Downloaded from www.Manualslib.

com manuals search engine

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

ENGINE
ENGINE REMOVAL 7
• Contents of this manual and specifications are subject
to change without prior notice for improvement of
vehicle quality.
CLUTCH / GEARSHIFT 8
• No part of this publication may be reproduced without
written permission of DAELIM MOTOR. A.C.GENERATOR / STARTER CLUTCH 9
CYLINDER HEAD / VALVES 10
CYLINDER / PISTON 11
CRANKCASE / TRANSMISSION /
CRANKSHAFT 12
EXTERNAL PARTS 13
FRAME

FRONT WHEEL/FRONT FORK/STEERING 14

REAR WHEEL /REAR SUSPENSION 15
HYDRAULIC BRAKE 16
ELECTRICAL SYSTEM

BATTERY / CHARGING SYSTEM 17

IGNITION SYSTEM 18
ELECTRIC STARTER 19
LIGHTS/METER/SWITCHES 20
TROUBLESHOOTING 21
WIRING DIAGRAM 22

Downloaded from www.Manualslib.com manuals search engine

 1. GENERAL INFORMATION
1
·······
SERVICE INFORMATION· 1-1 TORQUE VALUES·········· 1-12
··········
SERVICE RULES· 1-1 SYMBOLS / ABBREVIATIONS ··· 1-14
CAUTION WHEN WIRING ····· 1-5 TOOLS··············· 1-15
MODEL IDENTIFICATION ····· 1-9 WIRING DIAGRAM ········ 1-16
SPECIFICATIONS ········· 1-10

SERVICE INFORMATION

1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and always have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.

SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the
recommended parts. chasis.

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

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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION
11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
be performed with the right tool. applied pressure when removing press-fitted the
bearing.

13. Check the smooth rotation of inner or outer race of the 14. 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) SINGLE-SEALED TYPE DOUBLE-SEALED TYPE
• Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.

OPEN TYPE MANUFACTURER’S NAME, BEARING No.

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.
SNAP RING

CHAMFERED EDGE

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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION
19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
• Pay attention not to bend or damage the lip.
• Apply the grease to the lip.

CAVITY
MANUFACTURER’S NAME

CLIP

FITTING

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.

BOOTS

1-4
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

CAUTION WHEN WIRING

•Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord
When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of
around the connector. Connect the coupler to the the coupler. 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 . RED STRIPE
TESTER PLUG

WHITE WHITE
TUBE COUPLER.
BLACK TUBE
WHITE
•Recheck the condition of contact, securing and
continuity of each part after maintenance.
BLACK CORD RED STRIPE •When connecting the battery, the plus terminal must be
connected first.
•After connecting the terminal, apply the grease to the
terminal.

WHITE / RED CORD

•When disconnecting the battery, the minus terminal •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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION
•Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while
connecting. holding the coupler body. Pull while holding the wire
•Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
•The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- 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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION
•Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start
inserted into the terminal. using the wiring driver and release the torque.
•The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then
direction but in case of the plain connector, the draining insert until the groove is locked.
opening must face at the sky direction. •When removing T-start from the frame, replace it with
the new one.

DRAINING HOLE WIRING DRIVER GROOVE SIDE

•Wire band must be secured firmly in the specified •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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION
•In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively.
the sharp edge, protect both parts with tube or tape.

NOT TO
PULL!

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

•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
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

MODEL IDENTIFICATION

TOOL BOX
REAR CUSHION

RADIATOR

HELMET HOLDER

CALIPER

PILLION STEP BAR

BRAKE DISK

GEAR SHIFT PEDAL MAIN STAND SIDE STAND MAIN STEP BAR

FRAME
FRAME
FRAME SERIAL
SERIAL NUMBER
SERIAL NUMBER
NUMBER
ENGINE
ENGINE
ENGINE SERIAL
SERIAL
SERIAL NUMBER
NUMBER
NUMBER

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

•The engine serial number is stamped on left crankcase. •The frame serial number is stamped on the left side of
steering head.

1-9
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

SPECIFICATIONS
ITEM SPECIFICATIONS

OVERALL LENGTH 2,025mm

OVERALL WIDTH 778mm
OVERALL HEIGHT 1,180mm
DIMENSIONS WHEEL BASE 1,380mm
SEAT HEIGHT 780mm
GROUND CLEARANCE 139mm
DRY WEIGHT 173kgf
CURB WEIGHT 292kgf
TYPE Double Cradle
FRONT SUSPENSION / STROKE Telescopic / 130mm
REAR SUSPENSION / STROKE Swingarm / 28mm
FRONT TIRE SIZE (TYPE) 110/70-17 54P (Tubeless)
REAR TIRE SIZE (TYPE) 140/60-17 69P (Tubeless)
TIRE PRESSURE 1 PERSON FRONT 2.00kgf/cm2(200kPa)
REAR 2.00kgf/cm2(200kPa)
FRAME 2 PERSON FRONT 2.00kgf/cm2(200kPa)
REAR 2.25kgf/cm2(225kPa)
FRONT BRAKE Hydraulic Disk
REAR BRAKE Hydraulic Disk
FUEL CAPACITY 14.85ℓ
FUEL RESERVE CAPACITY 4.0ℓ
CASTER ANGLE 25.2°
TRAIL 93.5mm
FRONT FORK OIL CAPACITY 265±2.5cc
TYPE Liquid 4-stroke DOHC(4 Valve)
CYLINDER NUMBER, ARRANGEMENT 1 Cylinder, 20°Inclined from vertical
BORE AND STROKE 56.5 X 49.5mm
DISPLACEMENT 124.1cm3
COMPRESSION RATIO 11.8:1
VALVE TRAIN DOHC Chain Drive
OIL CAPACITY 1.5 ℓAfter Disassembly
1.35ℓAfter Draining and Oil Filter Change
ENGINE 1.3 ℓAfter Draining
LUBRICATION SYSTEM Wet Pressing and Spray
AIR FILTRATION TYPE Paper Filter
CYLINDER COMPRESSION 13.0kgf/cm2 (600rpm)
INTAKE VALVE OPEN 23°BTDC
CLOSED 55°ABDC (1.12mm Lift)
EXHAUST VALVE OPEN 66.3°BBDC
CLOSED 23.6°ATDC (1.12mm Lift)
VALVE CLEARANCE INTAKE 0.15±0.02mm
(A COOLING-OFF PERIOD) EXHAUST 0.20±0.02mm
ENGINE DRY WEIGHT 32.0kgf

1-10
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

ITEM SPECIFICATIONS

CLUTCH TYPE Multiplate Wet Clutch / 5

TRANSMISSION TYPE Constant Mesh
GEAR RATIO 1st 3.200(37/12 T)
DRIVE TRAIN GEAR RATIO 2nd 2.143(32/17 T)
GEAR RATIO 3rd 1.438(29/21 T)
GEAR RATIO 4th 1.095(23/21 T)
GEAR RATIO 5th 0.923(24/26 T)
GEARSHIFT PATTERN Left foot operated return system
Down 1-N-2-3-4-5 Up

IGNITION TYPE Full Transisterized

IGNITION TIMING “F” MARK 18°BTDC / 1,600(rpm)
FULL ADVANCE 30°BTDC / 8,500(rpm)
AC GENERATOR 12V-17A/5,000(rpm)
BATTERY CAPACITY 12V 10AH
SPARK PLUG CR9EH - 9
SPARK PLUG GAP 0.8 - 0.9mm
FUSE CAPACITY 30A
STARTING SYSTEM Starter Motor
ELECTRICAL HEADLIGHT (HIGH/LOW BEAM) 55W/55W
POSITION LAMP 5W
TURN SIGNAL LAMP 10W×4
STOP/TAIL LIGHTS 21W/5W
SPEEDOMETER LAMP 3W
NEUTRAL INDICATOR LAMP LED×1
HIGH BEAM INDICATOR LAMP LED
WINKER INDICATOR LAMP LED
LICENCE PLATE LAMP 5W
TACHOMETER LAMP LED×1
MALFUNCTION INDICATOR LAMP LED

1-11
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

TORQUE VALUES
ENGINE

Q’TY THREAD DIA TORQUE REFERENCE

ITEM (mm) kgf.m,(N.m)
CAM HOLDER BOLT(SHBOLT) 8 M6×1.0 1.0~1.2 Apply Engine Oil
CYLINDER HEAD SPECIAL SOCKET NUT 4 M10×1.25 3.5~4.5 Apply Engine Oil
CYLINDER HEAD COVER BOLT 4 M6×1.0 0.8~1.2
CAM CHAIN TENSIONER PIVOT BOLT 1 M6×1.0 0.8~1.2
CAM CHAIN TENSIONER LIFTER BOLT 2 M6×1.0 1.0~1.4
CAM CHAIN TENSIONER LIFTER SCREW 1 M6×1.0 0.35~0.5
PRIMARY DRIVE GEAR NUT 1 M16×1.0 6.0~7.0 Apply Engine Oil
CLUCH LOCK NUT 1 M16×1.0 6.0~7.0 Apply Engine Oil
FLYWHEEL BOLT 1 M12×1.25 5.0~6.0 Apply Engine Oil
STARTER CLUTCH SOCKET BOLT 3 M8×1.25 3.0~3.4 Remove negative screw
BEARING SET PLATE BOLT 2 M6×1.0 1.0~1.4 Remove negative screw
OIL FILTER COVER SOCKET BOLT 3 M10×1.25 1.0~1.4
SHIFT DRUM STOPPER ARM BOLT 1 M6×1.0 1.0~1.4
DRIVE SPROCKET BOLT 2 M6×1.0 1.0~1.4
R.CRANKCASE COVER BOLT 12 M6×1.0 1.0~1.2
OIL FILTER COVER BOLT 1 M6×1.0 1.0~1.2
L.CRANKCASE COVER BOLT 7 M6×1.0 1.0~1.2
A.C GENERATOR CAP 1 M14×1.5 0.4~0.8
CRANKSHAFT HOLE CAP 1 M30×1.5 1.0~2.0
CRANKCASE BOLT 10 M6×1.0 1.0~1.2
SPARK PLUG 1 M10×1.25 1.0~1.2
START MOTOR NUT 1 M6×1.0 1.0~1.4
TAPPET ADJUST HOLE CAP 1 M36×1.5 1.0~2.0
ENGIN TEMPERATURE SENSOR 1 M12×1.25 1.0~2.0

FRAME

ITEM Q’TY THREAD DIA TORQUE

(mm) kgf.m,(N.m) REFERENCE

REAR ENGIN HANGER BOLT(UPPER) 1 M10×1.25 4.5~5.5

REAR ENGIN HANGER BOLT(UNDER) 1 M10×1.25 5.0~6.0
FRONT ENGIN HANGER BOLT(UPPER/UNDER) 2 M10×1.25 4.5~5.5
FRONT ENGIN HANGER PLATE BOLT 4 M8×1.25 2.4~3.0
STEERING HANDLE PIPE BOLT 2 M8×1.25 2.4~3.0
SIDE STAND PIVOT SCREW 1 M10×1.25 1.0~2.0
SIDE STAND PIVOT NUT 1 M10×1.25 4.0~5.0 HEX NUT
SPEEDOMETER GEAR BOX SCREW 1 M 5×0.8 0.35~0.5
REAR AXLE NUT 1 M14×1.5 8.0~10.0 U- NUT
DRIVE SPROKET NUT 4 M10×1.25 5.5~6.5 U- NUT
REAR BRAKE OIL BOLT 2 M10×1.25 3.4~4.0

1-12
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

FRAME

ITEM Q’TY THREAD DIA TORQUE REFERENCE

(mm) kgf.m,(N,m)
REAR CALIPER BRACKET BOLT 2 M8×1.25 2.8~3.4
REAR MASTER CYLINDER HOLDER SOCKET BOLT 2 M6×1.0 1.0~1.4
FRONT AXLE NUT 1 M14×1.5 5.5~6.5 U- NUT
FRONT BRAKE DISK BOLT 6 M8×1.25 4.0~4.5
BRAKE OIL BOLT (FRONT/REAR) 4 M10×1.25 3.0~4.0
CALIPER BRACKET BOLT (FRONT/REAR) 4 M8×1.25 2.8~3.4
FRONT MASTER CYLINDER HOLDER BOLT 2 M6×1.0 1.0~1.4
STEERING STEM NUT 1 M22×1.0 6.0~9.0
STEERING TOP THREAD 1 M22×1.0 0.25~0.35
FORK TOP BRIDGE PINCH BOLT 2 M8×1.25 2.4~3.0
BOTTOM BRIDGE PINCH BOLT 2 M8×1.25 3.0~4.0
FORK HANDLE PIPE MOUNTING BOLT 2 M8×1.25 2.4~3.0
SWINGARM PIVOT NUT 1 M14×1.25 8.0~10.0 U- NUT
REAR CUSHION UPPER/UNDER BOLT 2 M10×1.25 3.5~4.5
CHAIN SLIDER SCREW 2 6mm Tapping 0.5~0.7
L. DOWNTUBE COMP ‘B’ 4 M8×1.25 4.0~4.5
HANDLE WEIGHT SOCKET BOLT 2 M8×1.25 1.8~2.5
REAR BRAKE DISK SOCKET BOLT 5 M8×1.25 4.0~4.5
*Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.

TORQUE TORQUE
TYPE TYPE
kgf·m N·m kgf·m N·m

15mm BOLT, NUT 4.0~6.0 0.45~0.6 5mm SCREW 3.4~5.0 0.35~0.5

16mm BOLT, NUT 8~12 0.8~1.2 6mm SCREW, FLANGE BOLT 7~11 0.7~1.1
(Include SH type)
18mm BOLT, NUT 18~25 1.8~2.5 6mm FLANGE BOLT, NUT 9.8~14 1.0~1.4

10mm BOLT, NUT 29~39 3.0~4.0 8mm FLANGE BOLT, NUT 24~29 2.4~3.0

12mm BOLT, NUT 49~59 5.0~6.0 10mm FLANGE BOLT, NUT 34~44 3.5~4.5
*SH(Small Head) : It describe 6mm bolt of 8mm flange bolt.

1-13
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

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

SYMBOL MEANING SYMBOL MEANING

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

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

SYMBOL CAUTION

Use recommended engine oil, unless otherwise specified.

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

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

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

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

Use silicone grease

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

Apply sealant

Replace the parts with new ones before assembly

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

Use Fork or Suspension Fluid

Use special tool

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

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

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

1-14
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

TOOLS
SPECIAL COMMON
DESCRIPTION REF. SEC. DESCRIPTION REF. SEC.
CLUTCH CENTER HOLDER 8 WRENCH, 8×9mm 2
ACG ROTOR PULLER 9 ADJUSTING WRENCH, B 2
VALVE GUIDE DRIVER 10 LOCK NUT WRENCH, 20×24mm 6
VALVE GUIDE REAMER 10 EXTENSION BAR 8, 14
UNIVERSAL BEARING PULLER 12 FLY WHEEL HOLDER 8, 9
BEARING REMOVER SET 12 VALVE SPRING COMPRESSOR 10
THREAD ADAPTER 12 DRIVER 12, 14, 15
ASSEMBLY SHAFT 12 ATTACHMENT 12, 14, 15
CRANK CASE ASSEMBLY COLOR 12 PILOT 12, 14, 15
BALL RACE DRIVER 14 FORK SEAL DRIVER BODY 14
STEERING STEM DRIVER 14 BEARING REMOVER HEAD 15
FORK SEAL DRIVER 14 BEARING REMOVER SHAFT 15
STEERING STEM SOCKET 14 LOCK NUT(M8) 10
SNAP RING PLIERS 16

TESTER, GAUGE
DESCRIPTION REFERENCE SECTION REMARK
COMPRESSION GAUGE 2
DIGITAL MULTI TESTER 17, 18
PVA TESTER 17, 18
BATTERY TESTER 18
TESTER RECORDER 5

VALVE SEAT CUTTER

DESCRIPTION REFERENCE SECTION REMARK

VALVE SEAT CUTTER 45° 10 24.5mm IN, EX

VALVE SEAT CUTTER 35° 10 23mm IN
VALVE SEAT CUTTER 35° 10 20mm EX
VALVE SEAT CUTTER 60° 10 22mm IN, EX
CUTTER HOLDER 5mm 10 Use with Valve Seat

1-15
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

WIRING DIAGRAM

1-16
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

1-17
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

1-18
Downloaded from www.Manualslib.com manuals search engine
 GENERAL INFORMATION

1-19
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION ··· 2-1 BRAKE SYSTEM · · · · · · 2-10
MAINTENANCE SCHEDULE ··· 2-3 BRAKE STOP SWITCH· ···· 2-11 2
FUEL LINE (FUEL TUBE) ··· 2-4 HEADLIGHT AIM· · · · · · · 2-11
THROTTLE GRIP OPERATION· ·· 2-4 CLUTCH SYSTEM· · · · · · · 2-11
AIR CLEANER · · · · · · · 2-5 SIDE STAND· · · · · · · · · 2-12
SPARK PLUG · · · · · · · 2-5 SUSPENSION · · · · · · · 2-13
VALVE CLEARANCE · · · · 2-6 BOLTS, NUTS, FASTENERS ··· 2-13
CYLINDER COMPRESSION PRESSURE · 2-7 WHEEL/TIRE· · · · · · · · · 2-14
DRIVE CHAIN· · · · · · · · · 2-8 STEERING STEM · · · · · · 2-14
DRIVE CHAIN SLIDER· · · · · 2-9 COOLANT LEVEL INSPECTION · · 2-15
BRAKE FLUID· ···· ··· 2-9 COOLANT REPLACEMENT ·· 2-15
BRAKE PAD WEAR· · · · · · 2-9

SERVICE INFORMATION

•The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.

•For information on engine oil and oil filter, refer to sections 3-3 and 3-4.
•Stand the main stand prior to beginning work.

SPECIFICATIONS
THROTTLE GRIP PLAY 2~6mm
SPARK PLUG CR9EH-9
SPARK PLUG GAP 0.8~0.9mm
IN. 0.15mm
VALVE CLEARANCE
EX. 0.20mm
CARBURETOR IDLE SPEED 1,600rpm±100rpm
CYLINDER COMPRESSION 13.0kgf/㎠ ( 600rpm )
DRIVE CHAIN SLACK 10~20mm
REAR BRAKE PEDAL FREE PLAY 10~20mm
CLUTCH LEVER FREE PLAY 10~20mm

TIRES
FRONT 2.00kgf/㎠ (200kPa, 29psi )
DRIVER ONLY
COLD TIRE REAR 2.00kgf/㎠ (200kPa, 29psi )
PRESSURE DRIVER AND A FRONT 2.00kgf/㎠ (200kPa, 29psi )
PASSENGER REAR 2.25kgf/㎠ (225kPa, 32psi )
FRONT 110/70-17 54S
TIRE SIZE
REAR 140/60-17 69S
FRONT 5.5mm
TIRE PART MINIMUM-DEPTH
REAR 7.0mm

2-1
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS
TORQUE VALUES
SPARK PLUG 1.0~1.2kgf-m
CYLINDER HEAD COVER BOLT 0.8~1.2kgf-m
AC GENERATOR CAP 0.4~0.8kgf-m
HOLE CAP 30mm 0.6~1.0kgf-m
AIR CLEANER CASE COVER SCREW 0.4~0.8kgf-m
REAR AXLE NUT 8.0~10.0kgf-m
DRIVE SPROCKET BOLT 1.0~1.4kgf-m
DRIVEN SPROCKET NUT 5.6~6.5kgf-m

TOOLS
WRENCH, 8×9mm
COMPRESSION GAUGE

2-2
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

MAINTENANCE SCHEDULE
• Perform the Self Inspections Before Operation at each scheduled maintenance period.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
R : REPLACE L : LUBRICATE C : CLEAN A : ADJUST

ODOMETER READING(NOTE 1)
FREQUENCY
x 1000Km 1/2 4 8 12 REMARK
ITEM
MONTH 6 12 18
＊ FUEL LINE I I I I
＊ FUEL FILTER R R R
＊ THROTTLE GRIP OPERATION I I I
AIR CLEANER ELEMENT R R R NOTE (2)
SPARK PLUG I R I
＊ VALVE CLEARANCE I I I I
＊ ENGINE OIL R R R R
ENGINE OIL FILTER ELEMENT R R R R
OIL FILTER SCREEN C C C C
＊ DRIVE CHAIN Every 1,000㎞ : I and L
＊ BRAKE FLUID I I I NOTE (3)
BRAKE /PAD WEAR I I I
＊ BRAKE SYSTEM I I I I
＊ BRAKE STOP SWITCH I I I
＊ HEADLIGHT AIM I I I
CLUTCH SYSTEM I I I I
SIDE STAND I I I
＊ SUSPENSION I I I
BOLTS, NUTS, FASTENERS I I
WHEELS/TIRES I I I
STEERING HEAD BEARING I I
RADIATOR COOLANT I I R I
RADIATOR CORE I I I I
RADIATOR CAP I I I

＊ If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to
perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs.
To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers.

NOTES : (1) After the odometer reading exceeds 1,200Km, repeat maintenance service at intervals indicated in the table.
(2) Service more frequently when riding in unusually wet or dusty areas.
(3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires
mechanical skill.

2-3
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

FUEL LINE (FUEL TUBE)

• Check the connection between injector and fuel tube.
• Check the fuel tube for deterioration, damage or
leakage. Replace it if necessary.

INJECTOR
INJECTOR
INJECTOR FUEL
FUEL TUBE
FUEL TUBE
TUBE

THROTTLE GRIP OPERATION

THROTTLE
THROTTLE
THROTTLE GRIP
GRIP
GRIP

• Check if the throttle grip operates smoothly in all

steering positions.
• If not operating smoothly, check the deterioration,
damage and kink of the throttle cable.
• Measure the free play at the throttle grip.

FREE PLAY : 2~6mm

FREEPLAY
FREEPLAY
FREEPLAY
FREEPLAY

•For simple adjustment, use the adjuster under the

throttle grip.

•Adjust the free play by loosening the lock nut and

turning the adjuster.
•After adjusting, tighten the lock nut.

THROTTLE
THROTTLE
THROTTLE CABLE
CABLE
CABLE

ADJUSTER
ADJUSTER
ADJUSTER
LOCK
LOCK NUT
LOCK NUT
NUT

•Major adjustments are made with the lower adjuster.

•Adjust the free play by loosening the lock nut and
turning the adjuster.
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER •After adjustment, tighten the lock nut securely.
•Recheck the throttle operation.
•Replace any damaged parts, if necessary.

LOCK
LOCK NUT
LOCK NUT
NUT

THROTTLE
THROTTLE
THROTTLE CABLE
CABLE
CABLE

2-4
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

SCREWS
SCREWS
SCREWS
AIR CLEANER
• Remove the seat. (⇨13-2)
• Loosen the 4 screws, remove the air cleaner cover.

AIR
AIR CLEANER
AIR CLEANER
AIR CLEANER
CLEANER
HOUSING COVER
HOUSING
HOUSING COVER
COVER

• Remove the air cleaner element.

• Also replace the filter any time it is excessively dirty or
damage.

• Install in the reverse order of removal.

•Do not reuse the filter element to clean by

AIR
AIR
AIR CLEANER
CLEANER
CLEANER
compressed air.
ELEMENT
ELEMENT
ELEMENT

SPARK PLUG
• Remove the spark plug cap.
• Check the plug for damage, contamination or deposits.
• If the spark plug is severely contaminated or damaged,
raplace with a new one. If the plug can be reused after
removing only the carbon, use plug cleaner and wire
brush to clean the plug.
• Always use a feeler gauge to check the gap.
SPARK
SPARK PLUG
SPARK PLUG WRENCH
PLUG WRENCH
WRENCH
GENUINE PLUG : CR9EH-9
SPARK PLUG GAP : 0.8~0.9mm
TORQUE : 1.1kgf·m

CHECK GAP,
DEPOSITS 0.8~0.9mm
•Make sure there is no dirt or debris on the seat of the
spark plug hole before inserting the spark plug.
•To prevent damage to the cylinder head, handtighten
the spark plug before using a wrench to tighten to the
CHECK WASHER specified torque.
FOR DAMAGE
•Do not overtighten the spark plug.
CHECK FOR • Assemble the spark plug.
CRACKS

2-5
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

“T” MARK
“T”
“T” MARK
MARK VALVE CLEARANCE

•Inspect and adjust valve clearance while the engine

is cold. (below 35° C/95°F)

• Remove the cylinder head cover.

• Remove the A.C generator cap and crankcase hole cap.
• Rotate the flywheel counterclockwise to align the "T"
mark with the index mark on the left crankcase cover.
• Make sure the piston is at TDC(Top Dead Center) on
the compression stroke.

• Measure the valve clearance with a feeler gauge.

VALVE CLEARANCE : INTAKE : 0.15mm
EXHAUST : 0.20mm

CAM
CAM
CAM SHAFT
SHAFT
SHAFT

SHIM
SHIM
SHIM
SHIM

FEELER
FEELER GAUGE
FEELER GAUGE
GAUGE

SHIM ADJUSTMENT
• If the valve clearance is out of standard, adjust the shim
as below.
- Remove the camshaft.
- Remove the valve lifter and shim.

VALVE
VALVE LIFTER
VALVE LIFTER
LIFTER •If the valve lifter is to be removed, use the special
tool.
•Be careful not to drop the shim into the cylinder
when remove the shim with valve lifter.
•If it is too difficult to remove the shim, use a tweezer
or magnet.
•Valve lifter, and shim should be preserved on the
assembly position distinguishably.

• Remove the valve lifter and clean by compressed air.

• Mop the oil from the attached area of shim, and
measure and record the thinkness with a micrometer.

SHIM
SHIM
SHIM VALVE
VALVE LIFTER
VALVE LIFTER
LIFTER

2-6
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

SHIM
SHIM
SHIM
SHIM
•The type of shim is 33
•The clearance of shim is 1,500mm to 2,300mm with
0.025mm clearance.
• Demanded thickness of shim :A
• Recorded clearance of the valve lifter : B
• Specified clearance of the valve lifter : C
(In :0.15mm / Ex : 0.20mm)
• Removed thickness of the shim : D
• how to calculate : A = (B-C)+D
Example)
B : 0.06mm
D : 1.875mm
C : 0.15mm(IN)
A = (0.06-0.15)+1.875mm
New thickness of the shim : 1.775mm

•Meaure the thickness of new shim and removed shim,

118800 118822 118855 118888 using a micrometer accurately.
•If the demanded thickness of shim is over 2,300mm,
1.800mm
1.800mm 1.825mm
1.825mm 1.850mm
1.850mm 1.875mm
1.875mm check the valve seat and remove the carbon deposit
and modify the valve seat.
• Install the chosen shim into the valve spring retainer.
• Apply the molybdenum to wet side of valve lifter and
install the lifter.
• Install the cam shaft and rotate the crank shaft for many
timed and recheck the valve clearance after setting the
shim.
• Apply the engine oil to O-ring of pulse generator cover
cap and install the cap.
TORQUE : 0.6kgf-m

CYLINDER COMPRESSION PRESSURE

• Warm up the engine to normal operating temperature.
• Stop the engine, disconnect the spark plug caps and
spark plug. install the compression gauge. open the
throttle completely and crank the engine with the
starter motor until the gauge reading stops rising.

Tool:compression gauge.
COMPRESSION
COMPRESSION PRESSURE
COMPRESSION PRESSURE GAUGE
PRESSURE GAUGE
GAUGE

•The maximum reading is usually reached within

4~7seconds
•compression 13.0kg f/㎠

If compression is low, check the following

-Incorrect valve clearance adjustment.
-Valve leakage.
-Leak the gasket from the cylinder head.
-Worn piston/cylinder.
If compression is high, check the following
-Carbon deposits on the piston head, cylinder head.
2-7
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

DRIVE CHAIN

•Because there is a danger which fingers get jammed

in the drive chain, never inspect or adjust it while
the engine is running.

DRIVE CHAIN SLACK ADJUSTMENT

CHAIN
CHAIN SLACK 10~20mm • Turn off the ignition switch, support the motorcycle
CHAIN SLACK
SLACK 10~20mm
10~20mm
on its main stand, and shift the transmission into
neutral.
• Check slack in the lower chain with a hand midway
between the sprockets.
CHAIN SLACK : 25~35mm
• Adjust the slack of drive chain if necessary.
• Adjust it by loosening the axle nut, loosening both
ADJUSTER
ADJUSTER
ADJUSTER SCALE
SCALE
SCALE lock nuts of adjust, and turning the adjusting nut.

WHEEL
WHEEL AXLE
WHEEL AXLE
WHEEL AXLE
AXLE

•Make sure that the chain adjuster scale are aligned

with the corresponding scale graduations on both
sides of the swing arm.

• Tighten the axle nut with the specified torque.

ADJUSTING
ADJUSTING NUT
ADJUSTING NUT
NUT LOCK
LOCK NUT
LOCK NUT
LOCK NUT
NUT
TORQUE : 8.8kgf·m

DRIVE SPROCKET
DRIVE
DRIVE SPROCKET
SPROCKET
DRIVE CHAIN INSPECTION
• Lubricate with #80-90 gear oil after removing the
contamination of chain with a cleaner, and drying
fully.
• Because an extremely lubricated oil splash while
the chain moves round, clean it with a piece of
cloth.
• After checking a wear and damage of the drive
chain, replace it if necessary.

DRIVE
DRIVE CHAIN
DRIVE CHAIN
CHAIN
• After inspecting an excessive wear and damage of
the drive sprocket, replace it if necessary.

DAMAGE WEAR

•Always replace the chain and sprocket as a set.

Because using the stretched chain and new sprocket
or similar case, the parts will damage quickly cause
by the pictch is not engage each other.

• Check the attaching bolts and nuts on the drive and

driven sprockets.
NORMAL
● If any are loose, tighten them to the specified torque.
DRIVE SPROCKET
DRIVE
DRIVE SPROCKET
SPROCKET
TORQUE :
DRIVE SPROCKET BOLT : 1.2kgf·m
DRIVE SPROCKET NUT : 5.9kgf·m
2-8
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

DRIVE CHAIN SLIDER

CHAIN
CHAIN SLIDER
CHAIN SLIDER
SLIDER • Inspect the drive chain slider for excessive wear or
damage.
• If it is worn to the wear indicator, replace the drive
WEAR
WEAR
WEAR
WEAR chain slider.
INDICATOR
INDICATOR
INDICATOR

BRAKE FLUID
BRAKE
BRAKE
BRAKE FLUID
BRAKE FLUID CHECKING
FLUID CHECKING
FLUID SCREEN
CHECKING SCREEN
CHECKING SCREEN
SCREEN

•Do not mix a dust or different types of fluid when

filling the brake fluid.
•Mind that the reservoir is level in checking and
filling it.
•Avoid spilling the fluid on painted, plastic, or
LOWER
LOWER LEVEL
LOWER LEVEL LINE
LEVEL LINE
LINE rubber parts.
• When the fluid level is low, check the brake pads
for wear. If the brake pads are not worn and the
fluid level is low, check entire system for leaks.

REAR
REAR
REAR BRAKE
BRAKE
BRAKE RESERVER
RESERVER
RESERVER VESSEL
VESSEL
VESSEL
FRONT BRAKE
• Turn the handlebar so that the reservoir is level and
check the front brake fluid reservoir level.
• If the level is near the lower level line, check the brake
UPPER pad wear.
LOWER

REAR BRAKE
• Place the motorcycle on a level surface, and support it
upright position.
• Check the rear brake fluid reservoir level.
• If the level is near the lower level line, check the brake
pad wear.

BRAKE PAD WEAR

FRONT BRAKE PADS
• Check the brake pads for wear.
• Replace the brake pads if either pad is worn to the
bottom of wear limit groove.

• Refer to page 16-6 for brake pad replacement.

FRONT
FRONT
FRONT CALLIPER
CALLIPER
CALLIPER WEAR
WEAR INDICATOR
WEAR INDICATOR
INDICATOR

2-9
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

REAR BRAKE PADS

• Check the brake pads for wear.
• Replace the brake pads if either pad is worn to the
bottom of wear limit groove.

• Refer to page 16-7 for brake pad replacement.

WEAR
WEAR
WEAR INDICATOR
INDICATOR
INDICATOR

REAR CALLIPER
REAR
REAR CALLIPER
CALLIPER

BRAKE SYSTEM
• Check to see if there is a crack and damage in the
front and rear brake hose.
If leak, replace it with new one.

BRAKE
BRAKE HOSE
BRAKE HOSE
HOSE

FRONT BRAKE LEVER FREE PLAY

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

10~20mm
10~20mm
10~20mm
10~20mm

REAR BRAKE PEDAL FREE PLAY

REAR BRAKE
REAR
REAR BRAKE PEDAL
BRAKE PEDAL
PEDAL • Adjust the brake pedal free play at the end part of
pedal.
BRAKE PEDAL FREE PLAY : 10~20mm

10~20mm
10~20mm
10~20mm

2-10
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

BRAKE PEDAL HEIGHT ADJUSTMENT

• Loosen the lock nut and turn the stopper bolt until
BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE JOINT
JOINT
JOINT the correct pedal height is obtained.
• After adjustment, tighten the lock nut securely.

•The adjustment faulty of height may caused that the

brake runs in state of operation.

• After adjusting the brake pedal height, inspect the

ADJUST NUT
operation of rear brake light switch and brake pedal,
ADJUST
ADJUST NUT
ADJUST NUT
NUT
and adjust them if necessary.

REAR
REAR
REAR STOP
STOP SWITCH
STOP SWITCH
SWITCH
BRAKE STOP SWITCH
• Adjust the brake stop switch by turning the adjust
nut, pressing the switch so that the brake light will
come on just before the brake pedal is depressed
and brake engagement begins.

ADJUST
ADJUST
ADJUST NUT
NUT
NUT

HEADLIGHT AIM
• Adjust the headlight beam vertically by turning the
headlight case adjustment bolts.
• It can be adjusted up/down and left/right by
adjustment bolt.

•Adjust the headlight beam as specified by local

laws and regulations.

•An improperly adjusted headlight may blind

oncoming drivers, or it may fail to light the road
for a safe distance.

CLUTCH
CLUTCH
CLUTCH LEVER
LEVER
LEVER
10~20mm
10~20mm
10~20mm CLUTCH SYSTEM
• Measure the clutch lever free play at the end of the
clutch lever.

FREE PLAY : 10~20mm

2-11
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

• Minor adjustments are made using the upper

LOCK
LOCK NUT
LOCK NUT
NUT
adjuster at the clutch lever.
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER • Loosen the lock nut and turn the adjuster.

CLUTCH
CLUTCH
CLUTCH CABLE
CABLE
CABLE

• Major adjustments are performed at the clutch arm.

LOCK ADJUSTER • Loosen the lock nut and turn the adjuster nut to
LOCK NUT
LOCK NUT
NUT ADJUSTER
ADJUSTER
adjust free play.
• Hold the adjuster nut securely while tightening the
lock nut.

• If proper free play cannot be obtained, or the clutch

slips during test ride, disassemble and inspect the
clutch.

CLUTCH
CLUTCH WIRE
CLUTCH WIRE HOLDER
WIRE HOLDER
HOLDER
CLUTCH
CLUTCH REVER
CLUTCH REVER
REVER

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 STAND
SIDE STAND
STAND

2-12
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

SUSPENSION

•Do not ride motorcycle with an unsatisfactory

suspension. Loose or worn suspension parts will
lead to deterioration in the vehicle's safety and
operation efficiency.

FRONT FORK
• Hold the brake lever, and compress the front fork up
and down several times to check the operating
conditions.
• Check the front fork for oil leakage, parts damage
or looseness.

REAR CUSHION
• Compress the rear cushion up and down several
times to check the operating conditions.
• Check the rear cushion for oil leakage, parts
damage or looseness.

WHEEL INSPECTION
• Erect the motorcycle with the main stand.
• Check a wear of the rear fork bush by moving the
rear wheel aside. If there is a free play, replace the
rear fork bush.
•Tighten all nuts and bolts of the rear suspension.

BOLTS, NUTS, FASTENERS

• Check that all frame nuts and bolts are tightened to
their correct torque values. (⇨2-3)
• Check that all safety clips, hose clamps and cable
stays are in place and properly secured.

2-13
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

WHEEL/TIRE

•Check the tire pressure when the tires have been

cooled off. Check the tread (the part making
contact with the road surface) and side for wear,
cracks or damage. Replace damaged tires.

STANDARD PRESSURE
㎏f/㎠ (kpa)
ITEM FRONT WHEEL REAR WHEEL
DRIVER ONLY 2.00(200) 2.00(200)
DRIVER AND A PASSENGER 2.00(200) 2.25(225)

• Check the tread depth at the tire center.

• If the tread depth has reached the service limit,
replace the tires.

SERVICE LIMIT : FRONT : 5.5 ± 0.5 mm

REAR : 7.0 ± 0.5mm

STEERING STEM

•Check that the cables do not interfere with

handlebar rotation.

• Erect the motorcycle securely and raise the front

wheel off the ground.
• Check that the handlebar moves freely from side to
side.
• If the handlebar moves unevenly, binds or has
vertical movement, inspect the steering stem.

2-14
Downloaded from www.Manualslib.com manuals search engine
 INSPECTIONS / ADJUSTMENTS

COOLANT LEVEL INSPECTION

• Erect the main stand prior to beginning work.
• Check the coolant level and the reserve tank.
• The level should be between the “UPPER” and
“LOWER” level lines.
• Fill the coolant to the reserve tank up to the “F”
(upper level).

•Unless the coolant is refilled or replaced, the

engine temperature too high or low.
•Fill to the “F”(UPPER LEVEL) line.

COOLANT REPLACEMENT
• Remove the radiator cap.

• Remove the drain bolt and drain the coolant. (Tilt

the vehicle to the right in order to assure complete
and rapid draining.)
• Install the drain bolt.

• Fill the radiator with new coolant.

±20cc
COOLANT CAPACITY : 1,100±
±20cc
RADIATOR CAPACITY : 1,000±
RESERVE TANK CAPACITY: 280±±20cc

• Start the engine. Bleed air from the coolant and

check the level of coolant.
• Install the radiator cap.
• Fill the coolant with the reserve tank up to the
upper level.

2-15
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 3. LUBRICATION

SERVICE INFORMATION ··· 3-1 OIL FILTER ELEMENT CHANGE · 3-4

TROUBLESHOOTING·····3-2 OIL PUMP ········· 3-4
ENGINE OIL LEVEL INSPECTION · 3-3 LUBRICATION POINTS ··· 3-7 3
ENGINE OIL CHANGE ····3-3

SERVICE INFORMATION
GENERAL SAFETY

1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
2. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after
handling the used oil.
3. The oil pump can be serviced without removing the engine from the frame.

ENGINE OIL

1.5ℓ (After disassembly)

OIL CAPACITY 1.35ℓ (After Oil filter change)
1.3ℓ (After Oil change)

Daelim pure oil (4cycle motics 4)

API service classification : SL grade
RECOMMENDED Viscosity : SAE10W-40
OIL (Use appropriate type of oil with viscosity satisfying
the atmospheric temperature in your riding area
based on the table shown on the right side.) -10 0 10 20 30 40℃

OIL PUMP Unit : mm

ITEM STANDARD VALUE SERVICE LIMIT
PUMP BODY CLEARANCE 0.15~0.20 0.25
ROTOR END CLEARANCE 0.15 0.20

TORQUE VALUES
OIL DRAIN CAP 1.5㎏f·m
OIL FILTER COVER BOLT 1.1㎏f·m

3-1
Downloaded from www.Manualslib.com manuals search engine
 LUBRICATION

TROUBLESHOOTING
Engine oil level too low
•Oil consumption naturally.
•External oil leaks.
•Worn piston ring or incorrect piston ring installation.
•Worn valve guide or seal.

Oil contamination
•Oil or filter not changed regularly.
•Faulty head gasket.
•Worn piston rings.

Low or no oil pressure

•Clogged oil orifice.
•Incorrect oil being used.

3-2
Downloaded from www.Manualslib.com manuals search engine
 LUBRICATION

ENGINE OIL LEVEL INSPECTION

OIL
OIL
OIL LEVEL
LEVEL
LEVEL GAUGE
GAUGE
GAUGE

• Erect the motorcycle by main stand.

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

ENGINE OIL CHANGE

• Loosen the drain plug bolt on the LH. crank case and
drain the oil.
• Loosen the oil drain cap on the RH. crank case.

• Clean filter screen with a clean wash. Check if the oil

filter screen seal rubber and O-ring of the tappet adjust
hole are in good condition.
• Unscrew the spark plug from the spark plug cap and
operate the starter motor for a second to remove the
remaining oil from the engine.
• Install the filter screen, spring and tappet adjust hole cap.

•Make the engine warm and erect the motorcycle

with side stand in order to assure complete and rapid
draining.

TORQUE : 1.5 kgf·m

• Fill the crankcase with recommened engine oil.

OIL CAPACITY: 1.5ℓ (After disassembly)

1.35ℓ (After oil filter change)
1.3ℓ (After oil change)
OIL
OIL
OIL FILTER
FILTER
FILTER SCREEN
SCREEN
SCREEN OIL DRAIN
OIL
OIL DRAIN CAP
DRAIN CAP
CAP RECOMMENDED ENGINE OIL :
Genuine oil
API classification : SL grade
viscosity : 10W-40
DRAIN
DRAIN PLUG
DRAIN PLUG BOLT
PLUG BOLT
BOLT
• Install the oil level gauge.
• Start the engine and let it idle for a few minutes.
• Stop the engine and recheck the oil level,if necessary,
supply the recommended oil.

• Check to see if the oil is leak.

TAPPET
TAPPET
TAPPET ADJUST
TAPPET ADJUST HOLE
ADJUST HOLE
ADJUST CAP
HOLE CAP
HOLE CAP
CAP

3-3
Downloaded from www.Manualslib.com manuals search engine
 LUBRICATION

OIL FILTER ELEMENT CHANGE

OIL
OIL FILTER
OIL FILTER
FILTER
MAINTENANCE
MAINTENANCE
MAINTENANCE OIL
OIL
OIL FILTER
FILTER
FILTER COVER
COVER
COVER • Remove the oilfilter maintenance cover on RH. side
COVER
COVER
COVER cowl.
• Drain the engine oil. (⇨3-3)

RH.
RH. SIDE
RH. SIDE COWL
SIDE COWL
COWL

• Remove the oilfilter cover bolt, filter cover, filter

OIL
OIL
OIL FILTER
FILTER
FILTER ELEMENT
ELEMENT
ELEMENT element and spring.
• Change the oilfilter element with a new one.

OIL SEAL
OIL
OIL SEAL
SEAL
• If the valve is turned on completely when it pushed, or
the valve is turned off automatically when it relocated
again, it is fine.
• Check the oil filtercover seal is in good condition.
• Change the oil filter cover seal with a new one.
• Install the filter element, spring and oil filter cover and
tighten the bolts to the specified torque.

TORQUE : 1.1 kgf·m (11 N·m)

• Fill the genuine engine oil to the crankcase. (⇨3-1)

RELIEF
RELIEF
RELIEF VALVE
VALVE SOCKET
VALVE SOCKET BOLT
SOCKET BOLT
BOLT

OIL PUMP
OIL
OIL PUMP
OIL PUMP GEAR
PUMP GEAR
GEAR
REMOVAL
• Drain the engine oil. (⇨3-3)
• Remove the oil filter. (⇨3-4)

3-4
Downloaded from www.Manualslib.com manuals search engine
 LUBRICATION

• Clean the oil pump body (inner and outer) and rotors
with fresh cleaning oil.

OUTER
OUTER ROTOR
OUTER ROTOR
ROTOR INNER
INNER ROTOR
INNER ROTOR
ROTOR

INSPECTION
INNER
INNER
INNER ROTOR
ROTOR
ROTOR • Install the inner and outer rotors into the oil pump
body.
• Measure the pump body clearance.

SERVICE LIMIT : 0.25mm

OUTER
OUTER ROTOR
OUTER ROTOR
ROTOR FEELER
FEELER GAUGE
FEELER GAUGE
GAUGE

• Measure the rotor end clearance.

SERVICE LIMIT : 0.20mm

ASSEMBLY
• Clean all parts with fresh cleaning oil.
• Install the lnner and outer rotor to the pump body.

•After installing, check the oil pump to operate

smoothly

INSTALLATION
• Install the oil filter cover to the RH.crank case.
•Fill the recommended oil into the crankcase. (⇨3-3)

3-5
Downloaded from www.Manualslib.com manuals search engine
 LUBRICATION

LUBRICATION POINTS
Use general grease

SECTION ROTATE SHEEL ALVANIA EP2 or SUITABLENESS WIDTH

〃 〃
SLIDING PART 〃
〃 〃
EDGE PART 〃
SLIDING PART 〃
INSIDE PART OF MASTER CYLINDER CUP DOT3 or DOT 4
SLIDING PART ASSEMBLY OIL CCI No.20 or SUITABLENESS WIDTH
〃 BRAKE GREASE SPECIAL
〃 〃
EDGE PART ASSEMBLY OIL CCI No.20 or SUITABLENESS WIDTH
SLIDING PART MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH
EDGE PART 〃
GEAR COUPLING DAPHNE EPONEX EP2 or SUITABLENESS WIDTH
INSIDE ULTRA CUSH OIL NO.10 SUITABLENESS WIDTH
EDGE PART LIQUID O-RING #400
SLIDING PART GREASE
CONCORDANT PART CEMEDINE #540 or SUITABLENESS WIDTH
SLIDING PART MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH
CASTING AND CONTACT INSIDE PART SILICON GREASE
CASTING INSIDE PART 〃
SLIDING PART MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH
〃 MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH
〃 MITSUBISHI MULTIPURPOSE No.20 or SUITABLENESS WIDTH

Apply oil or grease to the other sliding surfaces not shown here.

3-6
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 FUEL SYSTEM

4-0
Downloaded from www.Manualslib.com manuals search engine
 4. FUEL SYSTEM

SERVICE INFORMATION ·· 4-1 ········ 4-3

FUEL TANK·
TROUBLESHOOTING ···· 4-2 ···· 4-4
AIR CLEANER CASE·

SERVICE INFORMATION
4
GENERAL SAFETY

• Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore,
the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas.
• Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly
ventilated area.

STANDARD OF MAINTENANCE
• Fuel tank capacity : 14.85ℓ
• Reserve fuel capacity: 4.0ℓ
• Fuel pump specification : KGF38
Flow quantity : Mimnim 20ℓ/hr
Flow pressure : 380kpa
• Injector specification
Injector angle : 15°
Operation pressure : 380kpa

TORQUE VALUE
Air cleaner case cover screw 0.43kgf·m (4.3N·m)

TOOL
Float level gauge

TROUBLESHOOTING
Engine cranks but won’t start
• No fule in tank
• No fule to carburetor
• Cylinder flooded with fuel
• Clogged air cleaner
• No spark at plug

4-1
Downloaded from www.Manualslib.com manuals search engine
 FUEL SYSTEM

FUEL
FUEL
FUEL TANK
TANK
TANK FULE TANK
REMOVAL

•Do not smoke or allow flames or sparks in the

work area because gasoline is extremely
flammable. Immediately wipe off a leaked
gasoline.
• Remove the seat.

• Remove the fuel tank cover by looseing the 2

FUEL
FUEL TANK
FUEL TANK SERVE
TANK SERVE CORD
SERVE CORD
CORD special screws and washer bolt.

• Disconnect the fuel serve cord.

FUEL TUBE
TUBE
• After lift a section of the fuel tank, seperate a clip of the
FUEL
FUEL TUBE
fuel tank and the hose.
• Remove the fuel tank.
CLIP
CLIP
CLIP
INSTALLATION
• Install the fuel tank in the reverse order of removal.
• After installation, check if there is a gasoline leak.

FUEL FILLER CAP FUEL TANK SEALING RUBBER

FUEL PUMP
FUEL TANK COVER

FUEL CAP NECK FUEL TANK

4-2
Downloaded from www.Manualslib.com manuals search engine
 FUEL SYSTEM

AIR CLEANER CASE

AIR
AIR
AIR CLEANER
CLEANER CASE
CLEANER CASE
CASE
REMOVAL
• Remove the main seat.
• Remove the fuel tank.
• Remove the RH. LH. side covers.
• Remove the fuel tank rear stay.

FUEL
FUEL TANK
FUEL TANK REAR
TANK REAR STAY
REAR STAY
STAY

• Remove the battery.

• Remove the battery box by loosening the washer
bolt.
• Remove the air cleaner connecting tube band.
• Remove the air cleaner case mounting bolts, then
remove the air cleaner case.
INSTALLATION
• Install in the reverse order of removal.

•Insert the hook area of battery box into the front

hole of rear fender accurately when assemble the
air cleaner case.

AIR CLEANER ELEMENT AIR CLEANER CASE COVER

AIR CLEANER CASE

4-3
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 EMS(Engine Management System)

5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS 5-2
2. THE COMPONENT PARTS OF THE EMS 5-3
3. TERMINAL ARRANGEMENT OF THE ECU 5-4
4. WIRING DIAGRAM OF THE ECU 5-5
5. AN ERROR CHECK LIST FOR EACH TERMINAL OF ECU 5-5
6. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) 5-5 5
- SELF DIAGNOSTIC FUNCTION 5-5
- FAIL SAFE FUNCTION 5-6
- HOW TO CHECK THE FAULT CODE 5-8
- HOW TO SHOW THE FAULT CODE 5-9
- HOW TO READ THE FAULT CODE 5-9
- FAULT CODE TABLE 5-10
- HOW TO REMOVE THE FAULT CODE 5-11
- EMS TROUBLE SHOOTING 5-11
7. ECU (Electronic control unit) 5-12
8. THROTTLE BODY 5-13
9. INJECTOR 5-17
10. MAPAT 5-20
11. TPS (Throttle Position Sensor) 5-24
12. ETS (Engine Temperature Sensor) 5-27
13. ISA (Idle Speed Actuator) 5-30
14. O2 (Oxgen Sensor) 5-33
15. CHECKING OF ESS CIRCUIT 5-36
16. CHECKING OF MIL CIRCUIT 5-37
17. CKP (Crank Position Sensor) 5-38
18. FUEL PUMP 5-42
19. HOW TO USE SCAN 5-45
- ECU INITIALIZING 5-45
- ISA PWM ADJUSTING 5-47
- IGNITION TIMING CHECK 5-48
- ENGINE RPM CHECK 5-49

5-1
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

1.CAUTION WHEN REPAIRING THE EMS PARTS.

•If the fuse is short-circuited, find out the cause and repair, replace with the fuse having the specified capacity.
•Do not use the electlic wires or others instead of the fuse.
•Do not drop or throw the EMS parts, because these parts may be damaged by the impact of the drop.

•Do not touch the ECU terminal, because it may be damaged by the static.

•The ignition key off before assembly and disassembly of the ECU coupler.
Otherwise, it might be damage to ECU.

•Do not connect adversely the polarity of battery, otherwise, it might be broken the EMS parts

•While engine operating, do not disassemble the battery terminal.

Otherwise, it might cause damaged the EMS parts.

•Use the specified voltmeter and resistance meter.

5-2
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

2.THE COMPONENT PARTS OF THE EMS

EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.

1) INTAKE SYSTEM
As a system which controls and measures air to be necessary for combustion in engine, the intake system
is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air
cleaner and ISA(Idle Speed Actuator), etc.
In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means
that idle speed control system is installed in order to control small of quantity of air being necessary for
combustion.

2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to
injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division
pipe and injector.
The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter.
Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of
intake system.
Injector sprays fuel into the intake system by injection signals of ECU.

3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to
control proper spark time in cylinder, high-voltage system, and so forth.

4) CONTROL SYSTEM
① Various sensors to move electric signals converted by checking the current engine status
② Input interface which works various processes like regulating voltage levels, removal of noise, A/D
conversion, amplifying of inputted signals from above sensors.
③ Micro-computer which decides output value through various calculating, arithmetic and logic
processing.
④ Output interface to amplify the above output signals.
⑤ Actuator being mechanically worked by receiving the amplified output signals.

(Intake pressure sensor+Intake

temperature)

5-3
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

3. TERMINAL ARRANGEMENT OF THE ECU

ECU PIN NO. VS FUNCTION
PIN NO. FUNCTION PIN NO. FUNCTION
ECU Earth Third Gear
Oxygen sensor Earth Crank Position Signal B
Intake pressure sensor Earth Communication LOW
TPS. ETS Earth MIL
Engine KILL Battery Power
- Intake pressure sensor power(5V)
- Intake pressure sensor Signal
- Intake temperature sensor Signal
ECU Earth Neutral Gear
After main key turn on, Battery power Crank Position Signal A
- Communication HIGH
Oxygen sensor Signal Engine Speed Signal
Side stand Signal Idle Speed Actuator
- Oxygen sensor Heat
- Ignition coil Earth
- -
Battery Power supply Ignition Signal
TPS Power (5V) supply HEad lamp relay Signal
Throttle Position Sensor Signal Fuel pump relay Signal
Engine Temperature Sensor Signal Injector Signal

Remarks
•ECU PIN NO. 6,7,8,11,14,15,16,36 were not connected.
•Terminal arrangement is based on the ECU.

5-4
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

4. WIRING DIAGRAM OF THE ECU

5. AN ERROR CHECKLIST FOR EACH TERMINAL OF ECU

ERROR Checklist ERROR Checklist
PIN NO. Idle RPM PIN NO. Idle RPM
Durability SCAN tool
Starting
Stability
Driving Durability SCAN tool MIL Starting
Stability
Driving
communication
MIL
communication

ECU 01 O O O X O X ECU 23 O O O O X X
ECU 02 O X O X O O ECU 24 - - - - O X
ECU 03 O X O X O O ECU 25 X - X - X X
ECU 04 O X O X O O ECU 26 O X O X O O
ECU 05 X - X - O X ECU 27 O X O X O O
6, 7, 8 - - - - - - ECU 28 O X O X O O
ECU 09 O O O X O X ECU 29 X - X - O X
ECU 10 X - X - X X ECU 30 X - X - O X
ECU 11 - - - - - - ECU 31 O O O O X X
ECU 12 O X O X O O ECU 32 O O O O O O
ECU 13 X - X - O X ECU 33 O X O O O O
14,15,16 - - - - - - ECU 34 O X O X O O
ECU 17 X - X - X X ECU 35 X - X - O X
ECU 18 O X O X O O ECU 36 - - - - - -
ECU 19 O X O X O O ECU 37 X - X - O X
ECU 20 O X O X O O ECU 38 O O O O O O
ECU 21 O O O O O X ECU 39 X - X - O O
ECU 22 X - X - O X ECU 40 X - X - O O

5-5
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

6. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)

SELF-DIAGNOSTIC FUNCTION
The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation
normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL
(malfunction indicator lamp). It gives the rider that malfunction has occurred in the system.
However, the ECU takes fail-safe function, it enables to drive only temporary when that happen.
Normally, the MIL illuminates for 3 seconds, when the main key is turned on.

MIL(Malfuction Indicator Lamp)

when the ignition key ON.

MIL
OFF Able to engine start

Starting and driving are temporary

ON
Unable to engine start

Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMS’s
fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.

Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump

The MIL on and blink(when this function detects a malfunction in the system)

MIL

ON MIL on continuously, when the engine operating

Blink MIL blinks, when the main key is turn on (engine is stop)

5-6
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

FAIL-SAFE FUNCTION
If the ECU checks something wrong , the vehicle can be driven by its fail safe function.
However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation
can be impossible.

MIL

on
INTAKE : :MIL
MILoff
on/off
INTAKE

: MIL on on
: MIL

If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.

The value of intake pressure is fixed as the

INTAKE
pressure just before when the intake pressure
sensor is out of order.
INTAKE valve of
The value ofintake
intaketemperature
temperatureisisfixed
fixedastoa
20.25℃ when
temperature thebefore
just intakewhen
pressure
thesensor
intakeis out
of order. sensor is out of order.
pressure

△
! CAUTION

If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.

5-7
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

HOW TO CHECK THE FAULT CODE

There are two methods of checking the fault codes.
Use the MIL in the speedometer and the diagnostic tool.

First) Use the MIL in the Speedometer for checking.

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

Coupler to check the malfunction diagnosis

Wire color to check the malfunction diagnosis
-P/W : PINK/WHITE : CAN_L
-P/Y : PINK/YELLOW : CAN_H
-B : BLACK : IGNITION KEY
-G : GREEN : GROUND

Third) Use the wireharness for checking

❶ Coupler for checking (ECU 1 - ECU 20 PIN)
❶
❷

❷ Coupler for checking (ECU 21 - ECU 40 PIN)

Measure the wire harness for checking by connecting the ECU with main wire harness to check the ECU.
It has two coupler to check the terminal.
The wireharness to check the ECU arrangement

❶ Coupler for checking : ECU PIN no. 1,2,3,4,5,9,10,12,17,18,19,20 were connected.

ECU PIN no. 6,7,8,11,13,14,15,16 is not connected.

❷ Coupler for checking : ECU PIN no. 21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,37,39,40 were connected.

ECU PIN no. 36 is not connected.

5-8
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

HOW TO SHOW THE FAULT CODE

There are two methods to show the Fault codes.

First) The methods to show in engine operation

In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the
light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code,
stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be
verified.(refer to the fault code table)

Second) The ways of indication only turn on the ignition key.

When only ignition key is on and if the defect of each part brings out, the MIL keeps showing
the Fault code of defect part repeatedly in order to give defect information to driver.

△
! CAUTION

If the MIL on when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started.

HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS.
Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed.
E.g. ) The Fault code of ISA

ON

OFF

1.5 sec 3 sec

1 flashing cycle : 0.5 sec

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

When the vehicle is checked using the diagnosis tool.

- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.

5-9
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

FAULT CODES TABLE

MIL INDICATION Fault Priority

code no. Description
(The number of blinks) order

No failure

Crank position sensor failure(CKP)

Injection valve failure(IV)

Idle speed actuator failure (ISA)

Electrical fuel pump failure (EFP)

Intake Manifold absolute pressure signal

failure (IMP)

Throttle position signal failure (TPS)

O2 sensor heater output failure (LSH)

Lambda signal failure (VLS)

Engine temperature signal failure (TENG)

Breathing air temperature signal failure

(TBA)

Engine speed signal output failure (ESS)

Headlamp relay failure

Malfunction indicate lamp failure (MIL)

5-10
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

HOW TO REMOVE THE FAULT CODE

Remove the fault codes in two ways;

First) Full warm up

1. Starting the engine.

- The MIL blinks continuously because the ECU memorized the fault code yet.
2. Full warm up the engine (keep idling five minutes)
3. Turn off the ignition key after full warm up the engine
4. Turn on the ignition key again, and check whether the fault code is disappeared or not.

After full warm up, it is possible to check the fault code is removed with the ignition key on/off.

If many problems happened in the EMS parts at the same time, only one defect code will is displayed
by the priority order.
Even thought repair a fault and remove the memorized fault code, another fault code blinks.
at this time, revise the fault and remove the memorized fault code by the warm up.

Second) Malfunction diagnosis tool

(refer to the scan user’s manual)

EMS TROUBLE SHOOTING

Inspection before diagnosis
Inspection the following before malfunction diagnosis.
Quantity of engine oil and leakage
Quantity of fuel and leakage
Blocked of air cleaner
Condition of battery
Free play of throttle cable
Cutting of fuse
Leakage of emission gas
Connection of each coupler
Cylinder press pressure
Condition of spark plug

5-11
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

7.ECU(ELECTRONIC CONTROL UNIT)

It is located inside a pillion seat
SEAT
SEAT
SEAT
SEAT LOCK
LOCK
LOCK
△
! CAUTION

The key is off before disassembly.

Remove the setting grommet and center cover.

CENTER
CENTER COVER
CENTER COVER
CENTER COVER
COVER

COVER
COVER SETTING
COVER SETTING GROMMET
SETTING GROMMET
GROMMET

Remove
- ECU coupler
ECU
ECU
ECU GROUND
GROUND
GROUND WIRE
WIRE
WIRE - Remove the coupler in sequence
- Remove the 4 flange bolts securing ECU

❶
❶

FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS ❷
❷

Install
- Install in the reverse order of removal

△
! CAUTION

Be sure to assemble the ECU ground wire.

(The color is green)

5-12
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

8. THROTTLE BODY

Remove the seat support pipe.

Remove the fuel tank.

Loosen the screw securing air cleaner

connecting tube band.
Remove the throttle body and air cleaner.

AIR
AIR
AIR CLEANER
CLEANER
CLEANER

MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR
Remove the gasoline in fuel tube.
Disconnect fuel tube securing inject or cap.
Disconnect injector, MAPAT, throttle sensor,
ISA coupler.
Disconnect throttle cable.

INJECTOR
INJECTOR
INJECTOR

INSULATOR
INSULATOR
INSULATOR Loosen the 2 flange bolts securing insulator
and remove the throttle body assy.

5-13
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

DISCONNECT THE THROTTLE BODY

INJECTOR
INJECTOR
INJECTOR
Remove the each component parts securing
throttle body and check.
THROTTLE
THROTTLE
THROTTLE BODY
BODY
BODY

INSULATOR
INSULATOR
INSULATOR △
! CAUTION

Do not disconnect both the throttle adjust

MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR screw and adjust nut.

REMOVE
Loosen the throttle body 2 bolts securing the
insulator.
Disconnect the TPS (Throttle position sensor).
Disconnect the ISA(Idle speed actuator).
Disconnect the MAPAT.

△
! CAUTION

IDLE
IDLE
IDLE SPEED
IDLE SPEED ACTUATOR
SPEED ACTUATOR
ACTUATOR Do not disconnect the throttle valve.

CHECKING THE THROTTLE BODY

Checking the O-ring.
THROTTLE
THROTTLE
THROTTLE SHAFT
THROTTLE SHAFT
SHAFT
Checking the Throttle shaft.
Checking the Throttle valve.

O-RING
O-RING
O-RING

Checking the ISA.

Checking the TPS.

△
! CAUTION

Replace the O-ring with new one.

O-RING
O-RING
O-RING
O-RING

5-14
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

DISASSEMBLE THE INSULATOR

INJECTOR
INJECTOR
INJECTOR
Disconnect injector cap bolt.

MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR

O-RING
O-RING
O-RING

Disconnect injector and injector cap at the

same time from the insulator.
Disconnect injector and injector cap.

MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR INSULATOR
INSULATOR
INSULATOR
INSULATOR INJECTOR
INJECTOR
INJECTOR

CHECKING THE INSULATOR

CAP
CAP
CAP Check the O-ring.
Check the insulator inside.
Check the MAPAT sensor.
Check the injector
Assemble is the reverse order of removal.

△
! CAUTION

Replace the o-ring with new one.

MAPAT
MAPAT SENSOR
MAPAT SENSOR
SENSOR INJECTOR
INJECTOR
INJECTOR
INJECTOR

INSTALLATION OF INSULATOR AND

THROTTLE BODY
Installation of insulator and throttle body in
the reverse order of removal.
Check the o-ring when the insulator assembly.
Torque : 1.0 kgf m
△
! CAUTION

Replace the gasket with new one.

INSULATOR
INSULATOR
INSULATOR
INSULATOR
THROTTLE
THROTTLE BODY
THROTTLE BODY
BODY Install the assembled insulator and throttle
body to the cylinder head.
Torque : 1.2 kgf m
5-15
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

THROTTLE
THROTTLE
THROTTLE CABLE
CABLE
CABLE ASSEMBLY
Assemble the throttle cable.
Adjust the free play of throttle grip.

INSPECTION OF SENSOR AND

ACTUATOR
Connect each sensor and the actuator coupler.
Check the ISA.
Check the TPS.
Check the MAPAT sensor.
△
! CAUTION

Be sure to the valve of TPS is whether the

standard valve after it became assembly.

ADJUSTMENT OF IDLE SPEED

ACTUATOR (ISA)
△
! CAUTION

The ECU is always initilized, before the engine

is starting.
The vehicle is warms up enough to adjust the
idling speed.
ADJUST SCREW
ADJUST
ADJUST SCREW
SCREW Disconnect the RH. side cover.
Connect the coupler of scanner to the coupler
of diagnostic tool.
Press the POWER button on the scanner and
check the ISA value.

If the ISA value is not around 20% adjust it

using the adjust screw to around 20% in 80~90℃
of engine temperature.

ADJUST
ADJUST SCREW
ADJUST SCREW
SCREW

5-16
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

INJECTOR
INJECTOR
9.INJECTOR
Remove
• Remove the fuel tank.

△
! CAUTION

•The key is off before disassembly.

• After push the injector coupler, pulling it

upward.

❷
❷

❶
❶

• Remove the injector cap bolt.

△
! CAUTION

•Be sure to check the engine is cooling because

a little gasoline remains. it could be still hot
and it could be cause fire.
• Be sure to injector the gasoline, after remove
the coupler from the ignition coil.
• It could be damaged for the fire, sparked on the
spark plug.

• Remove the injector.

Assemble
• Install in reverse order of removal.

5-17
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING METHODS BY FAULT CODES

Checking of the Injector circuit
The fault code is displayed by MIL

Checking Circuit

40 : INJECTOR control
ECU 39 : FUEL PUMP control

INJECTOR FUEL PUMP RELAY

Coupler terminal is based on wire harness.

5-18
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING PROCEDURE

1) Turn off the ignition key.

2) Check to see if the injector coupler has come loose or the wire is peeling off.
If there is no problem, measured the resistance of injector.
3)Disassemble the injector coupler and measure the resistance between injector terminals.
The resistance of injector : 14.5±0.7[ ], 20
Remarks : measuring unit for resistance : resistance ‘ R ‘ [ ]
4)If there is no problem, check the continuity between each terminal and ground.
The resistance between each terminal and ground : ∞[ ]
If resistance value is not normal, replace injector with the new one.
5)If the resistance is normal, turns on the ignition key
- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.
6) Measure between the voltage of coupler.
Measuring terminal : BLACK/RED electric wire ~ ground
Measuring voltage : battery voltage – 1.0[V]over

Remarks : Measuring unit of voltage : voltage [V]

7) If the measured voltage is normal,
Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited
or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)
If there is no problem in the electric wires, ECU is broken
Replace the ECU with new one, it rechecks

8) If the measured voltage is not normal,

Check the Black/Red electric wire to see if they have been broken or have short-circuited.
Check the fuel pump relay.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).

5-19
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

10. MAPAT(Manifold Air pressure

❶
❶ sensor, Temperature sensor)
❷ It is Located on the left side of the throttle
❷
body.
Remove
Remove the MAPAT sensor coupler.

△
! CAUTION
MAPAT
MAPAT
MAPAT SENSOR
MAPAT SENSOR
SENSOR
SENSOR The key is off before disassembly.

Loosen the MAPAT sensor screw 2EA.

MAPAT sensor.

Assemble
• Install in reverse order of removal.

5-20
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit

Fault code number is displayed by MIL

The Fault code of intake pressure sensor The Fault code of intake temperature sensor

Checking circuit

MAPAT

33: Intake pressure sensor

: Inhalation pressureground
26 : 5V voltage
sensor GROUND
27
26::IMP
5V voltage
ECU 28
27::TBA
IMP 28 : TBA

Coupler terminal is based on the side of wire-harness

CHECKING PROCEDURE
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input 5 voltage of MAPAT’s coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)’s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
Remarks : Measuring unit of voltage : voltage [V]

5) If voltage value is not normal,

Check to see if the ECU coupler is loose or if there is a bad contact.
Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ to see if they have been broken short-circuited
Remark : refer to (5-16) if the intake pressure sensor is broken
refer to (5-16) if the intake temperature sensor is broken
After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).

5-21
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING OF THE INTAKE PRESSURE SENSOR

1) If voltage value is normal, turn off the ignition key.
Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler

2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler.
Refer to how to assemble or disassemble the ECU ( 5-32 )

3) Turn on the ignition key. Start engine and operate idle.

4) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor.
Measuring terminal : ECU No. 27(P/L:PINK/BLUE) ~ ECU No.3(P/G : PINK/GREEN)
Measuring voltage : 0.1[V] ~ 4.8[V]
Remarks : Measuring unit of voltage : Voltage [V]
The voltage of air pressure;
20[kPa]: 0.719 ~ 0.859[V]
107[kPa]: 4.154 ~ 4.294[V]

5) If the measured voltage is not normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’
electric wire to see if they have been broken or have
short- circuited. Connecting the wire harness for checking
Replace the MAPAT sensor with the new one and it rechecks.

If measuring voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire
to see if they have been broken or have short- circuited
if there is a bad contact.
badness of terminal No. 3, No. 26, No.27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
6) After repaired, refer to the fault code removal method to erase
the memorized fault code in the ECU.

5-22
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING OF INTAKE TEMPERATURE SENSOR

1) If voltage value is normal, turn off ignition key.
2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.
Resistance of intake pressure sensor : 2000±100[Ω], 25±1
Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)
Remarks : Measuring value for resistance : Resistance[ ]
The Voltage of air pressure;
24 ~ 26[ ] : 1800~2200[ ]
99 ~ 101[ ] : 161~206[ ]
3) If measuring resistance is not normal,
Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire
to see if they have been broken or have short- circuited
if there is a bad contact of terminal No. 3, No. 26, No. 27
of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
4) Turn on the ignition key. Start the engine and idling.
5) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor
- Measuring terminal: ECU No.28(TBA)
~ ECU No.3(IMP ground)
- Measuring voltage: 0.1[V] ~ 4.9[V]
Remarks : Measuring unit of voltage : Voltage [V]

6) If the measured voltage is not normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’
electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire
to see if they have been broken or have
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No.28 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace ECU with the new one, it rechecks.

7) After fault repaired, To erase the memorized fault code in

the ECU is refer to how to remove the fault code(5-11).

5-23
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

11.TPS(THROTTLE POSITION SENSOR)

❷
❷
It is located on the left side of throttle body.
❶
❶
Remove
Press the TPS coupler then remove it with
pulling.

△
! CAUTION

The key is off before disassembly.

Remove the TPS screw 2EA

MAPAT
MAPAT SENSOR
MAPAT SENSOR
MAPAT SENSOR
SENSOR SCREWS
SCREWS
SCREWS

Remove the TPS

Assemble
• Install in reverse order of removal.

5-24
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM

Fault code number is displayed by MIL

Checking circuit

The coupler terminal is based on the side of wire-harness

Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the ignition key.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPS’s coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit of voltage : Voltage [V]

If voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.
Check the ‘GR/B’’ electric wire, ‘W/R’ electric wire, ‘GR /L’ electric wire to see if they have been
broken or have short- circuited.

5) If the value of voltage is normal, turn off the ignition key.

5-25
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

Checking Procedure
6) Check continuty between the Sensor Ground Terminal of TPS and Earth.

The continuty TPS : 0~1.0[ ],20±1

Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH
Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ ]

7) If not problem, measure the resistance of TPS.

By turning round throttle Lever, measure the resistance.
The resistance of TPS
If the throttle is totally closed : 0.9~1.6[k ],20±1
If the throttle is totally opened : 2.3~2.6[k ],20±1
Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE) ~
ECU No.4 (W/R : WHITE/RED)

Remarks : Measuring value of resistance : Resistance[k ]

8) If resistance and the continuty are not abnormal.

Adjust correctly the position of TPS
Replace the TPS with the new one and re-check.

9) If resistance and continuty are normal, connect the coupler of TPS.

10) Turn on the ignition key.
11) Measure the TPS voltage of the wire-harness to check the ECU.
Rotate the throttle lever, measure the voltage
Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE) ~
ECU No.4 (W/R : WHITE/RED)
Output voltage of TPS
-If the throttle is totally closed : 0.1~0.6[V]
-If the throttle is totally opened : 4.0~5.5 [V]
Remarks : Measuring unit for voltage : Voltage [V]

12) If the measured voltage is abnormal,

Replace the TPS with the new one, and re-check.
If the measured voltage is normal,
Check the ‘GR/B’ electric wire, ‘GR/L’ electric wire, ‘W/R’ electric wire
to see if they have been broken or have short- circuited if there
is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, and recheck.

13) After fault repaired, To erase the memorized fault code in the ECU is refer
to how to remove the fault code(5-11).

5-26
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

THERMO
THERMO STAT
THERMO STAT
STAT 12.ETS(ENGINE TEMPERATURE SENSOR)
It is located on the left-hand side of cylinder
head.

Remove
After pressing the ETS coupler and pull it..

△
! CAUTION

ENG.
ENG. TEMP.
ENG. TEMP.
TEMP. The key is off, before disassembly.
SENSOR
SENSOR
SENSOR

Remove the ETS coupler.

❶
❶

❷
❷

ENG.
ENG. TEMP.
ENG. TEMP.
TEMP.
SENSOR
SENSOR
SENSOR

Remove the ETS.

Assemble
Install in reverse order of removal.

5-27
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)

Fault code number is displayed by MIL

CHECKING CIRCUIT

ETS

ECU 4 : SENSOR GROUND

50V SUPPLY VOLTAGE
20 : ETS

Coupler terminal is based on the side of wire-harness

ETS
ETS
Checking Procedure
1) Turn off the ignition key .
2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
~ ECU No.4 (W/R : WHITE/RED)

Measure the terminal voltage of ETS’s coupler.

Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit for voltage : voltage [V]

If the voltage value is not normal,

Check to see if the ECU coupler is loose, or bad contact.
Check the ‘G/L’’ electric wire, ‘W/R’ electric wire, ‘W/R’ electric wire to see if they have been
broken or have short- circuited.
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS :1.6[k ]~10.6[k ],20 ~80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [k ]

5-28
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

6-1) If the measured value is not normal,

Replace the ETS with the new one, recheck.

If the measured value is normal,

Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if
the ECU coupler is a bad contact ( No.4, No. 20.)
If the electric wire is no problem, ECU is broken.
Replace ECU with the new one, recheck.
6-2) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

Checking Procedure
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to 5-27)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperature’s change and tester’s value.

Characters of ETS

Temperature Resistance value

20 10.6[k ]~14.4[k ]
80 1.35[k ]~1.65[k ]
110 0.57[k ]~0.69[k ]
Measuring unit of resistance : Resistance ‘ R ‘[k ]
If the value of resistance is high or out of the standard value, replace the ETS with the new one.
△
! CAUTION

1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the Thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.

3) Install
Install in the reverse order of removal with standard torque.

ETS torque : 3.0[kgf m]

5-29
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

13.ISA(IDLE SPEED ACTUATOR)

❶
❶ Remove
Remove the ISA coupler

△
! CAUTION

❷
❷ The key is off, before disassembly.

Remove the injector cap firstly for

dismantling the ISA.

Remove the ISA screws. (2EA)

Remove the ISA.

Assemble
Install in reverse order of removal.

5-30
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.

Showing of defects codes by MIL

CHECKING CIRCUIT
ECU
39::ISA
33 FUEL PUMP CONTROL
CONTROL
39:FUEL PUMP CONTROL
40 : INJECTOR
40 39

ISA FUEL PUMP RELAY

Coupler terminal is based on the side of the wire-harness

CHECK PROCEDURE
1) Turn off ignition key .
2) Check to see if the ISA(Throttle Position Sensor) coupler is loose,
or bad.If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ],20
remarks : Measuring unit of resistance : Resistance ‘R’[ ]

4) If there is no problem, check about the level of electricity flow between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : ∞[ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-28 )

remarks : Measuring unit for resistance : Resistance ‘R’[ ]

5-31
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECK PROCEDURE
5) If the measured resistance and continuty is abnormal.
Replace ISA with the new one, and recheck.

6) If resistance and continuty is normal, connect the coupler of ISA.

7) Turn on ignition key
8) Measure ISA voltage of wire-harness to check ECU.
Measuring terminal : B/R electric wire ~ EARTH
Output voltage of ISA : BATTERY VOLTAGE[V]
Remarks : Voltage measuring unit : Voltage [V]

If the measured voltage is normal,

Check the ‘B/R’ electric wire, ‘L/G’ electric wire, ‘W/R’ electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, recheck.

If the measured voltage is abnormal,

Check the ‘B/R’’ electric wire, ‘L/G’ electric wire, ‘W/B’ electric wire to see if they have been
broken or have short- circuited.

9) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)

5-32
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

14.O2(Oxygen) SENSOR
It is located on the exhaust pipe

△
! CAUTION

The key is off before disassembly.

O2
O2
O2 SENSOR
SENSOR
SENSOR COUPLER
COUPLER
COUPLER

O2
O2 SENSOR
O2 SENSOR
SENSOR

Remove
Center cowl
O2 sensor coupler

O2 SENSOR
O2
O2 SENSOR
SENSOR O2
O2 SENSOR
O2 SENSOR COUPLER
SENSOR COUPLER
COUPLER

Check the O2 sensor.

Handle with care or fraglile.

Assemble
O2
O2 SENSOR
O2 SENSOR
SENSOR
Install in reverse order of removal.

5-33
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT

Fault code number is displayed by MIL

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.

CHECKING CIRCUIT

OXYGEN SENSOR

2 : LAMBDA SENSOR GROUND

ECU 12 : OXYGEN SENSOR SIGNAL
34 : OXYGEN SENSOR HEATER

Coupler terminal is based on the side of Wire-Harness.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

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

5-34
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

If the voltage value is abnormal,
Check to see if the ECU coupler is loose or if there is bad contact.
Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been
broken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key.

Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22
Measuring terminal (side of wire-harness) : oxygen(O2)4 terminal of sensor coupler
(B/BR : BLACK/BROWN) ~ ECU No.34(G/W :GREEN/WHITE)
Remarks : Measuring unit of Resistance : Resistance ‘R’[ ]

6) If the measured resistance is abnormal,

Replace the oxygen(O2)sensor with new one and recheck it.

If the measured resistance is normal,

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been
broken or have short- circuited.
If the electric wire is no problem, the ECU is broken.
Replace the ECU with new one, and recheck it.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) The wire-harness to checck the ECU is connected to the ECU with a coupler.
refer to the ECU assembly/disassembly.

4) Turn on the ignition key

5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.
Measuring terminal: ECU No.12(V :VIOLET)~ ECU No.2(V/B:VIOLET/BLACK)
Output voltage of oxygen(O2) sensor : 0.1~0.8[V]

Remark : Measuring unit of voltage : Voltage[V]

Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf

If the measured voltage is normal,

Check the ‘B/R’ electric wire, ‘V’ electric wire, ‘V/B’ electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 2, No. 12 of ECU coupler.
If there is no problem in wires, ECU is broken.
Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,

Check the ‘V’ electric wire, ‘V/B’ electric wire, ‘W/B’ electric wire to see if they have been
broken or have short- circuited.
6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)

5-35
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

15.CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT

Fault code number is displayed by MIL

CHECKING CIRCUIT
TACHOMETER

ECU
32 : ESS(ENGINE SPEED SIGNAL)

Coupler terminal is based on the side of Wire-Harness.

CHECK PROCEDURE
1) Turn off the ignition key .
2) Check the ESS coupler is loose, or bad.
If there is no problem, check the resistance of tachometer.
3) Check the resistance between each terminals and ground.
Measuring terminal: B electric wire ~ EARTH,
ECU NO. 32 (B/Y:BLACK/YELLOW) ~ EARTH
The resistance between each terminals and ground : ∞[ ]
If the measured resistance value is abnormal, replace the part with new one.
Refer to ( ) for assembly and disassembly
Remark : Measuring unit of voltage : Resistance [ ]

4) If the measured resistance and continuity are abnormal,

. Replace the tachometer with new one, and it rechecks.
5) If the resistance and continuity are normal, contact the tachometer coupler.
6)Turn on the ignition key.
7) Measure the voltage or tachometer of wire harness for ECU check.
Measuring terminal: B electric wire ~ G electric wire => Output Voltage: battery voltage
Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G electric wire =>Output voltage: 9[V]~15[V]
Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G Measuring the output voltage of
electric wire, using the PVA(peak voltage adapter) multi-tester tool.
Remark : Measuring unit of voltage : Voltage[V]

If the measured voltage is normal,

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see
if they have been broken or have short- circuited if there is a bad
contact of terminal No. 32 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see if they have been
broken or have short- circuited.
8) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)

5-36
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

16.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT

Fault code number is displayed by MIL

CHECKING CIRCUIT
ECU
24 : MALFUNCTION INDICATOR LAMP OUTPUT

MALFUNCTION INDICATOR LAMP(MIL)

CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
3) Turn on the ignition key.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the Lamp.
But If the Lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : B electric wire ~ EARTH => Output Voltage: battery voltage
Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~ EARTH => Output voltage:
battery voltage
Remarks : Measuring unit of voltage : Voltage[V]

If the measured voltage is normal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.

If the measured voltage is abnormal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been
broken or have short- circuited.

6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)

5-37
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

17.CKP(CRANK POSITION SENSOR)

Remove
- Remove the LH. side cover.
- Remove the ACG coupler.
- Remove the CKP coupler.

△
! CAUTION

Before disassembly, the key is off.

- Remove the LH. RR. cover.

LH.REAR
LH.REAR COVER
LH.REAR COVER
COVER - Remove the LH. crank case cover.

LH.CRANK
LH.CRANK CASE
LH.CRANK CASE COVER
CASE COVER
COVER

- Remove the 3 screws securing ACG stator.

- Remove the 2 screws securing CKP.

AC.
AC. GENERATOR
AC. GENERATOR
AC. GENERATOR
GENERATOR

Check the ACG stator and position sensor.

Take precaution not to use the stator comp (18
terminal) like the carburetor type stator.

5-38
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

Check the fly wheel.

Fly wheel for the EMS system have 10 spots on
the fly wheel protrusion. It is different with
carburetor type.
Check the mark or contamination on the
protrusion.

△
! CAUTION

When replace the fly wheel, check the 10 spots

SPOT
SPOT
of protrusion part.
SPOT

ASSEMBLY
Assembly is the reverse order of removal.

CHECKING OF CKP(Crank Position

Sensor)
MEASUREMENT RESISTANCE
Remove the LH. side cover.
Disconnect the ACG coupler and (L/G)
connector.
Measure the resistance between G and L.
STANDARD : 80~150Ω(20℃)

MEASUREMENT PVA
Disconnect the ACG (L/G) connector.
Connect the (+)cord of PVA tester to the green
terminal or ground wire.
Connect the (-)cord of PVA tester to the blue
terminal.
Crank the engine with the starter motor and
measure the peak voltage of crank position
sensor coil.
HIGHEST VOLTAGE : 1.5V Over.
TOOL : PVA Multy tester.

Assembly is the reverse order of removal.

5-39
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

CHECK THE CIRCUIT OF CKP

●Fault code number is displayed by MIL

CHECKING CIRCUIT

GREEN BLUE
녹색 청색

청색
BLUE 적색
RED

ECU PIN NUMBER

ECU 핀 번호
30 : CRANK SIGNAL-A 22 30
30 : 크랭크 신호 _ A
22 : 크랭크
22 : CRANK 신호 _ B
SIGNAL-B

CHECK PROCEDURE
1) Turn ON ignition key.
2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.
When start up the ENGINE SINK ON change “OFF’ to “ON”, it’s okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance.
- measuring resistance : 80 ~ 150[Ω]

5-40
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

4) Check if crank signal A,B wires is breaks or not.

Remove the ECU, connect wire harness for inspection to wire harness of vehicle.
Check the wiring of crank signal A
- Measure terminal : No. 30 pin of wire harness for inspection -
Red wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[Ω]

Check the wiring of crank signal B

- Measure terminal : No. 22 pin of wire harness for inspection -
Blue wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[Ω]
RED

5) After fault repaired, to erase the memorized fault code in the

ECU is refer to how to remove the fault code.(5-11)

BLUE

5-41
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

18.FUEL PUMP
It is located inside a fuel tank
Remove the seat.
Loosen the washer bolt, 2 flange bolts
securing fuel tank.
Loosen the 4 socket bolts and remove the fuel
filler cap.

△
! CAUTION

The key is off before disassembly.

Remove
Loosen the 2 special screws.
Remove the tank cover.

Remove the fuel tube.

Remove the fuel pump coupler.
Loosen the 4 special screws and remove the
fuel pump setting plate.

Remove the fuel pump.

5-42
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

18.FUEL PUMP

The terminal arrangement of the fuel pump

(The following color chart is the internal color of the fuel pump)

5-43
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

Check the fuel pump.

Remove the fuel pump.
Measure the resistance between terminals.

The FLOAT position Terminals resistance [Ω]

F : 192[mm] 30 ± 5[Ω]

1/2 : 138[mm] 300 ± 5[Ω]

E : 74[mm] 566± 3[Ω]

The float position is based on tank bottom plate.
Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)
wire of fuel unit terminal

※ Remark : measuring unit of resistance : resistance[Ω]

If the measured resistance value is out of standard at float position, replace the fuel unit.

CHECK THE BLOW PRESSURE OF FUEL PUMP

- Blow pressure : 3.8 Bar
- After remove fuel tube from the injector, turn the ignition key ON/OFF 3
times, when the fuel come out about 130cc over, it’s Okay.
If under 130cc, check the fuel pump. Replace it if necessary.
(Be sure to the resistance of battery is over 12.6V)

ASSEMBLY
Assembly is the reverse order of removal.

5-44
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

19.HOW TO USE SCAN

ECU INITIALIZING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn on the lgnition key.
Press the power button of the diagnostic tool.
Press the enter button in the initial screen.
Press the enter in the vehicle diagnosis screen.

Press the enter button on the resetting ECU values.

If the enter-key is press than the ECU will reset.

Press the rest button on the following screen.

5-45
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

Press the enter button when it is ready

When the ECU was initialized. turn off the lgnition

key and then turn on the ignition key.

5-46
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

ISA PWM ADJUSTING

The coupler to check the malfunction of vehicle
is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the button at the vehicle diagnostic screen.

Press the enter button on the current data.

By looking the displayed figure on the idle speed

actuator PWM, adjust the throttle adjust screw.
(Refer to 5-41)

5-47
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

IGNITION TIMING CHECK

The coupler to check the malfunction of vehicle

is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the enter button on the vehicle diagnosis
screen.

Press the enter button on the current data.

To check the ignition angle

5-48
Downloaded from www.Manualslib.com manuals search engine
 EMS(Engine Management System)

ENGINE RPM CHECK

The coupler to check the malfunction of vehicle

is connected to the coupler of diagnostic tool.
Start the engine.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the enter button on the vehicle diagnosis
screen.

Press the enter button on the current data.

Check the engine rpm on the engine speed

5-49
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

6-0
Downloaded from www.Manualslib.com manuals search engine
 6. COOLING SYSTEM

SERVICE INFORMATION····6-1 RADIATOR DISASSEMBLY · 6-5

STROUBLESHOOTING·····6-2 CHECK THERMOSTATIC SWITCH · 6-6
COOLANT··········6-3 RADIATOR INSTALLATION · 6-6
COOLING SYSTEM INSPECTION·6-3 WATER PUMP········6-7
COOLING SYSTEM TEST····6-4 TERMOSENSOR·······6-10
RADIATOR···········6-4 THERMOSTATIC·······6-10

6
SERVICE INFORMATION

•Do not remove the radiator cap if the coolant temperature is over 100°C.
•It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious
scalding.
•When the temperature is below, carefully remove the cap with a cloth.
•Cooling system service should be done while the engine is cool.
•Radiator coolant is toxic. Keep it away from skin, eyes and clothes.
- If any coolant gets on your skin or clothes, rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them with water and consults a doctor immediately.
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- Especially pay attention to reserve the coolant. Keep out of reach of children.

•Do not remove the radiator cap, except to refill or drain the cooling system after servicing the cooling system.
•Avoid spilling coolant on painted surfaces, if contaminated, do wash in water immediately.
•After disassembling or servicing the cooling system, check for leaks with a radiator cap tester.(sale at a market)

SPECIFICATIONS
RADIATOR CAP RELIEF PRESSURE 0.9±0.1kg/cm2
BEGIN TO OPEN 80±2° C
THERMOSTAT
FULLY OPEN 90±3° C
TEMPERATURE
VALVE LIFT 3.5~4.5mm
COOLANT CAPACITY Full : 1,100cc
RESERVE TANK : 280±20cc
Exchange : 1,000cc

TORQUE VALUE
WATER PUMP IMPELLER 1.0~1.4kgf·m
WATER PUMP COVER BOLT 0.8~1.2kgf·m

6-1
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

TROUBLESHOOTING

Engine temperature too high

Faulty temperature gauge or thermo sensor

Air in cooling system
Faulty thermostat stuck (Thermostat stuck closed)
Passages blocked in radiator, hoses or water jacket
Faulty fan motor switch
Faulty water pump

Engine temperature too low or unstable

Faulty temperature gauge or thermo sensor

Faulty thermostat stuck (Thermostat stuck open)
Faulty fan motor switch

Coolant leaks

Faulty water pump mechanical seal

Damaged or deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated gasket
Loose hose connection or clamp

6-2
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

COOLANT
COOLANT INSPECTION RADIATOR
Radiator coolant mixes the distilled water. WATER
Standard consistenly : 30~50%

Coolant mixes the light water and radiator liquid

COOLANT
about 5°C of tolerance inrespect to the minimum
temperature.
RADIATOR COOLANT MIXTURE CHART
(ANTICORROSIVE AND ANTIFREEZE)
Radiator coolant is toxic. Keep it away from When the whole capacity of coolant is 2000cc
(Unit:cc)
skin, eyes and clothes. Minimum temperature Mixture Ratio Distilled water
- If any coolant gets on your skin or clothes,
-9°C 20% 400 1,600
rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them -16°C 30% 600 1,400
with water and consults a doctor immediately. -25°C 40% 800 1,200
- If any coolant is swallowed, induce vomiting, -37°C 50% 1,000 1,000
gargle and consult a physician immediately. -44.5°C 60% 1,100 900
- Especially pay attention to reserve the coolant.
Keep out of reach of children.
HYDROMETER
(Sale at a market)
COOLING SYSTEM INSPECTION
SPECIFIC GRAVITY TEST OF COOLANT

Follow the hydrometer manufacturer’s instructions.

Check the coolant specific gravity using a hydrometer.

Check the contamination of the coolant.

COOLANT GRAVITY CHART

5 1.009 1.009 1.008 1.009 1.007 1.006 1.005 1.003 1.001 0.999 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.049 0.047 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071

6-3
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

COOLING SYSTEM TEST

RADIATOR CAP Install the redicator cap onto the radiator tester.
RADIATOR TESTER
Press it with specified pressure and it must keep
(SALE AT A MARKET) the pressure for at least six seconds.

• Apply water to the cap sealing surface before the

test.

Radiator Cap Relief Pressure : 0.9±0.15kg/cm2

SCREWS
SCREWS
SCREWS
SCREWS BOLT
BOLT
BOLT
BOLT

RADIATOR
INSPECTION
Remove the center cowl and side cowl.
Remove the RH. side cowl.

RADIATOR
RADIATOR
RADIATOR CAP
CAP
CAP Inspect the radiator soldered joints and shims for
leaks.
RESERVE
RESERVE
RESERVE TANK
TANK
TANK
Blow dirt out from between core fins with
compressed air.

RADIATOR
RADIATOR
RADIATOR
RADIATOR

WATER
WATER PUMP
WATER PUMP
PUMP REMOVAL
Remove the radiator cap.
Drain the coolant.
Disconnect the air vent tube from the radiator filler.
Remove the overflow tube clamp and disconnect
the overflow tube.

DRAIN
DRAIN
DRAIN BOLT
BOLT
BOLT

6-4
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

Loosen the hose band and disconnect the upper

hose and lower hose from the radiator.
Disconnect the thermostatic switch wire coupler.
Disconnect the fan motor wire coupler.

UPPER HOSE
UPPER
UPPER HOSE
HOSE
LOWER
LOWER
LOWER HOSE
HOSE
HOSE

Remove 2 bolts and 1 nut on the radiator.

FLANGE
FLANGE
FLANGE NUT
NUT
NUT

FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT
RADIATOR
RADIATOR
RADIATOR
RADIATOR

REMOVAL
Remove 3 bolts and then remove the fan/shroud from
the radiator.

FAN
FAN
FAN SHROUD
SHROUD
SHROUD

Connect the fan motor wire to battery.

Check the fan rotate well.

6-5
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

CHECK THERMOSTATIC SWITCH

REMOVAL
When coolant temperature is lower than 83~87℃
the thermostatic switch OFF.
When coolant temperature is over 88~92℃ the
thermostatic switch ON.

Install the fan shroud on the radiator with the 2

COOLING
COOLING
COOLING FAN
FAN
FAN SWITCH
SWITCH
SWITCH
bolts.

FLANGE
FLANGE
FLANGE BOLTS
BOLTS
BOLTS

RADIATOR INSTALLATION
Intall the radiator on the radiator bracket with the 2
bolts and 1 nut.

FLANGE BOLTS
FLANGE
FLANGE BOLTS
BOLTS

Connect the upper and lower hoses and tighten

PASS
PASS TUBE
PASS TUBE
TUBE securely them with hose bands.
Assemble the pass tube.
Connect the thermoseatic switch wire and fan
motor wire coupler.

6-6
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

Connect the overflow tube and tighten it securely

with the tube clamp.
Fill the radiator with coolant.
Connect the vent tube to the radiator filler.
After installation, check for coolant leaks.

• The coolant must be filled up to the inlet.

Put the transmission gear in neutral and start the

engine.
Idling the engine for a few minutes, deflate air in
cooling system with a snap slightly, then refill the
coolant.
After checking the amount of coolant in reserve
tank, if it is not enough, fill up it to the upper level.
Install the RH/LH side cowl and center cowl.

WATER PUMP
MECHANICAL SEAL (WATER SEAL)
CHECKING
CHECKING HOLE
CHECKING HOLE
HOLE
INSPECTION
At the checking hole, inspect the mechanical seal
for damage and leakage.
If the coolant leaks, disassemble the water pump,
check the mechanical seal and replace it.

INLET HOSE
INLET
INLET HOSE
HOSE WATER PUMP / IMPELLER REMOVAL
Remove the coolant inlet hose.

WATER
WATER PUMP
WATER PUMP COVER
PUMP COVER
COVER

6-7
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

Loosen the 3 bolts and remove the water pump

cover.
WATER
WATER
WATER PUMP
PUMP
PUMP COVER
COVER
COVER

DRAIN BOLT
DRAIN
DRAIN BOLT
BOLT

FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT

Remove the water pump impeller.

WATER
WATER
WATER PUMP
PUMP IMPELLER
PUMP IMPELLER
IMPELLER

• The impeller has left hand threads.

Inspect the mechanical (water) seal and seal

washer for wear or damage.
WATER PUMP
WATER
WATER PUMP BODY
PUMP BODY
BODY

• The mechanical seal and seal washer change with

a set.

WATER PUMP BODY REMOVAL

REMOVE
Water pump body.

6-8
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

Check the coolant checking hole.

O-RING
O-RING
O-RING Check the water pump body and O-ring for
damage and wear.

CHECKING
CHECKING
CHECKING HOLE
HOLE
HOLE

MECHANICAL SEAL REPLACEMENT

MECHANICAL
MECHANICAL
MECHANICAL SEAL
SEAL
SEAL Remove water pump assembly from the inside by
tool.
Replace the mechanical seal with new one.

• The mechanical seal and the seal washer change

with a set.

WATER PUMP / IMPELLER INSTALLATION

When the mechanical seal in replaced, a new seal
washer must be installed to the impeller.
Install in the reverse order of removal

Install the water pump cover.

Install in the reverse order of removal.

6-9
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

ENGINE COOLANT
THERMOSENSOR
THERMOSENSOR
THERMOSENSOR
TEMPERATURE GAUGE
REMOVAL
Remove RH.side cowl.
Drain the coolant.
Disconnect the engine coolant temperature gauge
wire.

Remove the engine coolant temperature gauge.

ENGINE COOLANT TEMPERATURE GAUGE INSPECTION

Soak the engine coolant temperature gauge in the
beaker(fill the beaker with water)
Heats up the beaker.
Measure the resistance.

Temperature(℃) 50 80 100 120

Resistance(Ω) 154 52 27 16
TEMPERATURE

INSTALLATION
Apply a sealant to the threads and install the
thermostat cover.
Connect the engine coolant temperature gauge
coupler.

6-10
Downloaded from www.Manualslib.com manuals search engine
 COOLING SYSTEM

THERMOSTAT
THERMOSTAT
THERMOSTAT
THERMOSTAT
REMOVAL
Disconnect the water hose from the thermostat
cover.
Remove the 2 bolts and separate the thermostat
cover.
Remove the thermostat from thermostat cover.

INSPECTION
Suspend the thermostat in a pan of water over a burner
and gradually raise the water temperature to check its
operation.

Technical data
Begins to open 80±2℃
Full-open 90℃±3℃
Valve lift 3.5~4.5mm

THERMOSTAT • Do not let the thermostat touch the pan as it will

give a false reading.
• Replace the thermostat if the valve stays open at
room temperature.
THERMOMETER • Test the thermostat after it is opened for about 5
minutes and hold the temperature at 70℃

INSTALLATION
Install in the reverse order of removal.

• When assembling, the location of air vent hole

must be upward.

6-11
Downloaded from www.Manualslib.com manuals search engine
 ENGINE REMOVAL/INSTALLATION

7-0
Downloaded from www.Manualslib.com manuals search engine
 7. ENGINE REMOVAL/INSTALLATION

······ 7-1
SERVICE INFORMATION· ······ 7-3
ENGINE INSTALLATION·
ENGINE REMOVAL·········· 7-2

SERVICE INFORMATION
GENERAL SAFETY

•Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to 7
damage the frame, engine, cable or harness.
•Attach tape to the frame to protect it during the engine removal or installation.

• The following works require engine removal for service.

- Cylinder head/valve
- Cylinder/piston
- Transmission
- Crank shaft

SPECIFICATION
ITEM SPECIFICATIONS
ENGINE OIL CAPACITY(AT DISASSEMBLY) 1.5ℓ

TORQUE VALUES :
ENGINE HANGER BOLT (FRONT ) : 4.9㎏f·m
(REAR ) : 4.9㎏f·m
GEAR CHANGE ARM BOLT : 1.2㎏f·m
DRIVE SPROCKET BOLT : 1.2㎏f·m
LH. DOWNTUBE MOUNTING BOLT (SPECIAL BOLT) : 4.2㎏f·m

7-1
Downloaded from www.Manualslib.com manuals search engine
 ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL
Drain the engine oil. (⇨3-3)
Remove the muffler. (⇨13-4)
Remove the battery ground cable and clutch cable.
Remove the throttlebody from the engine.

RADIATOR CAP
RADIATOR
RADIATOR CAP
CAP
Remove the RH. side cowl and LH.side cowl.
Drain the coolant.
-Remove the radiator cap
-Loosen the drain bolt from the water pump and
drain the coolant.

Loosen the hose band and remove the radiator hose

from the engine.

Disconnect the AC generator wire coupler and gear

LH.
LH. DOWN
LH. DOWN TUBE
DOWN TUBE COMP.
TUBE COMP. B
COMP. B
B position switch wire coupler.
Disconnect the starter motor cable.
Remove the gear change arm.
Remove the LH. rear cover.
Loosen the rear axle nut and drive chain adjuster
nut then remove the drive sprocket after pushing
the rear wheel forward.

GEAR
GEAR
GEAR CHANGE
CHANGE
CHANGE DRIVE
DRIVE
DRIVE SPROCKET
SPROCKET
SPROCKET

7-2
Downloaded from www.Manualslib.com manuals search engine
 ENGINE REMOVAL/INSTALLATION

Remove the 2 rear engine hanger bolts, then

remove the LH. downtube comp. B.

Remove the bolt and flange bolt securing engine

hanger plate then remove the engine.

FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS

ENGINE INSTALLATION
Engine installation is essentially the reverse order of
removal.

• Carefully align mounting points with the jack to

prevent damage from mounting bolt threads and
wire harness and cables.
• Be careful not to damage any part of the frame
and bolt nuts.
• Be sure to install the cables, tubes, and wires to
their correct positions(⇨ 1~8).

TORQUE :
ENGINE HANGER BOLTS :
(FRONT ) 4.9kgf·m(49N·m)
(REAR ) 4.9kgf·m(49N·m)
GEAR CHANGE ARM BOLT 1.2kgf·m(12N·m)
DRIVE SPROCKET BOLT 1.2kgf·m(12N·m)

Inspect the following after installing the engine.

- Engine oil level
- Throttle grip operation and free play.
- Clutch lever operation and free play.
- Drive chain slack

7-3
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

8-0
Downloaded from www.Manualslib.com manuals search engine
 8. CLUTCH / GEARSHIFT

SERVICE INFORMATION · · · 8-1 GEARSHIFT SPINDLE· ···· 8-7

TROUBLESHOOTING ····· 8-2 CLUTCH INSTALLATION· ···· 8-9
RH. CRANK······ · · · ·8-3 PRIMARY DRIVE GEAR· · · · · 8-10
CLUTCH REMOVAL·· · · · · 8-4 · 8-12
RH. CRANKCASE COVER INSTALLATION·

SERVICE INFORMATION
GENERAL SAFETY
•The clutch, gearshift spindle can be serviced with the engine in the frame.
•If the shift fork, drum and transmission require service, remove the engine and separate the crankcase.
•The quality and level of fluid affect clutch operation. If the clutch slips, check the fluid level before servicing
the clutch system.
8
SPECIFICATIONS Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
CLUTCH SPRING FREE LENGTH 35.5 34.2
CLUTCH DISK THICKNESS 2.9~3.0 2.6
CLUTCH PLATE WARPAGE 0.2
CLUTCH OUTER I.D 28.000~28.013 28.030
CLUTCH OUTER GUIDE O.D. 28-0.020~0.033 28.5±0.1

TORQUE VALUES
CLUTCH LOCK NUT 6.5kgf·m - Apply engine oil
DRUM STOPPER ARM BOLT 1.2kgf·m
PRIMARY DRIVE GEAR NUT 6.5kgf·m - Apply engine oil
RH. CRANKCASE COVER BOLT 1.1kgf·m
GEAR SHIFT PEDAL BOLT 1.2kgf·m

TOOLS
CLUTCH CENTER HOLDER
LOCK NUT WRENCH
EXTENSION BAR
FLYWHEEL HOLDER

8-1
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

TROUBLESHOOTING
Clutch working problem can be solved by adjusting a cable free play.

Clutch leverworking is too hard

Damaged, clogged or sticking clutch cable
Damaged lifter mechanism
Damaged clutch lifter plate bearing
Incorrect wiring of clutch cable

When gripping the clutch tightly, the vehicle moves

Too big clutch lever free play
Clutch plate warpage
Clutch lock nut loose
High fluid level or high fluid weight

Clutch slippage
Sticking lifter hydraulic system
Worn disks
Weak spring
Too small clutch lever free play

Difficult to engage the gear

Incorrect clutch adjustment(too big free play)
Bent shift fork
Bent shift fork shaft
Damaged gear shift spindle
Damaged shift drum guide groove
Damaged shift drum guide pin

Gear disengages
Worn the protrusion of a gear
Bent shift fork shaft
Damaged shift drum stopper
Worn shift drum guide groove
Worn gear shift fork groove

8-2
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

CABLE
CABLE
CABLE HOLDER
HOLDER
HOLDER
RH. CRANKCASE COVER
REMOVAL
Drain the engine oil and coolant.
Remove the clutch adjustor locknut and the
adjusting nut, then disconnect the clutch cable end
from the clutch lever.
Remove the right crankcase cover bolts and
remove the right crankcase cover.

RH.
RH. CRANK
RH. CRANK CASE
CRANK CASE COVER
CASE COVER
COVER

Remove the two dowel pins and gasket.

CLUTCH LEVER/LIFTER ROD REMOVAL

Remove the clutch lifter rod.
Remove the clutch lever and spring from the RH.
crankcase cover simultaneously.

LIFTER ROD
LIFTER
LIFTER ROD
ROD

Remove the clutch lever spring and O-ring from

CLUTCH LEVER
CLUTCH
CLUTCH LEVER SPRING
LEVER SPRING
SPRING the clutch lever.

Check the wear and damage of the lifter rod and

clutch lever and clutch lever spring.

CLUTCH LEVER
CLUTCH
CLUTCH LEVER
LEVER

8-3
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

HOLE
HOLE
HOLE
CLUTCH LEVER INSTALLATION
Apply the grease to the new O-ring, and install it to
the clutch lever.
Install the clutch lever spring into the hole of the
clutch lever ends.

SPRING
SPRING
SPRING ENDS
ENDS
ENDS

After installing the clutch lever into the RH.

crankcase cover, turn the clutch lever to the
clockwise and install the lifter rod aligning the
clutch lever with the RH. crankcase cover hole.

BEARING
BEARING
BEARING CLUTCH
CLUTCH
CLUTCH CLUTCH REMOVAL
PRIMARY
PRIMARY DRIVE
PRIMARY DRIVE GEAR
DRIVE GEAR
GEAR Remove the bearing.

WATER PUMP
WATER
WATER PUMP DRIVE
PUMP DRIVE GEAR
DRIVE GEAR
GEAR

Remove the clutch lock nut.

8-4
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

Remove the lock washer.

Remove the clutch inner assy.

Remove the spline washer.

SPLINE
SPLINE
SPLINE WASHER
WASHER
WASHER CLUTCH
CLUTCH
CLUTCH OUTER
OUTER
OUTER

Remove the clutch outer guide and thrust washer.

CLUTCH
CLUTCH
CLUTCH OUTER
OUTER
OUTER CLUTCH OUTER
CLUTCH
CLUTCH OUTER GUIDE
OUTER GUIDE
GUIDE

INSPECTION
LIFTER
LIFTER PLATE
LIFTER PLATE
LIFTER PLATE
PLATE BEARING
BEARING
BEARING
Remove the clutch center, disk plate, clutch spring
and check the other part each.
Inspect the lifter plate bearing for damage.
(It rotates by hand, if the free play is big, replace them)
Inspect the lifter plate for damage.
If necessary, replace them.

•Remove the clutch spring to diagonal direction.

8-5
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

Measure the clutch spring free length; replace the

springs if the measurement is not within the service
limit.

SERVICE LIMIT : 34.2mm

•Replace the clutch disks and plates as a set.(4EA)

CLUTCH
CLUTCH SPRING
CLUTCH SPRING
SPRING

Measure the disk thickness and replace the disks if

the service limit is exceeded.

SERVICE LIMIT : 2.6mm

Check for plate warpage on a surface plate using a

CLUTCH
CLUTCH
CLUTCH DISK
DISK
DISK feeler gauge; replace if the service limit is
exceeded.
SERVICE LIMIT : 0.2mm

CLUTCH
CLUTCH PLATE
CLUTCH PLATE
PLATE

•Warped clutch plates prevent the clutch from

disengaging properly.

Check the slots ( ) in the clutch outer for nicks or

indentations made by the clutch discs. If necessary
replace them.
Measure the inside diameter of clutch outer.
SERVICE LIMIT : 28.030mm

FEELER CAUGE
FEELER CAUGE
FEELER GAUGE
CAUGE
Measure the outside diameter of clutch outer guide.
CAUGE
SERVICE LIMIT : 27.950mm
CLUTCH CENTER
FRICTION DISK INSTALLATION
Apply the clean engine oil to the clutch friction
disk and pressure plate.
Install the 7pcs disks and 6pcs plates into the
clutch center by turns.
Install the spring, lifter plate and clutch spring
bolts to diagonal direction.

PRESSURE PLATE CLUTCH OUTER

•Check the condition that the pressure
plate is depressed the friction disk and
disk plate correctly.
8-6
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

GEAR SHIFT SPINDLE

GEAR CHANGE
GEAR
GEAR CHANGE ARM
CHANGE ARM
ARM REMOVAL
Loosen the hex bolt at LH. side and remove the
gear change arm.

GEAR
GEAR
Remove the RH. crankcase cover.(⇨ 8-3)
GEAR SHIFT
SHIFT SPINDLE
SHIFT SPINDLE
SPINDLE
Remove clutch assembly.(⇨ 8-4)
Remove the gear shift spindle and thrust washer.

Remove the gear shift cam bolt, cam and roller.

GEAR
GEAR SHIFT
GEAR SHIFT ARM
SHIFT ARM
ARM Remove the drum stopper bolt, drum stopper,
collar and spring.
Remove the pivot securing gear shift and remove
the spring and washer pivot.

INSPECTION
GEAR
GEAR SHIFT
GEAR SHIFT SPINDLE
SHIFT SPINDLE
SPINDLE
Check the gear shift spindle for wear or damage.
Inspect the gear shift plate for deformation, wear,
or other damage.
Check the return spring and gear shift plate spring
for wear or damage.

8-7
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

INSTALLATION
COLLAR
COLLAR
COLLAR
Install the collar, spring, drum stopper and bolt.
Tighten the bolt.

TORQUE : 1.2kgf·m

SPRING
STOPPER ARM
STOPPER
STOPPER ARM
ARM
COLLAR
STOPPER ARM SPRING
SPRING
SPRING

GEAR
GEAR SHIFT
GEAR SHIFT CAM
SHIFT CAM
CAM
Press the drum stopper and install the gear shift
cam, aligning the roller with the gear shift cam
hole.

Install the thrust washer into the gear shift spindle.

Install the gear shift spindle into the crank case,
aligning the teeth of the return spring with the
tappet of the right crank case as shown.

GEAR
GEAR
GEAR SHIFT
SHIFT SPINDLE
SHIFT SPINDLE
SPINDLE

Install the following:

- Clutch assembly.
- RH. crank case cover
Install the gear shift arm aligning its slit with the
punch mark on the gear shift spindle.
Install and tighten the pinch bolt to the specified
torque.

GEAR CHANGE
GEAR
GEAR CHANGE ARM
CHANGE ARM
ARM

8-8
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

CLUTCH INSTALLATION
OUTER
OUTER
OUTER GUIDE
GUIDE
GUIDE Coat the clutch outer guide with clean engine oil.

Install the trust washer and outer guide into the

main shaft.

CLUTCH
CLUTCH INNER
CLUTCH INNER ASSY
INNER ASSY
ASSY

CLUTCH
CLUTCH
CLUTCH OUTER
OUTER COMP.
OUTER COMP.
COMP.

Install the clutch outer into the main shaft.

CLUTCH
CLUTCH
CLUTCH OUTER
OUTER
OUTER Install the spline washer.

Install the clutch inner ass’y to clutch outer.

Install the lockwasher.
Apply the clean engine oil to the washer and install
the lock nut temporarily

8-9
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

Install the lock nut by pressing clutch center into

the clutch center holder.

TORQUE : 6.5kgf·m

Install the bearing.

PRIMARY DRIVE GEAR

LOCK
LOCK NUT
LOCK NUT
NUT REMOVAL
Remove the LH. crankcase cover.
Loosen the locknut.

Remove the water drive gear.

PRIMARY DRIVE
PRIMARY
PRIMARY DRIVE GEAR
DRIVE GEAR
GEAR WATER
WATER PUMP DRIVE GEAR Remove the primary drive gear and sub gear.
WATER PUMP
PUMP DRIVE
DRIVE GEAR
GEAR
Check the wear or damage and if have the problem
replace it.

SUB
SUB GEAR
SUB GEAR
GEAR

8-10
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

OUTER
OUTER GEAR
OUTER GEAR
GEAR
INSTALLATION
Insert the woodruff key into the key groove of the
PD
PD GEAR
PD GEAR
GEAR crankshaft.
Align the primary drive gear key groove with the
crankshaft key.
Align the sub gear and clutch outer groove and
install the gear.

Install the water pump drive gear.

WATER
WATER PUMP
WATER PUMP DRIVE
PUMP DRIVE GEAR
DRIVE GEAR
GEAR

Install the lock washer.

Coat the nut with clean engine oil, and temporarily
tighten the lock nut.

Tighten the primary drive gear lock nut.

TORQUE : 6.5kgf·m

8-11
Downloaded from www.Manualslib.com manuals search engine
 CLUTCH/GEARSHIFT

WATER
WATER
WATER PUMP
PUMP DRIVE
PUMP DRIVE GEAR
DRIVE GEAR
GEAR RH. CRANKCASE COVER
INSTALLATION
Remove the gasket from the crankcase surface.
Install the two dowel pins and a new gasket.

Install the crankcase cover bolts and clutch cable

holder.

TORQUE : 1.1kgf·m

Connect the clutch cable end to the clutch lever,

then install the clutch wire holder with the two
bolts.
Adjust the clutch lever free play. (⇨ 2-12)
Remove the oil level gauge, then fill the crankcase
with the recommended oil.(⇨ 3-3)

Connect the radiator hose

RADIATOR
RADIATOR HOSE
RADIATOR HOSE
HOSE Pour the coolant.

Install the side cowls and center cowl.

Install in the reverse order of removal.

8-12
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 A.C GENERATOR / STARTER CLUTCH

9-0
Downloaded from www.Manualslib.com manuals search engine
 9. A.C GENERATOR / FLY WHEEL

SERVICE INFORMATION ·· 9-1 STARTER CLUTCH ····· 9-5

······ 9-2
A.C GENERATOR· ·········· 9-6
STARTOR·

SERVICE INFORMATION
GENERAL SAFETY
This section covers removal and installation of the A.C. generator.
Refer to section 17 for inspection of the A.C. generator.
The A.C. generator/starter clutch service can be done with the engine installed in the frame.

SPECIFICATIONS Unit:mm

ITEM STANDARD VALUE SERVICE LIMIT

O.D. 39.622~39.635 39.607 9
STARTER DRIVEN GEAR
I.D 22.010~22.022 22.100
STARTER IDLE GEAR I.D 10.013~10.045 10.100
STARTER IDLE GEAR SHAFT O.D 9.991~10.000 9.970
REDUCTION GEAR I.D 10.013~10.045 10.100
REDUCTION GEAR SHAFT O.D 9.991~10.000 9.970

TORQUE VALUES
FLYWHEEL BOLT 5.5kgf·m(55N·m)
STARTER CLUTCH SOCKET BOLT 3.2kgf·m(32N·m)
LEFT CRANK CASE COVER BOLT 1.1kgf·m(11N·m)

TOOLS
ACG ROTOR PULLER
FLYWHEEL HOLDER

9-1
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

LH.
LH.
LH. REAR
REAR COVER
REAR COVER
COVER A.C GENERATOR REMOVAL
Remove the LH. rear cover.

Remove the AC. generator coupler connecting of

gear change switch.

Remove the starter reduction gear cover.

STARTER
STARTER REDUCTION
STARTER REDUCTION GEAR
REDUCTION GEAR COVER
GEAR COVER
COVER

Remove the starter reduction gear shaft and starter

reduction gear.

9-2
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

Remove the left crankcase cover bolts and left

LH.
LH.
LH. CRANK
CRANK CASE
CRANK CASE COVER
CASE COVER
COVER
crankcase cover.

FLY
FLY WHEEL
FLY WHEEL
WHEEL Remove the gasket and the dowel pins.

Remove the starter idle gear shaft.

STARTER
STARTER IDLE
STARTER IDLE
STARTER GEAR
IDLE GEAR
IDLE GEAR
GEAR GEAR
GEAR SHAFT
GEAR SHAFT
SHAFT

Hold the flywheel rotor with a flywheel holder, and

FLYWHEEL HOLDER
FLYWHEEL
FLYWHEEL HOLDER
HOLDER remove the rotor bolt.

TOOL : LOCKNUT WRENCH

FRY WHEEL HOLDER

9-3
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

After installing the ACG rotor puller on the rotor,

ACG
ACG
ACG ROTOR
ACG ROTOR PULLER
ROTOR PULLER
ROTOR PULLER
PULLER remove the rotor.

TOOL : ACG ROTOR PULLER

Remove the fly wheel and starter driven gear

GEAR
GEAR CHANGE
GEAR CHANGE SWITCH
CHANGE SWITCH
SWITCH collar.

STARTER
STARTER
STARTER DRIVEN
DRIVEN
DRIVEN GEAR
GEAR
GEAR COLLAR
COLLAR
COLLAR

STARTER IDLE GEAR INSPECTION

Inspect the wear and damage of starter ldle gear.
Measure the gear inside diameter.

SERVICE LIMIT : 10.100mm

STARTER IDLE
STARTER
STARTER IDLE GEAR
IDLE GEAR
GEAR
Measure the gear shaft outside diameter.

SERVICE LIMIT : 9.970mm

REDUCTION GEAR INSPECTION

Inspect the wear and damage of reduction gear.
Measure the gear inside diameter.

SERVICE LIMIT : 10.100mm

REDUCTION
REDUCTION
REDUCTION GEAR
GEAR
GEAR

Measure the gear shaft outside diameter.

SERVICE LIMIT : 9.970mm

9-4
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

SOCKET
SOCKET BOLTS
SOCKET BOLTS
SOCKET BOLTS
BOLTS STARTER CLUTCH
DISASSEMBLY
Remove the flywheel.
Remove the three socket bolts, and remove the
starter clutch (one way clutch) from the flywheel.

STARTER
STARTER
STARTER DRIVEN
DRIVEN GEAR
DRIVEN GEAR
GEAR

FLY
FLY
FLY WHEEL
WHEEL
WHEEL COMP
COMP
COMP

Check the starter driven gear for damage or wear.

Measure the starter driven gear I.D. and O.D.

SERVICE LIMIT : O.D. : 39.607mm

I.D. : 22.100mm

STARTER
STARTER DRIVEN
STARTER DRIVEN GEAR
DRIVEN GEAR
GEAR

STARTER
STARTER
STARTER ONE-WAY
STARTER ONE-WAY CLUTCH
ONE-WAY CLUTCH
ONE-WAY ASSY
CLUTCH ASSY
CLUTCH ASSY
ASSY
INSTALLTION
Check the one-way clutch for wear or damage.
Install the one-way clutch flange into the clutch
outer.
Apply the screw locking bond to the socket bolt
and install it.

TORQUE : 3.2kgf-m

Grip the flywheel.

Check the operation of the one-way clutch by
turning the driven gear.
You should be able to turn the driven gear
counterclockwise smoothly, but the gear should not
turn clockwise.(as like photo)

9-5
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

STATOR REMOVAL / INSTALLATION

WIRE
WIRE GUIDE
WIRE GUIDE
GUIDE
Remove the crank position sensor screw, then
remove crank position sensor.
Remove the wire guide using a long nose plier and
⊖ screwdriver.

Loosen the stator screw and remove the stator.

CRANK
CRANK POSITION
CRANK POSITION SENSOR
POSITION SENSOR
SENSOR Install in the reverse order of removal.
STATOR
STATOR
STATOR

•Fix the grommet to groove part correctly.

INSTALLTION
STARTER
STARTER DRIVEN
STARTER DRIVEN GEAR
DRIVEN GEAR COLLAR
GEAR COLLAR
COLLAR
Install the starter driven gear collar.
Clean the taper part of crank shaft and remove the
dust.
If installing the rotor with dust in taper part, the
key will be damaged. Because the contacted area
of taper will be small and it will occur the stress in
the woodruff key.

•After checking whether inside magnet of rotor is

attached by the bolts and nuts, install them. If
installing the rotor with the foreign material, the
starter coil is damaged.
9-6
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

Install the woodruff key into the crank shaft key

FLY
FLY
FLY WHEEL
WHEEL
WHEEL groove.

Install the rotor bolt temporarily.

After fixing the flywheel with holder, tighten the
fly wheel nut.

TORQUE : 5.5kgf-m
TOOLS : FLYWHEEL HOLDER
LOCKNUT WRENCH

IDLE
IDLE
IDLE GEAR
GEAR
GEAR Install starter idle gear and shaft.
Install new gasket and dowel pins.

Install the LH. crank shaft cover at this time be

ACG.
ACG. CHANGE
ACG. CHANGE SWITCH
CHANGE SWITCH WIRE
SWITCH WIRE
WIRE careful not to catch the wires in between the cover
and case.

9-7
Downloaded from www.Manualslib.com manuals search engine
 A.C GENERATOR / STARTER CLUTCH

Replace the O-ring with new one and install the

reduction gear cover.
Cover the reduction gear cover and install the two
bolts.
Install the LH. crank cover bolt.

TORQUE : 1.1kgf-m

Connect the AC. generator wire coupler and gear

change wire coupler.

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

TORQUE : 1.2kgf-m

9-8
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 CYLINDER HEAD / VALVES

10-0
Downloaded from www.Manualslib.com manuals search engine
 10. CYLINDER HEAD / VALVES
SERVICE INFORMATION・ ・・・ 10-1 VALVE SPRINGS ・・・・・・10-6
TROUBLESHOOTING・ ・・・・ 10-2 ・・・・・ ・ 10-7
VALVE GUIDES・
CAMSHAFT・ ・ ・ ・ ・ ・ ・ ・ ・ 10-3 VALVE SEATS ・・・・・ ・ 10-8
CYLINDER HEAD ・・・・・・ 10-4 ・10-8
CYLINDER HEAD ASSEMBLY・

SERVICE INFORMATION
GENERAL SAFETY
The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed
from the frame to maintain the cylinder head.
The oil of camshaft is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder
head.

SPECIFICATIONS
Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
IN 32.02~32.18 31.90
CAMSHAFT CAM HEIGHT
EX 31.72~31.88 31.60
VALVE SPRING FREE LENGTH IN,EX 41.40 40.00
IN 4.975~4.990 4.925
VALVE STEM OUTER DIAMETER
EX 4.995~4.970 4.905
VALVE,
VALVE GUIDE VALVE GUIDE INNER DIAMETER IN,EX 5.000~5.012 5.030
CLEARANCE BETWEEN IN 0.010~0.037 0.080
STEM AND GUIDE EX 0.030~0.057 0.100
VALVE SEAT WIDTH 0.7~0.9 1.3

TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT 1.0 kgf・m (10N・m)
SPARK PLUG 1.1 kgf・m (11N・m)
CYLINDER HEADSPECIAL SOCKET BOLT 4.0 kgf・m (40N・m)
CAM CHAIN TENSIONER LIFTER BOLT 1.2 kgf・m (12N・m)
CAM CHAIN TENSIONER LIFTER SCREW 0.4 kgf・m ( 4N・m)
CYLINDER HEAD COVER BOLT 1.0 kgf・m (10N・m)
CRANK SHAFT HOLE CAP 0.8 kgf・m ( 8N・m)
A.C.GENERATOR CAP 0.6 kgf・m ( 6N・m)

10-1
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES
TOOLS
VALVE GUIDE REAMER
VALVE GUIDE DRIVER
VALVE SPRING COMPRESSOR
VALVE SEAT CUTTER

TROUBLESHOOTING
Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,
or by tracing noises to the top-end with a sounding rod or stethoscope.

Low comperssion Rough idle

Valves Low cylinder compression
- Incorrect valve adjustment (see section 3)
- Valve springs damage Compression too high
- Incorrect valve timing Excessive carbon build-up on piston or combustion
- Uneven valve seating chamber
Cylinder head Excessive noise
- Leaking or damage head gasket Incorrect valve adjustment
- Warped or cracked cylinder head Sticking valve or broken valve spring
Damaged or worn camshaft
Cylinder, piston (see section 10,11) Loose or worn cam chain
Worn or damaged cam chain tensioner
Excessive white smoke
Worn valve guide or valve stem
Damaged valve stem seal
Worn or damaged piston ring

10-2
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

CAMSHAFT
SPARK
SPARK
SPARK PLUG
PLUG
PLUG
REMOVAL
Remove the side cowl.
Remove the noise suppressor cap assembly from
the spark plug.

Loosen the screw of the cam chain tensioner and

TENSIONER
TENSIONER
TENSIONER
remove the tensioner mounting bolt.
Remove the AC generator cap and crank shaft hole
cap out of the left crankcase cover.
Turn the crankshaft to the left, and align the“T”mark
of the flywheel with the index mark of the LH.
crankcase cover.
Verify that the piston is located at the top dead center.
(Make all camshaft lobes face downward.)
If all camshaft lobes face upward, rotate the crankshaft
to the left for 1 turn (180° ), and align the“T”mark
with the index mark once again.

Remove the fuel tank.

Loosen the 4 cylinder head cover special bolts and
remove the cover.

CYLINDER
CYLINDER HEAD
CYLINDER HEAD COVER
HEAD COVER
COVER

Remove the 8 flange bolts of the camshaft holder

CAM
CAM SHAFT
CAM SHAFT HOLDER
SHAFT HOLDER
HOLDER and remove the camshaft holder from the
cylinderhead.
Remove the cam chain from the camshaft.

10-3
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

CAM
CAM CHAIN
CAM CHAIN
CAM CHAIN
CHAIN
Remove the cam chain from the cam shaft.
Take precautions not to allow the cam chain to drop
into crankcase.
Remove the cam shaft.

Take precautions not to allow the cam chain to drop

into the crankcase.

Check the cam lobes of the camshaft for wear or

damage.
Measure the height of the cam lobe.

SERVICE LIMIT : IN : 31.9 mm

EX: 31.6 mm

Manually turn the camshaft bearing outer race, and

check if it turns smoothly.
Check the bearing for wear or damage.

BEARING
BEARING
BEARING
BEARING

CYLINDER
CYLINDER HEAD
CYLINDER HEAD SOCKET
HEAD SOCKET NUT
SOCKET NUT (M8X
NUT (M8X 4)
(M8X 4)
4)
CYLINDER HEAD
REMOVAL
Remove the cylinder head cover
Remove the camshaft.
Remove the cylinder head special socket nut(M8)
Remove the throttle body insulator.

10-4
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

CYLINDER HEAD DISASSEMBLY

Remove the cylinder head from cylinder.
Remove the cylinder head gasket, dowel pin
and cam chain guide.

Remove the valve spring cotter, retainer, spring

and valve using the valve spring compressor.
Tool: Valve spring compressor

To prevent the loss of tension, do not compress

the valve springs more than necessary to
remove the cotters.

IN
IN VALVE
IN VALVE
VALVE NOTE
Mark all parts during disassembly so they can
be placed back in their original locations.
Remove the valve stem seals and valve spring
seals, remove the carbon deposits from the
OUT
OUT
OUT VALVE
VALVE
VALVE combustion chamber.

INSPECTION
CYLINDER HEAD
Clean off the head gasket surface.
Inspect the spark plug assembly hole and the
crack of near valve seat. Check for the warp of
the cylinder head with a square and filler
gauge.
Service Limit : 0.1mm

Avoid damaging the gasket surfaces.

10-5
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

VALVE SPRING
Measure the free length of valve spring.
Service Limit : 40.0mm

If any valve spring is shorter than the service

limit, it must be replaced as a set.

INTERVAL BETWEEN VALVE STEM AND VALVE GUIDE

Inspect each valve for bending, burning, scratches or
abnormal wear.
Check the operating condition using the valve guide.
Measure and record external diameter of valve stem.
SERVICE LIMIT : IN : 4.925 mm
EX: 4.905 mm

Insert the valve guide reamer from the combustion

chamber side and ream the guide to remove any
carbon build-up before measuring the guide.

Rotate the reamer clockwise during the installation

and removal of reamer.
Otherwise, it may cause the damage to the inside of
the guide.

TOOL : VALVE GUIDE REAMER

Measure and record each valve guide inner diameter.

SERVICE LIMIT : 5.030 mm

Measure the gap between valve stem and guide.

SERVICE LIMIT : IN : 0.080 mm

EX: 0.100 mm
Measure the inner diameter of the new valve guide. If
the clearance is not within the service limit, replace the
valve.

10-6
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

VALVE GUIDES REPLACEMENT

Refinish the valve seats whenever the valve guides

are replaced to prevent uneven seating.
Replace the cylinder head with the temperature of
130℃ - 140℃.
Do not heat the cylinder head beyond 150℃.
Unskillful operation can give the burns.
Do not heat the cylinder head partly using the torch
that may cause the cylinder head warping.

Support the cylinder head and drive the old guides out
of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER

Avoid damaging the head when driving the valve

guide out.

Install the new O-ring to new valve guide.

Insert the valve guide from the upper part of cylinder
head.
TOOL : VALVE GUIDE DRIVER
After insert the valve guide, complete the valve guide
reamer by putting the valve guide reamer on the
cylinder head’s conbustion chamber.
TOOL : VALVE GUIDE REAMER

Take care not to tilt or lean the reamer in the guide

while reaming.
Otherwise, the valve is installed slanted, that causes
oil leaks from the stem seal and improper valve seat
contact and results in the valve seat refacing not able
to be performed.
Use cutting oil on the reamer during this operation.

Reface and clean the cylinder head.

Inspect and correct around the valve seat.

10-7
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

VALVE SEATS INSPECTION / REFACE

Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to each valve
face.
Tap the valve against the valve seat serveral times with
the valve guide reamer, without rotating the valve, to
check for proper valve seat contact.
Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and evenly all around the circumference.
If the valve seat width is not within specification,
reface the valve seat.

Valve faces cannot be ground. If a valve face is rough,

worn unevenly, or contacts the seat improperly, the
valve must be replaced.
Measure the valve seat width.
STANDARD VALUE : 0.7~0.9 mm
SERVICE LIMIT : 1.3 mm

VALVE SEAT CUTTER

Reface the worn valve seat by using valve seat cutters
°
70° and grinders.
°
20°

IN : 22mm IN : 23mm
EX : 22mm

Follow the refacer manufactuer’s operating

45° 30°
instructions.
Be careful not to grind the seat more than necessary.
IN : 24.5mm
EX : 20mm
EX : 24.5mm

CYLINDER HEAD ASSEMBLY

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

10-8
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

Install the valve springs with the narrow pitch forward to

cylinder head.

FOR
FOR CYLINDER
FOR CYLINDER HEAD
CYLINDER HEAD
HEAD

Install the spring retainer.

Using the valve spring compressor.
Install the valve cotters.

Do not compress the valve spring more than

necessary.

TOOL : VALVE SPRING COMPRESSOR

VALV
VALV
VALV E
E
E SPRING
SPRING
SPRING COMPRESSOR
COMPRESSOR
COMPRESSOR

Tap the valve stems gently 2~3times with a soft

hammer to firmly seat the cotters.

Take necessary precautions not to damage the valve.

Install the cam chain tensioner, and assemble pivot

bolts.
TORQUE : 1.0 kgf ・m

Install the spark plug.

TORQUE : 1.1 kgf ・m

10-9
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

CYLINDER HEAD INSTALLATION

Clean any gasket material from the cylinder surface.
Install the cam chain guide to the cylinder.
Install the dowel pins and new gasket.
Install the cylinder head.
(Install in reverse order of removal)

When install the ‘cylinder head special socket nut’ (M8

1.25), tighten them for 2times as shown picture.
① half installation→ ② Complete installation→
③ Complete installation→④ Complete installation→
① Complete installation

TORQUE : 4.0 kgf ・m

Assemble the shim in place.

After checking the comshaft for damage, put it to the
cylinder head.

Slowly rotate the crankshaft counterclockwise, and

align the“T”mark of the flywheel with the index
mark of the LH. crankcase cover.

Take precautions not to allow the cam chain to drop

into the camshaft timing gear while turning the
camshaft.

Apply engine oil to the camshaft then assemble the

LOCATION
LOCATION
LOCATION OF
OF TIMING
OF TIMING MARK
TIMING MARK
MARK
cam chain and cam sprocket after matching the cam
sprocket timing mark in parallel with the top of the
cylinder head.

10-10
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER HEAD / VALVES

CAM
CAM
CAM CHAIN
CHAIN GUIDE
CHAIN GUIDE
GUIDE Install the dowel pins on the cylinder head.
Install the camshaft holder.
Install the cam chain guide.

CAM
CAM SHAFT
CAM SHAFT HOLDER
SHAFT HOLDER
HOLDER

Remove the sealing screws and o-ring from the cam

chain tensioner.
Rotate the tensioner shaft clockwise with a small
screwdriver, and insert the shaft into the body
completely.
Assemble a new gasket to the tensioner lifter, and
install the tensioner lifter on the cylinder.
O-RING
O-RING
O-RING Install tensioner lifter bolt.
TORQUE : 1.2 kgf ・m

Install the O-ring and sealing screw to the tensioner

lifer.
TORQUE : 0.4 kgf ・m

If the cam chain tensioner lifter is dropped, the shaft

will advance by the spring force.

Fill clean engine oil into the operating parts of the

cylinder head.
Adjust the valve clearance.
If the valve clearance is unfit, adjust the shim.
Install the 30mm cap and A.C generator cap.

TORQUE :
・m
30mm CAP : 0.8kgf・
・m
A.C.GENERATOR CAP : 0.6kgf・

Remove oil from the cylinder head cover grooves, and

accurately assemble the gasket to the cylinder head
cover.
Install the cylinder head cover.
Tighten the cylinder head cover bolt.
TORQUE : 1.0 kgf ・m

10-11
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

11-0
Downloaded from www.Manualslib.com manuals search engine
 11. CYLINDER / PISTON

SERVICE INFORMATION・・・ 11-1 PISTON / PISTON RING ・・ 11-3

TROUBLESHOOTING・ ・・・ ・ 11-1 CYLINDER INSTALLATION ・ 11-6
CYLINDER REMOVAL・・・・・ 11-2

SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
Take care not to damage the cylinder wall and piston.

SPECIFICATIONS
Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
INNER DIAMETER 73.005~73.015 73.10
CYLINDERICAL - 0.10
CYLINDER
ROUNDLESS - 0.05
HEAD CONTACT WARPAGE - 0.10
PISTON SKIRT OUTER DIAMETER 72.985~72.965 72.60
PISTON PIN HOLE INNER DIAMETER 17.002~17.008 17.04
PISTON PIN OUTER DIAMETER 16.994~17.000 16.96
PISTON,
PISTON-TO-PISTON PIN CLEARANCE 0.002~0.014 0.02
PISTON PIN,
PISTON RING-TO- TOP 0.015~0.045 0.09
PISTON RING
GROOVE CLEARANCE SECOND 0.015~0.045 0.09
PISTON RING TOP / SECOND 0.35~0.45 0.50
JOINT GAP OIL RING (SIDE RAIL) 0.20~0.70 1.10
CYLINDER-TO-PISTON CLEARANCE 0.020~0.050 0.30
CONNECTING ROD SMALL END INNER DIAMETER 17.010~17.028 17.06
GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN 0.010~0.034 0.04

TROUBLESHOOTING
Compression too low Overheating
Worn piston Excessive carbon build-up on top of piston
Worn, damaged piston ring
Worn cylinder
Abnormal noise
Excessive smoke Worn cylinder and piston
Worn cylinder, piston or piston rings Worn connecting rod small end bearing or piston pin
Improper installation of piston ring Damaged piston ring
Scored or scratched piston or cylinder Excessive carbon build-up on top of piston

11-1
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

CYLINDER
CYLINDER HEAD
CYLINDER HEAD GASKET
HEAD GASKET
GASKET CYLINDER REMOVAL
Remove the
Remove the cylinder
cylinder head. 10-4 ))
head. (( 10-4
10-5
Remove the
Remove the cylinder
cylinder head
head gasket.
gasket.
Remove
Remove the
the cam
cam chain
chain guide
guide from
from the
the cylinder.
cylinder.
Remove
Remove the
the cylinder.
cylinder.

PISTON
PISTON
PISTON
PISTON CYLINDER
CYLINDER
CYLINDER Remove
Remove thethe gasket
gasket and
and dowel
dowel pin.
pin. Carefully
Carefully remove
remove
any
any adhering
adhering gasket
gasket material from
material from the
from the cylinder
thecylinder // head
cylindermating
head
mating
mating surface.
surface.
surface. Do
Do not
not scratch
scratch the
the surface.
surface.

Take care not to damage the cylinder interface.

INSPECTION
INSPECTION
INSPECTION
Inspect the cylinder wall for scratches and wear.
Inspect
Measure
Inspect the
theand
cylinder
record
cylinder wall
thefor
wall forcylinder
scratches
scratchesinner
and
and wear.
diameter at
wear.
Measure
Measure
three levelsand
and record
record
in both an Xthe
theand
cylinder
cylinder
Y axis. inner
inner diameter
diameter at
at
three levels
Take
three levels in both
both an
the maximum
in anreading
XX and
and YY axis.
toaxis.
determine the cylinder
Take the
Take
wear. the maximum
maximum reading
reading toto determine
determine the
the cylinder
cylinder
CYLINDER
CYLINDER
CYLINDER GAUGE
GAUGE
GAUGE wear.
SERVICE
wear. LIMIT : 73.005~73.015 mm
SERVICE
SERVICE LIMIT
LIMIT::: 56.60
SERVICELIMIT
LIMIT mm
56.60 mm
mm
Measure the piston outer diameter.
Measure the
Measure
Calculatethe piston
piston
the outer diameter.
outer diameter.clearance. Take the
piston-to-cylinder
Calculate the
Calculate
maximum the piston-to-cylinder
piston-to-cylinder
reading clearance.
to determine theclearance. Take the
clearance.Take the
maximum
SERVICE reading
maximumLIMIT to
to determine
: 0.30
reading mm
determine the
the clearance.
clearance.
SERVICE
SERVICE
SERVICELIMIT
LIMIT:: 0.30
LIMIT 0.30 mm
mm
Calculate the cylinder roundness and cylinderical at
Calculate
Calculate
three levelsthe
theincylinder
cylinder
an X and for
forYout-of-round
out-of-round
axis. Take at at three
the three levels
levels
maximum
in an
in an X
reading Xtoand
and YY axis.
axis.the
determine Take
Take the maximum
the maximum
roundness reading to
reading
and cylinderical. to
determineLIMIT
determine
SERVICE the out-of-round.
the out-of-round.
: ROUNDNESS : 0.05 mm
Calculate
Calculate thethe cylinder for
for taper
taper at
CYLINDERICAL
cylinder at :three levels
levels in
0.1 mm
three in an
an X
X
TOP
and
and Y Y axis.
axis. Take
Take thethe maximum
maximum reading
reading to to determine
determine
If
theany
the of the cylinder measurements exceed the service
taper.
taper.
If any
If any of
limits, of the cylinder
the
replace cylinder measurements exceed
measurements
the cylinder. exceed the
the service
service
MIDDLE limits, replace
limits,
SERVICE replace
LIMIT the
the cylinder.
cylinder.
: OUT-OF-ROUND : 0.2 mm , 0.50mm
SERVICE
SERVICE LIMIT
SERVICELIMIT
LIMIT:: OUT-OF-ROUND
LIMIT 0.05
OUT-OF-ROUND :: 0.05
0.75mm
0.05 mm
mm, 1.0mm
STANDARD LIMITTAPER
: 0.020~0.050
TAPER :: 0.1
0.1 mm
mm
mm
BOTTOM
If the piston outer diameter is oversize, boring the
cylinder to fit.

11-2
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

WARPAGE INSPECTION
Check the torsion of contact surface in gasket cylinder.
SERVICE LIMIT : 0.100 mm

PISTON
REMOVAL
Remove the piston pin clip.

Take precautions not to allow the piston pin clip to

drop into the crank case.

Remove the top ring.

Remove the second ring.

Do not damage or scratch the piston.

Measure the clearance between the piston ring and

piston grooves.
PISON
PISON RING
PISON RING
RING
SERVICE LIMIT : TOP : 0.090 mm
SECOND : 0.090 mm
OIL RING : 0.090 mm
RING
RING
RING CCC
YYY
Inspect the piston for wear or damage.
LLL
III
NNN
DD
D
EEE
RRR
PISTON
PISTON
PISTON
PISTON
ABNORMAL
ABNORMAL
ABNORMAL WEAR
WEAR
WEAR

11-3
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

Insert the piston ring into the inside cylinder, check the
piston ring clearance.

SERVICE LIMIT TOP/SECOND: 0.5mm

OIL RING : 1.10mm.

Push the rings into the cylinder with the top of the
PISTON
PISTON RING
PISTON RING
RING
piston to be sure they are squarely in the cylinder.

Measure the outer diameter of the piston at 10mm

from the bottom and 90°to the piston pin.
90°
°
°
°
90°
90°
90° Replace the piston if the service limit is exceeded.

SERVICE LIMIT : 72.965 - 72.985 mm

MICROMETER
MICROMETER
MICROMETER
MICROMETER
PISTON PIN INSPECTION
Measure the piston pin hole inside diameter.

SERVICE LIMIT : 17.002 - 17.008 mm

Measure the piston pin outer diameter.

SERVICE LIMIT : 16.994 ~ 17.000 mm

Calculate the clearance between the piston and the

piston pin.

SERVICE LIMIT : 0.008 mm

Measure the inner dismeter of the connecting rod small

end.
SERVICE LIMIT : 17.010 ~ 17.028 mm

Calculate the clearance between the inner diameter of

the connecting rod small end and pisto pin.

SERVICE LIMIT : 0.028 ~ 0.066 mm

CYLINDER GAUGE

11-4
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

PISTON / CYLINDER ASSEMBLY

TOP RIDNG
PISTON RING ASSEMBLY
SECOND RING
Clean the piston ring grooves and insert the piston
rings.
MARK

WHITE PAINTING
Be careful not to damage the piston and rings during
assembly.
Do not confuse the top and second rings.
TOP RING Space the ring end gaps 120 degrees apart.
Install the ring forward to the marking facing up.
SECOND RING Do not accord the side rail of oil ring

SIDE RAIL
After installation, the rings should rotate freely in the
ring grooves.
SPACER OIL RING

SIDE RAIL

PISTON / CYLINDER INSTALLATION

Remove gasket on the crank case surface.

Place a clean shop towel over the crankcase to prevent

the clip from falling into the crankcase.
Do not damage the contact place of gasket

GASKET
GASKET
GASKET

Insert the piston and piston into the conrod

PISTON
PISTON PIN
PISTON PIN CLIP
PIN CLIP
CLIP Install new piston pin clips.

“IN”MARK, it does toward to intake side.

Take care not to drop the piston pin clip into the
crankcase.
Do not align the clip’s end gap with the piston
cutout.

11-5
Downloaded from www.Manualslib.com manuals search engine
 CYLINDER / PISTON

CYLINDER INSTALLATION
Install a new cylinder gasket and dowel pins.
Coat the cylinder wall with clean engine oil and
lubricate the piston rings and install the cylinder.

Be careful not to damage the piston rings.

Be careful not to drop the cam chain into the
crankcase.

Install the lower part of the cam chain guide to the“ ”

part of the crankcase, and install the cam chain guide
by aligning the projection part with the “ ”part of
cylinder.

Install the cylinder head. ( 10-10 )

Install in reverse order of removal.

11-6
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 CRANKCASE/TRANSMISSION/CRANKSHAFT

12-0
Downloaded from www.Manualslib.com manuals search engine
 12. CRANKCASE/TRANSMISSION/CRANKSHAFT

・・・
SERVICE INFORMATION・ 12-1 ・・・・ 12-7
CRANKCASE BEARING・
TROUBLESHOOTING ・・・・ 12-2 ・ 12-8
CRANKSHAFT INSTALLATION・
・・ 12-3
CRANKCASE DISASSEMBLY・ TRANSMISSION ASSEMBLY ・ 12-9
・12-4
TRANSMISSION DISASSEMBLY・ ・・・ 12-11
CRANKCASE ASSEMBLY・
CRANKSHAFT ・・・・・・・・ 12-6

SERVICE INFORMATION
GENERAL SAFETY
To service the transmission, crank shaft and kick starter, the crankcase should be disassembled.
Before disassembling the crankcase, the following parts must be removed.
- CLUTCH, GEAR SHIFT SPINDLE ( SECTION 8)
- A.C. GENERATOR, STARTER CLUTCH ( SECTION 9)
- CYLINDER HEAD ( SECTION 10)
- CYLINDER, PISTON ( SECTION 11)
- STARTER MOTOR ( SECTION 19)

SPECIFICATIONS Unit: mm
ITEM STANDARD VALUE SERVICE LIMIT
I.D. 12.000~12.018 12.050
FORK
SHIFT FORK/SHAFT CLAW THICKNESS 4.930~5.000 4.500
SHAFT O.D. 11.976~11.994 11.960
MAIN SHAFT O.D. M3, M5 19.967~19.980 19.930
C1 16.466~16.484 16.440
COUNTER SHAFT O.D. C2 19.974~19.987 19.940
C4 19.959~19.980 19.930
M5 23.000~23.021 23.050
M3, C2 23.020~23.041 23.070
GEAR I.D.
C4 20.020~20.041 20.070
C1 20.000~20.021 20.050
TRANSMISSION M5 22.959~22.980 22.930
GEAR BUSHING O.D. M3, C2 22.979~23.000 22.950
C1 19.959~19.980 19.930
M3, C2 20.000~20.021 20.050
GEAR-TO-BUSHING I.D.
C1 16.500~16.518 16.550
GEAR-TO-BUSHING M3, M5
0.020~0.062 0.100
CLEARANCE C1, C2
GEAR-TO-SHAFT C4 0.040~0.082 0.120
CLEARANCE
M3 0.200~0.062 0.100
BUSH-TO-SHAFT
C1 0.016~0.052 0.090
CLEARANCE
C2 0.013~0.047 0.090

12-1
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Unit: mm
ITEM STANDARD VALUE SERVICE LIMIT
CONNECTING ROD BIG END SIDE
0.050~0.300 0.600
CLEARANCE
CONNECTING ROD BID END
CRANKSHAFT 0~0.008 0.050
VERTICAL DIRECTION CLEARANCE
RIGHT 0.100
CRANKSHAFT RUNOUT
LEFT 0.100

TORQUE VALUES
BEARING SETTING PLATE 1.2kgf m(12N m)
CRANKCASE BOLT 1.1kgf m(11N m)

TOOLS
UNIVERSAL BEARING PULLER
BEARING REMOVER SET
DRIVER
ATTACHMENT
PIROT
THREAD ADAPTER
ASSEMBLY SHAFT
CRANKCASE ASSEMBLY COLLAR

TROUBLESHOOTING

Hard to shift Engine noise

Incorrect clutch system adjustment Connecting rod big end bearing worn
(Free play is too big) Connecting rod bent
Shift fork bent Crank shaft main bearing worn or breakage
Shift fork shaft bent Transmission gear worn or breakage
Gear shift spindle claw bent
Shift drum guide grooves damaged
Shift fork guide spot damaged

Transmission jumps out of gear

Gear dogs worn
Shift fork shaft bent
Shift drum stopper damaged
Shift drum guide grooves worn
Shift fork grooves worn

12-2
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

RH.
RH.
RH. CRANK
CRANK
CRANK CASE
CASE
CASE CRANKCASE DISASSEMBLY
Drain the coolant.
The engine must be seperated from the frame.
( section 7)

Refer to the service information for removal of

necessary parts before disassembling the
crankcase.

Remove the LH. cover / Fly wheel.

Remove the RH. cover / Clutch.
Remove the Cylinder head / Cylinder / Piston.
Remove the 4pcs bolts from the RH. crankcase.
LH.
LH.
LH. CRANK
CRANK
CRANK CASE
CASE
CASE
Loosen the ten 11pcs bolts from the LH. crankcase
in a crisscross pattern, remove the bolts.

LH.
LH. CRANK
LH. CRANK CASE
CRANK CASE
CASE Place the crank case down, and separate the LH.
crankcase from the RH. crankcase by tapping the
crankcase with a soft hammer.

Be careful not to distort the mating surface of the

crankcase during removal.

BALANCE
BALANCE GEAR
BALANCE GEAR
GEAR MAIN
MAIN
MAIN SHAFT
SHAFT
SHAFT GASKET
GASKET
GASKET
GASKET Remove the dowel pins and gasket.

COUNT
COUNT
COUNT SHAFT
COUNT SHAFT
SHAFT

GEAR
GEAR SHIFT
GEAR SHIFT DRUM
SHIFT DRUM
DRUM

12-3
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

SHIFT
SHIFT FORK
SHIFT FORK SHAFT
FORK SHAFT
SHAFT TRANSMISSION DISASSEMBLY
Remove the shift fork shaft.
Remove the shift fork and the shift drum.

GEAR
GEAR
GEAR SHIFT
SHIFT
SHIFT DRUM
DRUM
DRUM

COUNTER SHAFT
COUNTER
COUNTER SHAFT
SHAFT
Remove the main shaft and the counter shaft as an
assembly.
MAIN SHAFT
MAIN
MAIN SHAFT
SHAFT

Remove the crank balancer gear.

CRANK
CRANK BALANCER
CRANK BALANCER GEAR
BALANCER GEAR
GEAR

INSPECTION
Check the shift fork for wear or damage.
Measure the shift fork inside diameter and the
shift fork claw thickness.

SERVICE LIMIT :
INSIDE DIAMETER : 12.050mm
CLAW THICKNESS : 4.500mm

Check the shift fork shaft for wear or damage.

Measure the shift fork shaft outside diameter in
shift fork operation part.

SERVICE LIMIT : 11.960mm

12-4
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT
Check the shift drum for wear or damage.
Check the shift drum guide groove for partial wear
or damage.

GEAR
GEAR
GEAR SHIFT
SHIFT DRUM
SHIFT DRUM
DRUM

Measure the main shaft and counter shaft outside

diameter.
MAIN
MAIN SHAFT
MAIN SHAFT
SHAFT
SERVICE LIMIT : M3, M5 : 19.930mm
C1 : 16.440mm
C2 : 19.940mm
C4 : 19.930mm
COUNTER SHAFT
COUNTER
COUNTER SHAFT
SHAFT

Check the gear holes teeth and threads for wear

MAIN
MAIN
MAIN GEAR
GEAR
GEAR and damage.
Measure the gear inside diameter.
SERVICE LIMIT : M5 : 23.050mm
M3, C2 : 23.070mm
C4 : 20.070mm
C1 : 20.050mm

Measure the gear bush inside diameter and outside

M3
M3
M3 M4
M4
M4
M4 M5
M5
M5 M2
M2
M2
M2 diameter.
SERVICE LIMIT :
M5 : OUTSIDE DIAMETER : 22.930mm
M3, M2 OUTSIDE DIAMETER : 22.950mm
C1 OUTSIDE DIAMETER : 19.930mm
M3, C2 INSIDE DIAMETER : 20.050mm
C1 INSIDE DIAMETER : 16.550mm
COUNTER
COUNTER
COUNTER GEAR
GEAR
GEAR
Measure out the gear-to-bush clearance.
SERVICE LIMIT :
M3, M5, C1, C2 : 0.100mm
Measure out the gear-to-shaft clearance.
SERVICE LIMIT : C4 :0.120mm
Measure out the bush-to-shaft clearance.
M2
SERVICE LIMIT : M3 : 0.100mm
M1
M1
M1 M3
M3
M3 M4
M4
M4 M5
M5
M5
M5 M2
M2
M2
C1 : 0.090mm
C2 : 0.090mm

12-5
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT
REMOVAL
Remove the transmission.
Remove the crankshaft from the RH. crankcase
using a hydraulic press.
Remove the remaining bearings in the
RH.crankcase with a driver handle and outer
driver.
TOOLS : DRIVER
ATTACHMENT
RH.
RH.
RH. CRANK
CRANK CASE
CRANK CASE
CASE

UNIVERSAL
UNIVERSAL
UNIVERSAL BEARING
BEARING
BEARING PULLER
PULLER
PULLER
If the bearing is left on the crankshaft, use a universal
bearing puller to remove it.
TOOL : UNIVERSAL BEARING PULLER

After removing the crankshaft from the RH.

crankcase, replace the RH. crankshaft bearing with a
new one.

INSPECTION
RIGHT
RIGHT
RIGHT LEFT
LEFT
LEFT
Place the crankshaft on a stand or V-block, and
measure the crankshaft runout using dial gauge.
SERVICE LIMIT : RIGHT : 0.100 mm
LEFT : 0.100 mm

90mm
90mm
90mm
90mm 75mm
75mm
75mm
75mm

Measure the side clearance between the crankshaft and

FEELER GAUGE
FEELER
FEELER GAUGE
GAUGE
connecting rod big end by the feeler gauge.
SERVICE LIMIT : 0.600mm
TOOL : FEELER GAUGE

12-6
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

Measure the connecting rod radial clearance in both X

and Y directions.
Replace the crankshaft if the service limit is exceeded.

SERVICE LIMIT : 0.050 mm

CRANKCASE BEARING
REMOVER
REMOVER
REMOVER 15mm
15mm
15mm
MAIN
MAIN SHAFT
MAIN SHAFT BEARING
SHAFT BEARING
BEARING Remove the transmission and crank shaft.

CRANK
CRANK
CRANK BALANCE
BALANCE
BALANCE INSPECTION
SHAFT
SHAFT
SHAFT BEARING
BEARING
BEARING
Turn the Inner race of bearing with fingers and
inspect for smooth turning. Also inspect that the
outer race is driven into the case exactly. If the
clearance is excessive, or the driving for the case is
loose, remove and replace them.
COUNTER
COUNTER
COUNTER
SHAFT
SHAFT
SHAFT
SHAFT CRANK
CRANK SHAFT
CRANK SHAFT BEARING
SHAFT BEARING
BEARING
BEARING
BEARING
BEARING
Replace the transmission bearing with the right
and left sets.
DRIVER
DRIVER
DRIVER
REPLACEMENT
LH. Crankcase
Remove the cranke balance shaft bearing, main
shaft bearing, crank shaft bearing with the tools.
TOOL : BEARING REMOVER SET
Remove the counter shaft bearing and oil seal.

Coat the new bearing with clean engine oil, and

install it into the crank case.
TOOLS : MAIN SHAFT BEARING :
- DRIVER
COUNTER
COUNTER SHAFT
COUNTER SHAFT OIL
SHAFT OIL SEAL
OIL SEAL
SEAL - ATTACHMENT
COUNTER SHAFT BEARING:
- DRIVER
- ATTACHMENT
- PILOT

Pressing the new counter shaft oil seal.

Inspect the gear shift spindle oil seal for wear and
damage, it must be replaced if necessary.

GEAR
GEAR
GEAR SHIFT
SHIFT SPINDLE
SHIFT SPINDLE OIL
SPINDLE OIL SEAL
OIL SEAL
SEAL

12-7
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

RH. Crank Case

Remove the main shaft bearing set plate.
Remove the main shaft bearing, counter shaft
bearing and crank shaft bearing from crankcase.

Apply the new bearing with clean engine oil and

install it into crankcase.

Insert closely the cooling jet into crankcase.

- Insert angle: 10 2
TOOLS :
MAIN SHAFT / COUNTER SHAFT / CRANK
BALANCER SHAFT BEARING
- DRIVER
- ATTACHMENT
- PILOT

Coat the socket bolt screw part with oil and install
the main shaft bearing set plate.

・m (12N・
TORQUE : 1.2kgf・ ・m)

CRANKSHAFT INSTALLATION
Coat a new left crankshaft bearing with clean
engine oil and install new bearings into the right
crankcase.
CRANK ASSEMBLY CRANK SHAFT
TOOLS : DRIVER
ATTACHMENT
PILOT

Install the crankshaft into the RH. crankcase with

the following tools:

TOOLS : ASSEMBLY SHAFT

CRANKSHAFT ASSEMBLY COLLAR

12-8
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

TRANSMISSION ASSEMBLY

C-1 GEAR
COUNTER TRANSMISSION SHAFT
C-3 GEAR

C-4 GEAR

C-5 GEAR

C-2 GEAR

DRIVE SPROCKET
MAIN SHAFT

M-3 GEAR

M-4 GEAR

M-5 GEAR M-2 GEAR

Apply the gear and gear bush with clean engine oil
COUNTER
COUNTER
and install the main shaft and counter shaft.
COUNTER SHAFT
SHAFT
SHAFT

Check the gears for freedom of movement or

rotation on the shaft.
MAIN
MAIN SHAFT
MAIN SHAFT
SHAFT

Note the installation direction of each snap ring.

Do not use the worn snap ring again.
Check the snap rings are seated in the grooves
spinning the rings. Align the end gaps of the snap
ring with the grooves of spline.

BALANCE
BALANCE
BALANCE DRIVE
DRIVE GEAR
DRIVE GEAR
GEAR
Install the balancer gear.
BALANCE
BALANCE
BALANCE DRIVEN
DRIVEN
DRIVEN GEAR
GEAR
GEAR

Align the balancer drive gear and balancer driven

gear with the marking location.
ALIGN
ALIGN THE
ALIGN THE GEAR
THE GEAR WITH
GEAR WITH THE
WITH THE MARKING
THE MARKING LOCATION
MARKING LOCATION
LOCATION

12-9
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

Install the main shaft and counter shaft on RH.

crank case together.

Check the marks on the shift forks.

- L. fork : “L” mark
- Center fork : “C” mark
- R. fork : “R” mark
RIGHT
RIGHT
RIGHT FORK
FORK
FORK CENTER FORK
CENTER
CENTER FORK
FORK LEFT
LEFT
LEFT FORK
FORK
FORK

COUNTER SHAFT
COUNTER
COUNTER SHAFT
SHAFT Install the L. fork mark and center fork and then
SHIFT
SHIFT DRUM
SHIFT DRUM
DRUM install R. fork.

Install the shift drum. Install the shift fork guide

pin into the guide groove of the drum.

MAIN
MAIN
MAIN SHAFT
SHAFT
SHAFT

Install the shift fork into the shift fork shaft, then
SHIFT
SHIFT FORK
SHIFT FORK
SHIFT SHAFT
FORK SHAFT
FORK SHAFT
SHAFT install the shift fork shaft into the RH. crankcase
assembling hole.

12-10
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

CRANKCASE ASSEMBLY
Install the dowel pins and a new gasket.

RH.
RH. CRANK
RH. CRANK CASE
CRANK CASE
CASE

Install the LH. crank case.

Make sure that there is no gap between the

mating surfaces of the right and left crankcase.

LH.
LH.
LH. CRANK
CRANK CASE
CRANK CASE
CASE

Tighten the LH. crankcase bolts in a crisscross

pattern in 2-3 steps.
・m(11N・
TORQUE : 1.1kgf・ ・m)

After replacing the o-ring of the gear change

switch to a new one, coat the new o-ring with
engine oil, then install the switch pin into the
groove of the shift drum.

Tighten the 4pcs of RH. crankcase bolt.

GEAR
GEAR
GEAR CHANGE
CHANGE SWITCH
CHANGE SWITCH
SWITCH
・m(11N・
TORQUE : 1.1kgf・ ・m)

12-11
Downloaded from www.Manualslib.com manuals search engine
 CRANKCASE/TRANSMISSION/CRANKSHAFT

Install the below parts.

- Clutch / RH. cover
- Cylinder / Cylinder head
- Flywheel / LH. cover
Install the engine on the frame. ( Section 7)
Pour the engine oil.
Pour the coolant.

Install of the cowl in the reverse order of removal.

12-12
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 EXTERNAL PARTS

13-0
Downloaded from www.Manualslib.com manuals search engine
 13. SEAT / EXHAUST MUFFLER

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

SERVICE INFORMATION
GENERAL SAFETY

Beware of the muffler after driving or engine stop, as it is still hot to be burnt especially never children touch on it.

13-1
Downloaded from www.Manualslib.com manuals search engine
 EXTERNAL PARTS

SIDE
SIDE
SIDE COVER
COVER
COVER
SIDE COVER / SEAT
SIDE COVER REMOVAL
Remove the seat.
Remove the RH/LH. side cover special bolts, then
remove the RH/HL. side covers.

Remove the side cover hook from the grommet of

the frame, by pulling the side cover forward.

SEAT REMOVAL
PILLION
PILLION SEAT
PILLION SEAT
SEAT
MAIN
MAIN
MAIN SEAT
SEAT
SEAT
Turn the helmet holder left to unlock the seat and
then pull the seat back and up.

Installation is in the reverse order of removal.

CENTER
CENTER COVER
CENTER COVER
COVER
REAR SEAT(PILLION SEAT)
Remove the seat.
Remove the center cover setting grommet and
center cover.

Remove a flange bolt, and then pull the seat front

and up.

Installation is in the reverse order of removal.

FRONT
FRONT BOLT
FRONT BOLT
BOLT

13-2
Downloaded from www.Manualslib.com manuals search engine
 EXTERNAL PARTS

REAR
REAR COWL
REAR COWL
COWL REAR COWL
Remove the below parts.
The seat.
The R/L. side cover.
The center cover.
The pillion seat.
The two flange bolts and 4 special
bolts.(RH./LH.)
The rear fender mounting 4 body cover
clips.(RH./LH.)
Carefully spread the bottom of both sides of the
rear cowl, then remove it.
Installation is in the reverse order of removal.

FAN
FAN MOTOR
FAN MOTOR RELAY
MOTOR RELAY
RELAY TAIL
TAIL
TAIL LIGHT
LIGHT
LIGHT REAR FENDER
Remove the seat.
Remove the RH. / LH. side cover.
Remove the center cover.
Remove the pillion seat.
Remove the rear cowl.
Remove the head light relay, winker relay from the
rear fender.
Remove the tail light, winker connector.

WINKER
WINKER RELAY
WINKER RELAY
RELAY
FUSE
FUSE BOX
FUSE BOX FUEL
BOX FUEL PUMP
FUEL PUMP
FUEL RELAY
PUMP RELAY
PUMP RELAY
RELAY

Remove the R/L special screws.

REAR
REAR
REAR FENDER
FENDER
FENDER Remove 4 pcs flange bolts on bottom of rear
fender.
Remove the rear fender from the frame.
Installation is in the reverse order of removal.

REAR
REAR
REAR WHEEL
WHEEL
WHEEL MUDGUARD
MUDGUARD
MUDGUARD
REAR WHEEL MUDGUARD
Remove the 4 rear wheel mudguard mounting bolts
and rear wheel mudguard.

Installation is in the reverse order of removal.

13-3
Downloaded from www.Manualslib.com manuals search engine
 EXTERNAL PARTS

MUFFLER/EXHAUST PIPE

Do not service the exhaust system while it is hot.

REMOVAL
Remove the exhaust pipe and 4 muffler body
mounting socket bolts.

MUFFLER
MUFFLER
MUFFLER
MUFFLER FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT

Remove the muffler mounting bolt/nut securing

MUFFLER
MUFFLER
MUFFLER pillion step bracket and remove the muffler.

Remove the exhaust pipe flange gasket.

FLANGE
FLANGE
FLANGE GASKET
GASKET
GASKET Remove the oxygen sensor.
Remove the 2pcs exhaust pipe joint cap nuts.

CAP
CAP NUT
CAP NUT
NUT

O2 SENSOR
O2
O2 SENSOR
SENSOR

13-4
Downloaded from www.Manualslib.com manuals search engine
 EXTERNAL PARTS

INSTALLATION
Install the removed parts in the reverse order of
removal.

Check the protrusion of the exhaust pipe stud bolt.

Install the new exhaust pipe gasket onto the exhaust
ports of the cylinder head.
Install the new gasket onto the exhaust pipe.
When install the muffler temporarily install the
flange bolt to the damper stay and the hex cap nut
then tighen the hex cap nut and the flange bolt.
FRONT
FRONT FENDER
FRONT FENDER
FENDER
FRONT FENDER
Remove the front fender mounting 6pcs special
screws. (RH/LH.)
Remove the front fender forward.
Install in the reverse order of removal.

13-5
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

14-0
Downloaded from www.Manualslib.com manuals search engine
 14. FRONT WHEEL/FRONT FORK/STEERING

・・・・14-1
SERVICE INFORMATION・ FRONT WHEEL ・・・・・ ・ 14-7
TROUBLESHOOTING・ ・・・・ ・ 14-2 FRONT FORK ・・・・・・ ・ 14-12
HANDLEBARS ・・・・・・・ 14-3 STEERING STEM ・・・・・ ・14-20

SERVICE INFORMATION
GENERAL SAFETY

A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk
with a brake degreasing agent.
Because inhaled asbestos fibers have been found to cause respiratory disease and cancer, work so that the fibers near
the brake pad can't spread to the brake cleaner.
When removing or installing tires from the rim, use the special tire lever and rim protector so that the rim can't be
damaged.
This section covers maintenance of the front wheel, front fork and steering stem. Refer to section 15 for front brake
service.
Use a jack or a hoist under the engine to support the motorcycle.

SPECIFICATIONS Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
FRONT AXLE DEFLELTION - 0.2
RADICAL - 2.0
FRONT WHEEL RIM VIBRATION
AXIAL - 2.0
FRONT FORK PIPE DEFLECTION - 0.2
FRONT FORK FLUID CAPACITY 245±2.5cc -
FORK SPRING FREE LENGTH 528.0 480.0

TORQUE VALUES
STEERING HANDLE PIPE BOLT 2.6kgf m(26N m)
FRONT BRAKE DISK BOLT 4.2kgf m(42N m)
FRONT AXLE NUT 5.9kgf m(59N m)
FORK TOP BRIDGE PINCH BOLT 2.6kgf m(26N m)
FORK BOTTOM BRIDGE PINCH BOLT 3.4kgf m(34N m)
FORK TUBE CAP BOLT 2.3kgf m(23N m)
FORK SOCKET BOLT 2.0kgf m(20N m) (Apply locking agent)
CALIPER BRACKET BOLT 3.0kgf m(30N m)
STEERING STEM NUT 7.4kgf m(74N m)
STEERING TOP THREAD NUT 2.5kgf m(25N m) (Initial torque)
0.3kgf m(3N m) (Last torque)
HANDLE WEIGHT SOCKET BOLT 2.0kgf m(20N m)

14-1
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING
TOOLS
SPECIAL TOOLS
BALL RACE DRIVER
STEERING STEM DRIVER
FORK SEAL DRIVER
STEERING STEM SOCKET

COMMON TOOLS
EXTENSION BAR
DRIVER
FORK SEAL DRIVER / BODY
LOCK NUT WRENCH
BEARING REMOVER SHAFT
REMOVER HEAD
ATTACHMENT
PILOT

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

Steers to one side Hard suspension

Damaged, incorrectly tightened steering head bearing Bend fork tube
Unbalance of left, right cushion Oil level too high
Bent front fork Oil viscosity too high
Bent front axle shaft and inclind tire Too much air in tire
Worn tire
Worn wheel bearing Strange noise of front cushion
Worn swing arm pivot Defective bottom case
Loose fork leg fasteners
Front wheel wobbling Insufficient fork oil
Deformed rim
Worn wheel bearings

14-2
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

HANDLE BARS
HANDLE WEIGHT
HANDLE
HANDLE WEIGHT CAP
WEIGHT CAP
CAP
REMOVAL
Loosen the socket bolt from the end of the RH. handle
grib.

Loosen the 2 screws.

STARTER
STARTER SWITCH
STARTER SWITCH
SWITCH

Remove the starter switch from RH. steering handle.

MASTER
MASTER CYLINDER
MASTER CYLINDER
CYLINDER Remove the front stop switch wire from the switch.
Loosen the 2 master cylinder holder bolts, remove the
holder and master cylinder.

14-3
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Remove the 2pcs screws on the left handlebar switch.

SCREW
SCREW
SCREW

Remove the winker switch.

CLUTCH
CLUTCH LEVER
CLUTCH LEVER
LEVER BRACKET
LEVER BRACKET
BRACKET
BRACKET
Loosen the 2pcs clutch lever bracket holder bolts.
Loosen the socket bolts on LH. handle grip end and
remove the handle weight cap.
Remove the LH. handle grip and choke lever from the
handle bar.

HOLDER
HOLDER
HOLDER

HANDLE
HANDLE PIPE
HANDLE PIPE ASSEMBLY
PIPE ASSEMBLY
ASSEMBLY
Loosen the handle pipe pinch RH/LH bolt.
SOCKET
SOCKET BOLT
SOCKET BOLT
BOLT Remove the handlebars from the front forks.

RH.
RH. HANDLE
RH. HANDLE PIPE
HANDLE PIPE
PIPE LH. HANDLE PIPE
LH.
LH. HANDLE
LH. HANDLE PIPE
HANDLE PIPE
PIPE

14-4
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

RH.
RH.
RH. HANDLE
HANDLE PIPE
HANDLE PIPE
PIPE LH.
LH.
LH. HANDLE
HANDLE PIPE
HANDLE PIPE
PIPE INSTALLATION
Install the handlebars onto the front forks.
Install the handle pipe while aligning its grooves with
the fork top bridge holes.
HOLE
HOLE
HOLE
HOLE Tighten the handle pipe pinch bolts to the specified
HOLE
HOLE
HOLE torque.
HOLE

・m
TORQUE : 2.6kgf・

RH.
RH.
RH. FRONT
FRONT
FRONT FORK
FORK
FORK RH.
RH.
RH. FRONT
FRONT
FRONT FORK
FORK
FORK

Install the clutch lever bracket with the “UP” mark of

the holder facing up.

Connect the throttle cable to the throttle pipe.

THROTTLE
THROTTLE CABLE
THROTTLE CABLE
CABLE Install the winker switch housing aligning its locating
pin with the hole in the handlebar.
Install the handle weight cap, tighten the socket bolts.

・m
TORQUE : 2.0kgf・

Install the master cylinder by aligning the end of the

master cylinder with the punch mark on the handle bar,
tighten the upper bolts firstly, then tighten the lower
bolts.
Connect the front stop switch wires.

14-5
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Insert the throttle pipe to the handle bar.

Wait 3-5 minutes and install the grip.
Rotate the grip for even application of the adhesive.
Clean the bonding surface to avoid oil, grease or
gasoline from attaching.

Leave in for minimum 1 hour until the bond it

dried.
LH. GRIP

CLUTCH
CLUTCH
Install the master cylinder with the “UP” mark of
CLUTCH CASE
CASE
CASE
the holder facing up.
Install the master cylinder by aligning the end of the
master cylinder with the punch mark on the
handlebar.
Tighten the upper bolt first, the lower bolt.

PUNCH MARK
PUNCH
PUNCH MARK
MARK
LH.
LH. HANDLE
LH. HANDLE PIPE
HANDLE PIPE
PIPE

Install the winker switch housing aligning it is

PUNCH MARK
PUNCH
PUNCH MARK
MARK
locating pin with the hole on the handle bar.

WINKER
WINKER SWITCH ASSY Insall the screws.
WINKER SWITCH
SWITCH ASSY
ASSY

14-6
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

FRONT WHEEL
CLAMP
CLAMP
CLAMP
REMOVAL
Loosen the brake hose clamp bolts and remove the
clamp.
Loosen the 2 flange bolts securing the bottom case
and remove the caliper.

BRAKE
BRAKE HOSE
BRAKE HOSE
HOSE

FRONT
FRONT
FRONT BRAKE
BRAKE
BRAKE CALLIPER
CALLIPER
CALLIPER SPEEDOMETER
SPEEDOMETER CABLE
SPEEDOMETER CABLE
SPEEDOMETER CABLE
CABLE

Remove the speedometer gear box screws and

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER CABLE
CABLE
CABLE remove the cable.

Loosen the axle screw and pull the speedometer

cable out of the speedometer gear box.
Remove the axle nut, front axle the front wheel and
R. side collar.

Don't operate the brake lever after removing

the front wheel.

INSPECTION
Axle
Measure the runout of the front axle.
Install the front axle in v-block and measure the
runout with dial gauge.
SERVICE LIMIT : 2.0mm
Wheel rim runout
Check the rim runout by placing the wheel in a
turning stand.
Spin the wheel slowly and read the runout using a
dial indicator.
SERVICE LIMIT : RADIAL : 2.0mm
SERVICE LIMIT : AXIAL : 2.0mm

14-7
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Remove the dust seal. BEARING INSPECTION

Turn the inner race of each bearing with finger.
Bearing should turn smoothly and quietly. Also check
that the bearing outer race fits tightly in the hub.
If the bearing is worn, replace the new one.

Replace the bearing in pairs.

OIL
OIL SEAL
OIL SEAL
SEAL DISASSEMBLY
Remove and speedometer gear box, oil seal and gar
box retainer.

SPEEDOMETER GEAR
SPEEDOMETER
SPEEDOMETER GEAR BOX
GEAR BOX
BOX GEAR
GEAR BOX
GEAR BOX RETAINER
BOX RETAINER
RETAINER

Loosen the 6 LH. brake disk bolts on front rim and

remove the brake disk.

Loosen the 6 RH. brake disk bolts on front rim and

remove the brake disk.

Check the disk for defects. ( 16-9)

14-8
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

WHEEL BEARING REPLACEMENT

BEARING REMOVER
BEARING
BEARING REMOVER
REMOVER Install the bearing remover head into the bearing.
HEAD
HEAD
HEAD Remove the distance collar and drive out the other
bearing.
TOOLS : BEARING REMOVER HEAD
BEARING REMOVER SHAFT

Always replace bearings as a sets, and never use

old bearings.
Apply sufficient amount of grease to the bearing.
Insert the right bearing with its seal surface facing
outside.
Do not tilt the bearing. Insert accurately.
Upon assembling the distance collar, insert the left
bearing with its seal surface facing outside.
TOOLS : DRIVER
ATTACHMENT
PILOT

SPEEDOMETER GEAR REPLACEMENT

Remove the speedometer gear and washer from the
speedometer gear box.

Check the gear for wear or damage.

SPEEDOMETER GEAR
SPEEDOMETER
SPEEDOMETER GEAR
GEAR
Install the washers.
Apply grease to the speedometer gear and install it.

WASHERS
WASHERS PINION
PINION GEAR
PINION GEAR
GEAR

14-9
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING
ASSEMBLY
FR. WHEEL SIDE COLLAR
FR. CASTING WHEEL

FR. WHEEL AXLE RADIAL BALL BEARING

RH. FR. BRAKE DISK GEAR BOX RETAINER

OIL SEAL
DUST SEAL

SPEEDOMETER GEAR
RADIAL BALL BEARING

FR. DISTANCE COLLAR

FR. TIRE
LH. FR. BRAKE DISK

SPEEDOMETER GEAR BOX ASSEMBLY

Install the brake disk on LH. front rim.

Install and tighten the new mounting bolts to the
specified torque.

・m (42N・
TORQUE : 4.2 kgf・ ・m)

Inatall the gear box retainer to wheel projection.

Apply grease to the rim part of LH. oil deal and
pressing to front rim.

GEAR
GEAR RETAINER
RETAINER

14-10
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Align the wheel hub tangs with the slots of the gear
box retainer, and assemble the speedometer gear box
seal.

Apply grease to the dust seal rim.

Install the dust seal.

INSTALLATION
Place the front wheel between the front forks.
Align the slot of the speedometer gear box with the
tangs of the left fork slider.
Insert the front axle into the speedometer gear box and
the wheel hub.
Install the axle nut.

・m
TORQUE : 5.9 kgf・

COLLAR
COLLAR
COLLAR
COLLAR

Install the speedometer cable and tighten it correctly

with the screw.

SCREW
SCREW
SCREW

14-11
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Install the RH/LH caliper and tighten the new

mounting bolts to the specified torque.
・m (30N・
TORQUE : 3.0kgf・ ・m)

CALLIPER
CALLIPER
CALLIPER

FRONT FORK
REMOVE
Remove the front fender. ( 13-5)
Remove the RH/LH front caliper.
Remove the front wheel. ( 14-7)

STEERING
STEERING
When the front fork will be disassembled, loosen the
STEERING HANDLE
HANDLE
HANDLE PIPE
PIPE
PIPE
fork pipe bolt, but do not remove it yet.

Support the motorcycle securely under the engine

not to turn over it.

Loosen the handle pipe pinch bolt.

Loosen the fork top bridge pinch bolt.

FORK
FORK TOP
FORK TOP BRIDGE
TOP BRIDGE
BRIDGE SOCKET
SOCKET BOLT
SOCKET BOLT
BOLT

Loosen the fork bottom pinch bolt and remove the fork
pipe from the handle pipe, fork top bridge and steering
stem.

STEERING
STEERING
STEERING STEM
STEM BOLT
STEM BOLT
BOLT

14-12
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

FRONT
FRONT FORK
FRONT FORK BOLT
FORK BOLT
BOLT DESASSEMBLY
Remove the front fork bolt.

If the bolt is completely loosened, the fork pipe

bolt may spring out by the force for the spring.
Remove the fork spring, and expand and release
the fork pipe several times to drain fork oil.

Wrap the bottom case with a piece of cloth, and

remove the socket bolt.

If the socket bolt turns idle cannot be removed,

temporarily assemble the spring and the fork tube
cap blot first.
Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.

Remove the piston ring, seat pipe and rebound spring

SEAT
SEAT PIPE
SEAT PIPE
PIPE from the fork pipe.

Remove the dust seal.

DUST
DUST SEAL
DUST SEAL
SEAL

BOTTOM CASE
BOTTOM
BOTTOM CASE
CASE

14-13
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Remove the oil seal stopper ring.

STOPPER
STOPPER RING
STOPPER RING
RING

Pull the fork pipe out until you feel resistance from the
slider bushing.
Then move it in and out, tapping the bushing lightly
until the fork pipe separates from the bottom case.

OIL SEAL
OIL
OIL SEAL
SEAL
BACK-UP RING
BACK-UP
BACK-UP RING
RING
Remove the slider bushing, guide bushing, back-up
ring, oil seal, stopper ring and dust seal from the fork
pipe.
SLIDER
SLIDER
SLIDER
BUSHING
BUSHING
BUSHING

DUST SEAL
DUST
DUST SEAL
SEAL

STOPPER RING
STOPPER
STOPPER RING
RING
GUIDE
GUIDE BUSHING
GUIDE BUSHING
BUSHING

INSPECTION
Place the fork spring on a level place, and measure the
free length.
If the free length deviates from the service limit,
replace the springs with new ones.
FORK
FORK SPRING
FORK SPRING
FORK SPRING
SPRING
SERVICE LIMIT : FORK SPRING : 480mm
REBOUND SPRING : 21.6mm
REBOUND
REBOUND
REBOUND SPRING
SPRING
SPRING

14-14
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING
Check components for damage or abnormal wear.
BOTTOM CASE
BOTTOM
BOTTOM CASE
CASE
Replace defective parts with new ones.

SEAT PIPE
SEAT
SEAT PIPE
PIPE

FORK
FORK
FORK PIPE
FORK PIPE
PIPE
PIPE

OIL LOCK
OIL
OIL LOCK PIECE
LOCK PIECE
PIECE

Place the fork pipe in V-block and measure the runout.

DIAL
DIAL GAUGE
DIAL GAUGE
GAUGE Actual runout is 1/2 the total indicator reading.
FORK
FORK PIPE
FORK PIPE
PIPE

SERVICE LIMIT : 0.2mm

Visually inspect the slider and fork pipe bushings.

Replace the bushings if there is excessive scoring or
SLIDER BUSHING scratching, or if the teflon is worn so that the copper
surface appears on more than 3/4 of the entire surface.
BACK-UP RING

CHECK POINTS

14-15
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

ASSEMBLY

DUST SEAL FR. FORK BOLT

FORK PIPE FR. FORK SPRING

OIL SEAL STOPPER RING

OIL SEAL

BACK UP RING

GUIDE BUSH

RH. BOTTOM CASE

SEAT PIPE
LH. BOTTOM CASE
OIL LOCK PIECE REBOUND SPRING

Before assembly, wash all parts with a non-flammable

solvent and wip them dry.
Install the oil lock piece onto the end of the seat pipe.
Install the seat pipe into the fork pipe.
Install the fork pipe into the bottom case.

SEAT
SEAT PIPE
SEAT PIPE
PIPE

OIL
OIL
OIL LOCK
OIL LOCK PIECE
LOCK PIECE
PIECE

Install the guide bush and slider bush.

Install the fork pipe into the bottom case.

14-16
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Wrap the bottom case with a piece of cloth, and fix it

STOPPER
STOPPER RING
STOPPER RING
RING
to the vise.
STOPPER RING
Apply screw locking agent to the socket bolt thread,
and assemble the socket bolt to the seat pipe.
・m (20 N・
TORQUE : 2.0 kgf・ ・m)
VISE

When a vise is used to hole the bottom case, do

not insert the case itself but insert the bracket.
BRACKET

Apply ATF(Automatic Transmission Filuid) to a new

oil seal.
FORK SEAL DRIVER Assemble the oil seal to the bottom case.
Install the oil seal with special tools until the
attachment groove of thebottom case set ring is
exposed.
ATTACHMENT TOOLS : OIL SEAL DRIVER
OIL SEAL DRIVER BODY

Install the oil seal stopper ring.

STOPPER
STOPPER
STOPPER RING
RING
RING Install the oil seal stopper ring into the bottom case
correctly.

DUST SEAL
DUST
DUST SEAL
SEAL
Install the dust seal.

14-17
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Pour the specified amount of automatic transmission

fluid(ATF) into the fork pipe.

CAPACITY : 245 2.5cc

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

FORK OIL

FORK OIL

Install the fork spring to the fork tube.

Install the spring with the smaller pitch side

facing downward.
UP
UP
UP WARD
WARD
WARD DOWN
DOWN
DOWN WARD
DOWN WARD
WARD
WARD

FORK SPRING
FORK
FORK SPRING
SPRING

Install the new O-ring to the fork cap bolt.

FORK
FORK CAP
FORK CAP BOLT
CAP BOLT
BOLT

O-RING
O-RING
O-RING
O-RING

Install the fork cap bolt to the fork pipe.

14-18
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

INSTALLATION
FORK
FORK
FORK TOP
TOP
TOP BRIDGE
BRIDGE
BRIDGE
Install the fork pipe through the bottom bridge, fork
top bridge and handle pipe.
Position the marking line of the fork pipe with the
upper surface of the top bridge as shown.

MARKING
MARKING
MARKING LINE
LINE
LINE

Tighten the fork top bridge pinch bolt to the specified

torque.
・m
TORQUE : 2.6 kgf・
Tighten the handle pipe pinch bolt to the specified
torque.
・m
TORQUE : 2.6 kgf・

Tighten the steering stem to the specified torque.

・m
TORQUE : 7.4 kgf・
Tighten the fork cap bolt to the specified torque.
・m
TORQUE : 2.3 kgf・

FRONT
FRONT
FRONT COWL
COWL
COWL
Install the following.
- Front wheel.
- Front fender.
- Front cowl
- Side cowls

14-19
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

FLANGE
FLANGE
FLANGE BOLT
BOLT
BOLT STEERING STEM
REMOVAL
Remove the following :
- Front wheel
- Kandle bars
- Front fork

Remove the 2 flange bolts and front brake hose stay.

JUNCTION
JUNCTION
JUNCTION VALVE
VALVE
VALVE

BRAKE
BRAKE
BRAKE OIL
OIL
OIL HOSE
HOSE
HOSE

Remove the steering stem nut.

STEERING
STEERING
STEERING STEM
STEM
STEM NUT
NUT
NUT

Remove the steering head top thread nut using the

STEERING
STEERING STEM
STEERING STEM SOCKET
STEM SOCKET
SOCKET special tool.
TOOL : STEERING STEM SOCKET

Remove the following :

- Steering top cone race
- Steering steel ball
STEERING
STEERING STEM
STEERING STEM
STEM - Steering stem

Place a shop towel under the steering stem to

catch the steel balls.
BEARING
BEARING
BEARING
BEARING
Check the steel ball, cone race, ball race for damage or
abnormal wear and replace as necessary.

14-20
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

RACE REPLACEMENT

Replace the cone reces and ball races in pairs.

Remove the top ball races bottom ball race from the
steering head using the ball race dirver.
TOOL : BALL RACE DRIVER

Install the new ball races of the frame using the driver
DRIVER
and attachment.

ATTACHMENT

Temporarily install the steering stem nut onto the stem

to prevent the threads from being damaged when
STEERING
STEERING STEM
STEERING STEM
STEM removing the bottom cone race from the stem.

Inspect the followings.

- Steering head top threads
- Steering cone top race
TOP
TOP
TOP CONE
CONE
CONE RACE
RACE
RACE BALL
BALL
BALL RACE
RACE
RACE
- Steering steel ball ass’y
- Steering ball race

STEERING
STEERING HEAD
STEERING HEAD
HEAD
TOP
TOP THREAD
TOP THREAD
THREAD STEEL
STEEL
STEEL BALL
BALL ASSY
BALL ASSY
ASSY

Install the new dust seal and washer into the steering
STEERING STEM
STEERING
STEERING STEM DRIVER
STEM DRIVER
DRIVER
stem.
Install a new bottom cone race into the steering stem
using a special tool and a hydraulic press.
TOOL : STEERING STEM DRIVER

BOTTOM CONE
BOTTOM
BOTTOM CONE RACE/DUST
CONE RACE/DUST SEAL
RACE/DUST SEAL
SEAL

14-21
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING
INSTALLATION
STEERING HEAD TOP THREAD
TOP CONE RACE
STEEL BALLS

STEEL BALL RACE

STEEL BALL RACE

STEEL BALLS

BOTTOM CONE RACE

DUST SEAL

WASHER

STEERING STEM

Apply grease to top and bottom ball races and install

the steel ball assy.
Instert the steering stem into the steering head pipe.
STEERING
STEERING
STEERING STEM
STEM
STEM Insall the steel ball and top cone race.

Tighten the steering head top thread.

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

14-22
Downloaded from www.Manualslib.com manuals search engine
 FRONT WHEEL/FRONT FORK/STEERING

Install the top bridge, washer and steering stem nut.

Temporarily install the R/L front forks, then tighten the
steering stem nut to the specified torque.

TORQUE : 7.4 kgf m

Install the front brake hose junction valve and tighten

the flange bolts.

Install the following:

- Front wheel
- Front fender
- Front cowl
- Side cowls

JUNCTION VALVE
JUNCTION
JUNCTION VALVE
VALVE

14-23
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

15-0
Downloaded from www.Manualslib.com manuals search engine
 15. REAR WHEEL/REAR SUSPENSION

SERVICE INFORMATION···· 15-1 REAR CUSHION ······ 15-7

TROUBLESHOOTING····· 15-2 SWINGARM········· 15-9
REAR WHEEL ········ 15-3

SERVICE INFORMATION

SPECIFICATIONS
Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
AXLE RUNOUT - 0.2
RADICAL - 2.0
REAR WHEEL RIM RUNOUT
AXIAL - 2.0
REAR CUSHION SPRING FREE LENGTH 131 -

TORQUE VALUES
REAR BRAKE DISK BLOT 4.2㎏f·m
REAR AXLE NUT 8.8㎏f·m
REAR CUSHION UPPER / DOWN BOLT 5.4㎏f·m
REAR CUSHION UNDER BOLT 4.0㎏f·m
SWINGARM PIVOT NUT 8.8㎏f·m
FINAL DRIVEN SPROCKET NUT 5.9㎏f·m

TOOLS
ATTACHMENT 15
PILOT
DRIVER
BEARING REMOVER SHAFT
BEARING REMOVER HEAD

15-1
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

TROUBLESHOOTING
Wobble rear wheel
Deformed rim
Worn rear wheel bearing
Damaged tire
Axle not tightened properly
Insufficient air in tire
Worn rear fork bush

Weak rear cushion

Weak spring
Incorrect rear damper

Hard rear cushion

Bent damper rod

Rear cushion noise

Loose fasteners

15-2
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

REAR WHEEL
REMOVAL
Erect the motorcycle using a main stand.

Loosen the chain adjust nuts and lock nuts.

Remove the axle nut (U-nut).

CHAIN
CHAIN
CHAIN ADJUST
ADJUST
ADJUST

REAR
REAR AXLE
REAR AXLE NUT
AXLE NUT
NUT
Push the rear wheel forward.
Remove the drive chain from the driven sprocket.

Remove the axle from the left side and remove the rear
wheel.

Remove the side collars.(2EA)

INSPECTION
AXLE SHAFT
AXLE
AXLE SHAFT
SHAFT Inspect the bending of axle shaft.
SERVICE LIMIT : 0.20mm

Spin the wheel slowly and read the runout.

DIAL GAUGE SERVICE LIMIT : RADIAL : 2.0mm

DIAL
DIAL GAUGE
DIAL GAUGE
GAUGE
SERVICE LIMIT : AXIAL : 2.0mm

15-3
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

REMOVAL
Remove the side collar.
Loosen the 5 disk bolts, remove the disk brake.
Remove the oil-seal.

SIDE
SIDE COLLAR
SIDE COLLAR
COLLAR

FINAL
FINAL
FINAL DRIVEN
DRIVEN SPROCKET
DRIVEN SPROCKET
SPROCKET
Remove the final driven sprocket.

Check the teeth of the final driven sprocket.

Replace the sprocket if worn or damaged.
GOOD ( O )

•Check the drive chain and driven sprocket at the

same time.
REPLACE ( X )

Check the rear wheel damper.

REAR
REAR WHEEL
REAR WHEEL DAMPER
WHEEL DAMPER
DAMPER
Replace the damper, if it damaged.

15-4
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

Turn the each bearing.

Replace it if damaged.

REPLACEMENT BEARING
Install the bearing remover into the bearing.
install the bearing remover shaft at the opposite
position, and remove the wheel bearing by heating
with a hammer.
After removing the distance collar, remove the other
bearing.
TOOLS :
BEARING REMOVER SHAFT
REMOVER HEAD

•If the wheel bearing was replaced, Be sure to

replace it with new one.

Apply the grease to the bearing.

Insert the new bearing in parallel with the seal side
facing outside. After inserting the distance collar, insert
the bearing of the right side with the seal facing
outside.
TOOLS :
DRIVER
ATTACHMENT
PILOT

ASSEMBLY

15-5
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

Install the dust seal after applying the grease.

Install the final driven sprocket.

Install the rear wheel sleeve.

TORQUE : 5.9 kgf·m

REAR
REAR
REAR WHEEL
WHEEL SLEEVE
WHEEL SLEEVE
SLEEVE

Install the brake disk with literal mark facing out.

Install and tighten the bolts to the specified torque.
TORQUE : 4.2 kgf·m

INSTALLATION
FT
FT
FT Install the side collar on RH. side rear wheel.
Place the rear wheel into the swingarm.
Install the drive chain over the driven sprocket.
Install the axle from the left side.

AXLE
AXLE
AXLE SHAFT
SHAFT
SHAFT REAR
REAR
REAR WHEEL
WHEEL
WHEEL SLEEVE
SLEEVE
SLEEVE

15-6
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

Install the axle nut temporary.

By tightening the chain adjust nut, adjust the drive

chain slack. (⇨2-8)

Tighten the axle nut to the specified torque.

TORQUE : 8.8 kgf·m

AXLE
AXLE
AXLE SHAFT
SHAFT
SHAFT

REAR CUSHION
REMOVAL
Raise and support the motorcycle with main stand.
SIDE COVER MUD GUARD
MUD
MUD GUARD
GUARD
SIDE
SIDE COVER
COVER Remove the rear wheel mudguard.
Remove the rear cushion lower flange bolt.

Remove the LH. side cover.

Loosen the rear cushion upper flange bolt, and remove
the rear cushion.

•The damper unit is filled with high pressure nitrogen

gas. Do not disassemble gas damper unit.

FLANGE
FLANGE
•Heating a gas-filled damper can lead to an explosive
FLANGE BOLTS
BOLTS
BOLTS
release of pressure which can cause a serious injury.

INSPECTION
Visually inspect the rear cushion for damage.

Check for the :

- Damper rod for bend or damage
- Damper unit for deformation or oil leaks
- Cushion rubber for wear or damage

Check all the other parts for wear or damage.

REAR
REAR
REAR CUSHION
CUSHION
CUSHION ASSY
ASSY
ASSY If necessary, replace the rear cushion as an assembly.

15-7
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

BUSHING REPLACEMENT
Remove the pivot collar and 2 dust seals.
Press out the bushing out of the rear cushion lower
mount using the special tools.
Install a new bushing into the lower cushion mount .
Apply grease to the new dust seal lips, install them into
the lower mount.
Install the pivot collar.

PIVOT
PIVOT COLLAR
PIVOT COLLAR
COLLAR
DUST
DUST SEAL
DUST SEAL
SEAL DUST
DUST SEAL
DUST SEAL
SEAL

REAR CUSHION DISPOSAL PROCEDURE

DRILLING PONT
Punch the damper case center to mark drilling.
Wrap the rear cushion inside a plastic bag.
DRILL Support the rear cushion upright in a vise.
PLASTIC BAG
Though the open end of the bag, insert a drill motor
with a sharp 2~3mm drill bit.
Hold the bag around the drill motor and briefly run the
drill motor inside the bag; this will inflate the bag with
air from the motor and help keep the bag from getting
caught in the bit when you start.

•Always wear eyes protection to avoid getting metal

shavings in your eyes when gas pressure is released.
•Drilling farther into the damper case than specified
can puncture the oil chamber.

INSTALLATION
Install the rear cushion into the frame and install the
rear cushion upper flange bolt to the specified torque.
TORQUE : 3.4 kgf·m
Install the LH. side cover.

UPPER FLANGE
UPPER
UPPER FLANGE BOLT
FLANGE BOLT
BOLT

15-8
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

Install the rear cushion lower mounting bolt.

Tighten the bolt to the specified torque.
TORQUE : 4.0 kgf·m
Install the rear wheel mudguard.

SWINGARM
REMOVAL
Remove the rear wheel. (⇨15-3)
Remove the mudguard mounting R/L (2EA) bolts and
rear wheel mudguard.

MUD
MUD GUARD
MUD GUARD
GUARD

SWING
SWING
SWING ARM
ARM
ARM

Remove the brake hose from the swingarm clamp.

REAR
REAR CUSHION
REAR CUSHION
CUSHION Remove the rear cushion and swing arm securing bolts
lower flange bolt.

BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE

FLANGE
FLANGE
FLANGE BOLT
BOLT
BOLT

Remove the U-nut and swingarm pivot bolt and then

remove the swingarm from the frame.

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

15-9
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

DISASSEMBLY/INSPECTION
Remove the upper and lower screws and chain slider.
Check the chain slider for wear or damage.
Remove the dust seal caps pivot distance center collar
and bush.
Check the dust seal caps, center collar and bush for
wear or damage.

ASSEMBLY
RR. FORK END CAP
ADJUSTER NUT
CHAIN ADJUSTER

LOCK NUT

RR. SWING ARM

DUST SEAL CAP

BUSH

O-RING CHAIN

PIVOT DISTANCE CENTER COLLAR CHAIN SLIDER

SWING ARM PIVOT BOLT

Apply grease to the center collar, bearing and bushes.

Install the center collar, bearings and bushes to the
swingarm.

15-10
Downloaded from www.Manualslib.com manuals search engine
 REAR WHEEL/REAR SUSPENSION

Install the dust seal caps into the swingarm.

Install the drive chain slider on the swingarm, then
tighten the screws.
TORQUE : 0.6 kgf·m ( 6 N·m)

SLIDER
SLIDER
SLIDER SCREWS
SCREWS
SCREWS

INSTALLATION
Apply thin coat of grease to the swingarm pivot bolt
surface.
Align the drive chain installed swingarm to drive slider
and install the frame.
Install the pivot bolt from the left side and tighten the
u-nut to the specified torque.
TORQUE : 8.8 kgf·m

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

Install the swingarm-to-rear cushion lower flange bolt,

then tighten the bolt to the specified torque.
TORQUE : 4.0 kgf·m
Install the brake hose to swingarm clamp correctly.
Install the rear caliper bracket into the groove of the
swingarm.

Install the rear wheel mudguard and tighten the

mudguard 4 mounting bolts.

Install the rear wheel. (⇨15-3)

Install the removed parts in the reverse order of

removal.

15-11
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

FRONT :

REAR :

16-0
Downloaded from www.Manualslib.com manuals search engine
 16. HYDRAULIC BRAKE

···· 16-1
SERVICE INFORMATION· ·· 16-9
FRONT MASTER CYLINEDR·
······ 16-2
TROUBLESHOOTING· ··· 16-13
REAR MASTER CYLINDER·
BRAKE FLUID REPLACEMENT/ ···· 16-18
FRONT BRAKE CALIPER·
··········· 16-3
AIR BLEEDING· ····· 16-20
REAR BRAKE CALIPER·
·········· 16-6
BRAKE PAD/DISK· ··········· 16-23
BRAKE PEDAL·

SERVICE INFORMATION
GENERAL SAFETY

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your
health.
·Avoid breathing dust particles.
·Never use an air hose or brush to clean brake assemblies use and OSHA-approved vacuum cleaner.

Don't put in dust or water when filling the reservoir.

Don't mix different types of fluid to prevent from changing chemically.
Don't use the removed brake fluid.
Avoid spilling brake fluid or painted plastic and rubber parts because of damaging them.
Cover the joint part of the hose to prevent the leak the brake fluid from leaked.
Clean the removed parts with brake fluid and check the airing of each part with a compressed air.
Arrange the removed parts not to be soiled with dust or dirt.
After checking if dust or dirt soils each part, install them.
Always replace the specified parts.
Brake pad can be removed without disconnecting the hose.
Bleed the air in case of removing the brake hose.

SPECIFICATIONS Unti : mm
ITEM STANDARD VALUE SERVICE LIMIT
SPECIFIED BRAKE FLUID DOT4 -
16
BRAKE DISK THICKNESS 4.0 3.5
BRAKE DISK VIBRATION 0.1 0.3
FRONT MASTER CYLINDER I. D. 14.000~14.043 14.055
MASTER PISTON O. D. 13.878~13.905 13.866
CALIPER CYLINDER I. D. 25.000~25.033 25.07
CALIPER PISTON O. D. 24.914~24.935 24.87
SPECIFIED BRAKE FLUID DOT4 -
BRAKE DISK THICKNESS 4.0 3.0
BRAKE DISK VIBRATION 0.1 0.3
REAR MASTER CYLINDER I. D. 12.700~12.743 12.755
MASTER PISTON O. D. 12.657~12.684 12.645
CALIPER CYLINDER I. D. 25.000~25.033 25.070
CALIPER PISTON O. D. 24.914~24.935 24.870
16-1
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE
TORQUE VALUES
BRAKE CALIPER BRACKET BOLT (FRONT/REAR) 3.0㎏f·m
BRAKE CALIPER BLEEDER VALVE (FRONT/REAR) 0.6㎏f·m
BRAKE CALIPER HANGER PIN (FRONT/REAR) 2.3㎏f·m
BRAKE PAD PIN BOLT (FRONT/REAR) 1.8㎏f·m
BRAKE OIL BOLT (FRONT/REAR) 3.4㎏f·m
MASTER CYLINDER RESERVE CAP SCREW 1.0㎏f·m
BRAKE LEVER PIVOT BOLT 1.0㎏f·m
BRAKE LEVER PIVOT LOCK NUT 1.0㎏f·m
REAR MASTER CYLINDER HOLDER SOCKET BOLT 1.2㎏f·m

TOOL
SNAP RING PLIERS

TROUBLESHOOTING Brake drags

Brake lever/pedal soft or spongy Contaminated brake pad / disk.
Air bubbles in the hydraulic system. Misaligned wheel.
Leaking hydraulic system. Clogged / restricted brake hose joint.
Contaminated brake pad / disk . Warped / deformed brake disk.
Worn caliper piston seal. Caliper not sliding properly.
Worn master cylinder piston seal. Clogged/restricted brake hydraulic system
Worn brake pad/disk. Sticking/worn caliper piston
Contaminated caliper. Clogged master cylinder port
Caliper not sliding properly.
Low brake fluid level.
Clogged fluid passage.
Warped / deformed brake disk.
Sticking / worn caliper piston.
Sticking / worn master cylinder piston.
Contaminated master cylinder.
Bent brake lever/pedal.

Brake lever/pedal hard

Clogged / restricted brake system.
Sticking / worn caliper piston.
Caliper not sliding properly.
Clogged / restricted fluid passage.
Worn caliper piston seal.
Sticking / worn master cylinder piston.
Bent brake lever/pedal.

16-2
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

MASTER
MASTER CYLINDER
MASTER CYLINDER CAP
CYLINDER CAP
CAP BRAKE FLUID REPLACEMENT/
AIR BLEEDING

Do not allow foreign material to enter the system

when filling the reservoir.
Avoid spilling fluid on painted, plastic, or rubber
parts.

DIAPHRAGM
DIAPHRAGM PLATE
DIAPHRAGM PLATE
PLATE BRAKE FLUID DRAINING
<Front brake>
Turn the handlebar until the reservoir is parallel to the
ground, before removing the reservoir cap.

Remove the 2 screws and master cylinder.

Remove the diaphragm plate and diaphragm from the
master cylinder.

Connect the bleeder hose to caliper bleeder valve.

Loosen the bleeder valve and pump the brake lever or

pedal.
Stop pumping the lever or pedal when no more fluid
frows cut of the bleeder valve.

16-3
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

RESERVOIR
RESERVOIR
RESERVOIR CAP
CAP
CAP
<Rear brake>
Remove the RH. side cover.
Remove the reservoir cap.

Remove the reservoir cap plate and diaphragm.

Drain the brake fluid as same way when the front
RESERVOIR
RESERVOIR
RESERVOIR TANK
TANK
TANK brake fluid drainning.

BRAKE FLUID FILLING

BLEEDER
Fill the reservoir with DOT4 brake fluid up to the
upper level.

•Do not mix different types of fluid. There are not

compatible.

Connect a recommended brake bleeder to the bleeder

valve.
Pump the brake bleeder and loosen the bleeder valve,
adding fluid when the fluid level in the master cylinder
reservoir is low.

Repeat the previous step procedures until air bubbles

do not appear in the plastic hose.

•If a brake bleeder is not available, fill the master

cylinder and operate the brake lever or pedal to
fill the system.

Tighten the bleeder valve.

16-4
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

FRONT
FRONT CALLIPER
FRONT CALLIPER
CALLIPER MASTER
MASTER
MASTER CYLINDER
CYLINDER
CYLINDER BRAKE BLEEDING
<When the brake bleeder is not available>
Connect a clear bleeder hose to the bleeder valve.
Pump up the system pressure with the lever or pedal
until there are no air bubbles in the fluid flowing out of
the master cylinder and lever or pedal resistance is felt.

1. Squeeze the brke lever or push the brake pedal, open

the bleeder valve 1/2 turn and then close the valve.

Do not release the brake lever or pedal until the bleeder

valve has been closed.
REAR CALLIPER
REAR
REAR CALLIPER
CALLIPER REAR
REAR
REAR PEDAL
PEDAL
PEDAL 2. Release the brake lever or pedal until the bleeder
valve has been closed.
3. Repeat steps 1 and 2 until bubbles cease to appear in
the fluid coming out of the bleeder valve.

BRAKE OIL
BRAKE
BRAKE OIL
OIL
Check the fluid level often, and add fluid if the fluid
level is near the lower level.
If no air leaks out of the bleeder hose, operate the
brake lever to check the presence of air.

Tighten the bleeder valve.

TORQUE : 0.6 kgf·m (6N·m)
Fill the fluid reservoir to the upper level.
Reinstall the diaphragm and diaphragm plate.

<Front brake>
Install the master cylinder cap, and tighten the screws.

<Rear brake>
Install the reservoir cap securely.
Install the RH. side cover.
Install the seat.

16-5
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE CLAMP
CLAMP
CLAMP BRAKE PAD/DISK
FRONT BRAKE PAD REPLACEMENT

When replacing brake pads, replace whole set.

Do not remove the brake hose when replacing brake
pads.
Remove the brake hose clamp from the front fork.
Remove the pin plug using the L. wrench.
FRONT
FRONT
FRONT CALIPER
CALIPER
CALIPER Loosen the hanger pin.
Remove the caliper bracket 2 bolts and remove the
brake capliper.

Press the caliper pistons all the way in to allow

installation of new brake pads.

BRAKE PADS
BRAKE PADS

Remove the pin plug.

Remove the hanger pin and replace the brake pads.

PIN
PIN
PIN PLUG
PLUG
PLUG

CALIPER
CALIPER PISTON
CALIPER PISTON
PISTON
Clean the inside of the caliper especially around the
caliper pistons.

16-6
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Make sure the brake pad spring is in place.

Install the new brake pads.

Install the hanger pin.

PAD
PAD
PAD SPRING
SPRING
SPRING

BRAKE
BRAKE PAD
BRAKE PAD
PAD

Install the brake caliper to the fork so the disk is

positioned between the pads.
Install and tighten the new brake caliper mounting
bolts to the specified torque.
TORQUE : 3.0 kgf·m (30 N·m)
Tighten the hanger pin and pin bolt.
TORQUE : 1.8 kgf·m (18 N·m)

REAR BRAKE PAD REPLACEMENT

Remove the rear wheel mudguard. (⇨13-3)
Remove the rear brake hose clamp.

Push the caliper pistons all the way in by pushing the

caliper body inward to allow installation of new brake
pads.

REAR
REAR BRAKE
REAR BRAKE CALIPER
BRAKE CALIPER
CALIPER

Loosen the dust plug.

Loosen the hanger pins.
Remove the rear caliper bracket bolts secured rear
caliper bracket and bracket caliper.

16-7
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Remove the hanger pins and brake pads.

BRAKE
BRAKE
BRAKE PAD
PAD
PAD

Make sure the brake pad spring is in place.

Install the new brake pads.

PAD
PAD SPRING
PAD SPRING
SPRING

Install the hanger pins.

TORQUE : 2.3 kgf·m

Install the brake caliper to the caliper bracket so the

disk is positioned between the pads.
Tighten the brake caliper mounting bolts.
TORQUE : 3.0 kgf·m
Tighten the pin plugs.
TORQUE : 1.8 kgf·m
Install the rear brake hose clamp.
Install the rear wheel mudguard.

16-8
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

BRAKE DISK INSPECTION

Visually inspect the brake disk for damage or crack.
Measure the brake disk thickness with a micrometer.
SERVICE LIMIT : FRONT: 3.5mm
REAR : 3.0mm
Replace the brake disk if the smallest measurement is
less than the service limit.

Measure the brake disk runout with a dial indicator.

SERVICE LIMIT : 0.3mm
Check the wheel bearing for excessive play, if the
warpage exceeds the service limit.
Replace the brake disk if the wheel bearings are
normal.

BRAKE
BRAKE
BRAKE STOP
STOP
STOP SWITCH
SWITCH
SWITCH
FRONT MASTER CYLINDER
REMOVAL
Drain the brake fluid. (16-3)
Disconnect the the front brake stop switch wire.
Remove the brake hose oil bolt and washers.

Brake fluid causes damage to the painted, plastic or

rubber parts. Do not spill fluid on these parts.
If contaminated, gently wipe off the fluid with a piece
of cloth or wash in water. Close hose joints properly to
prevent leakage of brake fluid.

Remove the bolts from the master cylinder holder and

remove the master cylinder assembly.

16-9
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

DISASSEMBLY
Remove the handle lever bolt/nut and RH. handle lever
assembly.

Loosen the screw and remove the front brake stop

STOP
STOP
STOP SWITCH
SWITCH
SWITCH switch.

Remove the boot.

BOOT
BOOT
BOOT

Remove the circlip from the master cylinder.

TOOL : SNAP RING PLIERS

Remove the master piston and spring.

Clean the inside of the cylinder and reservoir with

brake fluid.

16-10
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

INSPECTION
MASTER
MASTER
MASTER CYLINDER
MASTER CYLINDER PISTON
CYLINDER PISTON
CYLINDER PISTON
PISTON
Check the piston for abnormal scratches.
Check the primary cup and secondary cup for fatigue
or damage.

Measure the master cylinder piston O. D.

SERVICE LIMIT : 13.866mm

Check the master cylinder for abnormal scratches.

Measure the master cylinder I.D.

SERVICE LIMIT : 14.055mm

ASSEMBLY

MASTER CYLINDER PISTON SET

MASTER CYLINDER CAP

DIAPHRAGM PLATE

DIAPHRAGM

HANDLE LEVER BOLT

MASTER CYLINDER HOLDER

RH. HANDLE LEVER

FR. STOP SWITCH

16-11
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

MASTER CYLINDER
MASTER
MASTER CYLINDER
CYLINDER Coat all parts with clean brake fluid before assembly.

Dip the piston in brake fluid.

Install the spring into the piston.
SPRING
Install the piston assembly into the master cylinder.
SPRING
SPRING
SPRING

PISTON
PISTON
PISTON
PISTON

Install the circlip.

CIRCLIP
CIRCLIP
CIRCLIP
TOOL : SNAP RING PLIERS

Install the boot.

BOOT
BOOT
BOOT

Install the front stop switch and tighten the screw.

Install the RH. handle lever, tighten the bolt and nut.

FRONT
FRONT BRAKE
FRONT BRAKE STOP
BRAKE STOP SWITCH
STOP SWITCH
SWITCH

16-12
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

INSTALLATION
Place the master cylinder assembly on the handlebar.
Install the master cylinder holder with the "UP" mark
facing up.
Tighten the upper bolt first, then the lower bolt.

Install the oil bolt and new washer on brake hose.

Tighten the brake hose oil bolt.
TORQUE : 3.4 kgf·m

Connect the front brake switch wire.

Fill the reservoir to the upper level and bleed the brake
system. (⇨16-5)

REAR MASTER CYLINDER

REMOVAL
Drain the brake fluid. (⇨16-3)
Remove the rear reservoir mounting bolt.
Remove the rear brake hose oil bolt and washers.

Brake fluid causes damage to the painted, plastic or

rubber parts. Do not spill fluid on these parts.
If contaminated, gently wipe off the fluid with a piece
of cloth or wash in water. Close hose joints properly to
prevent leakage of brake fluid.

16-13
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Remove the two main step holder socket bolts and

main step bar assembly.
Unhook the rear brake stop switch spring from the
brake pedal spring.

Remove the 2 master cylinder bolts.

JOINT
JOINT
JOINT PIN
PIN
PIN Remove the joint pin C.
Remove the master cylinder mounting socket bolts and
master cylinder assembly.

DISASSEMBLY
TUBE
TUBE JOINT
TUBE JOINT PIPE
JOINT PIPE
PIPE
Remove the screw and tube joint pipe from the master
cylinder.

SCREW
SCREW
SCREW

Remove the boot.

SNAP RING
SNAP
SNAP RING PLIERS
RING PLIERS
PLIERS
BOOT
BOOT
BOOT
BOOT Remove the internal circlip using the tool from the
master cylinder body.
TOOL : SNAP RING PLIERS

SNAP
SNAP RING
SNAP RING
RING

16-14
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

MASTER CYLINDER
MASTER
MASTER CYLINDER
CYLINDER SPRING Remove the brake rod joint, rear piston and spring.
SPRING
SPRING BRAKE ROD
BRAKE
BRAKE ROD JOINT
ROD JOINT
JOINT
Clean the inside of the cylinder with brake fluid.
REAR
REAR PISTON
REAR PISTON
REAR PISTON
PISTON

REAR
REAR
REAR PISTON
REAR PISTON
PISTON
INSPECTION
Check the piston for abnormal scratches.
Check the primary cup and secondary cup for fatigue
or damage.

Measure the master rear piston O.D.

SERVICE LIMIT : 12.645mm

Check the master cylinder for abnormal scratches.

Measure the master cylinder I.D.

SERVICE LIMIT : 12.755mm

ASSEMBLY

16-15
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

MASTER CYLINDER
MASTER
MASTER CYLINDER
CYLINDER
Coat all parts with clean brake fluid before assembly.

SPRING
SPRING
SPRING
SPRING Dip the piston in brkae fluid.
Install the spring to the secondary cup.
Install the spring/secondary cup and master piston
BRAKE ROD
BRAKE
BRAKE ROD JOINT
ROD JOINT
JOINT
assembly.

PISTON
PISTON

Install the rear brake rod into the master cylinder.

SNAP RING
SNAP
SNAP RING PLIERS
RING PLIERS
PLIERS
BOOT
BOOT
BOOT Install the internal circlip.
TOOL : SNAP RING PLIERS
Install the boot.

SNAP
SNAP RING
SNAP RING
RING

Apply brake fluid to a new O-ring and install it into the

TUBE JOINT
TUBE
TUBE JOINT PIPE
JOINT PIPE
PIPE
O-RING
O-RING
O-RING tube joint pipe.
Install the tube joint pipe into the master cylinder.

Tighten the screw to the specified torque.

TUBE JOINT
TUBE
TUBE JOINT PIPE
JOINT PIPE
PIPE

SCREW
SCREW
SCREW

16-16
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

INSTALLATION
JOINT
JOINT PIN
JOINT PIN C
PIN C
C
Place the master cylinder into the main step holder,
install the master cylinder mounting socket bolts.
Connect the brake pedal to the brake rod joint.
Install the joint pin C and secure it with a new cotter
pin.

Hook the stop switch spring to the brake pedal spring.

Install the main step bar assembly to the frame, tighten
the socket bolts to the specified torque.
TORQUE : 3.5kgf·m
Tighten the master cylinder mounting socket bolts.

Install the brake hose with the oil bolt and new
washers.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4 kgf·m
Tighten the rear reserve mounting bolt.

Fill the brake fluid to the upper level and bleed the
brake system. (⇨16-5)
Adjust the brake pedal free-play. (⇨2-11)

FRONT
FRONT RH.
FRONT RH. BRAKE
RH. BRAKE CALIPER
BRAKE CALIPER
CALIPER FRONT BRAKE CALIPER
FRONT
FRONT LH.
FRONT LH. BRAKE
LH. BRAKE CALIPER
BRAKE CALIPER
CALIPER
REMOVAL
Drain the brake fluid from RH/LH brake caliper.
(⇨16-3)
Remove the oil bolt and oil bolt washer.
Remove the speedometer cable clamp.
Remove the caliper mounting bolts, caliper and the
brake pads. (⇨16-6)

OIL
OIL BOLT
OIL BOLT
BOLT

16-17
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Avoid spilling fluid on painted, plastic, or rubber

parts.
Keep oil off the brake disk or pad, because the
contaminated brake disk or pads reduce the braking
performance if contaminated.
Replace the pad with a new one and clean the disk.

DISASSEMBLY
Remove the pad spring, slide pin, caliper bracket and
boot from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
Install corrugated cardboard or soft wood sheet
between the pistons.
Apply small squirts of air pressure to the brake hose
assembly part to remove the pistons from the caliper.

Do not use high pressure air or bring the air gun too
close.
PISTON SEAL
PISTON
PISTON SEAL
SEAL Do not touch the inside of caliper.
Remove the piston seal and dust seal.

Be careful not to damage the caliper inside.

Clean the caliper inside and piston with brake fluid.

DUST
DUST SEAL
DUST SEAL
SEAL

INSPECTION
Check the caliper friction surface for damage or
scratches.

Measure the caliper I. D.

SERVICE LIMIT : 25.07mm

16-18
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Check the appearance of piston for damage or

scratches.

Measure the piston O. D.

SERVICE LIMIT : 24.87mm

ASSEMBLY
Clean the piston seal and dust seal with brake fluid,
install it into caliper groove.

When install the piston to the caliper the groove side of

piston have to toward pad.
PISTION SEAL
PISTION
PISTION SEAL
SEAL

CALIPER PISTON
CALIPER
CALIPER PISTON
PISTON

DUST SEAL
DUST
DUST SEAL
SEAL

Coat the sillicon grease on the boot.

Install the boot to the caliper groove.
Install the pad spring to the caliper.
Install the caliper pin bolt then install the caliper
bracket to caliper.
Install the brake pad to brake caliper.

16-19
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

INSTALLATION
Install the front caliper to front fork.
Tighten the caliper mounting bolts to the specified
torque.
TORQUE : 3.0kgf·m
Install the brake hose to the caliper body with two new
2 oil bolts washers and oil bolts.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4kgf·m (34 N·m)
Fill the brake fluid to upper level, bleed the brake
system. (16-5)

REAR BRAKE CALIPER

REMOVAL
Drain the brake fluid. (16-3)

Remove the oil bolt and oil washer.

OIL
OIL
OIL BOLTS
BOLTS
BOLTS

Remove the rear caliper bracket bolts, caliper and the

brake pads. (16-7)

DISASSEMBLY
Remove the spring, slide pin, caliper bracket and boot
from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.

16-20
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Wrap the caliper with piece of cloth to avoid piston

and brake fluid leakage and facing the piston
downward.
Remove the piston from the caliper while blowing the
low piessure air in the opening of the brake hose.

Do not use high perssure air or bring the airgun too

close.
Do not touch the inside of caliper.
AIR
AIR GUN
AIR GUN
GUN

Remove the piston seal and dust seal.

DUST
DUST SEAL
DUST SEAL
SEAL
Clean the caliper inside and piston with brake fluid.

PISTON SEAL
PISTON
PISTON SEAL
SEAL

INSPECTION
Check the appreance of caliper for damage or
scratches..
Measure the caliper I. D.
SERVICE LIMIT : 25.070mm
Check the appreance of pistons for damage or
scratches.
Measure the piston O. D.
SERVICE LIMIT : 24.870mm

ASSEMBLY
Clean the piston seal, dust seal with brake fluid install
it into caliper groove.

16-21
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

CALIPER
CALIPER
CALIPER
CALIPER PISTON SEAL
PISTON
PISTON SEAL
SEAL
Install the piston in the caliper with groove side of the
piston facing the pad.

DUST
DUST
DUST SEAL
SEAL
SEAL
PISTON
PISTON
PISTON

BOOT
BOOT
BOOT
Coat the silicone grease on the boot.
BOOT
Install the boot to the caliper groove.
Install the pad spring to the caliper.
Install the caliper pin bolt and the caliper bracket to
caliper.
Install the brake pad to brake caliper.

PAD SPRING
PAD
PAD SPRING
SPRING CALIPER BRACKET
CALIPER
CALIPER BRACKET
BRACKET

INSTALLATION
Install the rear caliper to rear caliper bracket.
Tighten the caliper mounting bolts to the specified
torque.
TORQUE : 3.0kgf·m
Install the brake hose to the caliper body with two new
2 oil bolts washers and oil bolts.
Tighten the oil bolt to the specified torque.
TORQUE : 3.4kgf·m (34 N·m)
Fill the brake fluid to upper level, bleed the brake
system. (16-5)

BRAKE
BRAKE PEDAL
BRAKE PEDAL
BRAKE PEDAL
PEDAL
BRAKE PEDAL
REMOVAL
Remove the main step holder mounting socket bolts
and main stepbar assembly.

Unhook the stop switch spring from the brake pedal

spring.

16-22
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC BRAKE

Strech and pull out the brake pedal joint cotter pin and
COTTER PIN
COTTER
COTTER PIN
PIN remove the joint pin C.
Remove the brake pedal spring from the brake pedal.
Remove the external cir-clip, washer and brake pedal.

INSTALLATION
Install the brake pedal to main step holder and
assemble the washer and external cir-clip.
Connect the brake pedal to the brake rod joint.
Install the joint pin C and secure it with a new cotter
pin.

Hook the stop switch spring to the brake pedal spring.

Install and tighten the main step bar socket bolts into
the frame to specified torque.

REAR
REAR
REAR BRAKE
BRAKE PEDAL
BRAKE PEDAL
PEDAL

16-23
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

BATTERY
ECU

FUSE BOX
REGULATOR/RECTIFIER

IGNITION COIL AC GENERATOR

Y G
Y R/W
ß/„Ø
Y MAIN
SWITCH FUSE
(30A)
(30A) B (CABLE)
R
AC GENERATOR

REGULATOR FUSE
RECTIFIER (15A) BATTERY
„Ł¯˝‚fi
(15A)

LOAD
”˛˙ˇ ECU B......Black
Y.......Yellow
G......Green
R......Red
W..... White
Lg.....Light green

17-0
Downloaded from www.Manualslib.com manuals search engine
 17. BATTERY/CHARGING SYSTEM

CHARGING DIAGRAM· ······ 17-0 CHARGING SYSTEM INSPECTION· 17-4

····· 17-1
SERVICE INFORMATION· REGULATOR/RECTIFIER ···· 17-5
TROUBLESHOOTING· ······ 17-2 A.C. GENERATOR CHARGING COIL
BATTERY ··········· 17-3 INSPECTION ········ 17-6

SERVICE INFORMATION

·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
·Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
·If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.

·This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
·When charging the battery, remove the battery from the frame.
·There is the possibility of damaging the regulator/rectifier, etc. If the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.

If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that
the battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss
in battery strength.
It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
For information on generator disassembly, refer to section 8.

SPECIFICATIONS
17
ITEM STANDARD VALUES
Capacity 12V - 10AH (MF)
BATTERY Terminal-to-terminal voltage (When fully charged) 13.0-13.2V
Current leakage Not to exceed 1mA
Charging Coil resistance value ( 20°
C) 0.1-1.5Ω(20° C)
A.C.GENERATOR
rpm at Charging Start 1,350 rpm (Headlight ON)
REGULATOR / Type Thyristor system
RECTIFIER Regulated Voltage 14.5±1.0V / 5,000(rpm)

TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, BATTERY TESTER, SCANNER

17-1
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

TROUBLESHOOTING
No power (Key turned on) Low power (Engine running)
Dead battery. Battery undercharged.
- Low fluid level. Battery is failing.
- Low specific gravity. Charging system failure.
- Charging system failure.
Disconnected battery cable. Intermittent power
Main fuse burned out. Loose battery connection.
Faulty ignition switch. Loose charging system connection.
Loose connection on short circuit in wire harness. Loose starting system connection.
Loose connection or short circuit in ignition system.
Low power (Key turned on) Loose connection or short circuit in lighting system.
Battery undercharged. Loose connection or short circuit in wire harness.
- Low fluid level.
- Low specific gravity. Charging System faulty
Charging system failure. Loose broken or shorted wire or connection.
Loose battery connection.
Faulty regulator rectifier.
Faulty A.C generator..

Charging System faulty

Check the battery current leakage.(⇨16-4) INCORRECT

Check the regulator rectifier.(⇨16-5)
CORRECT CORRECT
·Shorted harness wire.
·Faulty ignition switch.
INCORRECT
Measure the charging voltage.(⇨16-4) OVERCHARGED
·Faulty regulator rectifier.
(15V)
NOT CHARGING (14V)
14 ~ 15V ·Battery is failing

Check the voltage between the battery line and ·Open circuit in wire harness.
ABNORMAL
ground wire of regulator rectifier.(⇨16-5) ·Poorly connected coupler.

NORMAL

Check the resistance of the charging coil at INCORRECT ·Check the charging coil of theA.C
the charging coil line of regulator rectifier generator.(⇨16-6)
coupler.(⇨16-6)
NORMAL
·Poorly connected A.C generator coupler.
CORRECT ABNORMAL
·Faulty charging coil.

Check the regulator rectifier.(⇨16-5) ABNORMAL ·Faulty regulator rectifier.

NORMAL
·Faulty battery.

17-2
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

BATTERY
BATTERY
BATTERY
BATTERY BAND
BAND
BAND
REMOVAL/INSTALLATION
Remove the seat. (⇨13-2)
Remove the battery band.
Disconnect the negative (-) cable and then the positive
(+) cable and remove the battery.
Install the battery in the reverse order of removal with
the proper wiring.

•Connect the positive terminal first and then the

negative cable.

VOLTAGE INSPECTION
Measure the battery voltage using a multi tester.
VOLTAGE:
- Fully charged : 13.0~13.2V
- Under charged : Below 12.3V
TOOL : MULTI-TESTER

•Use a voltmeter that will accurately indicate 0.1V

difference.
•Never open the sealed filler cap.
•When measuring the battery voltage after
charging, leave it for at least 30 minutes, or the
accurate results cannot be obtained because the
battery voltage fluctuates just after charging.
BATTERY CHARGING
Remove the battery.
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the charger negative(-) cable to the battery
negative(-) terminal.

•Quick-charging should only be done in an

emergency ; slow charging is preferred.
•For battery charging ; do not exceed the charging
current and time specified on the battery. Using
excessive current or extending the charging time
may damage the battery.

17-3
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECITION
Turn the ignition switch off and disconnect the
negative battery cable from the battery.
Connect an ampere meter between negative (-)
terminal and ground cable.
With the ignition switch off, check for current leakage.
LEAK CURRENT : Not to exceed 1mA
TOOL : DIGITAL TESTER

•When measuring current using a tester, set it to a high

range, and then bring the range down to an
appropriate level. Current flow higher than the range
AMPERE METER selected may blow out the fuse in the tester.
•While measuring current, do not turn the ignition on.
A sudden surge of current may blow out the fuse in
the tester.
BATTERY ⊖ TERMINAL
If current leakage exceeds the standard value, a shorted
circuit is likely to exist.
CHARGING VOLTAGE INSPECTION

•Be sure that the battery is fully charged before

GROUND CABLE performing this test. The amount of current flow may
change abruptly if not sufficiently charged. Use a
battery whose specific gravity is 13.0 ~ 13.2V.
•When the engine is started using the starter motor, a
large amount of current may flow from the battery
temporarily.

After warming up the engine, replace the battery with a

⊖ ⊕
⊕ fully charged battery.
⊖ Connect a tester between the battery terminals.
Connect an ampere meter between the terminals of the
main fuse.

•If the probes are connected in reverse order, the

registered current flow direction when charging and
DIGITAL TESTER discharging the battery will be reversed as well.

AMPERE METER Turn the headlight ON and start the engine.

Gradually increase the engine speed and measure the
charging voltage at the specified rpm.

CONTROL VOLTAGE : 14.5±1.0V / 5,000rpm

TOOL : DIGITAL TESTER, AMPERE METER, SCANNER
MAIN
FUSE
TERMINALS
•Do not disconnect the battery or any cable in the
charging system without first switching off the
MAIN FUSE
ignition switch.
•Failure to follow this precaution can damage the
tester or electrical components.
17-4
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

REGULATOR RECTIFIER
REGULATOR
REGULATOR RECTIFIER
RECTIFIER REGULATOR/RECTIFIER
HARNESS SIDE CIRCUIT INSPECTION
Remove the seat. (⇨13-2)
Remove the LH. side cover. (⇨13-2)
Disconnect the regulator/rectifier coupler.
Inspect the wiring circuits at each terminal of the wire
harness side.

Inspection Items

ITEM INSPECTION
BATTERY Check that there is voltage between
WIRE(RED) battery line (+) and ground line.
GROUND Check continuity between ground and
WIRE(GREEN) frame.
Check that the resistance of the coil is
CHARGING within the specified range. (0.1~1.5Ω)
COIL WIRE
(YELLOW) Check not continuity between coil and
frame.
VOLTAGE Check that there is battery voltage
DETECTION between voltage detection line (+) and
LINE (BLACK) ground wire the ignition is ON.

REGULATOR / RECTIFIER UNIT INSPECTION

If all inspections on the wire harness side are normal
and there are no loose connections at the regulator
rectifier coupler, inspect the regulator rectifier unit by
measuring the resistance between the terminals.

•Resistance value will not be accurate if the probes

touch your fingers.
•Use the following recommended tester.
•Using another manufacturer’s equipment may not
allow you to obtain the specified values.

B
28~36
28~36

Replace the regulator rectifier unit if the resistance

value between the terminals is abnormal.
TOOL : MULTI TESTER
‘ ’ indicate more than 1[MΩ]

17-5
Downloaded from www.Manualslib.com manuals search engine
 BATTERY/CHARGING SYSTEM

REMOVAL/INSTALLATION
Disconnect the regulator/rectifier coupler.
Remove the regulator/rectifier unit mounting bolts and
regulator/rectifier.

Install the reguator/rectifier unit in the reverse order of

removal.

A.C. GENERATOR CHARGING

COIL INSPECTION
Remove the seat. (⇨13-2)
Remove the LH. side cover. (⇨13-2)
Disconnect the A.C generator cord coupler.
Measure the resistance between the yellow leads.
RESISTANCE VALUE : 0.1~1.5Ω (20℃)
If the resistance values are much larger than the
specified value, or if there is continuity between
terminals and earth terminals, replace the stator with a
new one.

• Install in the reverse order of removal.

•This test is done with the starter mounted to the

engine.

17-6
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 IGNITION SYSTEM

BATTERY
ECU

FUSE BOX

REGULATOR/RECTIFIER

IGNITION COIL AC GENERATOR

18-0
Downloaded from www.Manualslib.com manuals search engine
 18. IGNITION SYSTEM

······18-0
IGNITION DIAGRAM· · 18-3
CRANKPOSITIONSENSORINSPECTION·
···· 18-1
SERVICE INFORMATION· ·· 18-4
IGNITION COIL INSPECTION·
···· · 18-2
TROUBLESHOOTING· SIDE STAND SWITCH ······ 18-5

SERVICE INFORMATION
GENERAL SAFETY
Inspect the ignition system in proper sequence based on the troubleshooting.
Dropping or giving a shock to the ECU unit causes a trouble.
There should be battery voltage with the ignition and engine stop switched ON. Turn the main switch
OFF while serving.
TRANSISTOR ignition system is used and it can not be adjusted.
Couplers are connected to other couplers which have same colour.
Coil standard resistance may not be obtained due to the different measuring circumatances.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (⇨chapter 21-1 )

SPECIFICATIONS
Item Standard
Primary Coil 0.73±0.08Ω, 23℃±5℃
Ignition coil
resistance Secondary Without the spark
20℃(68℉) Coil plug cap (15KΩ)

Crank position sensor resistance 20℃(68℉) 80-150Ω,20℃

Ignition timing 100RPM)

IDLE (1,600±1 BTDC 18℃

18
TOOLS
DIGITAL TESTER
PVA MULTI-TESTER

18-1
Downloaded from www.Manualslib.com manuals search engine
 IGNITION SYSTEM

TROUBLESHOOTING
No spark at plug. (TOOL : PVA MUITI TESTER)
UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)

1. The multitester impedance is too low.

2. Cranking speed is too slow.
- Battery is undercharged
IGNITION COIL PRIMARY VOLTAGE

3. The sample timing of the tester and measured pulse were not
Low peak voltage. synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in ignition system.
5. Faulty ignition coil.
6. Faulty ECU unit (in case when above No. 1~5 are normal).

1. Incorrect peak voltage adaptor connections.

2. Faulty ignition switch.
3. Loose or poorly connected ECU unit connector.
No peak voltage.
4. Open circuit or poor connection in ground cord of the ECU unit.
5. Faulty peak voltage adaptor.
6. Faulty ECUunit (in case when above No. 1~6 are normal).

Peak voltage is normal, but no spark 1. Faulty spark plug or leaking ignition coil secondary current ampere.
jumps at plug. 2. Faulty ignition coil.

1. The multitester impedance is too low.

CRANK POSITION SENSOR

2. Cranking speed is too slow.

- Battery is undercharged (or operating force of the kick starter is
weak).
Low peak voltage.
3. The sample timing of the tester and measured pulse were not
synchronized.(System is normal if measured voltage is over the
standard voltage at least once.)
4. Faulty pulse generator (in case when above No. 1~3 are normal).

1. Faulty peak voltage adaptor.

No peak voltage.
2. Faulty crank position sensor

18-2
Downloaded from www.Manualslib.com manuals search engine
 IGNITION SYSTEM
Inspection Items
ITEM INSPECTION
MAIN SWITCH Check the battery voltage between main switch wire (black) and ground wire when the ignition is
ON
CRANK POSITION SENSOR Check the resistance of coil (between blue / yellow and green) is within the specified range.
( 80~150Ω, 20℃)
IGNITION COIL (PRIMARY COIL) Check the resistance of coil (between black / yellow and green) is within the specified range.
( 0.73~0.08Ω, 23℃±5℃)
GROUND WIRE Check continuity between ground and frame.
If measured data is out of standard, and there is no spark at plug, check the ignition coil by using a tester.
TOOL : DIGITAL TESTER

CRANK POSITION SENSOR INSPECTION

A.C. GENERATOR
A.C.
A.C. GENERATOR COUPLER
GENERATOR COUPLER
COUPLER
RESISTANCE MEASUREMENT
Remove the seat. (⇨13-2)
Remove the LH. side cover (⇨13-2)
Disconnect the A.C generator 4P coupler and
blue/yellow wire connector.
Measure the resistance between the green and
blue/yellow.

Ω (20℃
STANDARD VALUE : 80-150Ω ℃)

PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire
connector.
Connect the blue/yellow wire terminal to the PVA
tester (+) terminal.
Connect the PVA tester (-) terminal to the green wire
terminal or no painting area (ground)
Crank the engine with the starter motor and measure
the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V
TOOL : PVA MULTI TESTER
Install in the reverse order of removal.

18-3
Downloaded from www.Manualslib.com manuals search engine
 IGNITION SYSTEM

IGNITION
IGNITION COIL
IGNITION COIL
COIL
IGNITION COIL INSPECTION
Disconnect the ignition coil coupler.

PULL
PULL
PULL
Since the resistance value of the primary coil is small, it is
too diffcult to judgment even if the problem happen from
PUSH
PUSH
PUSH
PUSH the short circuit.

PRIMARY COIL
Measure the resistance between the two terminals of the
ignition primary coil.
If the resistance value is within the specified range the
coil is good.
If resistance is (infinite), replace the coil with a new one.
±0.08Ω
STANDARD VALUE : (Resistance) 0.73± Ω,
23℃±0.5℃(Voltage) over 100V

SECONDARY COIL
With the spark plug cap on, measure the resistance between
the primary coil terminal and the spark plug cap.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.

KΩ
REFERENCE VALUE : 15K

Dont’t measure the secondary coil voltage of ignition coil

18-4
Downloaded from www.Manualslib.com manuals search engine
 IGNITION SYSTEM

REPLACEMENT
Remove the high-tension cord from the plug, remove
the plug cap.
Remove the primary wire from the ignition coil.
Loosen the ignition coil mounting bolt securing the
frame, remove the ignition coil.

Install in the reverse order of removal.

SIDE STAND SWITCH

REMOVAL
Remove the RH side covver.
Remove the side stand switch couper connected with
main wire harness

Remove the side stand switch mounting screws and

remove the cord clamp and side stand switch.

INSPECTION
Check the following terminals.
ITEM
TERMINALS COLOR STANDARD
SIDE STAND SWITCH

ON PUSH BLACK/WHITE AND

(Side stand THE NORMAL IF THERE
SHAFT erected) SHAFT GREEN TERMINAL IS CONTINUITY
PUSH THE SHAFT
OFF RELEASE BLACK/WHITE AND
(Side stand THE NORMAL IF THERE
GREEN TERMINAL
pull back) SHAFT RELEASE THE SHAFT IS NO CONTINUITY

Install in the reverse order of removal.

18-5
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

STARTER
STARTER MAGNETIC
SWITCH B(CABLE) SWITCH
Y/R
/Y G
ÇOߗ
STARTER
FUSE MOTOR
HQUaI
G/W
B/ G/Y
B/W B/W B/W

Lg/R
SIDE STAND
MAIN B(CABLE) SWITCH
SWITCH

R/W
‫۽‬Oљ R

FUSE
GEAR
HSPaI
G POSITION
SWITCH

B......Black
NEUTRAL BATTERY Y.......Yellow
LAMP (12A 10AH) G......Green
R......Red
W..... White
B Lg/R
Lg.....Light green

19-0
Downloaded from www.Manualslib.com manuals search engine
 19. ELECTRIC STARTER

····
STARTING DIAGRAM· 19-0
STARTER MOTOR ······ 19-3
···· 19-1
SERVICE INFORMATION·
STARTER MAGNETIC SWITCH · 19-6
TROUBLESHOOTING ····· 19-2

SERVICE INFORMATION
GENERAL SAFETY

·Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.

The starter motor can be maintained without removing the engine from the vehicle.
A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
may be damaged.

SPECIFICATION Unit : mm
ITEM STANDARD VALUE SERVICE LIMIT
STARTER MOTOR BRUSH LENGTH 10.2mm 5.0mm

TOOLS
MULTI TESTER
VERNIER CALIPER
SCANNER

19

19-1
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

TROUBLESHOOTING
Starter motor will not turn.

Check for a blown out main fuse before servicing.

Make sure the battery is fully charged and in good condition.
Connect the starter motor (+) terminal to the
With the ignition switch“ON”
, check for a battery positive terminal. (Because a large
“CLICK” sound from starter magnetic “CLICK” heard amount of current flows, do not use thin
switch. (⇨19-6) wires).

Starter motor does not turn.

“CLICK” not heard Starter motor turns.

Faulty starter motor.

Loose or disconnected wire or cable.
Disconnect starter magnetic switch coupler,
Faulty starter magnetic switch.
and check the starter magnetic switch coil
NO CONTINUITY. Faulty neutral switch.
ground wire. (⇨19-6)
Faulty clutch switch.
Loose or poor contact at connector.
CONTINUITY.
Open circuit in wire harness.

Connect the starter magnetic switch coupler.

Measure the starter magnetic voltage at the NO VOLTAGE. Faulty ignition switch.
starter magnetic switch coupler. (⇨19-6)
Loose or poor contact at connector.
VOLTAGE MEASURED Open circuit in wire harness.

Check the starter magnetic switch operation. NORMAL Loose or poor contact at starter magnetic
(⇨19-6) switch coupler.
ABNORMAL Faulty starter magnetic switch.

Starter motor turns engine slowly.

Low battery voltage. Starter motor turns, but engine does not turn
Poorly connected battery terminal cable. Starter motor is running backwards.
Poorly connected starter motor cable. - Brushes assembled improperly.
Faulty starter motor. - Case assembled improperly.
- Terminals connected improperly.
Poorly connected battery ground cable.
Faulty starter clutch.
Damaged or worn brush.
Damaged or faulty starter drive gear
Starter motor and engine turns, but engine does
not start. Starter magnetic switch "Clicks", but engine
does not turn over
Faulty ignition system.
Crankshaft does not turn due to engine problems.
Engine problems.
Excessive reduction gear friction.

19-2
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

STARTER MOTOR
REMOVAL
With the ignition switch turned to "OFF", remove the
negative cable at the battery before servicing the starter
motor.
Remove the rubber cap.
Remove the nut and starter motor cable from the starter
motor.

Remove the starter motor mounting bolts and ground

cable.

•Always turn the ignition switch OFF before

servicing the starter motor. The motor could
suddenly start, causing serious injury.

DISASSEMBLY
FLANGE
FLANGE BOLTS
FLANGE BOLTS
BOLTS
Remove the following.
- O-ring
- Starter motor case bolts / spring washers
- Front cover
- Seal ring
- Lock washer
- Washer
- Cir-clip
- Rear cover ass’y
- 2 pcs washer
- Amature

INSPECTION
Check the bushing in the rear cover for wear or
damage.
Check the oil seal and bushing in the front cover for
wear or damage.

19-3
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

Check the commutator bars of the armature for

discoloration.
Discoloration of the commutator bars.→ Replace with
a new one.

Check for continuity between pairs of commutator

bars.
There should be continuity.

Check for continuity between each commtator bar

and armature shaft.
There should be no continuity.

Check for continuity between the insulated brush

and cable terminal.
There should be continuity.

19-4
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

Check for continuity between the cable terminal

and the case.
There should be no continuity.

Inspect the brushes for damage and measure the

brush length.
SERVICE LIMIT : 5 mm

Install the following :

- New O-ring
- Insulators
- Washer
- Washer nut
Install the brushes into the brush holder.
Install the brush holder into the motor case,
aligning the holder tab with the motor case groove.
Install the armature in the motor case, while
pushing in the brushes into the brush holder.

When installing the armature into the motor case,

hold the armature tightly to keep the magnet of the
case from pulling the armature against it.

•The coil may be damaged if the magnet pulls the

armature against the case.

Install the two washers.

Install a new seal ring onto the motor case.
Apply thin coat of grease to the armature shaft end.
Install the rear cover, aligning its mark with the
motor case mark.

19-5
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

INSTALLATION
Coat a new O-ring with oil and install it into the starter
motor groove.
Install the starter motor into the crankcase.

Install the ground cable and mounting bolts, and

tighten the bolts securely.
Install the clutch wire holder.

Install the starter motor cable, then tighten the terminal

nut securely.
Install the rubber cap securely.

STARTER MAGNETIC SWITCH

MAGNETIC
MAGNETIC
MAGNETIC SWITCH
SWITCH
SWITCH REMOVAL
Remove the seat. (⇨13-2)
Remove the RH. side cover. (13-2)
Disconnect the battery ⊕ wire cable from the starter
magnetic switch terminal.
Disconnect the starter motor cable from the starter
magnetic switch terrminal.
Disconnect the Yellow/Red and Green/Yellow
connector from the wire harness.
Remove the starter magnetic switch from the bracket
of the frame.

OPERATION INSPECTION
Shift the transmission into neutral.
Turn the ignition switch to "ON", and push the starter
switch button.

The coil is normal if the starter magnetic switch clicks.

If you don’t hear the switch "CLICK", inspect the
magnetic switch using the procedure below.

19-6
Downloaded from www.Manualslib.com manuals search engine
 ELECTRIC STARTER

STARTER MAGNETIC SWITCH

VOLTAGE INSPECTION
Connect the starter magnetic switch connector.
Shift the transmission into neutral.

Measure the voltage between the Yellow/Red wire

terminal(+) and ground (-).
If the battery voltage appears only when the starter
switch is pushed with the ignition switch to "ON", it is
normal.

CONTINUITY INSPECTION
Disconnect the wire connector of the magnetic switch.
Connect the positive wire to the yellow/red wire
terminal and the negative wire to the green/yellow wire
terminal.
There should be continuity.

INSTALLATION
Install in the reverse order of removal.

19-7
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/METER/SWITCHES

WINKER RELAY

HEADLIGHT RELAY

FUSE BOX
ECU

HORN

SPEEDOMETER

HEADLIGHT

BATTERY

HORN

20-0
Downloaded from www.Manualslib.com manuals search engine
 20. LIGHTS/SWITCHES/HORN

SYSTEM LOCATION········20-0 MAIN SWITCH ··········· 20-5

SERVICE INFORMATION·····20-1 HANDLEBAR SWITCHES ···· 20-6
TROUBLESHOOTING ······ 20-1 FRONT/REAR STOP SWITCH · 20-7
HEADLIGHT ············· 20-2 GEAR CHANGE SWITCH···· 20-8
FRONT/REAR WINKER ····· 20-3 HORN ················· 20-8
STOP/TAIL LIGHT ········· 20-3 WINKER RELAY ·········· 20-8
COMBINATION METER ····· 20-4

SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.
The following color codes are used throughout this section.
B = Black Y = Yellow L = Blue G = Green
R = Red W = White Br = Brown O = Orange
Sb = Sky Blue Lg = Light Green P = Pink V = Violet
Gr = Gray

TROUBLESHOOTING
Light not turned on when the main switch is ON Fuel meter indicator malfunctioning
Faulty light bulb Coupler separated.
Faulty switch Harness disconnected.
Faulty or disconnected wiring Float operation malfuction.
Fuse cut Fuel unit damaged.
Battery discharged
Fuel meter needle unstable
Dim headlight Coupler loose.
Battery discharged Fuel unit damaged.
Wiring and switch resistance high Meter damaged.
20
Headlight Hi-Low bean cannot be charged
Faulty light bulb
Faulty dimmer switch

20-1
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

HEADLIGHT
BULB REPLACEMENT

Loosen the flange bolt secured front cowl stay.

Remove the headlight, winker, speedometer coupler.

FLANGE
FLANGE
FLANGE BOLT
BOLT
BOLT

Remove the headlight dust cover.

HEAD
HEAD
HEAD LIGHT
LIGHT
LIGHT DUST
DUST
DUST COVER
COVER
COVER

Push the headlight retainer and remove the bulb.

If you touch the bulb with your bare hands, clean it

with a cloth moistened with denatured alcohol to
prevent early bulb failure.
Avoid touching Halogen headlight bulb. Finger
prints can create hot sport that cause a bulb to
break.
Install in the reverse order of removal

FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT HEADLIGHT
HEADLIGHT
HEADLIGHT CASE
CASE
CASE
HEADLIGHT CASE REMOVAL/INSTALLATION
Remove
- Center cowl
- Side cowl RH/CH
- Front cowl stay
- Inner panal
Remove the headlight case mounting bolts and
headlight case from the headlight stay.
Disconnect the all cords from the wiring.
Remove the headlight case.
Install in the reverse order of removal.

20-2
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

FRONT/REAR WINKER
BULB RREPLACEMENT
Remove the screw and winker lens.

FRONT
FRONT
FRONT WINKER
WINKER
WINKER

FRONT
FRONT WINKER While pushing the bulb, turn the bulb
FRONT WINKER
WINKER REAR
REAR
REAR WINKER
WINKER
WINKER counterclockwise to remove it and replace with a new
one.
Install the winker lens in the reverse order of removal.

STOP/TAIL LIGHT
REAR
REAR WINKER
REAR WINKER
WINKER
INSPECTION
Turn the ignition switch to "ON", and check the tail
light operation.
Check that the stop/tail light unit light on with the front
brake lever and/or rear brake pedal applied.
When ever any one does not turn on, replace the
stop/tail light bulb.

STOP/TAIL
STOP/TAIL LIGHT
STOP/TAIL LIGHT
LIGHT

BULB REPLACEMENT
Remove the screws and tail light lens.
Slightly press down on the bulb and turn it
counterclockwise.
Replace with a new bulb.

Install in the reverse order of removal.

20-3
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

COMBINATION METER
REMOVAL
Remove the side RH/LH cowl.
Rempve the front cowl.

Remove the inner pannel.

SUB PANNEL
SUB
SUB PANNEL
PANNEL Loosen the speedometer cable nut and remove the
cable from the meter.
COMBINATION
COMBINATION METER
COMBINATION METER
METER
Disconnect combination meter connect.

INNER
INNER PANNEL
INNER PANNEL
PANNEL

Loosen the combination meter mounting screws,

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER remove the combination meter.

INSTALLATION
Install in the reverse order of removal.

20-4
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

After installing, check to see if the each switch is

working properly.
connect the wire and cable accurately.

MAIN SWITCH
REMOVAL
Remove the main seat
Remove the fuel tank
Remove the main switcs coupler

HAZARD
HAZARD
HAZARD STARTER
STARTER
STARTER SWITCH
SWITCH
SWITCH COUPLER
COUPLER
COUPLER

WINKER.
WINKER. DIMMER
WINKER. DIMMER
WINKER. DIMMER
DIMMER
SWITCH
SWITCH
SWITCH COUPLER
COUPLER
COUPLER

MAIN
MAIN
MAIN SWITCH
SWITCH COUPLER
SWITCH COUPLER
COUPLER

INSPECTION
MAIN
MAIN SWITCH
MAIN SWITCH COUPLER
SWITCH COUPLER
COUPLER
Check for continuity between the wire terminals of the
main switch connector in each switch position.
Continuity should exist between the color coded wires
as follows:

MAIN SWITCH
BAT1 BAT2 KEY
ON KEY ON
OFF KEY OFF
LOCK KEY OFF/LOCK
COLOR R/W B -

20-5
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

HAZARD
HAZARD
HAZARD STARTER
STARTER
STARTER SWITCH
SWITCH
SWITCH COUPLER
COUPLER
COUPLER HANDLEBAR SWITCHES
Check for continuity between the wire terminals of the
handlebar switch connector.
Continuity should exist between the color coded wire
terminals as follows:

STARTER SWITCH
HEADLIGHT
HEADLIGHT SWITCH
HEADLIGHT SWITCH
SWITCH
ST 1 BAT 2
FREE

PUSH

COLOR Y/R B

HEADLIGHT SWITCH
W R L
OFF

STARTER
STARTER
STARTER SWITCH
SWITCH
SWITCH P

WINKER.DIMMER
WINKER.DIMMER SWITCH
WINKER.DIMMER SWITCH COUPLER
SWITCH COUPLER
COUPLER COLOR V Br Br/L

WINKER SWITCH
W R L
R
N
L
COLOR Gr SB O

WINKER
WINKER SWITCH
WINKER SWITCH
WINKER SWITCH
SWITCH
HORN SWITCH
HO BAT 2
FREE

PUSH

COLOR LG B

HORN
HORN SWITCH
HORN SWITCH
SWITCH
SWITCH

20-6
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

DIMMER SWITCH
PASSING
PASSING
PASSING SWITCH
SWITCH
SWITCH
BAT3 HI LO
Hi

(N)
Lo
COLOR B/W L W

PASSING SWITCH
BAT2 HI
DIMMER
DIMMER SWITCH
DIMMER SWITCH
SWITCH
Hi

COLOR B L

ASSEMBLY
Install in the reverse order of removal.

FRONT/REAR STOP SWITCH

FRONT
Disconnect the front stop switch connectors and check
for continuity between the terminals.

There should be continuity with the brake lever

applied, and there should be no continuity with the
brake lever is released.

BRAKE LEVER
BRAKE
BRAKE LEVER
LEVER STOP
STOP
STOP SWITCH
SWITCH
SWITCH

REAR
STOP
STOP
STOP SWITCH
SWITCH
SWITCH COUPLER
COUPLER
COUPLER
Remove the seat (⇨13-2)
Remove the RH. side cover. (⇨13-2)
Disconnect the rear stop switch connector and check
for continuity between the terminals.

There should be continuity with the brake pedal

applied, and there should be no continuity with the
brake pedal is released.

REAR
REAR BRAKE
REAR BRAKE PEDAL
BRAKE PEDAL
PEDAL

20-7
Downloaded from www.Manualslib.com manuals search engine
 LIGHTS/SWITCHES/HORN

GEAR CHANGE SWITCH

Remove the seat. (13-2)
Remove the LH. side cover. (13-2)
Disconnect the neutral switch connector from the
switch.
Shift the transmission into neutral and check for
continuity between the green/white wire terminal and
ground.
There should be continuity with the transmission is in
neutral, and no continuity when the transmission is into
gear.

HORN
Disconnect the wire connectors from the horn.

Connect the 12V battery to the horn terminal directly.

The horn is normal if it sounds when the 12V battery is
connected acress the horn terminals.

WINKER RELAY
Remove the rear seat. (⇨13-2)
Check the following:
- Battery condition
- Burned bulbs
- Burned fuse
- Main switch and winker switch function
- Loose connectors

If the above items are all normal, check the following:

1. Short the Black and Gray terminals of the winker relay
connector with a jumper wire.

Start the engine and check the winker light by

turning the switch to ON.

Light comes on Light does not come on

•Broken wire harness

•Faulty winker relay

•Poor connection of the connector

20-8
Downloaded from www.Manualslib.com manuals search engine
 21. TROUBLESHOOTING

ENGINE WON’T START

OR IS HARD TO START ····· 21-1 ········ 21-4
POOR HANDLING·
ENGINE LACKS POWER· ····· 21-2 POOR FRONT/REAR SUSPENSION
POOR PERFORMANCE PERFORMANCE········· 21-5
···· 21-3
(AT LOW AND IDLE SPEED)· ··········· 21-5
FUEL GAUGE·
POOR PERFORMANCE
········ 21-4
(AT HIGH SPEED)·

ENGINE WON’T START OR IS HARD TO START

INSPECTION CAUSE OF TROUBLE
1. Check fuel flow to carburetor. Fuel not supplied Fuel tank empty.
to the carburetor Clogged fuel tube or fuel filter.
Fuel is supplied Sticking float valve.
Clogged fuel tank cap hole.

2. Check the spark plug. Weak or no Faulty spark plug.

spark Contaminated spark plug.
Good spark Disconnected or shorted high tension wires.
Faulty pulse generator.
Faulty main switch.

3. Test cylinder compression. Low compression Low speed of starter crank.

Incorrect valve clearance.
Compression normal Faulty valve seat.
Worn cylinder and piston rings.
Seized valve.
Improper valve timing.

4. Start by following normal Engine starts Improper chock valve operation.

procedure. but stops. Improper chock cable free play.
Carburetor incorrectly adjusted.
Engine does not start.
Improper ignition timing.
Fuel contaminated.
Lean fuel mixture.

5. Remove and inspect spark plug. Wet plug Carburetor flooded.

Throttle valve open.
Dry plug Choke closed. 21
Air cleaner dirty.
6. Close the choke and start
engine again. Rich fuel mixture.

21-1
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING

ENGINE LACKS POWER

INSPECTION CAUSE OF TROUBLE

1. Check tire pressure. Pressure low Punctured tire.

Faulty tire valve.
Pressure normal

2. Raise wheels off ground and

rotate by hands. Wheel don’t rotate Dragged brake.
freely Worn or damaged wheel bearings.
Wheel rotate freely. Lacked wheel bearings lubrication.
D
Axle nut tightened excessively.

3. Accelerate suddenly. Engine speed not Clutch slipping.

changed. Worn clutch disk and plate.
Engine speed increased. Damaged clutch disk and plate.

4. Accelerate lightly. Engine speed Closed carburetor choke.

doesn’t increase. Clogged fuel aisle.
Engine speed increased. Clogged air cleaner.
Clogged fuel tank breather.
Clogged muffler.

5. Check ignition timing by

Incorrect Faulty ECU unit.
using scan.
Faulty pulse generator.
Correct

6. Check valve clearance Incorrect Improper valve adjustment.

Worn valve seat.
Correct

7. Measure the cylinder Low Improper valve operation.

compression. Worn cylinder and piston ring.
Worn cylinder head gasket.
Compression normal Incorrect valve timing.

8. Check the carburetor for Clogged Damaged fuel strainer or screen.

clogging.
Poor carburetor maintenance.

Not clogged

21-2
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING

INSPECTION CAUSE OF TROUBLE

9. Check the spark plug. Contaminated or Lean fuel mixture.
discolored Using spark plug with on incorrect heat
Not contaminated or not
discolored. range.

10. Check oil level. Level low or high Oil level too high.
Oil level too low.
Level normal
Contaminated oil.

11. Remove cylinder head

30mm hole cap, and inspect Valve train lubricated Oil level too low.
lubrication. improperly. Contaminated oil.
Faulty oil pump.
Valve train lubricated properly.
Clogged oil passage.

12. Check for engine overheating. Overheated Excessive carbon build-up in combustion
chamber.
Not overheated. Poor quality fuel being used.
Lean fuel mixture.
Clutch slipping.
13. Accelerate or run at high
Engine knocking Worn piston ring and cylinder.
speed.
Lean fuel mixture.
Engine does not knocking. Excessive carbon build-up in cambustion
chamber.
Incorrect ignition timing.

POOR PERFORMANCE (AT LOW AND IDLE SPEED)

INSPECTION CAUSE OF TROUBLE
1. Check ignition timing and Incorrect
valve clearance. Incorrect valve clearance.
Faulty ECU unit.
Correct Faulty pulse generator.

2. Check inlet pipe for leakage. Leaking Faulty insulator O-ring.

Loose throttlebody.
No leak

3. Check sparks. Weak or intermittent Carbon depasited on spark plug or spark

sparks plug contaminated.
Sparks normal.

21-3
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING

POOR PERFORMANCE(AT HIGH SPEED)

INSPECTION CAUSE OF TROUBLE
1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment.
valve clearance. Faulty ECU unit.
Faulty pulse generator.
Correct.

2. Disconnect fuel tube at Fuel flows No fuel to fuel tank.

carburetor. restricted. Carburetor choke closed.
Clogged fuel tube.
Fuel flows freely. Clogged fuel tank cap hole.
Clogged fuel strainer or screen.

3. Remove the carburetor and Clogged. Damaged fuel strainer or screen.

check for clogged jets.

No clogged.

4. Check valve timing Incorrect. Cam sprocket not installed properly.

Correct.

5. Check valve spring tension. Weak. Faulty valve spring.

POOR HANDLING
INSPECTION CAUSE OF TROUBLE
1. If steering is heavy. Too tight steering top thread.
Damaged steering bearings.

2. If either wheel is wobbling Excessive wheel bearing play.

Bent rim.
Improperly installed wheel hub.
Worn rear fork pivot bush.
Bent frame.
Rear fork pivot adjusting bolt is too tight.

3. If the motorcycle pulled to one side. Front and rear wheels are not aligned.
Bent front fork.
Bent rear fork.

21-4
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING

POOR FRONT/REAR SUSPENSION PERFORMANCE

INSPECTION CAUSE OF TROUBLE
1. Suspension excessively soft. Cushion spring weak.
Overloaded.
Damper oil leaks.
2. Suspension excessively hard. Fork pipe or cushion rod bent.

3. Noise from the suspension. Sliders stuck.

Cushion stopper rubber damaged.

FUEL GAUGE

GAUGE READING INACCURATE (IGNITION SWTICH ON)

INSPECTION CAUSE OF TROUBLE
1. Operate the turn signal to check the Signal continuously Fuse cut.
battery circuit. operates dim or does not Battery weak or totally discharged.
Signal operates satisfactorily. operate at all. Faulty ignition swtich.
Faulty terminal connection.
Wire harness damaged.

2. Remove the fuel level sensor, and Needle moves. 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. Balance coil damaged or shorted.
on the wire harness side.
Needle not moving.

4. Terminal joints loose or faulty Unsatisfactory Terminal loose.

connection. Faulty terminal connection.

Check Balance coil/lead shorted or

damaged.

21-5
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING
GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON)

INSPECTION CAUSE OF TROUBLE

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

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

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

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

5. Check each joint. Unsatisfactory Terminal connection loose or faulty

connection.

Satisfactory Balance coil/lead shorted or

damaged.

21-6
Downloaded from www.Manualslib.com manuals search engine
 MEMO

Downloaded from www.Manualslib.com manuals search engine

 MEMO

Downloaded from www.Manualslib.com manuals search engine

 MEMO

Downloaded from www.Manualslib.com manuals search engine

 MEMO

Downloaded from www.Manualslib.com manuals search engine

 22. WIRING DIAGRAM

Downloaded from www.Manualslib.com manuals search engine

 WIRING DIAGRAM

22

22-1
Downloaded from www.Manualslib.com manuals search engine
Downloaded from www.Manualslib.com manuals search engine
Downloaded from www.Manualslib.com manuals search engine
 22. WIRING DIAGRAM

33 34 35
01 08

09 16 36 37

17 24 38 39 40
25 32

1
2

1
2

1
2

1
2

Downloaded from www.Manualslib.com manuals search engine

 SERVICE MANUAL
2009. 10 PRINTED
COPY PROHIBIT
2009. 10 PUBLICATION

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine