advertisement
SERVICE MANUAL
XS 125
PREFACE
PREFACE
z This shop manual describes the technical feature and servicing procedures for the SANYANG XS125-K. z All information, illustrations, directions and specifications included in this publication are base on
SANYANG XS125-K. z SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever.
SANYANG INDUSTRY CO.,LTD.
SERVICE DIVISION
CONTENTS
CONTENTS
GENERAL INFORMATION ..........................................................................1
INSPECTION/ADJUSTMENT.......................................................................2
LUBRICATION SYSTEM..............................................................................3
ENGINE REMOVAL/INSTALLATION ..........................................................4
CYLINDER HEAD/VALVE............................................................................5
CLUTCH/OIL PUMP/GEAR SHIFT ..............................................................7
CRANK SHAFT/CRANK CASE/TRANSMISSION.......................................9
HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ..........................11
REAR WHEEL/REAR SUSPENSION ..........................................................12
BATTERY/CHARGING SYSTEM .................................................................13
1.GENERAL INFORMATION
SERVICE RULES ...............................1-1
SERVICE RULES:
(1)Use new packings, gaskets,O-rings and cotter pins space and clipes whenever reassembling.
TORQUE VALUES ............................. 1-3
SPECIFICATIONS..............................1-2 TROUBLE SHOOTING ...................... 1-4
(5)Clean all removed parts in or with solvent, and lubricate their sliding surfaces upon disassembly.
(2)When tightening bolts or nuts, begin on center or larger diameter bolts and tighten them in criss- cross pattern in two or more steps if necessary.
(6)Coat or fill parts with specified grease where specified.
(3)Use genuine SANYANG parts and lubricants or those equivalent. When parts are to be reused, they must be inspected carefully to make sure they are not damaged or deteriorated and in good usable condition.
(7)Upon assembling, check every possible part for proper installation and movement or operation.
(4)Use special tool when use of such a tool is
specified.
(8)Work safely and give your work your undivided
attention. Exchange signals as frequently as possi-
ble when a work involves two or more workers. Do
not run the engine unless the shop or working area
is well ventilated.
Symbol Marks:
:Apply engine oil.
:Apply grease.
NOTE: Things must be noticed.
CAUTION: Things that could cause damage to the engine parts.
WARNING: Things that could cause damage to the person or partner.
1-1
1.GENERAL INFORMATION
SPECIFICATIONS
ITEM
DIMENSIONS
FRAME
XS125-K
Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry weight
Type
Front suspension and travel
Rear suspension and travel
Front tire size and tire pressure
Rear tire size and tire pressure
Front brake
Rear brake
2040mm
750mm
1100mm
1280mm
150mm
130kg
Single pipe
Telescope 165mm
Swing arm 63mm
2.75-18 2.25Kg/C ㎡
90/90-18 2.50Kg/C ㎡
Disk type
Drum type
Fuel capacity
Fuel reserve capacity
Caster angle
Front fork oil capacity
14.5 liter
2.0 liter
26 °
160c.c
Type
Cylinder arrangement
Air cooled 4 stroke engine
Single cylinder 15~ inclinde from vertical
Bore & stroke 56.5 x49.5mm
Displacement 124.1c.c.
Compression ratio
Oil capacity
9.0:1
0.80 ~0.95liter (0.9 liter for change)
ENGINE
Intake valve closes 35 ° ABDC
Exhaust valve
Valve clearance
Idle speed
Clutch closes 5 ° ATDC
IN. 0.10mm
EX. 0.15mm
1400±100 rpm
Wet muti-plate type
DRIVE TRAIN
Primary reduction ratio
Gear ratio
Final reduction ratio
Gearshift pattern
Ignition system
Ignition timing
Starting system
4.05
I 2.769
II 1.722
III 1.318
IV 1.1250
V 0.962
2.53
"F" mark
1→N→2→3→4→5
C.D.I. unit
BTDC 15°±20° /1500rpm
Full advance
BTDC 29.5°±2° /4000rpm
Electrical motor and kickstarter
ELECTRICAL
Battery capacity 12N7A-3A(8AH)
Fuse 15A
Spark plug D7RC
Spark plug gap 0.6~0.7mm
1-2
ENGINE
TIGHTEN LOCATION
Starting clutch outer bolt socket
Cylinder stud bolt
Shift drum stopper hex bolt
Gear shift cam hex bolt
Cylinder stud bolt
Cylinder head cap nut
Driven gear hex bolt
Chain adjuster
Oil filter screen cover
Starter motor bolt
Oil pump HEX bolt
Primary drive gear nut
Cylinder head bolt
Cylinder head nut
Fly wheel bolt
Cylinder head cover
Reduction gear cover bolt
L. Crank case cover bolt
R. Crank case cover
Pluse bolt
A.C.G.flange bolt
FRAME
TIGHTEN LOCATION
Front wheel axle nut
Rear wheel axle nut
Rear fork pivot nut
Engine upper hanger nut
Engine front hanger nut
Handle pipe upper holder bolt
Steering stem nut
Front fork nut
Rear shock absorber
Rear brake torque link
Front fork top bridge
Front fork bottom bridge
Final drive sprocket
Seat bolt
Drive sprocket bolt
STANDARD TORQUE
5 mm bolt, nut
6 mm bolt, nut
8 mm bolt, nut
10 mm bolt, nut
12 mm bolt, nut
1.GENERAL INFORMATION
Q'TY
1
1
1
3
4
4
1
1
4
1
2
2
4
2
2
Q'TY
3
10
1
1
1
2
2
1
4
4
2
2
3
8
11
2
1
4
1
4
3
45~60
80~120
180~250
300~400
500~600
THREAD DIA(mm)
8
6
6
6
10
6
6
16
8
8
6
6
8
8
10
6
6
6
6
4
5
THREAD DIA(mm)
22
22
10
8
8
12
8
8
6
14
14
14
10
10
8
5 mm bolt
6 mm bolt
6 mm flange bolt, nut
8 mm flange bolt, nut
10 mm flange bolt, nut
TORQUE(kgf
· m)
1.0~1.50
0.80~1.20
0.80~1.20
0.80~1.20
1.80~2.20
2.80~3.00
1.00~1.50
0.80~1.20
1.50-3.00
0.80~1.20
0.70~1.10
4.00~5.00
2.80~3.20
2.80~3.20
4.00~5.00
0.80~1.20
0.80~1.20
0.80~1.20
0.80~1.20
0.40~0.50
0.40~0.70
TORQUE(kgf
· m)
6.00~8.00
10.00~12.00
8.00~10.00
4.00~5.50
4.50~5.50
1.80~ 2.50
6.00~9.00
4.00~5.00
3.00~4.00
1.50~2.00
4.00~5.50
4.00~5.00
2.70~3.30
2.00~2.50
1.00~1.40
0.35~0.50
0.70~1.10
1.00~1.40
2.40~3.00
3.50~4.50
1-3
1.GENERAL INFORMATION
Torque specifications listed below for respective locations.
TROUBLE SHOOTING
A. HARD START OR CANNOT START symptom inspection adjustment cause enough gasoline supplied for carbuertor spark plug jump normal compression engine dose not fire spark plug dry start engine with choke closed
1-4
loosen carburetor drain screw, check inner side for gasoline no gasoline supplied for carburetor remove spark plug,insert it into plug cap, check the spark by touching engine grid spark weak or no spark test cylinder compression pressure too low or no pressure follow the starter keypoints to re-start engine knocks, but no starting remove and check the spark plug again spark plug wet no gasoline in the tank fuel tube between gasoline tank and carburetor clogged.
float chamber fuel tube clogged gasoline cover air hole clogged fuel filter clogged fuel filter screen clogged gasoline auto fuel cup faulty spark plug faulty fouled spark plug
CDI unit fualty pulse coil faulty high voltage coil cable open or short high voltage coil open or short main switch faulty
A.C.G. faulty
Battery faulty valve too tight, no gap valve seat faulty cylinder, piston, piston ring faulty cylinder gasket leak valve burnt out valve timing faulty crankcase leak when wmpress
Fuel tube clogged muffler clogged auto air cut poor action inlet duct has air in ignition timing incorrect carburetor fuel adjusting screw set faulty air cleaner clogged carburetor fuel level too high auto air cut poor action throttle excessively
B. ROTATION ROUGH (LACKS POWER) symptom inspection adjustment start engine and slightly apply fuel
1.GENERAL INFORMATION
cause engine speed up engine speed can't up adjust ignition timing use timing tester air cleaner clogged fuel tube clogged air hole on the fuel tank cap blocked exhaust tube clogged auto air cut faulty carburetor vacuum diaphragm worn auto fuel cup faulty ignition timing correct ignition timing incorrect faulty CDI unit faulty A.C.Generator valve adjuster poor valve clearance correct compression normal no clogged no fouled discolored oil lever normal valve clearance incorrect compression pressure check pressure to low carburetor block check block remove spark plug dirt and color change check crankcase oil level for too much or dirt oil too much check cylinder head lubrication valve clearance misadjustment valve seat worn fualty valve seat cylinder, piston worn gasket leak valve timing incorrect piston ring worn remove and clean remove dirt spark plug improper heat range spark plug clearance misadjustment too much oil too little oil oil no replacement normal no overheating no knock shock abnormal engine too hot overheated high speed continue working knocks oil tube clogged lean projection from oil pump piston, cylinder worn lean mixture poor gasoline carbon in burning chamber too much ignition timing too early (C.D.I. faulty) clutch slip carbon in burning chamber too much poor gasoline clutch slip lean mixture ignition timing too early(C.D.I.faulty)
1-5
1.GENERAL INFORMATION
C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED) symptom inspection adjustment cause ignition timing adjustment normal adjust OK no air inlet sparking well good abnormal adjust carburetor fuel adjusting screw adjust faulty carburetor gasket has air inlet has air inlet
Remove spark plug,insert to the plugcap, check spark by toucning engine irongrid.
poor sparking no good faulty CDI unit faulty A.C.Generator valve gap adjust faulty lean mixture(loosen screw) rich mixture(tighten screw) insulator plate gasket poor carburetor locking nut loose insulator plate gasket torn vacuum tube crack poor or dirty spark plug faulty CDI unit faulty A.C.Genertor poor ignition coil spark plug cable open or short poor main switch vacuum tube damaged air inlet duct clogged, damaged
1-6
D. ROTATION ROUGH (HIGH SPEED) symptom inspection adjustment ignition timing adjustment
1.GENERAL INFORMATION
cause normal abnormal valve clearance adjustment faulty CDI unit faulty pulse generator normal abnormal poor adjustment valve seat faulty normal no blocked timing correct check auto fuel cup for fuel supplied.
abnormal carburetor blocked blocked valve timing adjusting inspection timing incorrect too little fuel in the fuel tank fuel tube, fuel filter clogged air hole on the fuel tank colgs auto fuel cup faulty clean cam sprocket aligning marks incorrect good check valve spring spring broken loose elasticity faulty spring
1-7
1.GENERAL INFORMATION
E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE) symptom inspection adjustment measure battery voltage.
and then start engine battery voltage can't rise battery voltage rise to normal value,after engine stops, the voltage return to original. normal abnormal hsa voltage normal poor charge (over charge) voltage over normal voltage normal normal can't meet specification no voltage abnormal poor contact
1-8
check voltage regulator rectifier coupler check the voltage between voltage red wire and frame body(grounding) with mult-meter(+).(-) terminals. measure the resistance of
AC generator coil after engine starter, measure the voltage between voltage regulaton
/rectifier red (+) wire and
green (-) wire connected with
frame body. check voltage regulator/ rectifier coupler for poor contact. measure the resistance of voltage adjuster unit cause reach battery life faulty battery coupler poor contact red wire open voltage adjuster white wire open coil faulty connector.poor contact
AC generator white wire open faulty battery
Coupler poor contact. green wire poor grounding faulty voltage regulator/rectifier
1.GENERAL INFORMATION
F.SPARK PLUG NO SPARK symptom spark wear of no spark spark strong no slack normal normal slack abnormal abnormal normal normal abnormal abnormal abnormal
Inspection adjustment replace with new spark plug and test again.
Check spark cap and high voltage cable for slack check CDI unit plug for slack
Check the resistance between the wires. terminals of CDI unit.
Check related portions use CDI tester for CDI unit use CDI tester to check ignition voltage coil cause original spark plug faulty spark plug cap slack plug poor contact fualty main switch. faulty trigger magntic coil poor pulse coil poor IGN coil control cable open connector.socket poor contact faulty CDI unit faulty IGN coil
1-9
2.INSPECTION/ADJUSTMENT
ENGINE
MAINTENANCE SCHEDULE ................2-2
SERVICE INFORMATION .....................2-3
ENGINE OIL/OIL FILTER ......................2-4
SPARK PLUG........................................2-5
COMPRESSION TEST..........................2-6
VALVE CLEARANCE ............................2-7
IGNITION TIMING .................................2-8
CAM CHAIN TENSION ADJUSTMENT.2-9
THROTTLE GRIP ADJUSTMENT .........2-10
IDLING SPEED ADJUSTMENT.............2-11
FRAME
AIR CLEANER................................... 2-12
CLUTCH ADJUSTMENT ................... 2-12
BRAKE ADJUSTMENT ..................... 2-13
DRIVE CHAIN ADJUSTMENT .......... 2-14
WHEELS/RIM.................................... 2-15
SUSPENSION ................................... 2-16
STEERING ........................................ 2-17
BATTERY .......................................... 2-17
HEAD LIGHT AIM.............................. 2-18
STOPLIGHT SWITCH ....................... 2-18
2-1
2.INSPECTION/ADJUSTMENT
MAINTENANCE SCHEDULE
Item
Check Items
Maintenance kilometer
Maintenance
Interval
1 Air cleaner
300KM
NEW
I
Every
1000KM
1 Month
Every
3000KM
3 Months
Every
6000KM
6 Months
I
C
C
R
C
C
Replacement for every 5000KM R
2 Gasoline filter
3 Oil filter
4
5
Oil filter screen
Engine Oil
Cleaning for every 5000km C
Replacement for every 1000KM R
6 Wheels tires I I
7 Battery I
8 Brake and operation free play
12 Spark plug
13 Clutch
15 Exhaust muffler
17 Ignition timing
19 Idle speed
22 Engine bolt torque
23 Deposit of exhaust outlet
Every
12000KM
1 Year
R
R
I I
I
I I
I R
I I
L
I I
I I
I I
I I
I I
I I
I
24
Cylinder head/cylinder
Piston exhaust system deposit
I
I I
I I
I I
I I
The table is refered to the driving distance about 1000km per month
I-inspection, cleaning, adjustment or replacement (if necessary)R-replacement C-leaning L-lubrication
REMARK: Ridden in unusually dusty areas, require more frequently air filter element cleaning.
2-2
2.INSPECTION/ADJUSTMENT
SERVICE INFORMATION
SPECIFICATION
ENGINE
Oil capacity
Spark plug gap
Spark plug gap
0.9 liter
A6RTC
0.6-0.7mm
FRAME
Clutch lever free play
Drive chain stack
Front brake lever free play
Valve clearance IN 0.08mm
EX 0.10mm
Cylinder compression 9.5kg/c ㎡±1kg/c ㎡
SPECIAL TOOL
Valve clearance adjuster
TORQUE VALVES
Right crankcase cover
Rear brake pedal free play
Throttle grip free play
0.80-1.20 kgf
· m
Front fork top bridge bolt
Front fork bottom bridge bolt
Rear wheel axle nut
Rear shock absorber nut
Rear fork pivot bolt
1.00-1.40 kgf
· m
2.00-2.50 kgf
· m
4.00-5.50 kgf
· m
3.00-4.00 kgf
· m
3.50-4.50 kgf
· m
10-20mm
10-20mm
10-20mm
20-30mm
2-6mm
2-3
2.INSPECTION/ADJUSTMENT
OIL/OIL FILTER
OIL LEVEL CHECK
Start and warm up the engine for few minutes,then stop the engine.
Check the oil level with oil level gauge after a few minutes.
If the oil level is near the lower mark,fill the crankcase to the upper level mark with the recommended grade oil.
OIL REPLACEMENT
NOTE:
Drain the engine oil while the engine is warm.
Remove the oil filter screen cover, and drain the engine oil.
NOTE :
Make sure that the oil filter screen cover O-ring is in good condition.
Fill the crankcase up to the upper level mark on the oil level gauge with the recommended oil:SAE15W-40
API:SH/CD
OIL FILTER SCREEN COVER
2-4
2.INSPECTION/ADJUSTMENT
OIL FILTER SCREEN CLEANING
Remove the oil filter cap, oil filter screen and drain the engine oil.
Operate the kick starter several times to drain residual oil completely.
Clean the oil filter screen with compressed air.
Install the oil filter screen, spring and screen cap.
Fill the crankcase with the recommended oil.
OIL CAPACITY:0.9L
SPARK PLUG
Disconnect the spark plug cap and remove the spark plug .
Visually inspect the spark plug electrodes for wear.
The center electrode should have square edges and side electrode should have a constant thickness.
Discard the spark plug if there is apparent wear or if the insulator is cracked and/or chipped .If the spark plug deposits can be removed by sandblasting or wire brushing,the spark plug can be reused.
Inspect the gap with a feeler gauge and adjust by bending the side electrode.
Standard gap:0.6-0.7mm
NOTE:
To install turn finger tight then tighten with a spark plug wrench.
OIL FILTER SCREEN
COVER
2-5
2.INSPECTION/ADJUSTMENT
COMPRESSION TEST
Warm up the engine.
Stop the engine .Remove spark plug .Insert the compression gauge.
Push in the choke lever .Open the throttle grip fully.
Electrical start engine several times.
NOTE:
y Watch for compression leaking at the gauge connection. y
Crank the engine until the gauge reading stops rising .The maximum reading is usually reached in several times.
Compression:9.5kg/c ㎡±1kg/c ㎡
Low compression can be caused by: y Improper calve adjustment. y Valve leakage . y Blown cylinder head gasket. y Worn piston rings or cylinder.
High compression can be caused by: y
Carbon deposits in combustion chamber or on piston head.
ELECTRICAL
START ENGINE
2-6
2.INSPECTION/ADJUSTMENT
VALVE CLEARANCE
NOTE:
Inspect and adjust the valve clearance while the engine is cold.
Remove the timing inspection hole cap and crankshaft hole cap.
Rotate the generator rotor counterclockwise and align the “T”mark on the generator rotor with the index mark in the left crankcase
(piston must be at T.D.C.of the compression stroke).
Inspect the intake and exhaust valve clearance by inserting a feeler gauge between the adjusting screw and valve stem,valve clearance:
Intake: 0.08mm
Exhaust: 0.10mm
Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag in the feeler gauge.
NOTE:
Inspect the valve clearance again after tightened the lock nut.
LOCK NUT
ALIGN
MARK
ALIGN
MARK
ADJUSTING
SCREW
2-7
2.INSPECTION/ADJUSTMENT
Install the valve adjuster caps and generator cap.
NOTE:
Check the O-ring for damage and spread oil before installing the caps.
IGNITION TIMING
The C.D.I.ignition timing is not adjustable.
If the ignition timing is not correct ,check the C.D.I.unit and A.C.generator and replace any faulty parts.
Use the standard tester to check the ignition timing.
Spark plug inspection and adjustment.
Replace the coil if there is no sparks at plug.
IGNITION TIMING INSPECTION
Remove the generator cover and check the ignition timing with a timing light.
Timing is correct if the index mark aligns with the
“F”mark within ±3°at 1500rpm.
Ignition timing :10°BTDC/1500rpm.
Ignition coil continuity test :
Check the resistance of the primary coil and secondary coil.
1.Primary coil 0.31±0.03Ω
2.Secondary coil 4.0±0.4kΩ
O-RING
2-8
2.INSPECTION/ADJUSTMENT
Inspect the C.D.I unit with C.D.I tester.
Replace the faulty C.D.I unit.
SWITCH C.D.I. normal C.D.I faulty
1. OFF
2. P
3. EXT
4. ONI no sparks no sparks no sparks sparks
-------
------- sparks no sparks
5. ONZ sparks
CAM CHAIN TENSIONER
ADJUESTER no sparks
The cam chain tension is kept by the tensioner push rod that is compressed by the spring.
CAUTION:
If remove any parts that is related with the cam chain ,remove the cam chain tensioner adjuester first.
CAM CHAIN TENSIONER
ADJUESTER
2-9
2.INSPECTION/ADJUSTMENT
CARBURETOR
THROTTLE GRIP FREE PLAY
Check throttle grip free play.
Free play:2-6mm
THROTTLE GRIP ADJUSTMENT
Loosen the lock nut and turn the adjuster to adjust.
ADJUSTER NUT
2-10
2.INSPECTION/ADJUSTMENT
IDLING SPEED ADJUSTMENT
Warm up the engine.
Turn the stop screw to obtain the idling speed of
1100rpm.
Turn the air screw to the maximum speed,then turn the stop screw to obtain the specified idling speed.
Idling speed:1500±100 rpm.
NOTE:
Turn the air screw clockwise for making fuel –air mixture lean.
Turn counterclockwise for rich.
STOP SCREW
AIR SCREW
2-11
2.INSPECTION/ADJUSTMENT
AIR CLEANER
Remove the left side cover.
Remove the air cleaner cover.
Remove the air cleaner element.
NOTE:
Clean the cleaner element periodically.(Refer to maintenance schedule.)
Assemble air cleaner element in reverse order of disassemble.
CLUTCH ADJUSTMENT
CLUTCH LEVER FREE PLAY
Measure the clutch free play at the tip of the clutch lever.
Free play :10-20mm
SCREWS
AIR CLEANER
ELEMENT
2-12
2.INSPECTION/ADJUSTMENT
FREE PLAY ADJUSTMENT
Loosen the lock nut and turn the adjuster.
Turn the adjuster ,clockwise for decreasing the free play ,counterclockwise for increasing the free play.
.
BRAKE ADJUSTMENT
FRONT BRAKE LEVER FREE PLAY
Measure the brake free play at the tip of the brake lever.
Free play:10-20mm
BRAKE PAD WEAR INSPECTION
Check for brake pad wear by operating the bake lever.
Check the brake pads for wear by looking through the slot indicated by the arrow cast on the caliper assembly.
Replace the brake pads if the wear line on the pads reaches the edge of the brake disc.
LOCK NUT
ADJUSTER NUT
10~20mm
2-13
2.INSPECTION/ADJUSTMENT
REAR BRAKE PEDAL FREE PLAY
Measure the brake pedal free play before the brake start to engage.
Free play :20-30mm
REAR BRAKE PEDAL
ADJUSTMENT
Turn the brake adjuster nut clockwise to decrease the free play and counterclockwise to increase the play.
CAUTION:
The adjuster nuts indentation should seat against the brake arm pin properly.
DRIVE CHAIN ADJUSTMENT
Place the motorcycle on its main stand and shift the transmission into neutral.
Remove chain cap and check the drive chain slack by moving up and down with the fingers.
Chain slack:10-20mm
ADJUSTING NUTS
10~20m
20~30mm
2-14
2.INSPECTION/ADJUSTMENT
Loose the rear wheel axle nut for adjusting.
Turn the adjusting nuts on both adjusters as necessary.
CAUTION:
Tighten the axle nut.
TORQUE:10.00-12.00
kgf
·
m
Recheck the drive chain slack and free wheel rotation.
Lubricate the drive chain with chain lubricant.
WHEEL/RIM
Stand the motorcycle,check the tires for cuts,imbedded nails,or other sharp objects.
Check the tire pressure.
ADJUSTING NUTS
Cold tire
One rider
Two riders pressure
Front 2.25 kg/c ㎡
Rear 2.50 kg/c ㎡
Front 2.50 kg/c ㎡
Rear 2.50 kg/c ㎡
Max.load 120kg
Tire size
Min. depth of tread
Front 2.75-18
Rear 90/90-15
Front 1.5mm
Rear 2.0mm
2-15
2.INSPECTION/ADJUSTMENT
SUSPENSION
FRONT SUSPENSION
Check the action of the front forks by compressing them several times with the front brake applied .
If there are abnormal noises or rattles ,check all the fasteners and tighten them to the specified torque.
TORQUE:
Front fork top bridge bolt :1.00-1.40 kgf
· m
Frint fork bottom bridge bolt :2.40-3.00 kgf
· m
Axle nut:6.00-8.00 kgf
· m
REAR SUSPENSION
Check for abnormal noises and leaks by compressing the rear suspension several times.
Check the rear suspension nut for loosing
Torque:3.00-4.00 kgf
· m
Move the rear wheel side ways with force to see if the swing arm bushings are worn.
Rear fork torque:8.00-10.00 kgf
· m
2-16
2.INSPECTION/ADJUSTMENT
STEERING
Raise the front wheel off the ground and check that the handlebar rotates freely.If the handlebar moves unevenly ,binds or has vertical movement,adjust the steering head nut.
BATTERY
Inspect the battery fluid level ,if the fluid level nears the lower level mark,fill with distilled water to the upper level mark .
Clean the battery terminals with warm water.
Check the specific gravity of the battery electrolyte.(13-3)
NOTE:
Do not overfill. Add only distilled water.
Tap water will shorten the service life of the battery.
WARNING:
Keep the electrolyte away from eyes ,skin and clothes. If touched it ,wash them with clean water quickly.
2-17
2.INSPECTION/ADJUSTMENT
HEADLIGHT AIM
Adjust vertically by turning headlight up and down with the headlight bolts loosening.
Fasten the bolts after adjustment.
STOPLIGHT SWITCH
The stoplight should come on when the brake pedal is depressed 20mm from the standard pedal position.If the action is abmormal, adjust by turning the stoplight switch adjusting nut.
ADJUST NUTS
STOPLIGHT SWITCH
ADJUSTING NUT
2-18
3.LUBRICATION SYSTEM
OIL LINE OF
CAM SHAFT
CAM SHAFT
MAIN SHAFT
COUNTER SHAFT
PISTON
OIL ORIFICE OF
CRANKSHAFT
OIL PUMP
OIL FILTER
3-0
3.LUBRICATION SYSTEM
TROUBLE SHOOTING
OIL LEVEL TOO LOW
1. Natural consumption
2. Oil leaks
3. Worn piston rings
OIL CONTAMINATION
1. Oil not changed often enough
2. Faulty cylinder head gasket
OIL PRESSURE TOO LOW
1. Oil filter clogged
2. Oil pump damaged
OIL PRESSURE TOO HIGH
1. Oil filter or line clogged
2. Oil not recommended
NO OIL PRESSURE
1. Oil level too Iow
2. Oil pump damaged
SERVICE INFORMATION
NOTICE:
Inspection and service of oil pump can be serviced with the engine installed on the frame.
Oil pump service --- 7-9
Oil filter cleaning --- 2-4 ~ 2-5
SPECIFICATIONS
Oil capacity
Oil recommended
Oil pump delivery
0.85~0.90 liter
SAE 15W-40 API:SH/CD
3.5 liter above / min. / 4600rpm
3-1
4.ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION ..................4-1
ENGINE REMOVAL ...........................4-2
ENGINE INSTALLATION .................. 4-4
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The following parts can be serviced with the engine installed on the frame: y Generator y Clutch y Oil pump y Cam shaft / Rocker arm y Shift spindle y Cam chain tensioner y Kick starter arm
The following parts must be serviced with the engine removed off the frame: y Cylinder head y Cylinder y Piston y Crankshaft y Transmission y Kick starter shift
During removal and installation, jack or adjustable support is required to maneuver the engine.
TORQUE VALUES
Engine hanger 10mm bolt / nut
Drain bolt
Gearshift pedal bolt
Kick starter pedal bolt
4.50-5.50 kgf·m
3.00-5.00 kgf·m
0.80-1.20 kgf·m
0.80-1.20 kgf·m
4-1
4.ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil.
Turn the fuel cock to “OFF” and disconnect the fuel tubes and all connect tubes.
Remove the right and left side covers.
Remove the gear change pedal and left crank case rear cover.
Disconnect the A.C. generator wire of the connector and remove the generator wire.
Remove the wire clamp screw and clamp.
GEAR CHANGE PEDAL
LEFT CRANKCASE RR.COVER
A.C. GENERATOR WIRE
4-2
4.ENGINE REMOVAL/INSTALLATION
Remove the clutch cable.
Remove the spark plug cap.
Remove the muffler.
Loosen carburetor clip.
Separate the carburetor pipe and the cylinder head by removing the attaching bolts.
Remove the crankcase breather tube.
Loosen the rear wheel axle nut.
Loosen the drive chain adjusting nut and push the rear wheel forward.
Remove the drive chain clip, and remove the drive chain.
CLUTCH CABLE
BREATHER TUBE
CLIP
ADJUSTING NUT
WHEEL AXLE NUT
4-3
4.ENGINE REMOVAL/INSTALLATION
Remove the front engine hanger bolt.
NOTE:
Places jack or padded block under the engine before removing the front engine hanger.
Disconnect the starter motor wire.
Remove the 10mm bolts of the rear engine hanger.
Remove the engine.
BOLTS
NOTE:
Prevent damage to wire harnesses and cables during operation.
ENGINE INSTALLATION
Follow the reverse procedure of removal to install the engine.
Notice the following items during installation: y Route all wire harnesses and cables properly. y Adjust the throttle grip free play (P2-10) y Adjust the clutch lever free play (P2-12) y Adjust the drive chain slack (P2-14) y Fill the crankcase with the recommended grade oil to the proper level.
SAE 15W-40 APl: SH / CD
FRONT ENGINE HANGER
BOLT
4-4
5.
CYLINDER HEAD/ VALVE
TROUBLE SHOOTING........................... 5-1
SERVICE INFORMATION ...................... 5-2
CAM SHAFT REMOVAL ........................ 5-3
CYLINDER HEAD/ROCKER ARM
REMOVAL .............................................. 5-4
CYLINDER HEAD DISASSEMBLY ........ 5-6
VALVE GUIDE REPLACEMENT........ 5-8
VALVE SEAT INSPECTION/REFACING
... 5-9
VALVE SEAT GRINDING................... 5-10
CYLINDER HEAD ASSEMBLY .......... 5-13
CYLINDER HEAD INSTALLATION .... 5-14
CAM SHAFT INSTALLATION ........... 5-15
VALVE/VALVE GUIDE INSPECTION .... 5-7
TROUBLE SHOOTING
LOW COMPRESSION
1. Valve
Incorrect valve clearance
Burned or bent valves
Incorrect valve timing
Broken valve spring
2. Cylinder head
Leaking or damaged head gasket
Warped or cranked cylinder head
HIGH COMPRESSION
1. Excessive carbon buildup on piston or combustion chamber.
ABNORMAL NOISE
I. Incorrect valve clearance
2. Broken valve spring
3. Worn rocker arm or camshaft
4. Loose or worn cam chain
5. Worn cam chain tensioner
6. Worn cam sprocket teeth
5-1
5.INSPECTION/ADJUSTMENT
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Camshaft, rocker arm shaft and rocker arm can be serviced with the engine installed on the frame.
Camshaft lubrication oil is fed to the cylinder head through an oil control orifice in the engine case.
Be sure this orifice is not clogged and the O-ring and dowel pins are in place before installing the cylinder head.
During assembly, apply molybdenum disulfide grease to the camshaft bearings, and pour clean engine oil into the cylinder head.
TORQUE VALUES
Cylinder head bolt
Cylinder 6mm bolt
Cam sprocket
2.80-3.00 kgf
· m
1.40 –1.80 kgf
· m
0.80-1.20 kgf
· m
SPEClFICATIONS
Cam lift
Camshaft
Valve spring
Valve guide
Rocker arm I.D.
Rocker arm shaft
I.D.
O.D. 11.966~11.984 mm 11.966mm below
Free length
Stall length
Valve clearance
O.D.
Guide I.D.
Stem to guide
Clearance
Valve seat width
→36.21mm 18.17±1.82kgf
→29.21mm 57±4.28 kgf
(IN)0.06±0.02mm
(EX)0.10±0.02mm
IN 5.450~5.465mm 5.42mm
EX 5.430~5.455mm 5.40mm
IN 5.475~5.485mm 5.50mm
EX 5.475~5.485mm 5.50mm
IN 0.010~0.035mm 0.08mm
EX 0.03~0.055mm 0.10mm
1.45~1.15mm 1.6mm
5-2
5.
CYLINDER HEAD/ VALVE
CAMSHAFT REMOVAL
NOTE:
The camshaft, rocker arm and rocker arm shaft can be serviced with the engine installed on the frame.
Remove the cam sprocket cover.
Remove the crankshaft hole cap and the timing inspection hole cap.
Rotate the generator rotor counterclockwise and locate the piston at the T.D.C. of the compressing stroke.
Remove the cam sprocket bolts and remove the cam sprocket.
NOTE:
Take care not to drop then bolt into the crankcase.
Suspend the cam chain with a wire to prevent it from falling into the crankcase.
Remove the camshaft.
CAM SPROCKET
COVER
INDEX MARK
“O” MARK
5-3
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD
REMOVAL
Remove the cam chain tensioner bolt.
Remove the 8mm bolt.
Remove the 4 cylinder head nuts.
Remove the dowel pins.
Remove cam chain tensioner.
Remove the cylinder head.
Remove the rocker arm shaft.
Remove the rocker arms.
8mm BOLT
CAM CHAIN TENSIONER BOLT
5-4
5.
CYLINDER HEAD/ VALVE
CAMSHAFT INSPECTION
Inspect the cams of the camshaft for wear.
Service limit:
Inlet: 31.25mm
Exhaust: 30.87mm
ROCKER ARM INSPECTION
Inspect the rocker arm I.D. and the rocker arm for wear, damage or clogged oil holes.
Rocker arm I.D.
Service limit: φ12.018mm
ROCKER ARM SHAFT INSPECTION
Inspect rocker arm shaft for wear or damage.
Rocker arm shaft O.D.
Service limit :φ11.966mm
5-5
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD DISASSEMBIY
Remove carbon deposits from the combustion chamber. Remove valve spring and valve spring and valve with a valve spring compressor.
CYLINDER HEAD INSPECTION
Remove gasket from cylinder head with a scraper.
Check the cylinder head for crack.
Check the cylinder head for warpage with a straight edge and a feeler gauge.
Service limit: 0.10mm
VALVE SPRING INSPECTION
Measure the free length of the inner and outer valve spring.
Service limit: 39mm below
VALVE COTTER
VALVE
SPRING RETAINER
5-6
5.
CYLINDER HEAD/ VALVE
VALVE/VALVE GUIDE
INSPECTION
Inspect valves for scratches, burning or wear.
Check the valve movement in the guide.
Measure the valve stem O.D.
Service limit:
Intake: ∮5.42mm
Exhaust:∮5.40mm
NOTE:
Remove any carbon buildup before checking the valve guide I.D.
Guide I.D. service limit
Intake: ∮5.50mm
Exhaust : ∮5.50mm
Measure the valve guide I.D. and calculate the stem to guide clearance.
Service limit:
Intake: 0.08mm
Exhaust: 0.10mm
If the stem to guide clearance exceeds the service limit, replace the valve or guide to fit.
NOTE:
The guide must be reamed when replacing a new one.
5-7
5.INSPECTION/ADJUSTMENT
VALVE GUIDE
REPLACEMENT
Drive out the valve guide from the combustion chamber side with a 5mm valve guide remover.
NOTE:
When driving out the valve guide, do not damage the cylinder head.
Install the new valve guide from the top of the cylinder head, and ream it with a reamer, then clean the cylinder head.
VALVE GUODE REMOVER
5-8
5.
CYLINDER HEAD/ VALVE
VALVE SEAT INSPECTION/ REFACING
Clean intake and exhaust valves to remove carbon deposits.
Apply a light coating of prussian blue to each valve face.
Insert each valve into the guide and rotate them two cycles.
Remove the valve and inspect the face.
CAUTION:
If the valve face is burned or damaged or unevenly, replace the valve.
Inspect the valve seat.
If the seat is too wide or too narrow, the seat must be refinished.
CONTACT AREA
VALVE SEAT
SERVICE LIMIT
1.5mm
SERVICE LIMIT
1.8mm
5-9
5.INSPECTION/ADJUSTMENT
VALVE SEAT GRINDING
NOTE:
Follow the instructions described in the cutter instruction manual.
Remove any roughness from the seat by applying 4~5 kg pressure, turning the cutter left and right.
NOTE:
Add engine oil to the face when operating.
Using a 45 degree cutter,remove any roughness from the seat.
CUTTER
ROUGHNESS
60°
32°
45°
4~5kg
CUTTER HOLDER
TURN RIGHT AND LEFT
45°
VALVE SEAT
5-10
5.
CYLINDER HEAD/ VALVE
Using a 32 degree cutter, remove 1/4 of the existing valve seat material.
Remove the bottom 1/4 of the old seat by using a 60 degree cutter.
Finish the seat to the proper width by using a 45 degree cutter.
32 o
CUTTER
VALVE SEAT
60 o
CUTTER
45 o
CUTTER
5-11
5.INSPECTION/ADJUSTMENT
If the contact area is too high on the valve,the seat must be lowered using a 37.5 degree cutter, then finish with a 45 degree cutter.
If the contact area is too low on the valve,the seat must be raised using a 63.5 degree cutter, then finish with a 45 degree cutter.
After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure.
CONTACT AREA
TOO HIGH
CUT BOTTOM END
CUT TOP END
CONTACT AREA TOO LOW
63.5
o
5-12
5.
CYLINDER HEAD/ VALVE
CYLINDER HEAD ASSEMBLY
Compress the valve springs with a valve spring compressor and install the valve cotters into the valve retainer.
CAUTION:
Do not compress the valve spring more than necessary.
NOTE:
Install a new valve stem seal when assembling.
Lubricate each valve stem with the engine oil then insert them into the guides.
Install the valve spring and retainers.
NOTE:
Install the valve springs with the tightly wound coils facing the cylinder head.
Tap the valve stems gently with a plastic hammer to firmly seat the cotters.
VALVE COTTER
VALVE
SPRING RETAINER
5-13
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD INSTALLATION
CAMSHAFT AND CAMSPROCKET
ASSEMBLY
NOTE:
Rocker arms must be installed at the right position.
Clean the cylinder head gasket surface of any gasket material.
Install the new gasket, O-ring and dowel pins and chain guide.
NOTE:
Do not allow dust and dirt to enter the cylinder.
Install the cylinder head.
NOTE:
Support the cam chain to keep it from falling into the crankcase.
Install the cam chain tensioner set and bolt and washer.
Install dowel pins.
ROCKER ARM
8mm BOLT
TENSIONER BOLT
5-14
5.
CYLINDER HEAD/ VALVE
CAM SHAFT
INSTALLATION
Rotate the generator rotor and align the "T" mark with the index mark.
Install the camshaft comp.
When intalling camshaft set, please take care that.The line on the camsprocket should be in parallel with the surface of cylinder head.(The IN/EX cam should be faced down).
Install the camshaft holder.
Install the cylinder head nuts.
TORQUE:2.80 ~ 3.00
kgf
· m
CAUTION:
The cap nut of the four holder nuts must be installed at the left-front side.
Install the 6mm bolts.
Install the cam chain chain tensioner.
Install the auto-tensioner. (Lock the spring cap bolt first.)
Release the auto-tensioner lock bolt.
Adjust the valve clearance.(2-7)
Install the cylinder head cover.
Install the R/L cylinder head side cover.
Install the 6mm special bolts.
NOTE:
If the cylinder head side cover gasket is damaged or broken, replace with a new one.
“O” MARK INDEX MARK
5-15
6. CYLINDER/PISTON
TROUBLE SHOOTING.......................6-1
SERVICE INFORMATION ..................6-1
CYLINDER REMOVAL .......................6-2
PISTON REMOVAL............................6-3
PISTON/PISTON RING INSPECTION
......... 6-3
PISTON RING INSTALLATION............ 6-5
PISTON INSTALLATION...................... 6-6
CYLINDER INSTALLATION ................. 6-6
TROUBLE SHOOTING
LOW COMPRESSION
1. Worn cylinder or piston rings.
EXCESSIVE SMOKE
1. Worn cylinder,piston or piston rings.
2. Improper installation of piston rings.
3. Scored or scratched piston or cylinder wall.
SERVICE INFORNATION
GENERAL STRUCTIONS
OVERHEATING
1. Excessive carbon build-up on piston or
combustion chamber wall.
KNOCKING OR ABNORMAL NOISE
1. Worn piston or cylinder.
2. Excessive carbon build-up
XS125-K
ITEM
STANDARD CERVICE LIMIT
Cylinder
Cylinder I.D. 56.495~56.515mm 56.52mm
Runout 0.05mm 0.05mm
Taper 0.05mm 0.05mm
Piston ring to ring groove clearance
Top 0.025~0.055mm 0.060mm
Second 0.015~0.040mm 0.045mm
Top 0.10~0.30mm 0.5mm
Piston ring
End gap
Second 0.10~0.30mm 0.5mm
Oil ring
Piston rings groove clearance
Piston O.D.
Piston pin bore
Connecting rod small end I.D.
0.30~0.90mm
56.485~56.505mm 56.48mm
15.05mm
15.07mm
Piston pin O.D.
Piston ring thickness
Top
Second
Cylinder to piston clearnace
15.002~15.008mm
15.016~15.034mm
14.994~15.000mm
0.97~0.99mm
0.97~0.99mm
0.005~0.015mm
14.994mm
1.460mm
1.460mm
0.11mm
6-1
6.CYLINDER/PISTON
CYLINDER REMOVAL
Remove the cylinder head.
Remove the dowel pins and gasket.
Remove the cylinder.
NOTE:
Avoid the dowel pins falling into the crankcase during removing the cylinder.
Remove the dowel pins and gasket.
Clean the cylinder gasket surface of any gasket material.
NOTE:
Avoid damaging the cylinder gasket surface during this operation.
CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D.
NOTE:
According to the right picture measure the cylinder runout.
Service limit:
ITEM XS125-K
Runout 0.05mm
Taper 0.05mm
I.D. 56.52mm
6-2
PISTON REMOVAL
Remove the piston pin clip with pliers.
Press the piston pin out of piston, remove the piston.
NOTE:
Avoid the clip falling into the crankcase.
PISTON / PISTON RING
INSPECTION
Measure the piston ring-to-ring groove clearance.
Service limit .
Top ring: 0.13mm
Second ring: 0.12mm
Remove the piston rings.
Inspect the piston for damage or cracks.
Inspect the piston groove for wear.
Insert each piston ring into the cylinder and measure the ring end gap.
Top / Second ring : 0.5mm
6. CYLINDER/PISTON
6-3
6.CYLINDER/PISTON
Measure the piston O.D. at the skirt.
Service limit: 56.48mm
NOTE:
Measure the piston O.D. at a point from the bottom.
Calculate the piston-to-cylinder clearance.
Service limit:0.11mm
Measure the piston pin bore I.D.
Service limit:15.05mm
Measure the piston pin O.D.
Service limit:14.994mm
Measure the top/second ring thickness.
Service limit: 1.460mm
6-4
PISTON RING INSTALLATION
Install the piston rings.
NOTE: y Avoid piston and piston ring damage during installation. y All rings should be installed with the markings facing up. y After installation, the piston rings should be free to rotate in the grooves.
Space the piston ring end gaps 120 degree apart.
6. CYLINDER/PISTON
TOP RING
SECOND
RING
OIL RING
TOP RING
SECOND RING
OIL RING
6-5
6.CYLINDER/PISTON
PISTON INSTALLATION
Install the piston, piston pin and piston pin clip.
NOTE: y Position the "IN" mark on the piston to the carburetor side. y Do not let the piston pin clip fall into the crankcase.
NOTE: y Use new piston pin clip whenever disassembling. y Do not align the piston pin clip end gap with the piston cutout.
CYLINDER INSTALLATION
Install the cylinder gasket and dowel pins.
Clean the cylinder gasket surface of any gasket material.
NOTE:
Avoid damaging the cylinder gasket surface during this operation.
Install the cylinder.
NOTE:
Avoid piston and piston rings damage during installation.
Install the cylinder gasket and dowel pins.
Install the cylinder head.(5-8)
NOTE:
Coat the cylinder and piston with the engine oil before installing the cylinder.
6-6
PISTON PIN CLIP
CUTOUT
END GAP
7.CLUTCH/OIL PUMP/GEAR SHIFT
TROUBLE SHOOTING.......................7-1
SERVICE INFORMATION ..................7-1
RIGHT CRANKCASE COVER REMOVAL
.7-2
OIL PUMP .......................................... 7-7
GEARSHIFT LINKAGE ...................... 7-9
RIGHT CRANKCASE COVER INSTALLATION
.... 7-11
CLUTCH .............................................7-2
TROUBLE SHOOTING
Faulty clutch operation can be corrected by adjusting the clutch lever free play.
CLUTCH SPINS WHEN ACCELERATING
1. No free play
2. Discs worn
3. Spring weak
CLUTCH DISENGAGED ( MOTORCYCLE
CREEPS )
1. Too much free play
2. Plates warped
EXCESSIVE LEVER PRESSURE
1. Clutch cable kicked, damaged or dirty
2. Lifter mechanism damaged
SERVICE INFORMATION
GENERAL INSTRUCTION
This section covers removal, installation and servicing of the clutch, oil pump, filter and gearshift linkage. All these operations can be accomplished with the engine in the frame.
HARD SHIFTING
1. Stopper plate bent
2. Improper clutch adjustment
GEARSHIFT PEDAL WON'T RETURN
1. Return spring broken or weak
2. Shift spindle bent
JUMPS OUT OF GEAR
1. Stopper arm spring broken
LOW OIL PRESSURE
1. Oil pump drive gear worn
2. Faulty oil pump
COMMON TOOLS
22mm wrench socket
Air wrench
TORQUE VALUES
Right crankcase cover
Kick starter pedal
Step bar
SPECIFICATIONS
0.80 ~ 1.20 kgf
· m
1.00 ~ 1.50 kgf
· m
1.80 ~ 2.00 kgf
· m
Clutch
Oil pump
Leve
Free play
Spring free length
10~20mm ------------
30.6mm 28.6mm
Friction plate thickness 3.0mm 2.8mm
Clutch plate warpage ------- 0.2mm
Tip clearance
Rotor-to-body clearance
End clearance
0.30mm
0.25~0.31mm
0~0.06mm
0.35mm
0.40mm
0.11mm
7-1
7.CLUTCH/OIL PUMP/GEAR SHIFT
RIGHT CRANKCASE COVER
REMOVAL
Drain oil from the engine.
Disconnect the clutch cable.
Remove the kick starter arm.
Remove the right crankcase cover.
CLUTCH
CLUTCH REMOVAL
Remove the clutch lifter rod.
Remove the oil filter rotor cover.
Remove the 16mm lock nut with a lock nut wrench.
Remove the oil filter rotor.
LIFTER ROD
CLUTCH CABLE
FILTER ROTOR COVER
OIL FILTER ROTOR
7-2
7.CLUTCH/OIL PUMP/GEAR SHIFT
Remove the bearing, clutch bolt, clutch lifter plate and clutch spring.
CLUTCH BOLT
CLUTCH LIFTER PLATE
CLUTCH SPRING INSPECTION
Measure the clutch springs free length.
Service limit: 28.6mm
Remove the 20mm set ring.
Remove the clutch center, disks, plates and pressure plate.
SET RING
7-3
7.CLUTCH/OIL PUMP/GEAR SHIFT
CLUTCH PLATE
CLUTCH CENTER
CLUTCH PRESSURE
CLUTCH FRICTION DISC
INSPECTION
Replace the clutch disks if they have any score or discoloration.
Measure the clutch friction disk thickness.
SERVICE LIMIT: 2.8mm
CLUTCH PLATE INSPECTION
Check the plates for warpage on a surface plate using a feeler gauge.
Service limit: 0.2mm
CLUTCH OUTER
7-4
Remove the 20 mm washer and clutch outer.
CLUTCH OUTER INSPECTION
Check the clutch outer for cracks or indentation.
7.CLUTCH/OIL PUMP/GEAR SHIFT
CLUTCH OUTER INSTALLATION
Install the clutch outer, 20mm washer on the main shaft.
NOTE:
WASHER
20mm WASHER
When installing the washer, it should fit with the main shaft groove.
Install the clutch pressure plate, friction discs, clutch plates and clutch center.
7-5
7.CLUTCH/OIL PUMP/GEAR SHIFT
Install and tighten the 20mm set ring.
Install the clutch springs, lifter plate and tighten the bolts.
Install the bearing.
NOTE:
Tighten the bolts in a crisscross pattern in two or three steps.
LOCK NUT
TORQUE :0.80-1.20 kgf
· m
Install the oil filter rotor.
Install the lock washer and 16mm lock nut.
Tighten the 16mm lock nut.
TORQUE :4.00-5.00 kgf·m
Install the filter rotor cover.
Check the oil through for a smooth operation without binding.
Install the lifter rod.
Install the dowel pins and a new gasket.
Install the right crankcase cover
Connect the clutch cable.
Install the exhaust muffler and step bar.
Fill the crankcase with the recommended oil
Adjust the clutch lever free play.
CLUTCH LIFTER PLATE
Dowel pin
LIFTER ROD
BEARING
FILTER ROTOR COVER
7-6
7.CLUTCH/OIL PUMP/GEAR SHIFT
OIL PUMP
OIL PUMP REMOVAL
Remove the right crankcase cove.
Remove the oil filter rotor.
Remove the oil pump cover.
Remove the oil pump drive gear.
Remove the 6 mm screws and oil pump.
OIL PUMP DISASSEMBLY
Remove the oil pump plate.
OIL PUMP INSPECTION
Measure the inner rotor-to-outer rotor clearance.
SERVICE LIMIT: 0.35mm
OIL PUMP
6mm SCREWS
OIL PUMP DRIVE GEAR
OIL PUMP PLATE
7-7
7.CLUTCH/OIL PUMP/GEAR SHIFT
Measure the outer rotor-to-body clearance.
Service limit: 0.40mm
Measure the rotor-to-cover clearance.
NOTE:
Measure the clearance with the gasket installed.
Service limit: 0.11mm
OIL PUMP ASSEMBLY
Install the oil pump drive gear and gear shaft on the pump body.
Install the oil pump cover.
NOTE:
Align the cutout in inner rotor with the cutout on the shaft.
DRIVE SHAFT
Check the oil pump for rotating freely.
OIL PUMP COVER
7-8
DRIVE GEAR
OIL PUMP BODY
OIL PUMP INSTALLATION
Install new O-rings.
Install the oil pump to the right crankcase.
GEARSHIFT LINKAGE
GEARSHIFT LINKAGE DISASSEMBLY
Remove the clutch.
Remove the gearshift pedal.
Remove the gearshift spindle.
7.CLUTCH/OIL PUMP/GEAR SHIFT
O-RING
OIL PUMP
GEARSHIFT SPINDLE
7-9
7.CLUTCH/OIL PUMP/GEAR SHIFT
Remove the gearshift drum stopper arm.
Remove the gearshift cam.
Check each part for wear or damage.
GEARSHIFT LINKAGE ASSEMBLY
Install the four 4mm roller.
Align the hole of the gearshift cam with the roller, then install the gearshift cam.
Install the gearshift drum stopper.
NOTE
After installation, check the drum stopper operation.
GEARSHIFT CAM
GEARSHIFT SPINDLE
GEARSHIFT CAM
GEARSHIFT CAM
GEARSHIFT DRUM
STOPPER ARM
4MM ROLLER
GEARSHIFT DRUM
STOPPER
7-10
Install the gearshift spindle.
NOTE :
Align the gearshift return spring on the projection of the crankcase.
Check the gearshift linkage for smooth operation.
Install the clutch, oil pump and oil filter rotor.
RIGHT CRANKCASE COVER
INSTALLATION
Install the dowel pins and a new gasket.
Install the right crankcase cover and tighten the screws.
Connect the clutch cable.
Install the kick starter pedal.
Fill the crankcase with the recommended oil.
Adjust the clutch lever free play.
7.CLUTCH/OIL PUMP/GEAR SHIFT
CLUTCH
DRIVE GEAR
OIL PUMP
7-11
8. A.C.GENERATOR
SERVICE INFORMATION..................8-1
LEFT CRANKCASE COVER REMOVAL
...........8-2
FLYWHEEL REMOVAL .....................8-2
FLYWHEEL INSTALLATION.............8-3
LEFT CRANKCASE COVER INSTALLATION
.... 8-3
STARTER MOTOR REMOVAL ......... 8-4
STARTER DRIVEN GEAR REMOVAL
..... 8-4
STARTER MOTOR GEAR SET ......... 8-4
SERVICE INFORMATION
GENERAL INSTRUCTION
This section covers removal and installation of the AC generator and starter motor.
These operation can be done with the engine installed in the frame.
Special tool
Rotor puller
TORQUE VALVE
Flywheel bolt 2.60~3.20kgf.m
8-1
8. A.C.GENERATOR
LEFT CRANKCASE COVER
REMOVAL
Remove the gearshift pedal.
Remove the left crankcase rear cover.
Disconnect the AC generator and pulse generator wire connector.
Remove the left crankcase cover.
NOTE:
Generator stator is in the left crankcase cover, it can be removed by removing the attaching screws.
FLYWHEEL REMOVAL
Remove the flywheel bolt.
Remove the flywheel with the rotor puller.
LEFT CRANKCASE
COVER
FLYWHEEL SETTING BOLT
LEFT CRANKCASE
REAR COVER
GEARSHIFT PEDAL
8-2
STATOR COIL INSPECTION
NOTE :
This inspection can be made with the stator in the frame.
Check the starter for continuity.
Continuity should exist between:
Yellow and pink,
Black/red and ground,
Blue/white and green/white
Pink,yellow,blue/white and green/white should not continue with the ground.
Yellow and green.
Replace the stator and pulse generator assembly if necessary.
FLYWHEEL INSTALLATION
Reverse the procedure of removal to assembly.
NOTE : y Check wire for security in its place. y
Do not interfere the wire with the flywheel.
Install and tighten the flywheel.
TORQUE: 4.00~5.00 kgf
·· m
LEFT CRANKCASE
COVER INSTALLATION
Install the left crankcase cover (with stator coil)
Connect the generator wire connectors.
Route the neutral switch wire through the groove in the left crankcase cover.
Install the left crankcase rear cover.
Install the gearshift pedal.
FLYWHEEL BOLT
8. A.C.GENERATOR
GENERATOR WIRE
CONNECTORS
8-3
8. A.C.GENERATOR
STARTER MOTOR REMOVAL
Disconnect the starter motor wire from the motor..
Remove the starter motor by removing the bolts.
STARTER DRIVEN GEAR REMOVAL
Remove the left crankcase cover .
Remove the flywheel.
Remove the starter driven gear.
STARTER MOTOR GEAR SET
1. Starter driven gear
2 Starter reduce gear
3 Starter motor
Install the starter motor and gear in the reverse order of removal.
8-4
BOLTS
STARTER MOTOR
ELECTRIC CONNECTOR
STARTER DRIVEN GEAR
STARTER DRIVEN GEAR
STARTER REDUCE GEAR
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
TROUBLE SHOOTING.......................9-1
SERVICE INFORMATION ..................9-2
TRANSMISSION DISASSEMBLY ...... 9-5
TRANSMISSION ASSEMBLY ............ 9-8
CRANKCASE SEPARATION .............9-2 KICK STARTER DISASSEMBLY ....... 9-10
CRANKSHAFT REMOVAL .................9-3 CRANKCASE ASSEMBLY ................. 9-11
TROUBLE SHOOTING
HARD TO SHIFT
1. Shift fork bent
2. Shift fork shaft bent
TRANSMISSION JUMPS OUT OF GEAR
1. Gear dogs worn
2. Shift fork bent or damaged
3. Shift fork shaft bent
SERVICE INFORMATION
CRANKSHAFT NOISE
1. Worn connecting rod big end bearing
2. Bent connecting rod
3. Worn crankshaft bearing
GEAR NOISE
1. Worn transmission gears
2. Worn spline shafts
GENERAL INSTRUCTION
Transmission and crankshaft repairs require crankcase separation.
Remove the following parts before separating the crankcase:
Engine removal
Cylinder head removal
Cylinder / Piston removal
Clutch / oil pump / Gearshift linkage removal
Left crankcase cover removal
Flywheel removal
4-2
5-2
6-2
7-2
8-2
8-2
SPECIAL TOOLS
Bearing driver
Bearing driver pilot
SPECIFICATIONS
Gearshift fork
I.D. 12.000~12.018mm 12.05mm
Claw thickness 4.925~5.000mm 4.80mm
Shift fork shaft O.D. 11.976~11.994mm 11.9mm
Crankshaft
Connecting rod small End I.D. 15.016~15.034mm 15.08mm
Connecting rod big
End side clearance
Axial 0.10~0.30mm 0.6mm radial 0.000~0.008mm 0.030mm
9-1
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
CRANKCASE SEPARATION
Remove the right crankcover and internal parts.
(7-3~ 7-13)
Remove left cover and internal parts.
9-2
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Remove the left crankcover all 6mm attaching bolts.
Separate the left crankcase from the right crankcase.
Remove the gasket and dowel pins.
CRANKCASE
CRANKSHAFT REMOVAL
Remove the left crankcase.
Remove the crankshaft.
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance with a feeler gauge.
Service limit: 0.60mm
Measure the connecting rod big end radial clearance.
Service limit:0.05mm
CRANKCASE
9-3
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Support the crankshaft bearings on a V-block and measure the runout using a gauge.
NOTE:
Coat the bearing and connecting rod big end with engine oil before installation.
Service limit: 0.050mm
Measure the connecting rod small end I.D.
Connecting rod small end I.D.
Service limit: ∮15.08mm
CRANKSHAFT BEARING
INSPECTION
Spin the crankshaft bearing by hand and check for play. The bearing must be replaced if it is noisy or has excessive play.
FREE PLAY
FREE PLAY
AXIAL
RADIAL
9-4
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
TRANSMISSION
SHIFT FORK
SHAFT
DISASSEMBLY
Remove the crankshaft.
Remove the shift fork shaft.
Remove the shift drum.
Remove the shift forks.
COUNTER
SHAFT
MAIN SHAFT SHIFT DRUM
SHIFT FORK SHAFT
SHIFT DRUM
SHIFT FORK
SHIFT FORK AND SHIFT FORK
SHAFT INSPECTION
Check the shift fork for wear, bending or damage.
Measure the shift fork I.D.
Service limit: 12.05mm
Measure each shift fork claw thickness.
Service limit: 4.80mm
CHECK FOR WEAR
OR DAMAGE
9-5
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Measure the shift fork shaft O.D.
Service limit: 11.976mm
SHIFT DRUM INSPECTION
Check the gearshift drum for wear or damage.
Disassemble the transmission gears.
Check each gear for wear or damage and replace if necessary.
Check the crankcase oil orifice for clogged, blowing through with compressing air if necessary.
9-6
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Check the crankcase bearings, replace them if they have excessive free play or noisy.
AXIAL
FREE PLAY
FREE PLAY
RADIAL
BEARING INSTALLATION
Install the bearings into the left, right crankcase with special tools.
NOTE:
Install the bearing horizontally, to prevent bearing damage.
9-7
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
TRANSMISSION ASSEMBLY
NOTE:
Before assembling,coat each gears with engine oil.
C1
Main shaft
C3
M3
M4
C4
Assemble the gears of the countershaft and mainshaft.
NOTE:
M5
Counter shaft
M2
C2
Driver sprocket
Seat the snap ring in the ring groove properly.
9-8
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Install the crankshaft assemblies in the right crankcase.
Install the mainshaft and countershaft assemblies in the right crankcase.
CRANKSHAFT
NOTE:
Keep the thrust washers in place during installation.
Install the mainshaft, countershaft and shift forks.
Install the gearshift drum.
Install the shift fork shaft.
NOTE
:
Engage the shift fork guide pin with the drum groove by raising the shift fork.
After assembling, check each part for moving freely.
SHIFT FORK
MAINSHAFT
SHIFT FORK SHAFT GEARSHIFT DRUM
9-9
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
KICK STARTER DISASSEMBLY
Remove the kick starter spindle assembly.
Remove the kick starter spindle from the engine.
Remove the thrust washer and drive ratchet.
Measure the I.D. of the pinion.
Service limit:24.96mm
Measure the pinion sliding O.D. of the spindle.
Service limit:24.80mm
KICK STARTER SPINDLE
9-10
9.
CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
KICK STARTER ASSEMBLY
Reverse the operation of diassembly for assembing.
CRANK CASE ASSEMBLY
Install the gasket and dowel pins.
Install the left crankcase on the right crankcase.
NOTE:
Make sure that the gasket is in place.
9-11
TROUBLE SHOOTING.......................10-1
SERVICE INFORMATION ..................10-1
CARBURETOR REMOVAL ................10-2
THROTTLE VALVE DISASSEMBLY ..10-2
FLOAT/FLOAT VALVE/JETS DISASSEMBLY
10-3
TROUBLE SHOOTING
ENGINE CRANKS BUT NOT START
1. No fuel in the fuel tank
2. No fuel in the carburetor
3. Too much fuel in the combustion chamber
4. No spark at the spark plug ( ignition malfunction )
5. Air cleaner clogged
ENGINE IDLE ROUGHLY
1. Idling speed incorrect
2. Ignition malfunction
3. Low compression
4. Rich mixture
5. Lean mixture
6. Air cleaner clogged
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Take cautions when dealing this operation.
Always work in a well-ventilated area and away from sparks or open flames. When assembling, note the
10. CARBURETOR
FLOAT/FLOAT VALVE/JETS ASSEMBLY
.... 10-5
FLOAT/LEVEL ADJUSTMENT........... 10-5
THROTTLE VALVE ASSEMBLY........ 10-5
CARBURETOR INSTALLATION ........ 10-6
7. Air leaking into intake pipe
8. Fuel contaminated
LEAN MIXTURE
1. Carburetor jets clogged
2. Float chamber vent clogged
3. Fuel filter clogged
4. Fuel line restricted
5. Float level too Iow
6. Float valve faulty
RICH MIXTURE
1. Choke stuck closed
2. Float valve faulty
3. Float level too high locations of the jets and place them individually.
SPECIAL TOOL
Float gauge
10-1
10. CARBURETOR
CARBURETOR REMOVAL
Disconnect the fuel line.
Disconnect the all connect tubes.
Drain fuel from the carburetor.
WARNING:
Keep away from flames or sparks. Wipe up spilled gasoline at once.
Loosen the carburetor band.
THROTTLE VALVE DISASSEMBLY
Disconnect the throttle cable.
Remove the needle spring.
Remove the needle.
Check the needle and throttle valve for wear or damage.
CARBURETOR
NEEDLE SPRING
NEEDLE
BAND
THROTTLE CABLE
10-2
Remove the carburetor assembly.
FLOAT/FLOAT VALVE/JETS
DISASSEMBLE
Remove the float chamber body.
WARNING:
Pour the float chamber gasoline into the tank
Pull out the float pin, remove the float and float valve.
FLOAT VALVE INSPECTION
inspect the float valve surface for wear or damage.
10. CARBURETOR
WEAR OR DAMAGE
FLOAT PIN
FLOAT VALVE
10-3
10. CARBURETOR
Remove the main jet, needle jet and needle jet holder.
NOTE:
Avoid damage to the jets.
Remove the air screw.
NOTE
:
Before removeing air screw, record the number of relations until it rests lightly so it can be returned to its original position.
Check each part for damage.
Blow open all body openings with compressed air.
MAIN JET
NEEDLE JET
NEEDLE JET HOLDER
AIR SCREW
10-4
FLOAT/FLOAT VALVE/
JETS ASSEMBLY
Install the stop screw, air screw, main jet, needle jet and needle jet holder.
NOTE:
Do not damage jets at the time of assembly.
FLOAT LEVEL
ADJUSTMENT
If the float level is too high or too Iow,bend the float arm for adjusting.
Float level: 24mm
THROTTLE VALVE
ASSEMBLY
lnstall the jet needle in the valve and secure it with the clip retainer.
10. CARBURETOR
24mm
MAIN JET
10-5
10. CARBURETOR
Connect the throttle cable.
NOTE:
Route the throttle cable end through the adjuster and the carburetor top. Make sure that the throttle cable is pulled tightly.
NOTE:
When installing the throttle valve, align the throttle vale groove with the pilot screw.
CARBURETOR
INSTALLATION
Installation is essentially in the reverse odrer of removal.
After Installation ,adjust:
Throttle grip free play (2-10).
Idling speed (2-11).
AIR SCREW
Throttle stop screw
10-6
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
TROUBLE SHOOTING.......................11-1
SERVICE INFORMATION ..................11-1
HEADLIGHT .......................................11-2
METER ...............................................11-3
HANDLE BAR .................................... 11-3
FRONT WHEEL ................................. 11-4
FRONT FORK .................................... 11-7
STEERING STEM .............................. 11-8
TROUBLE SHOOTING
FRONT WHEEL WOBBLING
1. Axle not tightened properly
2.Worn front wheel bearing
3. Distorted rim
HARD STEERING
1. Steering stem nut too tight
2. Faulty steering stem bearing
3. Insufficient tire pressure
SOFT SUSPENSION
1. Weak rear fork spring
2. Insufficient fluid in the front forks
HARD SUSPENSION
1. Bent front fork
2. Too much fluid in the front forks
STEERS TO ONE SIDE
1. Bent front axle
2. Bent front fork
3. Faulty front wheel
4. Misadjusted shock absorber
FRONT SUSPENSION NOISE
1. Bent front fork
2. Insufficient fluid in the front fork
3. Loose front fork fasteners
SERVICE INFORMATION
GENERAL INSTRUCTIONS
This section covers the removal, inspection and installation of the front wheel, front fork and steering.
Before removing the front wheel, place a block under the engine.
TORQUE VALUES
Front wheel axle nut
Handlebar upper holder
Steering stem nut
Front fork top bridge
Front fork bottom bridge
SPECIFICATIONS
6.00 ~ 8.00 kgf
· m
1.00 ~ 1.40 kgf
· m
6.00 ~ 8.00 kgf
· m
4.00 ~ 5.50 kgf
· m
4.00 ~ 5.50 kgf
· m
STANDARD SERVICE LIMIT
…………………
2.0mm Axle runout
Axial
Rim runout
Radial
…………………
…………………
2.0mm
2.0mm
11-1
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
HEADLIGHT
HEADLIGHT REMOVAL
Remove the headlight screw.
Remove the headlight case.
Disconnect the wire connector.
HEADLIGHT WIRING
Route the wires through the headlight
Connect the wires Color-to-color.
HEADLIGHT INSTALLATION
Install the headlight.
Install the headlight case aligning the mark to the holder, tighten the bolts. screw bolt
11-2
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
METER
METER REMOVAL
Remove the headlight case .
Disconnect each wire and connector.
Disconnect the meter cables.
Remove the setting screws.
Remove the meter.
HANDLEBAR
setting screws
HANDLEBAR REMOVAL
Remove the wire harness.
Remove the light switch and throttle cable, remove the turn signal switch assembly.
Remove the handlebar upper holder bolts.
Disconnect the front brake and clutch cable from the lever.
Remove the handlebar holders and take off the handlebar.
HANDLE BAR INSTALLATION
Connect the front brake and clutch cable to the lever.
Install the handlebar on the lower holder.
NOTE:
Align the punch marks on the handlebar with the top of the handlebar lower holder.
Install the handlebar holders.
NOTE:
Tighten the forward bolts to the specified torque first, then tighten the rear bolts to the same torque.
TORQUE:100~140 kg-m
Install the light switch and throttle grip.
11-3
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
NOTE:
Coat the throttle grip hole with grease.
Install the winker switch assembly.
NOTE:
Align the punch mark on the handlebar with the split in the housing.
FRONT WHEEL
FRONT WHEEL REMOVAL
Raise the front wheel off the ground by placing a block under the engine.
Disconnect the speedometer cable and front brake cable.
Remove the axle nut.
Pull out the axle, remove the front wheel.
FRONT WHEEL AXLE
SHAFT INSPECTION
Place the axle on V-blocks and measure the runout, the actual runout is 1/2 of the total indicator reading.
Service limit: 0.2mm under
WHEEL BEARING INSPECTION
Shake the bearing back and forth and spin it by hand, replace the bearing with a new one if it is noisy or has excessive play.
11-4
11.
FRONT BRAKE
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
FRONT BRAKE DISC INSPECTION
(
DISC
BRAKE
)
Replace the brake pads if the wear indicator mark is pointed.
Measure the brake disc thickness.
Service limit: 3.5mm
FRONT BRAKE DISASSEMBLY
Remove the caliper by removing the two caliper mounting bolts.
Remove the pad guide bolts.
Remove the brake pads.
CAUTION:
Do not operate the brake lever after the caliper removal to avoid brake pads sticky.
FRONT BRAKE ASSEMBLY
Reverse the procedures of disassembly to install the brake pads.
Tighten the brake pad guide bolts.
FRONT BRAKE LINING INSPECTION
(DRUM BRAKE)
Measure the brake lining thickness.
Service limit: 2.0mm
11-5
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
FRONT BRAKE PANEL INSPECTION
Remove the brake shoes and springs.
Remove the brake arm and brake cam.
Remove the speedmeter drive gear and dust seal.
FRONT BRAKE PANEL ASSEMBLY
Install a new dust seal.
Apply grease to the speedometer gear and install the gear.
Apply grease to the sliding surfaces of the brake cam and shoes as shown in the figure above.
Install the brake cam and brake arm aligning the punch mark on the brake arm with the panch mark on the cam.
Install the brake shoes and springs.
FRONT WHEEL RIM INSPECTION
Check the wheel rim runout by placing the wheel on the turning stand.
Service limit:
Axial: 2.0mm under
Radial: 2.0mm under
FRONT WHEEL ASSEMBLY
Apply grease to the wheel bearings.
Install the right bearing and center collar.
Install the left bearing and dust seal.
Install the side collar.
NOTE:
Install the bearing with the sealed end facing the outside.
BRAKE CAM
BRAKE SHOES
BRAKE ARM
11-6
11.
FRONT WHEEL
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
INSTALLATION
Install the front wheel.
Install the axle shaft from the right side.
Tighten the axle nut.
TORQUE: 6.00-8.00 kgf
· m
Connect the speedometer cable.
FRONT FORK
FRONT FORK REMOVAL
Remove the front wheel.
Remove the brake caliper bolts.
Remove the front fender.
Remove the fork top bridge bolts.
Loosen the fork bottom bridge, remove the front shock absorber assembly.
TOP BRIDGE BOLTS
BOLTS
BOTTOM BRIDGE BOLTS
11-7
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
If the front fork is too soft or too hard, refill or drain the shock absorber fluid.
Shock absorber fluid:
CUSHION OIL
Standard capacity :160c.c
FRONT FORK
INSTALLATION
Install the front fork from the bottom.
NOTE:
Turn the front fork left and right by hand while installing.
Tighten the fork top bridge bolts.
TORQUE: 4.00-5.50 kgf
· m
Tighten the fork bottom bridge bolts.
TORQUE: 4.00-5.50 kgf
· m
Install the front fender.
Install the front wheel.
STEERING STEM
FRONT FORK TOP REMOVAL
Remove the handlebar.
Remove the headlight and meter assembly.
Remove the front fork.
Remove the steering stem nut and washer.
11-8
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
STEERING STEM DISASSEMBLY
Remove the front fork top bridge bolts.
NOTE:
Do not let the steel balls fall.
Remove the steel balls cone brace,steering stem and steel balls.
Check the top and bottom cone races and steel balls for wear or damage and replace if necessary.
STEERING STEM ASSEMBLY
Install the steel balls cone brace.
STEEL
BALLS
STEERING
STEM
STEERING
LOCK
DRIVE OUT
DRIVER
STEEL
BALLS
TOP CONE
BRACE
BOTTOM
CONE BRACE
DRIVE IN
DRIVER HOLDER
11-9
11.
HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
Grease the steel balls and cone braces, install the steering stem.
Install the steering top nut and tighten it until snug against the upper cone braces.
Back the top nut out 1/8 turn to let steering stem be able to rotor freely.
Install the front fork top bridge.
Install the front fork.
Tighten the front fork bottom bridge bolts.
TORQUE: 4.00-5.50 kgf
· m
TOP BRIDGE BOLT
Tighten the steering stem nut.
TORQUE: 6.00-8.00 kgf
· m
Tighten the front fork top bridge bolts.
TORQUE: 4.00-5.50 kgf
· m
Install the handlebar, meter, headlight and front wheel.
FRONT FORK
TOP BRIDGE
11-10
12. REAR WHEEL/REAR SUSPENSION
TROUBLE SHOOTING.......................12-1
SERVICE INFORMATION ..................12-1
REAR WHEEL ....................................12-2
REAR BRAKE PANEL........................12-5
TROUBLE SHOOTING
SHOCK ABSORBER.......................... 12-6
REAR FORK ...................................... 12-8
REAR BRAKE PEDAL........................ 12-9
WOBBLE OR VIBRATION IN
MOTORCYCLE
1. Loose rear wheel bearing
2. Distorted rim
3. Tire pressure too high
4. Loose axle nut
SOFT SUSPENSION
1. Weak spring
2. Shock absorber faulty or too soft
HARD SUSPENSION
1. Bent damper shaft
2. Faulty shock absorber stopper rubber
SUSPENSION NOISE
1. Loose fasteners
2. Faulty shock absorber stopper rubber
3. Damper leaking
4. Damper and spring binding
POOR BRAKE PERFORMANCE
1. Improper brake adjustment
2. Brake linings oily or worn
3. Worn brake drum
4. Brake arm serrations improperly engaged
SERVICE INFORMATION
TORQUE VALUES
Rear wheel axle nut
Rear fork pivot bolt nut
Rear brake torque link nut
Shock absorber nut
Final driven sprocket
Drive sprocket bolt
SPECIFICATIONS
10.00 ~ 12.00 kgf·m
8.00 ~ l0.00 kgf·m
1.50 ~ 2.00 kgf·m
3.00 ~ 4.00 kgf·m
2.70 ~3.30 kgf·m
1.00 ~ 1.40 kgf·m
ITEM
STANDARD SERVICE LIMIT
Rear axle runout
0~0.01mm 0.2mm
……… 2.0mm
Axial
Rim runout
Brake drum I.D
Radial
………
2.0mm
150mm 152mm
Brake lining thickness
4.3mm 2.0mm
Shook absorber spring free length
Rear fork bushing clearance
195.3mm 183mm
0.2~0.3mm
0.5mm
12-1
12. REAR WHEEL/REAR SUSPENSION
REAR WHEEL
REAR WHEEL REMOVAL
Raise the rear wheel off the ground on the main stand.
Remove the exhaust muffler.
Disconnect the brake rod from the brake arm.
Disconnect the brake torque link from the brake panel.
Remove the axle nut and loose the chain adjusting nut. Pull out the axle shaft and remove the drive chain from the drive sprocket, then remove the rear wheel.
AXLE INSPECTION
Set the axle in the V-blocks and measure the runout.
The actual runout is 1/2 of the total indicator reading. service limit: 0.2mm under
ADJUSTING NUT
12-2
12. REAR WHEEL/REAR SUSPENSION
BEARING FREE PLAY INSPECTION
Shake the bearing back and forth and spin it by hand, replace it with a new one if it is noisy or has excessive free play.
WHEEL RIM RUNOUT INSPECTION
Check the rim runout by placing the wheel in a turning stand. Turn the wheel by hand and read the runout using a dial indicator gauge.
TORQUE: 0.25-0.50 kgf·m
Runout:
Axial: 2.0mm under
Radial: 2.0mm under
FINAL DRIVEN SPROCKET
INSPECTION
Check the condition of the final driven sprocket teeth.
Replace the sprocket if it is worn.
NOTE:
The drive chain and drive sprocket must be also inspected for wear.
DAMPER RUBBER INSPECTION
Check the damper rubbers for wear or damage and replace if necessary.
GOOD
NOT GOOD
12-3
12. REAR WHEEL/REAR SUSPENSION
FINAL DRIVEN SPROCKET ASSEMBLY
Install the drive sprocket and new lock plates on the driven flange and tighten them with the bolts and nuts.
TORQUE:240~300 kg f·cm
Bend up the lock plate tabs against the nuts.
Install the driven flange on the wheel hub.
12-4
12. REAR WHEEL/REAR SUSPENSION
Measure the brake drum I.D.
Service limit: ∮152mm
REAR BRAKE PANEL
NOTE:
Grease the place as figure.
BRAKE SHOE INSPECTION
Measure the lining thickness.
Service limit: 2.0mm
BRAKE SHOE REPLACEMENT
Separate the brake shoes with the brake cam.
Remove the brake shoes and springs.
Grease the brake cam.
Install the new brake shoes.
WARNING:
Contaminated brake lining reduces stopping power.
Keep grease off the lining.
BRAKE ARM
BRAKE CAM
BRAKE
SHOE
12-5
12. REAR WHEEL/REAR SUSPENSION
Install the hold arm.
Install the brake linkage.
Adjust the drive chain tension (2-13).
Drive chain slack: 10 ~ 20mm
Tighten the chain tension adjusters.
Tighten the axle nut.
TORQUE: 1000~1200 kg f
· cm
Apply engine oil to the drive chain.
Install the step bar and the muffler.
SHOCK ABSORBER
SHOCK ABSORBER REMOVAL
Remove the left and right shock absorber assembly.
SHOCK ABSORBER DISASSEMBLY
Compress the shock absorber spring with a shock absorber compressor.
Loosen the lock nut, remove the upper holder.
ADJUSTING NUT
HOLDER
12-6
Remove the spring and rubber.
12. REAR WHEEL/REAR SUSPENSION
SHOCK ABSORBER SPRING
INSPECTION
Measure the shock absorber spring free length.
Service limit: 183mm
Check the shock absorber for noisy or leaks.
SHOCK ABSORBER ASSEMBLY
NOTE:
Install the spring with the tightly wound coils at the top.
TORQUE: 1.50-2.50kgf·m
SHOCK ABSORBER INSTALLATION
Tighten the shock absorber upper and lower mounting nuts.
TORQUE: 3.00-4.00 kgf·m
Check the shock absorber operation.
NOTE: y Adjust the right and left absorber to the same scales. y
The standard position is "1".
SPRING COMPRESSOR
HOLDER
SPRING COMPRESSOR
12-7
12. REAR WHEEL/REAR SUSPENSION
REAR FORK
REAR FORK REMOVAL
Remove the muffler.
Remove the rear wheel (12-3).
Remove the rear shock absorber (12-9).
Remove the drive chain cover.
Remove the rear fork mounting bolts.
REAR FORK DISASSEMBLY/ASSEMBLY
NOTE:
Drive the bushings out with a soft hammer, making sure that they are not damaged. Lubricate with grease after installation.
REAR FORK INSPECTION
Inspect the pivot bushing for cracks or damage.
Check each part for wear or damage.
BUSH
REAR FORK
PIVOT BOLT
CHAIN ADJUSTER
12-8
12. REAR WHEEL/REAR SUSPENSION
REAR FORK INSTALLATION
Install the rear fork.
TORQUE: 8.00~10.00 kgf·m
Install the rear shock absorber and rear wheel.
Install the muffler.
REAR BRAKE PEDAL
Remove the muffler.
Remove the brake linkage rod.
Remove the brake light switch spring.
Remove the brake return spring.
Adjust the rear brake after installation.
NOTE :
Do not forget to install the brake light switch spring.
ADJUSTING BOLT
12-9
13. BATTERY/CHARGING SYSTEM
TROUBLE SHOOTING.......................13-1
SERVICE INFORMATION ..................13-2
TROUBLE SHOOTING
BATTERY ........................................... 13-3
CHARGING SYSTEM ........................ 13-4
NO POWER --- KEY TURNED ON
1. Dead battery
-- Battery electrolyte evaporated
-- Battery not charged
-- Charging system failure
2. Disconnected battery cable
3. Main fuse burned out
4. Faulty ignition switch
LOW POWER --- KEY TURNED ON
1. Weak battery
-- Low battery electrolyte level
-- Charging system failure
2. Loose battery connection
LOW POWER --- ENGINE RUNNING
1. Battery undercharged
-- One or more dead cells
-- Low battery electrolyte level
2. Charging system failure
3. Generator failure
4. Faulty voltage regulator
5. Faulty ignition coil
6. C.D.I. UNIT failure
INTERMITTENT POWER
1. Loose battery connection
2. Loose charging system connection
3. Loose connection or short circuit in ignition system
4. Loose connection or short circuit in light system
13-1
13. BATTERY/CHARGING SYSTEM
CHARGING SYSTEM FAILURE
1. Loose broken or shorted wire
2. Faulty voltage regulator
3. Faulty generator
4. Battery undercharged
SERVICE INFORMATION
GENERAL INSTRUCTIONS
1. Battery acid level should be checked and refill with distilled water when necessary.
2. When charging the battery, quick-charging should only be done in an emergency; slow charging is preferred.
3. Remove the battery from the motorcycle for charging whenever possible. If battery must be charged on the motorcycle, keep away from flames or sparks.
4. The parts of charging system can be tested on the motorcycle.
5.Refer to section 8 for generator removal and installation.
SPECIFICATIONS
Battery
Capacity
Electrolyte specific gravity
Charging current
12V & 8AH
1.260-1.280 (20℃/68°F)
0.9A
A.C. generator
Charging output
Charging rpm
76W/5,000rpm
1,200 rpm max. (Day)
2,400 rpm max. (Night)
Rectifier One-way full wave
Fuse 15A
13-2
BATTERY
BATTERY REMOVAL AND
INSTALLATION
Remove the right side cover.
Disconnect the battery negative cable first, then the battery positive cable.
Disconnect the battery band, remove the battery.
BATTERY INSTALLATION
Put the battery on the battery rack.
Install the battery band.
Connect the battery positive cable first, then the battery negative cable.
Install the right side cover.
SPECIFIC GRAVITY TEST
Test each cell by using a hydrometer.
SPECIFIC GRAVITY :
13. BATTERY/CHARGING SYSTEM
1.220 or below
(20℃/68 °F )
Undercharged
NOTE :
• The battery must be recharged if the specific gravity is below 1.23.
• The specific gravity varies with the temperature as shown in the accompanying table.
• Replace the battery if sulfating is evident.
•
The battery must be replaced if there are pastes on the bottom of each cell.
WARNING:
The battery electrolyte contains sulfuric acid.
Protect your skin, eyes and clothing. Note the followings:
1. In case of contact, flush thoroughly with water.
2. In case of drinking, drink mass of water or milk, and eat the white of an egg or drink vegetable oil.
3. Cover the eyes when operating at short distance, in case of contact, flush thoroughly with water and spread of eye-ointment.
4. Keep flames and sparks away from a charging battery.
5.Place the charging battery in a ventilated area.
13-3
13. BATTERY/CHARGING SYSTEM
Connect the charger positive(+) cable to the battery positive (+) terminal, negative (-) cable to the battery negative (-) terminal.
Charge the battery until the specific gravity of the electrolyte is 1.260-1.280 (20℃/68℉ )
Charging current: 0.7A max.
WARNING:
Before charging a battery, remove the cap from each cell.
Keep flames and sparks away from a charging battery.
Connect the cables first, then turn on the power.
Discontinue charging if the electrolyte temperature exceeds 45 ℃ (113℉).
CAUTION:
Quick-charging only be done in an emergency; slow-charging is preferred.
After installed the battery, coat the terminals with clean grease to keep from oxidation.
CAUTION:
Route the breather tube as shown on the battery caution label.
CHARGING SYSTEM
PERFORMANCE TEST
Warm up the engine before taking readings.
Connect a voltmeter and an ammeter to check charging output.
NOTE:
Use a fully charged battery to check the charging system output.
VOLTMETER
BATTERY
AMMETER
13-4
13. BATTERY/CHARGING SYSTEM
STATOR COILS TEST
NOTE:
This test can be made with the stator on the frame.
Disconnect and measure the A.C. generator connectors with a multi-meter.
Conductivity should exist between :
Pink- yellow,blue/white-green/white,black/red-ground.
Pink,yellow,blue/white,green/white should not conduct electricity with ground.
RECTIFIER
Disconnect the rectifier connector and check its performance.
WARNING:
Do not use high voltage power, especially the ohmmeter, or the rectifier will be burnt out.
(-)
RECTIFIER
(+)
GREEN
√
√ ∞
∞
√
∞
√
∞
∞
√
∞
YELLOW
PINK
√ ∞ ∞ ∞
BLACK
√ ∞ ∞ ∞
Rectifier is normal if there is continuity only in the direction shown.Replace the rectifier if there is continuty in reverse direction.
13-5
14. IGNITION SYSTEM
TROUBLE SHOOTING.......................14-1
SERVICE INFORMATION ..................14-2
TROUBLE SHOOTING
ENGINE CRANKS BUT NOT START
1. No sparks at the spark plug
2. Improper ignition timing
3. Faulty plug
NO SPARKS AT THE SPARK PLUG
1. No current in primary circuit
2. High tension cord broken
3. Faulty ignition coil
4. Faulty A.C. generator
5. Faulty C.D.I. unit
ENGINE RUNS BUT ROUGHLY
1. Primary circuit
-- C.D.I. unit failure
-- Faulty A.C. generator
-- Faulty ignition coil
-- Loose wires
-- Poorly contacted switch terminals
2. Secondary circuit
-- Faulty,spark plug
-- Faulty high tension cord
-- Faulty ignition coil
3. Ignition timing
-- Faulty A.C. generator
-- Faulty C.D.I. unit
IGNITION COIL .................................... 14-3
C.D.I.
Green/white
Black/ yellow
Green
Black/red
Blue/white
Black/white
14-1
14. IGNITION SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTION
This section contains the ignition system.
Be sure that the battery is fully charged before diagnosing troubles in the ignition system.
Also refer to the following pages:
Spark plug 2-5
2-8 Ignition timing adjustment
SPECIFICATIONS
Spark plug:
Spark plug gap:
Ignition timing :Initial
Full advance
D7RC
0.6~0.7mm(0.024-0.028in)
15°±2°/1500rpm
29.5°±2° /4000rpm
14-2
IGNITION COIL
IGNITION COIL REMOVAL
Remove the seat.
Remove the fuel tank.
Remove the spark plug cap.
Disconnect all wires to the ignition coil.
Remove the ignition coil.
IGNITION COIL TEST
Check the ignition coil output using a tripolar tester.
NOTE:
Follow the instructions described in the user’s manual.
Check the primary circuit, it is normal if there is conductivity when connecting a ohmmeter.
PRIMARY COIL 0.31±0.03KΩ
SECONDARY COIL 4.0±0.4KΩ
14. IGNITION SYSTEM
IGNITION COIL
14-3
15. SWITCHES/HORN
TROUBLE SHOOTING.......................15-1
SERVICE INFORMATION ..................15-2
MAIN/DIMMER SWITCH ....................15-3
WINKER/HORN SWITCH...................15-3
HEADLIGHT SWITCH ........................15-3
TROUBLE SHOOTING
NO LIGHTS COME ON WHEN IGNITION
SWITCH IS TURNED ON:
1. Battery low
2. Wiring loose or blown
3. Fuse blown
4. Open or shorted wiring
5. Faulty combination switch
6. Bulb at fault or burned out
ALL LIGHTS COME ON BUT DIMLY WHEN
IGNITION SWITCH IS TURNED ON:
1. Battery low
2. Wiring or switch has excessive resistance
HEADLIGHT BEAMS DO NOT SHIFT WHEN
HIGH-LOW SWITCH IS OPERATED:
1. Faulty dimmer switch
2. Faulty headlight switch
HEADLIGHT SWITCH........................ 15-3
START/HAZARD SWITCH ................. 15-3
FRONT/REAR BRAKELIGHT SWTICH
..... 15-4
HORN SWTICH.................................. 15-4
15-1
15. SWITCHES/HORN
SERVICE INFORMATION
GENERAL INSTRUCTIONS
All electrical wires are color-coded. Check the color before connecting wires.
All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
A conductivity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a galvanometer or voltmeter to the terminals or connections.
SPECIFICATIONS
Winker light
Tail / Stop light
Speedometer light
Neutral pilot
Winker indicator
High beam pilot
12V 10W
12V 5W/21W
12V 3.4W x 2
12V 3.4W
12V 3.4W
12V 1.7W
15-2
15. SWITCHES/HORN
MAIN SWITCH DIMMER SWITCH
WIRE COLOR
BLACK/
WHITE
GREEN RED BLACK
BROWN/
RED
BROWN
WIRE COLOR
BROWN/WHITE
Br/W
B/W
G R B
Br/R
Br
WHITE
W
BLUE
L
SWITCH POSITION
SWITCH POSITION
○ ○
○ ○
○ ○
○
○
○
○
P
○ ○ ○ ○
WINKER SWITCH HORN SWITCH
WIRE COLOR
WIRE COLOR
SKY BLUE
SB
GRAY
Gr
ORANGE
O
GREEN
G
SWITCH POSITION
SWITCH POSITION
○
○ ○
LIGHT GREEN
LG
○
○
○
●
●
LIGHT SWITCH
WIRE COLOR
BLACK
B
BROWN
Br
BROWN/WHITE
Br/W
SWITCH POSITION
○ ○ ○
○ ○
●
START SWTICH HAZARD SWITCH
WIRE COLOR
WIRE COLOR
YELLOW/RED
Y/R
BLACK
B
GRAY
Gr
ORANGE
O
SWITCH POSITION
SWITCH POSITION
SKY
BLUE
SB
○ ○ ○ ○
● ●
15-3
15. SWITCHES/HORN
FRONT LIGHTBRAKE SWITCH
Check that the front brakelight switch for conductivity between the BLACK and GREEN/YELLOW wires. The switch is normal if there is conductivity with the front brake applied.
STOP SWITCH
REAR LIGHTBRAKE SWITCH
The switch is normal if there is conductivity with the rear brake applied.
ADJUSTING SCREW
HORN
Connect the horn to a 12V battery for testing its performance. Adjust the horn if the noise is not loud enough.
BATTERY
ATTACHING NUT
15-4
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project