SANYANG HD 200 Service manual

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HOW TO USE THIS MANUAL
MECHANISM ILLUSTRATIONS
HD125 / 200
SERVICE MANUAL
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Contents
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This service manual contains the technical data of each component inspection and
repair for the SANYANG HD 125 / 200 motorcycle. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment” so that provides technician with service guidelines.
If the style and construction of the motorcycle, HD 125 / 200, are different from that
of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
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Contents
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for SANYANG HD 125/200 motorcycles. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the CD-R version, and can be access to these items
by click the mouse.
If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, onto the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back the
homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the content.
In addition, there is a “To this chapter contents” button at the second page of each
content so that clicking the button can back to the contents of this chapter.
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CONTENTS
Page
Content
Index
1-1 ~ 1-18
GENERAL INFORMATION
1
2-1 ~ 2-16
SERVICE MAINTENANCE INFORMATION
2
3-1 ~ 3-8
LUBRICATION SYSTEM
3
4-1 ~ 4-12
FUEL SYSTEM
4
5-1 ~ 5-8
ENGINE REMOVAL
5
6-1 ~ 6-14
CYLINDER HEAD/VALVE
6
7-1 ~ 7-8
CYLINDER/PISTON
7
8-1 ~ 8-14
“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
8
9-1 ~ 9-10
FINAL DRIVING MECHANISM
9
10-1 ~ 10-8
ALTERNATOR
10
11-1 ~ 11-8
CRANKSHAFT/ CRANKCASE
11
12-1 ~ 12-14
COOLING SYSTEM
12
13-1 ~ 13-16
BODY COVER
13
14-1 ~ 14-14
BRAKE SYSTEM
14
15-1 ~ 15-10
STEERING/FRONT WHEEL/SUSPENSION
15
16-1 ~ 16-6
REAR WHEEL/SUSPENSION
16
17-1 ~ 17-20
ELECTRICAL EQUIPMENT
17
18-1 ~ 18-2
ELECTRICAL DIAGRAM
18
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Contents
MECHANISM ILLUSTRATIONS
LH12W / LH18W
Battery/CDI
Front brake lever
Oil lever / Oil filter
Water pump
AC. Generator
Winker relay
Horn
Fuel unit
Radiator
Ignition coil
Rear brake lever
Luggage box
Spark plug
Fuel tank cap
Front winker light
Tail light/
Rear winker light
Headlight
Air cleaner
Gear oil drain bolt
Engine number
Engine oil drain bolt
Winker light / Horn /
Dimmer & Passing switches
Headlight/Start switches
Main switch
Radiator filler cap
Reserve tank cap
Fuse box /
Regulator rectifier
Starter relay
Headlight relay
Exhaust muffler
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Contents
1. GENERAL INFORMATION
Symbols and Marks............................... 1-1
Specifications..................................... 1-10
General safety........................................ 1-2
Torque Values .................................... 1-11
Service Precautions .............................. 1-3
Troubles Diagnosis ............................ 1-13
Specifications ........................................ 1-9
Parts to Be Greased ........................... 1-17
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are needed, in
case supplemental information is procedures needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.
Warning
Caution
Means that serious injury or even death may result if procedures are not
followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
Engine oil
damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
Grease
King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil
# 140)
Apply sealant, medium strength sealant should be used unless otherwise
Locking sealant
specified.
Oil seal
Apply with lubricant.。
Renew
Replace with a new part before installation.
Brake fluid
Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools
Special tools
Correct
Meaning correct installation.
Wrong
Meaning wrong installation.
Indication
Indication of components.
Directions
Indicates position and operation directions
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
1-1
1
To this chapter contents
1. GENERAL INFORMATION
General safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you
have to run your engine in a closed area, be sure
to use an extractor.
Caution
Exhaust contains toxic gas which may cause one
to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified.
We recommend that you wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.
1-2
Battery
Caution
• Battery emits explosive gases; flame is strictly
prohibited. Keep the place well ventilated
when charging the battery.
• Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
do not be spray on your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery acid
in your eyes, flush it off immediately with
water and then go to hospital to see an
ophthalmologist.
• If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a
doctor.
• Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
To this chapter contents
1. GENERAL INFORMATION
Service Precautions
y Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
y Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
y Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
y Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and oil.
Check these parts before installation to make
sure that they are in good condition, replace if
necessary.
y When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
y Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
y When servicing this motorcycle, use only metric
tools. Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
y Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on the
part's surface may fall into the engine, chassis,
or brake system to cause a damage.
y Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on
them.
y Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
y Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
To this chapter contents
1. GENERAL INFORMATION
y The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole to
compare its length with other bolts, if its length
out side the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.
y Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
y The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go
to their connections so that there is enough
room below the enlarged ends for tightening the
clamps.
Groove
y Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
Clamp
Connector
y Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
Boots
y When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, check the shaft on
which the oil seal is to be installed for
smoothness and for burrs that may damage the
oil seal.
y The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner race
or outer race). In this case, the bearing should
be replaced. To avoid damaging the bearing,
use equal force on both races.
Manufacturer's name
Both of these examples can result in
bearing damage.
1-4
To this chapter contents
1. GENERAL INFORMATION
y Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
y After service completed, make sure all
connection points is secured.
Battery positive (+) cable should be connected
firstly.
y And the two posts of battery have to be greased
after connected the cables.
y Check if positions and operation for installed
parts is in correct and properly.
y Make sure service safety each other when
conducting by two persons.
y Make sure that the battery post caps are
located in properly after the battery posts had
been serviced.
y If fuse burned, it has to find out the cause and
solved it. And then replace with specified
capacity fuse.
y Note that do not let parts fall down.
Capacity
verification
y Before battery removal operation, it has to
remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and
create spark.
1-5
To this chapter contents
1. GENERAL INFORMATION
y
When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service
operation.
y
Do not pull the wires as removing a connector
or wires. Hold the connector body.
y Insert the terminal completely.
Check if the terminal is covered by the boot.
Do not let boot open facing up.
y Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
y Make sure if the connector pins are bent,
extruded or loosen.
y Wire band and wire harness have to be
clamped secured properly.
y Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
y Do not squeeze wires against the weld or its
clamp.
y Check if the connector is covered by the twin
connector boot completely and secured
properly.
y Before terminal connection, check if the boot is
crack or the terminal is loose.
1-6
To this chapter contents
1. GENERAL INFORMATION
y Do not let the wire harness contact with rotating,
moving or vibrating components as routing the
harness.
y Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner. Thoroughly clean the surface where
tape is to be applied.
y Keep wire harnesses far away from the hot
parts.
y Secure the rubber boot firmly as applying it on
wire harness.
Never Touch
y Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
y Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
y Route harnesses so that they neither pull too
tight nor have excessive slack.
y Never clamp or squeeze the wire harness as
installing other components.
Never clamp or
squeeze the wire
harness
Never too tight
1-7
To this chapter contents
1. GENERAL INFORMATION
y Do not let the wire harness been twisted as
installation.
y With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
y Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
y Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?
1-8
To this chapter contents
1. GENERAL INFORMATION
Specifications
Overall Length
2064 mm
Overall Width
760 mm
Overall Height
1165 mm
Wheel Base
1385 mm
Front
53 kg
Rear
82 kg
Total
135 kg
Passengers/Weight
Two /110 kg
Front
75 kg
Rear
Total
Curb Weight
Weight
SANYANG
Total Weight
Cylinder
LH18W-6
Suspension
System
Tire Specifications
Brake System
Front
Telescopic Fork
Rear
Unit Swing
Front
100 / 80 – 16 50P/TL
Rear
120 / 80 - 16 60P/TL
Front
Disk (ψ220mm)
Rear
Drum (ψ130mm)
Max. Speed
Above 108 km/hr
Climb Ability
Below 28°
170 kg
Primary
Reduction
Belt
245 kg
Secondary
Reduction
Gear
Performance
Reduction
Type
4-Stroke Engine
Clutch
Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline 80°
Transmission
C.V.T.
Fuel Used
Unleaded
Speedometer
0 ~ 140 km/hr
Cycle/Cooling
4-stroke/water cooled
Horn
93~112 dB/A
Bore
Engine
MODEL
Stroke
Number/Arrange
ment
Muffler
Expansion & Pulse
Type
Exhaust Pipe Position and
Direction
Right side, and
Backward
Lubrication System
Forced circulation &
splashing
61 mm
58.6 mm
Single Cylinder
Displacement
171.2 cc
Compression Ratio
10.8 : 1
Max. HP
11.4kw / 8000rpm
Max. Torque
15.3Nm / 6500rpm
Exhaust
Concentrati
on
Dimension
MAKER
Solid Particulate
CO
Below 5.5 g/ km
HC
Below 1.0g/ km
E.E.C.
─
Ignition
C.D.I.
P.C.V.
─
Starting System
Power & Foot
Catalytic reaction control
system
─
1-9
To this chapter contents
1. GENERAL INFORMATION
Specifications
Dimension
MAKER
Overall Length
2064 mm
Overall Width
706 mm
Overall Height
1165 mm
Wheel Base
1385 mm
LH12W-6
Front
Telescopic Fork
Rear
Unit Swing
Front
100 / 80 -16 50P/TL
Rear
120 / 80 -16 60P/TL
Front
Disk (ψ220mm)
Rear
Drum (ψ130mm)
Max. Speed
Above 100 km/hr
Climb Ability
Below 28°
Suspension System
Tire Specifications
53 kg
Rear
82 kg
Total
135 kg
Passengers/ Weight
Two/110 kg
Front
75 kg
Rear
170 kg
Primary
Reduction
Belt
Total
245 kg
Secondary
Reduction
Gear
Total Weight
Reduction
Clutch
Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline 80°
Transmission
C.V.T.
Fuel Used
Unleaded
Speedometer
0 ~ 140 km/hr
Cycle/Cooling
4-Stroke/Water Cooled
Horn
93~112 dB/A
Stroke
Number /
Arrangement
48.8 mm
Single Cylinder
Displacement
124.5 cc
Compression Ratio
10.5 : 1
Max. Torque
Muffler
Expansion & Pulse
Type
Exhaust Pipe Position and
Direction
Right side, and
Backward
Lubrication System
Forced circulation &
splashing
57 mm
9.2kw / 8500rpm
10.9Nm / 6500rpm
Exhaust
Concentr
ation
Cylinder
Performance
4-Stroke Engine
Max. HP
1-10
Brake System
Type
Bore
Engine
MODEL
Front
Curb Weight
Weight
SANYANG
Solid Particulate
CO
Below 5.5g/km
HC
Below 1.2 g/km
E.E.C.
─
Ignition
C.D.I.
P.C.V.
─
Starting System
Power & Foot
Catalytic Reaction Control
System
Yes
To this chapter contents
1. GENERAL INFORMATION
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard
values for not listed in the table.
Standard Torque Values for Reference
Type
Type
Tighten Torque
Tighten Torque
5 mm bolt、nut
0.45~0.6kgf-m
6 mm bolt、nut
0.8~1.2kgf-m
6 mm screw、SH nut
0.35~0.5kgf-m
0.7~ 1.1kgf-m
8 mm bolt、nut
1.8~2.5kgf-m
6 mm bolt、nut
1.0 ~1.4kgf-m
10 mm bolt、nut
12 mm bolt、nut
3.0~4.0kgf-m
5.0~6.0kgf-m
8 mm bolt、nut
10 mm bolt、nut
2.4 ~3.0kgf-m
3.5~4.5kgf-m
5 mm screw
Engine Torque Values
Item
Cylinder head nut
Cylinder head right bolt
Cylinder head stud bolt (inlet pipe)
Cylinder head stud bolt (EX. pipe)
Tappet adjustment hole cap bolt
Tappet adjustment screw nut
Spark plug
Carburetor insulator bolt
Cylinder stud bolt
Engine left cover bolt
Engine oil draining bolt
Engine oil strainer cap
Mission draining bolt
Mission filling bolt
Clutch driving plate nut
Clutch outer nut
Drive face nut
Flywheel nut
Crankcase bolts
Mission case bolt
Q’ty Thread Dia. (mm) Torque Value(kgf-m)
4
2
2
2
6
4
1
2
4
7
1
1
1
1
1
1
1
1
7
7
8
8
6
7
6
5
10
6
8
6
12
30
8
10
28
12
12
12
6
8
2.0~2.4
2.0~2.4
0.7~1.1
0.5~1.0
1.0~1.4
0.7~1.1
1.0~1.2
0.7~1.1
0.7~1.1
1.1~1.5
1.1~1.5
1.3~1.7
0.8~1.2
0.8~1.2
5.0~6.0
5.0~6.0
5.0~6.0
5.0~6.0
0.8~1.2
2.0~2.4
Remarks
Apply oil to thread
1-11
To this chapter contents
1. GENERAL INFORMATION
Frame Torque Values
Item
Stopper nut for engine hanger
rubber
Engine hanger nut
Engine hanger bolt
Engine connection bolt
Front wheel axle nut
Rear wheel shaft nut
Rear fork
Rear cushion upper bolt
Rear cushion under bolt
Nut for steering post
Front cushion
Brake lever nut
Nut for the rear brake arm
Front brake hose bolt
Front brake caliper bolt
Front brake disk mounting bolt
Air-bleed valve
Speedometer cable locking screw
Exhaust muffler bolt
Exhaust muffler connection nut
1-12
Q’ty Thread Dia. (mm) Torque Value(kgf-m)
1
8
1.8~2.2
2
1
1
1
1
2
2
2
1
4
2
1
4
4
7
1
1
3
2
12
12
10
12
14
8
10
8
10
8
6
6
10
6
8
5
5
8
7
4.0~5.0
4.0~5.0
3.5~4.5
5.0~7.0
10.0~12.0
4.0~5.0
3.5~4.5
2.4~3.0
4.0~5.0
2.4~3.0
0.8~1.2
0.5~0.6
3.0~4.0
3.0~3.5
4.0~4.5
0.5~0.6
0.15~0.3
3.2~3.8
1.0~1.2
Remarks
To this chapter contents
1. GENERAL INFORMATION
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment
Fault condition
Loosen carburetor drain bolt to
check if there is gasoline inside
the carburetor
Fuel supplied tom
carburetor sufficient
No fuel is supplied to
carburetor
Remove spark plug, install it
into spark plug cap, and perform
a spark test against engine
ground.
Check if sparks
Malfunction of spark plug
Spark plug foul
Malfunction of CDI set
Malfunction of AC generator
Ignition coil is in open or short circuit
Ignition coil leads open or short circuit
Malfunction of main switch
Low compression
pressure or no pressure
1.
2.
3.
4.
5.
Piston ring seized
Malfunction of cylinder valves
Worn cylinder and piston ring
Cylinder gasket leak
Sand hole in compression parts
There are some signs of
ignition, nut engine can
not be started
1. Malfunction of throttle valve operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
Wet spark plug
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
Blowing clogged
1. Malfunction of automatic by- starter
Weak sparks, no spark at
all
Re-start by following the starting
procedures
No ignition
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum
hose
7. Fuel filter clogged
1.
2.
3.
4.
5.
6.
7.
Perform cylinder compression
pressure test.
Cylinder compression
pressure normal
Probable causes
Remove the spark plug again
and check it.
Dry spark plug
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Blowing in normal
1-13
To this chapter contents
1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment
Fault condition
Probable causes
Try gradual acceleration and
check engine speed
Engine speed can be
increased.
Engine speed can not be
increased.
clogged
4. Exhaust pipe clogged
5. Fuel nozzle clogged in carburetor.
6. Fuel nozzle clogged in carburetor.
Check ignition timing (Using
ignition lamp)
Ignition timing correct
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation system
Incorrect ignition timing
1. Malfunction of CDI
2. Malfunction of AC alternator
Check cylinder compression
pressure (using compression
pressure gauge)
Compression pressure
correct
No compression pressure
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Seized piston ring
Check if carburetor jet is
clogged
No clogged
Clogged
1. Remove foreign
Remove spark plug
No foul or discoloration
Fouled and discoloration
Check if engine over heat
Normal
Engine overheat
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling system
Continually drive in acceleration
or high speed
1. Too much carbon deposited in
combustion chamber
No knock
1-14
Knock
2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced
To this chapter contents
1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment
Fault condition
Probable causes
Check ignition timing (using
ignition lamp)
Abnormal
Normal
Adjust the air screw of
carburetor
Good
Poor
1. Incorrect ignition timing
(malfunction of CDI or AC
alternator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
Air sucked through carburetor
gasket
No air sucked
Air sucked
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground
Good spark
Poor
D. Engine runs sluggish (High speed)
Check and adjustment
Fault condition
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
5. Vacuum hose crack
1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
Probable causes
Check ignition timing
Normal
Abnormal
1. Malfunction of CDI
2. Malfunction of AC alternator
Check for fuel supplying system
in automatic fuel cup
Good
Abnormal
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Clogged
1. Cleaning
Check if carburetor clogged
No clogged
1-15
To this chapter contents
1. GENERAL INFORMATION
E. Clutch, driving and driving pulley
FAULT CONDITIONS
Engine can be started but
motorcycle can not be moved.
Engine running and misfire as
motorcycle initial forward moving or
jumping suddenly (rear wheel
rotating as engine in running)
Poor initial driving ( Poor climbing
performance)
1-16
PROBABLE CAUSES
1. Drive belt worn out or deformation
2. Ramp plate of movable drive face damaged
3. Driving pulley spring broken
4. Clutch weights broken
5. Drive slide-shaft gear groove broken
6. Transmission gear damaged
1. Clutch weights spring broken
2. Clutch outer stuck with clutch weights
3. Connection parts in clutch and shaft worn out or burned
1. Drive belt worn out or deformation
2. Weight roller worn out
3. Movable drive face shaft worn out
4. Driven pulley spring deformation
5. Driven pulley shaft worn out
6. Greased in drive belt and driven face.
To this chapter contents
1. GENERAL INFORMATION
Parts to Be Greased
Acceleration cable/ Front &
rear brake lever pivot
Steering shaft bearing
Speedometer gear/
Seat catch
Side stand pivot
Main stand pivot
Rear wheel bearing
front wheel bearing
1-17
To this chapter contents
1. GENERAL INFORMATION
Note:
1-18
Home page
Contents
2. MAINTENANCE INFORMATION
Precautions in Operation ······················ 2-1
Periodical Maintenance Schedule ········ 2-2
Brake Light Switch/Starting Inhibitor
Switch ················································· 2-10
Fuel Lines / Cable ·································· 2-3
Headlight Beam Distance ·················· 2-10
Air Cleaner·············································· 2-4
Clutch Disc Wear································ 2-10
Spark Plug ·············································· 2-4
Side Stand··········································· 2-11
Valve Clearance ····································· 2-5
Cushion··············································· 2-11
Carburetor Idle Speed Adjustment······· 2-6
Nuts, Bolts Tightness ························ 2-11
Ignition System ······································ 2-7
Wheel/Tire ··········································· 2-12
Cylinder Compression Pressure ·········· 2-7
Steering Handle Top Bearing ············ 2-12
Drive Belt ················································ 2-8
Special Tools List······························· 2-13
Brake System (Front Disk Brake) ········· 2-8
Precautions in Operation
Specification
Fuel Tank Capacity
Capacity
1000 c.c.
Change
800 c.c.
Capacity
110 c.c.
Change
100 c.c.
Engine + radiator
780 c.c.
Reservoir upper
420 c.c.
Engine Oil
Transmission Gear oil
Capacity of coolant
8000 c.c.
Clearance of throttle valve
Spark plug
2~6 mm
Type
NGK CR8E
Gap
0.8 mm
“F” Mark in idling speed
BTDC 13º / 1000 rpm
Full timing advanced
BTDC 27º / 6000 rpm
Idling speed
1600±100 rpm
Cylinder compression pressure
12.0 ±2 kgf/cm²
Valve clearance: IN/EX
0.12 ± 0.02 mm
Tire dimension
Tire pressure (cold)
Battery
Front
100/80-16 50P
Rear
120/80-16 60P
Single
Front: 1.75 kg/cm²
rear : 2.25 kg/cm²
Two persons
Front: 1.75 kg/cm²
rear : 2.50 kg/cm²
12V8Ah (MF battery) type: YTX9-BS
2-1
2
To this chapter contents
2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
6 month
every
6000KM
1 year
every
12,000KM
R
1
☆Air cleaner
I
3 month
every
3,000KM
C
2
☆2nd air jet leaner
I
C
3
☆Fuel filter
I
4
☆Oil filter
C
C
5
☆Engine oil change
R
Replacement for every 1000 km
Maintenance
Code
6
Item
Tire pressure
Every
300KM
1 Month
every
1,000KM
I
I
Battery inspection
I
I
8
Brake & free ply check
I
I
9
10
11
12
Steering handle check
Cushion operation check
Every screw tightening
h k
Gear oil check for leaking
I
I
I
I
I
14
☆Gear oil change
R
15
I
I
13
I
R
Replacement for every 5000 km
Frame lubrication
L
16
Exhaust pipe
17
☆Ignition timing
I
I
18
☆emission check in Idling
A
I
19
☆Throttle operation
I
I
20
☆Engine bolt tightening
I
I
21
☆CVT driving device(belt)
I
22
☆CVT driving device(roller)
C
23
Lights/electrical
equipment/multi-meters
I
I
24
Main/side stands & springs
I
25
Fuel lines
I
26
Cushions
27
Cam chain
I
I
I
I
I
I
☆Valve clearance
☆Crankcase evaporative
30
☆Crankcase blow-by
31
☆2nd air jet system
I
32
I
I
34
☆Evaporative control system
Lines & connections in cooling
t
Coolant reservoir
I
I
35
Coolant
I
I
33
R
I
29
28
R
I
I
☆Spark plug check or change
R
I
7
15 month
every
14,500KM
I
A
I
C
Replacement for every 2000 km
I
C
I
R
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain
the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
Remarks: 1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items must
be performed normally periodical maintenance following the use r manual instructions. They are prohibited to
be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system-Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal-Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious
lower. Than ever
2-2
To this chapter contents
2. MAINTENANCE INFORMATION
Fuel Lines / Cable
Fuel tank
Vacuum hose
Remove luggage box.
Remove rear carrier.
Remove body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.
Fuel filter
Acceleration Operation
Fuel hose
Throttle grip
Have a wide open of throttle valve as handle in
any position and release it to let back original (full
closed) position.
Check handle if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure the throttle grip free play in its flange
part.
Adjustment can be done in either end.
Secondary adjustment is conducted from top side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut.
Adjustment nut
Adjustment nut
Primary adjustment is conducted from bottom
side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
Free play: 2~6 mm.
Lock nut
2~6 mm
2-3
To this chapter contents
2. MAINTENANCE INFORMATION
Air Cleaner
6 screws
Air Cleaner Element
Remove 6 screws from the air cleaner cover and
then remove the cover.
Remove 4 screws, and then remove the air
cleaner element.
4 screws
Caution
The air cleaner element is made of paper so do
not soap it into water or wash it with water.
Spark Plug
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Spark plug cap
Measure the spark plug gap.
Spark plug gap:0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten torque: 1.0~1.2kgf-m
Connect spark plug cap.
Recommended spark plug: CR8E
0.8mm
2-4
To this chapter contents
2. MAINTENANCE INFORMATION
Valve Clearance
Timing mark
Caution
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove trunk.
Remove central cover.
Remove valve adjustment cap.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.
Valve clearance inspection and adjustment.
Check & adjust valve clearance with feeler gauge.
Valve clearance (IN/EX): 0.12 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.
2-5
To this chapter contents
2. MAINTENANCE INFORMATION
Carburetor Idle Speed Adjustment
Ignition cable
Caution
y Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
y Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the motorcycle with main stand and warm up
engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Open carburetor cover from the luggage box.
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1600 ± 100 rpm
Stopper screw
Emission adjustment in idle speed
Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the idle speed adjustment screw and let
engine runs in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that
emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm
2-6
Air adjustment screw
To this chapter contents
2. MAINTENANCE INFORMATION
Ignition System
Caution
y C.D.I ignition system is set by manufacturer so
it can not be adjusted.
y Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Remove right side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover.
Connect tachometer and ignition lamp.
Start engine.
As engine in idle speed: 1600 rpm, aim at the
mark “F” with the ignition lamp. Then, it is means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it is means that the
ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if
malfunction of these parts is found.
Cylinder Compression Pressure
Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
y Incorrect valve clearance.
y Valve leaking.
y Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
2-7
To this chapter contents
2. MAINTENANCE INFORMATION
Drive Belt
Remove mounting bolt located under air cleaner.
Remove 7 bolts of the engine left side cover and
the cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.
Width limit: 18.5mm or above
7 bolts
Teeth
Width
Brake System (Front Disk Brake)
Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found
Brake hose
Caution
y In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
y Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
y Do not mix non-compatible brake fluid together.
LOWER
2-8
To this chapter contents
2. MAINTENANCE INFORMATION
Filling Out Brake Fluid
Tighten the drain valve, and add brake fluid.
Operate the brake lever so that brake fluid
contents inside the brake system hoses.
Screws
Master cylinder cap
Diaphragm plate
Air Bleed Operation
Upper
Diaphragm
Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release
the brake lever.
Air bubble
Drain valve
Added Brake Fluid
Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent from
damage brake system or reducing brake
performance.
Transparent hose
Lining
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.
Caution
It is not necessary to remove brake hose when
replacing the brake lining.
Remove the brake clipper bolt, and take out the
clipper.
Brake disk
Brake caliper
Caution
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
Pry out the brake lining with a flat driver if lining is
clipped.
Caliper bolt
2-9
To this chapter contents
2. MAINTENANCE INFORMATION
Make sure the brake lining condition. Replace
the lining if the brake lining wear limitation groove
close to the brake disc.
Brake lining wear
limitation groove
Lining
Brake Lining Replacement
Compress the caliper and let the brake lining out
of the caliper mounting plate. Compress the brake
lining locking spring. Remove the inner brake
lining firstly and then remove the outer brake
lining.
Compress the brake caliper at first as installation.
Install the inner brake lining firstly, and then install
the outer brake lining.
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set.
Master cylinder
Brake Light Switch/Starting Inhibitor
Switch
The brake lamp switch is to light up brake lamp as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.
Brake switch
Headlight Beam Distance
Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.
Caution
y To adjust the headlight beam follows related
regulations.
y Improper headlight beam adjustment will
make in coming driver dazzled or insufficient
lighting.
Adjust screw
Clutch Disc Wear
Run the motorcycle and increase throttle valve
opening gradually to check clutch operation.
If the motorcycle is in forward moving and shaking,
check clutch disc condition. Replace it
Clutch weight
Drive plate
2-10
To this chapter contents
2. MAINTENANCE INFORMATION
Side Stand
Check side stand spring for damage or looseness.
Press down side stand and pull it with spring
gauge. If gauge reading is over 2 kg, it means that
the spring capacity is in normal.
Check if side stand set is operated smoothly.
Make sure that side stand is no bending or
deformation.
Side stand
Cushion
Warning
y Do not ride the motorcycle with poor cushion.
y Looseness, wear or damage cushion will make
poor stability and drive-ability.
Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Park motorcycle with main stand.
Turn the rear wheel forcefully and check if engine
bracket bushing worn out
Replace the bushing if looseness found.
Tighten all nuts and bolts.
Nuts, Bolts Tightness
Perform periodical maintenance in accord with the
Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamps, and
wire holders for security.
2-11
To this chapter contents
2. MAINTENANCE INFORMATION
Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.
Check if tire surface is ticked with nails, stones or
other materials.
Appointed tire pressure
Tire size
Load for
Tire
under
90 Kg
pressure as
cold engine
Full loaded
(Kg/cm²)
Front tire
Rear tire
1.75
2.25
1.75
2.5
Check if front and rear tires’ pressure is in normal.
Measure tire thread depth from tire central
surface.
Replace the tire if the depth is not come with
following specification:
Front tire: 1.5 mm
Rear tire: 2.0 mm
Steering Handle Top Bearing
Caution
Check all wires and cables if they are interfered
with the rotation of steering handle bar.
Lift the front wheel out of ground.
Turn handle from right to left alternative and check
if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
adjust the handle top bearing.
2-12
〝△〞mark
磨損極限指標
To this chapter contents
2. MAINTENANCE INFORMATION
Special Tools List
NAME
NO
R/L. CRANK DISASS. TOOL
SYM-1120000-H9A
NAME
CRANK SHAFT PULLER
NAME
NO
SYM-1130000-H9A
NO
NO
NAME
CRANK SHAFT BRG. FIXING
SOCKET
SYM-9100210-H9A
VALVE COTTER REMOVE &
ASSEMBLY TOOL
NAME
NO
NAME
NO
SYM-1471110/20
NO
NAME
UNIVERSAL HOLDER
NAME
NO
SYM-2210100
NO
CRANK CASE BUSH PULLER
SYM-1120310
TAPPET ADJUSTING WRENCH
SYM-9001200
CLUTCH NUT WRENCH
SYM-9020200
SYM-9100200-H9A
(ψ22mm)
(ψ30mm)
NAME
L. CRANK SHAFT BRG. DRIVER
NAME
NO
NAME
CRANK CASE BUSH PULLER
SYM-1120320
TAPPET ADJUSTER
NO
SYM-9001209
NAME
CLUTCH SPRING
COMPRESSOR
NO
SYM-2301000
2-13
To this chapter contents
2. MAINTENANCE INFORMATION
NAME
NO
INNER BEARING PULLER
SYM-6204002
NAME
NO
(12*20*5)
NAME
NO
WATER PUMP OIL SEAL
DRIVER
SYM-9120500-H9A
OUTER BEARING PULLER
SYM-6204001
NAME
NO
AC.G. FLYWHEEL PULLER
SYM-3110A00
(6901)
NAME
NO
(6301)
WATER PUMP BEARING
DRIVER
SYM-9100100
NAME
NO
(6204)
SYM-1721700-H9A
(6203/6004UZ)
NAME
BEARING DRIVER
NAME
BEARING DRIVER
NAME
NO
SYM-9610000
NO
SYM-9110400
NO
(20*32*6)
WATER PUMP MECHANICL
SEAL DRIVER
BEARING DRIVER Ø17mm
SYM-9620000
(27*42*7)
(25*40*8)
NAME
OIL SEAL DRIVER
NAME
OIL SEAL DRIVER
NAME
OIL SEAL DRIVER
NO
SYM-9120200
NO
SYM-9121600
NO
SYM-9125500
2-14
To this chapter contents
2. MAINTENANCE INFORMATION
NAME
Drive shaft puller
NAME
NO
SYM-1130000-L
NO
NAME
SYM-1130010
NAME Extension bush (long)
NO
NAME
NAME
NO
NO
NAME
NAME
NAME
NO
NO
NO
NAME
NAME
NAME
NO
NO
NO
NO
Extension bush (short)
Drive shaft install bush
SYM-1130032
SYM-1130031
2-15
To this chapter contents
2. MAINTENANCE INFORMATION
Note:
2-16
Home page
Contents
3. LUBRICATION SYSTEM
Precautions in Operation ···················· 3-2
Engine Oil Strainer Clean ···················· 3-3
Troubleshooting ·································· 3-2
Oil Pump ··············································· 3-4
Engine Oil ············································· 3-3
Gear Oil ················································· 3-7
3
Valve Rocker Arm
Press-In Lubrication
Cam Shaft
Oil Route
Spray Lubrication
Con-Rod
Spray Lubrication
Press-In Lubrication
Oil Route
Oil through
Rotate Direction
Oil Strainer
Oil Pump
3-1
To this chapter contents
3. LUBRICATION SYSTEM
Precautions in Operation
General Information:
z
This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity
Change: 800 c.c.
SAE 10W-30 (Recommended
King serial oils)
Oil viscosity
Gear oil
Disassembly: 1000 c.c.
Disassembly:
Change:
110 c.c.
100 c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)
單位:mm
Items
Standard (mm)
Limit (mm)
0.15
0.20
Clearance between outer rotor and body
0.15~0.20
0.25
Clearance between rotor side and body
0.04~0.09
0.12
Inner rotor clearance
Oil pump
Torque value
Torque value oil strainer cap
1.5~3.0kgf-m
Gear oil drain plug
1.0~1.5kgf-m
Gear oil inspection bolt
1.0~1.5kgf-m
Oil pump connection bolt
0.8~1.2kgf-m
Troubleshooting
Low engine oil level
Dirty oil
y Oil leaking
y Valve guide or seat worn out
y Piston ring worn out
y No oil change in periodical
y Cylinder head gasket damage
y Piston ring worn out
Low oil pressure
y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage
3-2
To this chapter contents
3. LUBRICATION SYSTEM
Engine Oil
Turn off engine, and park the motorcycle in flat
surface with main stand.
Check oil level with oil dipstick
So not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Caution
Drain bolt
Drain oil as engine warmed up so that make sure
oil can be drained smoothly and completely.
Place a oil pan under the motorcycle, and remove
oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value:1.9~2.5kgf-m
Engine Oil Strainer Clean
Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Oil strainer cap
Torque value:1.9~2.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.
Engine oil capacity: 0.8L when replacing
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
3-3
To this chapter contents
3. LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
Remove snap ring and take out oil pump driving
chain and sprocket.
Clip
Make sure that pump shaft can be rotated freely.
Remove 2 bolts on the oil pump, and then
remove oil pump.
2 screws
Oil Pump Disassembly
Remove the screws on oil pump cover and
disassemble the pump as illustration shown.
Oil Pump Inspection
Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
3-4
To this chapter contents
3. LUBRICATION SYSTEM
Check clearance between inner and outer rotors.
Limit: 0.20 mm
Check clearance between rotor side face and
pump body
Limit: 0.12 mm
Oil Pump Re-assembly
Install inner and outer rotors into the pump body
Align the indent on driving shaft with that of inner
rotor. Install the driving shaft
Install fixing pin
Pin
1 Screw
Install the oil pump cover and fixing pin properly
3-5
To this chapter contents
3. LUBRICATION SYSTEM
Oil Pump Installation
Install the oil pump, and then tighten bolts.
Torque value:0.8~1.2kgf-m
Make sure that oil pump shaft can be rotated
freely.
Install oil pump driving chain and sprocket, and
then install snap ring onto oil pump shaft.
Install starting gear and generator.
(Refer to chapter 10)
3-6
To this chapter contents
3. LUBRICATION SYSTEM
Gear Oil
Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off engine and remove oil inspection bolt.
Gear oil Inspection Bolt
Gear lubrication oil quantity has to be measured
with measure device.
If oil level is too low, add gear oil. Recommended
using King series oils.
Install oil inspection bolt.
Gear oil drain plug
Gear Oil Change
Remove oil level inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after drained.
Torque value: 1.0~1.4kgf-m
Make sure that the drain plug washer can be
re-used.
Add oil to specified quantity from the inspection
hole.
Gear Oil Quantity: 100 c.c. when replacing
Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
3-7
To this chapter contents
3. LUBRICATION SYSTEM
Notes:
3-8
Home page
Contents
4. FUEL SYSTEM
Precautions in Operation....................4-2
Auto By-Starter .................................. 4-7
Trouble Diagnosis...............................4-3
Float Chamber.................................... 4-8
Carburetor removal.............................4-4
Fuel Tank ............................................ 4-10
Vacuum chamber ................................4-4
Air Cleaner.......................................... 4-11
Air Cut-Off Valve .................................4-6
4
To fuel vapor separator
4-1
To this chapter contents
4. FUEL SYSTEM
Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.
Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
y There is a drain screw in the float chamber for draining residual gasoline.
y Do not disassemble auto by-starter and air cut valve arbitrarily.
Specification
ITEM
LH12W-6
LH18W-6
24 mm
25 mm
I.D. number
CVK039
CVK066
Fuel level
20.5 mm
20.5 mm
Main injector
#105
#108
Idle injector
#35
#35
Idle speed
1600±100 rpm
1600±100 rpm
2~6 mm
2~6 mm
2 1/4 turns
1 1/2 turns
Carburetor diameter
Throttle handle clearance
Pilot screw
Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge
4-2
To this chapter contents
4. FUEL SYSTEM
Trouble Diagnosis
Poor engine start
Mixture too lean
y
y
y
y
y
y
y
y
y
y
y
y
y
No fuel in fuel tank
Clogged fuel tube
Too much fuel in cylinder
No spark from spark plug(malfunction of ignition
system )
y Clogged air cleaner
y Malfunction of auto by-starter
y Malfunction of throttle operation
Clogged fuel injector
Vacuum piston stick and closed
Malfunction of float valve
Fuel level too low in float chamber
Clogged fuel tank cap vent
Clogged fuel filter
Obstructed fuel pipe
Clogged air vent hose
Air existing in intake system
Stall after started
y
y
y
y
y
y
Malfunction of auto by-starter
Incorrect ignition timing
Malfunction of carburetor
Dirty engine oil
Air existing in intake system
Incorrect idle speed
Mixture too rich
y
y
y
y
y
Clogged air injector
Malfunction of float valve
Fuel level too high in float chamber
Malfunction of auto by-starter
Dirty air cleaner
Rough idle
y
y
y
y
Malfunction of ignition system
Incorrect idle speed
Malfunction of carburetor
Dirty fuel
Intermittently misfire as acceleration
y Malfunction of ignition system
Late ignition timing
y Malfunction of ignition system
y Malfunction of carburetor
Power insufficiency and fuel consuming
y Fuel system clogged
y Malfunction of ignition system
4-3
To this chapter contents
4. FUEL SYSTEM
Carburetor removal
Throttle cable
Remove the luggage box.
Loosen the adjustment nut and fixing nut of throttle
valve cable, and release the cable from carburetor.
Disconnect automatic by-starter connector.
Release the clamp strip of air cleaner.
Auto by-starter
Remove fuel pipe, vacuum hose.
Release the clamp strip of carburetor insulator.
Air cleaner clamp
Air cleaner clamp
Fuel pipe
Vacuum hose
2 Screws
Vacuum chamber
Removal
Loosen drain screw, and drain out residual fuel in
float chamber.
Remove 2 screws of vacuum chamber cover and
the cover.
Remove compress spring and vacuum piston.
4-4
Spring
To this chapter contents
4. FUEL SYSTEM
Check if the vacuum piston for wear out, crack or
other damage.
Check if the diaphragm for damage or crack.
Installation
Install needle, spring and needle seat to vacuum
piston.
Needle seat
Spring
Piston
Needle
Install vacuum piston to carburetor body and align
the indent on the diaphragm.
Install compress spring.
Install vacuum chamber cover and tighten 2
screws.
2 Screws
Caution
y Do not damage vacuum diaphragm.
y When tightening the vacuum chamber screw,
hold down vacuum piston.
4-5
To this chapter contents
4. FUEL SYSTEM
Air Cut-Off Valve
Inspection
Disconnect vacuum hose and air vent hose from
the air cut-off valve.
Connect a hose from vacuum hose connector to
vacuum pump.
Connect air pump to air vent hose.
Apply with specified vacuum to air cut-off valve.
Vacuum value: 420~500 mm-Hg
Pump compressed air from air pump to air vent
hose.
Caution
The vacuum can not be over 600 mm-Hg. Or the
air cut-off will be damaged.
If the valve is in normal, it will restrict air-flow.
If air-flow is no restrict, replace carburetor
assembly.
4-6
To this chapter contents
4. FUEL SYSTEM
Auto By-Starter
Inspection
Turn off engine and waiting for over 10 minutes for
cooling.
Check resistance across the two terminals of the
auto by-starter.
Resistance value: Max. 10Ω (Measured after
engine stopped for more than 10 minutes)
Replace the auto starter with a new one if
resistance value exceeds standard.
Remove carburetor, allow it to cool off for 30
minutes.
Connect a pressure tester from air pump.
Connect by-starter circuit.
Pump compressed air to the circuit.
Replace the auto by-starter if the circuit clogged.
Connect battery posts (12V) to starter’s
connectors. After 5 minutes, test the by-starter
circuit with compressed air. If air flows through
the circuit, then, replace the starter.
Removal
Screw ×1
Auto by– starter
Remove fixing plate screw, and then remove the
plate and auto by-starter from carburetor.
Valve inspection
Check if auto by-starter and valve needle for
damage or wear out.
Plate
Screw ×1
Installation
Install auto by-starter to the bottom of carburetor
body.
Install fixing plate to the upper groove of auto
by-starter, and install its flat surface to carburetor.
Install screw and tighten it.
Needle
4-7
To this chapter contents
4. FUEL SYSTEM
Float Chamber
Pin
3 Screws
Float
Disassembly
Remove 3 mounting screws and remove float
chamber cover.
Remove the float pin and float.
Checking
Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.
Caution
Float
Pin
In case of worn out or dirt, the float valve and
valve seat will not tightly close causing fuel level
to increase and as a result, fuel flooding. A worn
out or dirty float valve must be replaced with a
new a new one.
1 Screw
Float valve
Remove main jet, fuel needle jet holder, needle jet,
slow jet, pilot screw.
Needle jet
Slow jet
Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
the way down and note the number of turns.
y Do not turn adjust screw forcefully to avoid
damaging valve seat face.
Clean jets with cleaning fluid. Then use
compressed air to blow the dirt off.
Blow carburetor body passages with compressed
air.
Needle jet
Needle jet holder
Slow jet
Main jet
4-8
To this chapter contents
4. FUEL SYSTEM
Assembly
Install main jet, fuel needle jet holder, fuel needle
jet slow jet and pilot screw.
Caution
Set the pilot screw in according to number of turns
noted before it was removed.
Install the float valve, float, and float pin.
Checking fuel level
Caution
Pilot screw
y Check again to ensure float valve, float for
proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber
face is vertical to the main jet.
Fuel level: 20.5 mm
Installation of carburetor
Install carburetor in the reverse order of removal.
Following adjustments must be made after
installation.
˙Throttle cable adjustment.
˙Idle adjustment
Float gauge
Adjustment of pilot screw
Caution
y Pilot screw was set at factory, so no
adjustment is needed. Note the number of
turns it takes to screw it all the way in for ease
of installation.
y The main stand must be used to support the
motorcycle to perform the adjustments.
Use a tachometer when adjusting engine RPM.
Screw in adjustment screw gently, then back up to
standard turns.
Standard turns:2±1/2(1 1/2~2 1/2) turns
Warm up engine, adjust the stopper screw of
throttle valve to standard RPM.
Idle speed rpm: 1600 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust
front end. Press test key on the analyzer.
Adjust the pilot screw and read CO reading on the
analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments, make sure rpm
and CO value are in standard value after engine
running in stable. If rpm and CO value fluctuated,
repeat the procedures described above for
adjusting to standard value.
Throttle cable adjust nut
Idle adjustment screw
Pilot screw
4-9
To this chapter contents
4. FUEL SYSTEM
Fuel Tank
Fuel unit removal
Open the seat.
Remove the luggage box (6 bolts and 1 screw).
Remove rear carrier (4 bolts).)
Remove body cover.
Disconnect fuel unit connector.
Remove fuel unit (4 screws).
Caution
˙Do not bend the float arm of fuel unit
˙Do not fill out too much fuel to fuel tank.
Fuel unit connector
Fuel unit inspection. (Refer to electrical equipment
chapter 17)
Fuel unit installation
Install the gauge in the reverse order of removal.
Caution
Do not forget to install the gasket of fuel unit or
damage it.
Fuel cut valve
Fuel tank removal
Remove the Fuel cut valve assembly and Fuel
tube.
Fuel tube
Remove fuel tank (4 screws).
Installation
Install the tank in the reverse order of removal.
4-10
4 bolts
To this chapter contents
4. FUEL SYSTEM
Air Cleaner
Clamp strip of air cleaner
Removal
Open the seat.
Remove the luggage box (6 bolts and 1 screw).
Loosen the clamp strip of air cleaner.
Remove the Vapor hose.
Remove the Air cleaner (2 bolts).
Installation
Install the tank in the reverse order of removal.
Cleaning air cleaner element
Remove air cleaner cover (6 screws).
6 Screws
Remove the Air cleaner element. (Screw×4)
With compressed air to cleaning dirty around the
element. Replace it if it is too dirty to clean.
Screw×4
Caution
The air cleaner element is made of paper so do
not soap it into water or wash it with water.
4-11
To this chapter contents
4. FUEL SYSTEM
Notes:
4-12
Home page
Contents
5. ENGINE REMOVAL
Precautions in Operation ....................5-1
Removal of Engine ..............................5-2
Engine Hanger removal.......................5-5
Removal of Engine Hanger Bush .........5-6
Engine Hanger Installation ...................5-7
Engine Installation.................................5-7
Precautions in Operation
General Information
y
y
y
y
y
The engine has to be supported with special service tools that can be lifted or adjustable.
The following parts can be serviced as engine mounted on frame.
Carburetor.
Driving pulley, driving belt, clutch, and driving disc assembly.
Final gear reduction mechanism.
5
Specification
Item
Capacity
Replacement
800 c.c.
Disassembly
1000 c.c.
Replacement
100 c.c.
Disassembly
110 c.c.
Engine & radiator
780 c.c.
Reservoir
420 c.c. AS indicator shown
Total
1200 c.c.
Engine oil capacity
Gear oil capacity
Coolant capacity
Torque Value
Engine mounting bolt
Rear cushion upper connection bolt
Rear cushion under connection bolt
Engine hanger bolt
Rear wheel axle nut
4.0~5.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
4.0~5.0kgf-m
11.0~13.0kgf-m
5-1
To this chapter contents
5. ENGINE REMOVAL
Removal of Engine
Auto by-starter &
AC. G. coupler
Open seat and remove the luggage box (6 bolts
and 1 screw).
Remove rear carrier (4 bolts).
Remove battery cover (2 screws).
Remove battery negative (-) post.
Remove battery positive (+) post.
Remove tail light connector.
Remove right and left body cover (2 bolts).
Disconnect the auto by-starter wire connector.
Disconnect A.C.G wire connectors.
A.C.G wire coupler
Remove starter motor wire from relay.
Remove spark plug cap.
Spark plug cap
Remove fuel pipe, vacuum tube and throttle valve
wire from carburetor.
Loosen the screw of air cleaner duct strip, and
then remove the duct.
5-2
Starter relay
To this chapter contents
5. ENGINE REMOVAL
Remove water hoses from water pump.
Water hoses
Water pump
Remove the thermo-sensor wire.
Remove the muffler (3 bolts, 2 nuts).
Thermo-sensor wire
3 bolts
2 nuts
Remove rear inner fender
Right side
Left side
2 Bolts
1 Bolt
5-3
To this chapter contents
5. ENGINE REMOVAL
Remove the mounting bolt of right-rear cushion.
2 Bolts
Remove the rear fork mounting bolt. (2 bolts)
Remove rear wheel mounting nut.
Rear wheel axle nut
Remove rear fork and collars.
Remove rear wheel.
Remove the mounting bolt of left-rear cushion.
Left-rear cushion bolt
5-4
To this chapter contents
5. ENGINE REMOVAL
Remove the right and left side engine hanger
mounting bolts and nuts, then remove engine.
Left side
Caution
˙Support engine and frame separately with
special supporters to prevent from engine or
frame falling down.
Engine hanger nut and bolt
Right side
Engine mounting nut and bolt
Engine Hanger removal
Remove the engine mounting bolt and nut, then
remove engine hanger.
Engine mounting nut and bolt
5-5
To this chapter contents
5. ENGINE REMOVAL
Removal of Engine Hanger Bush
Check if engine hanger bush and cushion rubber
bush for damage.
Pressing out
If engine hanger and the rear cushion rubber bush
damaged. Then, with the bush remover / presser,
Ø 30mm & Ø 22mm, to press the bush out, and
replace it with new one.
Engine hanger bush: ψ 30mm
Rear cushion bush: ψ 22mm
Place the detent section of the bush remover
toward the bush, and drive both the pressing ring
and bolt in to press the bush out.
Pressing In
Place the flat section of the remover toward the
bush, and then drive the bush, pressing ring, and
bolt in to install the bush.
5-6
Bush
To this chapter contents
5. ENGINE REMOVAL
Engine Hanger Installation
Install engine hanger onto engine.
Install engine mounting bolts & nuts and then
tighten the nuts.
Torque value: 4.0~5.0kgf-m
Engine Installation
Check if the bush of engine hanger parts and
cushion for damage.
Install engine in the reverse procedures of
removal.
Caution
y Pay attention of foot & hand safety as engine
installation to avoid hurting.
y Do not bend or twist wires.
y Cables wires have to be routed in accordance
with normal layout.
y Small-end bearing collar has to forward to
inside (bearing) as assembling the rear fork.
Bearing collar
Engine hanger Bolt:
Torque value: 4.0~5.0kgf-m
Rear cushion bolt:
Torque value: upper:3.5~4.5kgf-m
under:2.4~3.0kgf-m
Rear wheel axle nut:
Torque value: 11.0~13.0kgf-m
5-7
To this chapter contents
5. ENGINE REMOVAL
Note:
5-8
Home page
Contents
6. CYLINDER HEAD/VALVE
Mechanism Diagram ··························· 6-1
Valve Stem Replacement··················· 6-8
Precautions in Operation ··················· 6-2
Valve Seat Inspection and Service ··· 6-9
Troubleshooting·································· 6-3
Cylinder Head Reassembly ··············· 6-11
Cylinder Head Removal······················ 6-4
Cylinder Head Installation ················· 6-12
Cylinder Head Disassembly··············· 6-6
Valve Clearance Adjustment············· 6-14
Cylinder Head Inspection··················· 6-7
Mechanism Diagram
0.8~1.2kgf-m
6
0.8~1.2kgf-m
2.0~2.4kgf-m
1.0~1.2kgf-m
2.0~2.4kgf-m
6-1
To this chapter contents
6. CYLINDER HEAD/VALVE
Precautions in Operation
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
y Cylinder head service can be carried out when engine is in frame.
Specification
Item
Standard
Limit
12+/2 kg/cm2
---
Intake
30.800~30.920
3.075
Exhaust
30.411~30.531
30.26
ID of valve rocker arm
12.000~12.018
12.10
OD of valve rocker arm shaft
11.966~11.984
11.910
Intake
4.975~4.990
4.900
Exhaust
4.955~4.970
4.900
5.000~5.012
5.030
Intake
0.010~0.037
0.080
Exhaust
0.030~0.057
0.100
Free length of valve spring
35.000
31.500
Valve seat width
1.000
1.6
---
0.05
Compression pressure
Camshaft
Rocker arm
Valve
Height of cam lobe
OD of valve stem
Guide seat
Clearance between
valve stem and guide
Tilt angle of cylinder head
Torque Value
Cylinder head bolt (LH)
Cylinder head Nut
Sealing bolt of cam chain auto-tensioner
Bolt of cam chain auto-tensioner
Cam sprocket cover bolts
Cam sprocket bolt
Spark plug
Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-2
2.0~2.4kgf-m
2.0~2.4kgf-m
0.8~1.2kgf-m
1.2~1.6kgf-m
0.8~1.2kgf-m
0.8~1.2kgf-m
1.0~1.2kgf-m
To this chapter contents
6. CYLINDER HEAD/VALVE
Troubleshooting
Engine performance will be effected by troubles on engine top parts. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure
1. Valve
y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston ring worn out.
High compression pressure
y Too much carbon deposit on combustion chamber or piston head
Noise
y
y
y
y
y
y
y
Improper valve clearance adjustment
Burnt valve or damaged valve spring
Camshaft wear out or damage
Chain wear out or looseness
Auto-tensioner wear out or damage
Camshaft sprocket
Rocker arm or rocker arm shaft wear out
6-3
To this chapter contents
6. CYLINDER HEAD/VALVE
Cylinder Head Removal
Vacuum tube
Clamp strip
Remove seat, luggage box and body cover.
Remove engine. (Refer to chapter 5)
Remove the clamp strip bolt of carburetor, and
disconnect vacuum tube from the carburetor
insulator.
Remove Air Injection system (AI) pipe mounting
bolt.
AI. Pipe bolt
Remove 1 bolt of thermostat and then remove the
thermostat.
Remove hole cap for the adjustment bolt of cam
chain tensioner, and then loosen the tensioner by
turning a flat-driver in C.W direction.
Thermostat bolt
Hole cap of adjustment bolt
Remove the side cover mounting blots of cylinder
head, and then take out the side cover.
Remove cam sprocket bolts and then remove the
sprocket by prying chain out.
6-4
2 bolts
2 bolts
To this chapter contents
6. CYLINDER HEAD/VALVE
Remove the 2 cylinder head mounting bolts from
cylinder head right side, and then remove 4 nuts
and washers from cylinder head upper side.
2 Insulator bolts
4 Nuts
Cylinder head mounting
Remove the cylinder head.
Remove 2 bolts of carburetor insulator and then
take the insulator out.
Carburetor insulator
Remove cylinder head gasket and 2 dowel pins.
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Dowel pin
Caution
Gasket
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide
6-5
To this chapter contents
6. CYLINDER HEAD/VALVE
Cylinder Head Disassembly
Remove the hole cap of intake & exhaust valve
clearance adjustment. There are 6 bolts. Then,
remove the cap.
Remove the rocker arm pin stopper plate, and
then screw a 5mm bolt into the rocker arm pin.
Finally, remove the pin and the rocker arm.
Screw a 6 mm bolt into cam sprocket mounting
bolt hole, and then pull the camshaft out.
Stopper plate bolt
Use a valve compressor to press the valve spring.
Caution
y In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.
Special Service Tool:
Valve spring remover (SYM-1471110)
Valve spring installer (SYM-1471120)
Remove valve stem guide seal.
Clean carbon deposits in combustion chamber.
Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of cylinder
head.
6-6
To this chapter contents
6. CYLINDER HEAD/VALVE
Cylinder Head Inspection
Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.5 mm
Valve spring free length
Measure the free length of intake and exhaust
valve springs.
Service limit: 28.90 mm
Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
Valve guide
Caution
Before measuring the valve guide, clean carbon
deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner
diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.08 mm
EX→0.10 mm
5.0 mm valve guide reamer
6-7
To this chapter contents
6. CYLINDER HEAD/VALVE
Caution
If clearance between valve stem and valve guide
exceeded service limit, check whether the new
clearance that only replaces new valve guide is
within service limit or not. If so, replace valve
guide.
Correct it with reamer after replacement.
If clearance still exceeds service limit after
replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve
guide.
Valve Stem Replacement
Valve guide driver
5.0mm
Heat up cylinder head to 100~150 ℃ with heated
plate or toaster.
Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
y Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old
valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Valve guide driver
5.0 mm
Caution
y Check if new valve guide is deformation after
pressed it in.
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150℃.
Adjust the valve guide driver and let valve guide
height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve guide
with reamer.
Caution
y Using cutting oil when correcting valve guide
with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-8
Valve guide reamer 5.0 mm
To this chapter contents
6. CYLINDER HEAD/VALVE
Valve Seat Inspection and Service
Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other
manual grinding tool.
Caution
y Do not let emery enter into between valve stem
and valve guide.
y Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and
valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is
roughness, wear out, or incomplete contacted
with valve seat.
Valve seat width
Valve seat inspection
If the valve seat is too width, narrow or rough,
correct it.
Valve seat width
Service limit: 1.6mm
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve
seat chamfer cutter.
Refer to operation manual of the valve seat
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any rough
or uneven surface from valve seat.
Caution
Roughness
45°
After valve guide had been replaced, it has to be
ground with 45° valve seal chamfer cutter to
correct its seat face.
Use 32° cutter to cut a quarter upper part out.
Old valve seat width
32°
6-9
To this chapter contents
6. CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower part out.
Remove the cutter and check new valve seat.
Old valve seat width
60°
Use 45° cutter to grind the valve seat to specified
width.
1.0mm
Caution
Make sure that all roughness and uneven faces
had been ground.
Grind valve seat again if necessary.
45°
Coat the valve seat surface with red paint.
Install the valve through valve guide until the valve
contacting with valve seat, slightly press down the
valve but do not rotate it so that a seal track will be
created on contact surface.
Contact surface too high
Old valve seat width
Caution
32°
The contact surfaces of valve and valve seat are
very important to the valve sealing capacity.
If the contact surface too high, grind the valve seat
with 32° cutter.
Then, grind the valve seat to specified width.
Contact surface too low
Old valve seat width
If the contact surface too low, grind the valve seat
with 60° cutter.
Then, grind the valve seat to specified width.
60°
6-10
To this chapter contents
6. CYLINDER HEAD/VALVE
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and valve
after ground.
Cylinder Head Reassembly
Intake valve
Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Caution
The closed coils of valve spring should face down
to combustion chamber.
Valve spring retainer
Exhaust valve
Valve cotter
Valve stem seal
Valve spring
Use valve spring compressor to press valve
spring.
Caution
In order to avoid damaging the valve stem and
the cylinder head, in the combustion chamber
place a rag between the valve spring
remover/installer as compressing the valve spring
directly.
Special Service Tool:
Valve spring remover (SYM-1471110)
Valve spring installer (SYM-1471120)
Tap valve stem to make valve retainer and valve
stem sealing properly.
Caution
Place and hold cylinder head on to working table
so that can prevent from valve damaged.
6-11
To this chapter contents
6. CYLINDER HEAD/VALVE
Cylinder Head Installation
Install a new O-ring into the indent of carburetor
insulator, and then install the insulator onto
cylinder head with 2 bolts.
Carburetor insulator
Install camshaft into cylinder head, and align
rocker pin with rocker arm pin hole. Then, insert
the rocker arm pin.
Install rocker arm pin mounting plate.
Stopper plate bolt
Dowel pin
Clean up all residues and foreign materials onto
the matching surfaces of both cylinder and
cylinder head.
Install chain guide.
Install 2 set pins and cylinder head gasket.
Gasket
Caution
Do not damage the matching surfaces of cylinder
and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide
Loosen the tensioner by turning a flat-driver in
C.W direction.
Install cylinder head.
6-12
To this chapter contents
6. CYLINDER HEAD/VALVE
Tighten 4 nuts and washers on the cylinder head
upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head side cover.
Torque value: 2.0~2.4kgf-m
4 Nuts
2 Insulator bolts
Install and tighten spark plug
Torque value: 2.0~2.4kgf-m
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can not
be exceeded standard value in order to avoid
causing cylinder head deformation, engine noise
and leaking so that motorcycle’s performance be
effected.
Cylinder head mounting bolts
Install cam chain on to sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolt.
Caution
Make sure timing marks are matched.
Timing mark
Thermostat bolt
Install a new O-ring onto thermostat and tighten its
mounting bolts.
Loosen sprocket chain tensioner and let it contact
with chain plate tightly. Tighten the bolt cap of
tensioner adjustment hole.
Hole cap of adjustment bolt
Install Air Injection system (AI) pipe. (2 bolts)
Install carburetor insulator onto carburetor and
tighten clamp strip bolt. Install the vacuum hose
of carburetor insulator.
Vacuum tube
Clamp strip
AI. Pipe bolts
6-13
To this chapter contents
6. CYLINDER HEAD/VALVE
Valve Clearance Adjustment
Loosen valve clearance adjustment nuts and bolts
located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.12 ± 0.02 mm
EX 0.12 ± 0.02 mm
Install the valve clearance adjustment hole cap.
(3 bolts)
Caution
The gasket is paper type. In case of broken,
replace it and clean the Remnant gasket.
Start the engine after assembly. Remove the
intake valve adjustment hole cap and make sure
that engine oil flows onto the cylinder head.
Stop the engine after confirmed, and then install
the intake valve adjustment hole cap.
Install the seat, luggage box and the body cover.
Caution
y If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
y When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.
6-14
Home page
Contents
7. CYLINDER/PISTON
Mechanism Diagram ······························ 7-1
Piston Removal ··································7-4
Precautions in Operation ······················ 7-2
Piston Ring Installation ·····················7-6
Trouble Diagnosis·································· 7-2
Piston Installation ······························7-7
Cylinder Removal··································· 7-3
Cylinder Installation ···························7-7
Mechanism Diagram
7
7-1
To this chapter contents
7. CYLINDER/PISTON
Precautions in Operation
General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification
Unit:mm
LH12W & LH18W
Item
Cylinder
Limit
56.995~57.015
57.016
-
0.050
0.015~0.050
0.090
2 ring
0.015~0.050
0.090
Top ring
0.150~0.300
0.500
2 ring
0.300~0.450
0.650
Oil ring side rail
0.200~0.700
-
56.985~57.005
56.900
0.010~0.040
0.100
15.002~15.008
15.040
14.960~15.000
14.930
0.002~0.014
0.020
15.016~15.034
15.060
Standard
Limit
ID ( LA18W not included)
Bend
Clearance between piston
rings
Piston/
Standard
Ring-end gap
Piston ring
Top ring
nd
nd
OD of piston ( LA18W not included)
Clearance between piston and cylinder
ID of piston pin boss
OD of piston pin
Clearance between piston and piston pin
ID of connecting rod small-end
LH18W
Item
Cylinder
ID
60.995~61.015
61.016
Piston
OD of piston
60.985~61.005
60.900
Trouble Diagnosis
Low or Unstable Compression Pressure
Smoking in Exhaust Pipe
y Cylinder or piston ring worn out
y Piston or piston ring worn out
y Piston ring installation improperly
y Cylinder or piston damage
Knock or Noise
Engine Overheat
y Cylinder or piston ring worn out
y Carbon deposits on cylinder head top-side
y Piston pin hole and piston pin wear out
y Carbon deposits on cylinder head top side
y Cooling pipe clogged or not enough in coolant
flow
7-2
To this chapter contents
7. CYLINDER/PISTON
Cylinder Removal
Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.
Coolant hose
Remove cylinder gasket and dowel pin.
Cover the holes of crankcase and cam chain with
a piece of cloth.
Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective
in the cylinder.
Service limit: LH12W: 57.016
LH18W: 61.10 mm
Top
Center
Bottom
Check cylinder if warp.
Service limit: 0.05 mm
7-3
To this chapter contents
7. CYLINDER/PISTON
Piston Removal
Plug crankcase opening with a cleaning cloth to
prevent from piston pin snap ring or other foreign
materials falling into crankcase when
disassembling.
Hold another snap ring with pliers.
Push out the piston pin from the side that not
removed the snap ring.
Inspection
Measure clearance between piston ring and its
grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
Remove piston rings
Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.
Place piston rings respective into cylinder below
20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
7-4
To this chapter contents
7. CYLINDER/PISTON
Measure the outer diameter of piston pin.
Service Limit: 15.040 mm
Measure the inner diameter of connecting rod
small end.
Service Limit: 15.06 mm
Measure the inner diameter of piston pin hole.
Service Limit: 15.04 mm
Calculate clearance between piston pin and its
hole.
Service Limit: 0.02 mm
Measure piston outer diameter.
Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit:60.90 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
7-5
To this chapter contents
7. CYLINDER/PISTON
Piston Ring Installation
Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.
Top ring
2
nd
ring
Oil ring
Top groove
2
nd
groove
Oil groove
7-6
To this chapter contents
7. CYLINDER/PISTON
Piston Installation
Install piston and piston pin, and place the IN
marks on the piston top side forward to intake
valve.
Install new piston pin snap ring.
Caution
y Do not let the opening of piston pin snap ring
align with the opening piston ring.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.
Cylinder Installation
Clean up all residues and foreign materials on
the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
Install dowel pins and new gasket.
Coat engine oil to inside of cylinder, piston and
piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because piston and piston rings will be
damaged.。
Install coolant hose onto cylinder.
Install cylinder head (refer to Chapter 6).
Coolant hose
7-7
To this chapter contents
7. CYLINDER/PISTON
Notes:
7-8
Home page
Contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Mechanism Diagram ··························· 8-1
Driving Belt···········································8-4
Maintenance Description ···················· 8-2
Drive Face·············································8-6
Trouble Diagnosis ······························· 8-2
Clutch Outer/Driven Pulley··················8-9
Left Crankcase Cover ························· 8-3
Mechanism Diagram
3.5~4.5kgf-m
5.0~6.0kgf-m
8
5.0~6.0kgf-m
8-1
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Maintenance Description
Precautions in Operation
General Information
y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
y Driving belt and driving pulley must be free of grease.
Specification
Unit:mm
Item
Standard value (mm)
Limit (mm)
19.000
17.500
ID of drive face boss
27.000~27.021
27.060
OD of drive face
26.970~26.990
26.940
OD of roller
19.950~20.100
19.500
130.000~130.200
130.500
4.000~4.100
2.000
88.300
83.200
OD of driven pulley
33.965~33.985
33.940
ID of drive face
34.000~34.025
34.060
Driving belt width
ID of clutch outer
Thickness of clutch weight
Free length of driven pulley spring
Torque value
Special Service Tools
y Driven face nut: 5.0~6.0kgf-m
y Clutch outer nut: 5.0~6.0kgf-m
Clutch spring compressor: SYM-2301000
Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can
Insufficient horsepower or poor high
not be moved
speed performance
1. Worn driving Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
1. Worn driving belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
8-2
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Left Crankcase Cover
Left crankcase cover removal
Remove body cover.
Remove air cleaner. (2 bolts)
Remove L crankcase cover. (7 bolts)
Left crankcase cover install
Install left crankcase cover in the reverse
procedures of removal.
8-3
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Driving Belt
Removal
Remove left crankcase cover
Hold drive face with universal holder, and remove
nut and drive face.
Universal holder
Hold clutch outer with universal holder, and
remove nut and clutch outer.
Nut
Caution
y Using special service tools for tightening or
loosening the nut.
y Fixed rear wheel or rear brake will damage
reduction gear system.
Drive belt
Universal holder
Push the driving belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove driving
belt.
Remove the driving belt from the groove of driven
pulley.
Inspection
Check the driving belt for crack or wear. Replace
it if necessary.
Measure the width of driving belt as diagram
shown.
Service Limit: 17.5 mm
Replace the belt if exceeds the service limit.
Caution
y Using the genuine parts for replacement.
y The surfaces of driving belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.
8-4
Belt tooth
Width
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Installation
Caution
Pull out driven face to avoid it closing.
Driven face
Install driving belt onto driven pulley.
Install the driven pulley that has installed the belt
onto drive shaft.
On the drive belt another end to the movable drive
face.
Install the clutch outer with universal holder, and
Clutch outer
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Nut
Universal holder
Install the drive face with universal holder, and
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Universal holder
8-5
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Drive Face
Removal
Remove left crankcase cover.
Hold generator flywheel with universal holder, and
then remove drive face nut.
Remove drive face.
Universal holder
Remove driving belt and movable drive face comp
Movable drive face
from crankshaft.
Crankshaft
Remove ramp plate.
Ramp plate
Remove weight rollers from movable drive face.
Movable drive face
Weight roller
8-6
Drive face boss
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Inspection
Weight roller
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be effected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 19.50 mm
Weight: 14.5g
Movable drive face
Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive face,
Drive face boss
and replace it if it exceed service limit.
Service limit: 26.94 mm
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 27.06 mm
Reassembly/installation
Install weight rollers.
Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Closure surface
Install ramp plate.
Guide collar
Ramp plate
8-7
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
With 4~5g grease spreads wipes drives in the
movable drive face axis hole.
Install drive face boss.
Caution
The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.
Drive face boss
Install movable drive face comp. onto crankshaft.
Movable drive face
Drive face boss
Crank shaft
Driven pulley installation
Press down
Press driving belt into pulley groove, and then pull
the belt onto drive shaft.
Drive belt
Nut
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.
Hold drive face with universal holder.
Tighten nut to specified torque.
Torque value: 5.0~6.0kgf-m
Install left crankcase cover.
8-8
Drive face
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch Outer/Driven Pulley
Clutch nut wrench
Disassembly
Remove drive belt and clutch outer/driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.
Caution
Do not press the compressor too much.
Clutch spring compressor
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
clutch weight and spring from driven pulley.
Remove seal collar from driven pulley.
Collar
Remove guide pin, guide pin roller, and movable
driven face, and then remove O-ring & oil seal
seat from movable driven face.
Movable driven face
Guide pin
Seal
O-ring
Guide pin
Guide pin roller
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 130.5 mm
Inner
diameter
Clutch outer
8-9
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch lining
Measure each clutch weight thickness.
it if exceeds service limit.
Service limit: 2.0 mm
Clutch lining
Replace
Clutch weight
Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 83.2 mm
Free length
Driven pulley
Check following items:
y If both surfaces are damaged or worn.
y If guide pin groove is damaged or worn.
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm
Driven face
Movable driven face
Guide pin groove
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
8-10
Needle bearing
Outer ball bearing
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Clutch weight Replacement
Spring
Driving plate
Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.
Caution
Some of models are equipped with one mounting
plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight
Check if shock absorption rubber is damage or
deformation.
Replace it if necessary.
Shock absorption rubber
Apply with grease onto setting pins.
Setting pin
Install new clutch weight onto setting pin and then
push to the specified location.
Shock absorption rubber
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.
Caution
Grease or lubricant will damage the clutch weight
and effect the block’s connection capacity.
Clutch weight
Install the spring into groove with pliers.
Spring
8-11
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Install snap ring and mounting plate onto setting
pin.
Snap ring
Replacement of Driven Pulley Bearing
Remove inner bearing.
Outer bearing
Clipper
Caution
y If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
y If the pulley equipped with ball bearing, it has to
remove snap ring and then the bearing.
Inner needle
bearing
Snap ring
Remove snap ring and then push bearing forward
to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified oil.
Snap ring
Specified oil
Outer bearing
Install new inner bearing.
Bearing end
Caution
y Its sealing end should be forwarded to outside
as bearing installation.
y Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of driving face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
8-12
Inner bearing
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Installation of Clutch OUTER/Driven Pulley
Oil seal
Assembly
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.
Specified grease
O-ring
Install the movable driven face onto driven face.
Install the guide pin and guide pin roller.
Movable driven face
O-ring
Oil seal
Guide pin
Guide pin
Guide pin roller
Install the collar.
Collar
Install driving belt, spring and clutch weight COMP.
into clutch spring compressor, and press down the
assembly by turning manual lever until mounting
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m
Install clutch outer/driven pulley and driving belt
onto driving shaft.
Clutch nut wrench
Clutch spring compressor
8-13
To this chapter contents
8. V-BELT DRIVING SYSTEM/KICK STARTER
Notes:
8-14
Home page
Contents
9. FINAL DRIVING MECHANISM
Mechanism Diagram ··························· 9-1
Inspection of Final Driving Mechanism
······························································· 9-4
Precautions in operation ···················· 9-2
Trouble Diagnosis ······························· 9-2
Bearing Replacement ·························· 9-5
Disassembly of Final Driving Mechanism
······························································ 9-3
Re-assembly of Final Driving Mechanism
······························································· 9-8
Mechanism Diagram
Bearing (6004)
Final shaft
Final gear
9
Counter gear
Bearing (6301)
Bearing (6004)
Counter shaft
Bearing (CSB301)
Bearing (6301)
Drive shaft
1.0~1.4kgf-m
Bearing (6204)
9-1
To this chapter contents
9. FINAL DRIVING MECHANISM
Precautions in operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 110 c.c. (100 c.c. when replacing)
Torque value
Gear box cover
1.0~1.4kgf-m
Tools
Special tools
Bearing (6203/6004UZ) driver: SYM-9620000
Bearing (6204) driver: SYM-9110400
Bearing (6301) driver: SYM-9610000
Oil seal (27*42*7) driver: SYM-9125500
Oil seal (20*32*6) driver: SYM-9120200
Inner bearing puller: SYM-6204002
Outer bearing puller: SYM-6204001
Drive shaft puller: SYM-1130000-L
Drive shaft install bush: SYM-1130010
Extension bush (long): SYM-1130031
Extension bush (short): SYM-1130032
Trouble Diagnosis
Engine can be started but motorcycle can not be moved.
y Damaged driving gear
y Burnt out driving gear
Noise
y Worn or burnt gear
y Worn gear
Gear oil leaks
y Excessive gear oil.
y Worn or damage oil seal
9-2
To this chapter contents
9. FINAL DRIVING MECHANISM
Disassembly of Final Driving
Mechanism
Remove driven pulley.
Drain gear oil out from gear box.
Remove gear box cover bolts and then remove the
cover and drive shaft.
7 bolts
Counter shaft & gear
Remove final gear and shaft.
Remove counter shaft and gear.
Final shaft & gear
Gasket
Remove gasket and dowel pin.
Dowel pin
Remove the drive shaft.
In order to avoid damaging the gear box cover, in
the cover place a rag between the cover and table.
Caution
y If non- essential do not remove the drive
shaft from the cover upper side.
y If remove the drive shaft from the gear box
cover, then its bearing has to be replaced.
9-3
To this chapter contents
9. FINAL DRIVING MECHANISM
Inspection of Final Driving
Mechanism
Check if the countershaft is wear or damage.
Check if the final shaft and gear are burn, wear or
damage.
Check bearings on gear box.
Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Check gear box cover bearing as the same way
above, and replace it if necessary.
Caution
y If remove the drive shaft from the cover upper
side, then its bearing has to be replaced.
Check drive shaft and gear for wear or damage.
9-4
Oil seal
Bearing
To this chapter contents
9. FINAL DRIVING MECHANISM
Bearing Replacement
Caution
y Never install used bearings. Once bearing
removed, it has to be replaced with new one.
Remove driving shaft bearing and counter shaft
bearing from left crankcase using following tools:
Special tool:
Inner bearing puller
Install new drive shaft bearing and counter shaft
bearing into left crankcase.
Special tool:
Bearing driver (6301)
Remove oil seal, and then remove final shaft
bearing from left crankcase.
Special tool:
Inner bearing puller
9-5
To this chapter contents
9. FINAL DRIVING MECHANISM
Install new final shaft seal.
Special tool:
Oil seal driver (27*42*7)
Oil seal driver
Install new final shaft bearing.
Special tool:
Bearing driver (6203/6004UZ)
Bearing driver
Press out the drive shaft from gear box cover.
Using shaft protector as operation.
Remove oil seal from gear box cover and discard
the seal.
Use inner bearing puller to remove the final shaft
bearing and counter shaft bearing from the cover.
Special tool:
Inner bearing puller
Inner bearing puller
If the drive shaft is pulled out with its bearing, then
remove the bearing with bearing puller and shaft
protector.
Special tool:
Multi-functional bearing puller or Outer bearing
puller
Shaft protector
Protector
Bearing puller
9-6
To this chapter contents
9. FINAL DRIVING MECHANISM
Install a new drive shaft bearing onto gear box
cover.
Special tool:
Bearing driver (6204)
Bearing driver
Install a new final shaft bearing and counter shaft
bearing onto gear box cover.
Special tool:
Bearing driver (6203/6004UZ)
Bearing driver (6301)
Install drive shaft.
Special tool:
Drive shaft puller
Drive shaft install bush
Extension bush (long)
Extension bush (short)
Bearing driver
Install bush
Drive shaft puller
9-7
To this chapter contents
9. FINAL DRIVING MECHANISM
Re-assembly of Final Driving
Mechanism
Apply with grease onto the oil seal lip of final
driving shaft.
Final shaft
Install countershaft, counter gear, final shaft and
final driving gear.
Countershaft
Final drive gear
Install dowel pin and new gasket.
Dowel pin
Install gear box cover and bolts, and tighten.
Torque value: 1.0~1.4kgf-m
7 bolts
9-8
Gasket
To this chapter contents
9. FINAL DRIVING MECHANISM
Apply with grease onto new oil seal lip, and then
install the oil seal.
Special tool:
Oil seal driver (20*32*6)
Oil seal driver
Install driven pulley/clutch outer/belt.
Install movable drive face, drive face and left
crankcase.
Install rear wheel.
Add gear oil.
9-9
To this chapter contents
9. FINAL DRIVING MECHANISM
Notes:
9-10
Home page
Contents
10. ALTERNATOR/STARTING CLUTCH
Mechanism Diagram ··························10-1
Starting Clutch ··································· 10-4
Precautions in Operation···················10-2
Flywheel Installation·························· 10-7
Right Crankcase Cover Removal ······10-3
A.C.G. Set Installation························ 10-7
A.C.G. Set Removal····························10-3
Right Crankcase Cover Installation·· 10-7
Flywheel Removal ······························10-3
Mechanism Diagram
1.0~1.4kgf-m
10
5.0~6.0kgf-m
0.8~1.2kgf-m
10-1
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Precautions in Operation
General information
y Refer to chapter 5: Engine removal and installation
y Refer to chapter 16: The troubleshooting and inspection of alternator
y Refer to chapter 16: The service procedures and precaution items of starter motor
Specification
Item
Standard value (mm)
Limit (mm)
ID of starting clutch gear
20.026~20.045
20.100
OD of starting clutch gear
42.175~42.200
42.100
Torque value
Flywheel nut
5.0~6.0kgf-m
Starting clutch hexagon bolt
1.0~1.4kgf-m with adhesive
8 mm bolts
0.8~1.2kgf-m
12 mm bolts
1.0~1.4kgf-m
Tools
Special tools
A.C.G. flywheel puller: SYM-3110A00
Universal holder: SYM-2210100
10-2
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Right Crankcase Cover Removal
9 bolts
Remove 9 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.
2 bolts
A.C.G. Set Removal
Remove 2 mounted bolts from pulse generator
and then remove it.
Remove 3 screws from right crankcase cover and
A.C.G. set.
3 screws
Flywheel Removal
Remove left crankcase cover.
Remove oil through from crankshaft.
Hold the flywheel by drive face with universal
holder, and remove its nut.
Special tool:
Universal Holder
10-3
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Remove the oil through guide pin from crankshaft.
Pull out flywheel with A.C.G. flywheel puller.
Special tool:
A.C.G. Flywheel puller
Starting Clutch
Removal
Remove starting driven gear.
Remove mounting plate, starter reduction gear,
and the shaft.
10-4
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Starting Clutch Inspection
Check the starting clutch gear for wear or damage.
Measure the ID and OD of the starting clutch gear.
Service Limit: ID: 20.1 mm
OD: 42.10 mm
Check the starting reduction gear and shaft for
wear or damage.
Install one way clutch onto starting clutch gear.
Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
(View as shown in this figure.)
Remove the rollers, spring caps, and springs of
clutch on the one way clutch that located on the
back of flywheel.
Check each roller and plug for wear or damage.
Install rollers, plugs and springs.
Spring
Roller
Spring cap
10-5
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Remove 3 hexagon bolts with air and hex socket
wrenches.
Disassembly
Install the components in the reverse procedures
of removal.
Caution
Tape a tightening tape onto the thread of hexagon
bolt.
Torque value: 1.0~1.4kgf-m
Installation
Install reduction gear shaft and reduction gear.
Install starting clutch gear onto crankshaft.
10-6
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Flywheel Installation
Align the key on crankshaft with the flywheel
groove, and then install the flywheel.
Insert the oil through guide pin onto crankshaft.
Make sure that there is no other material stock on
it. If so, clean it up.
Hold the flywheel with flywheel holder, and tighten
its nut.
Torque value: 5.0~6.0kgf-m
Tool:
Flywheel holder
Install spring and oil through.
A.C.G. Set Installation
2 bolts
Install the A.C.G. set onto right crankcase cover (3
screws).
Install pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed under
pulse generator.
3 screws
Wire
Right Crankcase Cover Installation
Install dowel pin and new gasket.
Install right crankcase cover onto the crankcase.
Note: Align the water pump shaft indent with the oil
pump shaft.
Install right crankcase cover (9 screws).
10-7
To this chapter contents
10. ALTERNATOR/STARTING CLUTCH
Install the water pump cover onto crankcase
cover.
Connect water hose to the right crankcase cover
and water pump cover.
10-8
Home page
Contents
11. CRANKCASE / CRANK
Mechanism Diagram ··························11-1
Disassembly of crankcase ················ 11-3
General information ···························11-2
Crankshaft Inspection ······················· 11-5
Trouble diagnosis ······························11-2
Assembly of crankcase ····················· 11-6
Mechanism Diagram
1.2~1.6kgf-m
11
1.0~1.5kgf-m
0.8~1.2kgf-m
1.5~3.0kgf-m
11-1
To this chapter contents
11. CRANKCASE / CRANK
General information
Operational precautions
y This Section concerns disassembly of the crankcase for repair purpose.
y Remove following components before disassembling crankcase.
-Engine
Section 5
-Cylinder head
Section 6
-Cylinder and piston
Section 7
-Drive pulley and driven pulley
Section 8
-AC generator/Start driven gear
Section 10
-Starting motor
Section 16
y In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing
chain, it is preferably to replace crankshaft as a unit.
Specification
Crankshaft
Unit: mm
Item
Connecting rod side clearance of the big end
Vertical clearance of the big end of the connecting rod
Run-out
Torque value
Bolts for crankcase
Bolts for cam chain adjuster
0.8~1.2kgf-m
1.2~1.6kgf-m
Tools
Special tools
R/L. crank disassemble/ install tool: SYM-1300001-H9A
L. crank shaft bearing driver: SYM-9100200-H9A
Crank shaft bearing fixing socket: SYM-9100210-H9A
Crank shaft puller: SYM-1130000-H9A
L. crank shaft oil seal driver (25*40*8): SYM-9121600
Outer bearing puller: SYM-6204010
Inner bearing puller: SYM-6204020
Clutch nut wrench: SYM-9020200
Trouble diagnosis
Engine noise
y Loose crankshaft bearing
y Loose crankshaft pin bearing
y Worn out piston pin and pin hole
11-2
Standard
0.100~0.400
0~0.008
-
Limit
0.600
0.050
0.100
To this chapter contents
11. CRANKCASE / CRANK
Disassembly of crankcase
Tensioner
Remove the cam chain setting plate, and then
remove cam chain.
Loosen the bolt and remove the tensioner.
Cam chain setting plate
2 bolts
Loosen 2 bolts on the right crankcase.
Loosen 4 bolts on the left crankcase.
4 bolts
Place right crankshaft case downward and left up
crankcase.
Caution
Care should be taken not to damage the contact
surfaces.
6
R/L. crank disassemble/install tool
11-3
To this chapter contents
11. CRANKCASE / CRANK
Remove crank by left crank shaft.
Refer to chapter 2: Special tools
Special tool:
R/L. crank case disassemble/install tool
(SYM-1120000-H9A)
Remove crankshaft from right crankcase.
Remove gasket and dowel pins.
Scrape gasket residues off the crankcase contact
surface.
Caution
Do not damage contact surface of the gasket.
It is better to moisten the gasket residue for
easy scrapping.
Check any damage in oil seal.
Replace with new one if damaged.
11-4
To this chapter contents
11. CRANKCASE / CRANK
Crankshaft Inspection
Use a thickness gauge to measure left and right
clearance of connecting rod big end.
Service limit: 0.6 mm
Measure point for the crank
big end of the connecting rod.
Measure the clearance of the big end at the
vertical directions.
Service limit: 0.05 mm
Place the crankshaft on a V-block, measure
run-out of the crankshaft.
Service limit: 0.10 mm
90 mm
60 mm
Check crankshaft bearing
Use hand to crank the bearing to see it moves
freely, smoothly and noiseless.
Check the inner ring to see it links firmly on the
bearing.
If any roughness, noise and loose linkage are
detected, replace the bearing with new one.
Caution
The bearing shall be replaced in pair.
Special tool: outer bearing puller
Crank bearing
11-5
To this chapter contents
11. CRANKCASE / CRANK
Assembly of crankcase
Special tool:
R/L. crank case disassemble/install tool
L. crank shaft bearing driver
Crank shaft bearing fixing socket
Crank shaft puller
Clutch nut wrench
The new bearing and bearing driver, puts on the
left crank case.
Left crank shaft bearing driver
Install R/L. crank case disassemble/install tool on
the left crank case.
Again turns on crank shaft puller on the bearing
driver spiral tooth.
Gradually tightens the crank shaft puller upper cap
nut, presses in the bearing to locate.
After the bearing presses in to locate, opens the
R/L. crank case disassemble/install tool, takes
down the bearing driver.
Clutch nut
wrench
Crank shaft
puller
Crank case disassemble/install tool
Installs crank to the left crank case.
Direct the crank shaft bearing fixing socket to
crank shaft.
Crank shaft
bearing fixing
socket
11-6
To this chapter contents
11. CRANKCASE / CRANK
Install R/L. crank case disassemble/install tool on
the left crank case.
Again turns on crank shaft puller on the crankshaft
spiral tooth.
Crank shaft
puller
Caution
Crank shaft puller lock into on as far as possible
the crank spiral tooth, prevented pulls the bad
crank spiral tooth.
Crank case disassemble/install tool
Gradually tightens the crank shaft puller upper cap
nut, drags into the crank to locate.
Install 2 new dowel pin and new gasket.
Install the right crankcase onto the left crankcase.
Tighten 2 bolts on the crankcase.
Torque value: 0.8~1.2kgf-m
2 bolts
11-7
To this chapter contents
11. CRANKCASE / CRANK
Tighten 4 bolts on the crankcase.
Torque value: 0.8~1.2kgf-m
4 bolts
Clean the crankshaft.
Apply a layer of grease on the lip of oil seal, Puts
on the left crank shaft.
Install the oil seal in the left crankcase with care
not to damage the lip of the oil seal.
By oil seal driver (25×40×8), oil seal will knock into
locate.
Special tool:
Oil seal driver (25*40*8)
Install the tensioner and tighten the bolts.
Torque value: 1.2 ~1.6kgf-m
Install the cam chain.
Install the cam chain setting plate.
Oil seal
driver
Tensioner
Cam chain setting plate
11-8
Home page
Contents
12. COOLING SYSTEM
Mechanism Diagram ··························12-1
System Test········································ 12-5
General Information ···························12-2
Radiator ·············································· 12-6
Trouble Diagnosis ······························12-2
Water Pump ········································ 12-8
Trouble Diagnosis for Cooling System
·····························································12-3
Thermostat ········································· 12-12
Thermo switch (fan)
Mechanism Diagram
Cooling fan
Radiator filler cap
Reserve tank
Radiator filler cap
Radiator
Thermo unit (temp meter)
Thermostat
Cooling fan
12
Thermo switch (fan)
Reserve tank
Water pump
Coolant inlet pipe
Coolant outlet pipe
By-pass pipe
12-1
To this chapter contents
12. COOLING SYSTEM
General Information
General
Warning:
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant
may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless
the engine is completely cooled down.
y
y
y
y
y
y
Refill the radiator with distilled water or specified additives.
Add coolant to the reservoir.
The cooling system can be serviced on the motorcycle.
Never spill the coolant to the painted surface.
Test the cooling system for any leakage after the repair.
Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.
Technical Specification
Item
Specification
0.75~1.05 kg/cm2
780 c.c.
420 c.c.
Begins to activate at 71-80℃
Stroke: 3.5 ~ 4.5 mm/80℃
Not-pressure: 107.7℃
Pressurized: 125.6℃
Pressure to open filler cap
Capacity of coolant: Engine + radiator
Reservoir upper
Thermostat
Boiling point
Torque Value
For water pump rotor
1.0~1.4kgf-m
Tools Requirement
Special tools
Water pump bearing driver (6901): SYM-9100100
Water pump oil seal driver (Inner): SYM-9120500-H9A
Water pump mechanical seal driver: SYM-1721700-H9A
Inner bearing puller: SYM-6204020
Trouble Diagnosis
The engine temperature is too high
The engine temperature is too low
y The water thermometer and the temperature
sensor do not work properly.
y The thermostat is stuck to closed.
y Insufficient coolant.
y The water hose and jacket are clogged.
y Fan motor malfunction.
y The filler cap of the radiator malfunction.
y The water thermometer and the temperature
sensor malfunction.
y The thermostat is stuck to open.
Coolant is leaking
y The water pump mechanical seal does not
function properly.
y The O ring is deteriorated.
y The water hose is broken or aged.
12-2
To this chapter contents
12. COOLING SYSTEM
Trouble Diagnosis for Cooling System
The temperature indicated is too high
Y
A. Stop and waiting for the
engine is completely
cooled down, open cap to
check the capacity of
coolant in radiator.
A1.Refill the radiator with
coolant then check for any
leakage?
N
Water leaking problem
N
Y
B. Turn on main switch and
check the water
temperature indicator
back to zero?
Y
N
B-1. Measure thermo unit to
confirm voltage 6V↑?
N
Replace thermo unit
Y
Y
B-2. Inspect the circuits of
water temperature have
short or earth?
Y
Short or earth handle
N
Meter problem
C. Open radiator cap and
softly throttle, inspect
coolant have circulated?
C-1. Eng. stop and remove
water pump cover, start
the motor to inspect pump
its rotation?
N
Water pump repair
Y
Y
D. Close radiator cap,
measure thermo unit to
confirm voltage reduced
comply with temperature
rise?
N
Water hose clogged
N
Replace thermo unit
Y
Next page
12-3
To this chapter contents
12. COOLING SYSTEM
Preceding page
E. Keep eng. 3000~4000 rpm
and inspect cooling fan was
operating after the
temperature gauge over 3
checks?
N
E-1. Measure thermal switch to
confirm voltage be
changed (12→0V)?
N
Replace thermal switch
Y
Y
F. Confirm the cooling fan was
convulsion?
Y
Meter unusual
E-2. Connect cooling fan
terminals with
battery(12V) directly to
inspect its operation?
N
Replace cooling fan
Y
If circuit connect reverse
cooling fan will forward,
correct and check again.
E-3. Keep eng. 3000~4000
rpm and inspect coolant
flow into reserve tank
after the temperature
gauge over 3 checks?
Y
E-4. Remove thermostat from
holder then heats it by
water directly to check its
operation?
Y
For bleed the air bubbles
completely, open radiator cap
and start engine while engine
is cool then press water hose
softly by hand to bleeding.
Turn the throttle repeatedly
until the coolant surface
becomes stable.
N
Replace thermostat
Refill with coolant then
check again
Notice the water hose
can’t any unsuitable
bend or twist and
bleed the air bubbles
completely.
12-4
To this chapter contents
12. COOLING SYSTEM
System Test
Test on the filler cap
Hermetically seal the filler cap, apply water and
pressure to the filler cap. Replace it with new one
if found failing to maintain the specified pressure
within a given time limit, or the opening pressure is
too high or too low. The specified pressure shall
be maintained at least for 6 seconds in the test
Relief pressure for the filler cap: 0.75-1.05
kg/cm2
Apply pressure to the radiator, engine and water
hose to check for any leakage
Caution
Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
Pressure tester
Filler cap
Radiator cap
If the system fails to maintain the specified
pressure for at least 6 seconds, repair or replace
parts.
Change of coolant
Warning
Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down, otherwise, you may get scalded.
Remove the front cover, and then remove filler
cap.
Place a water pan under the water pump, loosen
the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Refilling system with coolant and bleeding the air
bubbles.
y Run the engine, and remove by-pass pipe.
y Check by-pass hole whether has the air bubble
to emit.
y If emits without the air bubble, only has the
coolant to flow out, then backflow pipe joint on,
engine flameout.
y Remove radiator filler cap.
y Starts the engine, inspects does not have the air
bubble in the radiator coolant, also the coolant
liquid level is stable.
y Stop the engine. Add coolant to proper level if
necessary.
y Screw and tighten up the radiator filler cap.
Drain bolt
Caution
In order to avoid the water tank rusting, please do
not use the unclear trade mark refrigerant.
Coolant recommended: SYM Bramax radiator
agent.
Concentration: 50%
By-pass pipe
12-5
To this chapter contents
12. COOLING SYSTEM
Check reserve tank
y Remove the front cover, and then remove
reserve tank filler cap.
y Check the liquid level in the reservoir. Add
coolant to proper level if too low.
y Reinstall the reserve tank filler cap.
Caution
The reserve tank liquid level coca too is not high,
after avoids the water temperature elevating, in
the cooling system the refrigerant backflow
floods.
Viewing window
Radiator
Check
Remove the front cover, check for any leakage
from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure water
jet to clean it.
Care shall be taken when straightening the sink
fan.
Removal
Coolant leakage
Sets at a vessel underneath the water pump,
dismantles the drain bolt to leak off in the cooling
system refrigerant.
Drain bolt
Remove front cover.
Disconnect the couplers for the thermo switch and
fan motor.
Remove coolant inlet pipe.
Loosen the radiator 2 bolts.
2 bolts
Coolant inlet pipe
Thermo switch
coupler
Cooling fan coupler
12-6
To this chapter contents
12. COOLING SYSTEM
Remove coolant outlet pipe and reserve tank pipe,
and then remove radiator and cooling fan.
Reserve tank pipe
Coolant outlet pipe
Disassembly
Loosen the 4 bolts from the fan duct, and then
remove the fan duct and radiator plate.
Loosen the 4 bolts from the fan and remove the
fan.
Loosen 3 screws from the fan motor, and take off
the fan motor.
Remove nut to remove the fan from fan motor.
Cooling fan
bolts x3
Cooling fan bolts x4
Assembly
Install fan motor onto fan shroud and insert the fan
into the motor shaft.
Apply a coat of the adhesive to the shaft thread of
the motor, and then install the washer and the lock
nut.
Tighten the fan shroud onto the radiator with four
bolts. Please refer to chapter 17 for the inspection
of the thermo switch.
Radiator plate
Cooling fan duct
Caution
Liquid packing must be applied to the thermo
switch before installing to avoid damaging the
radiator.
Thermo switch
Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.
12-7
To this chapter contents
12. COOLING SYSTEM
Water Pump
Check water pump seal / cooling
system divulges inspection
y Disassembles the refrigerant drain bolt,
overflows little buckles the N actually fluid,
confirmed overflows the refrigerant whether has
the greasy dirt.
y Turns on lathe the engine oil gauge rule, the
inspection engine oil whether does have
bleaches situation of the emulsified.
If has the above two kind of interior to divulge the
phenomenon, possibly for the water pump inner
two seal damages, the engine cooling system
damages or the cylinder and the cylinder head
gasket damages, please first dismantles the right
crank case to say A confirms the replacement
water pump seal, if does not have the question to
take apart for overhaul cooling system of system
again the cylinder head, the cylinder.
Drain bolt
Removal of water pump
Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen three bolts and remove the pump cover.
Loosen 9 bolts and remove the right cover.
Take off the gasket and dowel pin.
Turn pump rotor clockwise and remove.
Caution
The rotor is provided with left turn thread.
Remove the circlip from the right crankcase cover.
Remove the water pump shaft and the inner
bearing.
Remove the outside bearing by inner bearing
puller.
Rotate the inner ring of bearing, the bearing shall
move smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it with new one.
12-8
To this chapter contents
12. COOLING SYSTEM
Check any wear and damage of the mechanical
seal and inside seal.
Mechanical seal
Caution
The mechanical seal and inside seal must be
replaced as a unit.
Replacement of Mechanical Seal
Water pump bearing
driver
Remove the inside bearing by inner bearing puller.
Drive the mechanical seal and inner seal out of the
right crankcase.
Special tools:
Inner bearing puller
Water pump bearing driver
Caution
Replace a new mechanical seal after removing
it.
Mechanical seal
Apply a coat of sealant to the mating surfaces of
the right crankcase before installing the new
mechanical seal.
Install the mechanical seal onto the right
crankcase.
Special tools:
Water pump mechanical seal driver
Water pump mechanical
seal driver
12-9
To this chapter contents
12. COOLING SYSTEM
Install the new inner seal onto the right crankcase.
Special tools:
Water pump oil seal driver (inner)
Install a new outside bearing to the right
crankcase cover.
Special tools:
Water pump bearing driver (6901)
Water pump oil seal
driver (inner)
Water pump bearing
driver (6901)
Caution
Do not reuse old bearing. It must be replaced
with a new one once it has been removed.
Mount the water pump shaft and the inner bearing
to the right crankcase cover.
Inner bearing
Water pump shaft
Install the circlip to hold the inner bearing.
12-10
To this chapter contents
12. COOLING SYSTEM
Install the seal washer into the rotor.
Caution
Washer must be replaced together with the
mechanical seal.
Install the rotor onto the water pump shaft and
tighten.
Torque Value: 1.0~1.4kgf-m
Water pump rotor
Caution
The rotor is left thread.
Install the dowel pin and right cover gasket.
The rotation water pump rotor, causes the water
pump drive shaft scoop channel, aligns the oil
pump drive shaft flange, install the right crank case.
(bolts × 9)
Install the dowel pin and new gasket.
Install the water pump cover with 4 bolts.
12-11
To this chapter contents
12. COOLING SYSTEM
Thermostat
By-pass pipe
Temperature sensor
Please refer to chapter 17 for inspection of
temperature sensor.
Removal
Remove the luggage box and body cover.
Drain out the coolant.
Disconnect the cable of temperature sensor.
Disconnect the by-pass pipe.
Remove the thermostat set. (1 bolt)
Installation
Bolt
Apply a coat of sealant or equivalent to the thread
of temperature sensor and install it on the holder.
Connect the cable to the temperature sensor.
Refill the coolant and bleed out the air bubble
(Page 12-5).
Install the luggage box and body cover.
Temperature sensor
Disassembly
Remove the temperature sensor and O-ring from
the thermostat body.
O-ring
Remove 2 bolts and separate the thermostat body
from the cover.
2 bolts
Remove the thermostat.
12-12
To this chapter contents
12. COOLING SYSTEM
Inspection
Visually inspect thermostat for any damage.
Place the thermostat into heated water to check its
operation.
Caution
Whenever the thermostat and the thermometer
are in contact to the wall of heated water
container, the reading displayed is incorrect. If
the valve of the thermostat remains open at
room temperature or the valve operation is not
corresponding to the temperature change, then
it must be replaced.
Technical Data
Valve begins to open
Valve stroke
71 ~ 80℃
3.5 ~ 4.5 mm at 80℃
Assembly
Install in reverse order of removal.
Caution
Always use a new O-ring and apply a coat of
grease on it before installing.
Refill the specified coolant as necessary.
12-13
To this chapter contents
12. COOLING SYSTEM
Notes:
12-14
Home page
Contents
13. BODY COVER
Mechanism Diagram ····················· 13-1
Rear carrier·····································13-9
Maintenance··································· 13-2
Body cover ·····································13-10
Front cover····································· 13-3
Inner box·········································13-11
Handle front cover························· 13-4
Floor panel ·····································13-12
Handle rear cover ·························· 13-5
Front fender····································13-13
Side cover ······································ 13-6
Rear fender·····································13-15
Front under spoiler ······················· 13-7
Center fender ·································13-15
Luggage box ·································· 13-8
Mechanism Diagram
Seat
Rear carrier
Luggage box
Handle rear cover
Right body
cover
Right side cover
Rear fender
13
Inner box
Center cover
Handle front cover
Left body cover
Center fender
Floor panel
Front cover
Right front fender B
Left side cover
Front under spoiler
Under cover
Left front fender B
Front fender
13-1
To this chapter contents
13. BODY COVER
Maintenance
Body covers disassemble sequence:
Handle front cover
Front cover
Seat & Luggage box
Handle rear cover
Front under spoiler
Rear carrier
Inner box
Body cover
Right front fender B
Left front fender B
Rear fender
Front fender
Center cover
Center cover
Floor panel
Center fender
Under cover
Under cover
y
y
y
y
y
Be careful not to damage various covers in assembly or disassembly operation.
Never injure hooks molded on the body covers.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the guard and the covers during assembly.
13-2
To this chapter contents
13. BODY COVER
Front cover
Remove
Loosen 8 screw frome the front cover.
8 screws
Loosen 2 screw bottom of front handle cover.
2 screws
Remove headlight coupler, and then remove front
cover.
electric cord coupling
Installation
Install in reverse order of removal procedures.
13-3
To this chapter contents
13. BODY COVER
Handle front cover
Disassembly
Loosen 2 screws from handle rear cover rear side.
2 Screws
Loosen 1 screw from front handle cover.
Screw×1
Remove front winker light cord coupler.
Remove the handle front cover.
13-4
Coupler
To this chapter contents
13. BODY COVER
Handle rear cover
Speedometer cable
Remover
Remove front cover.
Remove speedometer cable.
Disconnect each switch connectors.
Each switch connectors
Remove electric line coupler from the radiator.
Coupler
Loosen 2 screws from the handle rear cover.
2 Screws
Loosen 1 screw from backside of the handle rear
cover.
Remove handle rear cover.
2 screws
13-5
To this chapter contents
13. BODY COVER
Side cover
Remove
Loosen 2 screws from the lift side cover.
2 screws
Loosen 2 screws from the right side cover.
2 screws
Remove the right & left side cover.
Installation
Install in reverse order of removal procedures.
13-6
To this chapter contents
13. BODY COVER
Front under spoiler
Remove
Remove front cover.
Loosen 4 screw of the inner box side.
4 screws
Loosen 2 screws from front side of the front under
spoiler.
2 bolts
Remove the front under spoiler.
Installation
Install in reverse order of removal procedures.
13-7
To this chapter contents
13. BODY COVER
Luggage box
4 nuts
Remove
Open seat.
Loosen 4 nuts & 2 bolt of the luggage box.
2 bolts
Loosen 1 screw from front side of the body cover.
1 screw
Remove the luggage box.
Installation
Install in reverse order of removal procedures.
13-8
To this chapter contents
13. BODY COVER
Rear carrier
Remove
Loosen 4 bolts from the rear carrier.
4 bolts
Remove the rear carrier.
Installation
Install in reverse order of removal procedures.
13-9
To this chapter contents
13. BODY COVER
Body cover
Rubber
Remove
Remove luggage box and rear carrier.
Remove the fuel tank cap and rubber.
Fuel tank cap
Loosen 2 bolts from the taillight underneath.
2 bolts
Loosen 1 screw from the center cover.
1 screw
Remove electric line coupler from the taillight and
seat look cable.
Remove right and left body covers.
Installation
Install in reverse order of removal procedures.
Taillight coupler
13-10
To this chapter contents
13. BODY COVER
Inner box
Main switch cover
Remove
Remove the front cover.
Loosen 1 bolt from the setting at hook and remove
the hook.
Remove main switch cover.
1 bolt
Loosen 2 screws from the under spoiler.
2 bolts
Remove the inner box.
Installation
Install in reverse order of removal procedures.
13-11
To this chapter contents
13. BODY COVER
Floor panel
Remove
Loosen 4 screws from the right & left step bar.
Remove the right & left step bar covers.
4 screws
Loosen 2 screws from the right & left step bar, and
2 bolts
then remove step bars.
Remove the battery and CDI.
Loosen 4 bolts from the floor panel.
4 bolts
CDI
Remove the floor panel.
Installation
Install in reverse order of removal procedures.
13-12
To this chapter contents
13. BODY COVER
Front fender
Remove
Remove right & left front fender B. (4 bolts)
4 bolts
Upward pushes, after causes the tenon to fall off
front, again takes out the front fender B.
Caution
y When disassemble age must pay attention,
whether the tenon is separated from.
y Cannot hardly pull out, is easy to create the
tenon to break off.
Remove speedometer cable. (1 screw)
1 screw
From front fender left side remove brake pipe clip.
Brake pipe position
13-13
To this chapter contents
13. BODY COVER
Use T flex socket wrench, remove front fender in
upside bolt. (3 bolts)
3 bolts
Downward presses the front fender, will cause it to
be separated from the front cushion, and then take
down to front.
Installation
Install in reverse order of removal procedures.
13-14
To this chapter contents
13. BODY COVER
Rear fender
Remove luggage box and seat.
Remove rear carrier.
Remove body cover.
Remove fuel tank.
Remove rear fender upper side bolts. (2 bolts)
2 bolts
Remove rear fender.
Installation
Install in reverse order of removal procedures.
Center fender
Remove air cleaner.
Remove center fender left side bolt. (1 bolt)
2 bolts
Remove center fender right side bolts, and then
remove center fender. (2 bolts)
Installation
Install in reverse order of removal procedures.
2 bolts
13-15
To this chapter contents
13. BODY COVER
Note:
13-16
Home page
Contents
14. BRAKE
Mechanism Diagram-Front Disk Brake 14-1
Brake fluid replacement / Air-bleed···· 14-7
Mechanism Diagram-Rear Drum Brake 14-2
Disk Brake-Caliper ······························· 14-8
Maintenance Description ······················ 14-3
Brake Disk ············································ 14-9
Trouble Diagnosis ································· 14-4
Disk Brake - Master Cylinder ·············· 14-9
Disk Brake System Inspection ············· 14-5
Rear Drum Brake·································· 14-12
Adding Brake Fluid································ 14-6
Mechanism Diagram-Front Disk Brake
0.5~0.6kgf-m
3.0~4.0kgf-m
0.8~1.2kgf-m
14
4.0~4.5kgf-m
14-1
To this chapter contents
14. BRAKE
Mechanism Diagram-Rear Drum Brake
14-2
To this chapter contents
14. BRAKE
Maintenance Description
Operational precautions
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or
dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
y The brake caliper can be removed without removing the hydraulic system.
y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
y While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
y Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
y Check the operation of the brake system before riding.
Specifications
Item
Standard (mm)
Limit (mm)
4.000
2.500
< 0.100
0.300
Master cylinder inner diameter
11.000 - 11.043
11.055
Master cylinder outer diameter
10.957 - 10.984
10.945
Diameter of front disk
220.000
-
Diameter of rear brake drum
130.000
-
Thickness of front brake lining
5.100
2.000
Thickness of rear brake lining
5.100
2.000
The thickness of front and rear brake disk
Front and rear brake disk eccentricity
Torque values
Front brake hose bolts
3.0~4.0kgf-m
Bolt for front brake caliper
3.0~3.5kgf-m
Bolts for the front brake disk
4.0~4.5kgf-m
Brake lever nut
0.8~1.2kgf-m
Nut for the rear brake arm
0.5~0.6kgf-m
Air-bleed valve
0.5~0.6kgf-m
14-3
To this chapter contents
14. BRAKE
Trouble Diagnosis
Disk Brake
Soft brake lever
1.
2.
3.
4.
5.
6.
7.
8.
9.
Air inside the hydraulic system
Hydraulic system leaking
Worn master piston
Worn brake pad
Poor brake caliper
Worn brake lining/disk
Low brake fluid
Blocked brake hose
Warp/bent brake disk
10. Bent brake lever
Uneven brake
1.
2.
3.
4.
5.
Dirty brake lining/disk
Poor wheel alignment
Clogged brake hose
Deformed or warped brake disk
Restricted brake hose and fittings
Tight brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or warped brake disk
Hard operation of brake lever
1.
2.
3.
4.
5.
Blocked brake system
Poor brake caliper
Blocked brake pipe
Seized/worn master cylinder piston
Bent brake lever
Drum Brake
Poor brake performance
1. Improper brake adjustment
2. Worn brake lining
3. Worn brake drum
4. Worn brake cam
5. Improper brake lining installation
6. Seized brake cable
7. Dirty brake lining
8. Dirty brake drum
9. Brake pad worn in brake cam area.
10. Poor contact between brake arm and camshaft
indent
Brake noise
1.
2.
3.
4.
Dirty lining
Deformed brake disk
Poor brake caliper installation
Imbalance brake disk or wheel
Tight operation or low return speed of
brake lever
1.
2.
3.
4.
5.
6.
7.
Worn/broken/crack return spring
Worn drum
Dirty brake lining
Brake seized caused from dirty brake drum
Seized brake cable
Worn brake cam
Improper brake lining installation
Brake noise
1.
2.
3.
4.
14-4
Worn brake lining
Worn drum
Dirty brake lining
Dirty brake drum
To this chapter contents
14. BRAKE
Disk Brake System Inspection
Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube seam
whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.
Check the brake from behind the brake caliper.
The brake pad must be replaced with new lining
when the brake pad wear limit reaches the brake
disk.
Brake caliper
Brake lining wear
limit grooves
Brake disk
Park the motorcycle on a level ground, and check
if fluid level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 3).
Caution
y The vehicles inclined or just stop, the survey oil
level could not be accurate, had to settle the
3~5 minute.
y In order to prevent has the chemical change,
please do not use counterfeiting or other
unclear trade marks brake fluid.
y Uses by all means must with the trade mark
brake fluid, guarantees the ghost vehicle
efficiency.
14-5
To this chapter contents
14. BRAKE
Adding Brake Fluid
Master cylinder
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid please do not surpass the
upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in their damages.
Remove the master cylinder cap and diaphragm.
Increases the high quality brake fluid, uses by all
means must with the trade mark brake fluid joins
in the master cylinder.
Clean the dirty brake disk.
Screw
Master cylinder cap
Diaphragm plate
Upper
level
Diaphragm
Caution
y The dirty brake lining or disk will reduce the
brake performance.
y To mixed non-compatible brake fluid will
reduce brake performance.
y Foreign materials will block the system
causing brake performance to be reduced or
totally lost.
14-6
Lower level
To this chapter contents
14. BRAKE
Brake fluid replacement / Air-bleed
Air-bleed valve
Connect drain hose to air-bleed valve.
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out.
Close the drain valve and add specified brake fluid
into the brake master cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
Connect one end of transparent hose to the drain
valve, and put the other end into a container.
Open the drain valve around 1/4 turns, and at the
same time hold the brake lever until the there is no
air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.
If brake is still soft, please bleed the system as
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the
valve.
Bubble
Air-bleed valve
Transparent hose
Caution
y Do not release the brake lever before the
drain valve is closed.
y Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air enter into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
14-7
To this chapter contents
14. BRAKE
Disk Brake - Caliper
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Brake hose bolt
Remove two caliper bolts and the caliper.
Disassembly
Make sure the brake lining condition. Replace
the lining if the brake lining wear limitation groove
close to the brake disk.
Caliper bolts
Brake lining replacement
Compress the caliper and let the brake lining out
of the caliper mounting plate.
Compress the brake lining locking spring.
Remove the inner brake lining firstly and then
remove the outer brake lining.
Compress the brake caliper at first as installation.
Install the inner brake lining firstly, and then install
the outer brake lining.
Brake lining
wear limitation
groove
Installation
Install the brake caliper and tighten the attaching
bolts securely.
Locking spring
Brake lining
Torque: 3.3kgf-m
Caution
Brake lining
Caliper plate
y Use M8 x 35 mm flange bolt only.
y Long bolt will impair the operation of brake
disk.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.5kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
14-8
Brake caliper
Locking spring
Brake piston
To this chapter contents
14. BRAKE
Brake Disk
Brake disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit: 2.0 mm
Micrometer
Remove the brake disk from wheel.
Check the disk for deformation and bend.
Allowable limit: 0.30 mm
Caution
y The dirty brake lining or disk will reduce the
brake performance.
y Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the
operator should dress the mouthpiece and
the glove, use vacuum cleaner clean it.
Disk Brake - Master Cylinder
Master Cylinder Removal
Caution
Do not let foreign materials enter into the
cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.
2 bolts
Remove the front and rear handlebar guards.
Remove the leads of brake lamp switch.
Drain out the brake fluid.
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder bolts and the master
cylinder.
Remove the rubber pad.
Remove the cir clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Cir clip
Rubber boot
Piston
Piston cup
Spring
Master cylinder
14-9
To this chapter contents
14. BRAKE
Master Cylinder Inspection
Check the master cylinder for damage or scratch.
Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit: 12.550 mm
缸規
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit: 12.654 mm
活塞
分厘卡
Master Cylinder Assembly
Caution
y It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
y Make sure there is no dust on all
components before assembling.
Apply clean brake fluid to the piston cup, and then
install the cup onto the piston.
Install the larger end of the spring onto the master
cylinder.
The master cup’s cavity should be face inside of
master cylinder when installing the master cup.
Install the cir clip.
Caution
y Never install cup lip in the opposite direction.
y Make sure the cir clip is seated securely in
the groove.
Install the rubber pad into groove properly.
14-10
Cir clip
Rubber boot
Piston
Piston cup
Spring
Master cylinder
To this chapter contents
14. BRAKE
Master Cylinder Install
Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
Install the brake lever, and connect leads to brake
light switch.
2 bolts
Connect brake hoses with 2 new washers.
Tighten the brake hose bolt to the specified torque
value.
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Washer
Caution
Improper routing may damage leads, hoses or
pipes.
Brake light
switch
Brake hose
Caution
Kink of brake leads, hose or pipe may reduce
brake performance.
Add specified brake fluid and bleed the system.
14-11
To this chapter contents
14. BRAKE
Rear Drum Brake
Remove brake drum
Remove wheel and brake drum.
To use vacuum cleaner or other alternatives to
avoid danger caused from dusts.
Caution
y Inhaling brake lining ashes may cause
disorders of respiration system, therefore,
never use compressed air or dry brush to
clean brake parts.
y Brake performance will be reduced by grease
on brake lining.
Brake drum
Inspection brake drum
Check brake drum for damage or wear out, and
replace it if necessary.
Measure the inner diameter of brake drum and
record the max. value.
Allowable limit: 131.0mm
Caution
y Clean the rust onto the brake drum with
#120 sand-paper.
y Measure the inner diameter of brake drum
with micrometer.
Brake lining
Brake lining inspection
Measure the thickness of brake lining at three
points (both ends and center).
If the thickness is less than specified value or if it
is contaminated by oil or grease, replace as a set.
Service limit: Rear: 2.0 mm
Remove brake lining
Brake cam
To both hands pulls open brake lining, remove
brake lining from brake.
Caution
Spring
Brake linings must be replaced as a shoes.
Lock pin
Brake lining
14-12
To this chapter contents
14. BRAKE
Install brake lining
Apply with a thin coat of grease to the brake cam
and the anchor pin.
Install brake cam.
Never allow brake linings to be contaminated by
oil or grease.
Wipe off the excessive grease from brake cam
and the anchor pin.
Brake cam
Lock pin
Caution
Brake efficiency will be reduced if brake linings
is contaminated by oil or grease.
Spring
Brake lining
Rear brake panel
Apply a thin cost of grease between the oil seals
on the brake cam shaft.
Install the brake cam and arm after aligning it with
the punched point.
Brake cam
O-ring
Brake arm
Tighten the bolts and nuts to specified torque:
Torque value: 0.5~0.6kgf-m
Hook on the return spring.
Brake arm
Brake cam
Bolt
Return spring
14-13
To this chapter contents
14. BRAKE
Notes:
14-14
Home page
Contents
15. STEERING / FRONT WHEEL / FRONT CUSHION
Mechanism Diagram ··························15-1
Front Wheel ········································ 15-5
Operational Precautions ····················15-2
Front Cushion ···································· 15-8
Trouble Diagnosis ······························15-2
Steering Stem····································· 15-9
Steering Handle ··································15-3
Mechanism Diagram
4.0~5.0kgf-m
1.0~2.0kgf-m
0.2~0.3kgf-m
2.4~3.0kgf-m
15
4.0~4.5kgf-m
5.0~7.0kgf-m
15-1
To this chapter contents
15. STEERING / FRONT WHEEL / FRONT CUSHION
Operational Precautions
General
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of
the tire.
Torque Values
Nut for the front wheel axle
Nut for the steering handle
Lock nut for the steering handle stem
Top crown for the steering handle stem
Locating screw for the speedometer cable
Front cushion upper lock bolt
Special Tools
Steering handle top thread wrench
Inner bearing puller
Steering nut wrench
Driver 32*35mm
Driver 42*47mm
5.0 ~ 7.0kgf-m
4.0 ~ 5.0kgf-m
1.0 ~ 2.0kgf-m
0.2 ~ 0.3kgf-m
0.15 ~0.3kgf-m
2.4 ~ 3.0kgf-m
SYM-5320000
SYM-6204020
SYM-6204010
Trouble Diagnosis
Hard to steer
The front wheel rim run-out
y The steering handle stem nut is too tight.
y The ball and the top crown of the steering
handle stem are damaged.
y Insufficient tire pressure.
y
y
y
y
The rim is bent.
The wheel axle nut is not tightened enough.
Side-worn or poor tire.
The bearing clearance of the wheel axle is too
large.
The steering handlebar is tilted
y Uneven arrangement of the front cushion.
y The front fork is bent.
y The front wheel axle is bent.
Soft front cushion
y The front cushion spring is worn out.
y The oil seal of the front cushion is leaking.
Noise in front cushion
y Front cushion is warped.
y The joint of the front cushion gets loose.
15-2
To this chapter contents
15. STEERING / FRONT WHEEL / FRONT CUSHION
Steering Handle
Holder
Removal
Remove the handle front cover, handle rear cover
and front cover. (Refer to chapter 13)
Loosen the lock bolts for the master cylinder of the
front brake.
Caution
Do not let foreign materials enter into the cylinder.
Master cylinder
2 bolts
Remove throttle holder, cap, cable and grip after
mounting screw removed.
Screw
Remove rear brake lever mounting nut and bolt,
and then remove brake lever and cable.
Remove rear brake lever bracket after mounting
bolt removed.
Bracket holder bolt
Brake lever nut
Brake lever screw
Brake cable
Loosen handle mounting nut.
Remove handle mounting bolt, and then remove
the handle.
Bolt
Nut
15-3
To this chapter contents
15. STEERING / FRONT WHEEL / FRONT CUSHION
Installation
Install handle and align with bolt hole.
Install bolt and nut and then tighten it.
Torque value: 4.5kgf-m
Bolt
Nut
Apply with grease onto throttle cable and the
sliding surface of handle.
Align the lock pin of the throttle bracket with the
hole on the handle, and then install the throttle
bracket.
Caution
When installs the throttle cable, first spreads the
grease in the terminal to receive the throttle grip
again.
y After installs the handle, inspects the throttle
grip, whether may change to in the direction the
handle time the free position, the freedom does
moves.
Screw
Install the lock bolts for the master cylinder of the
front brake.
Holder
Master cylinder
Align the lock pin with the hole on the handle and
also install brake lever bracket. Then, tighten the
brake lever bracket bolt.
Install brake cable, lever on to bracket, and then
tighten lever screw and nut.
After the installment completes, carries on the
following inspection and the adjustment:
y Throttle grip operation.
y All electric appliances, the meter function.
2 bolts
Brake holder bolt
Brake lever nut
Brake lever screw
Brake cable
15-4
To this chapter contents
15. STEERING / FRONT WHEEL / FRONT CUSHION
Front Wheel
Remove
First by the bracket strut frame base, causes the
front wheel to float off.
Remove the speedometer cable.
Turn loose the axle nut.
Speedometer cable
Shaft nut
Pull out the front wheel axle.
Remove the front wheel.
Caution
Care shall be taken not to push the brake lever
to avoid the brake pad being squeezed out. In
case that the brake pad is accidentally squeezed
out, use a screwdriver to force it back to the
place.
Wheel axle
Inspection
Wheel axle
Place the wheel axle on a V block, measure its run
out.
Service limit: 0.2 mm
Wheel axle
Bearing
Use finger to move the inner ring of each bearing,
it shall move smoothly and quietly. Check the
outer ring is securely attached on the wheel hub.
If the motion of the inner ring of the bearing is not
smooth, or noisy and loose when being moved,
remove and discard it.
Free play
Free play
Caution
The bearing shall be replaced in pair.
15-5
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15. STEERING / FRONT WHEEL / FRONT CUSHION
Wheel
Place the wheel on to a rotation seat to check its
rim wobbling.
Turn the wheel with hand and measure its rim
wobbling value with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)
Disassembly
Remove 5 bolts and brake disk.
Remove dust seal, bearing and dist collar from left
side.
Remove dust seal, bearing and retainer hear box
from right side.
Special tools:
Inner bearing puller (SYM-6204020)
Assembly
Fill out the block of bearing by grease.
Drive the left bearing, dust seal and install the dist.
collar.
Install the right side bearing.
Speedometer gear box
Dist collar
Caution
y Carefully install the bearing in correct and
evenly.
y Bearing outer face should be faced up as
bearing installation.
Install the brake disk and then tighten the bolts
Torque value: 4.5kgf-m
Dust seal
Retainer hear box
Bearing
Dust seal
Install right side dust seal.
Lubricate the retainer with grease and install into
the wheel hub.
Align the flange part on the speedometer gear with
the slot of wheel hub.
Caution
Contaminated brake lining will reduce brake
performance so the brake lining, brake drum
and disc must be free of grease.
Apply with grease onto the left side dust seal.
Install the dust seal and side collar.
15-6
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15. STEERING / FRONT WHEEL / FRONT CUSHION
Installation
Open out brake lining with brake caliper.
Place the front wheel between the front cushion.
Wheel axle
Caution
Gear box groove
Align the gear box groove with the stopper
flange.
Insert the wheel axle into the wheel and the install
the wheel axle nut.
Front fork stopper
Tighten the nut.
Torque value: 5.0~7.0kgf-m
Connect the speedometer cable to the
speedometer gear box.
Speedometer cable
Shaft nut
15-7
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15. STEERING / FRONT WHEEL / FRONT CUSHION
Front Cushion
Remove
Remove front cover, front under spoiler and front
fender.
Remove front brake caliper.
Remove front wheel.
Remove front cushion upper mounting bolts, and
then remove front cushion.
4 bolts
Installation
Align the cover flange with upper level of the
cushion clamp, and then tighten bolts.
Torque value: 2.7kgf-m
Install the removed components in reverse order
of removal procedures.
15-8
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15. STEERING / FRONT WHEEL / FRONT CUSHION
Steering Stem
Remove
Remove handle, front wheel and front cushion.
Remove the steering stem mounting nut.
Remove top cone race and front fork.
Steering lock nut
Caution
Place the steel ball onto a parts container to
prevent from missing.
Top cone-race
Slightly tap the top and bottom ball bearing seats
with a plastic hammer to remove the seats.
Remove bottom cone race body with a punch.
Caution
Do not damage the steering stem.
Installation
Install a new bottom cone race onto the steering
stem.
Push the cone race until to mounted position.
Steering stem mounting nut
Top cone race
Top ball
bearing seat
Caution
Do not tilt the ball bearing seats as installation.
Bottom ball
bearing seat
Apply with grease onto the ball bearing seats, and
install steel balls onto the seats.
(Top: 26 balls, bottom: 29 balls)
Steel balls
Bottom cone race
Lubricate the top cone race seat with grease.
Screw the cone race in to top ball bearing seat till
touching, and then screw out the cane race
1/4~3/8 turns.
Torque value: 0.25kgf-m
Steering lock nut
Return 1/2 turns
Caution
Check the steering stem that should be rotated
freely and no clearance in vertical direction.
Locking to
1/4~3/8 turns
Top cone-race
15-9
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15. STEERING / FRONT WHEEL / FRONT CUSHION
Install the steering stem mounting nut and tighten
the nut by means of holding the top cone race
body.
Torque value: 1.0~2.0kgf-m
Steering lock nut
Install in reverse order of removal procedures.
Top cone-race
Shake steering handle up & down, left & right, and
front & rear to check if it is loosen, has too much
resistance and pulls to one side.
Check steering handle if it is being pulled too tight
by the brake cables.
15-10
Home page
Contents
16. REAR WHEEL / REAR FORK / REAR CUSHION
Mechanism Diagram ··························· 16-1
Muffler ················································· 16-3
Operational Precaution ······················· 16-2
Rear Wheel ········································· 16-3
Trouble Diagnosis ······························· 16-2
Rear Cushion······································ 16-5
Mechanism Diagram
3.5~4.5kgf-m
2.4~3.0kgf-m
1.0~1.2kgf-m
4.0~5.0kgf-m
16
10.0~12.0kgf-m
3.2~3.8kgf-m
16-1
To this chapter contents
16. REAR WHEEL / REAR FORK / REAR CUSHION
Operational Precaution
General
Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation
of the tires.
Service data
Unit: mm
Item
Standard
Allowable Limit
Radial
-
2.0
Axial
-
2.0
Thickness of rear brake lining
5.1
2.0
Sustaining stroke of rear cushion
72
-
Run-out of rear rim
Torque Value
Rear wheel shaft nut
Rear cushion upper bolt
Rear cushion under bolt
Rear fork mounting bolt
Exhaust muffler mounting nut
Exhaust muffler mounting bolt
10.0~12.0kgf-m
3.5~4.5kgf-m
2.4~3.0kgf-m
4.0~5.0kgf-m
1.0~1.2kgf-m
3.2~3.8kgf-m
Trouble Diagnosis
Run-out of rear wheel
Poor Performance of Brake
y Deformed or bent wheel hub.
y Improper tires.
y Loose wheel shaft.
y
y
y
y
y
y
y
y
Soft Cushion
y The spring is too weak.
Noisy Brake
y
y
y
y
Worn brake lining.
Offset brake disc.
Improper assembly of brake caliper.
Brake disc or wheel imbalance.
16-2
Improperly adjusted brake.
Contaminated brake disc.
Worn brake lining.
Air inside brake fluid pipe.
Grease on brake disc.
The brake fluid piping is clogged.
The brake fluid pipe is deformed or bent.
Insufficient amount of brake fluid in the
reservoir.
To this chapter contents
16. REAR WHEEL / REAR FORK / REAR CUSHION
Muffler
Removal
Loosen the 2 nuts from exhaust muffler front side.
2 nuts
Loosen the 3 mounting bolts by exhaust muffler
right side.
Remove the exhaust muffler.
Installation
Install in reverse order of removal procedures.
Caution
Replace the front side muffler pipe gasket if worn
or deformed.
Torque Value
For mounting bolt: 3.2 ~ 3.8kgf-m
For mounting nut: 1.0 ~ 1.2kgf-m
Rear Wheel
3 bolts
Cushion under bolt
Removal
Remove the exhaust muffler.
Remove the lower bolt of the right side rear
cushion.
Remove 2 bolts of the rear fork.
Remove 1 nut of the rear wheel shaft, and then
remove outside collar.
Fork bolts
Wheel shaft nut
Remove the rear fork, fork inside collar, and then
remove the rear wheel.
16-3
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16. REAR WHEEL / REAR FORK / REAR CUSHION
Inspection
Rear wheel rim
Place the wheel rim on a rotational support.
Rotate it by hand and measure the run-out with a
dial indicator.
Run-out limit: 2.0 mm
Rear fork bearing
Rotate the inner ring of the bearing with a finger.
The bearing should move smoothly and quietly.
Check the fit of the bearing and rim.
Replace the bearing if its motion is not smooth or
noisy.
Replacement of rear fork bearing
Remove the outside dust seal of the rear fork.
Use inner cir clip plier to remove the bearing lock
clip.
Pull off the rear fork bearing by means of the inner
bearing puller.
Remove the inside dust seal.
Free play
Free play
Dust seal
Inside collar
Clip
Caution
Never reuse the old dust seal on the bearing.
Outside collar
Bearing
Dust seal
Press in the bearing into the rear fork by bearing
driver.
Install the oil bearing lock clip.
Install new dust seals into rear fork two side.
Clip
Outside collar
16-4
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16. REAR WHEEL / REAR FORK / REAR CUSHION
Installation
Install the rear wheel.
Install the inside collar on the rear fork.
Install the rear fork onto the rear wheel shaft.
Mount the outside collar on the rear fork.
Tighten the rear wheel shaft nut.
Install the rear fork mounting bolts and tighten the
bolts.
Align the rear cushion with the rear fork hole;
tighten the cushion with bolts.
Install the exhaust muffler, first tighten front side
mounting nuts, and then tighten the mounting
bolts.
Torque Value
Rear wheel shaft nut: 10.0~12.0kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Rear fork mounting bolt: 4.0~5.0kgf-m
Exhaust muffler mounting nut: 1.0~1.2kgf-m
Exhaust muffler mounting bolt: 3.2~3.8kgf-m
Cushion under bolt
Caution
Fork bolts
Attention must be paid to their direction when
rear fork collars are installed. The small ends of
inner and outer collars must face to rear fork
bearing.
Wheel shaft nut
Rear Cushion
Removal
Remove the luggage box, rear carrier and body
covers.
Loosen the mounting bolts of the air cleaner (2
bolts).
Remove the exhaust muffler (3 bolts, 2 nuts).
Remove the under bolts by left / right rear
cushions.
Remove the upper bolts by left / right rear
cushions, and then remove the cushion.
Installation
Upper bolt
Install in reverse order of removal procedures.
Caution
The rear cushion must be replaced as a unit.
Never disassemble the rear cushion as that
would damage the structure.
Torque Value
Rear cushion upper bolt: 3.5~4.5kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Under bolt
16-5
To this chapter contents
16. REAR WHEEL / REAR FORK / REAR CUSHION
Notes:
16-6
Home page
Contents
17. ELECTRICAL SYSTEM
Mechanism Diagram ··························17-1
Meters················································17-11
Maintenance Data·······························17-2
Light / Bulb········································17-12
Technical Specification······················17-2
Switch / Horn·····································17-14
Trouble Diagnosis ······························17-3
Fuel Unit ············································17-17
Battery ·················································17-4
Cooling Fan Thermo Switch ············17-18
Charging System ································17-5
Thermo Unit ······································17-19
Ignition System···································17-8
Water Temperature Meter ················17-19
Starting System ··································17-10
Mechanism Diagram
Horn
Winker relay
Main switch
Dimmer & winker & horn switch
Start switch & light switch
C.D.I. unit
Battery
Spark plug
AC. Generator
Starter relay
Ignition coil
Fuse box
Regulator rectifier
Headlight relay
Fuel unit
17
17-1
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17. ELECTRICAL SYSTEM
Maintenance Data
Operational precaution
y When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
y The model of the spark plug and the tightening torque.
y The ignition timing.
y Adjustment of headlight.
y Removal and installation of AC generator.
y The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.
y To recharge the battery, remove the battery from rack without removing ventilation caps.
y Unless in emergency, never rapid charge the battery.
y The voltage must be checked with the voltmeter while charging the battery.
y As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check
C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary.
Technical Specification
Charging system
Description
Battery
Specification
Capacity
12V8Ah
Charging rate
0.9A / 5 hours (standard)
4A / 1 hour (fast charging)
Leak current
< 1 mA
Charging current
1.2 A / 2000 rpm
Control voltage in charging
14.5 + 0.5 V / 2000 rpm
Ignition system
Description
Spark plug
Ignition coil and
resistance
Ignition timing
17-2
Specification
Model
NGK CR8E (Recommended)
Gap
0.6 - 0.7 mm
Primary winding
0.17 ± 10% Ω
Secondary winding
“F” mark
Without cap: 3.1 ± 10 KΩ
With cap:8.1 ± 10 KΩ
13° TDC / 1000 rpm
27°TDC / 6000 rpm
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17. ELECTRICAL SYSTEM
Trouble Diagnosis
No voltage
y
y
y
y
Battery discharged
The cable disconnected
The fuse is blown
Improper operation of the main switch
Charging system does not operate
properly
y
y
y
y
Burnt fuse
Poor contact, open or short circuit
Poor regulator
Poor ACG
Low voltage
y
y
y
y
The battery is not fully charged
Poor contact
Poor charging system
Poor voltage regulator
No spark produced by spark plug
y The spark plug is out of work
y The cable is poorly connected, open or
short-circuited
- Between AC.G. and C.D.I.
y Poor connection between C.D.I. and ignition
coil
- Poor connection between C.D.I. and the
main switch
y Poor main switch
y Poor C.D.I.
y AC.G. is out of work
Starter motor does not work
The fuse is blown
The battery is not fully charge
Poor main switch
Poor starter switch
The front and rear brake switches do not
operate correctly
y Starter relay is out of work
y The ignition coil is poorly connected, open or
short-circuited
y The starter motor is out of work
y
y
y
y
y
Engine does not crank smoothly
y Primary winding circuit
- Poor ignition coil
- Poor connection of cable and connectors
- Poor main switch
y Secondary winding circuit
- Poor ignition coil
- Poor spark plug
- Poor ignition coil cable
- Current leakage in the spark plug
y Incorrect ignition timing
- Poor AC.G.
- Improper installation of the pulse sensor
- Poor C.D.I.
Weak starter motor
y
y
y
y
Poor charging system
The battery is not fully charged
Poor connection in the windings
The motor gear is jammed by foreign material
Starter motor is working, but engine does
not crank
y Poor starter motor pinion
y The starter motor run in reverse direction
y Poor battery
Intermittent power supply
y The connector of the charging system becomes
loose
y Poor connection of the battery cable
y Poor connection or short-circuit of the
discharging system
y Poor connection or short-circuit of the power
generation system
17-3
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17. ELECTRICAL SYSTEM
Battery
Removal
Loosen 5 screws and remove the battery cover.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery from the motorcycle.
5 screws
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 13.0~13.2 V at 20℃
Undercharged: Below 12.3 V at 20℃
Charging
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard
Maximum
Charging current
0.9A
4.0A
Charging time
5H
1H
Warning
y Keep flames away while recharging.
y Charging is completely controlled by the
ON/OFF switch on the charger, not by
battery cables.
Caution
y Never rapid charge the battery unless in
emergency.
y Verify the battery is recharged with current
and duration prescribed above.
y Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable terminal with grease.
17-4
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17. ELECTRICAL SYSTEM
Charging System
Charging circuit
Main switch
Green
Red
Black
Yellow
Yellow
Yellow
Fuse 20A
Battery
Yellow
Regulator rectifier
Auto by-starter
AC. Generator
Current Leakage Inspection
Turn the main switch to OFF position, and remove
the negative cable terminal (-) from the battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal.
Battery negative terminal
Caution
y In the current leakage test, set the current
range at the largest scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.
y Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified value, it
may indicate a short circuit.
Allowable current leakage: Less than 1mA
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.
17-5
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17. ELECTRICAL SYSTEM
Inspection on Charging Voltage
Voltmeter
Ammeter
Connect a tachometer.
Turn on the headlight to high beam and start the
engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 + 0.5 V / 2000 rpm
Caution
Fuse connector
Caution
y Before conducting the inspection, be sure that
the battery is fully charged. If undercharged,
the current changes dramatically.
y Use a fully charged battery having a voltage
larger than 13.0 V
y While starting the engine, the starter motor
draws large amount of current from the
battery.
After the engine is warmed up, replace original
battery with a fully charged battery.
Connect a digital voltmeter to the battery
terminals.
Connect an ammeter between both ends of the
main fuse.
Caution
When the probe is reversibly connected, use a
voltmeter having an indication that the current
flows from the positive or the negative direction
and the measurement should be at zero,
ammeter at one direction only.
Caution
y Do not use short-circuit cable.
y It is possible to measure the current by
connecting an ammeter between the battery
positive terminal and the cable position
terminal, however, while the starter motor is
activated, the surge current the motor draws
from the battery may damage the ammeter.
Use the kick starter to start the engine.
y The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the cable
while there is current flowing through. It may
damage the ammeter.
17-6
To replace the old battery, use a new battery with
the same current and voltage.
The following problems are related to the charging
system, follow the instructions provided in the
checking list to correct it if any one of the problems
takes place.
(1) The charging voltage can not exceed the
voltage between two battery terminals and
the charging current is in the discharging
direction.
(2) The charging voltage and current are too
much higher than the standard values.
The following problems are not related to the
charging system; correct it if any by following
steps indicate in the checking list.
(1) The standard charging voltage and current
can only reach when the revolution of the
engine exceeds the specified rpm.
- Bulbs used exceed their rate and
consume too much power.
- The replacement battery is aged and
does not have enough capacity.
(2) The charging voltage is normal, but the
current is not.
- The replacement battery is aged and
does not have enough capacity.
- Battery used do not have enough
electricity or is over charged.
- The fuse of the ammeter is blown.
- The ammeter is improperly connected.
(3) The charging current is normal, but the
voltage is not.
- The fuse of the voltmeter is blown.
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17. ELECTRICAL SYSTEM
Inspection on regulator rectifier
Remove the luggage box, rear carrier and body
covers.
Disconnect two 3 pin couplers of the regulator
rectifier.
Inspection the rectifier coupler to the wire harness
passes the condition.
Item
Main switch
connection
Battery
connection
Charging coil
Check Points Standard Value
R–B
Battery voltage
(ON)
R–G
Battery voltage
Y–Y
0.17 ~ 0.8Ω
If the readings measured are not normal, check
parts in the circuit.
If the parts are normal, then trouble is in the wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
Regulator rectifier
17-7
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17. ELECTRICAL SYSTEM
Ignition System
Ignition circuit diagram
CDI. Unit
Green/white
Green
Black/yellow
Black/white
Black/red
Ignition
coil
Blue/Yellow
Main switch
Spark plug
Green
Pulse generator
Exciting coil
C.D.I unit
Disconnect connectors of the C.D.I unit.
Check the following connectors as indicated in the table at the harness side.
Item
Points to check
Result
Main switch
Black/white ~ green
-
Exciting coil
Black/red ~ green
100~200Ω
Green/White ~ Blue/yellow
50~170Ω
Black/yellow ~ green
0.17±10%Ω
Black/yellow ~ with no cap
3.6±10%Ω
Black/yellow ~ with cap
7.3~11KΩ
Pulse generator
Primary circuit
Ignition coil
Secondary circuit
17-8
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17. ELECTRICAL SYSTEM
Inspection on Ignition Coil
Remove the luggage box.
Disengage the connector of the ignition coil and
the spark plug cap.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 0.17Ω ± 10%
Remove the cap from the spark plug and measure
the resistance between the spark plug and the
primary winding.
Standard resistance:
With no cap: 3.6Ω ± 10%
With cap:
7.3~11 KΩ
Ignition coil
Replacement
Loosen the lock bolt and replace the ignition coil if
necessary.
Spark plug
Inspection on Exciting Coil
Caution
Exciting coil coupler
The test can be carried out without removing the
exciting coil from the engine.
Remove the luggage box, rear carrier and body
covers.
Disconnect coupler of the exciting coil.
Measure the resistance between the black/red
terminal and the earth.
Standard resistance: 100~200Ω
Please refer to the Section 10 for disassembly of
coil.
Inspection of Pulse Generator
Disconnect the coupler of the pulse generator and
measure the resistance between the terminals of
green/white and blue/yellow.
Standard resistance: 50~170Ω
Pulse generator coupler
17-9
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17. ELECTRICAL SYSTEM
Starting System
Starting circuit diagram
Main switch
Battery
Main fuse 20A
Red
Fuse 10A
Starter relay
Starter motor
Brake switch
Yellow/red
Starter switch
Inspection on starter relay
Open the main switch.
Press the brake.
Push down the starter switch.
If a sound of “Looh Looh” is heard, it indicates the
relay function normally.
Remove the luggage box.
Disconnect the negative cable terminal of the
battery.
Disconnect the cable positive terminal from the
relay.
Disconnect the positive cable of the starter motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal end.
Connect the yellow/red cable to the battery
positive terminal and the green/yellow cable to the
battery negative terminal.
Check the continuity of the large terminal end.
If there is no continuity, replace the relay.
17-10
Green/yellow
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17. ELECTRICAL SYSTEM
Removal of Starter motor
Remove the battery cover (5 screws).
Disconnect the cable negative terminal (-), then
the cable positive terminal (+).
Remove the luggage box.
Remove the air cleaner.
Loosen the lock bolts and remove the starter
motor.
2 Bolts
Installation of Starter motor
Install in reverse order of removal procedures.
Meters
Removal
Remove handle front cover.
Remove the front cover, and then remove meter
coupler and handle switch coupler.
Remove speedometer cable.
Meter cable
Remove handle rear cover and speedometer.
Loosen 3 screws, and then remove speedometer
from handle rear cover.
Installation of Starter motor
Install in reverse order of removal procedures.
3 screws
17-11
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17. ELECTRICAL SYSTEM
Light / Bulb
Replacing bulb for headlight
Remove the front cover.
Headlight adjustment screw
Disconnect the terminal coupler and the rubber
sleeve from the headlight.
Headlight
Remove the bulb spring holder and the bulb.
Replace with new bulb if necessary.
Headlight
Position light
Position light
Caution
y Never touch the bulb with finger, which will
create a heat point.
y Clean the fingerprint left on the bulb with
alcohol.
Holder
Install the bulb of the headlight in reverse order of
removal.
Upon completion of replacement, turn on the main
switch to ensure the headlight works well.
Adjust the beam and distance of the headlight if
necessary.
17-12
Headlight
Bulb
Position light
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17. ELECTRICAL SYSTEM
Replacing the Front winker light Bulb
Loosen fixing screws and remove the handle front
cover (screw x 3).
Replace with new front winker light bulb.
Replacing Bulb of taillight
Remove the taillight lens (2 screws).
2 Screws
Replace taillight or winker light bulb.
17-13
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17. ELECTRICAL SYSTEM
Switch / Horn
Main Switch
Inspection
Remove the front cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below:
Pin
BAT1
Position
BAT2
I
E
LOCK
Main switch
OFF
ON
Wire Color
Red
Black
Black /
White
Green
Replacement of main switch
Disconnect the coupler of the main switch and
loosen the lock bolts (bolt x 2).
Remove the main switch.
Install the new main switch and tighten the lock
bolts (bolt x 2).
Install the main switch coupler.
2 bolts
Handle switch
Remove the handle front cover and rear cover.
Disconnect the coupler of handle.
Check the continuity between two points as
indicated in the table below.
Headlight switch
Start Switch / Headlight Switch
Pin
ST
BAT2
Yellow
/ Red
Green
Position
FREE
Wire Color
Start switch
Headlight Switch
Pin
Position
BAT3
TL
HL
White
/ Green
Brown
Blue
/ White
Headlight switch
●
Wire color
Start switch
17-14
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17. ELECTRICAL SYSTEM
Dimmer and Passing switch
Pin
HL
Position
LO
Dimmer and passing switch
HI
PASS
PASSING
Winker switch
Wire color Brown White
/ White
Blue
White /
Green
Horn switch
Dimmer and passing switch
Winker switch
Pin
Position
R
WR
L
FROM R
Winker switch
N PUSH OFF
Horn switch
FROM L
Wire color
Light
green
Gray
Orange
Horn switch
Pin
Position
BAT3
HO
White/ Green
Light green
FREE
Wire Color
17-15
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17. ELECTRICAL SYSTEM
Brake Switch
While grasp the brake lever firmly, the terminals of
white/green and green/yellow of the brake should
have continuity.
Replace the switch if damaged.
Brake switch
Horn
Remove the front cover.
喇叭
Apply 12 V power source to two terminals of the
horn, the horn should sound.
Replace the horn if necessary.
17-16
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17. ELECTRICAL SYSTEM
Fuel Unit
Fuel unit
Open the seat.
Remove the luggage box.
Remove the rear carrier.
Remove the body cover.
Disconnect the coupler of the fuel unit.
Fuel unit coupler
Remove the fuel unit (screw x 4).
Caution
y Great care shall be taken not to damage or
bend the float arm of the gauge.
When the float arm shifts to the F position or the E
position, the resistance measured shall be as
follows:
Position
Resistance
E (Empty)
97.5~107.5 Ω
F (Full)
4~10 Ω
Full
Connect the wiring to the fuel unit and the
ohmmeter as shown.
Empty
Connect the fuel unit coupler to the wire harness.
Turn on the main switch.
Move the float arm to verify the proper position the
fuel gauge needle indicates.
Arm Position
Needle Position
Up (Full)
F (Full)
Down (Empty)
E (Empty)
Caution
While conducting the test, turn on the direction
indication lamp to make sure that the battery is in
serviceable condition.
17-17
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17. ELECTRICAL SYSTEM
Cooling Fan Thermo Switch
The thermo switch mounted on the radiator
controls the operation of the cooling fan motor.
In case that the fan motor fails to work, disconnect
the green and black/blue leads and connect jump
wires to the terminals, then, turn on the main
switch, the fan motor should operate.
If the fan motor still fails to run, measure battery
voltage between the green and black/blue leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit.
If the fan motor runs, check the thermo switch in
the manner as described below:
Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and closing
temperatures, confirm the switch is open circuited
at room temperature, increase the coolant
temperature gradually. The switch should have a
continuity at 98-102℃.
Thermo switch
Caution
y Keep the coolant at a constant temperature at
least for three minutes. Sudden increase the
coolant temperature will cause the
thermometer and the tester to indicate wrong
readings.
y Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
y The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.
17-18
Thermometer
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17. ELECTRICAL SYSTEM
Thermo unit
Remove the thermo unit.
Hang the thermo unit in an oil heater, heat the oil
and measure the resistance at each temperature.
Temperature
50°C
80°C
100°C
120°C
Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2
Caution
Thermo unit
y Wear gloves and goggles when performing
this test.
Caution
y Engine oil should be used as a heating
medium as the test temperature must be
higher than 100℃.
y Contacting the container wall by the
thermometer and the thermo unit may result in
wrong readings.
Thermo unit
Water Temperature Meter
Disconnect the water temperature meter and
connect it to engine ground.
Turn on the main switch.
The needle of the meter should move to other end,
H position.
Caution
y Do not ground the water temperature more
than 5 seconds, or the meter will be damaged.
17-19
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17. ELECTRICAL SYSTEM
Notes:
17-20
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18. ELECTRICAL DIAGRAM
HD125 / 200 ELECTRICAL DIAGRAM
18
18-1
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18. ELECTRICAL DIAGRAM
Notes:
18-2
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