DAELIM S4 Specifications

SM62-1003-01E
ENGINE
FRAME
ELECTRICAL SYSTEM
Contents of this manual and specifications are
subject to change without prior notice for
improvement of vehicle quality.
No part of this publication may be reproduced
without written permission of DAELIM Motor Co.,
Ltd.,
GENERAL
CONTENTS
SERVICE INFORMATION
1
INSPECTIONS / ADJUSTMENTS
2
EXTERNAL PARTS
3
LUBRICATION SYSTEM
4
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
LH. CRANK CASE COVER / KICK STARTER /
CONTINUOUSLY VARIABLE TRANSMISSION
7
AC GENERATOR
8
CYLINDER HEAD / VALVE
9
CYLINDER / PISTON
10
TRANSMISSION / CRANKSHAFT / 11
CRANKCASE
FRONT WHEEL / FRONT FORK 12
/ STEERING / BRAKE
REAR WHEEL / REAR BRAKE / 13
REAR CUSHION
CHARGING SYSTEM
14
IGNITION SYSTEM
15
STARTER SYSTEM
16
LIGHTS / SWITCHES / HORN
17
TROUBLE SHOOTING
18
WIRING DIAGRAM
19
SERVICE INFORMATION
1. SERVICE INFORMATION
SERIAL NUMBER LOCATION ··· 1-1
········· 1-2
SPECIFICATIONS·
·········· 1-4
TWIST TORQUE·
···· 1-5
SYMBOLS / ABBREVIATIONS·
··········1-6
LUBRICATION OIL·
·········· 1-7
WIRING DIAGRAM·
··········1-11
GENERAL SAFETY·
CAUTION WHEN WIRING ······1-15
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
FRAME SERIAL NUMBER LOCATION
1
SERVICE INFORMATION
SPECIFICATION
ITEM
DIMENSIONS
FRAME
OVERALL LENGTH
OVERALL WIDTH
OVERALL HEIGHT
WHEEL BASE
SEAT HEIGHT
GROUND CLEARANCE
DRY WEIGHT
GROSS WEIGHT
TYPE
FRONT SUSPENSION
REAR SUSPENSION
FRONT TIRE SIZE/TYPE
REAR TIRE SIZE/TYPE
TIRE PRESSURE 1 person FRONT
REAR
2 persons FRONT
REAR
FRONT BRAKE
REAR BRAKE
FUEL TANK CAPACITY Full capacity
Reserve capacity
CASTER ANGLE
TYPE
CYLINDERS, ARRANGEMENT
BORE X STROKE
DISPLACEMENT
COMPRESSION RATIO
VALVES
ENGINE OIL CAPACITY
ENGINE
TRANSMISSION OIL CAPACITY
LUBRICATION TYPE
AIR CLEANER TYPE
COMPRESSION PRESSURE
INTAKE VALVE IN VALVE OPEN
CLOSE
EX VALVE OPEN
CLOSE
VALVE CLEARANCE INTAKE
EXHAUST
SPECIFICATION
1.790mm
670mm
1.102mm
1.250mm
750mm
120mm
94kg
224kg
Underbone
Telescopic
Swing Arm
3.50 -10 51J
3.50 -10 51J
2.00kg/㎠
2.00kg/㎠
2.00kg/㎠
2.25kg/㎠
-Hydraulic
-Mechanical Drum
5.0L
1.5L
27°
Air cooled 4cycle SOHC engine
1(single cylinder), front angle 90°
39.0×39.5mm
49.5cc
10.5 : 1
SOHC chain drive
0.85L (Full capacity)
0.70L (at changing)
0.12L (Full capacity)
Forced pressure splash type
Paper filter
10kg/cm2 (600rpm)
0°BTDC
25°ABDC
33°BBDC
0°ATDC
0.1mm
0.1mm
SERVICE INFORMATION
ITEM
TYPE/ VENTURY BORE
CARBURETOR
PD19J
CHOKE TYPE
Auto-bystarter
MAIN JET
#110
PILOTSCREWREVERSEREVOLUTIONSPEED
1 3/4
FLOAT LEVEL
11mm
CLUTCH TYPE
1,700±100 rpm
Automatic Transmission(V-belt type)
PRIMARY REDUCTION
3.533
SECONDARY REDUCTION
3.714
IGNITION SYSTEM
ELECTRICAL
SYSTEM
CV type(vacumm)/Φ16mm
MODEL MARK
IDLE SPPED
DRIVE TRAIN
SPECIFICATION
AC-CDI
IGNITION TIMING F MARK
BTDC 14°
BATTERY CAPACITY
12V 6Ah
SPARK PLUG
CR6HSA
SPARK PLUG GAP
0.6~0.7mm
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT(HIGH / LOW)
WINKER LIGHT(HIGH/LOW)
TAIL/ STOP LIGHT
HIGH-BEAM PILOT LAMP
15A
STARTER MOTOR / KICK
12V 35 / 35W
12V 10W
12V 21 / 5W
12V 3W
WINKER PILOT LAMP
12V 3W X 2
SPEEDOMETER LAMP
12V 1.7W X 2
SERVICE INFORMATION
TORQUE VALUES
ENGINE
ITEM
TAPPET ADJUSTING ROLL CAP
OIL DRAIN PLUG BOLT
VALVE ADJUST SCREW LOCK NUT
CYLINDER HEAD BOLT
FLYWHEEL NUT
DRIVE FACE NUT
CLUTCH OUTER BOLT
SPARK PLUG
DRIVE PLATE
CAM SHAFT HOLDER NUT
CAM CHAIN TENSIONER FLANGE BOLT
CAM CHAIN TENSIONER PAN SCREW
CYLINDER HEAD COVER BOLT
MISSION COVER BOLT
MISSION COVER DRAIN BOLT
MISSION COVER CHECK BOLT
COOLING FAN BOLT
STARTER MOTOR FLANGE BOLT
Q’TY
THREAD DIA
(mm)
TORQUE VALUE
1
1
2
2
1
1
1
1
1
4
2
1
4
8
1
1
3
2
30
12
5
6
12
12
10
10
28
7
6
6
6
6
8
8
6
6
1.5 kgf·m
2.5 kgf·m
1.1 kgf·m
1.1 kgf·m
5.5 kgf·m
5.5 kgf·m
4.0 kgf·m
1.2 kgf·m
5.5 kgf·m
2.0 kgf·m
1.0 kgf·m
0.4 kgf·m
1.1 kgf·m
1.2 kgf·m
1.0 kgf·m
0.9 kgf·m
1.0 kgf·m
0.9 kgf·m
Q’TY
THREAD DIA
(mm)
TORQUE VALUE
1
1
1
1
1
2
3
2
1
1
1
1
1
1
1
1
26
26
10
12
10
6
8
22
16
8
8
10
10
10
10
10
7.0 kgf·m
0.25 kgf·m
4.5 kgf·m
6.0 kgf·m
3.0 kgf·m
1.2 kgf·m
4.25 kgf·m
2.25 kgf·m
12 kgf·m
4.0 kgf·m
4.0 kgf·m
3.5 kgf·m
4.5 kgf·m
4.0 kgf·m
1.5 kgf·m
4.5 kgf·m
REFERENCE
Apply the engine oil
Apply the engine oil
FRAME
ITEM
STEERING LOCK NUT
STEERING TOP NUT
HANDLE BAR LOCK NUT
FRONT AXLE NUT
FRONT CALIPER BRACKET BOLT
FRONT MASTER CYLINDER HOLDER BOLT
FRONT DISK PLATE BOLT
FRONT FORK BOLT
REAR WHEEL AXLE NUT
REAR CUSHION UPPER BOLT
REAR CUSHION UNDER BOLT
REAR CUSHION UPPER METAL LOCK NUT
ENGINE HANGER UPPER BOLT
MAIN STAND BOLT
SIDE STAND PIVOT SCREW
SIDE STAND PIVOT NUT
REFERENCE
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.
ITEM
TORQUE VALUE
ITEM
TORQUE VALUE
5mm BOLT, NUT
6mm BOLT, NUT
8mm BOLT, NUT
10mm BOLT, NUT
12mm BOLT, NUT
0.5 kgf·m
1.0 kgf·m
2.2 kgf·m
3.5 kgf·m
5.5 kgf·m
5mm SCREW
6mm SCREW
6mm SCREW BOLT, NUT
8mm SCREW BOLT, NUT
10mm SCREW BOLT, NUT
0.4 kgf·m
0.9 kgf·m
1.2 kgf·m
2.7 kgf·m
4.0 kgf·m
SERVICE INFORMATION
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.
SYMBOL
MEANING
SYMBOL
MEANING
Indicates important work. Minor injury or
Indicates dangerous area. Serious
WARNING
CAUTION
vehicle part damage may result if instruction
accident may result if instructions are not
are not followed.
followed.
Indicates general safety matters. Provides
NOTE
safety and appropriate handling procedures.
The following abbreviations are used in this manual.
ASS’Y
ASSEMBLY
LH.
Left
RH.
Right
The following symbols indicate oil adding, oil change, or parts.
SYMBOL
CAUTION
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)
Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent)
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2
or equivalent)
Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent)
Use silicone grease
Apply a locking agent. Use the agent of the middle strength, unless otherwise specified
Apply sealant
Replace the parts with new ones before assembly
Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified
Use Fork or Suspension Fluid
Use special tool
Use option tool. These tools are obtained as you order parts.
( 3-1)
Indicates reference page. (Example : Refer to page 3-1)
Special grease, etc. that do not correspond to the above are indicated without using symbols.
SERVICE INFORMATION
LUBRICATION OIL
ENGINE PARTS
APPLICATION AREA
VALVE GUIDE / VALVE STEM WORKING AREA
REMARKS
•SAE15W-40 or SAE10W-40
CONTACT AREA OF CAM SHAFT
•API SL
CONTACT AREA OF VALVE ROCKER ARM
CAM SHAFT DRIVE CHAIN
PISTON & PISTON RING GROVE
INSIDE CYLINDER
CONNECTING ROD PISTON PIN HOLE
CONNECTING ROD
CRANK SHAFT
OIL PUMP DRIVE CHAIN
COUNTER SHAFT GEAR
FINAL GEAR
BEARING
SURFACE OF O-RING
OIL SEAL
AREA OF FRICTION SPRING WORK / SHAFT WORK
AREA OF SHAFT WORK
HEAT RESISTENT GREASE
SERVICE INFORMATION
WIRING DIAGRAM
WINKER RELAY
MAGNETIC
SWITCH
REGULATOR
RECTIFIER
SAI PIPE
SIDE STAND
SPEEDOMETER CABLE
FUEL TANK
CDI UNIT
FUEL COCK
FUEL HOSE
REAR BRAKE
CABLE
SERVICE INFORMATION
WINKER RELAY
HORN
FUEL TANK
CDI UNIT
MAGNETIC SWITCH
IGNITION COIL
REGULATOR RECTIFIER
ACG COUPLER
SAI PIPE
MUFFLER
FRONT BRAKE CALIPER
SERVICE INFORMATION
MASTER CYLINDER
SPEEDOMETER
WINKER RELAY
BRAKE HOSE
KEY SET
HORN
SERVICE INFORMATION
BATTERY CABLE
SAI PIPE
ACG COUPLER
REGURATOR
RECTIFIER
MAGNETIC SWITCH
CDI UNIT
FUEL TANK
CARBURATOR
SERVICE INFORMATION
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or
recommended parts.
2. Before maintenance, remove deposit or dust from the
chasis.
SERVICE INFORMATION
3. Store the parts of each system discriminatively to install
each part in the right place.
4. After removing gasket, O-ring, piston pin clip and cotter
pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.
6. Check necessary place and measure necessary data
during installation. When installing, return to the state
before removing.
7. Align the bolts to uniform the tightening points before
tightening them when you don’t know the bolt length.
8. Bolts, nuts and pieces must be tightened from the bigger
diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
9. Check to see if the rubber part is worn out when
removing it and replace it if necessary. Some rubber part
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
10. Recommended grease must be applied to or filled in
the specified place.
SERVICE INFORMATION
11. Maintenance needed to use the specialized tools must
performed with the right tool.
12. Never reuse the ball bearing removed with the ball
applied pressure when removing press-fitted the
bearing.
13. Check the smooth rotation of inner or outer race of the
ball bearing by rotating it manually.
• Replace the ball bearing having excessive axial/
longitudinal hanging.
•Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball
bearing)
• Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
14. Pay attention to installation direction in case of the
single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way
that the face marked with manufacturer and size
should direct to the outer axle.
SINGLE-SEALED TYPE DOUBLE-SEALED TYPE
OPEN TYPE
15. When blowing the ball bearing with compressed air
after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.
MANUFACTURER’S NAME, BEARING No.
16. Install the snap ring so that chamfered side directs to
the load-applied side. After installation, check the
proper installation by rotating the snap ring.
SNAP RING
CHAMFERED EDGE
17. Check each part for proper tightening and operation
after installation.
18. The brake fluid and coolant can damage the painted
plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
SERVICE INFORMATION
19. Install the oil seal so that the manufacturer marked
surface directs outer surface.(direction not covered
with oil)
• Pay attention not to bend or damage the lip
• Apply the grease to the lip
20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.
CAVITY
MANUFACTURER’S NAME
CLIP
FITTING
21. Keep the pneumatic system interior or the engine
interior from the infiltration of dust.
22. Install the gasket mounted in the contact surface of
each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively.
Transformed or damaged cable may cause malfunction
or damage.
24. Install the boots with the installing groove by inserting
the boots into the groove.
BOOTS
SERVICE INFORMATION
CAUTION WHEN WIRING
•Each cord must be connected depending on its color.
When connecting different cord, attach color tube
around the connector. Connect the coupler to the
connector with same color and same pin number.
•Identify the two-colored cord by main color first and
then spriped color .
BLACK TUBE
WHITE
TUBE
•When measuring voltage or resistance of the cord
terminal using tester, contact the tester plug behind of
the coupler. Pay attention not to open the cord terminal
and contact the tester plug from the front of the coupler
in case of water-proof coupler.
RED STRIPE
TESTER PLUG
WHITE
COUPLER.
WHITE
RED STRIPE
BLACK CORD
•Recheck the condition of contact, securing and
continuity of each part after maintenance.
•When connecting the battery, the plus terminal must be
connected first.
•After connecting the terminal, apply the grease to the
terminal.
WHITE / RED CORD
•When disconnecting the battery, the minus terminal
must be disconnected first.
•Make sure that the tool such as spanner do not contact
with the frame.
•Connect covers to the terminal after maintenance.
•If the fuse is short-circuited, find out the cause and
repair. Replace with the fuse having the specified
capacity.
•If there is rust in the terminal, remove the rust with sand
paper prior to connecting.
VALIDATION
OF CAPACITY!
REMOVE
THE
RUST!
SERVICE INFORMATION
•Turn off the main switch before connecting/disconnecting.
•Release the lock to disconnect the lock of the coupler.
•The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
•When disconnecting the coupler, disconnect it while
holding the coupler body. Pull while holding the wire
harness cord and do not remove the coupler connection.
•Insert the lock of the coupler until the lock is fully
secured.
•Release the lock by inserting the coupler slightly and
then narrowing connection to remove the coupler.
•Pay attention not to damage the vinyl cover of the
coupler.
•Check to see if there is bended terminal and secure it to
avoid disconnecting.
•If the wire harness coating is damaged, repair by
winding vinyl tape or replace it.
•Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.
SERVICE INFORMATION
•Insert the connector until the vinyl cover is fully
inserted into the terminal.
•The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.
DRAINING HOLE
•When removing T-start, broaden the groove of T-start
using the wiring driver and release the torque.
•Connect the harness and the hose to T-start and then
insert until the groove is locked.
•When removing T-start from the frame, replace it with
the new one.
WIRING DRIVER
GROOVE SIDE
•Wire band must be secured firmly in the specified
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.
•Secure the wire harness firmly using the clamp.
•In case of the weld clamp, do not clamp in the welded
part.
•When clamping the wire harness, make sure that the
harness is not contacted with the shaft or rotating part.
•When clamping the wire, pay attention not to contact
with hot part.
•The wire harness must be routed without contacting
with the end of the lamp or any sharp edge.
•The wire harness must be routed without contacting
with the end of the bolt or the piece.
SERVICE INFORMATION
•In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape.
•The wire must not hang down or be pulled excessively.
NOT TO
PULL!
•If necessary, lock the wire harness properly.
•When mounting parts, make sure that the wire harness
is not pressed by the parts.
•Do not twist the wire harness.
•Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
•Prior to using the tester, please read the manual carefully and understand the contents.
•When testing the resistance of the tester, the zero
adjustment must be performed before testing.
•Do not drop or throw the parts especially
semiconductor contained parts because these parts may
be damaged by the impact of the drop.
Is this
measurement range or
configuration in accord
with the manual?
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION ··· 2-1
MAINTENANCE SCHEDULE ·· 2-3
FUEL LINE·········· 2-4
THROTTLE GRIP OPERATION·· 2-4
AIR CLEANER ······· 2-5
SPARK PLUG ······· 2-5
VALVE GAP ········ 2-5
CYLINDER COMPRESSION PRESSURE · 2-6
CARBURETOR IDLING···· 2-7
TRANSMISSION OIL····· 2-7
ENGINE OIL········· 2-7
DRIVE BELT·········2-7
BRAKE FLUID········2-8
BRAKE PAD/SHOE····· 2-8
SIDE STAND········ 2-9
SUSPENSION ······· 2-9
FASTENING BOLTS, NUTS· · · 2-9
WHEELS/TIRES······· 2-10
STEERING STEM······ 2-10
BATTERY········· 2-10
LUBRICATION POINTS····2-11
SERVICE INFORMATION
WARNING
●The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
●Refer to the chapter 4 about the engine fluid
●Stand the main stand prior to the beginning work
EPAIR STANDARDS
THROTTLE GRIP DIFFE
SPARK PLUG
SPARK PLUG GAP
IN
EX
VALVE GAP
CARBURETOR IDLE SPEED
CYLINDER COMPRES SION PRESSURE
TIRE PRESSUR AT COLD
ROLLING
TIRE SIZE
ONE PERSON
TWO PERSONS
FRONT
REAR
FRONT
REAR
FRONT
REAR
2-6mm
CR6HSA
0.6~0.7mm
0.1mm
0.1mm
1,700±100rpm
10kg/cm2 (600rpm)
2.00 kgf/cm2 (28psi)
2.00 kgf・cm2 (28psi)
2.00 kgf・cm2 (28psi)
2.25 kgf・cm2 (33psi)
3.50 -10 51J
3.50 -10 51J
2
INSPECTIONS / ADJUSTMENTS
TORQUE
SPARK PLUG
1.2㎏f・m
CYLINDER HEAD COVER BOLT
0.9㎏f・m
VALVE ADJUSTING NUT
1.1㎏f・m
TOOL
WRENCH 8×9mm
ADJUST WRENCH
COMPRESSION GAUGE
INSPECTIONS / ADJUSTMENTS
REGULAR INSPECTION SCHEDULE
● Carry out pre-operation check at each scheduled maintenance period based on the information described in the
owner’s manual.
I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
R : REPLACE L : LUBRICATE C : CLEAN
ODOMETER READING(NOTE 1)
FREQUENCY
ITEM
FUEL LINE(FUEL TUBE)
500km
4,000km
8,000km
12,000km
1 month
6 months
12 months
18 months
I
I
I
I
I
I
I
THROTTLE GRIP OPERATION
AIR CLEANER
C
C
R
C
SPARK PLUG
I
I
I
I
VALVE GAP
I
I
I
I
R
TRANSMISSION OIL
ENGINE OIL
R
R
R
R
ENGINE OIL FILTER SCREEN
C
C
C
C
CARBURETOR IDLE SPEED
I
I
I
I
DRIVE BELT
I
I
I
WEIGHT ROLLER
I
I
I
SLIDE PIECE
I
I
I
L
L
L
I
I
I
GREASING AT INNER PART OF
MOVABLE DRIVE FACE
BRAKE FLUID
BRAKE SHOE/PAD WEAR
I
I
I
I
BRAKE SYSTEM
I
I
I
I
I
I
I
I
I
I
SIDE STAND
I
I
I
SUSPENSION
I
I
I
BRAKE STOP SWITCH
HEADLIGHT ADJUSTMENT
BOLTS, NUTS, FASTENERS
I
STEERING HEAD BEARING
I
NOTE 2
NOTE 3
NOTE 3
I
I
WHEELS/TIRES
NOTE
I
I
I
I
I
I
NOTE 3
* If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology
contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections.
To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops,
dealers or other designated repair shops.
NOTE
1. After the odometer reading exceeds 12,000km, repeat maintenance service at intervals indicated in the table.
2. After riding in areas with high humidity or pollution, carry out maintenance service more frequently.
3. Replace every 2 years. Proper technology is required for this job.
INSPECTIONS / ADJUSTMENTS
FUEL
STRAINER
FUEL
FUELSTRAINER
STRAINER
FUEL
STRAINER
FUEL
FUEL COCK
COCK
FUEL
COCK
FUEL
TUBE
FUEL
FUELTUBE
TUBE
FUEL
FUEL LINE(FUEL TUBE)
● Remove the luggage box.
● Check the fuel line connected to the fuel cock and
carburetor. If the fuel line is cracked, damaged or
leaks, replace it.
CARBURETOR
CARBURETOR
CARBURETOR
THROTTLE GRIP OPERATION
● Check to see if the throttle grip operates smoothly in
any steering position.
● If the throttle grip does not operate properly, check
the throttle cable for aging, damage or kinking.
● Check the throttle grip free play.
FREE
FREE PLAY
PLAY
FREE
PLAY
FREE PLAY : 2~6 mm
LOCK
NUT
LOCK
LOCKNUT
NUT
LOCK
ADJUST
NUT
ADJUST
ADJUST NUT
NUT
THROTTLE
THROTTLE
CABLE
THROTTLECABLE
CABLE
CARBURETOR
CARBURETOR
CARBURETOR
CARBURETOR
● For minute adjustment, to adjust the adjuster nut
under the throttle grip.
● Remove the rubber.
● Loosen the lock nut, turn adjuster nut and adjust of it.
LOCKNUT
NUT
LOCK
NUT
LOCK
RUBBER
RUBBER
RUBBER
● For main adjustment of the throttle grip freeplay,
adjust the nut on the carburetor side.
● Loosen the lock nut, turn the adjuster nut and adjust
of it.
THROTTLE
THROTTLE
CABLE
THROTTLECABLE
CABLE
ADJUSTNUT
NUT
ADJUST
ADJUST
NUT
INSPECTIONS / ADJUSTMENTS
AIR
AIR
CLEANER
AIRCLEANER
CLEANER
AIR CLEANER
● Loosen the 6 screws securing the air cleaner case
cover and remove it.
AIR
CLEANER
ELEMENT
AIR
AIRCLEANER
CLEANERELEMENT
ELEMENT
AIR
● Remove the air cleaner element.
● Check the element, if it is dirty or damaged, replace it
.
CAUTION
•Clean away dirt by tapping slightly the paper
element if its surfae has very dirty or there is much
dirty on it. Also, blow away dirt sticked to the
surface of filter from the inner side (carburetor) of
the filter.
SPARK PLUG
CHECK THE CAP,
CONTAMINATION.
0.6 ~ 0.7mm
CHECK THE
DAMAGE OF
SEALING WASHER.
CHECK THE
CRACK.
● Remove the center cover.
● Remove the spark plug cap and disassemble the plug.
● If the spark plug is severely contaminated or
damaged, replace with a new one. If the plug can be
reused after removing only carbon, use plug cleaner
and wire brush to clean the plug.
● Always use the feeler gauge to check the gap.
GENUINE PLUG : CR6HSA
SPARK PLUG GAP : 0.6~0.7mm
TORQUE :1.2 kgf·m
CAUTION
CYLINDER
HEAD
COVER
CYLINDER
CYLINDERHEAD
HEADCOVER
COVER
CYLINDER
FRANGE
BOLTS
FRANGE
FRANGEBOLTS
BOLTS
FRANGE
•First, assmeble it temporarily by hand and tighten
completely the spark plug by using of the spark
plug wrench.
VALVE CLEARANCE
● Remove luggage vox
● Remove center cover
● Disassemble 4 cylinder head cover bolts
● Disassemble 2 cap nut 6mm
CAP
NUT
6mm
CAP
CAPNUT
NUT6mm
6mm
SAI
PIPE
SAI
SAIPIPE
PIPE
SAI
INSPECTIONS / ADJUSTMENTS
CAUTION
TURN
TURN
TURN
•Inspect and adjust the valve clearance when the
engine is cold(35℃).
•Remove cooling fan cover.
•Turn the flywheel counterclockwise , and align the
“T” mark of the flywheel with index mark of the
RH. crankcase cover.
•Verify that the piston is located at the top dead
center.
● Measure the valve clearance with feeler gauge.
REMOVE
REMOVE
FAN
COVER
RUBBER
PLUG
REMOVEFAN
FANCOVER
COVERRUBBER
RUBBERPLUG
PLUG
VALVE CLEARANCE : INTAKE 0.1±0.02MM
EXHAUST0.1±0.02MM
● Loosen the lock nut with a valve wrench,and set
valve clearance to the prescribed level by turning the
adjusting screw with a valve adjusting wrench,and
tighten the lock nut.
● After setting clearance to the prescribed level, hold
the adjuster screw with a valve adjusting wrench,and
tighten the lock nut.
ROCKER
ARM
ROCKER
ROCKERARM
ARM
ROCKER
VALVE
VALVE
VALVE
VALVE
ROCKER
ROCKER
ROCKER
ARM,
LOCK
ARM,
ARM,LOCK
LOCK
NUT
NUT
NUT
TORQUE :1.1 kgf.m
TOOL: WRENCH 8X9 MM
ADJUST WRENCH
FILLER GUAGE
● Measure the valve clearance again.
● Install the cylinder head cover and tighten the bolts.
TORQUE :0.9 kgf·m
SPARK
PLUG
WENCH
SPARK
SPARKPLUG
PLUGWENCH
WENCH
SPARK
PLUG
WENCH
CYLINDER COMPRESSION
PRESSURE
● Start and warm up the engine.
● Stop the engine, and remove the spark plug cap and
spark plug.
● Install the compression gauge.
● Open the throttle completely, and crank the engine
with the starter motor until the gauge reading rising.
TOOL : COMPRESSION GAUGE
NOTE
•The maximum reading is usually reached within
4~7 seconds.
COMPRESSION PRESSURE : 10 kgf/cm2 (600RPM)
COMPRESSION
COMPRESSION
GAUGE
COMPRESSIONGAUGE
GAUGE
● If the pressure is low, check the following:
-Inadequate valve clearance adjustment
-Valve leakage
-Leakage from the cylinder head gasket
-Piston/ cylinder worn.
● If pressure is high, check the following:
-Carbon deposits on the piston head, and cylinder
head
INSPECTIONS / ADJUSTMENTS
CARBURETOR IDL SPEED
THROTTLE
THROTTLE
STOP
SCREW
THROTTLESTOP
STOPSCREW
SCREW
● Turn the main key to the left , disassemble the lock
nut and raise up the seat.
● Remove the carburetor maintenance cover on the
luggage box.
● Connect to the ignition code
● Meet the speficied RPM by adjusting the throttle stop
screw with the ⊕ screw driver.
NOTE
CARBURETOR
CARBURETOR
CARBURETOR
CARBURETOR
TRANSMISSION
OIL
CHECK
HOLE
TRANSMISSION
TRANSMISSIONOIL
OILCHECK
CHECKHOLE
HOLE
•Erect the motorcycle on the main stand.
•After checking all engine adjustments whether
satisfying cifications, adjust them.
•Heat the engine to make accurate idling inspection
and adjustment.
•Turn the throttle stop screw and make adjustments
to the prescribde speed.
IDLE : 1,800±100 rpm
CAUTION
•Do not excessive adjustment the pilot screw it
could be effect to starting.
•Refer to the page 5-9 for adjusting the pilot screw.
TRANSMISSION OIL
INSPECTION
● Loosen the oil check blot and measure the oil level.
● If the oil level is low, add the oil(SAE80W-90).
● Tighten the oil check bolt.
DRAINBOLT
BOLT
DRAIN
DRAIN
BOLT
TRANSMISSION OIL CAPACITY : 0.12 L
NOTE
TOP
LINE
TOP
TOPLINE
LINE
TOP
BOTOM
LINE
BOTOM
BOTOMLINE
LINE
BOTOM
•Make sure that the oil sealing washer is in good
condition.
•Replace the transmission when it is contaminated
seriously.
•Erect the transmission when it is contaminated
seriously.
ENGINE OIL
INSPECTION
● Warm up the engine so that heat up the engine oil
fully.
● Stop the engine and loosen the oil level gauge then,
check the oil level.
● It is good if the oil surface is between the lower level
line and upper that of the sight glass. If the oil level
is near the lower level line or below that, refuel the
recommended oil to the upper level line.
OIL
LEVER
GAUGE
OIL
OILLEVER
LEVERGAUGE
GAUGE
OIL
DRIVE
DRIVE
FACE
DRIVEFACE
FACE
ENGINE OIL CAPACITY : 0.8 L
NOTE
•Erect the motorcycle on the main stand and try.
DRIVE BELT
DRIVE
BELT
DRIVE
DRIVEBELT
BELT
DRIVE
BELT
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
● Remove the 2 air cleaner mounting bolts.
● Remove the kick arm.
● Remove the LH. Crankcase cover.
● Check the drive belt for excessive wear or damage
● Check the schedule maintenance period, replace the
new drive belt if possible.
INSPECTIONS / ADJUSTMENTS
BRAKE FLUID
BRAKE
BRAKE
FLUID
CHECK
WINDOW
BRAKEFLUID
FLUIDCHECK
CHECKWINDOW
WINDOW
MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER
● Check the oil level of front master cylinder.
● I f the oil level is near the lower limit level , remove
the oil cup cap, diaphragm and fill DOT3 or DOT4
brake fluid to the top limit line.
● If the brake fluid reaches to the lower limit line,
check the leaking of the brake system entirely.
NOTE
•If the brake pad is worn severely, brake fluid level
can be down.
BRAKE PAD / SHOE
BRAKE PAD REPLACEMENT
● Check the brake pads for wear.
● If the red mark on the pad reaches to the brake disk,
replace the pads.
● Check the front brake hose for crack and damage,
replace it immediately if the brake fluid leaks.
NOTE
•Replace the brake pads in sets.
ABRASIONLIMIT
LIMIT
ABRASION
LIMIT
ABRASION
BRAKE SHOE REPLACEMENT
● If the arrow mark of the wear limit with the
indication mark when the parking brake lever is
tightly depressed, it indicates the brake lining has
reached to the service limit. Replace the brake shoes.
● Adjustment of rear brake tolerance.
- Adjust the tolerance by turning adjust nut.
ADJUST
ADJUST
NUT
ADJUSTNUT
NUT
BRAKE LEVER CLEARANCE
● Check the clearance after pulling the lever.
CLEARANCE
CLEARANCE
CLEARANCE
FRONT: 10~20 MM
REAR : 10~20 MM
INSPECTIONS / ADJUSTMENTS
SIDE STAND
● Erect the main stand.
● If pull the lower end of side stand by hand, check
whether it moves smoothly.
● If it doesn’t move freely, pour grease into its pivot
side.
● If it moves too freely, check the side stand spring.
● Check the axial movement of side stand.
SIDE
SIDE
STAND
SIDESTAND
STAND
SUSPENSION
NOTE
•Do not ride motorcycle with an unsatisfactory
suspension.
•Loosen or worn suspension parts will lead to
deterioration in the vehicle’s safety and operation
efficiency.
FRONT WHEEL
FRONT
FRONT
CUSHION
FRONTCUSHION
CUSHION
● Hold the brake lever, and compress the front cushion
up and down several times to check the efficient
operation.
● Check the front fork for oil leakage, parts damage or
looseness.
REAR WHEEL
● Compress the rear cushion up and down several
times to check the operating conditions.
● Check the front fork for oil leakage, parts or
looseness.
REAR
REAR
CUSHION
REARCUSHION
CUSHION
STEERING STEM
NOTE
•Check the cable if it interferes with the handle
operation.
● Lift the front wheel and check if the handle moves
right and left smoothly.
● If the handle moves heavily, check if the cable or
electric codes interfere with the handle. If the handle
moves normally, remove the steering stem and
check the ball race for being worn or damaged.
INSPECTIONS / ADJUSTMENTS
WHEELS / TIRES
NOTE
•Check the tire pressure when the tires have been
cooled off. Check the thread (the part making
contact with the road surface)and side for being
worn, cracked or damaged. Replace damaged tires.
STANDARD PRESSURE
㎏f/㎠(psi)
TIRE
PRESSURE
GAUGE
TIRE
TIREPRESSURE
PRESSUREGAUGE
GAUGE
TIRE
PRESSURE
GAUGE
ITEM
DRIVER ONLY
FRONT WHEEL REAR WHEEL
2.00(28psi)
2.00(28psi)
DRIVERANDAPASSENGER
2.00(28psi)
2.25(32psi)
F
FASTENING BOLTS, NUTS
● Meeting the schedule of regular inspection,
● Check whether the nuts, bolts of all vehicles are
fastened by specified torques.
● Check all pins, clips, hose clamp and cable stay
F
BATTERY
● Remove the battery cover.
● Check the looseness of the terminals.
● If the terminals are loose, check and clean the
contacted area.
● Measure the battery voltage
- COMPLETE CHARGING :12.6~13.0 V
- INCOMPLETE CHARGING : UNDER 12.9 V
● If the terminal part get rusted, remove the battery and
pour the warm water then, clean it with a wire brush.
INSPECTIONS / ADJUSTMENTS
LUBRICATION POINTS
Unless specifically designated, use generd grease to lubricate the lubrication points.
For stiding parts not shown here, add oil or grease.
CONTROL CABLE LUBRICATION
Remove and clean regularly the upper assembly of the throttle cable, and apply oil.
If the cable has expanded, replace it.
FRONT BRAKE LEVER PIVOT
TROTTLE GRIP
STEERING BEARING
SIDE / MAIN STAND PIVOT
WHEEL BEARING /
SPEEDOMETER GEAR
WHEEL BEARING
4
MEMO
3. EXTERNAL PARTS
SERVICE INFORMATION···3-1
ASSEMBLY-DISASEMBLY PRECEDURE 3-2
SEAT············3-2
LUGGAGE BOX ·······3-3
REAR CARRIER ·······3-3
CENTER COVER ·······3-3
BODY COVER ········3-4
REAR FENDER ·······3-4
FLOOR SIDE COVER ·····3-5
FLOOR PANEL ·······3-5
UNDER COVER ·······3-6
FRONT COVER ·······3-6
INNER BOX ·········3-7
FRONT FENDER COVER ···3-7
FRONT UNDER COVER ····3-8
FRONT HANDLE COVER ··· 3-8
REAR HANDLE COVER ····3-8
SPEEDOMETER ·······3-9
REAR WHEEL MUD GUARD ··3-9
REAR SPLAER COVER ····3-9
MUFFLER ········· 3-9
SERVICE INFORMATION
CAUTION
● This section describes external parts removal / installation
● Do not apply unreasonable force when disassembling or assembling covers to prevent their possible damage.
● Because the muffler is hot, do not service it immediately after the engine is stopped.
● When diassembling the front wheel, be careful about the turn over of the vehicle
EXTERNAL PARTS
MAINTENANCE PROCEDURE
NAME OF FRAME COVERS
FLOW CHART(ASSEMBLY/DISASSEMBLY)
● This chart shows arrows connected in the order of disassembling covers
① SEAT
⑥ BODY COVER
⑪ FRONT COVER
⑯ FRONT HANDLE COVER
② LUGGAGE BOX
⑦ REAR FENDER
⑫ INNER BOX
⑰ REAR HANDLE COVER
③ REAR CARRIER
⑧ FLOOR SIDE COVER
⑬ FRONT FENDER
⑱ REARWHEELMUDGUARD
④ BATTERY COVER
⑨ FLOOR PANEL
⑭ FRONT WHEEL
⑲REAR SPLASH COVER
⑤ CENTER COVER
⑩ UNDER COVER
⑮ FRONT UNDER COVER
NOTE
•At disassembling front wheel, be careful for the turn over of the vehicle.
EXTERNAL PARTS
SEAT REMOVAL /
ASSEMBLY
● Unlock the seat lock by turing the main key to the
left.
● Disassemble the frange nut and hinge pin
● Remove the seat
● Install in the reverse order of removal
MAIN
KEY
MAIN
MAINKEY
KEY
HINGE
HINGE
PIN
HINGEPIN
PIN
CIGAR
CIGAR
JACK
CIGARJACK
JACK
WASHER
WASHER
BOLT
WASHERBOLT
BOLT
FUEL
FUEL
TANK
CAP
FUELTANK
TANKCAP
CAP
LUGGAGE BOX REMOVAL /
ASSEMBLY
● Loosen 4 washer bolts in the luggage box
● Loosen the fuel tank cap
● Lifting up the luggage box, loosen cigar jack coupler
● Loosen the luggage box
● Install in the reverse order of removal
REAR CARRIER REMOVAL /
ASSEMBLY
SOCKET
BOLT
REAR
CARRIER
SOCKETBOLT
BOLT
REAR
REARCARRIER
CARRIER SOCKET
● Loosen 3 socket bolts
● Loosen rear carrier
● Install in the reverse order of removal.
CENTER COVER REMOVAL
/ ASSEMBLY
TAPPING
TAPPINGSCREWS
SCREWS
TAPPING
SCREWS
● Loosen 2 tapping screws of battery cover, then
loosen Battery cover .
● Loosen 2 tapping screws.
CENTER
CENTER
COVER
CENTERCOVER
COVER
BATTERY
COVER
BATTERY
BATTERYCOVER
COVER
BATTERY
COVER
EXTERNAL PARTS
● Loosen center cover
● Install in the reverse order of removal
TAPPING
TAPPINGSCREWS
SCREWS
TAPPING
SCREWS
.
CENTER
CENTER
COVER
CENTERCOVER
COVER
BODY
BODY
COVER
BODYCOVER
COVER
TAPPING
TAPPING
SCREWS
TAPPINGSCREWS
SCREWS
BODY COVER REMOVAL /
ASSEMBLY
● Remove luggage box
● Remove rear carrier
● Loosen 2 tapping screws being installed at the RH /
LH body side cover.
● Loosen 2 washer bolts installed from rear fender
● Disassemble tail light codes, then on condition that
rear fender is installed, by pulling back and opening
left-right sides, disassemble body cover.
● Install in the reverse order of removal.
WASHER
WASHER
BOLTS
WASHERBOLTS
BOLTS
REAR
FENDER
REAR
REARFENDER
FENDER
REAR
FENDER
REAR FENDER REMOVAL /
ASSEMBLY
BODYCOVER
COVER
BODY
BODY
COVER
● Remove body cover.
REAR
FENDER
REAR
REARFENDER
FENDER
EXTERNAL PARTS
● Loosen 5 tapping screws installed at body cover and
Disassemble rear fender
● Install in the reverse order of removal
BODY
COVER
BODY
BODYCOVER
COVER
BODY
COVER
REAR
REAR
FENDER
REARFENDER
FENDER
FLOOR SIDE COVER
REMOVAL / ASSEMBLY
FLOOR
FLOOR
SIDE
COVER
FLOORSIDE
SIDECOVER
COVER
● Loosen 4 left-right special screws of floor side
● Loosen 2 tapping screws installed at left and right of
floor side cover
● Disassemble floor side covers of RH/LH
● Install in the reverse order of removal.
SPECIAL
SPECIALSCREWS
SCREWS
SPECIAL
SCREWS
TAPPING
TAPPING
SCREW
TAPPINGSCREW
SCREW
FLOOR PANEL REMOVAL /
ASSEMBLY
BATTERY
BATTERY
BATTERY
● Remove battery cover
● Remove center cover
● Remove body cover
● Disassmble floor side cover
● Remove battery.
WASHER
WASHER
BOLTS
WASHERBOLTS
BOLTS
SCREWS
SCREWS
SCREWS
SCREWS
● Disassemble 4 floor panel caps
● Loosen 4 washer bolts
● Loosen 2 screws and 2 special screws installed at
floor panel.
EXTERNAL PARTS
● Untie 2 washer bolts in the side of floor panel.
● Pull backward and disassemble floor panel.
● Install in the reverse order of removal.
FLOOR
FLOOR
PANEL
FLOORPANEL
PANEL
WASHER
WASHERBOLTS
BOLTS
WASHER
BOLTS
UNDER COVER REMOVAL /
ASSEMBLY
UNDER
COVER
UNDER
UNDERCOVER
COVER
UNDER
COVER
● Disassemble floor side cover.
● Loosen 4 left-right washer bolts installed at under
cover.
● Disassemble under cover.
● Install in the reverse order of removal.
WASHER
WASHERBOLTS
BOLTS
WASHER
BOLTS
INNER
INNER
BOX
INNERBOX
BOX
FRONT COVER REMOVAL /
ASSEMBLY
● Loosen 2 washer screws installed at inner box.
WASHER
SCREWS
WASHER
WASHERSCREWS
SCREWS
WASHER
SCREWS
WASHER
WASHER
SCREWS
WASHERSCREWS
SCREWS
FRONT
COVER
FRONT
FRONTCOVER
COVER
FRONT
COVER
● Loosen 4 washer screws installed at front cover.
● Disassemble head light coupler.
● Disassemble front cover.
● Install in the reverse order of removal.
EXTERNAL PARTS
INNER
INNER
COVER
INNERCOVER
COVER
TAPPING
SCREWS
TAPPING
TAPPINGSCREWS
SCREWS
TAPPING
SCREWS
FRONT
UNDER
COVER
FRONT
FRONTUNDER
UNDERCOVER
COVER
INNER BOX REMOVAL /
ASSEMBLY
● Remove the following parts.
① Luggage box
② Rear carrier
③ Center cover
④ Body cover
⑤ Floor side cover
⑥ Floor panel
⑦ Front cover
● Loosen 2 tapping screws installed at front under
cover.
● Loosen main key cap by turning it
DIS
DIS
ASSEMBLY
DISASSEMBLY
ASSEMBLY
INNERCOVER
COVER
INNER
INNER
COVER
BAG
BAG
HOLDER
BAGHOLDER
HOLDER
● Disassemble 4 tapping screws installed at inner box
● Loosen step bolt installed at back holder
● Diassemble inner box
● Install in the reverse order fo removal.
TAPPING
TAPPING
SCREWS
TAPPINGSCREWS
SCREWS
FRONT FENDER COVER
REMOVAL / ASSEMBLY
FRONT
FRONTFENDER
FENDER
FRONT
FENDER
● Loosen 4 left-right special screws installed at front
fender
● Disassemble front fender
● Install in the reverse order of removal.
SPECIAL
SPECIAL
CREWS
SPECIALSSSCREWS
CREWS
EXTERNAL PARTS
FRONT UNDER COVER
REMOVAL / ASSEMBLY
WASHER
BOLT
WASHER
WASHERBOLT
BOLT
FRONTUNDER
UNDERCOVER
COVER
FRONT
FRONT
UNDER
COVER
WASHER
SCREW
WASHER
WASHERSCREW
SCREW
WASHER
SCREW
● Disassemble the following parts.
- Front cover, Front fender / Front wheel
● Untie washer screw, tapping screw installed on inner
cover.
● Untie 1 washer bolt installed at front under cover.
● Disassemble front under cover.
● Install in the reverse order of removal.
FRONT HANDLE COVER
REMOVAL / ASSEMBLY
● Untie 1 washer screw, 2 tapping screws installed at
front handle cover.
FRONTHANDLE
HANDLE
FRONT
FRONT
HANDLE
COVER
COVER
COVER
TAPPING
TAPPING
SCREW
TAPPINGSCREW
SCREW
● Untie 2 tapping screws installed at rear handle cover.
● Disassemble front handle cover after disconnecting
left, right winker couplers.
● Install in the reverse order of removal.
TAPPING
TAPPING
SCREW
TAPPINGSCREW
SCREW
REAR
REAR
HANDLE
COVER
REARHANDLE
HANDLECOVER
COVER
WASHER
SCREW
WASHER
WASHERSCREW
SCREW
REAR HANDLE COVER
REMOVAL / ASSEMBLY
TAPPINGSCREW
SCREW
TAPPING
TAPPING
SCREW
● Separate front handle cover.
● Untie 2 tapping screws installed at rear handle cover.
● Separate speedometer cable.
● Separate speedometer codes.
● Separate rear handle cover.
● Install in the reverse order of removal.
SPEEDOMETER
CABLE
SPEEDOMETER
SPEEDOMETERCABLE
CABLE
SPEEDOMETER
CABLE
EXTERNAL PARTS
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
REAR
REAR
HANDLE
COVER
REARHANDLE
HANDLECOVER
COVER
SPEEDOMETER REMOVAL /
ASSEMBLY
● Disassemble front handle cover.
● Disassemble speedometer cable.
● Disconnect coupler and wires.
● Disassemble rear handle cover.
● Disassemble 3 tapping screws and speedometer
cover.
● Disasemble speedometer.
● Install in the reverse order of removal.
REAR WHEEL MUD GUARD
REMOVAL / ASSEMBLY
REAR
REARWHEEL
WHEELMUD
MUDGUARD
GUARD
REAR
WHEEL
MUD
GUARD
● Untie 2 washer bolts installed at rear wheel mud
guard of RH side.
● Untie 1 washer bolt installed at mud guard after
disassembling air cleaner of LH side.
● Disassemble rear wheel mud guard.
● Install in the reverse order of removal.
WASHERBOLTS
BOLTS
WASHER
WASHER
BOLTS
REARCUSHION
CUSHION
REAR
CUSHION
REAR
REAR
CUSHION
UPPER
BOLT
REARCUSHION
CUSHIONUPPER
UPPERBOLT
BOLT REAR
REAR
REAR
SPLASH
COVER
REARSPLASH
SPLASHCOVER
COVER
REAR SPLASH COVER
REMOVAL / ASSEMBLY
● Disassemble the following parts.
-Luggage box
-Center cover
-Body cover
● Untie 3 flange bolts installed at rear splash cover.
● Untie rear cushion upper bolt.
● Disassemble rear splash cover.
● Install in the reverse order of removal.
FRANGE
BOLTS
FRANGE
FRANGEBOLTS
BOLTS
FRANGE
BOLTS
MUFFLER
MUFFLER
MUFFLER
MUFFLER
CAP
CAPNUTS
NUTS
CAP
NUTS
MUFFLER REMOVAL
ASSEMBLY
/
● Untie 2 flange bolts installed at muffler comp.
● Untie two 6 mm cap nuts installed at cylinder head.
● Disassemble muffler by pulling slightly it downward.
● Install in the reverse order of removal.
CAUTION
•Because the muffler is hot, do not repair promptly
at the stop of vehicle.
FRANGE
FRANGE
BOLTS
FRANGEBOLTS
BOLTS
MEMO
4. LUBRICATION SYSTEM
SERVICE INFORMATION ··· 4-1
TROUBLE SHOOTING···· 4-1
ENGINE OIL LEVEL CHECK·····4-2
REPLACEMENT OF ENGINE OIL·· 4-3
OIL FUMP·········· 4-3
TRANSMISSION OIL·······4-5
SERVICE INFORMATION
WARNING
•The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for
a long time.
•Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
•It is not desirable to handle used oil frequently ; however, wash your hands thoroughly with soap and water
immediately after handling the used oil.
•The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
OIL CAPACITY
RECOMMENDED OIL
0.85L(at disassembling)
0.70L(at changing)
DAELIM Geguine oil
API Service classification SL grade
Viscocity : 10W-40
(Use appropriate type of oil with viscocity satisfying the atmospheric temperature.
In your riding area based on the table shown on the right side)
TRANSMISSION OIL
OIL CAPACITY
RECOMMENDED OIL
0.12L(Full capacity)
0.10L(at changing)
DAELIM Geguine mission oil or SAE 80W/90
TORQUE VALUES
TAPPET ADJUSTING HOLE CAP
OIL PUMP BOLT
OIL DRAIN PLUG BOLT
1.5kgf·m
1.1kgf·m
2.5kgf·m
Temperature to the air
LUBRICATION SYSTEM
TROUBLE SHOOTING
Oil level low
●Natural oil consumption
●External oil leaking
●Worn piston ring or incorrect piston ring installation
●Worn valve guide or valve stem seal
Oil contamination
●Oil or filter not changed often enough
●Faulty cylinder head gasket
●Piston ring worn
Low or no oil pressure
●Clogged oil filter screen
●Incorret oil used
LUBRICATION SYSTEM
OILLEVEL
LEVELGAUGE
GAUGE
OIL
OIL
LEVEL
GAUGE
APPROPRIATE
LINE
APPROPRIATE
APPROPRIATELINE
LINE
APPROPRIATE
LINE
UPPER
UPPER
UPPER
UPPER
ENGINE OIL LEVEL CHECK
● Erect the motorcycle on the main stand.
● Start the engine and let it be warm fully.
● Stop the engine, remove the oil gauge
● Check the oil level line. If the engine oil is
insufficient, add the engine oil.
LOWER
LOWER
LOWER
LOWER
ENGINE OIL CHANGE
NOTE
•Make the engine warm and erect the motorcycle
with side stand in order to assure complete and
rapid draining.
OIL
DRAIN
BOLT
HOLE
OIL
OILDRAIN
DRAINBOLT
BOLTHOLE
HOLE
OIL
DRAIN
BOLT
HOLE
● Loosen the drain oil bolt and drain the engine oil.
● Start the kick starter arm for several times to drain
any oil which may be left in the engine.
● Tighten the engine oil drain bolt.
TORQUE : 2.5 kgf·m
OIL
FELTER
SCREEN
OIL
OILFELTER
FELTERSCREEN
SCREEN
OIL
FELTER
SCREEN
TAPPET
TAPPET
ADJUSTING
HOLE
CAP
TAPPETADJUSTING
ADJUSTINGHOLE
HOLECAP
CAP
CAUTION
•It is extremely important to replace oil filter or
clean the oil filter screen at the first maintenance
interval 500km by loosen the tappet adjust hole
cap.
•Clean the oil filter screen with fresh cleaning oil
every 4,000km.
•Check the hole cap o-ring for satisfactory
condition.
•If there are not in good condition, replace it with
new one.
•Tighten the hole cap with specified torque.
TORQUE : 1.5 kgf·m
● Fill the recommended engine oil with engine oil cap.
OIL CAPACITY : 0.85 L (After disassembly)
0.70 L (After oil change)
● Tighten the oil level gauge.
● Recommended engine oil :
DAELIM genuine oil.
API service classification SL grade
Viscosity : 10W-40
● Start the engine and let it idle for a few minutes.
● Stop the engine and check the engine oil level. If the
oil level is low, add the recommended engine oil.
● Check to see if the oil is leak..
OILLEVEL
LEVELGAUGE
GAUGE
OIL
OIL
LEVEL
GAUGE
LUBRICATION SYSTEM
OIL PUMP
INSPECTION
● Drain the engine oil.
● Untie 1 flange bolt and 2 tapping screws installed at
cooling fan cover.
COOLING
FAN
COVER
COOLING
COOLING FAN
FAN COVER
COVER
HEX
BOLT
HEX
HEXBOLT
BOLT
AC
ACGENERATOR
GENERATOR
AC
GENERATOR
● Disassemble cooling fan.
● Disassemble AC generat.
FRANGE
BOLT
FRANGE
FRANGEBOLT
BOLT
FRANGE
BOLT
RH.
RH.
CRANK
CASE
COVER
RH.CRANK
CRANKCASE
CASECOVER
COVER
● Disassemble RH. Crank case cover.
● Untie hex nut installed at oil pump drive gear.
● Untie oil pump drive gear.
HEX
HEX
NUT
HEXNUT
NUT
OIL
OIL
PUMP
DRIVE
GEAR
OILPUMP
PUMPDRIVE
DRIVEGEAR
GEAR
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
OIL
OIL
PUMP
OILPUMP
PUMP
● Untie 3 fixed flange bolts at oil pump.
● Untie oil pump.
.
LUBRICATION SYSTEM
OUTER
ROTOR
OUTER
OUTERROTOR
ROTOR
PUMP
BODY
PUMP
PUMPBODY
BODY
INNER
INNER
ROTOR
INNERROTOR
ROTOR
OIL PUMP DISASSEMBLY
DRIVE
GEAR
DRIVE
DRIVEGEAR
GEAR
DRIVE
GEAR
● Loosen the screw securing the oil pump plate.
● Remove the oil pump body and oil pump plate.
● Clean the oil pump body, inner rotor, outer rotor with
fresh cleaning oil.
PUMP
SHAFT
PUMP
PUMPSHAFT
SHAFT
PUMP
SHAFT
PUMP
PUMP
PLATE
PUMPPLATE
PLATE
OIL PUMP INSPECTION
FEELER
FEELER
GAUGE
FEELERGAUGE
GAUGE
PUMP
PUMP
BODY
PUMPBODY
BODY
● Install the inner and outer rotors into the oil pump
body exactly.
● Measure the end clearance pump body and outer
rotor.
SERVICE LIMIT : 0.2 MM
TOOL : FEELER GAUGE
OUTER
ROTOR
OUTER
OUTERROTOR
ROTOR
OUTER
ROTOR
● Measure the end clearance between inner and outer
rotor.
SERVICE LIMIT : 0.18 MM
INNER
INNER
ROTOR
INNERROTOR
ROTOR
OUTER
OUTER
ROTOR
OUTERROTOR
ROTOR
● Measure the pump side clearance and multi sides of
rotor.
SERVICE LIMIT : 0.12 MM
FEELER
FEELER
GAUGRE
FEELERGAUGRE
GAUGRE
LUBRICATION SYSTEM
ASSEMBLY
● Clean all parts with fresh cleaning oil.
● Install the inner and outer rotors into the oil pump
body.
● Install the oil pump plate into the pump body.
● Tighten the fan screw.
FAN
SCREWS
FAN
FANSCREWS
SCREWS
FAN
SCREWS
NOTE
•Check the oil pump to operate smoothly by turning
pump shaft.
INSTALLATION
● Assemble o-ring and dowel pin.
● Assemble oil pump to RH. Crank case.
OIL
OIL
RINGS
OILRINGS
RINGS
● Assemble the following parts
- Oil pump drive gear
- RH. Crank case cover
- A.C. Generator
- Cooling fan and cooling fan cover
- Muffler
LUBRICATION SYSTEM
TRANSMISSION OIL
INSPECTION
● Check the connection part of case for any leak.
● Loosen the oil check bolt and check to see if the oil
overflows from the oil check hole.
● If the oil amount is not enough , loosen the oil check
bolt and fill the recommended transmission oil to the
oil filter hole.
OIL CAPACITY : 0.12 L (After disassembly)
0.10 L (After oil change)
OIL
OIL
CHECK
HOLE
OILCHECK
CHECKHOLE
HOLE
OIL
DRAIN
BOLT
OIL
OILDRAIN
DRAINBOLT
BOLT
OIL
DRAIN
BOLT
OILCHECK
CHECKHOLE
HOLE
OIL
OIL
CHECK
HOLE
CAUTION
•Oil level inspection must be performed in the flat
ground with the vehicle being straight by raising
the main stand.
RECOMMENDED OIL : SAE 80W/90
● Tighten the oil check bolt.
TORQUE : 0.9 kgf·m
● Start the engine and check for leak.
OIL
DRAIN
BOLT
OIL
OILDRAIN
DRAINBOLT
BOLT
OIL
DRAIN
BOLT
MEMO
5. FUEL SYSTEM
SERVICE INFORMATION ·· 5-1
TROUBLESHOOTING ···· 5-2
FUEL TANK········ 5-3
CARBURETOR·······5-3
CARBURETOR INSULATOR· 5-6
PILOT SCREW ADJUSTMENT·5-9
FUEL COCK········5-11
SERVICE INFORMATION
GENERAL SAFETY
CAUTION
● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks.
Furthermore the evaporated(gasfied) gasoline is highly explosive. Work in a well-ventilated areas.
● Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or
poorly ventilated area.
● Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions.
● Pay particular attention to the position of O-ring. Replace with new ones when disassembled.
● If it is desired to store a vehicle for a period longer than 1 month, drain gasoline out of the carburetor float chamber.
Gasoline left in the float chamber will be deteriorated causing the slow jet to be cloggedwith deposits, and idling
may become unstable.
SPECIFICATIONS
FUEL TANK CAPACITY : 5.0ℓ
RESERVE FUEL CAPACITY : 1.5ℓ
CARBURETOR SPECIFICATIONS
ITEM
TYPE/ VENTURI DIAMETER
MODEL MARK
MAIN JET NO.
PILOT SCREW REVERSE-ROLLING
FLOAT LEVEL
IDLING SPEED
THROTTLE GRIP TOLLERANCE
TOOL
FLOAT LEVEL GAUGE
STANDARDS
CV TYPE(VACUUM)/Ø16
PD 19J
#80
2±1/2
11mm
1,700±100rpm
2-6mm
FUEL SYSTEM
TROUBLESHOOTING
The vehicle does not start.
Back firing
● No gasoline in fuel tank.
● Fuel is not coming out of carburetor.
● Too much fuel is flowing into cylinder.
● No spark emitted from spark plug.
● Air cleaner is blocked.
● Ignition system is damaged or works improperly.
● Mixture is too lean.
Insufficient power and high fuel consumption.
Idle is unstable and engine turns off after starting.
● Idle is adjusted improperly.
● Air/fuel mixture is either too lean or rich.
● Air cleaner is blocked.
● Suction system is experiencing secondary intake of air.
● Fuel system is blocked.
● Auto bystarter is damaged.
● Ignition system is damaged.
● Using low quality gasoline.
● Air screw is adjusted improperly.
● Carburetor is blocked.
● Compression pressure is low.
● Air cleaner is blocked.
● Ignition system is damaged.
● Mixture is too rich.
Air/Fuel mixture is extremely lean
● Jets of carburetor are blocked.
● Bad ventilation of air in tank cap.
● Fuel strainer screen is blocked.
● Fuel tube is bent, creased or blocked.
● Float valve is working badly.
● Oil level is low.
● Suction system is receiving secondary suction of air.
● Output capacity of fuel pump is insufficient..
Miss-fire at speeding.
Air/Fuel mixture is extremely rich.
● Ignition system is damaged.
● Mixture is too lean.
● Float valve is damaged.
● Air jets are blocked.
● Oil level is too high.
● Auto bystarter is damaged.
● Air cleaner is blocked.
FUEL SYSTEM
FUEL TANK
REMOVAL
● Remove luggage box.
● Untie 4 flange bolts installed at fuel tank.
FRANGE
FRANGE
BOLT
FRANGEBOLT
BOLT
● Remove the fuel unit wire coupler.
● Remove the tube located fuel tank and fuel filter.
● Remove the fuel tank joint pipe tube.
CAUTION
•Gasoline is extremely flammable. Avoid fire
during work and pay particular attention to electric
sparks.Furthermore, the evaporated(vaporized)
gasoline is highly explosive. Work in a wellventilated areas.
NOTE
FUEL
FUEL
UNIT
FUELUNIT
UNIT
•After removing the fuel tank, be sure to close the
fuel tank cap. (Gasoline is extremely flammable.)
● Remove fuel tank.
● Install in the reverse order of removal.
FUEL
TANK
FUEL
FUELTANK
TANK
CARBURETOR
REMOVAL
● Disassmeble luggage box.
● Untie screws installed at air cleaner.
● By untieing throttle cable lock nut, disconnect
throttle cable from carburetor.
● Disconnect fuel tube from carburetor.
● Disconnect auto by starter wires.
SCREW
SCREW
SCREW
CARBURETOR
CARBURETOR
CARBURETOR
CARBURETOR
FUEL SYSTEM
● Untie screws installed at insulator.
● Disconnect carburetor.
CARBURETOR
CARBURETOR
CARBURETOR
TOP
SET
TOP
TOPSET
SET
TOP
REMOVAL
● Loosen the drain screw and drain the fuel.
● Remove the drain tube and air band hose.
● Loosen the 2 diaphragm cover setting screws.
FANSCREWS
SCREWS
FAN
FAN
SCREWS
COMPRESSION
SPRING
COMPRESSION
COMPRESSION SPRING
SPRING
● Disconnect top set cover.
.
VACUUM
VACUUM
PISTON
VACUUMPISTON
PISTON
TOP
SET
TOP
TOP SET
SET
● Disconnect jet needle, spring seat from vacuum
piston.
VACUUM
PISTON
VACUUM
VACUUMPISTON
PISTON
VACUUM
PISTON
FUEL SYSTEM
INSPECTION
VACUUM
VACUUM
PISTON
VACUUMPISTON
PISTON JET NIDDLE COMP
JET NIDDLE
NIDDLE COMP
COMP
JET
● Check the jet needle for wear and replace if
necessary.
● Check the vacuum piston for damage and replace if
necessary.
● Check the diaphragm for damage, pin holes, bends
and replace if necessary.
NOTE
•Check the diaphragm adequately for crack in the
wrinkled and bent area.
SPRING
SPRING
SEAT
SPRINGSEAT
SEAT
● Loosen 3 screws from float chamber set.
ACCELERATION
ACCELERATION
PUMP
ACCELERATIONPUMP
PUMP
FLOAT
FLOAT
CHAMBER
SET
FLOATCHAMBER
CHAMBERSET
SET
● Loosen screw at float pin.
● Disassemble float pin, float, float valve.
FLOAT
FLOAT
FLOAT
CAUTION
•Do not damage the jets because it made of soft
material and also, do not use the wire when
cleaning the air and fuel passage.
•Otherwise, it will damage to the carburetor body,
eventually it will be effect the engine. Namely it is
cause of bad condition of engine.
FLOAT
FLOAT
PIN
FLOATPIN
PIN
● Check the float and valve seat for scores, scratches,
clogging and damage replace if necessary.
● Check the float valve operation.
FLOAT
FLOAT
VALVE
FLOATVALVE
VALVE
FUEL SYSTEM
● Remove the main jet, main jet holder, needle jet,
slow jet, pilot screw.
SLOW
SLOW
JET
SLOWJET
JET
MAIN
JET
MAIN
MAINJET
JET
MAIN
CLEAN
CLEAN
COMPRESSED
AIR
CLEANCOMPRESSED
COMPRESSEDAIR
AIR
● Clean the all jet and hole of carburetor body with
blow the compressed air.
CAUTION
•Turn in the pilot jet screw and record the number
of turns it takes before it seats lightly.
•Do not force pilot screw against its seat. The seat
will be damaged.
FUEL SYSTEM
COVER
COVER
COVER
COVER
COMPRESSION
COMPRESSION
COMPRESSION
SPRING
SPRING
SPRING
SPRING
● Disassemble accelerating pump.
● Loosen 2 screws, disconnect diaphragm,
compression spring.
● Check whether there are pin role, twist, damage of
diaphragm.
● Clean by compressed air fuel channel of diaphragm
cover.
DIAPHRAGM
DIAPHRAGM
COMP
DIAPHRAGMCOMP
COMP
ASSEMBLY
● Assemble needle jet, needle jet holder, main jet,
slow jet..
● Assemble O-ring washer of pilot screw, spring
screw.
● Assemble based on revultion point remembered at
the time of disassembling pilot screw.
● Measure float level.
FLOAT LEVEL : 11MM
TOOL : FLOAT LEVEL GAUGE
CAUTION
•Replace with new float chamber body o-ring.
● Assemble float valve, float, float pin.
● Assemble float body ass’y and 3 fan screws,
bracket.
FUEL SYSTEM
● Assemble accelerating pump.
CAUTION
•Assemble jet neeld fitting at assembled hole.
TOM
TOM
SET
TOMSET
SET
● Assemble vacuum piston, jet needle, spring seat.
● Assemble compression spring.
● Assemble tom set and install 2 screws.
CAUTION
•Be careful for vaccum piston not to pinch to tom
set.
•By keeping spring straight and reducing its length,
assemble cover.
COMPRESSION
SPRING
COMPRESSION
COMPRESSIONSPRING
SPRING
COMPRESSION
INSTALL
● Install carburetor to carburetor insulator.
● Assemble carburetor fixed type insulator band
screw.
● Assemble fuel tube to carburetor.
● Assemble auto bystarter wires.
●
●
●
●
Assemble throttle cable to carburetor.
Assemble air cleaner.
Assemble luggage box.
Assemble center cover.
CAUTION
•Check throttle grip tolerance after assembling
carburetor.
FUEL SYSTEM
INSULATOR
INSULATOR
INSULATOR
CARBURETOR INSULATOR
DIASSEMBLY
●
●
●
●
●
●
Disassemble luggage.
Disassemble carburetor.
Disassemble floating pressure fuel pump.
Disassemble 2 fixed nuts of inlet pipe.
Disassemble carburetor insulator.
Disassemble fixed band of carburetor insulator.
INLET
PIPE
INLET
INLETPIPE
PIPE
INSPECTION
● Check abrasion or damage of carburetor insulator.
● Check abrasion or damage of inlet pipe o-riing.
● Install in the reverse order of removal.
INSULATOR
INSULATOR
INLET
INLET
PIPE
INLETPIPE
PIPE
PILOT SCREW ADJUSTMENT
USING THE EMISSION ANALYZER(CO,HC)
● Open the seat and remove the carburetor
maintenance cover.
① Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given.(2±1/2)
② up the engine to operating temperature(60°C).
③ Adjust the idle speed with the throttle stop screw.
IDLE SPEED: 1700 °±100 RPM
PILOT
PILOT SCREW
SCREW
PILOT
SCREW
NOTE
MUFFLER
MUFFLER
MUFFLER
CO
ANALYZER
CO
CO ANALYZER
ANALYZER
•Before adjustment the pilot screw, check the
following items.
•Fuel system electrical system for troubling.
•Do not force the pilot screw against its seat. The
seat will be damaged.
•The spark plug for cleaning and gap adjusting.
•Valve clearance for adjusting.
•Emission analyzer for correction.
•Exhaust gas contains poisonous substance, so do
not
•adjusting in a closed or poorly ventilated area.
FUEL SYSTEM
THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
④ Extend the hose(60mm) at the tail pipe and insert the
probe of the emission analyzer to the tail pipe and
adjust the pilot screw with a 1/8, the Co to became
3~4%.
⑤ Adjust by the throttle stop screw, repeat step ④ and
⑤ until according the idle rpm (1,700rpm) and the
Co(3~4 %).
⑥ Snap lightly in idling and check to see if the rotation
is smoothly and to return is normal.
● Install the carburetor maintenance cover.
ACCELERATING
ACCELERATING
ACCELERATING
ACCELERATING
NOTE
•If the engine cannot be adjusted by turning the
pilot screw within a ¼ turn, check for other engine
problems.
EMISSION ANALYZER IS NOT EXIST
① Turn the pilot screw clockwise until its seats lightly,
then back it out to the specification given. (1 1/2)
② Warm up the engine until the engine oil temperature
reaches to approximately 60°C.
③ Adjust the idle speed with the throttle screw.
IDLE SPEED: 1700 °±100 RPM
PILOT
SCREW
PILOT
PILOTSCREW
SCREW
PILOT
NOTE
•Before adjustment the pilot screw, check the
following items.
•Fuel system electrical system for troubling.
•Do not force the pilot screw against its seat. The
seat will be damaged.
•The spark plug for cleaning and gap adjusting.
•Valve clearance for adjusting.
THROTTLE
THROTTLE
STOP
SCREW
THROTTLESTOP
STOPSCREW
SCREW
FUEL SYSTEM
ACCELERATING
ACCELERATING
ACCELERATING
④ When idling, check to see if the rotation is smoothly
and to return is normal.
⑤ Turn the throttle stop screw until the 1000 rpm, and
check the stopping of engine.
If the engine is stop, adjust the pilot screw with a 1/8
and repeat step ④ and ⑤.
(Check by snapping slightly and check whether
RPM goes down naturally.)
NOTE
•If the engine cannot be adjusted by turning the
pilot screw within a ¼ turn, check for other engine
problems.
⑥ After the final test of the starting and driving,
readjust if necessary. Assemble the carburetor
maintenance cover of luggage box.
PILOT
PILOT
SCREW
PILOTSCREW
SCREW
THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
● Assemble luggage box to carburetor maintenance
cover.
FUEL COCK
FUEL
STRAINER
FUEL
FUELSTRAINER
STRAINER
● Disassemble luggage box.
● Disconnect fuel tube A, B connected to fuel cock.
● Disassemble fuel cock.
● Install in the reverse order of removal.
FUEL
FUEL
COCK
FUELCOCK
COCK
INSPECTION
● Be sure to remove the diaphragms from the fuel auto
valve before using compressed air the blow out of
air passages. Compressed air will damage the
diaphragms or may forced them off the aluminum.
NOTE
FUEL
FUEL
COCK
FUELCOCK
COCK
•Place a clean container under the fuel tube.
LINK
SMALL
DIAPHRAGM
AIR VENT
FLOATING
PRESSURE
LINE
LARGE
DIAPHRAGM
SPRING
● Do repair after emptying gasoline in fuel tank.
● Connect the fuel auto valve vacuum tube to the
vacuum pump and apply vacuum. Be sure that the
fuel flows out smoothly.
● If the vacuum does not remain steady, it indicates
the diaphragm is incorrectly installed or damaged.
● If the vacuum remains steady, but the fuel flow is
not smooth, it indicates a clogged filter or
incorrectly installed diaphragm.
● If the fuel flows without the vacuum applied, the
diaphragm is incorrectly installed.
MEMO
6. ENGINE REMOVAL/INSPECTION
SERVICE INFORMATION····· 6-1
ENGINE REMOVAL/ASSEMBLY·· 6-2
SERVICE INFORMATION
GENERAL SAFETY
NOTE
•Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness.
•Attach tape to the frame to protect it during the engine removal or installation.
● The following works can be carried out without removing the engine from the vehicle body.
-TRANSMISSION (⇨SECTION 11)
-A.C. GENERATOR (⇨SECTION 8)
-KICK STARTER/ CONTINUOUSLY VARIABLE TRANSMISSION (⇨SECTION 7)
-STATOR MOTOR (⇨SECTION 16)
-CARBURETOR (⇨SECTION 5)
-EX. MUFFLER (⇨SECTION 3)
● Items to be worked after removing engine.
-CYLINDER HEAD, CYLINDER, CRANK SHAFT, CRANK SHAFT BEARING
● Engine oil capacity : 0.85L(when disassembling)
TORQUE VALUES
ENGINE HANGER BOLT : 4.5㎏f·m
ENGINE REMOVAL/INSPECTION
ENGINE REMOVAL / ASSEMBLY
CARBURETOR
CARBURETOR
CARBURETOR
● Release the seat lock by turning the main key and
open the seat.
● Remove the following parts.
- Luggage box.
- Air cleaner.
- Carburetor.
● Disconnect the A.C generator coupler and connector
wiring connected to the A.C generator, disconnect
the starter motor wiring cable.
● Remove spark plug cap cord from the engine.
● Remove the bleeder tube from the cylinder head
cover.
● Remove the EX. muffler.
MUFFLER
MUFFLER
MUFFLER
MUFFLER
● Loosen the lock nut securing rear wheel and remove
the rear wheel.
REAR
WHEEL
REAR
REARWHEEL
WHEEL
REAR
● Loosen the rear brake adjuster nut, and remove the
brake arm joint B, and remove the rear brake cable.
● Remove the engine hanger nut.
REAR
REAR
CUSHION
REARCUSHION
CUSHION
REAR
BRAKE
CABLE
REAR
REARBRAKE
BRAKECABLE
CABLE
REAR
ENGINE
ENGINE
HANGER
NUT
ENGINEHANGER
HANGERNUT
NUT
ENGINE REMOVAL/INSPECTION
● Loosen rear cushion under bolt.
REAR
CUSHION
UNDER
BOLT
REAR
REARCUSHION
CUSHIONUNDER
UNDERBOLT
BOLT
● Fix the jar-key for the motorcycles to under the
vehicle.
● Loosen the flange bolt securing the engine hanger
and remove the engine from the frame.
JAR-KEY
JAR-KEY
JAR-KEY
ASSEMBLY
● Install in the reverse order of removal.
NOTE
•Take precaution not to damage wiring and cable.
•Take precaution not to damage the threaded part of
bolts.
•Arrange the cable, tubes and wiring in the right
positions
TORQUE : ENGINE HANGER NUT : 4.5 kgf·m
● Check the following after the engine is installed.
- Engine oil leakage.
- Inspection of throttle cable operation.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
7. BELT TYPE CONTINUOUSLY VARIABLE
TRANSMISSION / KICK STARTER
SERVICE INFORMATION···7-1
SERVICE STANDARD· · · · 7-1
TROUBLESHOOTING· · · · 7-1
LH.CRANKCASECOVERREMOVAL· 7-2
KICK STARTER· · · · · · 7-2
DRIVE BELT· · · · · · · · 7-4
DRIVEN PULLEY ASS’Y· · · · 7-6
MOVABLE DRIVE FACE· · · 7-11
SERVICE INFORMATION
GENERAL SAFETY
● Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced due to
oil contact.
● Do not operate starter motor while the LH. crank case front cover is removed.
NOTE
·Take precautions not ot apply the grease oil to the movable drive face or weight roller.
SPECIFICATIONS
ITEM
STANDARD
SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER
20.000~20.021mm
20.10mm
DRIVE FACE BOSS OUTER DIAMETER
19.959~19.980mm
19.91mm
DRIVE BELT WIDTH
17.5mm
16.5mm
WEIGHT ROLLER OUTER DIAMETER
15.920~16.080mm
15.40mm
CLUTCH OUTER AND INNER DIAMETER
107.000~107.087mm
107.50mm
TROUBLESHOOTING
Engine starts but motorcycle does not work.
● Drive belt worn.
● Ramp plate damaged.
● Clutch shoe worn or damaged.
● Movable driven face spring cut.
Engine stops, or the vehicle runs suddenly,
after starting.
● Clutch shoe spring cut.
Vehicle unable to run at the maximum speed,
or lack of output
● Drive belt worn.
● Defective movable driven face spring.
● Weight roller worn.
● Pulley face contaminated.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
LH. CRANK CASE COVER
REMOVAL
● Loosen 10 flange bolts assemble at LH. Side cover.
KICK
KICK
STARTER
ARM
KICKSTARTER
STARTERARM
ARM
● Disassemble LH. Side cover.
● Disassemble gasket and dowel pin.
DOWELPIN
PIN
DOWEL
DOWEL
PIN
GASKET
GASKET
GASKET
● Inspect LH. crank case cover.
● Install the new gasket and dowel pin after removing
the gasket of crankcase surface.
● Install in the reverse order of removal.
.
NOTE
·When not knowing the length of bolt, arrange
assembled positions regularly before assembling it,
then assemble it.
·When assembling bolts, assemble them diagonally
based on standard specification assembly torques.
KICK STARTER
KICK
RETURN
SPRING
KICK
KICKRETURN
RETURNSPRING
SPRING
KICK
KICKDRIVEN
DRIVENGEAR
GEAR
KICK
DRIVEN
GEAR
DISASSEMBLE
● Disassemble LH. Side cover.
● Disassemble fixed flange bolt of kick starter arm.
● Disassemble kick starter arm.
● Disassemble external circlip 14mm.
● Disassemble kick starter spindle washer.
● Disassemble kick starter spindle.
● Disassemble kick starter spindle spring.
● Disassemble kick starter spindle bush.
KICK
STARTER
SPINDLE
KICK
KICKSTARTER
STARTERSPINDLE
SPINDLE
KICK
STARTER
SPINDLE
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
CIR
CIR
CLIP
CIRCLIP
CLIP
KICK
KICK
SPINDLE
BUSH
KICKSPINDLE
SPINDLEBUSH
BUSH
CHECK
● Check whether kick starter spindle worn, damage
and gears worn, damage.
● Check whether return spring defect or damage.
● Check whether kick starter spindle bushing worn or
damage.
KICK
KICK
SPINDLE
WASHER
KICKSPINDLE
SPINDLEWASHER
WASHER
KICK
KICKSTARTER
STARTERSPINDLE
SPINDLE KICK SPINDLE BUSH B
KICK
STARTER
SPINDLE
KICKSPINDLE
SPINDLEBUSH
BUSHBB
KICK
KICK
RETURN
SPRING
KICK
KICKRETURN
RETURNSPRING
SPRING
KICK
RETURN
SPRING
● Check kick driven gear worn, damage.
● Check friction spring defect, damage.
KICK
DRIVEN
GEAR
KICK
KICKDRIVEN
DRIVENGEAR
GEAR
KICK
DRIVEN
GEAR
PRICTION
PRICTION
START
PRICTIONSTART
START
GEAR
GEAR
SPRING
GEARSPRING
SPRING
THRUST
WASHER
THRUST
THRUSTWASHER
WASHER
KICK
KICKSPINDLE
SPINDLEBUSH
BUSHB
KICK
SPINDLE
BUSH
BB
ASSEMBLY
● Assemble kick spindle bush to LH. Side cover.
● Assemble kick spindle bush B to LH. Side cover.
● Assemble kick spindle spring to LH. Side cover.
● Assemble kick spindle to LH .Side cover.
● Assemble kick starter spindle washer.
● Assemble cir clip 14mm to LH. Side cover.
● Assemble kick starter arm.
● Assemble thrust washer.
KICK
SPINDLE
BUSH
KICK
KICKSPINDLE
SPINDLEBUSH
BUSH
KICK
SPINDLE
BUSH
KICK
KICK
RETURN
SPRING
KICKRETURN
RETURNSPRING
SPRING
● Turn kick starter spindle by kick starter arm, then
assemble gear on condition of pulling ‘ ’ of LH.
Side cover.
CAUTION
KICK
DRIVEN
GEAR
KICKDRIVEN
DRIVENGEAR
GEAR
KICK
DRIVEN
GEAR
KICK
STARTER
SPINDLE
KICK
KICKSTARTER
STARTERSPINDLE
SPINDLE KICK
KICK
STARTER
SPINDLE
·Assemble correctly kick starter spindle to the home
by fixing using hand.
·Apply grease into gear side and assemble home of
kick driven gear.
·Check whether kick driven gear and kick starter
spindle work well after assembly.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
DRIVEFACE
FACE
DRIVE
DRIVE
FACE
DRIVEN
PULLEY
ASS’
YY
DRIVEN
YY
DRIVENPULLEY
PULLEYASS’
ASS’
DRIVEN
PULLEY
ASS’
DRIVE BELT
REMOVAL
● Disassemble LH. Side cover. (⇨7-2)
● Disassemble 2 dowel pins and gasket.
CAUTION
·Be careful for missing of dowel pin. When
disassembling gasket, be careful its torn.
DRIVE
BELT
DRIVE
DRIVEBELT
BELT
● Diassemble start pinion ass’y in order to do easy
repair.
STARTER PINION
CLUTCH
OUTER
CLUTCH
CLUTCHOUTER
OUTER
DRIVE
FACE
DRIVE
DRIVEFACE
FACE
DRIVE
FACE
DRIVE
BELT
DRIVE
DRIVEBELT
BELT
DRIVEN
PULLEY
SUB
DRIVEN
DRIVENPULLEY
PULLEYSUB
SUB
DRIVEN
PULLEY
SUB
● Install special tool(universal holder) to clutcu outer,
Then disassmble 10 mm nut
● Disassemble clutch outer.
● On condition that drive belt is assembled at driven
pulley sub, extract to the outside of drive face.
● Disassemble belt from driven pulley sub.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
INSPECTION
COG
WIDTH
● Check the drive belt for cracks, cog seperation and
wear ; Replace as necessary.
● Measure the width of the drive belt → replace the
belt if the service limit is exceeded.
SERVICE LIMIT : 16.5mm
NOTE
·Use only a genuine DAELIM replacement drive
belt.
·Do not get oil or greasde on the drive belt or pulley
side.
·Clean off any grease or oil before reinstalling.
DRIVEN PULLEY SUB ASS’Y
INSTALLATION
● Like left pucture, turn the pulley clockwise and
spread the faces apart while installing the drive belt.
NOTE
·Hold the pulley faces apart preventing them from
closing.
● Hang on drive belt assembled at driven pulley sub
ass’y.
● Between drive face and movable drive face, then
assemble it to drive shaft in reverse side.
DRIVEN
PULLEY
SUB
ASS’
YY
DRIVEN
YY
DRIVENPULLEY
PULLEYSUB
SUBASS’
ASS’
DRIVEN
PULLEY
SUB
ASS’
● Assemble clutch outer to driven pulley sub ass’y.
● Temporarily install flange nut 10mm to driven pulley,
tighten the nut to the specified torque.
・m
TORQUE : 4.Okgf・
TOOL : UNIVERSAL HOLDER
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
DRIVEN PULLEY ASS’Y
REMOVAL
● Remove the LH. crank case cover. (⇨7-2 )
● By using universal holder, grip clutch outer and
diassemble flange nut, then disassemble clutch outer.
TOOL : UNIVERSAL HOLDER
DRIVE FACE HOLDER
● Disassemble driven pulley ass’y from drive shaft.
● Disassemble drive belt.
SPECIAL
SPECIAL
NUT
SPECIALNUT
NUT
CLUTCH
CLUTCH
SPRING
COMPRESSOR
CLUTCHSPRING
SPRINGCOMPRESSOR
COMPRESSOR
DISASSEMBLY
● Disassemble special nut 28mm.
TOOL : CLUTCH SPRING COMPRESSOR
LOCK NUT WRENCH
● Disassemble drive plate ass’y.
● Disassemble driven face spring.
● Disassemble driven face spring guide.
DRIVE
DRIVE PLATE
PLATE
DRIVE
PLATE
DRIVEN
FACE
SPRING
DRIVEN
DRIVENFACE
FACESPRING
SPRING
DRIVEN
MOVABLE
DRIVEN
FACE
MOVABLE
MOVABLE DRIVEN
DRIVEN FACE
FACE
SPRING
GUIDE
SPRING
SPRINGGUIDE
GUIDE
SPRING
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
● Disassemble seal collar.
DRIVEN
FACE
COMP
DRIVEN
DRIVENFACE
FACECOMP
COMP
DRIVEN
SEAL
SEAL
COLLAR
SEALCOLLAR
COLLAR
● Pull out roller guide pin and guide roller.
MOVABLE
MOVABLE DRIVEN
DRIVEN FACE
FACE
MOVABLE
DRIVEN
FACE
GUIDE
GUIDE
PIN
GUIDEPIN
PIN
DRIVEN
DRIVEN
FACE
DRIVENFACE
FACE
MOVABLE
MOVABLE
DRIVEN
FACE
MOVABLEDRIVEN
DRIVENFACE
FACE
DRIVEN
FACE
DRIVEN
DRIVENFACE
FACE
DRIVEN
● Pull out movable driven face.
● Disassemble O-ring from movable driven face.
● Disassmeble oil seal from movable driven face.
GUIDE
GUIDE
PIN
GUIDEPIN
PIN
OIL
SEAL
OIL
OILSEAL
SEAL
OIL
MOVABLE
MOVABLE
DRIVEN
FACE
MOVABLEDRIVEN
DRIVENFACE
FACE
MOVABLE
● Disassemble movable driven face.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
NIDDLE
BEARING
(INNER)
NIDDLE
NIDDLE BEARING
BEARING (INNER)
(INNER)
BALL
BALL
BEARING
(OUTER)
BALLBEARING
BEARING(OUTER)
(OUTER)
INSPECTION
● Check each part
● Check driven face needling bearing(inside) for
damage or excessive play and replace necessary.
Turn the inner race of the outer bearing with your
finger. Check that the bearing turns smoothly and
quietly, and that the bearing outer race fits securely.
● Measure the free length of the driven pulley spring
and replace if the service limit is exceeded.
MOVABLE
MOVABLE
DRIVEN
FACE
SPRING
MOVABLEDRIVEN
DRIVENFACE
FACESPRING
SPRING
SERVICE LIMIT : 163.7MM
FREE
PLAY
FREE
FREEPLAY
PLAY
FREE
● Check worn or damage of clutch outer.
● Measure the inner diameter of clutch outer.
SERVICE LIMIT : 107.5MM
CLUTCH
OUTER
CLUTCH
CLUTCHOUTER
OUTER
CLUTCH
● Check damage or worn of clutch shoe.
● Measure the thickness of each shoe.
● Replace if the service limit is exceedede.
SERVICE LIMIT : 1.5 MM
CLUTCH
CLUTCH
SHOE
CLUTCHSHOE
SHOE
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
● Check damage or worn of movable drive face.
● Check whether worn of movable driven face guide
home.
● Measure inner diameter of movable driven face.
SERVICE LIMIT : 34.06MM
MOVABLE
DRIVEN
FACE
MOVABLE
MOVABLEDRIVEN
DRIVENFACE
FACE
MOVABLE
DRIVEN
FACE
● Check worn or damage of driven face.
● Measure outer diameter of driven face.
SERVICE LIMIT : 33.94MM
DRIVEN
DRIVEN
FACE
DRIVENFACE
FACE
REPLACE DRIVEN FACE BEARING
● Replace inner bearing.
● Remove snap ring, disassemble outer bearing to the
side of inner bearing.
● Assemble new replacement outer bearing.
● Assemble snap ring.
● Apply grease to the designated position of right side
picture.
OUTER BEARING
APPLYING GREASE CAPACITY : 9.0~9.5g
INNER BEARING
● Assemble new replacement inner bearing.
SNAP RING
INNER BEARING
NOTE
•Assemble completely cir clip to the home.
SEAT SIDE
•Input inner bearing by press.
TOOL : Bearing driver attachment
GREASE
APPLYING
RANGE
SNAP RING
INNER BEARING
(NEEDLE)
OUTER BEARING
Driver pilot
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
MOVABLE
MOVABLE
DRIVEN
FACE
MOVABLEDRIVEN
DRIVENFACE
FACE
DRIVEN
FACE
DRIVEN
DRIVEN FACE
FACE
ASSEMBLY
● Assemble oil seal, o-ring to movable driven face.
● Assemble movable driven face to driven face.
● Assemble guide roller and roller pin.
GUIDE
PIN
GUIDE
GUIDEPIN
PIN
GUIDE
PIN
MOVABLE
MOVABLE
DRIVEN
FACE
MOVABLEDRIVEN
DRIVENFACE
FACE
● Assemble movable driven face to driven face.
● Assemble guide roller and roller pin.
● Assemble seal collar.
SEAL
SEAL
COLLAR
SEALCOLLAR
COLLAR
LOCK NUT WRENCH
ASSEMBLY
● Assemble spring guide and drive face, drive plate
ass’y.
● Compress special nut 28mm to be assembled by
clutch spring compressor
● Fix clutch spring compressor like right picture,
assemble lock nut based on designated torque by
using lock nut wrench.
● Remove spring compressor.
TORQUE : 5.5kgf·m
TOOL : LOCK NUT WRENCH
CLUTCH SPRING COMPRESSOR
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
DRIVEN PULLEY ASSEMBLY
DRIVEN
PULLEY
SUB
DRIVEN
DRIVEN PULLEY
PULLEY SUB
SUB
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
● Turn right driven pulley ass’y and widen
maximumly assembled home for belt
● Assemble drive belt to drive pulley sub ass’y, then
assemble to drive shaft.
● Assemble clutch outer to driven pulley sub ass’y,
assemble temporarily special flange nut.
● After fixing clutch outer to universal holder, then
fasten flange nut 10mm as the specified torque.
TORQUE : 4.0kgf·m
TOOL : UNIVERSAL HOLDER
● Assemble LH. Side cover.
DRIVE
DRIVE FACE
FACE
DRIVE
FACE
MOVABLE DRIVE FACE
REMOVAL
● Disassemble LH. Side cover.
● Disassemble start pinion ass’y.
● Hold the drive face using the clutch center holder
and remove hex nut 12mm and drive face.
TOOL : DRIVE FACE
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
CVT
CVT
COOLING
FAN
CVTCOOLING
COOLINGFAN
FAN
●
●
●
●
●
Disassemble kick starter rachet.
Disassemble CVT cooling fan.
Disassemble drive face.
Disassemble drive face boss.
Disassemble movable drive face.
KICKSTARTER
STARTERRATCHET
RATCHET
KICK
STARTER
RATCHET
KICK
INSPECTION
● The weight rollers push on the movable drive
face(by centrifugal force).
● Worn or damaged weight rollers will interfere with
this force, is a reason of bad working of drive face.
LAMP
LAMP
PLATE
LAMPPLATE
PLATE WEIGHT
WEIGHTROLLER
WEIGHT
ROLLER
ROLLER
DRIVE
FACE
BOSS
DRIVE
DRIVEFACE
FACEBOSS
BOSS
DRIVE
● Damage or side worn of weight roller→ replace
● Measure outer diameter of weight roller.
SERVICE LIMIT : 15.4MM
● Measure inner diameter of movable drive face.
SERVICE LIMIT : 20.1MM
DRIVE
FACE
BOSS
DRIVE
DRIVEFACE
FACEBOSS
BOSS
DRIVE
FACE
BOSS
● Measure outer diameter of movable drive face boss.
SERVICE LIMIT : 19.91MM
● Damage or worn of movable drive face boss →
replace.
MOVABLE
MOVABLE
DRIVE
FACE
MOVABLEDRIVE
DRIVEFACE
FACE
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
KICK
KICK
STARTER
RATCHET
KICKSTARTER
STARTERRATCHET
RATCHET
DRIVE
DRIVE
FACE
DRIVEFACE
FACE
● Check drive face.
● Check worn or damage of CVT cooling fan.
CVTCOOLING
COOLINGFAN
FAN
CVT
CVT
COOLING
FAN
ASSEMBLY
● Assemble weight rollers to movable drive face.
● Assemble lamp plate.
LAMP
LAMP
PLATE
LAMPPLATE
PLATE
WEIGHTROLLER
ROLLER
WEIGHT
ROLLER
WEIGHT
NOTE
•Do not apply grease to the pulley side of movable
drive face
- If done, clean it.
● Assemble movable drive face boss and movable
drive face to LH. Crank shaft.
● Assemble drive belt to crank shaft.
RATCHET
RATCHET
RATCHET
RATCHET
● Assemble drive face.
● Assemble CVT cooling fan and rachet.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
● Assemble drive face to the serration side of LH.
Crank shaft, then assemble hext nut 12mm.
FLANGE
NUT
FLANGE
FLANGENUT
NUT
FLANGE
NUT
● By using drive face holde, fasten drive face nut.
TORQUE : 5.5kgf·m
TOOL : DRIVE FACE
NOTE
•Assemble drive pulley nut as specified torque.
•Assemble by completely fitting drive face and
crankshaft sereration.
•Fix fly wheel to universal holder if drive pulley
holder can not be used.
● Assemble 2 dowel pins and gasket
● Assemble LH. Side cover .
7-14
MEMO
A.C. GENERATOR /RH. CRANK CASE COVER
8. A.C. GENERATOR /RH. CRANK CASE COVER
SERVICES INFORMATION········8-1
COOLING FAN COVER··········8-2
AC GENERATOR·············8-4
RH. CRANK CASE COVER········8-4
SERVICE INFORMATION
GENERAL SAFETY
● This section describes the removal and assembling of the A.C. generator.
● For the information of A.C. generator inspection, refer to the section 15.
● The charging systme can be maintained without removing the engine.
TORQUE VALUES
FLY WHEEL NUT
RH. CRANK CASE COVER BOLT
TOOL
A.C.G. ROTOR PULLER
5.5kgf·m
1.0kgf·m
A.C. GENERATOR /RH. CRANK CASE COVER
COOLING
COOLING
FAN
COVER
COOLINGFAN
FANCOVER
COVER
COOLING FAN COVER
REMOVAL
● Remove the muffler.
● Loosen the 1 tapping screws and 2 flange bolts
securing the cooling fan.
UPPER
UPPER
HOOD
UPPERHOOD
HOOD
COOLING
COOLING
FAN
COOLINGFAN
FAN
● Upper hood and low hood can be remove after
removing the engine from the frame.
LOW
HOOD
LOW
LOWHOOD
HOOD
LOW
FLYWHEEL
WHEEL
FLY
FLY
WHEEL
A.C GERNERATOR
REMOVAL
● Remove the cooling fan cover.
● Remove the cooling fan.
FLY
FLY WHEEL
WHEEL
FLY
WHEEL
UNIVERSAL
UNIVERSAL
HOLDER
UNIVERSALHOLDER
HOLDER
● Install the universal holder on flywheel.
● If the universal holder cannot be used, remove the
LH. crankcase cover at the left side of crankshaft
and hold the drive face with the drive face holder.
● Untie hex nut 12mm.
A.C. GENERATOR /RH. CRANK CASE COVER
● Loosen the flange nit securing the fly wheel and
remove the flywheel using the A.C.G. rotor puller.
CAUTION
ACG
ACG
ROTOR
PULLER
ACGROTOR
ROTORPULLER
PULLER
HEX
HEX
BOLT
HEXBOLT
BOLT
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
ACG
ACG
ACG
•The flywheel may easily remove if you rotate the
puller while tapping the roller shaft metal hammer.
•Always use a holder and a puller to remove the
flywheel. Do not try to remove the flywheel by
hammering directly on it. The crank shaft or
components could be damaged.
•After disassembling fly wheel, check whether
woodruff key damaged or not.
TOOL: A.C.G ROTOR PULLER
UNIVERSAL HOLDER
DRIVE FACE HOLDER
● Loosen the 2 flange bolts securing stator and
remove the stator.
● Loosen the 2 bolts securing the pulse generator and
remove it.
DISASSEMBLE
● ACG wire coupler and connecter connected with
wire harness.
ASSEMBLY
● Assemble ACG stator to RH. crank case cover.
● Clean crank shaft taper side.
● Clean the inside of fly wheel.
● Check woodruff key, assemble the home of fly wheel
to woodruff key.
A.C. GENERATOR /RH. CRANK CASE COVER
● If the universal holder cannot be used, remove the
LH.crankcase cover at left side of the crankshaft, and
hold the drive face with the drive face holder.
TORQUE : 5.5kgf·m
TOOL : UNIVERSAL HOLDER
● Assemble cooling fan.(⇨8-2 )
● Assemble ACG. cord coupler and connector at wire
harness, and cramp cords.
● Assemble cooling fan cover.
COOLING
FAN
COOLING
COOLING FAN
FAN
RH. CRANK CASE COVER
REMOVAL
● Disassemble the following parts.
- Muffler
- Cooling fan cover
- Cooling fan
● Remove engine oil.
● Untie 8 flange bolts assembled at RH. Crank case
cover.
● Disassemble RH. Crank case cover.
RH.CRANK
RH.CRANK
CASE
COVER
RH.CRANKCASE
CASECOVER
COVER
A.C. GENERATOR /RH. CRANK CASE COVER
● Pull out gasket and dowel pin.
DOWEL
PIN
DOWEL
DOWELPIN
PIN
DOWEL
OIL
OIL
PUMP
REDUCTION
GEAR
OILPUMP
PUMPREDUCTION
REDUCTIONGEAR
GEAR
● Check worn or damage of oil seal, if necessary,
replace with the new oil seal.
● Disassemble RH. Crank case cover oil seal and
replace with the new one.
OIL
OIL
SEAL
OILSEAL
SEAL
ASSEMBLY
● Assemble RH. Crank case cover.
● Assemble AC Generator.
● Assemble muffler.
NOTE
•Assemble completely by fitting correctly to the
home.
● Assemble fly wheel.
● Assemble cooling fan.
● Assemble cooling fan cover.
CYLINDER HEAD / VALVES
9. CYLINDER HEAD / CYLINDER / PISTON
SERVICE INFORMATION ···9-1
TROUBLE SHOOTING ····· 9-2
CAM SHAFT········· 9-3
CYLINDER HEAD·······9-5
VALVE SPRING········ 9-6
IN / EX VALVE ········9-6
VALVE GUIDE········ 9-7
VALVE SEAT·········9-8
IN / EX VALVE ASSEMBLY·· 9-8
CYLINDER HEAD ASSEMBLY· 9-10
CAM SHAFT ASSEMBLY··· 9-10
SERVICE INFORMATION
GENERAL SAFETY
● The rocker arm and the camshaft can be served without removing the engine.
● The oil of camshaft is supplied through the cylinder head oil hole.
● Clean th oil hole prior to assembling the cylinder head.
SPECIFICATIONS
UNIT : mm
STANDARD VALUE
SERVICE LIMIT
ROCKER ARM INNER DIAMETER
10.000-10.015
10.10
ROCKER ARM OUTER DIAMETER
9.972-9.987
9.91
IN
25.736 ~ 25.741
25.68
EX
25.55 ~ 25.60
25.52
-
0.05
ITEM
ROCKER ARM
CAM SHAFT
CAM HEIGHT
CYLINDER HEAD WARFAGE
VALVE
VALVE GUIDE
VALVESPRINGFREELENGTH
IN
34.1 ~ 30.5
32.6 ~ 29
VALVE STEM OUTER
DIAMETER
IN
4.975-4.990
4.965
EX
4.965-4.980
4.955
IN, EX
5.000-5.012
5.040
IN
0.010-0.040
0.075
EX
0.020-0.050
0.085
0.8
1.3
VALVE GUIDE IN. DIAMETER
CLEARANCE BETWEEN
STEM AND GUIDE
VALVE SEAT WIDTH
TORQUE VALUES
SPARK PLUG
CAM SHAFT HOLDER 7mm NUT
CAM CHAIN TENSIONER BOLT
CAM CHAIN TENSIONER SEALING BOLT
CYLINDER HEAD COVER BOLT
CYLINDER HEAD BOLT
TAPPET ADJUST NUT
1.2kgf·m
2.0kgf·m
1.1kgf·m
0.4kgf·m
1.1kgf·m
1.2kgf·m
1.1kgf·m
CYLINDER HEAD / VALVES
TOOL
-VALVE GUIDE REAMER
-VALVE GUIDE DRIVER
-VALVE SPRING COMPRESSOR
TROUBLESHOOTING
● Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test or by tracing noises to the top-end with a sounding rod or stethoscope.
Low compression
● Valves
- Incorrect valve adjustment
- Burned or bent valve
- Incorrect valve timing
- Broken valve spring
- Uneven valve seating
● Cylinder head
- Leaking or damage head gasket
- Warped or cracked cylinder head
● Cylinder head defect
Excessive smoke
● Worn valve guide or valve stem
● Damaged valve stem seal
● Worn or damaged piston ring
Rough idle
● Low cylinder compression
Compression too high
● Excessive carbon built-up on piston or combustion chamber
Excessive noise
● Incorrect valve adjustment
● Sticking valve or broken valve spring
● Damaged or worn camshaft
● Worn rocker arm and / or shaft
● Loose or worn cam chain
● Worn or damaged cam chain tensioner
● Damaged cylinder head gasket
● Incorrect spark plug installation
CYLINDER HEAD / VALVES
FLANGE
FLANGE
BOLTS
FLANGEBOLTS
BOLTS
CYLINDER
HEAD
COVER
CYLINDER
CYLINDERHEAD
HEADCOVER
COVER
CYLINDER
CAMSHAFT
REMOVAL
●
●
●
●
Remove the luggage box.
Remove the center cover.
Untie 4 cylinder head cover bolts.
Untie 2 SAI pipe cap nuts and cover.
SAI
SAI
PIPE
SAIPIPE
PIPE
NOTE
•The camshaft can be maintained without removing
the engine.
MARK
TTTMARK
MARK
● Remove the cooling fan cover.
● Turn the crankshaft to the left and align the ”T”
mark of the flywheel with the index mark of the
RH. Crankcase cover.
● Verify that the piston is located at the top dead
center.
● If all camshaft lobes face downward, rotate the
camshaft to the left for one turn(360°), and align
“T” mark with the index mark once again.
● Loosen the pan screw of the cam chain tensioner
and remove the tensioner lifter.
SPRING
SPRING
SPRING
TENSIONER
TENSIONER
LIFT
TENSIONERLIFT
LIFT
FLANGE
NUTS
FLANGE
FLANGENUTS
NUTS
FLANGE
NUTS
CAM
CAM
SHAFT
HOLDER
CAMSHAFT
SHAFTHOLDER
HOLDER
● Loosen the 4 camshaft holder 7mm nuts.
● Remove the camshaft holder from cylinder head.
CYLINDER HEAD / VALVES
CAM
CAM
SHAFT
CAMSHAFT
SHAFT
CAM
CAM
CHAIN
CAMCHAIN
CHAIN
● Remove the cam chain from the cam shaft.
NOTE
•Take precautions not to allow the cam chain to
drop into the crankcase.
● Install the 5mm bolt into the rocker arm shaft and
by pulling bolt, remove the rocker arm shaft..
● Remove the rocker arm.
● Remove the other side rocker arm in the same order.
SHAFT
SHAFT
SHAFT
SHAFT
CAM
SHAFT
HOLDER
CAM
CAMSHAFT
SHAFTHOLDER
HOLDER
INSPECTION
● Check the rocker arm and rocker arm shaft for wear
or damage.
● Measure the inner diameter of the rocker arm.
ROCKER
ARM
ROCKER
ROCKERARM
ARM
ROCKER
ARM
SERVICE LIMIT: 10.10 MM
ROCKERARM
ARM
ROCKER
ROCKER
ARM
SHAFT
SHAFT
SHAFT
CAM
CAM
SHAFT
CAMSHAFT
SHAFT
● Measure the outer diameter of rocker arm shaft.
SERVICE LIMIT: 9.91 MM
● Check the cam lobed of the camshaft for wear or
damage.
SERVICE LIMIT: IN: 25.68MM
EX: 25.52 MM
CYLINDER HEAD / VALVES
BEARING
BEARING
BEARING
● Manually turn the shaft bearing outer race, and
check if it turns smoothly.
● Check damage or worn of bearing, if yes, replace it.
● Install in the reverse order of removal.
CAUTION
•Be sure to check the valve clearance.
CYLINDER
CYLINDER HEAD
HEAD
CYLINDER
HEAD
CYLINDER HEAD
REMOVAL
● Remove the engine(6-2).
● Remove the shroud comp(upper, under hood).
● Remove the cylinder head cover.
● Remove the cam shaft holder.
● Remove the cam shaft.
● Remove the S.A.I pipe.
● Remove the cylinder head.
● Remove the cylinder head gasket, dowel pin and
cam chain guide from the cylinder.
CYLINDER
CYLINDER
HEAD
GASKET
CYLINDERHEAD
HEADGASKET
GASKET
REMOVAL
SPARK
SPARK
PLUG
SPARKPLUG
PLUG
● Remove the spark plug from the cylinder head.
CYLINDER HEAD / VALVES
● Remove the valve spring compressor, valve spring,
valve cotter, retainer, sparing and valve.
VALVE
SPRING
VALVE
VALVESPRING
SPRING
TOOL: VALVE SPRING COMPRESSOR
NOTE
VALVE
VALVE
SPRING
VALVESPRING
SPRING
COMPRESSOR
COMPRESSOR
COMPRESSOR
COMPRESSOR
•To prevent the loss of tension, do not compree the
spring more than necessary.
•Mark the disassembled parts so that they can be
reassembled in to the original position.
INSPECTION
● Remove the carbon deposits from the inside of
combustions chamber.
● Check the spark plug assembling hole and the valve
seat for cracks.
● Using a square and a feeler gauge, check the
cylinder head distortion.
SERVICE LIMIT: 0.05 MM
NOTE
•Take precautions not to damage the cylinder head
gasket attachment.
FEELER
GAUGE
FEELER
FEELERGAUGE
GAUGE
VALVE SPRING
INSPECTION
● Measure the free length of the inner and outer valve
springs.
B
A
FREE LENGTH : IN 30.5 MM
EX 34.1MM
NOTE
INNER
INNER
VALVE
SPRING
INNERVALVE
VALVESPRING
SPRING
OUTER
OUTER
VALVE
SPRING
OUTERVALVE
VALVESPRING
SPRING
VALVE
VALVE
VALVE
VALVE
•Replace the valve spring with new one if the length
of any one is less than service limit.
IN / EX VALVE
INSPECTION
● Inspection in/ex. valve stem for bent, seized,
abnormal wear of step.
● Insert the valves in their original positions in the
cylinder head.
● Measure and record the in/ex.valve stem outer
diameter.
SERVICE LIMIT: IN 4.965
EX 4.955
CYLINDER HEAD / VALVES
VALVE
GUIDE
VALVE
VALVE GUIDE
GUIDE
VALVE
GUIDE
REAMER
REAMER
REAMER
REAMER
VALVE GUIDE
INSPECTION
● Insert the valve guide reamer from the combustion
chamber side and ream the guide to remove any
carbon built-up before measuring the guide.
NOTE
•Take care to tilt or lean the reamer in the guide
while reaming.
•Rotate the reamer clockwise, never
counterclockwise when inserting and removing.
TOOL: VALVE GUIDE REAMER
● Measure and record each valve guid inner diameter.
SERVICE LIMIT: IN 5.04 MM
EX 5.05MM
● Measure the guide to stem clearance.
SERVICE LIMIT: IN 0.075 MM
EX 0.085 MM
● Measure the inner diameter of the new valve guide.
If the measure clearance is not within the service
limit, replace the valve.
VALVE
VALVE
GUIDE
VALVE GUIDE
GUIDE
DRIVER
DRIVER
DRIVER
REPLACEMENT
● Heat the cylinder head to 130°C ~ 140°C.(270°F ~
285°F).
NOTE
•Do not heat the cylinder head beyond 150°
C(300°
F).
•Because there is burnt risk, do not unskifully work.
•Do not heat locally by using of gas burner when
getting cylinder head warm.
•When replacing valve guide, be sure to correct
valve seat.
● Support the cylinder head and drive the old guides
out of the combustion chamber side of cylinder
head.
VALVE
GUIDE
VALVE
VALVE GUIDE
GUIDE
DRIVER
DRIVER
DRIVER
DRIVER
NOTE
•Avoid damaging the cylinder head when driving
the valve guide out.
● Install the new o-ring into the new valve guide.
CYLINDER HEAD / VALVES
● Insert the valve guide at upside of cylinder head.
TOOL: VALVE GUIDE DRIVE
VALVE
VALVE
GUIDE
REAMER
VALVE GUIDE
GUIDEREAMER
REAMER
● Insert the valve guide at upside of cylinder
head.Insert the valve guide at upside of cylinder
head.
NOTE
•Take care not to tilt or lean the reamer in the guide
while reaming.
•Otherwise the valve is installed slanted that cause
oil leaks from the stem seal and improper valve
seat contact and results in the valve seat refacing
not able to be performed.
•Use cutting oil on the reamer during this operation.
•Use cutting oil on the reamer during this operation.
TOOL: VALVE GUIDE DRIVER
● Reface the valve seats and clean the cylinder head
thoroughly to remove any metal particles.
VALVE SEAT
INSPECTION
EX
EX
VALVE
EXVALVE
VALVE
● Clean all the intake and exhaust valves thoroughly
to remove carbon deposits.
● Apply a light coating of Prussian Blue to each valve
face.
● Tap the valve against the valve seat several times
with the valve reamer, without rotating the valve to
check for proper valve seat contact.
● Remove the valve and inspect the valve seat face.
● The valve seat contact should be within the
specified width and evenly all around the
circumstance.
● If the valve leans, check the gap between valve
guide and stem replace the valve guide if it doesn’t
work well.
IN
INVALVE
VALVE
IN
VALVE
NOTE
•Valve faces and stem tips cannot be ground. If a
valve face or stem tip is rough, worn unevenly or
contacts the seat improperly, the valve must be
replaced.
IN/ EX.VALVE ASSEMBLY
● Install new stem seals and valve spring seat.
● Lubricate each valve stem with molybdenum
disulfide grease and insert the valve into the valve
guide.
● Turning a valve too fast can damage the stem seals.
● Check the valve for working properly with up and
down.
CYLINDER HEAD / VALVES
● For valve spring with varying pitch, install the valve
springs with the narrow pitch end facing down.
● Install the spring retainer.
● Compress the valve springs and install the valve
cotter.
NOTE
•Compressing the valve spring more than necessary
when installing the valve cotters may cause looss
of valve spring tension.
TOOL: VALVE SPRING COMPRESSOR
VALVE
VALVE
STEM
VALVESTEM
STEM
● Tap the valve stems gently with a soft hammer to
firmly seat the cotters.
NOTE
•Take necessary precaution not to damage the valve.
SPARK
SPARKPLUG
PLUG
SPARK
PLUG
● Take necessary precaution not to damage the valve.
TORQUE:1.2 kgf·m
CYLINDER HEAD / VALVES
CYLINDER
CYLINDER
HEAD
CYLINDERHEAD
HEAD
CYLINDER HEAD ASSEMBLY
● Clean the gasket material from the cylinder mating
surface.
● Install the cam chain guide to the cylinder.
● Install the dowel pins and new gasket.
● Install the cylinder head.
CAMSHAFT ASSEMBLY
● Apply engine to the rocker arm shaft, and assembly
the rocker arm to the camshaft holder.
● Align cam shaft with the bolt hole of the camshaft
holder and the fitting side of the rocker arm shaft.
CYLINDER HEAD / VALVES
● Apply engine oil to the camshaft and install it on the
cylinder head with the cam thread facing
downward.
● Assembly the cam chain and cam sprocket after
matching the cam sprocket timing mark in parallel
with the top pf the cylinder head.
● Slowly rotate the crankshaft counterclockwise and
align the “T” mark of the flywheel with the index
mark of the RH. crank case cover.
CAUTION
•Take precautions not to allow the cam chain to
come off the camshaft tinning gear while turning
the camshaft.
“T”
MARK
“T”
MARK
“T”
MARK
“T”
MARK
● Install the dowel pins on the cylinder head.
● Assemble cam shaft holder.
WASHER
WASHER
WASHER
WASHER
● Assemble washer to cam shaft holder.
CAUTION
•The hole of the camshaft holder and the fitting
section of rocker arm shaft fit section must be in
alignment.
CYLINDER HEAD / VALVES
● Install flange nut and tighten them driving with 2-3
times.
TORQUE : 2.0kgf·m
BOLT
BOLT
BOLT
SPRING
SPRING
SPRING
PUSH
PUSH
PUSH
● Pull out spring from cam chain tensioner lifter.
● Push the tensioner shaft clockwise with a small
driver like the right picture, and insert the shaft into
the body completely.
● Assemble new gasket to tensioner lifter and
tensioner lift to cylinder.
● Assemble flange bolt
● Insert tensioner lift spring and assemble with bolt.
TORQUE : 1.1kgf·m
TENSIONER
TENSIONER
LIFT
TENSIONERLIFT
LIFT
FEELER
GAUGE
FEELER
FEELERGAUGE
GAUGE
FEELER
● Fill the clean engine oil into the operating parts of
the cylinder head.
● Adjust the valve clearance.
ROCKER
ROCKER
ARM
ROCKERARM
ARM
TAPPET
WRENCH
TAPPET
TAPPETWRENCH
WRENCH
● Remove oil from the cylinder head cover grooves
and accurately assemble the gasket to the cover.
● Install the cylinder head cover bolts.
TORQUE : 1.1kgf·m
● Install the shroud comp.
● Install the engine frame.
MEMO
CYLINDER / PISTON
10. CYLINDER / PISTON
SERVICE INFORMATION···················10-1
TROUBLESHOOTING ····················10-1
CYLINDER··························10-2
PISTON· ··························10-3
PISTON / CYLINDER INSTALLATION··············10-5
SERVICE INFORMATION
GENERAL SAFETY
● Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike
the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to
the cylinder pins.
● Take care not to damage the cylinder wall and piston
● Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
Unit : mm
ITEM
INNER DIAMETER
TAPER
CYLINDER
OUT-OF-ROUND
HEAD CONTACT WARPAGE
PISTON SKIRT OUTER DIAMETER
PISTON PIN HOLE INNER DIAMETER
PISTON,
PISTON PINOUTER DIAMETER
PISTON
PISTON TO PISTON PIN CLEARANCE
P I N ,
TOP
PISTONRINGTO
PISTON
GROOVECLEARANCE
SECOND
RING
PISTON RING
OIL RING
JOINT GAP
CYLINDER TO PISTON CLEARANCE
CONNECTINGRODSMALLENDINNERDIAMETER
GAPBETWEENCONNECTINGRODSMALLENDANDPISTONPIN
STANDARD VALUE
39.000-39.010mm
38.970-38.980mm
13.008-13.012mm
12.994-13.000mm
0.008-0.018mm
0.05-0.15mm
0.05-0.17mm
SERVICE LIMIT
39.04mm
0.05mm
0.05mm
0.05mm
38.92mm
13.04mm
12.98mm
0.04mm
0.04mm
0.04mm
0.1-0.6mm
0.8mm
0.020-0.040mm
13.013-13.028mm
0.013-0.034mm
0.08mm
13.05mm
0.06mm
TROUBLESHOOTING
Compression pressure too low
Over heated
● Piston worn
● Piston ring worn or damaged
● Cylinder worn
● Excessive carbon built up on top of piston
Emission of white gas from muffler
● Cylinder, piston, piston rings worn
● Bad adjustment of piston rings
● Piston, cylinder worn
Abnormal engine noise
● Cylinder, piston worn
● Worn connecting rod small end bearing or piston pins
● Damaged piston rings
● Excessive carbon built up on top of piston
CYLINDER / PISTON
CYLINDER
CYLINDER
CYLINDER
CYLINDER
CYLINDER
REMOVAL
●
●
●
●
●
●
Remove the engine from the engine.
Remove the cylinder head cover.
Remove the cam shaft holder
Remove the cylinder head.
Remove the cam chain guide from the cylinder.
Remove the cylinder
CAM
SHAFT
HOLDER
CAM
CAMSHAFT
SHAFTHOLDER
HOLDER
CAM
SHAFT
HOLDER
● Remove the gasket and dowel pin.
● Remove any adhering gasket material from the
cylinder/ head mating surface.
NOTE
•Take care not to damage the cylinder mating
surface.
CAK
CHAIN
CAK
CAKCHAIN
CHAIN
INSPECTION
● Measure and record the cylinder inner diameter at
three levels in both an X and Y axis.
● Take the maximum reading to determine the cylinder
wear.
CYLINDER
CYLINDER
GAUGE
CYLINDERGAUGE
GAUGE
SERVICE LIMIT : 39.04 MM
● Measure the piston outer diameter.
● Calculate the piston-to-cylinder clearance. Take the
maximum reading to determine the clearance.
SERVICE LIMIT : 0.08 MM
Y
TOP
MIDDLE
LOW
X
● Calculate the cylinder for out-of round at three levels
in an X and Y axis. Take the maximum reading to
determine the out-of-round.
● Calculate the cylinder for taper at three levels in X
and Y axis. Take the maximum reading to determine
the taper,
● If any of the cylinder measurements exceed the
service limits, replace the cylinder.
SERVICE LIMIT: OUT-OF-ROUND :0.05MM
TAPER: 0.05MM
CYLINDER / PISTON
● Check the cylinder for warpage by placing a straight
edge and feeler gauge across the stud holes. Replace
the cylinder if the service limit is exceeded.
SERVICE LIMIT: 0.05MM
PISTON
PISTON
PISTON
PISTON
REMOVAL
● Remove the piston clip.
NOTE
•Do not allow to drip the piston pin clip into the
inside of crank case.
PIN
PIN
CLIP
PINCLIP
CLIP
● After removing the piston pin, then remove the
piston.
● Remove the piston ring.
NOTE
•Do not damage to the piston by piston ring when
removing.
PISTON
PISTON
RING
PISTONRING
RING
RING
RING
RING
C
C
C
YYY
LLL
III
N
N
N
D
D
D
EEE
R
R
R
PISTON
PISTON
SIDEWORN
WORN
PISTON SIDE
SIDE
WORN
PISTONRING
RING
PISTON
PISTON
RING
● Check for the piston ring.
● Measure the clearance between the piston ring and
piston grooves.
SERVICE LIMIT: TOP: 0.4MM
SECOND: 0.4MM
● Check whether the piston is worn or damaged.
CYLINDER / PISTON
FEELER
GAUGE
FEELER
FEELERGAUGE
GAUGE
FEELER
GAUGE
● Inset the piston ring into the inside of cylinder, check
the clearance of piston ring.
NOTE
PISTON
PISTON
RING
PISTONRING
RING
•Inset the piston ring in parallel by the head of
piston.
SERVICE LIMIT: TOP/SECOND: 0.40MM
OIL RING (SIDE RAIL): 0.8 MM
TOOL: FEELER GAUGE
● Measure and record the piston outer 90° to the piston
pin bore and the point specified(10 mm), near the
bottom of the piston skirt.
90°
90°
90°
SERVICE LIMIT: 38.92 MM
MICROMETER
MICROMETER
MICROMETER
MICROMETER
● Measure the piston pin hole inner diameter.
SERVICE LIMIT: 13.04 MM
● Measure the piston pin outer diameter.
SERVICE LIMIT: 12.98 MM
● Calculate the clearance between the piston and piston
pin.
SERVICE LIMIT: 0.04 MM
● Replace with the set parts if worn or damaged.
● Measure the inner diameter of connecting rod small
end.
SERVICE LIMIT: 13.05 MM
● Calculate the connecting rod small end top-to-piston
pin clearance.
SERVICE LIMIT: 0.06MM
CYLINDER / PISTON
PISTON / CYLINDER
INSTALLATION
TOP RING
MARK
SECOND RING
PISTON ASSEMBLY
● Clean the piston head, ring lands and skirts.
R
NOTE
TOP RING
SECOND RING
•Be careful not to damage the piston and rings
during assembly
•Carefully install the piston rings onto the piston
with the markings facing up.
•Do not confuse the top and second rings.
SIDE RAIL
SPACER
SIDE RAIL
20mm
● Space the ring end gaps 120 degrees apart.
● Do not accord the side rail of oil ring.
● After installation, the rings should rotate freely in
the ring grooves.
IN
PISTON
PISTON / CYLINDER
● Remove the gasket on the crank case surface.
NOTE
•Do not damage the contact place of gasket.
•Place a clean shop towel over the crankcase to
prevent the clip from falling into the crankcase.
CRANKSHAFT
SHAFT
CRANK
CRANK
SHAFT
PISTON
SHAFT
PISTON
PISTONSHAFT
SHAFT
PISTON
SHAFT
● Install the piston and piston pin into the connecting
rod.
● Install the new piston pin clip pin.
NOTE
•”IN” mark it does toward to intake side.
•Take care not to drop the piston pin clip into the
crankcase.
•Do not align the clip’
s end gap with the piston
outcut.
CYLINDER / PISTON
● Install the new gasket and dowel pins.
CYLINDER
CYLINDER
CYLINDER
CYLINDER
● Coat the cylinder wall with clean the engine oil and
lubricate the piston rings and install the cylinder.
NOTE
•Be careful not to damage the piston rings.
•Be careful not to drop the cam chain into the
crankcase.
● Install the lower part of the cam chain guide to the
groove part of the crankcase and install the cam
chain guide by aligning the projection part with the
groove part of cylinder.
● Install the cylinder head.
● Install the cam shaft.
● Install the cylinder head cover.
● Install the engine into the frame.
CAM
CAM
CHAIN
CAMCHAIN
CHAIN
MEMO
TRANSMISSION/CRANKSHAFT/CRANKCASE
11. TRANSMISSION/CRANKSHAFT/CRANKCASE
SERVICE INFORMATION····11-1
TROUBLE SHOOTING·····11-2
TRANSMISSION········11-3
TRANSMISSION BEARING···11-4
CRANKCASE REMOVAL····11-7
CRANK SHAFT REMOVAL····11-8
CRANK SHAFT INSTALLATION···11-9
CRANK CASE INSTALLATION··11-10
SERVICE INFORMATION
GENERAL SAFETY
● This section describes how to remove the crank case and to maintain the transmission and the crankshaft.
● Service transmission without removing the engine from the vehicle. However, to prevent damage to the LH. Crank
case, remove the engine and disassemble the rear brake prior to changing the LH. Crank case bearing
● Always use special tools to change the drive shaft. Fix the bearing inner race, and install the shaft
● The following parts must be removed prior to removing the crank case. Follow the removal procedure specified in
each section.
- Drain the engine oil
- Remove the carburetor
- Remove the engine
- Remove the cylinder head, cylinder, piston
- Remove the cooling fan, flywheel, RH. Crank case cover
- Remove the LH. Crank case cover, drive face, driven pulley
- Remove transmission
● When replacing the LH crank case, follow the below procedure specified in each section.
- Disassemble the transmission (⇨SECTION 11)
SPECIFICATIONS
단위 : mm
ITEM
CRANK
SHAFT
STANDARD VALUE
SERVICE LIMIT
CONNECTING ROD
0.1~0.3mm
0.5mm
CONNECTING ROD BIG END
0.1~0.4mm
0.6mm
Right
-
0.1mm
Left
-
0.1mm
CRANK SHAFT SHAKING
TRANSMISSION OIL
OIL CAPACITY
RECOMMENDED OIL
0.12L(Full capacity)
0.10L(After oil change)
DAELIM genuine mission oil or SAE 80W/90
TRANSMISSION/CRANKSHAFT/CRANKCASE
TORQUE
CRANK CASE BOLT
1.1kgf·m
TOOL
- UNIVERSAL BEARING PULLER
- CRANK SHAFT ASSEMBLER COLLAR SHAFT
- DRIVE HANDLE
- DRIVE OUTER
- BEARING REMOVER SET
TROUBLESHOOTING
Engine Noise
● Connecting rod big and small ends loose.
● Crank pin bearing loose.
Engine started but unable to move out
● Transmission damage.
● Transmission seized.
Noise during operation
● Gear worn, overheated, cracked.
● Bearing worn.
Oil leaks
● Excessive oil level.
● Oil seal worn, damaged.
TRANSMISSION/CRANKSHAFT/CRANKCASE
TRANSMISSION
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
DISASSEMBLY
● Loosen the drain bolt, drain the mission oil.
● Remove the LH. crankcase cover.
● Remove the driven pulley, drive face.
● Remove the muffler.
● Remove the rear wheel.
● Loosen the bolts assembled at LH. Crank case and
remove the transmission cover.
DRAIN
BOLT
DRAIN
DRAIN BOLT
BOLT
RH.
RH.
CRANK
CASE
RH.CRANK
CRANKCASE
CASE
DRIVE
DRIVE
SHAFT
DRIVESHAFT
SHAFT
● Remove the gasket and dowel pin in LH. Crank case.
LH.
LH.
CRANK
CASE
LH.CRANK
CRANKCASE
CASE
● Remove the drive shaft from the transmission cover
by using a hydraulic press.
NOTE
•Take precautions not to damage the cover joints.
DRIVE
SHAFT
DRIVE
DRIVESHAFT
SHAFT
DRIVE
SHAFT
● Remove the oil seal of drive shaft.
FINAL
SHAFT
GEAR
FINAL
FINALSHAFT
SHAFTGEAR
GEAR
FINAL
SHAFT
GEAR
MISSION
COVER
MISSION
MISSIONCOVER
COVER
MISSION
COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER
SHAFT
● Remove the final shaft and counter shaft comp
installed at misson cover.
TRANSMISSION/CRANKSHAFT/CRANKCASE
INSPECTION
● Check the drive shaft for wear or damage.
DRIVE
DRIVE
SHAFT
DRIVESHAFT
SHAFT
● Check the final shaft and gear for wear or damage.
COUNTER
COUNTER
SHAFT
COUNTERSHAFT
SHAFT
FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT
● Check the final shaft and the worn or damage of
gears.
TRANSMISSION BEARING
● Disassemble crank shaft and transmission.
INSPECTION
MISSION
COVER
MISSION
MISSIONCOVER
COVER
MISSION
● Check whether transmission bearing smoothly
works or not by turning the inner race of bearing by
fingers.
● Check whether the outer race is correctly put
pressure into crank case.
● If the looseness degree is excessive over and the put
pressure of case is loose, diassemble and replac
with the new one.
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Replace the bearings if necessary.
● Press the bearing to the case with special tool.
TOOL: BEARING REMOVER SET
ASSEMBLY
● Install the drive shaft on the transmission cover.
● Install a new drive shaft oil seal.
TOOL: CRANK ASSEMBLY SHAFT
CRANK ASSEMBLY COLLAR
● Check whether bearing, oil seal in LH. Crank case
are worn or damaged.
REPLACEMENT
TOOL : BEARING REMOVER SET
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Apply clean engine oil to the new bearing and insert
by pressure to crank case.
TOOL : DRIVER HANDLE, DRIVER OUTER
● Assemble the new final shaft oil seal.
● Assemble drive shaft to LH. Crank case.
● Assemble the new drive shaft oil seal.
TOOL : DRIVER HANDLE
● Assemble final shaft and counter shaft to crank case
mission cover.
● Assemble the new gasket and dowel pin.
● Install transmission cover by flange bolt.
- Rear wheel.
- Muffler
- Continuously variable transmission
- LH. crank case cover
● Loosen the oil check bolt, fill the transmission oil.
OIL CAPACITY : 0.12L
TRANSMISSION/CRANKSHAFT/CRANKCASE
CRANK CASE REMOVAL
● Remove the engine from the frame.
● Remove the RH./LH. crank case cover.
● Remove the parts to disassemble crankcase.
● Loosen the 1 flange bolt from the RH. crank case.
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
● Face the LH. crankcase downward, and remove the
RH. crankase from the LH. crankcase while tapping
a new places on the LH. crankcase with a plastic
hammer.
NOTE
•Be careful not to distort the mating surface of the
crank case during removal.
RH.
CRANK
CASE
RH.
RH.CRANK
CRANKCASE
CASE
RH.
CRANK
CASE
CRANK
CRANK
SHAFT
CRANKSHAFT
SHAFT
● Remove the dowel pin and gasket.
● Remove the crankshaft.
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Check RH. Crank case.
● Check LH. Crank case.
CRANK SHAFT REMOVAL
● If the bearing is left on the crankshaft, use a bearing
puller to remove it.
TOOL: UNIVERSAL BERING PULLER
CRANK
CRANK
CRANK
DIAL
DIAL
DIAL
DIAL
GAUGE
GAUGE
GAUGE
INSPECTION
● Place the crankshaft on a stand or V-block, and
measure the crankshaft runout using dial gauge.
SERVICE LIMIT: RIGHT: 0.1MM
LEFT: 0.1 MM
TRANSMISSION/CRANKSHAFT/CRANKCASE
● Measure the side clearance by inserting the feeler
gauge between the crankshaft and connecting rod big
ends.
TOOL: FEELER GAUGE
SERVICE LIMIT: 0.5MM
FEELER
FEELER
GAUGE
FEELERGAUGE
GAUGE
● Measure the connecting rod radial clearance in both
X and Y directions.
SERVICE LIMIT: 0.6MM
DIAL
DIAL
GAUGE
DIALGAUGE
GAUGE
CRANK SHAFT INSTALLATION
● Put the LH. crank case toward the downward, hang
the cam chain into the inside crankcase.
CAM
CHAIN
CAM
CAMCHAIN
CHAIN
CAM
CHAIN
● Insert the crankshaft and install the cam chain into
the timing sprocket.
TRANSMISSION/CRANKSHAFT/CRANKCASE
CRANK CASE INSTALLATION
● Install the dowel pins and a new gasket.
● Pulling the cam chain and check to see if the
crankshaft installed correctly.
● Install the RH. Crankcase to the LH. crank case.
NOTE
•Make sure that the gasket is completely attached
without any clearance.
● Assemble one RH. Crank case flange bolt.
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
● Regarding the installing the engine assy, refer to the
manual.
● Install the engine to the frame(-> section 6).
MEMO
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
12. FR. WHEEL / FR. BRAKE / FR. FORK / STEERING STEM
SERVICE INFORMATION···12-1
TROUBLE SHOOTING··· 12-2
STEERING HANDLE·····12-3
FRONT WHEEL REMOVAL··12-4
FRONT WHEEL BEARING···12-5
SPEEDOMETER GEAR BOX· 12-6
FRONT WHEEL ASSEMBLY··12-7
FRONT BRAKE ······12-7
BRAKE FLUID REPLACEMENT·12-10
FRONT CALIPER ···· 12-12
FRONT FORK······ 12-15
STEERING STEM ···· 12-20
SERVICE INFORMATION
GENERAL SAFETY
CAUTION
● Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking
performance. If contaminated, replace the pad with a new one, and clean the disk
● Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged
● Place a jack underneath the engine to support the 2-wheeled vehicle.
SPECIFICATIONS
ITEM
STANDARD VALUE
AXLE SHAFT RUN OUT
FRONT WHEEL RIM RUN OUT
RADICAL
SERVICE LIMIT
-
0.2mm
-
2.0mm
AXIAL
FRONT CUSHION SPRING FREE LENGTH
-
2.0mm
232mm
185mm
BRAKE DISK THICKNESS
4.0mm
3.5mm
MASTER CYLINDER INNER DIAMETER
12.700~12.727mm
12.744mm
MASTER CYLINDER PISTON OUTER DIAMETER
12.623~12.650mm
12.606mm
BRAKE CALIPER PISTON OR DIAMETER
25.000~25.033mm
24.889mm
BRAKE CALIPER CYLINDER INNER DIAMETER
24.914~24.935mm
25.043mm
TORQUE VALUES
STEERING STEM NUT
7.0kgf・m
STEERING TOP CON RACE
0.25kgf・m
FRONT CUSHION BOLT
2.25kgf・m
FRONT AXLE NUT
6.0kgf・m
BRAKE CALIPER BOLT
3.0kgf・m
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
TROUBLESHOOTING
Hard steering
Bad working brake
● Steering bearing adjustment nut too tight.
● Faulty steering stem bearings.
● Damaged steering stem bearings.
● Insufficient tire pressure.
● Rim deformed.
● Bad wheel bearing.
● Mixed air in brake system
● Getting damp to brake fluid
● Contaminated brake pad, disk
● Worn master cylinder piston seal
● Worn brake pad
● Worn caliper piston seal
● Contamination inside of caliper
● Bad contact of the side of caliper slide
● Worn brake pad, disk
● Insufficiency of brake fluid
● The channel of brake fluid is blocked
● Bent disk or deformed
● Seized caliper piston, worn
● Seized master cylinder piston, worn
● Worn disk
● Contamination inside master cylinder
● Bent brake lever
Wheel turning heavy
Brake lever not turned back to the original
position
Steer to one side or does not track straight
● Bent fork.
● Bent front axle.
● Bent frame.
● Worn or damaged tire.
● Worn wheel bearing.
Front wheel wobbling
● Bad wheel bearing.
Weak Front suspension
● Weak spring.
Front cushion noise
● Looseness of front cushion assembled position.
● Blocked in brake system
● Seized caliper piston
● Bad contact of caliper slide side
● Blocked in the channel of brake fluid
● Worn caliper piston seal
● Seized master cylinder piston, worn
● Brake lever power
Braking power lessens
● Contamination of brake pad, disk
● Wrong wheel alignement
● Worn brake pad, disk
● Bent disk, deformed
● Bad contact of the side of caliper slide
● Contamination due to dirt in oil pressure system
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
FRONT
FRONTHANDLE
HANDLECOVER
COVER
FRONT
HANDLE
COVER
WASHER
SCREW
WASHER
WASHERSCREW
SCREW
WASHER
SCREW
STEERING HANDLE
REMOVAL
● Remove the front handle cover 1 washer screw and
3 tapping screws.
TAPPING
TAPPING
SCREW
TAPPINGSCREW
SCREW
● Remove Remove 2 tapping screws assembled at
front handle cover.
TAPPING
TAPPINGSCREW
SCREW
TAPPING
SCREW
REAR
HANDLE
COVER
REAR
REARHANDLE
HANDLECOVER
COVER
REAR
HANDLE
COVER
WASHER
SCREW
WASHER
WASHERSCREW
SCREW
TAPPING
TAPPINGSCREW
SCREW
TAPPING
SCREW
REAR
HANDLE
COVER
REAR
REARHANDLE
HANDLECOVER
COVER
● Remove Remove the front handle cover from the
handle bar.
● Remove the speedometer cable from the
speedometer.
● Remove 2 tapping screws, 1 washer screw securing
handle bar and remove the rear handle cover.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
LH.
HANDLE
BRACKET
LH.
LH.HANDLE
HANDLEBRACKET
BRACKET
FAN
FAN SCREW
SCREW
FAN
SCREW
RH.
RH. HANDLE
HANDLE SWITCH
SWITCH
RH.
HANDLE
SWITCH
● Loosen the master cylinder holder bolt.
● Remove the master cylinder.
● Loosen the screw securing the throttle bracket and
remove it.
● Loosen the bolt securing LH. handle bracket and
remove it.
● Loosen the front / rear brake switch and remove it.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Disconnect the throttle cable from the throttle grip
and remove the throttle grip.
● Loosen the hex flange bolt securing handle bar and
remove the handle bar.
HANDLE
HANDLE
BAR
HANDLEBAR
BAR
FRANGE
BOLT
FRANGE
FRANGEBOLT
BOLT
FRANGE
BOLT
INSTALLATION
HANDLE
HANDLE
BAR
HANDLEBAR
BAR
● Install the handle bar to the steering stem.
● Assemble handle bar bushing(setting collar) fit to the
home.
● Insert the hex flange bolt and tighten the locknut..
TORQUE VALUE : 4.5kgf·m
HANDLE
BAR
BUSHING
HANDLE
HANDLEBAR
BARBUSHING
BUSHING
HANDLE
BAR
BUSHING
● Apply the grease to the throttle cable and install the
throttle bracket.
● Install the front brake master cylinder.
● Install the LH. handle bracket.
LH.
HANDLE
BRACKET
LH.
LH.HANDLE
HANDLEBRACKET
BRACKET
LH.
HANDLE
BRACKET
RH.
HANDLE
BRACKET
RH.
RH.HANDLE
HANDLEBRACKET
BRACKET
RH.
HANDLE
BRACKET
NOTE
•Adjust the throttle grip free play to 2-6mm.
● Install in the reverse order of removal.
FRONT WHEEL
REMOVAL
● Support the vehicle securely under the engine to
raise the front wheel.
● Remove the speedometer cable.
● Loosen the axle nut and remove the wheel.
FRONT
FRONT
WHEEL
FRONTWHEEL
WHEEL
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
INSPECTION
● Check the front axle for deflection. Place the front
axle on a V-block, and measure deflection with a dial
gauge.
SERVICE LIMIT: 0.2 MM
FRONT
FRONT
AXLE
FRONTAXLE
AXLE
● Place the front wheel on an inspection stand. Slowly
turn the wheel, and check the rim for wobbles with a
dial gauge.
SERVICE LIMIT: RADIAL 2.0MM
AXIAL 2.0 MM
ROLL
ROLL
ROLL
FRONT WHEEL BEARING
INSPECTION
● Turn the inner race of each bearing with finger.
Bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
hub. If the bearing is worn, replace the new one.
REMOVAL
BEARINGREMOVER
REMOVERHEAD
HEAD
BEARING
BEARING
REMOVER
HEAD
● Install the bearing remover head and the remover
shaft on the wheel and remove the bearing and
distance collar.
TOOL: BEARING REMOVER HEAD
BEARING REMOVER
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
ASSEMBLY
DRIVER
HANDLE
DRIVER
DRIVERHANDLE
HANDLEAA
DRIVER
HANDLE
AA
● Apply sufficient amount of grease to the bearing.
● Insert the right bearing with its seal surface facing
outside.
● Upon assembling the distance collar, insert the left
bearing with its seal surface facing outside.
TOOL: DRIVER HANDLE A
OUTER DRIVER
NOTE
•Do not tilt the bearing. Insert accurately.
SPEEDOMETER GEAR BOX
INSPECTION
● Remove the speedometer gear box from the front
wheel.
● Remove the speedometer gear from the
speedometer gear box
SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX
GEAR
GEARBOX
BOXRETAINER
RETAINER
SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX
● Check the gear for wear or damage.
SPEEDOMETER
SPEEDOMETER
GEAR
SPEEDOMETERGEAR
GEAR
GEAR
BOX
RETAINER
GEAR
GEARBOX
BOXRETAINER
RETAINER
GEAR
BOX
RETAINER
ASSEMBLY
● Apply grease to the speedometer and install it.
● Install the gear box retainer.
DUST
SEAL
DUST
DUSTSEAL
SEAL
DUST
SEAL
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
SPEEDOMETER
GEAR
BOX
SPEEDOMETER
SPEEDOMETERGEAR
GEARBOX
BOX
SPEEDOMETER
GEAR
BOX
● Align the wheel hub with the projection area of the
speedometer gear box retainer, and install.
● Apply grease to the dust seal rim.
● Install the dust seal, and align the projection area of
speedometer gear box retainer with the gear groove
to assemble the speedometer gear box.
FRONT WHEEL
INSTALLATION
● Insert the front wheel between the front forks.
● Insert the disk, taking precautions not to damage the
pad, and assemble the wheel.
● Align the slots of the speedometer gear with tangs of
the left fork slider.
● Insert the front axle into the speedometer gear box
and the wheel hub.
● Install the axle nut.
● Install the speedometer cable and tighten with
screws.
● Place the front wheel on the ground, and tighten the
axle nut to the specified torque.
TORQUE VALUE : 5.0~7.0kgf·m
BRAKE DISK INSPECTION
● Check crack or damage of brake disk
● Measure the thickness of brake disk by micrometer.
TSERVICE LIMIT : FRONT 3.5MM
● If the minimum measured is lower than service
limit, replace brake disk.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Measure the bent or twist of brake disk.
TRANSMISSION OIL CAPACITY : 0.12 L
● If the bent or twist exceeds over the service limit,
check the tolerance of wheel bearing
● If the wheel bearing works regularly, replace brake
disk.
MASTER SYLINDER
FRONT BRAKE
MASTER CYLINDER REMOVAL
● Remove the front handle cover.
● Drain the brake fluid.
● Remove the front stop switch coupler.
NOTE
BRAKEHOSE
HOSE
BRAKE
BRAKE
HOSE
•The brake fluid can damage the painted plastic or
rubber parts. Keep these parts from contacting with
them and wash these parts with water in case of
contact.
•Cover the joint part of the hose to prevent the leak
the brake fluid from leaked.
•Clean the removed parts with brake fluid and
check the airing of each part with compressed air.
•Arrange the removed parts not to be soiled with
dust or dirt.
REMOVAL
● Loosen the brake hose oil bolts.
● Loosen the master cylinder holder bolts.
● Remove the master cylinder.
● Remove the front stop switch.
● Remove the boot and cir clip from the master
cylinder.
TOOL: SNAP RING PLIERS
MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER
CIR
CLIP
CIR
CIRCLIP
CLIP
CIR
CLIP
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
MASTER CYLINDER BODY
STOP SWITCH
LEVER
● Remove the cylinder, spring from the master
cylinder.
● Clean the inside of master cylinder, reserve, master
piston with the brake fluid.
DIAPHRAGM
PLATE
SPRING
CYLINDER
DIAPHRAGM
CIR CLIP
BOOT
OIL CUP CAP
INSPECTION
PRIMARY
PRIMARY
CUP
PRIMARYCUP
CUP
SECONDARY
SECONDARY
CAP
SECONDARYCAP
CAP
● Check the piston periphery for scores, scratched or
nicks.
● Check the primary and secondary cups for wear.
CYLINDER
CYLINDER
CYLINDER
NOTE
•If there is any leak of fluid, when installing new
piston, it may indicate the side wear of the cylinder
by the direction of the piston contacting face. In
this case, the master cylinder must be replaced
also.
● Check the master cylinder for scores, scratched or
nicks and replace if necessary.
ASSEMBLY
CAUTION
•Replace the piston, spring, cups and snap ring as a
set.
•Be sure that each part is free from dust or dirt
before reassembly.
•When cleaning with the brake fluid, use the
specified brake fluid.
● Apply the recommendatory brake fluid to the cup,
cylinder and inside of cylinder, and install the
spring, primary cup, piston.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
NOTE
•When installing the cups, do not allow to close the
cup ends.
•nstall the spring with it’s smaller direction of coil
ends toward the piston.
● Install the cir clip to the mater cylinder groove firmly.
TOOL: SNAP RING PLIER
● Assemble boot to master cylinder.
BOOT
BOOT
BOOT
INSTALLATION
● Install the front master cylinder to the handle.
NOTE
•Install the holder with its“UP”mark facing
upwards, and align the holder joint with the punch
mark on the handle bar.
•Tighten the holder upper bolt first.
● Install the brake hose to the master cylinder with 2
new sealing washers and the hose bolt.
TORQUE : 3.0 kgf·m
● Loosen the 2 flat screws, remove the oil cup cap,
diaphragm.
● Fill the brake fluid and bleed air.
● Install the diaphragm, diaphragm plate and oil cup
cap, tighten the 2 flat screws.
“UP”
MARK
“UP”
MARK
“UP”
MARK
DIAPHRAGM
DIAPHRAGM
PLATE
DIAPHRAGMPLATE
PLATE
BRAKE FLUID REPLACEMENT
NOTE
•A contaminate disk or pad reduces braking power.
Do not allow the disk or pad to be contaminated by
oil.
•Replace contaminated pads, and remove pollutants
from the disk completely.
•Check the brake fluid level often and replenish
new fluid as requires.
•Do not spill fluid on painted, plastic or rubber
parts.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Remove the master cylinder cup cap.
● Remove the master cylinder cup cap, diaphragm
plate, and diaphragm from the master cylinder.
Connect the bleeder hose to the bleeder valve.
Loosen the bleeder valve, and pump the brake lever
repeatedly.
● When there is no more fluid flowing out of the
bleeder valve. Stop pumping the brake lever.
AIR BLEEDING
BRAKE BLEEDER
<When the brake bleeder is available>
● Remove the master cylinder cup cap, diaphragm
plate, and diaphragm from the master cylinder.
Connect the bleeder hose to the bleeder valve.
Loosen the bleeder valve, and pump the brake lever
repeatedly.
● When there is no more fluid flowing out of the
bleeder valve. Stop pumping the brake lever.
NOTE
•Check the fluid level often, and replenish fluid if
the amount of fluid is reduced to the lower level.
•Read the user’s manual carefully prior to
disassembling or using the brake bleeder.
•Protect the bleeder valve with tape to prevent air
from entering the bleeder valve.
● Repeat the above procedures until no air bubbles
appear in the bleeder hose.
● Squeeze the bleeder valve and operate the brake
lever to check the ingress of air.
<When the brake bleeder is not available>
● Fill the brake fluid up to the upper limit line.
● Connect the transparent bleeder hose to the bleeder
valve and place the other end of hose in a container.
① Squeeze the brake lever, then open the bleeder valve
1/2 turn, and close the valve.
NOTE
•Do not release the brake lever until the bleeder
valve has been closed.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
BLEEDER
BLEEDER
SCREW
BLEEDERSCREW
SCREW
② Release the brake lever slowly and wait several
seconds after it reaches the end of its travel
③ Repeat the above steps ① and ② until bubbles cease
to appear in the fluid at the end of the hose
● Check the fluid level often, and add fluid if the fluid
lever is near the lower level.
● If no air leaks out of the bleeder hose, operate the
brake lever to check the presence of air.
● Tighten the bleeder valve.
TORQUE: 0.4~0.7 : 5.5kgf·m
CALIPER
CALIPER
CALIPER
OIL
OILCUP
CUPCAP
CAP
OIL
CUP
CAP
● Fill the brake fluid to the upper level. Install the
diaphragm, diaphragm plate, master cylinder cap.
TORQUE: 1.0kgf·m
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
BRAKE
BRAKE
HOSE
BRAKEHOSE
HOSE
BRAKE CALIPER
REMOVAL
● Drain the brake fluid.
● Loosen the oil bolt of brake hose.
● Loosen the flange bolt securing the caliper and
remove the front caliper.
FRONT
CALIPER
FRONT
FRONTCALIPER
CALIPER
FRONT
CALIPER
NOTE
CALIPER
BRACKET
CALIPER
CALIPERBRACKET
BRACKET
CALIPER
BRACKET
•Avoid spilling fluid on painted, plastic or rubber
parts.
CAUTION
•Keep oil off the brake or pad, because the
contaminated brake disk or pads reduce the
braking performance if contaminated.
•Replace the pad with a ne one and clean the disk.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
REMOVAL
AIRGUN
GUN
AIR
GUN
AIR
● Remove the pad spring, pad comp, caliper bracket,
boot from the caliper body.
● If there is any wear or damage in the boot, replace it
with a new one.
● Wrap the caliper with a piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
● Remove the piston from the caliper while blowing
the low-pressure air in the opening of the brake hose.
NOTE
•Never use the high-pressure air or bring the air gun
too close.
•Never touch the inside of the caliper.
● Remove the piston seal and dust seal.
NOTE
•Pay attention not to damage the inner surface of the
caliper.
DUST
DUST
SEAL
DUSTSEAL
SEAL
PISTON
PISTON
SEAL
PISTONSEAL
SEAL
● Clean the piston and inside of the caliper with the
brake fluid.
INSPECTION
● Check the caliper bore for scoring, scratches, or
other fluid.
CALIPER
BODY
CALIPER
CALIPERBODY
BODY
CALIPER
BODY
● Check the caliper piston outer diameter part for
scratches or other damage.
● Measure the piston outer diameter.
PISTON
PISTON
PISTON
PISTON
SERVICE LIMIT : 24.889MM
MICROMETER
MICROMETER
MICROMETER
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Measure the caliper inner diameter.
DIAL
DIAL
GAUGE
DIALGAUGE
GAUGE
DUST SEAL
PAD
PISTON SEAL
PISTON
SERVICE LIMIT: 25.043 MM
● Clean the piston seal and dust seal with the brake
fluid and install them in caliper.
● Install the piston in the caliper with the groove side
of the piston facing the pad.
PAD SPRING
BRACKET CALIPER BODY
PAD
PAD
SPRING
PADSPRING
SPRING
● Install the pad spring the caliper.
● Install the caliper pin bolt and the caliper bracket to
the caliper.
● Install the brake pad to the caliper.
INSTALLATION
● Install the brake caliper to the front fork, and front
axle.
● Install the caliper to the specified torque.
TORQUE: 3.0kgf·m
● Install the brake hose to the caliper body with the
new 2 oil bolts washers and oil bolts.
● Install the oil bolt to the specified torque.
TORQUE: 3.0kgf·m
● Fill the brake fluid and bleed air.
FRONT
FRONT
BRAKE
CALIPER
FRONTBRAKE
BRAKECALIPER
CALIPER
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
FRONT FORK
STEERING
STEERING
COMP
STEERINGCOMP
COMP
FRONT
FRONT
FORK
FRONTFORK
FORK
● Remove the front under cover.
● Remove the front caliper.
● Remove the front fender.
● Remove the front rear wheel.
● When removing the front fork, loosen the fork pipe
bolt lightly.
NOTE
•Support the vehicle securely under the engine not
to turn over it.
•Loosen the fork pipe bolt, but do not remove it.
FRONT
FRONT
FORK
BOLT
FRONTFORK
FORKBOLT
BOLT
FRONT
FRONT
FORK
FRONTFORK
FORK
● Loosen the 4 setting bolts securing the RH./LH.
fron fork, remove the RH./LH. front fork.
● After removing the RH. front wheel, loosen the
flange bolt and the remove the front brake hose
clamp A.
REMOVAL
● Remove the front fork bolt.
CAUTION
•If the screw is completely loosened, the fork pipe
bolt may spring out by the force of the spring. Take
precautions.
•Remove the fork spring and expand and release the
fork pipe several times to drain fork oil.
● Wrap the bottom case with a piece of cloth, and
remove the socket bolt.
SOCKETBOLT
BOLT
SOCKET
BOLT
SOCKET
NOTE
•If the socket bolt turns idle, but cannot be removed,
temporarily assemble the spring and the fork tube
cap bolt first.
•Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Remove the dust seal.
DUST
DUST
SEAL
DUSTSEAL
SEAL
● Remove the fork pipe from the bottom case.
● Remove the piston and rebound spring from the
fork pipe.
● Remove the oil seal stop ring.
OIL
OIL
SEAL
STOP
RING
OILSEAL
SEALSTOP
STOPRING
RING
● Remove the oil seal.
NOTE
OIL
OIL
SEAL
OILSEAL
SEAL
•Take precaution not to damage the interior and
exterior rim of the bottom case.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
INSPECTION
● Place the fork spring on a level place, and measure
the free length.
● If the free length deviates from the service limit,
replace the springs with now ones.
SERVICE LIMIT: 232 MM
FRONT
FORK
SPRING
FRONT
FRONTFORK
FORKSPRING
SPRING
FRONT
FORK
SPRING
BOTTOM CASE
OIL LOCK PEACE
OIL SEAL
DUST SEAL
● Check components for damage or abnormal wear.
Replace defective parts with new ones.
REBOUND SPRING OIL SEAL STOP RING
PIPE SEAT
SOCKET
BOLT
CUSHION SPRING
FORK PIPE
● Set the fork pipe on a V-blocks, and measure fork
pipe deflection by rotating with a dial gauge.
● Replace if the defletion is greater than 0.2mm.
● Check the contact side of slider bush.
● Replace bottom case when serisously damaged.
FORK
FORK
PIPE
FORKPIPE
PIPE
ASSEMBLY
BOTTOM
CASE
BOTTOM
BOTTOMCASE
CASE
BOTTOM
FORK
SEAL
DRIVE
FORK
FORKSEAL
SEALDRIVE
DRIVE
FORK
SEAL
DRIVE
● Wash parts with clean oil prior to assembling.
● Assemble the rebound spring and fork piston to the
fork pipe.
● Assemble oil seal
● Assemble oil seal stop ring
● Apply ATF to the new oil seal.
● Assemble the oil seal to the bottom case.
● Insert the oil seal with special tools until the
attachment groove of the bottom case set ring is
exposed.
TOOL: FORK SEAL DRIVER
FORK SEAL DRIVER BODY
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Assemble the fork pipe to the bottom case.
● Assemble the springs to the fork pipe.
NOTE
•Install the spring with the smaller pitch side facing
downward.
● Accurately assemble the stop ring to the bottom
case.
● Install the dust seal.
● Fix bottom case by wrapping cloth fix to vice.
● Assemble to fork piston by applying screw lock gell
to the screw side of socket bolt.
TORQUE VALUE : 2.0kgf·m
NOTE
•When fix bottom case to vice, do not insert bottom
case directly and surely insert to the side of
bracket.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
● Fill a prescribed amount of automatic transmission
fluid in to the fork pipe.
CAPACITY: 90 ㎤
● Slowly press the fork tube 2-3 times to discharge air.
● Check the oil level the fork tube is completely
compressed condition.
● Install the fork pipe bolt toe the fork pipe.
INSTALLATION
● Align the part of groove with the setting bolt
connection.
● Install 8mm front fork setting bolt.
TORQUE VALUE : 2.5kgf·m
● Install the brake hose clip to the RH. Front brake
fork.
● Install in the reverse order of removal.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
STEERING STEM
REMOVAL
●
●
●
●
●
HANDLE BAR
BAR
HANDLE
HANDLE
BAR
BUSHING
BUSHING
BUSHING
BUSHING
Remove the handle cover.
Remove the rear handle cover.
Remove the front cover.
Remove the handle bar.
Remove the front wheel.
NOTE
•Be careful not to turn over the vehicle.
● Remove the steering lock nut.
● Remove the steering top nut.
LOCK
LOCK
NUT
LOCKNUT
NUT
TOP
TOP
NUT
TOPNUT
NUT
BALL
BALL
COVER
BALLCOVER
COVER
● Remove ball cover.
● Remove steering top con race.
● Check damage or worn by disassembling steering
stem ball ass’y.
STEERING
STEM
BALL
STEERING
STEERINGSTEM
STEMBALL
BALL
STEERING
STEM
BALL
ASS’
Y
ASS’
Y
ASS’
Y
● Check damage or worn by disassembling steering
under ball ass’y.
STEERINGSTEM
STEM
STEERING
STEERING
STEM
UNDER BALL
BALL ASS’
ASS’
Y
UNDER
Y
UNDER
BALL
ASS’
Y
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
INSTALLATION
● Apply grease to steering bottom con race, then
assemble steering stem ball ass’y.
● Assemble steering stem to frame body head pipe.
● Apply grease to frame body head pipe,then
assemble steering stem ball ass’y.
● Assemble steering top con race
● Assemble temporarily top nut after doing ball cover.
BEARINGTOP
TOPCONE
CONE
BEARING
BEARING
TOP
CONE
RACE
RACE
RACE
HEAD
HEAD
PIPE
HEADPIPE
PIPE
TOPNUT
NUT
TOP
TOP
NUT
● Completely fasten top nut then diassemble 1/8.
TORQUE : 0.25 kgf·m
● Check whether moves left and right smoothly and
tolerance between up and down.
LOCK
LOCK
NUT
LOCKNUT
NUT
BALLCOVER
COVER
BALL
BALL
COVER
STEERING
STEM
SOCKET
STEERING
STEERING STEM
STEM SOCKET
SOCKET
● Assemble temporarily by assembling steering stem
lock nut.
TOOL : TOOL : STEERING STEM LOCK NUT
SOCKET, STEERING STEM SOCKET
● After temporarily assembling front fork, assemble
steering stem lock nut.
TORQUE : 7.0 kgf·m
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
HANDLE
HANDLEBAR
BAR
HANDLE
BAR
● Assemble the following parts.
- Front fork.
- Front wheel.
- Handle bar.
- Handle cover.
- Front cover.
● Check the followings after assembling
● By meeting the regular inspection schedule, check
fixing of all nuts, bolts which are fixed based on the
regular torque standards
● Check all pin, clips, hose clamps and cable stay.
MEMO
REAR WHEEL / REAR BRAKE / REAR CUSHION
13. REAR WHEEL / REAR BRAKE / REAR CUSHION
SERVICE INFORMATION···13-1
TROUBLE SHOOTING····13-2
REAR WHEEL········13-3
REAR BRAKE·······13-4
REAR CUSHION······13-6
SERVICE INFORMATION
GENERAL SAFETY
● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the
brake drum, and replace the brake shoe.
● Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to
clean brake assemblies. Use a brake cleaner, designed to mininize the hazard caused by airborne asbestos fibers.
SPECIFICATIONS
ITEM
STANDARD VALUE
SERVICE LIMIT
-
0.2mm
RADICAL
-
2.0mm
AXIAL
-
2.0mm
110.0mm
110.5mm
REAR BRAKE LINING THICKNESS
4.0mm
2.0mm (Worn limit marking)
REAR CUSHION SPRING FREE LENGTH
185mm
-
AXLE SHAFT RUN OUT
REAR WHEEL RIM WOBBLES
REAR BRAKE DRUM INNER DIAMETER
TORQUE VALUES
REAR CUSHION UPPER BOLT
REAR CUSHION LOWER BOLT
REAR CUSHION ROD LOCK NUT
REAR AXLE NUT
3.5~4.5kgf・m
3.5~4.5kgf・m
3.0~4.5kgf・m
11~13kgf・m
REAR WHEEL / REAR BRAKE / REAR CUSHION
TROUBLE SHOOTING
Rear wheel wobbling or vibration
● Deformed wheel, rim
● Bad tire
● Axle bad fastening
● Bad tire air pressure
● Improper wheel balancing
Soft rear suspension
● Bad spring
● Bad rear damper, oil leakage
Hard suspension
● Twisted damper rod
● Bad tire air pressure
Rear cushion noise
● Looseness of fastening and assmbled points
REAR WHEEL / REAR BRAKE / REAR CUSHION
REAR WHEEL
REMOVAL
● Erect the motorcycle on the main stand.
● Remove the muffler.
MUFFLER
MUFFLER
MUFFLER
MUFFLER
● Untie rear wheel flange lock nut 16mm.
LOCK
LOCK
NUT
LOCKNUT
NUT
REAR
WHEEL
REAR
REARWHEEL
WHEEL
REAR
● Remove the rear wheel.
INSPECTION
● Check the rim for wobbles by rotating the wheel.
SERVICE LIMIT: RADIAL 2.0 MM
AXIAL 2.0 MM
REAR WHEEL / REAR BRAKE / REAR CUSHION
LOCK
NUT
LOCK
LOCKNUT
NUT
LOCK
NUT
INSTALLATION
● Assemble rear wheel by flange lock nut 16mm.
TORQUE : 1.2 kgf·m
● Install in the reverse order of removal.
NOTE
•After installing the rear wheel, be sure to adjust the
brake lever free play.
REAR BRAKE
● Remove the rear wheel.
INSPECTION
● Measure the brake drum for inner diameter.
SERVICE LIMIT: 110.5MM
BRAKE
LINING
BRAKE
BRAKELINING
LINING
BRAKE
● Measure the brake lining for thickness.
SERVICE LIMIT: 2.0 MM
REAR WHEEL / REAR BRAKE / REAR CUSHION
REMOVAL
● Manually open the brake shoe and remove it.
● Remove the shoe spring from the brake shoe.
BRAKE SHOE
SHOE SPRING
SHOE SPRING
BRAKE SHOE
BRAKE CAM
BRAKE
BRAKE
CAM
BRAKECAM
CAM
● Loosen the rear brake arm fixing bolt.
● Remove the rear brake arm.
● Remove the rear brake cam..
BRAKE
ARM
BRAKE
BRAKEARM
ARM
BRAKE
SHOE
BRAKE
BRAKESHOE
SHOE
BRAKE
SHOE
INSTALLATION
●
●
●
●
●
Apply the small amount of grease to the brake cam.
Install the brake.
Install the rear brake arm.
Install the brake shoe, spring.
Install the brake shoe to the brake cam.
NOTE
•Align the punched marks of the brake arm and the
brake cam before assembly.
•Remove the excessive grease after assembling the
shoe.
● Install the rear wheel.
● Install the lock nut.
● Assemble muffler.
NOTE
•Check the brake for smooth operation.
REAR WHEEL / REAR BRAKE / REAR CUSHION
REAR
REAR
CUSHION
REARCUSHION
CUSHION
REAR CUSHION
REMOVAL
● Loosen the top and bottom rear cushion setting bolt.
REAR
CUSHION
BOLT
REAR
REARCUSHION
CUSHIONBOLT
BOLT
REAR
CUSHION
BOLT
NOTE
•Support the frame firmly prior to working.
REMOVAL
COMPRESSOR
COMPRESSORATTACHMENT
ATTACHMENT
COMPRESSOR
ATTACHMENT
● Install the compressor attachment as shown in the
picture.
● Install the cushion on the cushion compressor, and
compress the spring.
TOOL :
REAR CUSHION CONPRESSOR ATTACHMENT
REAR CUSHION COMPRESSOR
REAR
CUSHION
REAR
REARCUSHION
CUSHION
REAR
CUSHION
UPPER
METAL
UPPER
UPPERMETAL
METAL
UPPER
METAL
● Fix the upper metal, and loosen the lock nut.
● Remove the upper metal.
● Remove rear cushion.
REAR
REAR
DAMPER
COMP.
REARDAMPER
DAMPERCOMP.
COMP.
UPPER
UPPER
METAL
UPPERMETAL
METAL
SPRING
SPRING
SPRING
SPRING
REAR WHEEL / REAR BRAKE / REAR CUSHION
INSPECTION
● Measure the rear cushion spring free length.
● Check the damper rod for deflection or damage.
SERVICE LIMIT: 185 MM
INSTALLATION
● Install the spring, stop rubber.
● Apply thread locking agent to the lock nut, and
install the rear cushion compressor attachment on
damper rod.
● Fix the upper metal, and tighten the lock nut.
TORQUE: 3.5 kgf·m
TOOL: REAR CUSHION COMPRESSOR
REAR CUSHION COMPRESSOR ATTACHMENT
INSTALLATION
● Install the rear cushion.
● Tighten the cushion upper metal with securing bolts.
TORQUE: UPPER SIDE 4.0 kgf·m
LOWER SIDE 4.0 kgf·m
● Install in the reverse order of removal.
CHARGING SYSTEM
WINKER RELAY
MAGNETIC
SWITCH
FUEL TANK
CDI UNIT
FUEL COCKE
REGULATER
RECTIFIER
FUEL HOSE
SAI PIPE
SPEEDOMETER CABLE
C H A R G I N G
D I A G R A M
W
G
R
R
REGURATOR
RECTIFIER
BATTERY
(12V 3AH)
Y
Y
REGISTER
5W 6.7
G
FUSE(7A)
AC. GENERATOR
AUTO BY
STARTER
REAR BRAKE CABLE
SIDE STAND
Y
Y
Y
DIMMER S/W
L
W
HEADLIGHT
(12V 35/35W)
SPEEDOMETER LICENSE PLATE
LIGHT
LIGHTING
(12V 5W)
(12V 3Wx2EA)
TAIL LIGHT
(12V 5W)
14. CHARGING SYSTEM
SERVICE INFORMATION·····14-1
TROUBLE SHOOTING· · · · · 14-2
B AT T E RY · · · · · · · · ·14-3
CHARGING SYSTEM INSPECTION· 14-4
AC GENERATOR INSPECTION·14-5
REGULATOR RECTIFIER INSPECTION·14-5
SERVICE INFORMATION
WARNING
·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
·Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss
of eye sight. If the contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a
doctor.
·If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the
skin, make sure to change clothing that has come into contact with battery acid and wash the battery acid from the
clothes.
CAUTION
·This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take
special care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
·When charging the battery, remove the battery from the frame and do not open stopper.
·There is the possibility of damaging the regulator/rectifier, etc. if the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
● If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged
state, the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note
here that the battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced,
leadign to a loss in battery strengh.
● It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited
and if a state develops where voltage is not created between the temrinals, the regulator will not operate and
excessive voltage will develops where voltage is not created between the terminalsd, the regulator will not operate
and excessive voltage will develop in the battery and normal cell electrolytes will decrease.
● If the vehicle is not used for a long period, make sure to change the battery every three months. If not so, the battery
ability to store electricity is reduced.
SPECIFICATIONS
ITEM
BATTERY
AC. GENERATOR
Regulator Rectifier
TOOL
DIGITAL TESTER
PVA MULTI-TESTER
RPM TESTER
BATTERY TESTER
Capacity
Terminal to terminal voltage
Charging coil resistance value(20°
C)
Rpm at charging start
Regulator voltage
STANDARD VALUE
12V 6Ah
12.6~13.0V
0.5~1.5Ω
2,000rpm
14.5V /5.000rpm
CHARGING SYSTEM
TROUBLE SHOOTING
No power(key turned on)
Low power(engine running)
● Dead battery
- Low fluid level
- Complete discharged
● Disconnected battery cable
● Main fuse cut
● Faulty ignition switch
● Battery undercharged
● Battery is failing
● Charging system failure
Intermittent power
● Loose battery connection
● Loose charging system connection
● Loose starting systme connection
● Loose connection or short circuit in ignition system
● Loose connection or short circuit in lighting system
Low power(key turned on)
● Battery undercharged
- Low fluid level
- Battery discharged
● Charging system failure
● Loose battery connection
Charging system failure
● Loose, broken or short circuit wire or connection
● Faulty regulator rectifier
● Faulty A.C. Generator
CHARGING SYSTEM
Measure battery current leakage.
ABNORMAL
NORMAL
Check charge level.
UNDER 14V
Check the voltage of the register/rectifier
battery line and ground line.
Inspect the body of the register/rectifier.
NORMAL
OVER 15V
14~15V
ABNORMAL
ABNORMAL
·Short-circuited harness.
·Damaged main switch.
·Register/rectifier is switch.
Faulty battery.
Wire harness is short-circuited.
Coupeler is connected incorrectly.
NORMAL
Check the changing coil with the register
/rectifier coupler charging coil.
ABNORMAL
Check the A.C generator charging coil.
NORMAL
A.C generator coupler connected incorrectly.
ABNORMAL
Damaged charging coil.
CORRECT
Inspect the body of the register/rectifier.
ABNORMAL
Damaged register/rectifier.
NORMAL
Faulty battery.
CHARGING SYSTEM
BATTERY
BATTERY
BATTERY
BATTERY
BATTERY
SCREW
SCREW
SCREW
SCREW
● Loosen the screws and remove the battery cover.
● Disconnect the negative ⊖ battery cable first, and
then disconnect the positive ⊕ cable.
● Remove the battery.
● Install in the reverse order of removal.
⊕
⊕
⊖
⊖
BATTERYCOVER
COVER
BATTERY
BATTERY
COVER
BATTERY(OPEN-CIRCUIT VOLTAGE)
INSPECTION
● Remove the battery cover.
● Measure the voltage between the battery terminals.
FULL CHARGED : 12.6~13.0 V
INSUFFICIENTLY CHARGED : UNDER 12.3 V
NOTE
•Use a voltmeter that will accurately indicate 0.1V
difference.
•When measuring the battery voltage after charging,
leave it for at least 30 minutes, or the accurate
results cannot be obtained because the battery
voltage fluctuates just after charging.
BATTERY CHARGING
● Remove the battery.
● Connect the charging ⊕ cable and battery ⊕
terminal.
● Connect the charging ⊖ cable and battery ⊖
terminal.
⊕
⊕
⊖
⊖
NOTE
⊕
⊕
⊖
⊖
AMMETER
•Be sure to the battery charging is not allow to
exceed the specified charging time and current.
•To avoid the rapid charging could be possible to
reduce the battery life and cause of damage.
CHARGING SYSTEM
INSPECTION
LEAK TEST
BATTERY ⊖ TERMINAL
● Turn off the ignition switch, and disconnect the
ground ⊖ cable from the battery.
● Connect an ampere meter between negative ⊖
terminal and ground cable.
● With the ignition switch off, measure the leakage
current.
LEAK CURRENT : 0.1A(BELOW)
EARTH CABLE
CHARGING SYSTEM
CAUTION
•Current flow larger than the range selected may
blow out the fuse in the tester.
•While measuring current, do not turn the ignition
on. A sudden surge of current may blow out the
fuse in the tester.
BATTERY⊖
TERMINAL
BATTERY⊖TERMINAL
TERMINAL
BATTERY⊖
BATTERY⊖
TERMINAL
CHARGING VOLTAGE INSPECTION
CAUTION
VOLT METER
AM METER
MAIN FUSE
TERMINAL
MAIN FUSE
•Be sure that the battery is fully charged before
performing this test. The amount of current flow
may change abruptly if not sufficiently charged.
Use a battery whose voltage between its terminals
is 12.6~13.0V.
•When engine is started using the starter motor, a
large amount of current may flow from the battery
temporarily. Use the kick starter to start the engine.
•If the probes are connected in reverse order, the
registered current flow direction when charging
and discharging the battery will be reversed as
well.
● Connect a tester between the battery terminals.
● Remove the main fuse and connect an ampere meter
between the terminals.
● Connect a RPM tester to the high-tension cord.
● Gradually increase the engine speed and measure the
charging voltage and charging current.
CHARGING CURRENT: 2.0~2.5A/3,000RPM
±0.5V/5,000 RPM
CONTROL VOLTAGE: 14.5±
CAUTION
•Take precaution not to control the tester or wiring
when flowing the current.
•It can cause the damage for the other parts by
overflowing the current.
● Install in the reverse order of removal.
A.C
GENERATOR
COUPLER
A.C
A.CGENERATOR
GENERATORCOUPLER
COUPLER
A.C
GENERATOR
COUPLER
A.C GENERATOR
INSPECTION
● Disconnect the coupler of the A.C generator cord.
CHARGING SYSTEM
● Measure the resistance between the yellow and
white lead.
● If the resistance values are much larger than the
specified value, or if there is continuity between
terminals and earth terminals, replace the stator with
a new one.
RESISTANCE VALUE: 0.5~1.5Ω (20°C)
REGULATOR RECTIFIER
INSPECTION
● Remove the regulator rectifier coupler.
REGURATOR
RECTIFIER
REGURATOR
REGURATORRECTIFIER
RECTIFIER
REGURATOR
CDI
CDI
CDI
MAGNETIC
MAGNETIC
SWITCH
MAGNETICSWITCH
SWITCH
● Measure the resistance between each terminal.
Unit : MΩ(20°C)
R
R
Y
W
G
2,751
Y
W
4.95
G
∞
13.94
1,248
1,248
● If the resistance between each terminal are
bbnormal, replce it.
IGNITION SYSTEM
WINKER RELAY
FUEL TANK
HORN
CDI UNIT
MAGNETIC SWITCH
IGNITION COIL
REGULATOR RECTIFIER
ACG COUPLER
FRONT
BRAKE
CALIPER
SAI PIPE
MUFFLER
I G N I T I O N
S Y S T E M
SIDE STAND S/W
KILL S/W
G
B/W
B/R
B/Y
G
L/Y
IGNITION
COIL
G
SPARK
PLUG
PULSE
GENERATOR
AC. GENERATOR
G
CDI UNIT
G
15. IGNITION SYSTEM
SERVICE INFORMATION····15-1
TROUBLE SHOOTING····15-2
CDI UNIT INSPECTION····15-3
PULSE GENERATOR INSPECTION· 15-3
IGNITION COIL INSPECTION·· 15-4
SERVICE INFORMATION
GENERAL SAFETY
● Follow the steps described in the troubleshooting flow chart when servicing the igntion system
● The CDI unit may be damaged, if dropped
● If the connector is disconnected when the current is flowing, the execessive voltage may damage the unit
● Always turn off the ignition switch before servicing
● The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition
timing.
● Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
● Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
● A faulty iginition system is often related to poorly connected connectors. Check those connections before proceeding
● This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are
also included, it may be difficult to make a correct determination
● Conduct inspection on the main switch by referring to the wiring system continuity chart. (⇨19-1 )
GENERAL SAFETY
ITEM
STANDARD VALUE
0.1~0.5Ω
PRIMARY COIL
IGNITION COIL
RESISTANCE
VALUE 20℃
PULSE GENERATOR COIL RESISTANCE VALUE 20℃
SPARK PLUG
SPARK PLUG GAP
TOOL
MULTI TESTER
PVA MULTI-TESTER
WITH PLUG CAP
6.5~9.8㏀
WITHOUT PLUG CAP
2.7~3.5㏀
SECONDARY COIL
50~200Ω
CR6HSA
0.6~0.7mm
IGNITION SYSTEM
TROUBLE SHOOTING
Spark plug does not emit sparks.
UNUSUAL CONDITION
POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER)
IGNITION COIL PRIMARY VOLTAGE
EXCITE COIL
PULSE GENERATOR
Low peak voltage.
1. Cranking speed is low.
- Battery is low or kick power is weak.
2. Poorly connected connectors or an open circuit in ignition
system
3. Faulty ignition coil
4. Faulty CDI unit(in case when above No. 1~4 are normal)
No peak voltage.
1. Incorrect peak voltage adaptor connections.
2. Faulty ignition switch.
3. Loose or poorly connected CDI unit connector.
4. Open circuit or poor connection in ground cord of the CDI unit.
5. Faulty CDI unit(in case when above No.1~5 are normal)
Peak voltage is normal, nut no spark
jump at plug.
1. Faulty spark plug or leaking ignition coil secondary current
ampere
2. Faulty ignition coil.
Low peak voltage.
1. Cranking speed is too slow
- Battery is undercharged(or operating force of the kick starter
is weak)
No peak voltage.
1. Cranking speed is too slow
- Battery is undercharged(or operating force of the kick starter
is weak)
IGNITION SYSTEM
CDI
CDIUNIT
UNIT
CDI
UNIT
CDI UNIT INSPECTION
CDI IGNITION CIRCUIT INSPECTION
NOTE
•Follow the step described in the troubleshooting
flow chart when servicing the ignition system.
● Remove the front cover.
● Disconnect the coupler from the CDI unit, and
check the ignition system circuits from the wiring
coupler side.
INSPECTION ITEMS
ITEM
INSPECTION
JUDGEMENT
Check that there is battery voltage
EXCITE INPUT between main switch
VOLTAGE
wire(black/red)and ground wire when PVA 225 ±25V
the ignition is ON
Check that the resistance of coil
PULSE
white/red and green)is
GERNERATOR (between
within specified range
OVER 1.5V
Check that the resistance of coil
IGNITION
black/ yellow and green) is
(PRIMARY)COIL (between
within the specified range.(0.1~0.5 Ω)
225 ±25V
GROUND
WIRE
Check continuity between ground
and frame
Continuoty
● If there is no CDI output voltage, because CDI is
faulty, replace it.
TOOLS: MULTI- TESTER
NOTE
•Read tester manual carefully prior to using the
tester.
● Install in the reverse order of removal.
PULSE GENERATOR
INSPECTION
RESISTANCE MEASUREMENT
PULSE
PULSE
LINE
PULSELINE
LINE
● Release the seat lock with the main key.
● Remove the luggage box(3-2).
● Disconnect the A.C generator 3P coupler and
black/red and white/red wire connector.
● Measure the resistance between the blue and yellow
and engine ground.
Ω (20°C)
STANDARD VALUE: 50~200Ω
PVC MEASUREMENT
● Disconnect the A.C generator blue/yellow wire
connector.
● Connect the peak voltage adaptor probes to the pulse
generator wire terminal of the wire harness side
connector and ground.
● Crank the engine with the lick starter or starter motor
and measure the peak voltage of pulse generator.
PEAK VOLTAGE: OVER 1.5 V
TOOL: PVA MULTI TESTER
● Install in the reverse order of removal.
IGNITION SYSTEM
IGNITION COIL INSPECTION
● Remove the luggage box( 3-2)
● Remove the primary wire.
NOTE
•Since the resistance value of primary coil is
inherently very small, it is difficult to distinguish it
from a shorted wire.
● Measure the peak voltage of the ignition coil primary
side first.
● If the resistance value is withtin the specified range
the coil is good.
● It resistance ∞ (infinite), replace the coil with a new
one
STANDARD VALUE: 0.1~0.5Ω
● Remove spark plug cap from plug.
● On condition that there is plug cap, measure the
resistance between plug cap and the primary
terminal.
● If the resistance shows ∞ (open wire), pull out plug
cap and measure the secondary resistance.
STANDARD VALUE : 6.5~9.8 kΩ
● Measure resistance between the primary coil terminal
and high-tension cord.
● If the resistance is ∞ (open wire), replace the coil
with a new one.
STANDARD VALUE : 2.7~3.5 kΩ
SPARK
PLUG
CAP
SPARK
SPARKPLUG
PLUGCAP
CAP
SPARK
PLUG
CAP
● Check the primpary voltage of ignition coil.
● On condition that iginition cord is connected,
connect the peak voltage adaptor(+) cord to green
terminal, and (-) cord to black terminal. Then start
vehicle and check.
STANDARD VALUE : 100~250V
REPLACEMENT
IGNITION
COIL
IGNITION
IGNITIONCOIL
COIL
IGNITION
COIL
● Remove the high-tension cord from the plug,
remove the plug cap.
● Remove the wire from the ignition coil.
● Remove the primary wire from the ignition coil.
● Loosen the ignition coil fixing bolt securing the
frame, remove the ignition coil.
● Install in the reverse order of removal.
MEMO
STARTING SYSTEM
WINKER RELAY
MAGNETIC
SWITCH
FUEL TANK
CDI UNIT
FUEL COCK
REGULATER
RECTIFIER
FUEL HOSE
SAI PIPE
SPEEDOMETER CABLE
S T A R T E R
SIDE STAND
S Y S T E M
R/W
REAR BRAKE CABLE
C I R C U I T
R
STARTER
MOTOR
FUSE
R
MAIN S/W
M
REAR STOP S/W
STARTER S/W
Y/R
B
G/Y
STARTER RELAY
G
G
FRONT STOP S/W
BATTERY
(12V3AH)
G
16. STARTING SYSTEM
SERVICE INFORMATION···· 16-1
TROUBLE SHOOTING ···· 16-2
STARTER MOTOR ······ 16-3
STARTER MAGNETIC SWITCH·16-6
SERVICE INFORMATION
GENERAL SAFETY
● The starter motor can be maintained without removing the engine from the vehicle.
● Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing
serious injury.
● A weak battery mau be unable to turn the starter motor quickly enough, or, supply adequete ignition current
● The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over.
● The engine may not be turned over if the stop switch is faulty.
SPECIFICATION
ITEM
STARTER MOTOR BRUSH LENGTH
TOOL
MULTI-TESTER
VERNIER CALIPER
STANDARD VALUE
11.0~11.05
SERVICE LIMIT
6.5mm
STARTING SYSTEM
TROUBLE SHOOTING
Starter motor does not rotate (No response from starter motor).
● Check to see if the fuse is burned out.
● Check to turn on the lamp of stop switch.
With the main switch turned to ON, squeeze
the brake lever. In this state push the starter
button and check if a clicking noise then an
operating noise is emitted from the starter
relay.
CLICK
Remove the starter moter " " wire, connect
in to the battery " " terminal and check to see
if the starter motor rotates (because a large
amount of current flows in this test, do not
use thin wire).
ROTATE
DOES NOT ROTATE
NO CLICK
● Incorrect starter
motor connection
Remove the coupler from the starter replay
and inspect the relay coil ground wire.
NO CONTINUITY
● Incorrect starter motor
● Faulty starter switch.
● Incorrect connection with the switch
terminals or harness disconnection.
CONTINUITY
Check the starter relay voltage in the starter
relay coupler with the coupler connected.
NO VOLTAGE
● Damaged main or starter switch.
● Incorrect connection with coupler connector.
● Disconnection in starter switch wire.
● Faulty brake stop switch.
NORMAL
● Loose or poor contact at starter relay switch
connector.
VOLTAGE MEASURED
Check the operation of the starter relay.
ABNORMAL
Starter motor rotates but crank shaft does't
● Incorrect starting clutch.
● Incorrect starter gear.
● Starting clutch slip.
Starter motor operates in free-wheel
● Internal fault of starter motor.
● Driven gear slips.
● Faulty starter relay switch.
Weak rotational power in starter motor
● Battery is insufficiently charged.
● Incorrect connection of battery terminal cord.
● Damaged starter motor.
● Ground wire is connected incorrectly
● Brush is damaged or worn.
Starter motor and crank shaft rotate but dose
not turn engine over.
● Incorrect starting system.
● Faulty engine.
STARTING SYSTEM
FLANGE
FLANGE
FLANGE
FLANGE
BOLT
BOLT
BOLT
BOLT
STARTER
STARTER
STARTER
MOTOR
MOTOR
MOTOR
STARTER MOTOR
REMOVAL
● Release the seat lock with the main key.
● Remove the luggage box.
● Remove the starter motor cable from the stater
magnetic switch.
● Loosen the 2 flange bolts securing the engine case,
remove the battery earth cable and starter motor.
● Remove the starter motor.
● Install in the reverse order of removal.
SCREW
SCREW
BOLT
SCREWBOLT
BOLT
CAUTION
•Always turn the ignition switch OFF before
servicing the starter motor. The motor could
suddenly start, causing serious injury.
•Accurately tighten the battery earth cable.
DISASSEMBLY
● Remove the starter motor cable.
● Before diassembling the starter motor mark the
position of the case and cover so the starter can be
assembled correctly later.
● Loosen the starter motor case bolts and remove the
motor cover.
INSPECTION
● Check whether worn and damaged on stater motor.
● Check continuity between ⊕ brush and the terminal
of cable cord.
● If continuity can be done, it shows normal.
CORD
CORD
CORD
CORD
TERMINAL
TERMINAL
TERMINAL
BRUSH
BRUSH
BRUSH
● Check the continuity of ⊕ and ⊖ of brush holder.
● If continuity can not be done, it shows normal.
⊖
⊖
⊖
⊖
⊕
⊕
⊕
⊕
STARTING SYSTEM
● the brush spring, and then remove the brush.
● Measure the brush length. Replace the brush if it is
worn beyond the service limit.
BRUSH
BRUSH
BRUSH
BRUSH
SERVICE LIMIT: 6.5 MM
NOTE
•If replacement, replace with a brush holder set.
● Check the commutator for
- Damage or abnormal wear. → Replace with a
new one.
- Discoloration of the commuttor bar. → Replace
with a ne one.
- Metalic debris between commutator bars →
Clean it off
COMMUTATOR
COMMUTATOR
COMMUTATOR
● For continuity between pairs of commutator bars.
- Make a continuity check between individual
commutator bars and the armature shaft.
- There should be no continuity.
● Check the needle bearing and oil seal.
- Do not rotate smoothly. → Replace with a new
one.
- Damage oil seal. → Replace with a new one.
OIL
SEAL
OIL
OILSEAL
SEAL
STARTING SYSTEM
STARTER MOTOR ASSEMBLY
● Install the brush and brush spring to the brush hold
set.
● Apply grease to both ends of the armature shaft, and
install the 2 washers.
FRONT
BRACKET
FRONT
FRONTBRACKET
BRACKET
● Push the brush, and insert the armature into the rear
bracket groove.
CAUTION
•The sliding surfaces of the brushes can be
damaged if they are not installed properly.
•When inserting the amature into the case, hold the
amature tightly to keep the magnet from pulling
the amature against the case.
FITTINGAT
ATASSEMBLY
ASSEMBLY
FITTING
FITTING
AT
ASSEMBLY
FRONT
FRONT
BRACKET
FRONTBRACKET
BRACKET
● Assemble rear bracket
● Assemble front bracket aligning york.
REAR
BRACKET
REAR
REARBRACKET
BRACKET
REAR
● Tighten the 2 set bolts.
NOTE
•When installing the cover, take care to prevent
damaging the oil seal lip with the shaft.
•Overtigntening the starter motor cable terminal
nuts may cause the inside the starter motor,
resulting in serious damage to the inner connectors.
STARTING SYSTEM
STARTER
STARTER MAGNETIC
MAGNETIC SWITCH
SWITCH
STARTER
MAGNETIC
SWITCH
STARTER MAGNETIC SWITCH
REMOVAL
● Remove the luggage box.
● Remove the battery (+) cable from the starter
magnetic switch terminal.
● Remove the starter motor cable from the starter
magnetic switch terminal.
● Disconnect the coupler connected to wire harness,
and starter magnetic switch.
INSPECTION
● Check if the starter magnetic switch “click” when it
is turened ON.
- Click but the engine does not start.
→ Poorly connected battery terminal and motor
terminal of the switch. (Check the starter
magnetic switch)
- No click → No starter magnetic switch input
voltage. (Faulty relay ground line and starter
magnetic switch)
STARTER
VOLTAGE
MAGNETIC
SWITCH
● Measure the voltage between the yellow / red wire
(+) and ground at the starter magnetic switch
connector.
● If battery voltage appears only when the starter
switch is pressed, it is normal.
● Check the resistance between terminals of starter
magnetic switch.
OPERATION CHECK
● Disconnect the magnetic switch wire connector.
● Apply battery voltage between trminals, when the
yellow / Red wire is connected to the positive (+)
battery terminal and the yellow / Green wire to the
negative (-) battery terminal. If there is continuity
between battery and motor terminal, it is normal.
● Install in the reverse order of removal.
17. LIGHTS// SWITCHES / HORN
SERVICE INFORMATION·····17-1
TROUBLE SHOOTING······17-1
HEADLIGHT BULB REPLACEMENT·17-2
FRONT WINKER·······17-2
REAR COMBINATION LIGHT·· 17-3
REAR WINKER········17-3
SPEEDOMETER ········17-3
MAIN SWITCH········17-4
HANDLE BAR SWITCH······17-4
HORN············17-5
FRONT/REAR STOP SWITCH···17-5
FUEL UNIT··········17-6
SERVICE INFORMATION
GENERAL SAFETY
● Connect the same color wires together. Connect couplers carrying the same color and the same number of pins
together.
● All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert
these tabs all the way until locked when assembling
● Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester
or and ohmmeter to the coupler terminal or connectors.
● The continuity test is conducted to check if electric power is connected between 2 terminals. If these is coil resistance
within circuits, or to check the large resistance resulting from the connector corrosion, an ohmmeter is required to
check the circuit resistance value.
TROUBLE SHOOTING
Light not turned on when the main switch is ON
Fuel meter indicator malfunctioning
● Faulty light bulb
● Faulty switch
● Faulty or disconnected wiring
● Fuse cut
● Battery discharged
● Coupler separated
● Harness disconnected
● Float operation malfunction
● Fuel unit damaged
Dim headlight
● Coupler loose
● Fuel unit damaged
● Meter damaged
● Battery discharged
● Wiring and switch resistance high
Headlight Hi-low beam can not be charged
● Faulty light bulb
● Faulty dimmer switch.
Fuel meter needle unstable
LIGHTS// SWITCHES / HORN
HEADLIGHT BULB
REMOVAL
●
●
●
●
●
HEADLIGHT
HEADLIGHT
BULB
HEADLIGHTBULB
BULB
Remove the front under cover.
Disconnect the headlight wiring.
Loosen the 4 setting bolts securing the front cover.
Remove the headlight assembly.
Install in the reverse order of removal.
BULB REPLACEMENT
● Pull off the headlight socket..
● Replace with a new bulb.
● Install in the reverse order of removal.
SPRING
SPRING
SPRING
SPRING
HEADLIGHT
BULB
HEADLIGHT
HEADLIGHTBULB
BULB
CAUTION
POSITION
POSITION LAMP
LAMP
POSITION
LAMP
•Headlight bulbs become very hot while the
headlight is ON, and remain hot for a while after
they are turned OFF. Be sure to turn the ignition
switch OFF and let the bulb cool down before
replacement.
•If you touch the bulb with your bare hands, clean it
with a cloth moistened with denatured alcohol to
prevent early bulb failrure.
•Avoid touching Halogen headlight bulb. Finger
prints can create hot spots that cause a bulb to
breake.
•Be sure to install the dust cover after replacing the
bulb.
FRONT WINKER
FRONT
WINKER
SOCKET
FRONT
FRONTWINKER
WINKERSOCKET
SOCKET
WINKER
WINKER
BULB
WINKERBULB
BULB
FRONT
FRONT
UNDER
COVER
FRONTUNDER
UNDERCOVER
COVER
BULB REPLACEMENT
● Remove the front handle cover.
● Remove the bulb from the socket and replace with a
new bulb.
● Install in the reverse order of removal.
LIGHTS// SWITCHES / HORN
REAR COMBINATION LIGHT
TAIL
TAIL
LIGHT
TAILLIGHT
LIGHT
REAR
WINKER
REAR
REARWINKER
WINKER
REAR
BULB REPLACEMENT
● Loosen the 2 taillight lens tapping screws of the rear
combination light.
● Pull off the tailight lens and remove it from the
groove.
● Remove the bulb from the socket and replace with a
new bulb.
● Install in the reverse order of removal.
TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
CAUTION
TAIL
TAIL
LIGHT
BULB
TAILLIGHT
LIGHTBULB
BULB
REAR
WINKER
BULB
REAR
REARWINKER
WINKERBULB
BULB
REAR
WINKER
BULB
•Do not apply excessive force when removing the
lens.
•Check the installation of the tail light and lens seal
accurately.
REAR WINKER
BULB REPLACEMENT
● Remove the tailihgt lens.
● Remove the winker lens.
● Remove the bulb from the socket and replace with a
new bulb.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
REMOVAL
●
●
●
●
Remove the front handle cover.
Remove the wiring coupler and speedometer cable.
Remove the winker relay, horn, wiring coupler.
Remove the speedometer wiring coupler of the
frame from the clamp and then remove the coupler
connected with wire harness.
LIGHTS// SWITCHES / HORN
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
● Disconnect the RH./LH.switch wire and remove the
speedometer and the 3 tapping screws securing the
rear handle cover.
● Remove the speedometer.
● Install in the reverse order of removal.
REAR
HANDLE
COVER
REAR
REARHANDLE
HANDLECOVER
COVER
REAR
HANDLE
COVER
TAPPING
TAPPING
SCREW
TAPPINGSCREW
SCREW
MAIN SWITCH
KEY
SET
KEY
KEYSET
SET
KEY
● Remove the front cover.
● Remove the main switch coupler.
● Check for continuity betwwen the wire terminal
TERMINAL
IG
E
BA1
BA2
GREEN
RED
BLACK
ON
OFF
LOCK
MAIN
MAIN SWITCH
SWITCH
MAIN
SWITCH
COLOR BLACK/WHITE
HANDLE BAR SWITCH
● Remove the front handle cover.
● Remove the coupler wiring.
● Check for continuity between trminal.
MAIN
MAIN
SWITCH
TERMINAL
MAINSWITCH
SWITCHTERMINAL
TERMINAL
WINKER SWITCH
DIMMER
SWITCH
DIMMER
DIMMERSWITCH
SWITCH
DIMMER
SWITCH
HORN
SWITCH
HORN
HORNSWITCH
SWITCH
HORN
WINKER
WINKER
SWITCH
WINKERSWITCH
SWITCH
R
N
L
COLOR
W
R
L
GRAY
SKY BLUE
ORANGE
LIGHTS// SWITCHES / HORN
DIMMER SWITCH
HI
(N)
LO
COLOR
BAT3
HI
LO
DG/Y
BLUE
PURPLE
HANDLE
HANDLE
SWITCH
COUPLER
HANDLESWITCH
SWITCHCOUPLER
COUPLER
HAZARD SWITCH
HAZARD
HAZARD
SWITCH
HAZARD
HAZARDSWITCH
SWITCH
HAZARD
SWITCH
OFF
HAZARD
COLOR
W
R
L
GRAY
SKY BLUE
ORANGE
STARTER SWITCH
FREE
PUSH
COLOR
STARTER
SWITCH
STARTER
STARTER SWITCH
SWITCH
ST
E
YELLOW/RED
GREEN/YELLOW
HORN
HORN
HORN
HORN
● Remove the wire connector from the horn.
● Connect the horn terminal with 12V battery. Normal
if it sounds
HORN SWITCH
BATTERY
BATTERY
BATTERY
PULL
PULL
THE
LEVER
PULLTHE
THELEVER
LEVER
FRONT
FRONT
STOP
SWITCH
FRONTSTOP
STOPSWITCH
SWITCH
FREE
PUSH
COLOR
HO
BAT2
LIGHT GREEN
BLACK
FRONT / REAR STOP
SWITCH
INSPECTION
● Remove the front handle cover.
● Check for continuity between the black and green /
yellow wire terminals inside the speedometer
assembly.
- When the brake lever is pulled - CONTINUITY
LIGHTS// SWITCHES / HORN
- When the brake lever is released - NO CONTINUITY
● Install in the reverse order of removal.
RELEASE
THE
LEVER
RELEASE
RELEASE THE
THE LEVER
LEVER
FUEL
FUEL
UNIT
FUELUNIT
UNIT
FUEL
FUEL
UNIT
RETAINER
FUELUNIT
UNITRETAINER
RETAINER
FUEL UNIT
● Remove the floor panel.
● Remove fuel unit coupler.
● Turn fuel unit retainer and remove.
● Remove fuel unit.
● Be careful not to damage the wire.
● Measure the resistance between the fuel unit upper
and lower.
FUEL
FUEL
TANK
FUELTANK
TANK
FUEL
FUEL
UNIT
FUELUNIT
UNIT
MEASURE THE RESISTANCE BETWEEN
THE TERMINAL
WIRE TERMINAL
UPPER
UPPER
LINE
UPPERLINE
LINE
GREEN & Y/W
GREEN & B/W
B/W & B/W
✽ Resistance value =
LOWER
LOWER LINE
LINE
LOWER
LINE
FLOAT UPPER LINE
30~40 Ω
500~600 Ω
550~650 Ω
Resistance between Y/W & Green
Resistance between L/W & Green
18. TROUBLESHOOTING
ENGINE WON’T START OR HARD TO START ··········· 18-1
ENGINE STALLS, HARD TO START, ROUGH IDLING··········18-2
POOR PERFORMANCE AT LOW SPEED AND IDLING ········ 18-3
POOR OPERATION ·····················18-4
ENGINE WON’T START OR HARD TO START
CAUSE OF TROUBLE
Open the drain screw, and check fuel
flow to the carburetor.
Fuel not supplied
to the carburetor.
·No fuel to fuel tank.
·Disconnected or damaged fuel pump
negative pressure tube.
·Clogged fuel tube.
·Clogged float valve.
·Clogged fuel strainer.
·Clogged fuel tank cap.
·Fuel pump malfunction.
Weak or no spark.
·Faulty spark plug.
·Contaminated spark plug.
·Faulty A.C. generator.
·Disconnected or shorted high
tension cord.
·Disconnected or shorted ignition coil
wire.
·faulty ignition switch.
·Faulty CDI unit.
Low or no cylinder
compression.
·Seized piston ring.
·Faulty valve clearance adjustment.
·Worn cylinder or piston ring.
·Leaking cylinder gasket.
·Warped or cracked cylinder head or
cylinder.
Engine starts but
stops immediately.
·Carbon deposited on spark plug.
·Idle speed misadjusted.
·Faulty ignition timing.
·Clogged air cleaner.
·Lean fuel mixture.
Spark plug wet.
·Flooded carburetor.
·Throttle valve excessively opened.
·Contaminated or clogged air cleaner.
·Rich fuel mixture.
Engine won’t start.
·Recheck the engine.
Fuel is supplied
Check the spark plug.
Good spark
Measure the cylinder compression.
Compression normal
Start the engine in the following
procedure.
Engine doesn’t start.
Remove the spark plug, and recheck it.
Dry spark plug
Restart the engine in the following
procedure.
Engine starts
Completion
ENGINE STALLS, HARD TO START, ROUGH IDLING
CAUSE OF TROUBLE
Open the drain screw, and check fuel
flow to the carburetor.
Fuel not supplied to
the carburetor.
·No fuel to fuel tank.
·Clogged fuel tube.
·Clogged float valve.
·Clogged fuel tank cap.
·Clogged fuel strainer.
·Disconnected or damaged fuel pump
negative pressure tube.
Contaminated or
discolored.
·Contaminated spark plug.
·Using spark plug with an incorrect
heat range.
Weak or intermittent
sparks.
·Faulty or contaminated spark plug.
·Faulty A.C generator.
·Faulty ignition coil.
·Disconnected or short high tension cord.
·Faulty ignition switch.
·Faulty pluse generator.
·Faulty CDI unit.
Low or no cylinder
compression.
·Worn cylinder or piston ring.
·Leaking cylinder gasket.
·Faulty valve clearance adjustment.
Incorrect
·Faulty A.C generator.
·Faulty CDI unit.
Misadjustment
·Lean fuel mixture.
·Rich fuel mixture.
Leak
·Faulty carburetor insulator tightening.
·Faulty carburetor insulator O-ring.
·Faulty insulator band tightening.
·Faulty insulator.
No continuity
·Lean fuel mixture.
·Rich fuel mixture.
Starter valve won’t
operate.
·Slow circuit clogged.
Fuel is supplied
Check the spark plug.
Not contaminated or not discolored
Insert the plug into cap, and check
sparks.
Sparks normal
Measure the cylinder compression.
(Using a compression gauge.)
Compression normal
Check the ignition timing.
Correct
Check the carburetor pilot screw
Adjustment normal
Check the intake air leak in the
connection part of carburetor insulator.
Not leak
Check for continuity between auto
bystarter terminals.
Continuity
Remove the auto bystarter from the
carburetor, check the starter valve.
Starter valve operates normally.
POOR PERFORMANCE AT LOW SPEED AND IDLING
CAUSE OF TROUBLE
Smoothly accelerate engine.
Engine speed does not
increase sufficiently.
·Clogged air cleaner.
·Insufficient fuel supply.
·Clogged fuel tank cap air hole
·Clogged muffler.
Abnormal
·Faulty CDI unit.
·Faulty A.C generator.
Low
·Worn cylinder or piston ring.
·Damaged cylinder head gasket.
·Cracked cylinder or cylinder head.
Clogged
·Poor carburetor maintenance.
Contaminated or
discolored.
·Poor plug maintenance
·Using spark plug with an incorrect
heat range.
·Lean mixture.
Overheated
·Worn cylinder or piston
·Lean fuel mixture
·Poor quality fuel being used.
·Excessive carbon built-up on
combustion chamber.
·Incorrect ignition timing.
·Damaged cooling fan.
Engine knocking
·Excessive carbon built-up on
combustion chamber.
·Poor quality fuel being used.
·Lean fuel mixture.
Engine speed increases.
Check the ignition timing.
Normal
Strongly kick the starter pedal, and the
cylinder compression.
Normal
Check the carburetor for clogging.
Not clogged
Check the spark plug.
Not contaminated or not discolored.
Check for engine overheating.
Not overheated.
Accelerate suddenly or run at
Engine does not knock.
Accelerate
Completion
POOR OPERATION
CLUTCH DRIVE / DRIVEN PULLEY
CAUSE OF TROUBLE
Engine starts but vehicle won’t move.
·Worn or damaged drive belt.
·Damaged ramp plate.
·Faulty weight roller.
·Faulty movable drive face.
·Damaged driven pulley weight shoe
spring.
·Faulty transmission.
·Seized transmission.
Engine stalls or vehicle creeps.
·Broken driven pulley weight spring.
·Seized clutch outer and weight.
Poor performance at start or lack of
power.
·Worn or slipped drive belt.
·Worn weight roller.
·Seized driven face bearing.
·Weak driven spring.
·Faulty movable driven face.
Poor performance at high speed or
lack of power.
·Worn or slipped drive belt.
·Worn weight roller.
·Worn driven pulley bearing.
Abnormal noise or odor.
·Oil or grease spilled on the drive belt
and inside pulley.
·Worn drive belt.
·Damaged driven face weight spring.
·Worn or seized driven pulley bearing.
HANDLE / WHEEL
Hard steering.
·Steering top thread too tight.
·Insufficient tire pressure.
·Damaged steering bearing.
·Damaged ball race.
·Faulty tire.
Steering wobbling.
·Insufficient tire pressure.
·Worn or faulty tire.
·Faulty wheel valance.
·Bent rim.
·Worn or damaged wheel bearing.
·Loose axle shaft.
Steers to one side or does not track
straight.
·Front and rear wheels not aligned.
·Bent front cushion.
·Bent rear cushion.
·Faulty engine hanger.
·Poor steering operation.
·Faulty wheel alignment.
Wheel turns hard.
·Faulty wheel bearing.
·Bent axle shaft.
·Bent brake disk.
·Faulty caliper piston.
POOR FRONT/REAR SUSPENSION PERFORMANCE
CAUSE OF TROUBLE
Soft suspension.
·Weak cushion spring
·Overloaded
·Oil leakage from damper unit
Hard suspension.
·Bent fork pipe or cushion rod
Suspension noisy.
·Worn slider
·Damaged cushion stopper rubber
MEMO
SERVICE MANUAL
2010. 03 PRINTED
2010. 03 PUBLICATION
COPY PROHIBIT
SM62-1003-01E