SERVICE MANUAL XS 125

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SERVICE MANUAL XS 125 | Manualzz

SERVICE MANUAL

XS 125

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CONTENTS

Contents

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

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CONTENTS

CONTENTS

GENERAL INFORMATION ..........................................................................1

INSPECTION/ADJUSTMENT.......................................................................2

LUBRICATION SYSTEM..............................................................................3

ENGINE REMOVAL/INSTALLATION ..........................................................4

CYLINDER HEAD/VALVE............................................................................5

CYLINDER/PISTON .....................................................................................6

CLUTCH/OIL PUMP/GEAR SHIFT ..............................................................7

A.C. GENERATOR .......................................................................................8

CRANK SHAFT/CRANK CASE/TRANSMISSION.......................................9

CARBURETOR.............................................................................................10

HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ..........................11

REAR WHEEL/REAR SUSPENSION ..........................................................12

BATTERY/CHARGING SYSTEM .................................................................13

IGNITION SYSTEM ......................................................................................14

SWITCHES/HORN........................................................................................15

WIRING DIAGRAM.......................................................................................16

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Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

This chapter Contents

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

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Contents

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

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3.LUBRICATION SYSTEM

Contents

OIL LINE OF

CAM SHAFT

CAM SHAFT

MAIN SHAFT

COUNTER SHAFT

PISTON

OIL ORIFICE OF

CRANKSHAFT

OIL PUMP

OIL FILTER

3-0

This chapter Contents

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

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Contents

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

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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

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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

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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

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Contents

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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

○ ○ ○ ○

● ●

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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

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