AXLE NUT 1 14 11.0㎏f·m
SPEEDOMETER CABLE SETTING SCREW 1 4 0.2㎏f·m
REAR BRAKE ARM BOLT 1 6 0.6㎏f·m
FRONT BRAKE DISK BOLT 3 8 3.9㎏f·m
REAR CUSHION UPPER BOLT 1 10 4.0㎏f·m
REAR CUSHION LOWER BOLT 1 10 4.0㎏f·m
ENGINE HANGER BRACKET NUT 2 10 5.0㎏f·m
(FRAME SIDE) (7.3㎏f·m)
EXHAUST PIPE JOINT NUT 3 6 1.2㎏f·m
MUFFLER BRACKET BOLT 2 8 3.3㎏f·m
EXHAUST PIPE PROTECTOR SCREW 4 6 0.5㎏f·m

STANDARD TWIST TORQUE

TWIST TORQUE TWIST TORQUE
TYPE TYPE
N-m kgf-m ft-lb N-m kgf-m ft-lb
5mm BOLT, NUT 5 0.5 4 5mm SCREW 4 0.4 3
6mm BOLT, NUT 10 1.0 7 6mm SCREW 9 0.9 7
8mm BOLT, NUT 21 2.1 15 6mm SCREW FLANGE BOLT, NUT 9 0.9 7
10mm BOLT, NUT 35 3.5 25 8mm SCREW FLANGE BOLT, NUT 27 2.7 20
12mm BOLT, NUT 55 5.5 40 10mm SCREW FLANGE BOLT, NUT 40 4.0 29

Bolts not appearing in the following table are tightened using standard torque.

1-15
SERVICE INFORMATION

SPECIALIZED TOOLS

TOOL NAME TOOL NO. USAGE CHAPTER

FLOAT LEVEL GAUGE 07401-001000 Carburetor Oil Level Measurement 5
BEARING DIRVER 07945-GC80000 Change of Driven Face Outer Bearing
BEARING REMOVER 07936-3710300 Disassembly of Driven Face Needle Bearing
REMOVER HANDLE 07936-3710100
REMOVER WEIGHT 07741-0010201
DRIVER HANDLE A 07749-0010000 Assembly of Driven Face Needle Bearing 7
OUTER DRIVER 24×26mm 07746-0010700
CLUTCH SPRING COMPRESSOR 07960-KM10000 Disassembly/Assembly of Clutch/Driven Face
SOCKET WRENCH 39mm 0723-03900
CLUTCH CENTER HOLDER 07724-0050001 Disassembly/Assembly of Driven Pulley/Driven Face
UNIVERSAL HOLDER 07725-0030000 Disassembly/Assembly of Clutch/Driven Pulley
CRANK ASSEMBLY 0740-00001 Assembly of Drive Shaft
DRIVER HANDLE A 0749-0010000 Assembly of Drive Shaft Bearing
OUTER DRIVER 37×40mm 07746-0010200
DRIVER PILOT, 17mm 07746-0040400
UNIVERSAL BEARING PULLER 0755-00001 Disassembly of Crank Shaft Bearing
9
CRANK CASE PULLER 0751-00003 Disassembly of R/L Crank Case, Crank Shaft
CRANK ASSEMBLY 0740-00001 Disassembly of R.Crank Case, Crank Shaft
OUTER DRIVER 52×55mm 07746-0010400 Assembly of Crank Shaft Bearing
DRIVER PILOT 20mm 07746-0040500
DRIVER HANDLE A 07749-0010000
CRANK ASSEMBLY 0740-00001 Assembly of R/L Crank Shaft Oil Seal
LOCK NUT WRENCH A 07916-1870101 Disassembly of Top Cone Race
LOCK NUT WRENCH B 07916-KM10000
BALL RACE REMOVER 07946-GA70000 Assembly of Ball Race 10
OUTER DRIVER, 42×47mm 07746-0010300
DRIVER HANDLE A 07749-0010000
SHOCK ABSORBER COMPRESSER 07GM-0010000 Disassembly/Assembly of Rear Cushion
COMPRESSER SCREW ASS’
Y 079GME-0010100 11
SPRING COMPRESSER ATTACHMENT 07967-GA70102
SPRING COMPRESSER ATTACHMENT 07JME-GW20100
UNIVERSAL HOLDER 07725-0030000 Disassembly/Assembly of Fly Wheel
13
A.G.G ROTOR PULLER 0750-00006 Disassembly of Fly Wheel

1-16
 SERVICE INFORMATION

LUBRICATION OIL
ENGINE PARTS
APPLICATION AREAS CAUTIONARY SUGGESTIONS OIL TYPE
CRANK CASE JOINING FACE Gasket Fluid(TB 1215)
CRANK CASE REVOLUTION PART Ultra-2 Super, 2-Cycle Oil
CYLINDER BIG REVOLUTION PART, FRICTION PART (Separation Lubrication Use)
TRANSMISSION(FINAL REDUCTION) Capacity : 0.09ℓ SAE 80W/90
KICK SPINDLE BUSH
STARTER PINION
STARTER DRIVE GEAR OPERATION PART Capacity : 5.0~5.6g Multi-Purpose Grease
MOVEABLE DRIVEN FACE
(DRIVEN FACE OPERATION PART)
OIL PUMP DRIVE GEAR Molybdenum Grease

FRAME PARTS
APPLICATION AREAS CAUTIONARY SUGGESTIONS OIL TYPE
FRONT WHEEL DUST SEAL EDGES Multi-Purpose Grease
FRONT PIVOT ARM BUSH FRICTION FACE
FRONT PIVOT ARM SEAL EDGES
REAR BRAKE CAM AXLE PART, CAM PART
WHOLE AREA OF REAR BRAKE CAM DUST SEAL
REAR BRAKE ANCHOR PIN AXLE PART
FRONT BRAKE OIL SEAL EDGES
FRONT BRAKE CAM AXLE PART, CAM PART
WHOLE AREA OF FRONT BRAKE CAM DUST SEAL
SPEEDOMETER GEAR/PINION INSIDE DIAMETER
PART, AXLE PART, GEAR TEETH PART
BALL RACE, BEARING REVOLUTION PART

HANDLE GRIP INSIDE AXLE PART Adhesives ROYAL BOND 1300

1-17
SERVICE INFORMATION

SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.

SYMBOL MEANING SYMBOL MEANING

Indicates important work. Minor injury or
Indicates dangerous area. Serious vehicle part damage may result if instruction
accident may result if instructions are not are not followed.
followed. Indicates general safety matters. Provides
safety and appropriate handling procedures.

The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when
performing maintenance.

SYMBOL CAUTION

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)

Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2
or equivalent)

Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)

Use silicone grease

Apply a locking agent. Use the agent of the middle strength, unless otherwise specified

Apply sealant

Replace the parts with new ones before assembly

Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified

Use Fork or Suspension Fluid

Use special tool

Use option tool. These tools are obtained as you order parts.

( 3-1) Indicates reference page. (Example : Refer to page 3-1)

Special grease, etc. that do not correspond to the above are indicated without using symbols.

1-18
 SERVICE INFORMATION

WIRING DIAGRAM

SIDE STAND SWITCH CODE

ACG COUPLER

FUSE

BATTERY CORD

START RELAY

FR. WINKER/HEADLIGHT COUPLER

BATTERY CORD

CDI UNIT

OIL PASS TUBE

OIL TUBE

IGNITION COIL

STARTER RELAY CODE

1-19
SERVICE INFORMATION

HEAD LICGHT SWITCH

WINKER SWITCH
STARTER SWITCH HORN SWITCH

RR. STOPSWITCH SWITCH CONNECTOR

FR. STOP SWITCH CONNETOR SPEEDOMETER CABLE
SPEEDOMETER CORD
WINKER RELAY

HORN COMP.
EARTH CORD
RR. BRAKE CABLE THROTTLE CABLE

FR. BRAKE HOSE RR. BRAKE CABLE

RESISTER COMP.
SPEEDOMETER CORD
SPEEDOMETER CABLE

WIRE HARNESS

WIRE HARNESS

THROTTLE CABLE RR. BRAKE CABLE

WIRE CLAMPS

1-20
 SERVICE INFORMATION

ACG CORD TUBE CLAMP

WIRE BAND

THROTTLE CABLE
OIL TUBE

SIDE STAND SWITCH CORD

THROTTLE CABLE

SIDE STAND SWITCH CORD

RR. BRAKE CABLE

THROTTLE CABLE
BY STARTER CORD CLAMP
RR. BRAKE CABLE
BY STARTER CORD

ACG CORD
BY STARTER CORD

SIDE STAND SWITCH CORD

RR. BRAKE CABLE

SIDE STAND SWITCH CORD
SIDE STAND SWITCH THROTTLE CABLE

THROTTLE CABLE
OIL PUMP ASS'Y

RR. BRAKE CABLE

ACG CORD
START MOTOR

OIL LEVEL SWITCH

FUEL UNIT
FUEL UNIT COUPLER
ACG CORD

START MOTOR FRAME WIRE HARNESS

OIL TANK
OIL LEVEL SWITCH CORD
OIL LEVEL SWITCH FUEL UNIT CORD

OIL TANK RIB

OIL LEVEL SWITCH CORD

1-21
MEMO
2. INSPECTIONS/ADJUSTMENTS

SERVICE INFORMATION 2-1 BRAKE FLUID 2-7

REGULAR INSPECTION SCHEDULE 2-2 BRAKE PAD/SHOE 2-7
FUEL LINE (FUEL TUBE) 2-3 BRAKE SYSTEM 2-8
2
FUEL LINE FOR CLOGGING 2-3 HEADLIGHT ADJUSTMENT 2-8
THROTTLE GRIP OPERATION 2-4 SIDE STAND 2-9
AIR CLEANER 2-4 SUSPENSION 2-9
SPARK PLUG 2-5 BOLTS, NUTS, FASTENERS 2-9
CYLINDER COMPRESSION PRESSURE 2-6 WHEELS/TIRES 2-9
CARBURETOR IDLING 2-6 STEERING HEAD BEARING 2-10
AIR SCREW ADJUSTMENT 2-6 BATTERY 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.

Stand the main stand prior to beginning work.

SPECIFICATIONS
ITEM STANDARD VALUE REFERANCE
THROTTLE GRIP FREE PLAY 2-6mm
SPARK PLUG BPR6HS
SPARK PLUG GAP 0.6∼0.7mm
CARBURETOR IDLE SPEED 2,000rpm
CYLINDER COMPRESSION PRESSURE 12㎏f/㎠ (600rpm)

TORQUE VALUES
SPARK PLUG 1.4㎏f·m
CYLINDER HEAD COVER BOLTS 1.0㎏f·m

2-1
INSPECTIONS / ADJUSTMENTS

REGULAR INSPECTION SCHEDULE

Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s
manual.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
R : REPLACE L : LUBRICATE C : CLEAN

ODOMETER READING(NOTE 1)
FREQUENCY
x 1000Km 1 4 8 12 REMARK
ITEM
MONTH 6 12 18
FUEL LINE(FUEL TUBE) I I I
THROTTLE GRIP OPERATION I I I I
OIL PUMP, OIL LINE I I I
AIR CLEANER C C C NOTE 2
SPARK PLUG I I I
CARBON REMOVAL Every 8,000㎞ : C
CARBURETOR IDLE SPEED I I I I
TRANSMISSION OIL R
BRAKE SHOE/PAD WEAR I I I I NOTE 3
BRAKE SYSTEM I I I I
BRAKE STOP SWITCH I I I I
HEADLIGHT ADJUSTMENT I I I
CLUTCH SHOE WEAR I I I
SUSPENSION I I I
BOLTS, NUTS, FASTENERS I I
WHEELS/TIRES I I I I
STEERING HEAD BEARING I I
DRIVE BELT I I I
WEIGHT ROLLER I I I
SLIDE PIECE I I I
DRIVEN FACE I
MOVEABLE DRIVE FACE I I I

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.

2-2
 INSPECTIONS / ADJUSTMENTS

FUEL LINE(FUEL TUBE)

● Remove the luggage box.( 3-3)
● 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.

FUEL LINE FOR CLOGGING

● Check the fuel tank cap and/or fuel tank breather tube
for clogging.
● Visually inspect the fuel strainer for contamination.
Check the fuel flow with the fuel strainer installed and
with the strainer removed.
Replace the fuel strainer if it is excessively contaminated
or if the fuel flow is not smooth.

OIL
OIL
OIL TANK
TANK
TANK CAP
CAP
CAP

Note the installation direction of the fuel strainer. Be

FUEL FLOW
sure to install it as shown in the drawing, i.e., with
the cup facing down. Fuel flows even though the
strainer is installed upside down, but it contaminates
the inner wall of the strainer and prevents visual
inspection of the strainer.
DIRT
DIRT
(Inner walls get ● Remove the fuel valve lock nut and check the fuel
contaiminated, strainer screen for contamination. Tighten the lock nut
making visual to the specified torque.
inspection
difficult)

2-3
INSPECTIONS / ADJUSTMENTS

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

THROTTLE
THROTTLE
THROTTLE GRIP
GRIP
GRIP

● If the throttle grip doesn’t move smoothly, adjust the

free play.
● Take off the rubber boots, loosen the lock nut, and turn
the adjuster to control the free play.
● After adjusting, tighten the lock nut, check the
operation of grip, and then put on the rubber boots.

THROTTLE
THROTTLE
THROTTLE CABLE
CABLE
CABLE

RUBBER
RUBBER BUSH
RUBBER BUSH
BUSH

AIR CLEANER
● Loosen the 5 setting screw assembled to the air cleaner
case cover, and then remove the air cleaner case cover.

● Remove the air cleaner element.

● Wash away any accumulated dust or dirt, by gently
squeezing it in non flammable or high flash point
AIR
AIR CLEANER
AIR CLEANER ELEMENT
CLEANER ELEMENT
ELEMENT
solvent.

Using gasoline or low flash point solvents for

cleaning parts may result in a fire or explosion.

Cleaning the element with gasoline or any acid,

alkaline, or organic, volatile type oil may cause
improper ignition, deterioration of the element, or a
loosening of the element adhesive.

2-4
 INSPECTIONS / ADJUSTMENTS
● Be sure to allow the element to dry thoroughly before
applying oil. Otherwise, the oil will be diluted by the
and the filtering ability of the filter will be much
less effective.
● Spread clean #80~90 gear oil on the element, rubbing
inthoroughly over the surface with both hands, and then
DRY squeeze out any excess oil.

WASH SQUEEZE SQUEEZE Using air filter oil when riding in extremely dusty
OUT OIL conditions prevents premature engine wear due to
dust/dirt drawn into the engine. Apply air filter oil to
GEAR OIL the entire surface of the element and rub it with both
(#80~90) hands to saturate the element with oil. Squeeze out
excess oil.

SPARK PLUG
● 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 plugs are severely contaminated or
damaged, raplace with new ones. If the plugs can be
reused after removing only the carbon, use plug cleaner
and wire brush to clean the plugs.
● Always use a feeler gauge to check the gap.

SPARK PLUG GAP : 0.6~0.7mm

SPARK
SPARK PLUG
SPARK PLUG WRENCH
PLUG WRENCH
WRENCH

CHECK GAP,
DEPOSITS 0.6 ~ 0.7mm
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, hand-
tighten the spark plug before using a wrench to
tighten to the specified torque.(torque : 14kgf·m)
CHECK WASHER Do not overtighten the spark plug.
FOR DAMAGE

CHECK FOR
CRACKS

● Spark plug specification change

BPR7HS
HIGH SPEED HIGH SPEED STANDARD LOW SPEED
SPEED
BPR7HS BPR6HS BR4HSA
BPR6HS The specification changes acconding to the speed.
STANDARD

BR4HSA LOW SPEED

DISTANCE

2-5
INSPECTIONS / ADJUSTMENTS

SPARK
SPARK
SPARK PLUG
PLUG
PLUG CAP
CAP
CAP
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.

Fix the vehicle securely.

Cut off the engine, and lock the high pressure cable.
While the engine is hot, pay attention not to get
burned.
COMPRESSION
COMPRESSION GAUGE
COMPRESSION GAUGE
GAUGE

The maximum reading is usually reached within

4~7 seconds
COMPRESSION PRESSURE : 10.0kg/cm2 (600rpm)
● If the pressure is low, check the following:
-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.

TOOL : COMPRESSION GAUGE

CARBURETOR IDLING
● Stand the vehicle on the main stand.
● Heat the engine to make accurate idling inspection and
adjustment.
● Verify all engine adjustments satisfy specifications.
Make adjustments, if necessary.
● Turn the throttle stop screw and make adjustments to
prescribed idling speed.

STANDARD RPM: 2,000rpm

THROTTLE
THROTTLE STOP
THROTTLE STOP SCREW
STOP SCREW
SCREW

AIR SCREW ADJUSTMENT

The air screw is factory pre-set. Adjustment is not

necessary unless the carburetor is overhauled or a
new air screw is installed.
Tightening the air screw against its seat will damage
the seat.

AIR
AIR SCREW
AIR SCREW
SCREW

2-6
 INSPECTIONS / ADJUSTMENTS

ADJUSTING
ADJUSTING WRENCH B
● Turn the air screw clockwise until it seats lightly then
ADJUSTING WRENCH
WRENCH B
B
back it out to the specification given. This is an initial
setting prior to the final air screw adjustment.
● Rev the engine up slightly from the idle speed and
make sure that engine speed rises and returns smoothly.
● Adjust by turning the air screw in or out within a 1/4
turn if necessary. If the engine cannot be adjusted by
turning the air screw within a 1/4 turn, check for other
engine problems.

THROTTLE
THROTTLE
THROTTLE GRIP
GRIP
GRIP

MASTER
MASTER
MASTER CYLINDER
CYLINDER
CYLINDER 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.
Foreign materials can clog the system, causing a
reduction or complete loss of braking ability.
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.
△
△MARK
MARK
MARK

Replace the brake pads in sets.

BRAKE SHOE REPLACEMENT

● If the arrow mark of the wear limit aligns with the ‘△’
mark when the rear brake lever is fully pressed, it
indicates the brake lining has reached the service limit.
Replace the brake shoes.

2-7
INSPECTIONS / ADJUSTMENTS

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.

BRAKE
BRAKE CALIPER
BRAKE CALIPER
BRAKE CALIPER
CALIPER

BRAKE LEVER FREE PLAY

● Check the free play after pulling the lever.

FRONT : 10~20mm
REAR : 10~20mm

REAR BRAKE FREE PLAY ADJUSTMENT

● Turn the adjuster nut to adjust the free play.
● After initial adjustment, check the operation of the rear
brake light switch. Make additional adjustments, if
necessary.

ADJUST NUT
ADJUST
ADJUST NUT
NUT

HEADLIGHT ADJUSTMENT
● Adjust the headlight beam level by operating the
adjusting screw located on the upper side of the front
fender.

Adjust the beam level according to local laws and

regulations.
Improper beam level adjustment may blind
oncoming drivers, or may incorrectly light the road
ahead.
ADJUSTING
ADJUSTING SCREW
ADJUSTING SCREW
SCREW

2-8
 INSPECTIONS / ADJUSTMENTS

SIDE STAND
● Erect the main stand.
● Pull the lower end of the side stand, and see if it moves
freely.
● If the side stand does not move smoothly, apply grease
to the pivot area.
● If the side stand moves too freely, check the side stand
spring.
● Check the axial movement of the side stand.

SIDE
SIDE
SIDE STAND
STAND
STAND

SUSPENSION

Do not ride motor cycle with an unsatisfactory

suspension. Loose or worn suspension parts will lead
to deterioration in the vehicle’s 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
F looseness.

BOLTS, NUTS, FASTENERS

● 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.

TIRE
TIRE
TIRE PRESSURE
TIRE PRESSURE GAUGE
PRESSURE GAUGE
GAUGE 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/
ITEM FRONT WHEEL REAR WHEEL
DRIVER ONLY 1.25 2.00
DRIVER AND A PASSENGER 1.25 2.00

2-9
INSPECTIONS / ADJUSTMENTS
● Check the tread depth at the tire center.
● If the tread depth has reached the service limit, replace
the tire.

WEAR INDICATOR LOCATION MARKING

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.

SPECIAL
SPECIAL SCREW
SPECIAL SCREW
SCREW BATTERY
● Remove a special screw securing the battery cover
from the floor panel.
● Check if the terminal is loose.
● If the terminal is loose, check and clean the contacting
surface and then tighten it.
● Apply grease thinly after tightening.
● If the terminal is rusted, remove the battery, pour warm
water and clean with the wire brush.

- FULL CHARGING VOLTAGE : 13.0~13.2V

- LOW CHARGING VOLTAGE : LESS THAN 12.3V
BATTERY
BATTERY COVER
BATTERY COVER
BATTERY COVER
COVER

Check the charging condition using the voltmeter.

Pay attention not to transform the battery terminal.
Never remove the filler cap.

2-10
3. EXTERNAL PARTS

SERVICE INFORMATION 3-1 FLOOR PANEL 3-4

MAINTENANCE PRECEDURE 3-2 FRONT COVER 3-5
LUGGAGE BOX 3-3 FRONT FENDER 3-5
BATTERY MAINTENCE LID 3-3 INNER COVER 3-5
CENTER COVER 3-3 FRONT UNDER COVER 3-6 3
REAR CARRIER 3-3 FRONT HANDLE COVER 3-6
BODY COVER 3-3 REAR HANDLE COVER 3-6
REAR FENDER 3-3 MUFFLER SEPARATION 3-7
FLOOR SIDE COVER 3-4

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

MAINTENANCE PROCEDURE
NAMES OF FRAME COVERS

● This chart shows arrows connected in the order of disassembling covers.

① LUGGAGE BOX/SEAT ⑦ FLOOR SIDE COVER ⑨ FRONT COVER ⑬ FRONT HANDLE

COVER

② BATTTERY ⑧ FLOOR PANEL ⑩ FRONT FENDER ⑭ REAR HANDLE

MAINTENCE LID COVER

③ CENTER COVER ⑪ INNER COVER

④ REAR CARRIER ⑫ FRONT UNDER

COVER

⑤ BODY COVER

⑥ REAR FENDER

3-2
 EXTERNAL PARTS

LUGGAGE BOX
● Loosen 3 washer bolts and 2 flange bolts.
OIL
OIL
OIL TANK
TANK
TANK CAP
CAP
CAP ● Remove the oil tank cap and the fuel tank cap.

Luggage box can be removed with the seat.

● Remove the luggage box.

● Install in the reverse order of removal.

SPECIAL
SPECIAL
SPECIAL SCREW
SCREW
SCREW Install the oil tank cap and the fuel tank cap
temporarily to prevent the foreign material from
entering after removing the luggage box.

BATTERY MAINTENCE LID

● Loosen 1 special screw and remove maintence cover.

CENTER COVER
● Loosen 2 tapping screw securing the floor panel.
● Loosen 2 special screw (R/L) securing the body cover.
● Remove the center cover.

If removal is difficult, recheck each connection and

then try removing again.

● Install in the reverse order of removal.

AIR
AIR
AIR SCREW
AIR SCREW
SCREW SPECIAL
SPECIAL SCREW
SPECIAL SCREW
SCREW

WASHER
WASHER
WASHER BOLTS
BOLTS
BOLTS REAR CARRIER
● Open the seat
● Loosen 2 washer bolts securing luggage box and 2
Flange bolts securing body cover.
● Remove the rear carrier.
● Install in the reverse order of removal.

Pay attention not to break of damage the rear carrier

when installing or removing.
FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS

3-3
EXTERNAL PARTS

BODY COVER
● Remove the luggage box. ( 3-3)
● Remove the center cover. ( 3-3)
● Remove the rear carrier. ( 3-3)
● Loosen 2 special screw (R/L) securing the frame body.
● Loosen 2 special screw secuning rear fender.
● Remove seat lock cable.
● Remove tail light, coupler of winker.
● Remove the body cover.
● Install in the reverse order of removal.

SPECIAL
SPECIAL
SPECIAL SCREW
SCREW
SCREW

WASHER
WASHER BOLTS
WASHER BOLTS
BOLTS REAR FENDER
● Luggage box. ( 3-3)
● Center cover. ( 3-3)
● Rear carrier. ( 3-3)
● Body cover. ( 3-4)
● Remove the 2 washer bolts securing frame body.
● Draw the rear part of the rear fender from the bracket in
the frame.
● Loosen the rear cushion under bolt, remove the rear fender.

If removal is difficult, recheck each connection and

try removing again.
● Install in the reverse order of removal.

FLOOR SIDE COVER

● Loosen the 2 washer screw located in the side of the
R,L floor side cover.
● Pull the front part of the floor side cover to remove the
floor panel.
● Remove the floor side cover.
● Install in the reverse order of removal.

WASHER
WASHER SCREW
WASHER SCREW
WASHER SCREW
SCREW

WASHER
WASHER BOLTS
WASHER BOLTS
WASHER BOLTS
BOLTS
FLOOR PANEL
● Remove the plug maintenance cover. ( 3-3 )
● Remove the center cover. ( 3-3)
● Loosen the tapping screw securing the battery cover to
remove the battery cover.
● Disconnect the battery wire to remove the battery and
loosen 1 washer bolt.
● Remove the CDI, winker relay coupler, fuse.
● Loosen the 2 washer bolts securing the floor panel.

3-4
 EXTERNAL PARTS
● Remove the floor panel from the connecting groove of
the inner box by lifting the rear part of the panel
slightly.
● Draw the floor panel moving it to the right and left to
remove it.
● Install in the reverse order of removal.

FRONT COVER
● Loosen the upper cover set screws (R/L) securing the
inner box.

SPECIAL BOLT
BOLT
● Loosen the upper cover set screws (R/L) securing the
SPECIAL
SPECIAL BOLT
front under cover.
● Loosen the special bolt securing the front of the front
cover.
Loosen
Loosen
Loosen thethe
the
screws
screws
● Draw the upper part of the front cover to remove it.
screws
from
from the
from the
the ● Disconnect the head light wiring and remove the front
inner
inner cover
inner cover
cover cover.
● Install in the reverse order of removal.

SETTING
SETTING BOLT
SETTING BOLT
SETTING BOLT
BOLT
Check for proper alignment of the connection (hook)
before performing installation.

SPECIAL
SPECIAL SCREW
SPECIAL SCREW
SCREW
FRONT FENDER
● Loosen the special screw (R/L) securing the front fork.
● Remove the front fender.
● Install in the reverse order of removal.

TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW
INNER COVER
SETTING
SETTING
SETTING ● Remove the center cover. ( 3-3)
SCREW
SCREW
SCREW ● Remove the floor side cover. ( 3-4)
● Remove the floor panel. ( 3-4)
● Remove the front cover. ( 3-5)
● Loosen the tapping screws (R/L) securing the front
under cover.
● Loosen the 1 set screw securing bag holder.
● Install in the reverse order of removal.

3-5
EXTERNAL PARTS

FRONT UNDER COVER

● Remove the front cover. ( 3-5)
● Remove the inner box. ( 3-5)
● Remove the front fender. ( 3-5)
● Remove the front wheel. ( 10-5 )
● Loosen the flange bolts securing the lower end of the
inner cover.
● Remove the front under cover.
● Install in the reverse order of removal.

FLANGE
FLANGE
FLANGE BOLTS
BOLTS
BOLTS Pay attention not to turn over the vehicle.

FRONT HANDLE COVER

● Remove the back mirror.
● Remove the master cylinder seal.
● Loosen the 2 tapping screws securing the rear handle
cover.
● Remove the front handle cover while pull the cover to
the front slightly.
● Install in the reverse order of removal.

TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW

REAR HANDLE COVER

● Remove the back mirror.
● Remove the front handle cover. ( 3-6)
● Remove the speedometer cable from the meter.
● Loosen the 2 tapping screws securing the steering
handle comp.
● Disconnect the right and left switch wiring.
● Remove the speedometer and rear handle cover from
the steering handle.
● Disconnect the right and left switch.
● Loosen the 3 tapping screws securing the speedometer
and the rear handle cover.
TAPPING
TAPPING
TAPPING SCREW
SCREW
SCREW ● Remove the rear handle cover.
● Install in the reverse order of removal.

Check each switch for proper operation after

installation.
Wires and cables must be connected properly.

3-6
 EXTERNAL PARTS

FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS
MUFFLER
EX. PIPE REMOVAL
● Loosen the 2 flange bolts securing the SAI reed valve
ass’y.
● Loosen 1 flange nut and 1 special nut securing the
cylinder comp.
● Loosen 2 flange bolts securing the RH. crank case.
● Remove the EX. pipe by drawing it to the ground.
● Install in the reverse order of removal.

Never perform the maintenance of the muffler right

after stopping the vehicle because the muffler is
extremely hot
FLANGE
FLANGE NUT
FLANGE NUT
NUT
MUFFLER COMP
● Loosen the 3 flange nuts securing the exhaust pipe
comp.
● Loosen 2 flange bolts securing the RH. crank case.
● Install in the reverse order of removal.
TIGHTENING TORQUE OF THE RH. CRANKCASE
: 3.3kgf m

When installing the gasket, replace it with the

new one.
Check to see if there is any evacuation after
installing the muffler.

S.A.I PIPE
● Remove 2 flange bolts securing the exhaust muffler
ass’y.
● Remove the upper flange bolt securing the muffler
comp.
● Remove the hose clip and tube.
● Install in the reverse order of removal.

3-7
EXTERNAL PARTS
AIR FILTER ASS’Y SECONDARY
HOSE CLIP ● Remove the seat.
● Remove the luggage box.
● Remove the hose clip and the hose.
A.I TUBE ● Install in the reverse order of removal.

AIR FILTER ASS’Y

SECONDARY

SCREW
GASKET

FLANGE BOLT

3-8
MEMO
LUBRICATION SYSTEM

THROTTLE SPEEDOMETER THROTTLE GRIP

BRAKE HOSE

STEERING BEARING

WHEEL BEARING

WHEEL BEARING
SIDESTAND PIVOT
SPEEDOMETER GEAR BOX

4-0
4. LUBRICATION SYSTEM

SERVICE INFORMATION 4-1 OIL PUMP BLEEDING 4-4

TROUBLESHOOTING 4-1 OIL PUMP, TUBE INSPECTION 4-5
OIL SYSTEM DRAWING 4-2 OIL PASS, TUBE INSPECTION 4-5
OIL PUMP DISASSEMBLY/ ENGINE OIL LEVEL INSPECTION 4-6
ASSEMBLY 4-3
TRANSMISSION OIL INSPECTION 4-7
OIL PUMP INSPECTION 4-3
OIL TANK DISASSEMBLY 4-7 4
OIL PUMP ADJUSTMENT 4-4

SERVICE INFORMATION

·Remove air from oil tube and oil pump if the oil tube is taken off or if air enters the oil tube.

● If the oil tube is disassembled, remove the air in the oil pass tube.
● Maintenanace on the oil pump is done without the engine being removed from the vehicle.
● When disassembling the oil pump, do not allow foreign substances from entering the engine or oil pump.
● Do not disassemble the oil pump assembly.
● If the oil tube is disassembled, place a tube clip or band on the oil tube to prevent oil from leaking out.

TROUBLESHOOTING
Overheating or engine clogging
● Faulty adjustment of oil pump(insufficient amount pumped).
● Bad quality of engine oil.
● Engine oil not being injected or blocked, bent strainer screen or oil tube.
● Entering of air in oil tube system.
● Faulty oil pump.
● Engine oil not being supplied from oil tank.
-Blocked oil tank cap air hole
-Blocked oil strainer screen

Excess exhaust smoke, accumulation of carbon on spark plug

● Faulty adjustment of oil pump(over-pumped amount).
● Bad quality of engine oil.

4-1
LUBRICATION SYSTEM

OIL SYSTEM DRAWING

OIL TANK

OIL TUBE

CARBURETOR

OIL PUMP

OIL PASS TUBE

OIL PUMP CONTROL CABLE

4-2
 LUBRICATION SYSTEM

OIL CONTROL
OIL
OIL CONTROL CABLE
CONTROL CABLE
CABLE
OIL PUMP DISASSEMBLY/ASSEMBLY
● Remove the luggage box.
● Remove the air cleaner.
● Remove the 2 bolts of oil pump cable stay.
● Remove oil tube on the side of oil pump.
● Remove oil pass tube.
● Remove setting plate of oil pump.
● Remove oil pump.
● Install in the reverse order of removal.

When assembling/disassembling the oil pump, do

not allow foreign substances from entering the
engine and oil tube by cleaning around the oil pump.
OIL
OIL
OIL PUMP
PUMP
PUMP If the air enters into the oil line, it may cause faulty
lubrication or engine sticking. Always remove the air
in the oil line after maintenance.
Pay attention not to damage the O-ring when
assembling the oil pump.

After
After
After separation
separation
separation of
of
of oil
oil
oil pump
pump
pump

OIL PUMP INSPECTION/ADJUSTMENT

O-RING ● Remove the oil pump.
● Rotate the shaft and check for proper rotation.
● Check the gear for wear, damage and leak of each seal.
● If the oil comes out from the outlet of the oil pump
after connecting the oil tube (which is connecting
between the tank and the oil pump) to the inlet and
rotating the shaft in the driving direction, consider the
oil pump is in good condition.
GEAR

4-3
LUBRICATION SYSTEM
ADJUSTMENT
CONTROL
CONTROL LEVER
CONTROL LEVER
LEVER

Perform after inspection and adjustment of throttle

cable.

● Check to see if the matching mark of the oil pump

body and control lever are aligned in a state where
the throttle grip is completely rotated.
● Adjustment is performed by loosening the oil pump
control cable lock nut and turning the control nut.
● While the engine is running, slightly open the throttle
and check to see if the control lever operates together
with the increase in engine rpms.

Do not adjust the control lever matching mark to the

closed side of the oil pump body matching mark. If
this is done, the amount of pumped oil is reduced,
negatively affecting the engine.
Make sure that the open axis stays within an 1mm
sphere.

● The following occurs when the oil pump is adjusted

incorrectly.
-When the oil pump lever is excessively opened :
Emitting of white exhaust gas or starting problems.
CABLE
CABLE STAY
CABLE STAY NUT
STAY NUT
NUT -When the oil pump lever is insufficiently opened :
Clogging of engine.

If the oil pump cable stay bolt is removed, apply the

screw locking compound to the bolt thread.

OIL PUMP BLEEDING

O-RING

Air infiltration in the oil pass may cause the engine

sticking. Always remove the air in the oil pass after
maintenance.
When disassembling the oil tube, air can be enter
into the oil tube and the oil pump because of the oil
GEAR leaking in the oil tube. Remove the air completely.
Do not allow foreign substances from entering the
oil pass.

4-4
 LUBRICATION SYSTEM

OIL PUMP/OIL TUBE

OIL
OIL
OIL PUMP
PUMP
PUMP ● Fill the oil tank with engine oil.
● Cap around the oil pump and the carburetor with dry
cloth.
● Locate the end of the oil tube in the level lower than
the oil tank and drain the oil to bleed the air.
● Install the oil tube in the oil pump.

●Incline the oil pump to locate the oil pump shaft at the
angle of 45。from the “▲”mark with oil tube
OIL PUMP SHAFT connected.

“▲”MARK

●In this state, locate the oil pump in the level lower
than the oil tank and drain the oil to bleed the air.
●Install the oil pump shaft in the oil pump after
completing the bleeding.
●Install the oil pump in the crankcase.

OIL PUMP SHAFT

OIL PASS TUBE

● Bend the oil pass tube in the “U” shape, keep the two
ends parallel with each other and fill the oil pass tube
OIL PASS TUBE with the oil.

4-5
LUBRICATION SYSTEM
● Connect the oil pump and then the carburetor quickly
with the both ends of the tube pressed to avoid the air
from entering.

Make sure that the tubes are arranged correctly.

● Start the engine.

Do not start the engine in the poorly-ventilated area.

● Open the oil pump control level fully and idle for
2minutes to bleed the air remained in the oil pass tube
OIL
OIL PUMP
OIL PUMP CABLE
PUMP CABLE STAY
CABLE STAY
STAY with the oil drained from the oil pump.

Do not increase the engine RPM more than required.

● Connect the oil control cable.

Adjust the oil pump if the adjustment nut of the oil

comtrol lever is loose.

ENGINE OIL LEVEL INSPECTION

● Check the engine oil level if the pilot lamp blinks
when the main switch is turned on.

LOW OIL WARNING LIGHT BLINKING LEVEL : 0.15

● Remove the oil tank cap and fill the oil tank with oil to
the level of the projected portion
OIL TANK
RECOMMENDED OIL : ULTRA 2 SUPER OIL

● Reinstall the oil tank cap and check to see if the pilot
lamp turns off when the main swich is turned on.

PROJECTED
AREA

4-6
 LUBRICATION SYSTEM

OIL
OIL
OIL CHECK
CHECK
CHECK BOLT
BOLT
BOLT TRANSMISSION OIL INSPECTION
● 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.

OIL
OIL LEVEL
OIL LEVEL SWITCH
LEVEL SWITCH CONNECTOR
SWITCH CONNECTOR
CONNECTOR RECOMMENDED OIL : SAE 80W / 90
OIL LEVEL SWITCH CONNECTOR

● Tighten the oil level check bolt.

·m
TIGHTENING TORQUE : 1.3kgf·

● Start the engine and check for leak.

OIL TANK DISASSEMBLY

● Remove the luggage box.
● Remove the body cover.
● Loosen 2 flange bolts securing fuel tank and seatcatch.
● Loosen 2 washer bolts of setting stay securing luggage
carrier.
● Remove the switch connector of oil tank and the tube
on the side of oil pump.
● Remove the oil level switch connector.
● Remove the tube on the side of oil pump.
● Install the tube clip or the valve in the oil tube to avoid
the oil from leaking.
● Remove the flange bolt securing the oil tank and press
the left and lower rear fender to remove the oil tank.
● Drain the oil from the oil tank.
● Remove the oil level switch.
● Remove the oil strainer.

OIL
OIL LEVEL
OIL LEVEL SWITCH
LEVEL SWITCH
SWITCH

INSPECTION
OIL STRAINER SCREEN ● Check the oil level switch and the oil tube for proper
installation.
AIR GUN
● Install in the reverse order of removal.

If the oil enters into the oil pass, it may cause

abnormal lubrication or engine sticking. Always
remove the air in the oil pass after maintenance.
Make sure that the oil tube is connected properly.
Drain the oil in the clean container.
Install the oil strainer after cleaning it.

4-7
FUEL SYSTEM

FUEL TANK

FUEL STRAINER

FUEL TUBE

CARBURETOR

5-0
5. FUEL SYSTEM

SERVICE INFORMATION 5-1 CARBURETOR CLEANNING 5-6

TROUBLESHOOTING 5-2 CARBURETOR INSPECTION 5-6
IDLING ADJUSTMENT 5-2 THROTTLE VALVE
FUEL TANK 5-3 REMOVAL/INSTALLATION 5-7
AIR CLEANER DISASSEMBLE 5-4 FUEL AUTOCOCK
AIR CLEANER ELEMENT REMOVAL/INSTALLATION 5-8
DISASSEMBLY 5-4
INLET PIPE REED VALVE
CARBURETOR REMOVAL/ REMOVAL/INSTALLATION 5-9
INSTALLATION 5-5 5
FLOOT CAAMBER/FLOOT JET REED VALVE INSPECTION 5-9
REMOVAL/INSTALLATION 5-5

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 3 weeks, 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 : 4.8ℓ

CARBURETOR
ITEM STANDARD ITEM STANDARD
TYPE/THROTTLE BORE PA35 PILOT SCREW OPENING 1 1/2(1 1/8)
VENTURI DIAMETER 14mm FLOAT LEVEL 12.2
MAIN JET No. #77(#65) IDLING SPEED 2,000rpm
SLOW JET No. #38(#35) THROTTLE GRIP FREE PLAY 2-6mm
“( )” MARKED CONTENTS APPLY TO EUROPE ONLY.

TOOL
FLOAT LEVEL GAUGE

5-1
FUEL SYSTEM

TROUBLESHOOTING

The vehicle does not start. Back firing

● No gasoline in fuel tank. ● Ignition system is damaged.

● Fuel is not coming out of carburetor. ● Mixture is too lean.
● 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. Insufficient power and high fuel consumption.
● Using low quality gasoline.
● Starter is damaged. ● Air cleaner is blocked.
● Throttle cable is working improperly. ● Ignition system is damaged.
● Fuel tank is functioning improperly. ● Mixture is too rich.

Idle is unstable and engine turns off after starting. Air/Fuel mixture is extremely lean

● Starter is damaged. ● Fuel jet is blocked.

● Ignition system is damaged. ● Float valve is damaged.
● Using low qualty gasoline. ● Oil level is low.
● Suction system is experiencing secondary intake of air. ● Bad ventilation of air in tank cap.
● Idle is adjusted improperly. ● Fuel strainer screen is blocked.
● Air screw is adjusted improperly. ● Fuel tube is bent, creased or blocked.
● Compression pressure is low. ● Suction system is receiving secondary suction of air.
● Air/Fuel mixture is either too lean or rich.
● Carburetor is blocked.

Air/Fuel mixture is extremely rich.

Mis-firing occurs when driving at high speeds. ● Air jet is blocked.

● Float valve is damaged.
● Ignition system is damaged. ● Oil level is too high.
● Mixture is too lean. ● Starter is damaged.
● Air cleaner is blocked.

5-2
 FUEL SYSTEM

IDLING ADJUSMENT
●Travel the vehicle 2~3km under the speed of 50km/h to
stabilize the combustion on normal temperature.
[IDLING RPM]
●Set the main stand on an even place to secure the
HIGH safety.
●Turn the stop screw to adjust the idling speed to
2,000rpm.
●Turn the air screw as 1/4 turn to find the highest engine
LOW rpm and adjust it to 2,000rpm.
LEFT STOP SCREW RIGHT Turning the air screw right-hand, the fuel will get
thicker, and turning left-side, it will be thinner.
●As engine speed is set to 2,000rpm by use of air screw,
lower the idling speed 20~50rpm.
(Standard air screw: 1 1/2 turn back)
●Slightly snap 2~3 times, and set to 2,000rpm by use of
the stop screw.
●Slightly snap 2~3 times again to increase the stability
[IDLING RPM] and smooth the restarting, and complete the adjustment
as 1,800~2,000rpm.
HIGH

LEAN RICH
LOW MIXTURE MIXTURE
LEFT AIR SCREW RIGHT

SEAT
SEAT
SEAT CATCH
CATCH
CATCH REAR
REAR
REAR CARRIER
CARRIER
CARRIER FUEL TANK
SETTING
SETTING STAY
SETTING STAY
SETTING STAY
STAY
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.

● Remove the following parts.

- Luggage box. ( 3-3)
- Plug maintenance lid.( 3-3 )
- Center cover. ( 3-3)
- Rear carrier. ( 3-3)
- Body cover. ( 3-3)
● Remove the fuel tube from the fuel auto cock.

Use the tube clip or the cap to prevent the gasoline

from leaking.

5-3
FUEL SYSTEM
● Remove the fuel unit wire coupler.
● Remove the rear fender. ( 3-7)
● Loosen the 2 flange bolts and remove the seat catch.
● Loosen the 2 flange bolts and remove the fuel tank
support stay.
● Loosen the 2 flange bolts and remove the fuel tank.

INSTALLATION
Install in the reverse order of removal.

Check for gasoline leakage.

“Gasoline”mark is on the fuel tank cap.
Check this mark when filling gasoline.

AIR CLEANER ELEMENT DISASSEMBLY

● Loosen the 5 air cleaner cover washer screws.
● Remove the air cleaner cover.
● Remove the air cleaner element.
● Install in the reverse order of disassembly.

WASHER
WASHER BOLT
WASHER BOLT
BOLT

AIR
AIR CLEANER
AIR CLEANER
AIR ELEMENT
CLEANER ELEMENT
CLEANER ELEMENT
ELEMENT
AIR CLEANER REMOVAL
● Loosen the air cleaner connecting bend screw pin.
● Loosen the 2 bottom air cleaner washer bolts.
● Loosen the top rear fender flange bolt.
● Remove the air cleaner from the carburetor.
● Install in the reverse order of removal.

CARBURETOR REMOVAL/INSTALLATION

Keep the fire away.

Open the drain screw to drain the gasoline in the
carburetor chamber.

CARBURETOR
CARBURETOR
CARBURETOR

5-4
 FUEL SYSTEM
● Remove the luggage box. ( 3-3)
THROTTLE
THROTTLE
THROTTLE VALVE
VALVE
VALVE ● Remove the plug maintenance cover. ( 3-3)
● Remove the center cover. ( 3-3)
● Remove the air cleaner. ( 5-4)
● Remove the wiring coupler of the auto by starter.
● Remove the oil pass tube.
● Remove the throttle valve set.
● Remove the 2 flange bolts securing the inlet pipe.
● Remove the carburetor insulator.
● Remove the carburetor.
● Install in the reverse order of removal.

CARBURETOR
CARBURETOR
CARBURETOR INSULATOR
INSULATOR
INSULATOR
Install the carburetor after aligning the throttle valve
cutaway and the throttle stop screw.
Tighten the top set correctly so that it is not released.

CARBURETOR DISASSEMBLY/ASSEMBLY
AUTO BY WASHER SCREW
● Remove the auto by starter cover.
STARTER COVER AUTO BY STARTER ● Loosen the 2 washer screws
SET PLATE
● Remove the auto by starter set plate.
AIR SCREW ● Remove the auto by starter.
● Remove the auto by starter O-ring.
● Assemble in the reverse order of disassembly.

THROTTLE
AUTO BY STOP
STARTER SCREW
Install the auto by starter in the carburetor body after
GASKET applying grease to the starter O-ring and then tighten
FLOAT firmly with set plate piece.
FLOAT PIN
VALVE
FLOAT
O-RING

FLOAT
CHAMBER

FLOAT CHAMBER/FLOAT/JET
DISASSEMBLY/ASSEMBLY
● Loosen the 2 float chamber screws.

WASHER
WASHER
WASHER SCREW
SCREW
SCREW

5-5
FUEL SYSTEM
INSPECTION
● Check the float valves and seats for cracks or damage.
● Check the float valve operation.
● Check the float valve level.

FLOAT LEVEL : 8mm

● Remove the main jet, needle jet holder, and needle jet,
and remove the slow jet.
● Remove the air screw, spring, washer, O-ring.
● Remove the throttle stop screw, spring, O-ring.
FLOAT
FLOAT VALVE
FLOAT VALVE
VALVE

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.

● Assemble in the reverse order of disassembly.

AIR GUN
AIR
AIR GUN
GUN

Tightening air screw against its seat will damage the

seat.

THROTTLE
STOP SCREW
Be sure to install the needle jet with the smaller hole
NEEDLE JET
toward the float chamber.
HOLDER
Install the air screw and its O-ring and washer in the
order as shown in the drawing. If the air screw and
carburetor body are replaced with the new ones,
WASHER adjustment is necessary.
O-RING MAIN JET

PILOT SCREW SLOW JET

CARBURETOR INSPECTION
AUTO BYSTARTER
● Connect an ohmmeter to the auto bystarter wire
connector terminals and measure the resistance. If the
resistance is greatly out of specification, it indicates a
faulty PTC in the auto bystarter. Replace the auto
bystarter.

The auto by starter might be normal if the resistance

is only slightly out of specification. However, be
sure to check all related parts for trouble.
Refer to the Model Specific manual for specified
resistance.

5-6
 FUEL SYSTEM
● Remove the carburetor and let it cool down for 30
minutes. Insert a vinyl tube into the fuel enrichening
circuit and blow into the tube.
● Air should flow into the circuit.
● If air does not flow into the circuit, replace the auto
bystarter.

● Connect the battery to the auto bystarter terminals and

wait for 5 minutes.
● Insert a vinyl tube into the fuel enrichening circuit and
blow into the tube.
● Air should not flow into the circuit. If air flows into the
circuit, replace the auto bystarter.

BATTERY

● Check the resister if the auto bystarter is normal but

engine is still hard to start.
A.C GENERATOR ● If there is a broken wire in the resister, current will not
flow to the PTC and the auto bystarter will not operate.
● If there is a shorted wire in the resister, current of a
higher voltage than specified will reach the PTC. This
will cause the fuel enrichening circuit to close too soon,
and starting will be difficult.
RESISTER

SPRING
THROTTLE VALVE
THROTTLE VALVE DISASSEMBLY
● Remove the throttle valve.
● Remove the throttle cable.
● Remove the throttle valve spring.
● Remove the needle clip.
● Remove the seal cap.
● Remove the clip.
● Remove the jet needle.
JET NEEDLE
CLIP NEEDLE CLIP

5-7
FUEL SYSTEM
ASSEMBLY
● Install the jet needle into the throttle valve and secure
THROTTLE CABLE
CUTAWAY with the retainer.
CUTOUT ● Route the throttle cable through the spring and
CABLE END
compress the spring fully.
● Attach the throttle cable end to the bottom of the
throttle valve and thread the throttle cable through the
slot in the valve.
SPRING
● Align the cutout in the throttle valve with the throttle
THROTTLE VALVE stop screw on the carburetor body and install the valve
on the carburetor.
THROTTLE STOP SCREW

Be sure that the throttle valve cutaway is toward the

air cleaner case side as it determines the volume of
air for fuel mixture.
● Operate the valve after installing the throttle valve.

FUEL AUTO COCK

REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3)
● Remove the plug maintenance cover. ( 3-3)
● Remove the center cover. ( 3-3)
● Remove the rear carrier. ( 3-3)
THROTTLE
THROTTLE
THROTTLE VALVE
VALVE
VALVE ● Remove the body cover. ( 3-3)
● Remove the fuel tube A, B connected to the carburetor.
● Remove the inlet pipe negative pressure tube.
● Remove the fuel tube A, B connected to the fuel tank.
● Remove the flange bolt securing the fuel auto cock and
the frame.
● Remove the fuel auto cock.
● Install in the reverse order of removal.

Be sure to remove the diaphragms from the fuel auto

valve before using compressed air to blow out the air
passages. Compressed air wil damage the
diaphragms or may force them off the aluminum
FUEL
FUEL
FUEL AUTO
AUTO
AUTO COCK
COCK
COCK
● Disconnect the fuel line and place it in a clean
container as shown.

FUEL LINE
SMALLER Place a clean container under the fuel tube.
DIAPHRAGM Refer to the Model Specific manual for replacement.
● Connect the fuel auto valve vacuum tube to the
vacuum pump and apply vacuum. Be sure that the fuel
flows out smoothly. If the vacuum does not remain
AIR VENT
steady, it indicates the diaphragm is incorrectly
LARGER installed or damaged. If the vacuum remains steady, but
DIAPHRAGM the fuel flow is not smooth, it indicates a clogged filter
VACUUM
LINE
or incorrectly installed diaphragm.
SPRING ● If the fuel flows without the vacuum applied, the
diaphragm is incorrectly installed.

5-8
 FUEL SYSTEM

INLET PIPE REED VALVE

REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3)
● Remove the air cleaner. ( 5-4)
● Remove the carburetor. ( 5-4)
● Remove the negative pressure tube connected to the
inlet pipe.
● Remove the oil pump cable. ( 4-3)
● Remove the fan cover and shroud.
● Remove the inlet pipe securing 4 flange bolts
connected to the L crank case.
INLET
INLET
INLET PIPE
PIPE
PIPE ● Remove the inlet pipe.
● Remove the reed valve.
● Install in the reverse order of removal.

INSPECTION
● Check the reed valve for fatigue or damage and replace
the reed valve assembly if necessary.
● Check the reed valve seat for cracks, damage and
clearance from the reed and replace the reed valve
assembly if necessary.

Be sure to replace the reed valve as an assembly.

Disassembling or bending the reed stopper will
cause engine trouble.

5-9
ENGINE REMOVAL/INSTALLATION

6-0
6. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION 6-1

ENGINE REMOVAL/INSTALLATION 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. 6
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 9
-A.C. GENERATOR SECTION 13
-KICK STARTER/ CONTINUOUSLY VARIABLE TRANSMISSION SECTION 7
-CYLINDER HEAD/ CYLINDER/ PISTON SECTION 8
-CARBURETOR SECTION 5
-OIL PUMP SECTION 4

● Items to be worked after removing engine

-CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING.

TORQUE VALUES :
ENGINE HANGER BOLT (ENGINE) : 5.0㎏f·m
(FRAME) : 7.3㎏f·m

6-1
ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3 )
● Remove the plug maintenance cover. ( 3-3 )
● Remove the center cover. ( 3-3 )
● Disconnect the AC generater coupler. ( 13-7 )
●Disconnect the carburetor auto bystarter coupler.
● Remove the spark plug cap.
● Remove the oil pump cable.
● Remove the oil tube connected to the oil pump.
● Remove the negative pressure tube connected to the
inlet pipe.
● Remove the fuel tube connected to the carburetor and
CARBURETOR
the auto cock.
CARBURETOR
CARBURETOR

● Loosen the carburetor cap top, remove the throttle valve.

● Loosen the rear brake adjust nut, remove the brake arm
joint B and rear brake cable.
● Loosen the under bolt at the end of rear cushion.

ADJUSTER
ADJUSTER
ADJUSTER NUT
ADJUSTER NUT
NUT

● Loosen the engine hanger U-nut.

● Loosen the engine hanger flange bolt.
● Remove the engine. (with the muffler and rear wheel
attached)

Take action to prevent oil from leaking (Install the

clip in the oil tube)
Take precautions not to damage the engine when
removing the engine from the chasis.

U-NUT
U-NUT
U-NUT
U-NUT

● Remove the muffler. ( 3-7 )

● Remove the rear wheel. ( 11-3 )
● Install in the reverse order of removal.

Take precautions not to damage wiring and cable.

Take precautions not to damage the threded part of
bolts.
Arrange the cable, tubes and wiring in the right
positions.

6-2
 ENGINE REMOVAL/INSTALLATION
● Check the following after the engine is assembled.
-Electric systems.
-Adjust of the rear brake free play.
-Inspection of the throttle cable operation.
-Inspection of the oil pump cable operation.

ADJUSTER
ADJUSTER
ADJUSTER NUT
NUT
NUT

6-3
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

GUIDE PIN SHOE SPRING

CLUTCH SHOE
MOVABLE DRIVEN CLUTCH OUTER
MOVABLE DRIVEN FACE DRIVE PLATE
FACE SPRING

DRIVEN FACE DRIVE BELT

DRIVE FACE

KICK DRIVEN GEAR

RAMP PLATE DRIVE FACE BOSS

WEIGHT ROLLER
MOVABLE DRIVE FACE
KICK STARTER SPINDLE
KICK STARTER RETURN SPRING

KICK SPINDLE BUSH

7-0
7. KICK STARTER/CONTINUOUSLY
VARIABLE TRANSMISSION
SERVICE INFORMATION 7-1 DRIVE FACE REMOVAL 7-5
SERVICE STANDARD 7-1 MOVABLE DRIVE FACE REMOVAL 7-6
TROUBLESHOOTING 7-1 MOVABLE DRIVE FACE INSPECTION 7-6
LH. SIDE COVER REMOVAL 7-2 MOVABLE DRIVE FACE ASSEMBLY 7-6
KICK STARTER REMOVAL 7-2 DRIVE FACE ASSEMBLY 7-7
KICK STARTER INSPECTION 7-3 DRIVEN PULLY REMOVAL/INSPECTION 7-8
KICK STARTER INSTALLATION 7-3 DRIVE FACE INSPECTION 7-10
DRIVE BELT REMOVAL 7-4 DRIVE FACE BEARING INSPECTION 7-10
DRIVE BELT INSPECTION 7-5 CLUTCH/DRIVEN PULLY ASSEMBLY 7-12
DRIVE BELT ASSEMBLY 7-5 DRIVEN PULLY ASSEMBLY 7-13

7
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 L. crank case front cover is removed.

·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 20.035-20.085mm 20.60mm
DRIVE FACE BOSS OUTER DIAMETER 20.011-20.025mm 19.97mm
DRIVE BELT WIDTH 17.5mm 16.50mm
WEIGHT ROLLER OUTER DIAMETER 15.920-16.080mm 15.40mm
CLUTCH OUTER AND INNER DIAMETER 107.0-107.2mm 107.50mm
DRIVEN FACE SPRING PLAY 98.1mm 32.80mm
DRIVEN FACE OUTER DIAMETER 33.965-33.985mm 33.94mm
DRIVEN FACE INNER DIAMETER 34.000-34.025mm 34.06mm

TROUBLESHOOTING
Engine starts but motorcycle does not work. Vehicle unable to run at the maximum speed, or
● Drive belt worn. lack of output
● Ramp plate damaged. ● Drive belt worn.
● Clutch shoe worn or damaged. ● Defective movable driven face spring.
● Movable driven face spring cut. ● Weight roller worn.
● Pulley face contaminated.
Engine stops, or the vehicle runs suddenly,
after starting.
● Clutch shoe spring cut.

7-1
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

L. SIDE COVER REMOVAL

● Remove the rear brake cable.
● Remove the 9 flange bolts securing LH. side cover.
● Remove the LH. side cover.

L.
L.
L. SIDE
SIDE
SIDE COVER
COVER
COVER

● Remove the gasket and the dowel pin.

·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 don’t know the bolt
length.
·Tighten the bolts diagonally with specified
tightening torque.
·m
TORQUE : 1.0kgf·

KICK STARTER
REMOVAL
● Remove the L. side cover.
● Remove the kick starter ratchet and the thrust washer
while rotating the kick starter arm.
● Loosen the flange bolt securing the kick starter arm,
remve the kick starter arm.
● Remove the 14mm external circlip.
● Remove the kick spindle washer.
● Remove the kick starter spindle.
● Remove the kick spindle spring, bush.
L.
L. SIDE
L. SIDE COVER
SIDE COVER
COVER

7-2
 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

INSPECTION
● Inspect wear and damage of the kick starter spindle
and gear portion.
● Inspect damage to return spring.
● Inspect defects and damage of the kick starter spindle
bushing.
● Inspect wear and damage of the kick starter ratchet.
● Inspect damage to friction spring.
KICK
KICK
KICK SPINDLE
KICK SPINDLE
SPINDLE
BUSH
BUSH
BUSH

RETURN
RETURN
RETURN SPRING
SPRING
SPRING
KICK
KICK
KICK STARTER
STARTER
STARTER SPINDLE
SPINDLE
SPINDLE
KICK STARTER SPINDLE

KICK STARTER INSTALLATION

● Install the kick spindle bush, spring in the L. side
cover.
● Install the kick starter spindle in the L. side cover.
● Install the kick starter spindle washer.
● Install the 14mm external circlip in the L. side cover.
● Install the kick starter arm.
● Install the kick spindle springn in the groove of the L.
side cover.
● Install the thrust washer.

THRUST
THRUST WASHER
THRUST WASHER
WASHER
KICK
KICK
KICK SPINDLE
SPINDLE
SPINDLE BUSH
BUSH
BUSH

·When installing the 14mm external circlip, keep

holding the spindle manually and install the circlip in
the groove correctly.
·Apply the grease to the kick starter ratchet groove
and gear.
·Check the kick starter ratchet and the kick starter
spindle for smooth operation after installation.

KICK DRIVEN
KICK
KICK DRIVEN GEAR
DRIVEN GEAR
GEAR

● Rotate the kick starter spindle using the kick starter

arm, draw the spindle to the L. side cover and
assemble the kick starter ratchet.

KICK
KICK
KICK DRIVEN
KICK DRIVEN GEAR
DRIVEN GEAR
DRIVEN GEAR
GEAR
KICK
KICK
KICK STARTER
STARTER
STARTER SPINDLE
SPINDLE
SPINDLE

7-3
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

DRIVE BELT
REMOVAL
● Remove the LH. side cover.
● Remove the 2 dowel pins and gasket.
● Remove the start pinion ass,y.

·Use the special tool when loosening the lock nut.

Holding the rear wheel or rear brake will damage the
final reduction system.
DRIVER
DRIVER
DRIVER FACE
FACE
FACE DRIVER
DRIVER
DRIVER BELT
BELT
BELT DRIVEN
DRIVEN
DRIVEN PULLEY
PULLEY
PULLEY

● Hold the clutch outer using the universal holder and

remove the nut.
● Remove the clutch outer.

TOOL: UNIVERSAL HOLDER

UNIVERSAL
UNIVERSAL
UNIVERSAL HOLDER
HOLDER
HOLDER

● Loosen the drive face setting nut 12mm with the clutch
center holder.
● Remove the drive face.

TOOL: CLUTCH CENTER HOLDER

● Remove the driven pulley/ clutch with the drive belt in

place.
● Remove the drive belt from the driven pulley groove
and drive pulley groove.

7-4
 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION
DRIVE BELT INSPECTION
● Check the drive belt for cracks, pry separation and
wear; replace as necessary.
COG ● Measure the width of the drive belt as shown.
● Replace the belt if the service limit is exceeded.
WIDTH
SERVICE LIMIT : 15.5mm

·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/clutch 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.

DRIVEN PULLEY ·Hold the pulley faces apart preventing them from
/CLUTCH closing.

DRIVE FACE
REMOVAL
● Remove the L. side cover. ( 7-2 )
● Hold the drive face using the clutch center holder and
remove the nut and washer.

TOOL : CLUTCH CENTER HOLDER

● Remove the drive face.

● Remove the flage nut, washer drive face from crank
shaft.

7-5
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

MOVABLE
MOVABLE DRIVE
MOVABLE DRIVE FACE
DRIVE FACE
FACE
MOVABLE DRIVE FACE DISASSEMBLY
● Remove the dirve face. ( 7-6 )
● Remove the movable drive face.

CRANK
CRANK
CRANK SHAFT
CRANK SHAFT
SHAFT
SHAFT DRIVE
DRIVE FACE
DRIVE FACE
DRIVE BOSS
FACE BOSS
FACE BOSS
BOSS

MOVABLE DRIVE FACE INSPECTION

● The weight rollers push on the movable drive pulley
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.

SERVICE LIMIT : 15.4mm

● 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

SERVICE LIMIT : 19.97mm

● Movable drive face inner diameter

SERVICE LIMIT : 20.6mm

MOVABLE DRIVE FACE ASSEMBLY/INSTALLATION

● Install the weight roller on the movable drive face.
● Install the ramp plate.
● Pack the inside of the movable drive face with the
specified amount of grease.
● Install the movable drive face boss.

RAMP
RAMP PLATE
RAMP PLATE
PLATE

MOVABLE
MOVABLE
MOVABLE DRIVE
DRIVE
DRIVE FACE
FACE
FACE
DRIVE
DRIVE FACE
DRIVE FACE BOSS
FACE BOSS
BOSS

7-6
 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

·Do not get the grease on the pulley face. Remove

any misplaced grease with a degreasing agent.

● Install the movable face assembly on the crankshaft.

DRIVE FACE INSTALLATION

SQUEEZE
● Squeeze the drive belt into the pulley groove and pull
the drive belt over the drive face shaft.
● Refer to drive belt assembly method.
● Install drive face, washer, drive pully nut on the
crank shaft.

DRIVE BELT

● Install the drive belt on the movable drive face.

● Install the drive face on the crank shaft serration.

● Install the washer and install flange nut.

7-7
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION
● Tighten the drive pulley nut to the specified torque.

·m
TORQUE VALUE : 5.5kgf·
TOOL : CLUTCH CENTER HOLDER

·Correctly match the drive pulley face and crank shaft

serration when assembling.
·If the universal holder cannot be used, remove the
cooling fan and hold the flywheel with the universal
holder.

● Install the driven pully auter.

● Tighten the driven pully outer to the specified
torque with universal holder.

CLUTCH/DRIVEN PULLEY
DISASSEMBLY
● Remove the L.side cover. ( 7-2 )
● Remove the drive face. ( 7-9 )

● Hold the clutch outer using the universal holder and

remove the flange nut, then remove the clutch outer.
● Remove the drive belt.
● Remove the driven pulley.
● Install in the reverse order of removal.

7-8
 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

CLUTCH SPRING DRIVEN PULLY SUB ASS’Y

CLUTCH / COMPRESSOR
DRIVEN FACE DISASSEMBLY
● The clutch/driven face are assembled toward the clutch
spring compressor.

·Make sure that the boss portions of the clutch/driven

face are matched with the clutch spring compressor
hole.
TOOL : CLUTCH SPRING COMPRESSOR

● Fix the clutch spring compressor with a vice, etc.

● Disassemble the 28mm special nut with a socket
wrench. Disassemble the clutch driven face form the
SOCKET clutch spring compressor.
WRENCH 39mm
TOOL : CLUTCH SPRING COMPRESSOR
SOCKET WRENCH 39× × 41mm

● Assembly is done in the reverse order of disassembly.

CLUTCH SPRING
COMPRESSOR

● Remove the seal collar from the driven pulley.

● Remove the guide pins and guide pin rollers and the
movable driven pulley face.
MOVABLE DRIVEN FACE OIL SEAL

·Some guide pin can be separated to the roller and the

pin.

● Remove the O-ring and oil seals from the movable

O-RING driven face.
GUIDE PIN

INSPECTION

Clutch outer

● Measure the I.D. at shoe contact surface of the clutch

outer. Replace the outer if the service limit is exceeded.

SERVICE LIMIT : 107.5mm

CLUTCH OUTER

7-9
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION
Clutch Shoe Inspection

● Measure the thickness of each shoe ; replace if the

service limit is exceeded.

SERVICE LIMIT : 2.0mm

CLUTCH SHOE

Movable Driven Face Spring Inspection

MOVABLE DRIVEN FACE SPRING ● Measure the free length of the driven pulley spring and
replace if the service limit is exceeded.

SERVICE LIMIT : 92.8mm

FREE LENGTH

Driven Face Inspection

● Check the following;
DRIVEN FACE -Both faces for damage or excessive wear.
-Guide pin groove for damage or deformation.
● Replace damaged or worn parts an necessary.
● Measure the O.D. of the driven face and the I.D. of the
movable driven face. Replace either part if the service
limit is exceeded.

Driven face outer diameter service limit : 33.94mm

Movable driven face inner diameter service limit : 34.06mm
MOVABLE DRIVEN FACE GUIDE PIN
GROOVE

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.

NEEDLE
OUTER BALL BEARING
BEARING

7-10
 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION
CLUTCH SHOE REPLACEMENT
SHOE SPRING DRIVE PLATE ● Remove the E-clip and washers, then remove the
clutch shoes and shoe springs from the drive plate.

·Some models use one retainer plate instead of three

washers.

CLUTCH SHOE ● Check the shoe springs for damage or loss of tension.
E-CLIP WASHER

● Check the damper rubbers and shoe springs for

damage or deformation; replace as necessary.
● Apply a small amount of grease on the pivot pins.
PIVOT PIN

DAMPER RUBBERS

● Install new clutch shoes on the pivot pins and push

them into place.
● Use a small amount of grease on the pivot pin and
DAMPER RUBBER
keep grease off of the brake shoes. Replace the brake
shoes if there is any grease on them.

·Grease or oil damages clutch shoes and can lead to a

loss of engaging ability.

CLUTCH SHOE

● Use pliers to hook the springs to the shoes.

● Install the E-clip and washers or retainer plate into the
pivot pins.
SHOE SPRING

·Apply only to the belt type gearless transmission.

·Wipe the grease came out from the pivot pin
thoroughly.

7-11
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

CLUTCH/DRIVEN PULLEY
OIL SEAL ASSEMBLY
● Install new oil seals and O-rings on the movable driven
pulley face.

●Lubricate the inside of the movable face with the

specified amount of grease.

GREASE APPLICATION : 5.0~5.5g

O-RING

● Install the movable face on the driven pulley face.

● Install the guide pins, or guide pins and guide pin
MOVABLE DRIVEN FACE rollers.

GUIDE PIN
DRIVEN FACE

● Install the seal collar.

SEAL COLLAR

● 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
SOCKET
tighten the lock nut to the specified torque using the
WRENCH 39mm
lock nut wrench.
·m
TORQUE VALUE : 4.0kgf·

CLUTCH ● Remove the spring compressor.

SPRING ● Install the clutch/driven pulley and drive belt onto the
COMPRESSOR dirve shaft.

TOOL : CLUTCH SPRING COMPRESSOR

SOKET WRENCH 39mm

7-12
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION

DRIVEN PULLEY ASSEMBLY

INSTALLMENT
● Rotate the driven pully ass’y to the right side and
enlarge the belt groove.
● Install the drive belt on the driven pully subass’y and
mount on to the drive shaft.

● Install the drive belt on the assemblying area of the

movable drive face.

● After assemblying the drive face in serration area of the

LH. crank shaft.
● Install the drive pully nut temperarily.

●Tighten the starter driven gear with stardard torque.

·m
STANDARD TORQUE : 5.5kgf·

7-13
KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION
● After assemblying the clutch outer, install the flange
nut temperarily.
● Fix the clutch outer with the universal holder, tighten
the flangenut with stardard torque.

·m
STANDARD TORQUE : 4.0kgf·

● Install the LH. crank case cover and tighten the bolts.

7-14
MEMO
CYLINDER HEAD / CYLINDER / PISTON

CYLINDER HEAD BOLT

CYLINDER HEAD

CYLINDER HEAD GASKET

CYLINDER
TOP RING
SECOND RING

CYLINDER GASKET
STOPPER PIN

PISTON CLIP

PISTON PIN

NEEDLE BEARING

8-0
8. CYLINDER HEAD/CYLINDER/PISTON

SERVICES INFORMATION 8-1

TROUBLESHOOTING 8-1
FAN COVER, SHROUD REMOVAL 8-2
CYLINDER HEAD/ CYLINDER/ PISTON 8-2

SERVICE INFORMATION
GENERAL SAFETY
● Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling
pin by striking the cylinder too hard.
● Take precautions not to damage the inside of the cylinder or the exterior part of the piston.
● Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.

SPECIFICATIONS
Unit : mm(in)
ITEM STANDARD VALUE SERVICE LIMIT
Inner diameter 40.005~40.010mm 40.05mm 8
CYLINDER Cylindricality - 0.10mm
Out of roundness - 0.10mm
PISTON, Piston skirt outer diameter 39.955~39.970mm 39.90mm
PISTON PIN, Piston pin hole inner diameter 12.002~12.008mm 12.03mm
PISTON RING Piston pin outer diameter 11.994~12.000mm 11.98mm
CYLINDER TO PISTON CLEARANCE 0.040~0.055mm 0.13mm

TROUBLESHOOTING
Comperssion low
● Worn cylinder or piston rings
● Leaking valve seats

Excessive smoke
● Worn cylinder or piston
● Improper installation of piston rings
● Scored or scratched piston or cylinder wall

Overheating
● Excessive carbon build-up on the piston combustion
● Incorrect spark plug

Knocking or abnormal noise

● Worn piston and cylinder
● Excessive carbon build-up
● Low octane fuel

8-1
CYLINDER HEAD / CYLINDER / PISTON

FAN COVER, SHROUD REMOVAL

● Remove the luggage box. ( 3-3 )
● Remove the plug maintenance cover. ( 3-3 )

SPARK PLUG
SPARK
SPARK PLUG CAP
PLUG CAP
CAP

● Loosen the 2 fan cover flange bolts.

FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS ● Loosen the 2 left shroud flange bolts.
● Remove the left shroud.

·Pay attention not to damage certain part when

removing
·Remove according to the working precedure.

● Install in the reverse order of removal.

FAN
FAN
FAN COVER
COVER
COVER CYLINDER HEAD/ CYLINDER/ PISTON
REMOVAL
● Remove the luggage box. ( 3-3 )
● Remove the the battery maintence lid. ( 3-3 )
● Remove the center cover. ( 3-3 )
● Remove the floor side cover. ( 3-4 )
● Remove the floor panel. ( 3-4 )
● Remove the exhaust muffler assembly. ( 3-7 )
● Remove the fan cover shroud.

MUFFLER
MUFFLER
MUFFLER
MUFFLER

8-2
 CYLINDER HEAD / CYLINDER / PISTON

SPRAK
Cylinder Head
SPRAK PLUG
SPRAK PLUG
PLUG
● Loosen the 4 cylinder head bolts.

·Bolts are loosened by rotating 2~3 times and

alternating to a diagonal bolt.

● Remove the cylinder head.

● Remove the cylinder head gasket.

CYLINDER
CYLINDER
CYLINDER HEAD
HEAD
HEAD

Cylinder

● Remove the cylinder.

CYLINDER
CYLINDER
CYLINDER

Piston/Piston Ring
PISTON
PISTON
PISTON
PISTON
● Remove the piston pin clip.
● Remove the piston pin.

·Be careful not to bend pins.

·Be careful not to damage the cylinder and crankcase
gasket face when cleaning.

● Remove the piston.

BEARING
BEARING
BEARING ● Remove the needle bearing from the small end of the
connecting rod.

8-3
CYLINDER HEAD / CYLINDER / 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.
·Mark and store the pistons and piston pins so that
they can be reinstalled in their original positions.

PISTON
PISTON
PISTON PIN
PIN
PIN CLIP
CLIP
CLIP PISTON
PISTON
PISTON PIN
PIN
PIN PISTON
PISTON
PISTON

INSPECTION
● There is more carbon deposit whitin the engine in case
of 2 cycle engine than 4 cycle engine because the
engine oil is burnt in the 2 cycle engine. Excessive
carbon deposit may cause self-ignition by the
overheating of the carbon in the combustion chamber
and the piston head and may damage the engine.
● Carbon deposit in the exhaust gas port disturbs exhaust
gas flow and causes decrease of the output. Remove
the carbon deposit periodically.

CYLINDER HEAD
CYLINDER
CYLINDER HEAD
HEAD

CYLINDER
CYLINDER
CYLINDER
CYLINDER

·Pay attention not to damage the combustion

chamber, the piston and the cylinder when removing
the carbon.

● Remove the cylinder head and remove the carbon with

the piston being in the top dead center.
● Dismount the cylinder, remove the carbon deposited in
the exhaust gas port and clean the remaining carbon in
the cylinder.

Cylinder Wear Inspection

● Inspect the cylinder wall for scratches and wear.
● Inspect the area near T.D.C (Top Dend Center)
carefully. This area is especially subject to wear due to
the possibility of borderline lubrication from heat and
CYLINDER top ring compression.
HEAD SIDE
WEAR

8-4
 CYLINDER HEAD / CYLINDER / PISTON
● Measure and record the cylinder I.D. at the three levels
in both an X and Y axis.
● Take the maximum reading to determine the cylinder
wear.
TOP

MIDDLE ·Avoid the intake and exhaust ports when measuring.

PORTS ● Measure the piston O.D.

BOTTOM
SERVICE LIMIT : 40.05mm

● Calculate the piston-to-cylinder clearance. Take the

maximum reading to detemine the clearance.

Piston Outer Diameter Inspection

MICROMETER ● Measure and record the piston O.D. 90。to the piston
pin bore and at the point specified in the Model
Spectific manual, near the bottom of the piston skirt.
● Replace the piston if the service limit is exceeded.

SERVICE LIMIT : 39.90mm

● Calculate the piston-to-cylinder clearance

SPECIFIED
DISTANCE

● Install the needle bearing and piston pin in the

connecting rod small end and check for excessive play.

Piston Pin Inspection

● Measure the piston pin O.D. at three points.

● Replace the piston pin if the service limit is exceeded.

SERVICE LIMIT : 11.98mm

MICROMETER

8-5
CYLINDER HEAD / CYLINDER / PISTON
Piston Pin Bore Inspection

● Measure the piston pin bore I.D. in an X and Y axis.

Take the maximum reading to determine the I.D.
●Replace the piston if the I.D. is over the service limit.

SERVICE LIMIT : 12.03mm

CYLINDER GAUGE

PISTON/PISTON RING INSTALLATION

TOP RING
● Clean the piston ring grooves.
● Lubricate the piston rings and ring grooves with clean
SECOND RING 2-stroke oil.
● Install the piston rings on the piston with the marks
facing up.

·Do not confuse the top and second rings. Be sure to

MARK install them in the proper grooves.
·Some 2-stroke engines use an expander ring behind
the second ring.

● In 2-stroke engines, the piston has stopper pins that

STOPPER PIN hold the piston rings away from the intake and exhaust
ports.
● Align the piston ring end gaps with the stopper pins.
● Check the fit of each ring in the groove by pressing the
ring into the groove. Make sure that it is flush with the
piston at several points around the ring.
● If the ring rides on the stopper pin, it is damaged
during assembly.

● Coat the needle bearing (2-stroke engine only) and

piston pin with the recommended oil. Lubricate the
piston pin
● Install the needle bearing into the connecting rod.
● Install the piston and insert the piston pin.

NEEDLE BEARING

8-6
 CYLINDER HEAD / CYLINDER / PISTON

PISTON PIN MARK

·The mark that is stamped on the piston head should
PISTON PIN CLIP be facing the correct direction.
“ ” MARK : TO INTAKE SIDE
“EX” MARK : TO EXHAUST SIDE
“ ”MARK : TO ONGOING SIDE
END GAP
“ ” MARK : TO INTAKE SIDE

● Install the new piston pin clips.

CUTOUT

·Take care not to drop the piston pin clip into the
crankcase.
CYLINDER
CYLINDER
CYLINDER HEAD
HEAD
HEAD
·Make sure to set the pistion pin clip in the groove
properly.
·Do not align the clip’s end gap with the piston
cutout.

CYLINDER/ CYLINDER HEAD

INSTALLATION
● Apply the engine oil inside of cylinder piston ring and
install them.
● Install the new piston pin clip.

8-7
TRANSMISSION/CRANKSHAFT/CRANKCASE

R. CRANK CASE

CRANK SHAFT

L. CRANK CASE

COUNTER GEAR FINAL GEAR

COUNTER
SHAFT
MISSION COVER

DRIVE SHAFT

9-0
9. TRANSMISSION/CRANKSHAFT/CRANKCASE

SERVICE INFORMATION 9-1 CRANKSHAFT REMOVAL 9-5

SERVICE STANDARD 9-1 CRANKSHAFT BEARING REMOVAL 9-5
TRANSMISSION/CRANKSHAFT/ CRANKCASE BEARING REMOVAL 9-6
CRANKCASE 9-2 CRANKSHAFT INSTALLATION 9-7

SERVICE INFORMATION
GENERAL SAFETY
● This section describes how to remove the crank case and to maintain the transmission and the crankshaft.
● Always use special tools to change the drive shaft. Fix the bearing inner race, andn 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 4 )
-CARBURETOR ( SECTION 5 )
-ENGINE ( SECTION 6 )
-CYLINDER HEAD/ CYLINDER/ PISTON ( SECTION 8 )
-AC GENERATOR ( SECTION 13 )
-DRIVE PULLEY ( SECTION 7 )
-CLUTCH/DRIVEN PULLEY ( SECTION 7 ) 9
-REED VALVE ( SECTION 5 )
● The following parts must be removed prior to changing the L. crank case. Follow the removal procedure specified in
each section.
-TRANSMISSION ( SECTION 9 )
-REAR BRAKE ( SECTION 12 )
● 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.

SERVICE STANDARD
ITEM STANDARD VALUE SERVICE LIMIT
Large end side clearance 0.15~0.55mm 0.60mm
CRANK Connecting rod large end right angle direction clearance 0.010~0.02mm 0.04mm
SHAFT Right 0.03mm 0.15mm
Crank shaft shaking
Left 0.05mm 0.10mm

9-1
TRANSMISSION/CRANKSHAFT/CRANKCASE

TRANSMISSION
TRANSMISSION
TRANSMISSION COVER
TRANSMISSION COVER
COVER TRANSMISSION/CRANKSHAFT/
CRANKCASE
DISASSEMBLY
● Remove the L. side cover. ( 7-2 )
● Remove the continuously variable transmission.
( SECTION 7 )
● Remove the exhaust muffler. ( 3-7 )
● Remove the rear wheel. ( 11-3)
● Install the oil sump under the cover of transmission.
● Loosen the 5 transmission cover flange bolts.
● Remove the transmission cover.

COUNTER
COUNTER
● Remove the final shaft gear.
COUNTER SHAFT
SHAFT
SHAFT
● Remove the thrust washer.
● Remove the countershaft.
● Remove the counter shaft gear.
● Remove the side washer.

COUNTER
COUNTER GEAR
COUNTER GEAR
GEAR FINAL
FINAL GEAR
FINAL GEAR
GEAR

● Remove the drive shaft from transmission cover with

BEARING
BEARING
BEARING
BEARING the press.

·Take precautions not to damage the cover joints.

● Remove the oil seal of the drive shaft.

DRIVE
DRIVE SHAFT
DRIVE SHAFT
SHAFT

INSPECTION
DRIVE
DRIVE SHAFT
DRIVE SHAFT
DRIVE SHAFT
SHAFT ● Inspect the drive shaft for wear or damage.

9-2
 TRANSMISSION/CRANKSHAFT/CRANKCASE
● Inspect the final shaft for wear or damage.

FINAL
FINAL
FINAL GEAR
GEAR
GEAR

COUNTER
COUNTER
COUNTER GEAR
GEAR
GEAR ● Inspect the countershaft for wear or damage.

COUNTER
COUNTER
COUNTER SHAFT
COUNTER SHAFT
SHAFT

BEARING
BEARING
BEARING Bearing Inspection

● Manually turn the bearing inner race installed inside

the transmission cover, and check if the race is turning
smoothly.
● Verify the outer race is accurately installed in the case.
● Replace the bearing, if necessary.

·Install the bearing with the carved mark directing to

the outside.

DRIVER HANDLE
DRIVER
DRIVER HANDLE A
HANDLE A
A
● Use special tools to push in the bearing into the case.

DRIVER
DRIVER
DRIVER TOOLS : DRIVER HANDLE A
PILOT
PILOT
PILOT OUTER DRIVER 52X55mm
DRIVER PILOT 20mm

● Check the L. crank case oil seal for wear or damage.

OUTER
OUTER DRIVER
OUTER DRIVER
DRIVER

9-3
TRANSMISSION/CRANKSHAFT/CRANKCASE
TRANSMISSION ASSEMBLY
● Install the drive shaft on the transmission cover.
● Install a new drive shaft oil seal.

TOOL : CRANK ASSEMBLY

FINAL GEAR
FINAL
FINAL GEAR
GEAR
● Install the thrust washer, final gear and counter gear,
side washer on the L. crankcase.

COUNTER
COUNTER
COUNTER GEAR
GEAR
GEAR

● Install new dowel pins.

● Install a new transmission cover seal on the
transmission cover.
● Install the transmission cover.
● Tighten the transmission cover with the flange bolts.

·Tighten bolts diagobally and alternately and tighten

with specified torque in the end.

● Remove the oil check bolt, release the transmission oil

OIL
OIL CHECK
OIL CHECK BOLT
CHECK BOLT
BOLT filler ACG cap or the L. 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 #80~90

TRANSMISSION OIL AMOUNT : 0.09

9-4
 TRANSMISSION/CRANKSHAFT/CRANKCASE
CRANKCASE
CRANKCASE PULLER
CRANKCASE PULLER
CRANKCASE PULLER
PULLER CRANKSHAFT REMOVAL
● Loosen the 6 R. crankcase flange bolts.
● Secure a crankcase puller on the R. crankcase and
remove the R. crankcase from the L. crankcase.

TOOL : CRANKCASE PULLER (0751-00003)

● Secure a crankcase puller on the L. crankcase and

remove the crankshaft from the L. crankcase.

R.
R. CRANKCASE
R. CRANKCASE
CRANKCASE

CRANKCASE
CRANKCASE
CRANKCASE PULLER
PULLER
PULLER
L.
L. CRANKCASE
L. CRANKCASE
L. CRANKCASE
CRANKCASE
·Be careful not to distort the mating surface of the
crank case during disassembly.
·Do not force to disassemble by pounding on the
crankshaft.

TOOL : CRANKCASE PULLER (0751-00003)

● Remove the oil seal from the R. and L. crankcases.

● Remove the dowel pin.

CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT

UNIVERSAL
UNIVERSAL BEARING
UNIVERSAL BEARING PULLER
BEARING PULLER
PULLER
CRANKSHAFT BEARING REMOVAL
● If the radial ball bearing is left on the crankshaft,
remove the bearings out of the crankshaft using a
bearing puller.

TOOL : UNIVERSAL BEARING PULLER (0755-00001)

CRANKSHAFT INSPECTION
● Place the crankshaft on a stand or V-block, and check
the journal vibration.

SERVICE LIMIT : RIGHT SIDE 0.1mm

LEFT SIDE 0.15mm

9-5
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Measure the side gap between the connecting rod big
end and the crank weight.

SERVICE LIMIT : 0.6mm

● Check the vertical shaft play of the connecting rod big

end from the X and Y direction.

SERVICE LIMIT : 0.05mm

CRANKCASE BEARING REMOVAL

● Remove the transmission and crankshaft.

INSPECTION
● Manually turn the bearing inner race to see if it rotates
smoothly.
● Check the outer race to see if it is accurately pressed
into the case.
● If the outer race is excessively loose, or is loosely
pressed into the case, remove in and replace with a
new one.
R.
R.
R. CRANKCASE
CRANKCASE
CRANKCASE

REPLACEMENT
BEARING
BEARING
BEARING REMOVER
REMOVER
REMOVER
L. Crankcase
● Use special tools to remove the drive shaft bearing.

TOOLS : BEARING REMOVER SET

REMOVER SHAFT
REMOVER HEAD

● Remove the final gear bearing and oil seal.

● Remove the counter gear bearing.

9-6
 TRANSMISSION/CRANKSHAFT/CRANKCASE
● Apply clean engine oil to a new bearing, and assemble
OIL
OIL
OIL SEAL
SEAL
SEAL it to the crank case.
● Install a new final gear oil seal.

DRIVER
DRIVER
DRIVER HANDLE
HANDLE
HANDLE CRANKSHAFT INSTALLATION
● Apply clean engine oil to the new R. crankshaft
bearing, and press in the bearing into the R. crank case.

TOOLS : DRIVER HANDLE A

OUTER DRIVER 52x55mm
DRIVER PILOT 20mm

DRIVER
DRIVER HANDLE
DRIVER HANDLE
HANDLE ● Use special tools to assemble the crankshaft bearing to
the L. crank case.

TOOLS : DRIVER HANDLE A

OUTER DRIVER 52x55mm
DRIVER PILOT 20mm

● Clean the crankcase using cleaning oil, and check for

rack and damage to each area.

·After removing the liquid gasket from the joining

face of the crankcase, amend the scratched areas
using oil ston.
·Apply 2-cycle oil to the radial ball bearings and the
connecting rod large end portion.

● Install the crankshaft to the L. crankcase.

·Install not to interfere with the case with being

CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT careful of connecting rod location.
ASSEMBLER
ASSEMBLER
ASSEMBLER TOOL : CRANKSHAFT ASSEMBLER

9-7
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Apply a liquid gasket to the L. crankcase joining face,
install the dowel pins.
● Install the R. crankcase.
● Install the 6 flange bolts.

·Make sure that there is no adhesion of gasoline to the

R., L. crankcase liquid gasket face.
·Do not apply excessive liquid gasket fluid
excessively.

TOOL : CRANKSHAFT ASSEMBLER

R.
R.
R. CRANKCASE
CRANKCASE
CRANKCASE

1.0mm
OIL
OIL SEAL
OIL SEAL DRIVER
SEAL DRIVER
DRIVER
·Make sure that the crankshaft is rotated smoothly
after installation (prior to oil seal installation).
·If the smooth rotation is not acquired, tap the
crankshaft bearing part of crankcase with plastic
hammer to ensure proper installation without
mismatch.

● Install a new L. oil seal in the crankcase end portion at

1.0mm depth.

● Install a new R. oil seal in the crankcase end portion at

5.0mm 5.0mm depth.

OIL
OIL SEAL
OIL SEAL DRIVER
SEAL DRIVER
DRIVER

9-8
MEMO
FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE

STEERING STEM
FRONT FORK

FRONT BRAKE DISK

FRONT TIRE
FRONT WHEEL RIM

10-0
10. FRONT WHEEL/FRONT FORK/STEERING

SERVICE INFORMATION 10-1 FRONT WHEEL 10-5

SPECIFICATION 10-1 TUBELESS TIRE 10-9
TROUBLESHOOTING 10-2 FRONT FORK 10-14
STEERING HANDLE 10-3 STEERING STEM 10-19

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.
● This section describes how to remove and maintain front wheels, front fork and steering system. For information on the
front brake system, refer to section 10.
● Place a jack underneath the engine to support the 2-wheeled vehicle.

SPECIFICATIONS
ITEM STANDARD VALUE SERVICE LIMIT 10
FRONT AXLE DEFLECTION - 0.2mm
RADICAL - 2.0mm
FRONT WHEEL RIM RUNOUT
AXIAL - 2.0mm
FRONT FORK TUBE DEFLECTION - 0.2mm
FRONT FORK OIL LEVEL 58㎤ -
FORK SPRING FREE LENGTH 263.5mm -

TORQUE VALUES

STEERING STEM LOCK NUT 7.0㎏·m

BRAKE DISK BOLT 3.9㎏f·m
FRONT AXLE NUT 6.0㎏f·m

10-1
FRONT WHEEL/FRONT FORK/STEERING

TROUBLESHOOTING
Hard steering
● Steering bearing adjustment nut too tight.
● Faulty steering stem bearings.
● Damaged steering stem bearings.
● Insufficient tire pressure.

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.

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.

10-2
 FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE
REMOVAL
● Remove the front cover. ( 3-5 )
● Remove the front handle cover. ( 3-6 )
● Remove the rear handle cover. ( 3-6 )
● Removal must be performed with the rear handle cover
and the speedometer installed.
● Loosen the throttle housing fixing pin screw.
● Remove the throttle upper housing.
● Remove the throttle under housing.
● Remove the throttle grip.
● Loosen the 2 master cylinder holder bolts, remove the
TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW master cylinder.

·Support master cylinder properly to prevent brake

fluid from leaking.
·If the master cylinder is dropped upside down, air
may enter the hydraulic system. Fix it to the vehicle
while maintaining the correct assembled location.

● Loosen the handle bracket fixing washer bolt.

● Remove the handle bracket bend.
● Remove the handle bracket.
● Remove the L. handle grip.
FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS

● Loosen the handle setting U-nut, remove the handle set

HANDLE
HANDLE BRACKET
HANDLE BRACKET
BRACKET collar and flange bolt.
● Remove the rear brake cable, front brake hose,
speedometer cable, handle cable from the guide.
● Remove the steering handle from the steering stem.

HANDLE BRACKET
HANDLE
HANDLE BRACKET BEND
BRACKET BEND
BEND

INSTALLATION
● Install steering handle to the steering stem.
● Install the handle setting bolt, U-nut, handle set collar.

·When installing the handle setting collar, match it

with the groove accurately.

·m
TORQUE VALUE : 5.0kgf·

HANDLE
HANDLE
HANDLE SETTING
SETTING
SETTING BOLT
BOLT
BOLT

10-3
FRONT WHEEL/FRONT FORK/STEERING
● Install the rear brake cable, front brake hose,
speedometer cable to the handle cable guide.
● Apply DAELIM Bond A to the inside surface of the
grip and to the clean surface of the left handle bar. Wait
3~6 minutes and install the grip.
(Bond A :ROYAL BOND 1300)

·Clean the bonding surface to avoid oil, grease or

gasoline from attatching.
·Leave it for minimum 1 hour until the bond is dried.
·Use the bond according to the bond manual enclosed
and install the grip while rotating it before the bond
is dried completely.
● Align the positioning pin with the handle hole and
install the L. handle bracket.

·m
TORQUE : 1.2kgf·

● Clean the throttle grip surface, apply the grease and

install the grip.
● Connect the throttle cable to the groove of the grip.
● Tighten the pin screws after assembling the under and
upper throttle housings.

POSITIONING
POSITIONING PIN
POSITIONING PIN
POSITIONING PIN
PIN

MASTER
MASTER
MASTER CYLINDER
CYLINDER
CYLINDER ·Check the throttle grip for smooth operation and
adjust the free play to 2~6mm.
THROTTLE
THROTTLE
THROTTLE HOUSING
HOUSING
HOUSING
● Match the master cylinder with the punch mark of the
handle, install it with the mark in the master cylinder
holder facing upwards or front and tighten the rear or
front first.

PUNCH
PUNCH
PUNCH
MARK
MARK
MARK
·Check to see if the cylinder is passing each cable and
wire harness directly and make sure that there is any
interference by rotating the handle to the right and
left.

● Install the rear handle cover. ( 3-6 )

MASTER
MASTER
MASTER CYLINDER
CYLINDER
CYLINDER SPEEDOMETER
SPEEDOMETER
SPEEDOMETER ● Install the front handle cover. ( 3-6 )
● Install the front cover. ( 3-5 )

10-4
 FRONT WHEEL/FRONT FORK/STEERING

FRONT WHEEL
REMOVAL
● Remove screws from the speedometer gear box, and
separate the speedometer cable.

·Loosen axle nuts. Support bottom of engine with a

jack until the front wheel is lifted.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER CABLE
CABLE
CABLE

● Loosen the axle nut.

● Remove the front axle.
● Remove the front wheel.

·Do not operate brake lever after the front wheel is

removed.

● Remove the speedometer gear box.

AXLE
AXLE
AXLE NUT
NUT
NUT

INSPECTION
DIAL GAUGE ● Check the front axle for deflection. Place the front axle
on a V-block, and measure deflection with a dial gauge.

SERVICE LIMIT : 0.2mm

AXLE

● Place the front wheel on an inspection stand. Slowly

DIAL
DIAL GAUGE
DIAL GAUGE
GAUGE
turn the wheel, and check the rim runout with a dial
gauge.

SERVICE LIMIT : Radial 2.0mm

Axial 2.0mm

10-5
FRONT WHEEL/FRONT FORK/STEERING
Bearing Inspection

● Manually turn the bearing inner race, and replace if it

makes noise or is worn. Check if the bearing outer race
is accurately fitted into the wheel hub, and replace
worn ones.

·Replace bearings in pairs (left and right set).

FRONT WHEEL DISASSEMBLY

● Remove the speedometer gear box, dust seal, and
speedometer gear retainer.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER GEAR
GEAR
GEAR BOX
BOX
BOX

● Remove the front brake collar A.

FRONT
FRONT
FRONT BRAKE
FRONT BRAKE COLLAR
BRAKE COLLAR A
COLLAR A
A

● Remove te dust seal and brake disc.

● Check the disc for defects.

DUST
DUST SEAL
DUST SEAL
SEAL

10-6
 FRONT WHEEL/FRONT FORK/STEERING
WHEEL BEARING REPLACEMENT
BEARING
BEARING
BEARING REMOVER
REMOVER
REMOVER ● 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.

DRIVER
DRIVER
DRIVER HANDLE
HANDLE
HANDLE ● 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
ATTACHMENT, 32x35mm
PILOT, 15mm

·The bearing inserted in the last must be inserted until

it contacts with the distance collar.
·Excessively inserted bearing can cause damage the
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER opposite side bearing.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER GEAR
GEAR
GEAR GEAR BOX
GEAR
GEAR BOX
BOX

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.

BRAKE DISK DISTANCE COLLAR

SPEEDOMETER TIRE
GEAR BOX R. SIDE COLLAR
RADIAL BEARING

NUT

OIL SEAL
RADIAL BEARING

AXLE

RIM

10-7
FRONT WHEEL/FRONT FORK/STEERING
FRONT WHEEL ASSEMBLY
● Apply grease to the right side dust seal rim.
● Install the right side dust seal.
● Install the brake disk.
● Install disk bolts.

·m
TORUE VALUE : 3.9kgf·

DUST
DUST
DUST SEAL
SEAL
SEAL

● Install the front brake collar A.

FRONT
FRONT
FRONT BRAKE
BRAKE
BRAKE COLLAR
COLLAR
COLLAR A
A
A

● Install speedometer gear box seal.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
GEAR
GEAR BOX
GEAR BOX
BOX

● Assembly speedometer gear box in speedometer gear

box seal.

SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETER GEAR BOX
GEAR BOX
BOX

10-8
 FRONT WHEEL/FRONT FORK/STEERING

VALVE CAP
TUBELESS TIRE
REMOVAL
● Remove the wheel.

·Single brake disk type : To prevent damage to the

disk, place the wheel on the level surface with the
disk facing up.
RIM VALVE
● Remove the valve cap and bleed air by pressing the
valve core.
● Remove the valve core after bleeding air completely.
● Remove the valve stem nut and push the valve stem
lightly.
● If a bead stopper is installed, loosen the lock nut and
push the bead stopper down.
● Collapse in the bead with a tire bead breaker.
● If no tire bead breaker is available, step on the side wall
to collapse the bead.

·Do not step on the rim.

● Collapse the bead into the rim center and slide the tire
out of position.

RIM CENTER

·Tire can be easily removed once the beads are

collapsed completely.

● Apply a mild detergent solution to the rim and tire

mating surfaces.
● Be sure that the bead is completely collapsed.
● Insert the tire lever from the opposite side of the valve
and raise the bead over the rim.

TIRE LEVER
·Be sure to use motorcycle tire levers.
·Do not apply the mild detergent solution to the rim
and tire mating surfaces of low pressure tire. Apply
water only.

RIM
PROTECTOR

10-9
FRONT WHEEL/FRONT FORK/STEERING
● Insert another tire lever at 30~50mm from the first tire
lever and remove the tire from the rim, little by little.
TIRE LEVER

·Do not try to remove the bead too much at one time.

RIM PROTECTOR

● Repeat the above procedures until half of bead is

removed. Then remove the remaining bead by hand.

TIRE LEVER

● Remove the another tire from the rim according to the

same procedures.
TIRE LEVER

RIM PROTECTOR

RIM VALVE REPLACEMENT

RIM VALVE
● Cut off the rim valve at its base.
● Apply mild detergent solution to a replacement rim
valve and insert it from inside of the rim.

·Be sure to use the recommended rim valve.

·Do not damage the valve hole.
·Replace the rim valve whenever installing a tubeless
tire.

10-10
 FRONT WHEEL/FRONT FORK/STEERING
RIM INSPECTION
● If using a solution (brake cleaner, gasoline, thinner)
when removing the rust and dirt, wipe off the
remainder when reassembling. It may damage the
rubber parts.
● If there is serious deformation, twist or crack, the air
may be leaked. Replace the damaged parts
immediately.
● If there is scratch on bead contacting face more than
RIM 0.5mm in depth or 1.0mm in width, replace the
damaged parts immediately.

·If the combination of tubeless tire and rim isn’t

proper, the tire may come off. It will cause a serious
accident. Pay attention to deal it.

TUBELESS TIRE INSTALLATION

Always use the exclusive tire lever for two-wheeled

vehicles.
Use the rim protector to prevent the scratch of rim.
In case of low pressure tire, if vegetable soapy water is
used, it may slip even after the rim and tire are installed.
Only use the water.

● If the tire has an light mark (yellow paint mark), install

the tire with this mark aligned with the valve.
● If the tire has an arrow mark, install the tire with the
mark pointing in the direction of rotation.
● Stand the tire upright, hold it with one hand and,
starting from the opposite side to the valve, install one
side of the tire on the rim as much as you can by hand.

● Be sure to assemble in the sequence shown.

● Place the wheel on the level surface and install the
remaining portion of the tire using two tire levers.

10-11
FRONT WHEEL/FRONT FORK/STEERING
● Install the other side of the bead while holding the
assembled portion of the bead with your knee to
prevent it from coming off.
● After 1/2 of the bead has been installed, insert the two
tire levers at a distance of 30~40mm to install it.
Repeat this procedure until 3/4 of the bead has been
installed.

TIRE LEVER

·Hold one tire lever upright to remove the other lever.

RIM
PROTECTOR

● Check out whether the bead is in the center of the rim

when 3/4 of the bead has been installed.

·The last portion of the bead is more difficult to

install. The rim and bead may be damaged if the
bead on the opposite side of the point where you are
working is not in the rim center.

● When the remaining bead is only 50~60mm, pull the

RIM PROTECTOR two levers up and over and completely install the bead.
● Install the valve core.

TIRE LEVER
VALVE CORE

10-12
 FRONT WHEEL/FRONT FORK/STEERING
● Apply a mild detergent solution to the bead again.
RUBBER HAMMER ● Tap on the tire tread surface with a rubber hammer so
that the tire and rim fit evenly around the
circumference.
● Be sure that the tire center and rim center are aligned.

● Inflate the tire to 1.5 times the standard recommended

pressure to seat the bead on the rim.

·When air charging, you may hear a loud sound as the

bead seats onto the rim. This is normal.
·When air charging, if air leaks out from between the
rim and bead, let the wheel stand with the valve at
the bottom and put air in while pushing down on the
tire.

● Check that the tire bead seats on the tire rim securely
and the rim line of the tire is concentric with the rim.
RIM LINE

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.

SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETER GEAR BOX
GEAR BOX
BOX

10-13
FRONT WHEEL/FRONT FORK/STEERING
● Install the axle nut.
● Assemble the speedometer cable, and tighten with
screws.
● Place the front wheel on the ground, and tighten the
axle nut to the prescribed torque.

·m
TORQUE VALUE : 6.0kgf·

AXLE
AXLE
AXLE NUT
NUT
NUT

FRONT FORK
REMOVAL
● Remove the front cover. ( 3-5 )
● Remove the front fender. ( 3-5 )
● Remove the front brake caliper. ( 12-7 )
● Remove the front wheel. ( 10-5 )
● Loosen the front brake hose stay bolt, remove the L.
fork.
● Remove the speedometer cable from R. fork
speedometer cable guide.
● Loosen the R. fork securing bolt, remove the
speedometer cable and guide.
SPEEDOMETER
SPEEDOMETER CABLE
SPEEDOMETER CABLE
CABLE

● Loosen the 2 steering stem front fork R., L. stay bolts.

● Remove the front fork.

FLANGE
FLANGE BOLTS
FLANGE BOLTS
FLANGE BOLTS
BOLTS

FRONT FORK DISASSEMBLY

● Remove the fork tube cap bolt.

10-14
 FRONT WHEEL/FRONT FORK/STEERING

·If the screw is completely loosened, the fork tube

SPRING
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.

·If the socket bolt turns idle but cannot be removed,

VISE 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.
RULLER

BRACKET

● Remove the dust seal.

DUST
DUST SEAL
DUST SEAL
SEAL

10-15
FRONT WHEEL/FRONT FORK/STEERING
● Remove the oil seal stopper ring.

OIL
OIL SEAL
OIL SEAL
SEAL
STOPPER
STOPPER
STOPPER RING
RING
RING

● Remove the oil seal.

·Take precautions not to damage the interior and

OIL
OIL
exterior rim of the bottom case.
OIL SEAL
SEAL
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.
FREE LENGTH Replace defective parts with new ones.

SERVICE LIMIT : 263.5mm

● Place the fork tube on a V-block, and measure

deflection with a dial gauge.
FORK SPRING
SERVICE LIMIT : Replace if the deflection is greater
than 0.2mm

10-16
 FRONT WHEEL/FRONT FORK/STEERING
● Check the slider bush contact face.
● If the slider bush is extensively damaged, replace the
bottom case.

FORK TUBE

FRONT FORK ASSEMBLY

● Wash parts with clean oil prior to assembling.

BOTTOM CASE ● 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.

·m
TORQUE VALUE : 2.0kgf·

·When a vise is used to hold the bottom case, do not

insert the case itself but insert the bracket.

● Apply ATF to a new oil seal.

● Assemble the oil seal to the bottom case.
FORK SEAL DRIVER
● 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 FORK SEAL DRIVER BODY
ATTACHMENT
● Install the oil seal stopper ring
● Accurately assemble the oil seal stopper ring to the
bottom case.

10-17
FRONT WHEEL/FRONT FORK/STEERING
● Install the dust seal.
FORK OIL ● Fill a prescribed amount of automatic transmission
fluid(ATF) into the fork tube.

CAPACITY : 58cm3

OIL ● Slowly press the fork tube 2-3 times to discharge air.
LEVEL

FORK
OIL

● Assemble the spring to the fork pipe.

FREE LENGTH
·Install the spring with the smaller pitch side facing
downward.

FORK SPRING

● Assemble the fork bolt to the fork tube.

FRONT FORK INSTALLATION

● Install the front fork to the steering stem.
● Install the front fork setting bolt.

·m
TORQUE VALUE : 4.0kgf·

SETTING
SETTING BOLTS
SETTING BOLTS
BOLTS

10-18
 FRONT WHEEL/FRONT FORK/STEERING
● Install the following parts.

- Front wheel ( 10-5 )

- Brake caliper ( 12-6 )
- Front fender ( 3-5 )
- Front cover ( 3-5 )

STEERING STEM
REMOVAL
● Front cover ( 3-5 )
● Front fender ( 3-5 )
● Front handle cover/rear handle cover ( 3-6 )
● Steering handle ( 10-3 )
● Front wheel ( 10-5 )
STEERING
STEERING
STEERING LOCK
LOCK
LOCK ● Front brake caliper ( 12-6 )
NUT
NUT
NUT SOCKET
SOCKET
SOCKET ● Front fork ( 10-14 )

● Loosen the steering stem lock nut.

● Remove the speedometer cable and front brake hose
from the steering stem bracket.
● Loosen the steering top cone race.
● Remove the steering stem.

STEERING
STEERING
STEERING
STEM
STEM SOCKET
STEM SOCKET
SOCKET

STEERING
STEERING BALL
STEERING BALL
BALL
·When the bottom case fixes in the vice, use the
bracket.

● Check the steel ball, cone race, and ball race for wear
or damage. Replace worn or damaged ones.

10-19
FRONT WHEEL/FRONT FORK/STEERING
● Remove the steering steel ball/ upper steering ball race/
steering bottom cone race.

UPPER
UPPER STEERING
UPPER STEERING BALL
STEERING BALL RACE
BALL RACE
RACE

● Remove the upper ball race/ steering bottom cone race.

TOOL : BALL RACE DRIVER

·Check all of the races and balls for damage or

abnormal wear and replace as necessary.
·If the vehicle has been involved in a collision, the
steering stem may be damaged.

BALL
BALL RACE
BALL RACE DRIVER
RACE DRIVER
DRIVER

STEERING STEM INSTALLATION

● Insert the upper/under ball race into the steering head
pipe.

● Using a steering stem driver, drive the steering stem

STEERING
STEERING STEM
bottom cone race into the steering stem.
STEERING STEM
STEM

10-20
 FRONT WHEEL/FRONT FORK/STEERING
● Insert the ball race after applying grease thereto.

● Install the top cone race and the steering head top
thread nut on the steering head.
● Tighten the top thread nut completely, and loosen by
1/8 turn.

TORQUE VALUE : 1.0 f m

● Check the top and bottom free play, and check for
smooth left and right movement.
STEERING STEM
STEERING
STEERING STEM
STEM
NUT SOCKET
NUT
NUT SOCKET
SOCKET

● Temporarily install the R/L front forks first, and tighten

the steering stem nuts.

·m
TORQUE VALUE : 7.0kgf·
TOOLS : LOCK NUT WRENCH
EXTENSION BAR

● Install the front fork.

● Install the following parts.

- Steering handle ( 10-3)

- Front wheel ( 10-5 )
- Front handle cover/ rear handle cover ( 3-6 )
- Front fender ( 3-5 )
- Front brake caliper ( 12-6 )

FRONT
FRONT BRAK
FRONT BRAK
FRONT BRAK
BRAK
CALIPER
CALIPER
CALIPER

10-21
FRONT WHEEL/FRONT FORK/STEERING

·Check the cables and wiring for interference.

● Install the front cover.

FRONT
FRONT
FRONT
COVER
COVER
COVER

10-22
11. REAR WHEEL/BRAKE/SUSPENSION

SERVICE INFORMATION 11-1 REAR WHEEL 11-3

SERVICE STANDARD 11-1 REAR BRAKE 11-4
TROUBLESHOOTING 11-2 REAR CUSHION 11-6

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 RUN OUT - 0.2 mm
RADICAL - 2.0 mm
REAR WHEEL RIM RUNOUT
AXIAL - 2.0 mm
REAR BRAKE DRUM INNER DIAMETER 110.0~110.3mm 111.0mm
REAR BRAKE LINING THICKNESS 4.0 mm 2.0 mm
REAR CUSHION SPRING FREE LENGTH 234.8mm -
11

TORQUE VALUES :

AXLE SHAFT RUN OUT 10.0~12.0㎏f·m

REAR CUSHION UPPER BOLT 3.5~4.5㎏f·m
REAR CUSHION LOWER BOLT 3.5~4.5㎏f·m

11-1
REAR WHEEL / BRAKE / SUSPENSION

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

11-2
 REAR WHEEL / BRAKE / SUSPENSION

REAR WHEEL
REMOVAL
● Support the motor cycle on the main stand.
● Loosen the rear brake adjuster, and remove the brake
cable.
● Remove the brake arm joint B.

ADJUST
ADJUST NUT
ADJUST NUT
NUT

● Remove the muffler. ( 3-7 )

● Remove the rear wheel mud guard.
● Loosen the rear wheel U nut.
● Remove the washer.
● Remove the rear wheel.

U-NUT
U-NUT
U-NUT
U-NUT

INSPECTION
● Turn the wheel, and check the rim for wobbles.

SERVICE LIMIT : Radical 2.0mm

Axial 2.0mm

INSTALLATION
● Insert the rear wheel over the final shaft.

11-3
REAR WHEEL / BRAKE / SUSPENSION
● Insert the washer, and tighten with the U nut.

·m
TORQUE VALUE : 6.0~8.0kgf·

● Install the brake arm joint B.

● Install the rear brake cable.
● Install the rear brake rod adjusting nut.
● Install the rear wheel mud guard.
● Install the muffler.

·Check the free play of the brake after the rear wheel
assemblying

REAR BRAKE
● Remove the rear wheel. ( 11-3 )

INSPECTION
● Measure the brake drum of inner diameter

SERVICE LIMIT : 111mm

● Measure the thickness of the brake lining.

SERVICE LIMIT : 2.0mm

11-4
 REAR WHEEL / BRAKE / SUSPENSION
REAR BRAKE DISASSEMBLY
● Manually open the brake shoe and remove it.
BRAKE SHOE ● Remove the shoe spring from the brake shoe.

SHOE SPRING

SHOE SPRING

BRAKE CAM
BRAKE SHOE

● Loosen the rear brake arm fixing bolt.

● Remove the rear brake arm, rear brake indicator, brake
cam, dust seal.
● Remove the rear brake cam.

REAR BRAKE
REAR
REAR BRAKE CAM
BRAKE CAM
CAM

REAR BRAKE ASSEMBLY/INSTALLATION

● Apply small amount of grease to the brake cam.
● Install the brake cam.
● Install the rear brake dust seal, indicator, rear brake
arm.

·Align the punch marks of the brake arm and the

brake cam before assembly.
·Remove the excessive grease after assembling the
shoe.
REAR BRAKE
REAR
REAR BRAKE CAM
BRAKE CAM
CAM

● Install the brake shoe and spring.

● Install the rear brake shoe to the rear brake cam.
● Install the rear wheel.
● Install the washer and U nut.

·Check the brake for smooth operation.

11-5
REAR WHEEL / BRAKE / SUSPENSION

REAR CUSHION
REAR
REAR
REAR CUSHION
CUSHION
CUSHION
REMOVAL
● Remove the luggage box. ( 3-3 )

● Loosen the top and bottom rear cushion setting bolts.

·Support the frame firmly prior to working.

SETTING
SETTING BOLTS
SETTING BOLTS
BOLTS

DISASSEMBLY
● Install the compressor attachment as shown in the
figure.
● Install the cushion on the cushion compressor, and
compress the spring.

TOOLS : COMPRESSOR ATTACHMENT

REAR COMPRESSOR

● Fix the bottom metal, and loosen the lock nut.

● Remove the bottom metal.
● Remove the stopper rubber, spring from the damper
component.

INSPECTION
● Measure the rear cushion spring free length.
SPRING
● Check the damper rod for deflection or damage.

FREE LENGTH

11-6
 REAR WHEEL / BRAKE / SUSPENSION
REAR CUSHION ASSEMBLY/INSTALLATION
● Assemble the spring, spring guide, and stopper rubber.

● Apply thread locking agent to the lock nut, and install

the rear cushion compressor attachment on the damper
rod.
● Fix the upper joint, and tighten the lock nut.

·m
TORQUE VALUE : 4.0kgf·
TOOLS : REAR CUSHION COMPRESSOR
REAR CUSHION COMPRESSOR ATTACHMENT

INSTALLATION
REAR
REAR
REAR CUSHION
CUSHION
CUSHION
● Install the rear cushion.
● Tighten the top and bottom of the cushion with bolt.

·m
TORQUE VALUE : UPPER SIDE 3.5kgf·
·m
LOWER SIDE 3.5kgf·

SETTING
SETTING BOLTS
SETTING BOLTS
BOLTS

11-7
BRAKE SYSTEM

12-0
12. BRAKE SYSTEM

SERVICE INFORMATION 12-1 BRAKE DISK INSPECTION 12-6

TROUBLESHOOTING 12-1 BRAKE CALIPER 12-7
BRAKE FLUID/BLEEDING 12-3 MASTER CYLINDER 12-9
BRAKE PAD REPLACEMENT 12-4

SERVICE INFORMATION
GENERAL SAFETY
● Do not allow foreign material to enter the system when replenishing brake fluid.
● To prevent chemical changes, do not mix different types of brake fluid.
● Do not use the old brake fluid again.
● Brake fluid can cause damage to painted, plastic, and rubber surfaces. Take precaution not to allow parts to be
contaminated by the brake fluid.
● Do not reuse sealing washers.
● Clean the disassembled parts with brake fluid, and check for any clogged passage with compressed air.
● Bleed the brake hose after removing it.

TROUBLESHOOTING
HYDRAULIC DISK BRAKE
Braking power unsatisfactory Hard brake lever movement or unsatisfactory
● Air in the brake system. return
● Moisture in brake fluid ● Brake system clogged
● Brake pad and disk contaminated. ● Caliper piston seized or worn 12
● Caliper piston seal worn ● Unsatisfactory caliper sliding part operation
● Master cylinder piston seal worn ● Brake fluid line clogged
● Brake pad worn ● Caliper piston seal worn
● Caliper inside contaminated ● Master cylinder piston seized or worn
● Unsatisfactory caliper sliding part operation ● Brake lever bent
● Lopsided wear of brake pad and disk
● Low brake fluid level Brake drag
● Clogged brake fluid line ● Brake pad and disk contaminated
● Disk bent or distorted ● Improper wheel alignment
● Caliper piston seized or worn ● Lopsided wear of brake pad and disk
● Master cylinder piston seized or worn ● Disk bent or distorted
● Disk worn ● Unsatisfactory caliper sliding part operation
● Master cylinder inside contaminated ● Hydraulic system contaminated with dust.
● Brake lever bent

12-1
BRAKE SYSTEM
MECHANICAL DRUM BRAKE
Poor brake performance
● Improperly adjusted brake
● Worn brake linings
● Worn brake drum
● Worn brake cam
● Improperly installed brake linings
● Brake cable sticking/needs lubrication
● Contaminated brake linings
● Contaminated brake drum
● Worn brake shoes at cam contact areas
● Improper engagement between brake arm and camshaft serrations

Brake lever hard or slow to return

● Worn/broken return spring
● Improperly adjusted brake
● Sticking brake drum due to contamination
● Worn brake shoes at cam contact areas
● Brake cable sticking/needs lubrication
● Worn brake cam
● Improperly installed brake linings

Brake squeaks
● Worn brake linings
● Worn brake drum
● Contaminated brake linings
● Contaminated brake drum

12-2
 BRAKE SYSTEM

MASTER
MASTER CYLINDER
MASTER CYLINDER
MASTER CYLINDER
CYLINDER BRAKE FLUID/BLEEDING
BRAKE FLUID CHANGE

·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 front handle cover. ( 3-6 )

● Remove the master cylinder cap, master cylinder
holder, 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.

FRONT CALIPER
FRONT
FRONT CALIPER
CALIPER
AIR BLEEDING
BLEEDER VALVE ● 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.

·Check fluid level often, and replenish fluid if the

amount of fluid is reduced to the lower level.
·Read the user’s 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 operation until there is no air flowing

out of the bleeder hose.
● Squeeze the bleeder valve and operate the brake lever
to check the ingress of air.
● Add brake fluid.

12-3
BRAKE SYSTEM
● If the brake bleeder is not used, do the following,
● First, fill the brake fluid up to the upper limit line.
● Connect the hose to the bleeder valve to receive brake
fluid.
① Squeeze the brake lever completely loosen the
bleeder valve 1/2 turn, and tighten it again.

·Do not release the brake lever unitl the bleeder valve
is tightened.

② Release the brake lever slowly to its fullest extent,

and leave it unattended for a few seconds.
③ Repeat the process specified in item ① and ②
until there is no more air bubbles coming out of the
bleeder valve.

● 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.
● Assemble the bleeder valve.

·m
TORQUE : 0.6kgf·

● Add brake fluid up to upper level. Install diaphragm

and mater cylinder cap.
BLEEDER
BLEEDER VALVE
BLEEDER VALVE
VALVE
·m
TORQUE VALUE : 1.0kgf·

BRAKE PAD REPLACEMENT

·When replacing brake pads, replace whole set.

·Do not remove the brake hose when replacing brake
pads.

● Loosen the hanger pin.

● Loosen the 2 front brake caliper fixing bolts from the

front fork.
● Remove the front caliper.

FIXING
FIXING
FIXING BOLTS
FIXING BOLTS
BOLTS

12-4
 BRAKE SYSTEM
● To install a new brake pad into the brake, press the
HANGER
HANGER
HANGER PIN
PIN
PIN piston to return to the original position.
● Remove the hanger pin, pad shim, and brake pad.

BRAKE
BRAKE
BRAKE PAD
PAD
PAD

● Verify that the pad spring is installed in specific

position.

PAD
PAD
PAD SPRING
PAD SPRING
SPRING

● Install a new brake pad, pad shim, and hanger pin.

HANGER
HANGER
HANGER PIN
PIN
PIN

● Install the brake caliper into the left front fork.

·Be careful not to damage the brake pad.

● Tighten the caliper braket bolt.

·m
TORQUE : 2.7kgf·

12-5
BRAKE SYSTEM
● Tighten the hanger pin.
HANGER
HANGER PIN
HANGER PIN
HANGER PIN
PIN

BRAKE DISK INSPECTION

● Measure the thickness of the disk.

SERVICE LIMIT : 3.0mm

·Measure the brake disk thickness at the several

points and replace if the smallest measurement is
less then the specified service limit.

● Check the brake disk for bent and twist.

SERVICE LIMIT : 0.4mm

·Replace the brake disk if the disk for damage or

cracks.

BRAKE CALIPER
REMOVAL
● Remove the brake oil bolts and the brake hose from the
brake caliper.
● Remove the caliper from the L. front fork and remove
the pad spring, hanger pin and brake pad.

12-6
 BRAKE SYSTEM

·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 isn’t clogged with the
compressed air.
·Keep the removed parts in order to avoid dust from
adhering.

DISASSEMBLY
● Remove the slide pin, the L. 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 the new one.
CALIPER
CALIPER
CALIPER ● 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.

AIR
AIR GUN
AIR GUN
GUN

·Never use the high-pressure air or bring the air gun

too close.
·Never touch the inside of the caliper

DUST
DUST SEAL
DUST SEAL
SEAL ● Disassemble the piston seal and the dust seal
PISTON
PISTON
PISTON SEAL
SEAL
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.

BRAKE CALIPER INSPECTION

Caliper Cylinder

● Check the caliper cylinder bore for scoring, scratches

or other damage.
● Measure the caliper cylinder I.D. in X and Y axis at
serveral points.
● Replace the caliper cylinder if the largest measurement
is beyond the specified service limit.
CYLINDER
CYLINDER
CYLINDER
GAUGE
GAUGE
GAUGE SERVICE LIMIT : 27.10 mm
CALIPER
CALIPER
CALIPER
CALIPER

12-7
BRAKE SYSTEM
Caliper Piston
CALIPER PISTON ● Measure the caliper piston O.D. in X and Y axis at
several points.
● Replace the caliper piston of the smallest measurement
is less than the specified service limit.

SERVICE LIMIT : 26.84 mm

MICROMETER

LH. BRACKET
LH.
LH. BRACKET
BRACKET BRAKE CALIPER ASSEMBLY/INSTALLATION
PAD
PAD
PAD
● Clean the piston seal and the dust seal with the brake
SPRING
SPRING
SPRING
SPRING
fluid and install them in the caliper. Install the piston in
the caliper with the groove side of the piston facing the
PSTON
PSTON
PSTON
PSTON pad.
SEAL
SEAL
SEAL

·Make sure that each part is free from dust or dirt

before reassembly.
·Replace the dust seals and piston seals as a set
whenever they are removed.
PIN
PIN BUSH
PIN BUSH
BUSH PSTON
PSTON
PSTON
PSTON ·When cleaning with the brake fluid, use the specified
DUST
DUST
DUST SEAL
DUST SEAL
SEAL brake fluid.
SLIDE
SLIDE PIN
SLIDE PIN
PIN

● 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 slide pin in the
caliper.
● Install the brake pad and the hanger pin in the caliper.

BRAKE
BRAKE
BRAKE PAD
PAD
PAD

● Connect the brake hose to the caliper, and install 2

sealing washers and the brake hose bolt.

·m
TORQUE : 3.5kgf·

● Install the slide pin cap.

● Fill the brake fluid, and bleed air.

12-8
 BRAKE SYSTEM

MASTER
MASTER CYLINDER
MASTER CYLINDER
MASTER CYLINDER
CYLINDER
MASTER CYLINDER
REMOVAL
● Remove the back mirror.
● Remove the front handle cover. ( 3-6 )
● Remove the rear handle cover. ( 3-6 )
● Disconnect the front brake switch wire.
● Drain the brake fluid.
● Remove the brake hose from the master cylinder.

MASTER ·Brake fluid causes damage to the painted, plastic or

CYLINDER rubber parts. Do not spill fluid on these parts.
·If contaminated, gently wipe off the fluid with a
piece of cloth or wash in water. Close hose joints
properly to prevent leakage of brake fluid.
·Clean the disassembled parts with brake fluid, and
use compressed air to verify each passage is not
clogged.
·Do not allow the disassembled parts to be
contaminated by waste material or dust.
FRONT STOP
SWITCH
● Remove the master cylinder holder, and lift out the
master cylinder.
DISASSEMBLY
MASTER
CYLINDER SET ● Remove the front stop switch.
MASTER ● Remove the piston boot, cir clip from the master
CYLINDER cylinder.
HOLDER
PISTON TOOL : SNAP RING PLIERS
BOOT
CIR CLIP ● Remove the washer, piston, spring from the master
cylinder.
● Clean the master cylinder, reserve, master piston with
the recommended brake fluid.

MASTER CYLINDER INSPECTION

MASTER CYLINDER ● Check the piston periphery for kink or scratch.
● Check the primary and secondary cups for wear.
● Measure the O.D of the master pin

SERVICE LIMIT : 10.90 mm

MICROMETER

12-9
BRAKE SYSTEM

MASTER CYLINDER
·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.
● Measure the master cylinder I.D. in X and Y axis at
several points.

SERVICE LIMIT : 11.08 mm

CYLINDER GAUGE

MASTER CYLINDER ASSEMBLY/INSTALLATION

MASTER CYLINDER PRIMARY CUP

SECONDARY CUP
·Replace the piston, spring, cups and snap ring as a
set.
·Be sure that each part is free from dust or dirt before
SNAP RING reassembly.
·When cleaning with the brake fluid, use the specified
brake fluid.
● Coat the piston cup with the fresh brake fluid and
SPRING MASTER CYLINDER install it on the piston. Install the spring with its larger
diameter end toward the master cylinder.

SPRING MASTER PISTON ·When installing the cups, do not allow the lips to
turn inside out. (Refer to the drawing.)
·Note the installation direction of the snap ring.
·Be certain that the snap ring is seated firmly in the
groove.

● Install the rubber boot in the groove properly.

TOOL : SNAP RING PLIERS
PRIMARY CUP

MASTER CYLINDER
MASTER
MASTER CYLINDER
CYLINDER
● Install the 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.

12-10
 BRAKE SYSTEM
● Install the brake hose to the master cylinder with 2 new
MASTER
MASTER
MASTER CYLINDER
MASTER CYLINDER
CYLINDER
CYLINDER sealing washers and the hose bolt.

·m
TORQUE VALUE : 3.5kgf·

● Connect the brake stop swtich wire.

● Fill the brake fluid, and bleed air.
● Install the rear handle cover. ( 3-6 )
● Install the front handle cover. ( 3-6 )
● Install the back mirror.

12-11
MEMO
13. BATTERY/CHARGING SYSTEM

SERVICE INFORMATION 13-1 CHARGING SYSTEM INSPECTION 13-4

CHARGING DEVICES LOCATION 13-2 HEADLIGHT VOLTAGE INSPECTION 13-6
TROUBLESHOOTING 13-3 REGULATOR/RECTIFIER INSPECTION 13-6
BATTERY REMOVAL/INSTALLATION 13-4 A.C. GENERATOR 13-7
BATTERY INSPECTION 13-4 RESISTER INSPECTION 13-9

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 noromal use, and although it will re-charge, its load is reduced, leading to a loss in 13
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.
● A new MF battery will not necessarily be ready for use in the vehicle with only the adding of battery acid. Make sure to
charge battery after the adding of battery water in the following instances :
-When open voltage (voltage between terminals) does not reach 12.4V after the adding of battery water : charge until
open voltage reaches at least 12. 8V.
-When battery acid temperature is under 0℃ : charge normally for 2-3 hours.
● See the part location drawing for the location of charging system parts. ( 13-2 )
● Follow the trouble shooting for charging equipment inspection. ( 13-3 )
● The charging equipment may ofter appear to be malfunctioning if the couplers or connectors are incorrectly attached.
Make sure to check these connections before starting maintenance work on the charging equipment.

13-1
CHARGING SYSTEM / AC GENERATOR

CHARGING DEVICE LOCATION

BATTERY

RESISTER

A.C. GENERATOR

WHITE GREEN

YELLOW RED RED

GREEN
A.C GENERATOR FUSE
7A

REGULATOR/
RECTIFIER

BATTERY
AUTO- (12V 3AH)
BYSTARTER

RESISTER YELLOW YELLOW YELLOW

(5W 6.7 ) DIMMER
SWITCH

BLUE WHITE
RESISTER
(30W 5.9 ) (HIGH) (LOW) SPEEDOMETER LIGHT TAIL LIGHT
(12V 3Wx2EA) (12V 5W)

HEADLIGHT
(12V 35/35W)

13-2
 CHARGING SYSTEM / AC GENERATOR

TROUBLESHOOTING
Battery is Overcharged
● Headlight bulb is out.
● No headlignt beam wire.
● Headlight register is damaged (disconnected).
● Lighting switch is connected incorrectly.
● Regulator/rectifier is not grounded or connected incorrectly.

Problems with the Charging System

Measure battery voltage leakage. ABNORMAL

Inspect the body of the register/rectifier.

NORMAL NORMAL
Short-circuited harness.
Damaged main switch.
ABNORMAL
Check charge level. OVER 15V Regulator/rectifier is damaged.

UNDER 14V
OVER 14~15V Battery is damaged.

Check the voltage of the regulator/rectifier Wire harness is short-circuited.

ABNORMAL
battery lines and the ground line. Coupeler is connected incorrectly.

NORMAL

Check the changing coil with the regulator/

rectifier coupler charging coil. ABNORMAL Check the AC generator charging coil
NORMAL
AC generator coupler connected incorrectly.
NORMAL ABNORMAL
Damaged charging coil.

Check the lighting coil at the regulator/ ABNORMAL

Inspact the AC generator charging/
rectifier coupler lighting coil line. lighting coil
NORMAL
NORMAL AC generator coupler connected incorrectly.
ABNORMAL
Damaged charging/lighting coil.
Check the headlight lighting control voltage. ABNORMAL Damaged regulator/ rectifier
(darkened headlight)
NORMAL

Inspect the headlight register. ABNORMAL Damaged headlight register.

NORMAL

Inspect the body of the register/rectifier. ABNORMAL Damaged regulator/ rectifier.

NORMAL
Damaged Battery

13-3
CHARGING SYSTEM / AC GENERATOR

SETTING
SETTING
SETTING BOLT
BOLT
BOLT
BATTERY REMOVAL/INSTALLATION
● Loosen the battery cover setting bolt.
● Remove the battery cover.
● After removing the negative “ ” terminal of battery
firstly, must remove the positive “ ” terminal of
battery.
● Install in the reverse order of removal.

BATTERY INSPECTION
CHARGE LEVEL (OPEN-CIRCUIT VOLTAGE)
INSPECTION
● Remove the battery cover and disconnect the battery
terminals.
● Measure the voltage between the battery terminals.
- FULLY CHARGED : 13.0-13.2V
- INSUFFICIENTLY CHARGED : Under 12.3V

·Use a digital voltmeter when measuring charge level.

● Measure 30minutes later.
TOOL : DIGITAL CIRCUIT TESTER

CHARGING SYSTEM INSPECTION

LEAK TEST
● Trun off the main switch, and remove the earth cable
from the battery. Connect an ampere meter between the
battery terminal and the earth cable, and check current
when the main switch is turned off.

·Use an ampere meter while sequentially changing its

measuring range from large to small. If the current
level greater than the measuring limit is measured,
the ampere meter fuse may be cut.
·Do not turn on the main switch while current is
being measured.
LEAK CURRENT : Not to exceed 1mA

BATTERY ADJUSTMENT VOLTAGE CHECK

● Connect the voltmeter between the battery terminals.
● Connect the amperemeter between the main fuse
termanals.
● Start the engine and measure the charging voltage and
ampere while incresae the rpm gradually.
AMPERE METER
CONTROL VOLTAGE (CHARGING SIDE) : 14.5 0.5V/5,000rpm
(LAMP SIDE) : 13.1~ 0.5V/5,000rpm
BATTERY TERMINAL

·Check with fully charge the battery which has the

voltage between terminal of 12.8~13.0V.
·In case that the engine is started by the starter motor,
EARTH CABLE measurement must be performed after accelating
(charging) for 10 seconds.

13-4
 CHARGING SYSTEM / AC GENERATOR
CHARGING VOLTAGE CHECK
VOLT METER ● Use the full change battery (12.8~13.2V)
● In case that charging the voltage is not controled
AMPERE METER
properly, the battery cannot be used due to the battery
solution dried up by over charging and the deformation
caused by the damage of the plates.
● Battery control voltage : 14.5 0.5V(5,000rpm)
MAIN FUSE
TERMINAL

· If you have 1EA of tester, measure current first.

MAIN FUSE CHARGING CURRENT CHECK
● Check the charging current passed through the
generator assy, regulator comp is normal with the
FILLER CAP
SAFETY VENT FILTER discharged battery.

CHARGING CURRENT : 1.5~2.4A/5,000rpm

TOOL : DIGITAL CIRCUIT TESTER

BATTERY CHARGING
● Remove the battery from the frame, and connect it to
the battery charger.
PLATE
-Connect the charger positive (+) cable to the battery
positive (+) terminal.
SEPARATOR -Connect the charger negative (-) cable to the battery
negative (-) terminal.
PLATE

·Do not connect the charger to the battery coupler

terminals.
● Never open the sealed filler cap.

·The battery generates hydrogen gas which can be

highly explosive. Do not smoke or allow flames or
sparks near the battery, easpecially while charging it.
BATTERY CHARGER ·Turn power ON/OFF at the charger, not at the
battery terminals. If the cable is disconnected or
connected at the battery terminal during charging,
spark may jump and ignite the flammable gas.
·Always remove the battery from the frame when
charging it. If the battery is charged while installed in
the frame, the electrolyte may spill and corrode the
frame components.
CHARGING CURRENT : 0.3A
CHARGING TIME : 8~10h

·Do not let the electrolyte temperature rise above 45

℃(113℉). If the electrolyte temperature becomes
too high, lower the charging current.
·Quick-charging will shorten the battery life and
cause battery damage. It chould only be done in
emergency; slow-charging is prefered.

13-5
CHARGING SYSTEM / AC GENERATOR

HEADLIGHT VOLTAGE INSPECTION

● Remove the front cover. ( 3-5)

·Check voltage with the headlight coupler connected.

● After starting the engine, place the dimmer switch to

HI and check the voltage between the blue (+) and
green (-) wires of the headlight coupler.

·Measurement is performed in AC area.

CONTROL VOLTAGE : 12.6~13.6V/5,000rpm

● If voltage is incorrect, check the regulator/rectifier.

REGULATOR/RECTIFIER INSPECTION
HARNESS CIRCUIT INSPECTION
● Remove the front cover. ( 3-5 )
● Remove the 4P coupler of the regulator/rectifier and
inspect the wiring circuit in the main harness side
terminal.

ITEM MEASUREMENT LOCATION LEVEL AREAS OF INSPECTION IF INCORRECT

BATTERY WIRE Voltage between red “ ” and green “ ”. There must be battery voltage. Damaged, disconnected main fuse/harness.
CHARGING ※ Resistance between white wire and 0.4~1.0Ω(20℃)
COIL earth wires. Disconnect the starter. AC generator (charging, lighting coil
※ Resistance between yellow wire and coupler connection damage) resister(6.7Ω
LIGHTING
earth wires. Disconnect dimmer 0.2~0.8Ω(20℃) 5W) headlight lighting circuit.
COIL
switch connection
Inspect ※ part after at least 10 minutes later.

REGULATOR/RECTIFIER INSPECTION
(BATEERY TERMINAL) (LAMP TERMINAL)
● If the inspection of the harness side proves to be
TERMINAL ARRANGEMENT satisfactory, check the regulator/rectifier coupler for
faulty connection, and measure the resistance between
the terminals of the regulator/rectifier.
RESISTANCE VALUE
Tester
Tester A L B E
A ∞ 3-50 ∞
L ∞ ∞ 5-100
(CHARGING TERMINAL) (EARTH TERMINAL) B ∞ ∞ ∞
E ∞ 5-100 ∞

13-6
 CHARGING SYSTEM / AC GENERATOR

COOLING
COOLING
COOLING FAN
FAN
FAN A.C. GENERATOR
REMOVAL
● Remove the luggage box. ( 3-3 )
● Remove the plug maintenance cover. ( 3-3 )
● Remove the center cover. ( 3-3 )
● Remove the floor side cover. ( 3-4 )
● Remove the floor panel. ( 3-4 )
● Remove the engine hanger side RH. cover. ( 3-5 )
● Remove the plug cap.
● Loosen the 3 washer screws, remove the fan cover and
the fan cover element A,B.
● Remove the fan cover rubber.
● Loosen the 2 flange bolts, remove the fan cover.
● Loosen the 4 cooling fan fixing flange bolts, remove
the cooling fan.
NUT
NUT
NUT
NUT ● Hold the flywheel with a universal holder.

TOOL : UNIVERSAL HOLDER

● Remove the flywheel with a ACG rotor puller.

TOOL : ACG ROTOR PULLER 0750-00004

● Remove the connector/coupler on the wire harness or

starter motor. Remove the ground wires.

FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL

● Loosen the 2 pulse generator fixing flange bolts,

remove the pulse generator.
● Loosen the 2 stator fixing flange bolts.
● Remove the grommet from the crankcase cover.
● Remove the stator.

·Insert the puller shaft and remove the flywheel after

inserting the ACG rotor puller and securing it with
spanner.
·The flywheel may easily removed if you rotate the
ACG
ACG
ACG ROTOR
ROTOR
ROTOR PULLER
PULLER
PULLER 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
WOODRUFF KEY
components could be damaged.
·Remove the woodruff key with care not to lose it.

CRANKSHAFT

13-7
CHARGING SYSTEM / AC GENERATOR
STATOR INSTALLATION
● Note the direction of stator, and install the stator on the
crankcase.
● Install the grommet to R. crankcase cover.
● Install AC generator wire coupler to wire harness.
● Install the connector to starter motor, then install the
ground wire.

STATOR
STATOR
STATOR COMP
COMP
COMP

FLYWHEEL INSTALLATION
● Clean the tapered portion of the crankshaft.
● If the flywheel is installed with dust or dirt on the taper,
the taper will not make secure contact with the
flywheel and there will be excessive force on the
woodruff key.
● Insert the woodruff key into the key groove in the
crankshaft.
● Set the flywheel groove to the woodruff key and install
the flywheel on the crankshaft.

WOODRUFF
WOODRUFF KEY
WOODRUFF KEY
KEY

·Before installing the flywheel, check that no nuts or

bolts are magnetically attached to the flywheel.
Installing the flywheel with anything attached to it
could damage the stator coil.

● Hold the flywheel rotor with a holder and tighten the

bolt (nut) to the specified torque.

FLYWHEEL
FLYWHEEL
FLYWHEEL

● Install the cooling fan.

● Install the fan cover.
● Install the luggage box. ( 3-3 )

COOLING
COOLING FAN
COOLING FAN
FAN

13-8
CHARGING SYSTEM / AC GENERATOR
A.C. GENERATOR(CHARGING COIL)
INSPECTION

·This test is done with the starter mounted to the

engine.
● Remove the center cover.
● Disconnect the AC generator coupler. ( 3-3 )
● Measure the resistance of the charging coil (between
the white wire and ground) and the lighting coil
(between the yellow wire and ground).

℃)
STANDARD RESISTANCE (20℃
Ω
BETWEEN WHITE WIRE AND GROUND : 0.4~1.0Ω
BETWEEN YELLOW WIRE AND GROUND : 0.2~0.8ΩΩ

RESISTER INSPECTION
● Remove the front cover. ( 3-5 )
● Measure the resistance between the register lead wire
and ground.

STANDARD VALUE (20℃ ℃)

Ω Ω
RESISTER (6.7Ω 5W) GREEN/BLACK/BODY GROUND : 6.3~7.1Ω
Ω
RESISTER (5.9Ω 30W)PINK/BODY GROUND : 5.6~6.5Ω Ω

·Problems with the resister are caused by operational

problems of the starter.

13-9
MEMO
14. IGNITION SYSTEM

SERVICE INFORMATION 14-1 EXCITE COIL INSPECTION 14-6

IGNITION DEVICES LOCATION 14-2 PULSE GENERATOR INSPECTION 14-6
TROUBLESHOOTING 14-3 IGNITION TIMING INSPECTION 14-7
IGNITION SYSTEM INSPECTION CDI UNIT 14-7
(PEAK VOLTAGE MEASUREMENT) 14-4 SIDE STAND IGNITION
IGNITION COIL 14-5 CUT-OFF SWITCH 14-8

SERVICE INFORMATION
GENERAL SAFETY
● Refer to the malfunction diagnosis when inspecting ignition devices.
● Because the ignition devices have installed electrical advancer devices, it is impossible to adjust ignition timing.
● Be careful when handling the ignition devices as they can become easily damaged if dropped or bumped. Also, do not
disconnect or connect the connectors and couplers when the main swtich is turned ON as excessive electric current can
cause damage in the unit. Always perform maintenance work on the ignition devices with the main switch turned OFF.
● Ignition devices can often appear to be malfuctioning when the couplers or connectors are disconnected. Check these
connections before working on.
● Use recommended spark plug. Using incorrect spark plug may make the engine run badly or damage the engine.
● 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 swtich by referring to the wiring diagram continuity chart. ( chapter 16 )

14

14-1
IGNITION SYSTEM

IGNITION DEVICES LOCATION

SPARK PLUG MAIN SWITCH

CDI UNIT

IG COIL
A.C. GENERATOR

BLUE/YELLOW GREEN

BLACK/RED BLACK/YELLOW

A.C BLACK/WHITE
GENERATOR
IGNITION SPARK
COIL PLUG

PULSE CDI UNIT

GENERATOR
SIDE
STAND MAIN SWITCH
SWITCH

14-2
 IGNITION SYSTEM

TROUBLESHOOTING
Spark plug does not emit sparks.

ABNORMAL STATE POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER)

1. Using a tester with a low internal resistance.

2. Cranking speed is low.
- Battery is low or kick power is weak.
3. Influence of tester sampling time (normal state if measured a
number of times and shows over the set voltage).
IGNITION COIL PRIMARY VOLTAGE

Maximum voltage is low.

4. Problem in ignition system wiring (disconnected, damaged).
5. Ignition coil is damaged.
6. Excite coil is damaged (measure peak voltage).
7. CDI unit is damaged (when no porblems in 1~6 and spark plug
does not emit sparks)

1. Adaptor is connected incorrectly.

2.Main switch damaged.
3. CDI unit coupler is connected incorrectly.
4. CDI unit ground wire disconnection.
No, or almost no peak voltage. 5. Damage to excite coil (measure peak voltage).
6. Pulse generator is damaged (measure peak voltage).
7. Peak voltage adaptor is damaged.
8. CDI unit is damaged (when no problems in 1~7 and no sparks
emitted from spark plug).

Spark plug peak voltage is normal but 1. Damage to spark plug or leakage of ignition coil secondary current.
spark plug does not emit sparks. 2. Damaged ignition coil.

1. Using a tester with a low internal resistance.

2. Cranking speed is too low.
EXCITE COIL

- Battery is insufficiently charged or kick power is weak.

Peak voltage is low.
3. Influence of tester sampling time (normal state if measured a
number of times and shows over the set voltage)
4. Excite coil is damaged (when 1~3 is okay).

1. Peak voltage adaptor is damaged.

No, or almost no peak voltage.
2. Excite coil is damaged.

1. Using a tester with a low internal resistance.

PULSE GENERATOR

2. Cranking speed is too low.

- Battery is insufficiently charged or kick power is weak.
Maximum voltage is low.
3. Influence of tester sampling time (normal state if measured a
number of times and shows over the set voltage).
4. Pulse generator is damaged (when 1~3 is okay).

1. Maximum voltage adaptor is damaged.

No, or almost no maximum voltage.
2. Pulse generator is damaged.

14-3
IGNITION SYSTEM

IGNITION SYSTEM INSPECTION

DIGITAL TESTER (PEAK VOLTAGE MEASUREMENT)

·When sparks are not emitted from spark plug, after

checking for disconnection in wires and looseness,
measure peak voltage for each wire.

● Connect the peak voltage adaptor to the digital tester.

DAELIM PVA MULTI TESTER
PEAK VOLTAGE ADAPTOR IGNITION COIL PRIMARY VOLTAGE

·Make sure each wire is correctly connected to ensure

IGNITION COIL UNIT SIDE INITIAL TERMINAL correct measurement.
·Inspect when there is cylinder compression pressure
and with the spark plug cap securely connected to
the spark plug.

● Remove the luggage box. ( 3-3 )

● With the ignition coil wire connected, contact the peak
voltage adaptor to the initial wire adaptor terminal
(black/yellow) and ground (on vehicle body.). Turn the
main swtich ON, operate the starter motor, and
measure the ignition coil initial side peak voltage.

CONTACT POINTS : BLACK/YELLOW TERMINAL “ ”-BODY EARTH “ ”

PEAK VOLTAGE : OVER 120V

·When measuring voltage, do not touch the metal part

of the handle rod as there is the danger of receiving
an electric shock.

EXCITE COIL

·Assemble the spark pug to the cylinder head, inspect

in a state having compression pressure.
● Remove the luggage box. ( 3-3 )
● Remove the CDI unit. ( 14-7 )
● Remove the coupler from the CDI unit contact the peak
voltage adaptor to the excite coil wire (black/red and
WIRE HARNESS UNIT COUPLER CDI UNIT
green) of the harness side coupler.
● Operate the starter motor and measure the excite coil
peak voltage.

CONTACT POINTS : BLACK/RED TERMINAL “ ”-BODY EARTH “ ”

PEAK VOLTAGE : OVER 120V

·When measuring voltage, do not touch the metal part

EXCITE COIL
of the handle rod as there is the danger of recieving
an electric shock.

14-4
 IGNITION SYSTEM
PULSE GENERATOR
UNIT COUPLER
WIRE HANESS

·Inspect with the spark plug assembled and while

there is compression pressure.

● Remove the CDI unit. ( 14-7 )

● Remove the coupler from the CDI unit and connect the
peak voltage adaptor to the pulse generator wire (blue/
yellow and green) of harness coupler.
● Operate the starter motor and measure the peak voltage
EXCITE COIL of the pulse generator coil.

CONTACT POINTS : BLUE/YELLOW TERMINAL “ ”-BODY EARTH“ ”

PEAK VOLTAGE : OVER 1.5V

·When measuring voltage, do not touch the metal part

of the handle rod as there is the danger of receiving
an electric shock.
● Perform the following inspections if measured peak
voltage in the CDI unit coupler portion is abnormal.
● Disconnect the AC generator cord coupler and connect
the adaptor.
● In the same manner as with the unit coupler side,
IGNITION
IGNITION COIL
IGNITION COIL
COIL measure peak voltage and compare with the first peak
voltage.
● When the measured value in the unit side is abnormal
and normal in the pulse generator side, the problem is
either incorrect coupler connection or disconnection of
the wire harness.
● When both measurements are abnormal, this indicates
a problem with the pulse generator. Refer to the
malfunction diagnosis are go through each step.

IGNITION COIL
REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3 )
FIXING
FIXING
● Remove the plug maintenance cover.
FIXING SCREW
FIXING SCREW
SCREW
● Remove the spark plug cap.
● Loosen the ignition coil fixing bolt.
● Disconnect the ignition coil wire.
● Remove the ignition coil.
● Install in the reverse order of removal.

·Arrange the cords in the right place.

INSPECTION (RESISTANCE MEASUREMENT)

● Remove the luggage box. ( 3-3 )
● Measure primary coil resistance between the green and
black/yellow terminals.
Ω (20℃
STANDARD VALUE : 0.1~0.5Ω ℃)

14-5
IGNITION SYSTEM
● Measure the secondary coil resistance between the plug
cap and green wire terminals.

RESISTANCE VALUE
℃)
(SPARK PLUG CAP CONNECTION) : 6.5~9.5㏀ (20℃

● The coil which the resistance value indicate

“∞”(disconnection) remove the plugcap, and measure
the resistance of secondary coil.
● Measure the resistance between the high tension code
and green code terminals.

℃ ).
RESISTANCE VALUE : 2.6 1.25㏀ (20℃

EXCITE COIL INSPECTION

·Assembly the spark plug to the cylinder head, and

inspect in an state having compression pressure.

● Remove the luggage box. ( 3-3 )

● Remove the connection of the AC Generator wire
connector (black/red), measure the resistance between
the terminal of AC generator and body earth.

Ω 20
STANDARD VALUE : 500Ω ℃)
(20℃

PULSE GENERATOR INSPECTION

·The inspection of pulse generator is performed in a

state assembling to the engine.

● Remove the luggage box. ( 3-3 )

● Remove the connection of the AC generator 6P
coupler, and measure the resistance between the blue/
yellow of starter and green code.

Ω 20
STANDARD VALUE : 100Ω ℃)
(20℃

IGNITION TIMING INSPECTION

·As a CDI device is used in this vehicle, there is no

need for adjusting ignition timing. If ignition timing
problems occur, inspect the CDI unit and the AC
generator and replace if any malfunctions are found
in the devices.
·Ignition timing inspection well read the instruction
manual of timing light or revolution-indicator, and
handle it exactly.

14-6
 IGNITION SYSTEM
● Warm up the engine.
● Remove the center cover.
● Remove the floor panel.
INDEX ● Remove the fan cover.
● Connect timing light to the high-tension cord.
● When engine rpms are at 1,800, ignition timing is
correct if the “F” mark and crank case index mark are
aligned.

IGNITION TIMING : 17 DEGREES 2 BTDC/1,800 rpms

F MARK

·Index mark must face the spark plug.

CDI UNIT
REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3 )
● Disconnect the coupler from the CDI unit and remove
CDI Unit.
● Install in the reverse order of removal.

CIRCUIT INSPECTION
● Remove the coupler from the CDI unit, and check the
ignition system circuits from the wiring coupler side.
CDI UNIT
CDI
CDI UNIT
UNIT

INSPECTION ITEM CHECK POINT STANDARD VALUE

PULSE GENERATOR BLUE/YELLOW AND GREEN 50~200Ω(20℃)
IGNITION COIL
-PRIMARYCOIL BLACK/YELLOW AND GREEN 0.1~0.5Ω(20℃)
-SECONDARY COIL GREEN AND HIGH-TENSION CORD
(ATTACH THE PLUG CAP) 6.3~10.3KΩ(20℃)
(DETACH THE PLUG-CAP) 3.3±0.5KΩ(20℃)

TESTING BY CDI TESTER

● Check the CDI unit spark performance by using a CDI
tester.

·Read tester manual carefully prior to using the tester.

SIDE STAND IGNITION

CUT-OFF SWITCH
INSPECTION
● Remove the plug maintenance cover/ center cover.
( 3-3 )
● Remove the coupler of the side stand switch.
● Check for continuity between the terminal as shown
SIDE
SIDE STAND
SIDE STAND SWITCH
STAND SWITCH
SWITCH
below:

14-7
IGNITION SYSTEM

ITEM TERMINAL SPECIFICATION

ON
(Side stand is BLACK/WHITE NO
Retracted) AND GREEN CONTINUITY

OFF
BLACK/WHITE
(Side stand is CONTINUITY
AND GREEN
Lowered)

SIDE STAND
SIDE
SIDE STAND SWITCH
STAND SWITCH
SWITCH

REMOVAL
● Remove the floor side cover. ( 3-4 )
● Remove the plug maintenance cover/ center cover.
( 3-3 )
● Remove the side stand switch mounting 2 bolts.
● Release the wire clamps and remove the side stand
switch.

INSTALLATION
SIDE STAND
SIDE
SIDE STAND
STAND ● Install in the reverse order of removal.
SWITCH
SWITCH COUPLER
COUPLER
SWITCH COUPLER

FAN
FAN SCREW
FAN SCREW
FAN SCREW
SCREW

14-8
15. STARTING SYSTEM

SERVICE INFORMATION 15-1 STARTER MOTOR 15-4

STARTING DEVICES LOCATION 15-2 STARTER RELAY INSPECTION 15-7
TROUBLESHOOTING 15-3 STARTER PINION GEAR INSPECTION 15-7

SERVICE INFORMATION
GENERAL SAFETY

·When performing maintenance on the starter motor and related parts, turn the main switch to OFF. There is the
danger of the starter motor unexpectedly operating if the main switch is not turned to OFF.

● First check connection with battery and battery charge level before beginning maintenance on the starter motor.
● It is possible for the starter motor coil to become damaged if the starter is operated when the engine does not turn over.

15

15-1
STARTING SYSTEM

STARTING DEVICES LOCATION

START SWITCH

START RELAY MAIN SWITCH

BATTERY

RED MAIN SWITCH

RED/WHITE

FUSE

REAR STOP SWITCH

STARTER STARTER
MOTOR SWITCH
GREEN

BLACK
GREEN
BATTERY
STARTER
RELAY GREEN/YELLOW
FRONT STOP
SWITCH
YELLOW/RED GREEN/YELLOW

15-2
 STARTING SYSTEM

TROUBLESHOOTING
Starter motor does not rotate (No response from starter motor).
● Check to see if the fuse is burned out.
● Check to turn on the lamp of stop switch.

With the main switch turned to ON, squeeze Remove the starter motor “ ” wire, connect
the brake lever. In this state push the starter it to the battery “ ” terminal and check to
button and check if a clicking noise then an CLICKS see if the starter motor rotates (because a
operating noise is emitted from the starter large amount of current flows in this test, do
relay. not use thin wire).

ROTATES DOES NOT ROTATE

NO CLICK.
● Incorrect starter ● Incorrect starter motor
motor connecion

● Faulty starter switch.

Remove the coupler from the starter replay
NO CONTINUITY. ● Incorrect connection with the switch
and inspect the relay coil ground wire.
terminals or harness disconnection.

CONTINUITY.

Check the starter relay voltage in the starter

NO VOLTAGE. ● Damaged main or starter switch.
relay coupler with the coupler connected.
● Incorrect connection with coupler connector.
VOLTAGE MEASURED. ● Disconnection in starter switch wire.
● Faulty brake stop switch.
Check the operation of the starter relay. NORMAL ● Loose or poor contact at starter relay switch
connector.
ABNORMAL ● Faulty starter relay switch.

Starter motor rotates but crank shaft does’t

● Incorrect starting clutch. Weak rotational power in starter motor
● Incorrect starter gear. ● Battery is insufficiently charged.
● Starting clutch slip ● Incorrect connection of battery terminal cord.
● Damaged starter motor.
Starter motor operates in free-wheel ● Ground wire is connected incorrectly
● Internal fault of starter motor ● Brush is damaged or worn.
● Driven gear slips.
Starter motor and crank shaft rotate but does
not turn engine over.
● Incorrect starting system.
● Faulty engine.

15-3
STARTING SYSTEM

FIXING
STARTER MOTOR
FIXING BOLT
FIXING BOLT
BOLT

REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3 )
● Remove the center cover. ( 3-3 )
● Remove the floor side RH. cover. ( 3-4 )
● Disconnect the starter wire connector, remove the wire
from the wire fixing clamp.
● Loosen the 2 starter motor fixing bolts.
● Remove the starter motor.
● Install in the reverse order of removal.

·Accurately tighten the earth wire.

STARTER MOTOR
·Turn off the main switch prior to servicing the starter
motor. If power is connected, the starter motor may
be activated and damaged.

DISASSEMBLY
● Remove the starter motor screws and remove the motor
cover.

WASHER SCREW
·Record the order so the parts can be installed
correctly later.

INSPECTION
● Check for continuity of the starter motor case.
-Between cord terminal“ ” and bracket“ ”: normal
BRUSH if no continuity.
-Between cord terminal and brush (black wire) :
FRONT
normal if there is continuity.
BRACKET
● If abnormal, replace with a new one.

● Measure the brush length. Replace the brush if it is

worn beyond the service limit.

SERVICE LIMIT : 3mm

BRUSH

15-4
 STARTING SYSTEM
● 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

● Check for continuity between pairs of commutator

COMMUTATOR BARS bars.
● Make a continuity check between individual
commutator bars and the armature shaft.
● There should be no continuity.

● Check the bearings.

-Do not rotate smoothly. Replace with a new one.
-Loose bearing. Replace with a new one.

BEARING

STARTER MOTOR ASSEMBLY

● Carefully insert the armature shaft into the front
bracket.
● Align the front bracket notch with the brush.

·The sliding surcfaces of the brushes can be damaged

if they are not installed properly.

FRONT BRACKET

15-5
STARTING SYSTEM
● Insert the brush spring into the brush holder and install
the front bracket.

·Insert the brush spring with care so that it does not

lean in the holder.

BRUSH HOLDER

● Apply grease to both ends of the armature shaft.

GREASE

● Install the starter motor cover.

·The coil may be damaged if the magnet pulls the

armature against the case.

STARTER MOTOR COVER

● Align the front bracket with the cover.

● Tighten the washer screw.

WASHER SCREW

15-6
 STARTING SYSTEM

STARTER RELAY INSPECTION

STARTER RELAY ● Remove the luggage box. ( 3-3 )
SWITCH BATTERY
● When battery voltage is applied between the starter
relay green/yellow wire and yellow/red terminals,
there should be continuity between the red and
red/white terminals. The terminals are distinguished by
the corresponding wire color of the wire harness
connector.

STARTER PINION GEAR INSPECTION

● Remove the L. side cover. ( 7-2 )
● Remove the drive face. ( 7-6 )
● Remove the starter pinion gear.
● Install in the reverse order of removal.

STARTER
STARTER
STARTER PINION
PINION
PINION GEAR
GEAR
GEAR DRIVE
DRIVE
DRIVE FACE
FACE
FACE

INSPECTION
● Wear or damage to the pinion, reduction gears.
STARTER PINION Replace with a new one.
● Worn journals. Replace with a new one.

REDUCTION GEAR

PINION GEAR

● Check if the pinion gear moves smoothly along the

axis.
● Pinion gear does not move smoothly. Replace with
a new one.

15-7
MEMO
16. LIGHTS/METER/SWITCHES

SERVICE INFORMATION 16-1 HANDLE SWITCH INSPECTION 16-4

TROUBLESHOOTING 16-1 FRONT STOP SWITCH INSPECTION 16-4
FUEL UNIT 16-2 BULBS REPLACEMENT 16-5
OIL LEVEL SWITCH 16-3 METER REPLACEMENT 16-6
MAIN SWITCH 16-3 HORN INSPECTION 16-7

SERVICE INFORMATION
GENERAL SAFETY
● Refer to tester owner’s manuals when performing continuity inspections.
● Refer to wiring diagram (chapter 17) for switch continuity.
● After inspecting and/or performing maintenance work make sure the wires and cables are properly placed and
connected.

TROUBLESHOOTING
Fuel meter indicator malfunctioning Oil indicator light not operating
● Coupler separated. (when there is oil).
● Harness disconnected. ● Burned out fuse.
● Float operation malfuction. ● Battery insufficiently charged.
● Fuel unit damaged. ● Main swtich damaged.
● Meter damaged. ● Meter damaged.
● Oil level switch damaged.
Fuel meter needle unstable ● Loose connector.
● Coupler loose. ● Harness disconnection.
● Fuel unit damaged.
● Meter damaged. Oil indicator does not turn off (when oil is out)
● Oil level switch damaged.
Headlight hi-lo not operating ● Green/red wire joined.
● Bulb malfunction.
● Dimmer switch damaged.

16

16-1
LIGHTS/METER/SWITCHES

FUEL
FUEL
FUEL UNIT
FUEL UNIT SET
UNIT SET
UNIT CAP
SET CAP
SET CAP
CAP
FUEL UNIT
REMOVAL
● Remove the luggage box. ( 3-3 )
● Remove the fuel unit wire from the wire harness.
● Turn the fuel unit fixing unit set cap comp to the left,
and remove it.
● Remove the fuel unit from the fuel tank.

·Be careful of prevention the fuel unit wire from

FUEL
FUEL UNIT
FUEL UNIT
UNIT damaging.
·When disassembling, be careful of prevention the
float arm from damaging.
BASE PACKING
BASE
BASE PACKING
PACKING
● Remove the base packing.

·Check for damage.

INSTALLATION
● Install the base packing to the fuel tank.
● Install the fuel unit.

·Install it aligning the part of the fuel unit with the

loop part of fuel tank.
·Check the fuel leakage.

INSPECTION
● Move the float upward and downward, and measure
the resistance between the terminals.

WIRE TERMINAL FLOAT UPPER LINE FLOAT LOWER LINE

GREEN AND YELLOW/WHITE 33 400~750
GREEN AND BLUE/WHITE 400~750 33
BLUE/WHITE AND BLUE/WHITE 450~750 450~750

FLOAT ● When the measured value differs greatly from the

standard value, replace the fuel unit.

16-2
 LIGHTS/METER/SWITCHES

OIL
OIL LEVEL
OIL LEVEL SWITCH
LEVEL SWITCH
SWITCH
OIL LEVEL SWITCH
REMOVAL/INSTALLATION
● Remove the luggage box. ( 3-3 )
● Remove the body cover.
● Loosen the bolt jointed with the fuel tank.
● Remove the wire of oil level switch.
● Remove the oil level switch from the oil tank.
● Install in the reverse order of removal.

OIL
OIL TANK
OIL TANK
TANK ·Disassemble after adjusting the oil level.

INSPECTION
● Move the float to farthest extreme up and down and
check the continuity of the terminals.
● It’s normal state if there is no continuity when the float
is up, but continuity when it is down.

FLOAT

MAIN SWITCH
REMOVAL/ INSTALLATION
● Remove the front cover. ( 3-5 )
● Remove the inner box. ( 3-5 )
● Disconnect the main switch coupler.
● Remove the seat lock cable.
● Loosen the 2 screws and remove the main switch.
● Install in the reverse order of removal.

MAIN
MAIN SWITCH
MAIN SWITCH
SWITCH

INSPECTION
● Inspect continuity of each terminal.

TERMINAL
ON
OFF
LOCK
COLOR BLACK/WHITE GREEN RED BLACK

16-3
LIGHTS/METER/SWITCHES

HANDLE SWITCH INSPECTION

● Remove the front handle cover. ( 3-6 )
● Remove the handle switch coupler, connector, and
inspect continuity of each terminal.
● If abnormal, inspect the switch.

LIGHTING SWITCH STARTER SWITCH

LIGHTING
LIGHTING
LIGHTING SWITCH
LIGHTING SWITCH
SWITCH
SWITCH FREE
OFF
(N) PUSH
PO COLOR YELLOW/RED GREEN
(N)
H
BROWN
COLOR / WHITE BROWN YELLOW PINK

STARTER
STARTER
STARTER SWITCH
SWITCH
SWITCH DIMMER SWITCH WINKER SWITCH

DIMMER
DIMMER SWITCH
DIMMER SWITCH
SWITCH LO L
N N
HI R
COLOR BROWN WHITE BLUE COLOR SKY BLUE ORANGE GRAY

HORN SWITCH

FREE
WINKER
WINKER
WINKER PUSH
SWITCH
SWITCH
SWITCH
COLOR LIGHT GREEN BLACK
HORN
HORN
HORN SWITCH
HORN SWITCH
SWITCH

FRONT STOP SWITCH INSPECTION

● Remove the front handle cover. ( 3-6 )
● Remove the black wire and green/yellow wire
terminals inside the speedometer assembly, and check
the following.
-When the brake lever is pulled - continuity.
-When the brake lever is released - no continuity.

FRONT
FRONT
FRONT STOP
STOP
STOP SWITCH
SWITCH
SWITCH

16-4
 LIGHTS/METER/SWITCHES

BULBS REPLACEMENT
HEADLIGHT BULB
● Remove the front cover. ( 3-5 )
● Remove the headlight rubber cover.
● Push down on the socket and turn to the left.
● Replace with new bulb.

HEADLIGHT
HEADLIGHT
HEADLIGHT RUBBER
RUBBER
RUBBER COVER
COVER
COVER

HEADLIGHT
HEADLIGHT
HEADLIGHT BULB
BULB
BULB

·Before replacing the bulb, be sure to check the

swtiches for loose connection of the connectors.

● Install in the reverse order of removal.

·Headlight bulbs become very hot while the headlight

is ON, and remain hot for a while after they are
turned OFF.
·Be sure to turn the ignition switch OFF and let the
bulb cool down before replacement.

·If you touch the bulb with your bare hands, clean it
with a cloth moistened with denatured alcohol to
prevent early bulb failure.
·Be sure to install the dust cover after replacing the
bulb.

FRONT WINKER BULB

● Remove the front cover. ( 3-5 )
● Remove the bulb from the socket, replace with new bulb.
● Install in the reverse order of removal.

PAN
PAN
PAN SCREW
SCREW
SCREW

16-5
LIGHTS/METER/SWITCHES
REAR WINKER BULB REPLACEMENT
● Press the winker lens groove and open the winker lens
using plain screwdriver.
● Remove the bulb from the socket, replace with new bulb.
● Install in the reverse order of removal.

·Pay attention not to damage the lens.

·Do not apply excessive force when removing the
lens.

PAN
PAN
PAN SCREW
PAN SCREW
SCREW

TAILLIGHT BULB REPLACEMENT

● Loosen the 2 pan screws, remove the tail light lens.
● Replace the tail stop light bulb with the new one.

·Pay attention not to damage the tail light lens when

removing it.

PAN
PAN
PAN SCREW
SCREW
SCREW

METER BULB REPLACEMENT

BULB
BULB
BULB
BULB
● Remove the front handle cover. ( 3-6 )
● Remove the bulb socket, replace with new bulb.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER

METERS REPLACEMENT
● Remove the front cover. ( 3-5 )
● Remove the front handle cover. ( 3-6 )
● Remove the front/rear stop swtich wire.
● Remove the speedometer cable from the meter.
● Loosen the 4 steering handle tapping screws.
● Remove the speedometer coupler connected to the wire
harness
● Remove the speedometer wiring from the steering
handle cable guide.
● Remove the speedometer and the gear handle cover
assemblied from the steering handle.
● Roose the 3 tapping screws securing the speedometer
and the rear handle cover.
● Disconnect the R/L wiring.
● Remove the speedometer assembly.
● Install in the reverse order of removal.

16-6
 LIGHTS/METER/SWITCHES

·Check the each switch for proper operation.

·The wire and cable must be connected accurately.

HORN
HORN
HORN HORN INSPECTION
● Remove the front cover. ( 3-5 )
● Remove the horn wiring, and connect a fully charged
12V battery. Check the sound quality for any
abnormalities.

LICENCE LAMP
● Loosen 2 screws.
● Remove the lamp cover.
● Replace the lamp (12V 4W)
● Install in the reverse order of removal.

LICENCE
LICENCE
LICENCE LAMP
LAMP
LAMP

BULB
BULB
BULB

16-7
MEMO
 WIRING DIAGRAM
17. WIRING DIAGRAM

17

17-1
18. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START 18-1

ENGINE OUTPUT INSUFFICIENT 18-2
POOR PERFORMANCE AT LOW SPEED AND IDLING 18-3
POOR PERFORMANCE AT HIGH SPEED 18-3
UNSATISFACTORY OPERATION 18-4
FUEL GAUGE 18-6
STARTER MOTOR 18-7

ENGINE DOES NOT START OR IS HARD TO START

CAUSE OF TROUBLE
1. Open the drain screw, and check fuel Fuel not supplied (1)Fuel tank empty.
flow to the carburetor. to the carburetor. (2)Fuel tube up to the fuel tank
Fuel is supplied.
clogged, or the vacuum tube or fuel
tube up to the inlet pipe clogged.
(3)Float valve clogged.
(4)Fuel tank cap air hole clogged.
(5)Fuel supply pipe frozen.
(6)Fuel strainer clogged.

2. Check spark plugs. Weak or no spark. (1)Faulty spark plug.

(2)Contaminated spark plug.
Good spark (3)Faulty CDI unit.
(4)Faulty A.C. generator.
(5)Disconnected or shorted high
tension cord.
(6)Disconnected or shorted ignition
coil.
(7)Faulty main switch.

3. Test cylinder pressure. Low cylinder pressure. (1)Piston ring seized.

Pressure normal (2)Cylinder and piston ring won.
(3)Cylinder and cylinder head cracked.
(4)Crank case air leaks.
(5)Cylinder head gasket damaged.

4. Start engine in the following Engine starts but (1)Manifold air leaks.
procedure. stops immediately. (2)Inadequate ignition timing.
Engine will not start.

18
5. Remove spark plugs. Plugs wet. (1)Carburetor flooded.
(2)Faulty control box.
Dry plugs
(3)Throttle valve excessively opened.

18-1
TROUBLESHOOTING

ENGINE OUTPUT INSUFFICIENT

CAUSE OF TROUBLE
1. Gently accelerate engine. Engine speed does not (1) Air cleaner clogged.
Engine speed increases. increase sufficiently. (2) Insufficient fuel supply.
(3) Fuel tank cap air hole clogged.
(4) Muffler clogged.

2. Check ignition timing. Abnormal (1) Faulty CDI unit.

Normal (2) Faulty A.C generator.

3. Press the kick starter pedal to check Low (1) Cylinder and piston ring worn.
the cylinder pressure. (2) Cylinder head gasket damaged.
Normal (3) Cylinder and cylinder head cracked.

4. Check the carburetor for clogging. Clogged. (1) Unsatisfactory carburetor

Not clogged. maintenance.

5. Remove spark plugs. Contaminated or (1) Unsatisfactory plug maintenance.

Not contaminated or discolored. discolored. (2) Plugs with incorrect heat value
used.
(3) Rich fuel mixture.

6. Check for engine overheating. Overheated. (1) Cylinder or piston worn.

Not overheated. (2) Lean fuel mixture.
(3) Poor quality fuel used.
(4) Carbon deposit inside the
combustion chamber excessive.
(5) Ignition timing incorrect.

7. Accelerate suddenly or run at. Engine knocks. (1) Carbon deposit inside the
Engine does not knock. combustion chamber excessive.
(2) Poor quality fuel used.
(3) Lean fuel mixture.

18-2
 TROUBLESHOOTING

POOR PERFORMANCE AT LOW SPEED AND IDLING

CAUSE OF TROUBLE
1. Check ignition timing. Abnormal (1) Faulty CDI unit.
Normal

2. Check the carburetor air screw. Incorrect (1) Excessive fuel mixture.
Correct (Loosen screw to correct
adjustment level.)
(2) Lean fuel mixture.
(Tighten screw to correct
adjustment level.)

3. Check the area around the manifold Leaking (1) Faulty insulator packing.
for air leakage. (2) Loose carburetor.
No leak. (3) Faulty inlet pipe packing.
(4) Faulty insulator O-ring.

Weak or intermittent (1) Carbon deposited on spark plugs or

4. Check sparks. sparks. spark plugs contaminated.
Sparks normal. (2) Faulty CDI unit.
(3) Faulty ignition coil.
(4) Faulty A.C. generator.
(5) Faulty main switch.

POOR PERFORMANCE AT HIGH SPEED

CAUSE OF TROUBLE
1. Check ignition timing. Incorrect (1) Faulty CDI unit.
Correct (2) Faulty A.C. generator.

2. Remove the fuel tube from the fuel Insufficient fuel supply. (1) Fuel tank empty.
valve. (2) Fuel tube or fuel filter clogged.
Fuel flows. (3)Fuel tank cap air hole clogged.

3. Remove the carburetor, and check Clogged. (1) Clean.

for clogged jets.
Not clogged.

18-3
TROUBLESHOOTING

UNSATISFACTORY OPERATION

CLUTCH DRIVE/DRIVEN PULLEY CAUSE OF TROUBLE

1. Engine starts but motorcycle does not move. (1) Drive belt worn or slips.
(2) Ramp plate damaged.
(3) Drive face spring damaged.
(4) Clutch lining came off.
(5) Driven pulley shaft spline damaged.
(6) Faulty transmission.
(7) Transmission seized.

2. Vehicle moves slow, engine starts but stops (1) Shoe spring damaged.
immediately. (2) Clutch outer and weight seized.
(3) Pivot seized.

3. Engine weak at start. (1) Drive belt worn or slips.

(2) Weight roller worn.
(3) Drive pulley bearing seized.
(4) Weak drive face spring.
(5) Drive pulley bearing worn or seized.

4. Engine weak at high speed. (1) Drive belt worn or slips.

(2) Weight roller worn.
(3) Drive pulley bearing worn.

5. Abnormal noise or odor. (1) Oil or grease spilled on the drive belt and inside pulley.
(2) Drive belt worn.
(3) Weak drive face spring.
(4) Driven pulley bearing worn or seized.

POOR MECHANICAL PERFORMANCE Check tire pressure.

CAUSE OF TROUBLE
1. Steering is heavy. (1) Steering head adjuster excessively tightened.
(2) Steering cone race or steel ball damaged.

2. Wheels wobbling. (1) Excessive wheel bearing play.

(2) Rim bent.
(3) Axle nut loose.

3. Motorcycle pulls to one side. (1) Front wheel and rear wheel not aligned.
(2) Front fork bent.

18-4
 TROUBLESHOOTING

POOR FRONT/REAR SUSPENSION PERFORMANCE Check tire pressure.

CAUSE OF TROUBLE
1. Suspension excessively soft. (1) Cushion spring weak.
(2) Overloaded.
(3) Damper oil leaks.

2. Suspension excessively hard. (1) Fork pipe or cushion rod bent.

3. Noise from the suspension. (1) Sliders stuck.

(2) Cushion stopper rubber damaged.

POOR BRAKE PERFORMANCE Check brake adjustment.

CAUSE OF TROUBLE
1. If the arrow were mark and the brake (1) Brake shoe worn.
panel mark match with each other. (2) Brake cam worn.
(3) Shoe and cam contact surface worn.
(4) Brake drum worn.

2. Brake noise. (1) Brake shoe worn.

(2) Foreign matter in the brake lining.
(3) Brake drum and shoe contact surface curved.

3. Poor braking. (1) Brake wire defective or expanded.

(2) Only part of the brake shoe makes contact with the
brake drum.
(3) Clay or moisture inside the brake drum.
(4) Brake lining contaminated by grease or oil.

18-5
TROUBLESHOOTING

FUEL GAUGE

GAUGE READING INACCURATE (IGNITION SWTICH ON) CAUSE OF TROUBLE

1. Operate the turn signal to check the Signal continuously (1) Fuse cut.
battery circuit. operates dim or does not (2) Battery weak or totally discharged.
Signal operates satisfactorily. operate at all. (3) Faulty ignition swtich.
(4) Faulty terminal connection.
(5) Wire harness damaged.

2. Remove the fuel level sensor, and Needle moves. (1) Faulty float.
move float to check the status of
operation.
Float up : Full position
Float down : Empty position
Needle not moving.

3. Short-circuit the tank unit terminal Needle not moving. (1) Balance coil damaged or shorted.
on the wire harness side.
Needle not moving.

4. Terminal joints loose or faulty Unsatisfactory (1) Terminal loose.

connection. (2) Faulty terminal connection.

Check (1) Balance coil/lead shorted or

damaged.

GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. CAUSE OF TROUBLE

(IGNITION SWTICH ON)
1. Operate the turn signal to check the Signal continuously (1) Fuse cut.
battery circuit. operates dim or does not (2) Battery weak or totally discharged.
Signal operates satisfactorily. operate at all. (3) Ignition switch damaged or shorted.
(4) Terminal loose of faulty connection.
(5) Wire harness damaged.

2. Remove the tank and operate the Needle not moving. (1) Faulty fuel level sensor connection.
float.
Needle moving.

3. Move the float rapidly. One up/down Needle not moving. (1) Damper oil inside the meter
motion per second. insufficient.
Needle moving.

4. Start the engine, and measure the Resistance changed (1) Faulty connection between the
fuel level sensor resistance. significantly. sliding arm and the resistance.
Resistance not changed.

5. Check each joint. Unsatisfactory (1) Terminal connection loose or faulty

connection.

Satisfactory (1) Balance coil/lead shorted or

damaged.

18-6
 TROUBLESHOOTING

STARTER MOTOR

STARTING MOTOR WILL NOT TURN CAUSE OF TROUBLE

1. Apply the brake and check the brake Light not activated. (1) Fuse cut.
stop light for operation. (2) Battery weak or totally discharged.
Light is activated.
(3) Faulty stop switch.
(4) Faulty terminal connection.
(5) Ignition swtich damaged or shorted.

2. Operate the turn signal to check the Signal continuously (1) Battery totally discharged.
battery circuit. operates dim or does not
operate at all.
Signal operates satisfactorily.
(60~120 signaling/second)

3. Press the starter switch to check the Unsatisfactory (1) Faulty starter switch connection.
starter magnetic. (2) Starter magnetic damaged or
Satisfactory shorted.
(3) Connector and terminals loose.

4. Connect the starter to battery and Starter does not turn. (1) Worn brush worn.
check operation. Light not activated. (2) Faulty connection between the rotor
Starter turns. and brush.
(3) Faulty the starter motor subwire
connection.
(4) Terminal loose.

(1) Wire harness damaged.

STARTER MOTOR TURNS SLOW OR FAILS TO CRANK MOTOR CAUSE OF TROUBLE

1. Operate the turn signal to check the Signal continuously (1) Battery totally discharged.
battery circuit. operates dim or does not
Signal operates satisfactorily. operate at all.

2. Connect the starter subwire to the Operates sitisfactory. (1) Connector/terminal loose.
battery. (2) Faulty starter relay connector.
Turns slowly.
(with speed not changing)

3. Operate the kick starter. Operates heavy. (1) Engine seized.

Operates light. (1) Faulty connection between the rotor
and brush.

STARTER ROTATE WITHOUT STOPPING CAUSE OF TROUBLE

1. Turn off the ignition switch. (1) Pinion seized.
Will not stop

Starter relay connection seized.

18-7
MEMO