SANYANG | HD 125 | Service manual | SANYANG HD 125 Service manual

SERVICE MANUAL
中华战马修护手册
PREFACE
PREFACE
l This shop manual describes the technical feature and
servicing procedures for the SANYANG XS125-K.
l All information, illustrations, directions and
specifications included in this publication are base on
SANYANG XS125-K.
l SANYANG reserves the right to make changes at any
time without notice and without incurring any
obligation whatever.
SANYANG INDUSTRY CO.,LTD.
SERVICE DIVISION
CONTENTS
CONTENTS
GENERAL INFORMATION.............................................................................1
INSPECTION/ADJUSTMENT ........................................................................2
LUBRICATION SYSTEM................................................................................3
ENGINE REMOVAL/INSTALLATION ...........................................................4
CYLINDER HEAD/VALVE ..............................................................................5
CYLINDER/PISTON ........................................................................................6
CLUTCH/OIL PUMP/GEAR SHIFT................................................................7
A.C. GENERATOR ..........................................................................................8
CRANK SHAFT/CRANK CASE/TRANSMISSION........................................9
CARBURETOR ................................................................................................10
HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK .........................11
REAR WHEEL/REAR SUSPENSION.............................................................12
BATTERY/CHARGING SYSTEM ..................................................................13
IGNITION SYSTEM .........................................................................................14
SWITCHES/HORN...........................................................................................15
WIRING DIAGRAM ..........................................................................................16
1.GENERAL INFORMATION
SERVICE RULES ...................................1-1
SPECIFICATIONS ..................................1-2
TORQUE VALUES .................................1-3
TROUBLE SHOOTING ...........................1-4
SERVICE RULES:
(1)Use new packings, gaskets,O-rings and cotter
pins space and clipes whenever reassembling.
(5)Clean all removed parts in or with solvent, and
lubricate their sliding surfaces upon disassembly.
(2)When tightening bolts or nuts, begin on center or
larger diameter bolts and tighten them in crisscross pattern in two or more steps if necessary.
(6)Coat or fill parts with specified grease where
specified.
(3)Use genuine SANYANG parts and lubricants or
those equivalent. When parts are to be reused,
they must be inspected carefully to make sure they
are not damaged or deteriorated and in good
usable condition.
(7)Upon assembling, check every possible part for
proper installation and movement or operation.
(4)Use special tool when use of such a tool is
specified.
(8)Work safely and give your work your undivided
attention. Exchange signals as frequently as possible when a work involves two or more workers. Do
not run the engine unless the shop or working area
is well ventilated.
Symbol Marks:
:Apply engine oil.
:Apply grease.
NOTE: Things must be noticed.
CAUTION: Things that could cause damage to the
engine parts.
WARNING: Things that could cause damage to
the person or partner.
1-1
1.GENERAL INFORMATION
SPECIFICATIONS
ITEM
FRAME
Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry weight
Type
Front suspension and travel
Rear suspension and travel
Front tire size and tire pressure
Rear tire size and tire pressure
Front brake
Rear brake
Fuel capacity
Fuel reserve capacity
Caster angle
Front fork oil capacity
Type
Cylinder arrangement
Bore & stroke
Displacement
Compression ratio
Oil capacity
ENGINE
Intake valve
DIMENSIONS
Exhaust valve
Valve clearance
XS125-K
opens
2040mm
750mm
1100mm
1280mm
150mm
130kg
Single pipe
Telescope
165mm
Swing arm
63mm
2.75-18
2.25Kg/C ㎡
90/90-18
2.50Kg/C ㎡
Disk type
Drum type
14.5 liter
2.0 liter
26 °
160c.c
Air cooled 4 stroke engine
Single cylinder 15~ inclinde from vertical
56.5 x49.5mm
124.1c.c.
9.0:1
0.80 ~0.95liter (0.9 liter for change)
5°BTDC
closes
opens
closes
IN.
35 °ABDC
30°BBDC
5 °ATDC
0.10mm
EX.
0.15mm
1400±100 rpm
Wet muti-plate type
5-speed internationl
4.05
2.769
Idle speed
Clutch
Transmission
Primary reduction ratio
I
DRIVE TRAIN
Gear ratio
II
III
IV
V
Final reduction ratio
Gearshift pattern
Ignition system
Ignition timing
ELECTRICAL
1-2
Starting system
Alternator
Battery capacity
Fuse
Spark plug
Spark plug gap
"F" mark
Full advance
1.722
1.318
1.1250
0.962
2.53
1→N→2→3→4→5
C.D.I. unit
BTDC 15°±20°/1500rpm
BTDC 29.5°±2°/4000rpm
Electrical motor and kickstarter
A.C. generator
12N7A-3A(8AH)
15A
D7RC
0.6~0.7mm
1.GENERAL INFORMATION
ENGINE
TIGHTEN LOCATION
Starting clutch outer bolt socket
Cylinder stud bolt
Shift drum stopper hex bolt
Gear shift cam hex bolt
Cylinder stud bolt
Cylinder head cap nut
Driven gear hex bolt
Chain adjuster
Oil filter screen cover
Starter moror bolt
Oil pump HEX bolt
Primary drive gear nut
Cylinder head bolt
Cylinder head nut
Fly wheel bolt
Cylinder head cover
Reduction gear cover bolt
L. Crank case cover bolt
R. Crank case cover
A.C.G.pluse bolt
A.C.G.flange bolt
Q'TY
3
10
1
1
4
4
2
2
1
2
2
1
1
4
1
4
3
8
11
2
3
THREAD DIA(mm)
8
6
6
6
8
8
6
6
10
6
6
16
8
8
10
6
6
6
6
4
5
TORQUE(kgf・cm)
100~150
80~120
80~120
80~120
180~220
280~300
100~150
80~120
150-300
80~120
70~110
400~500
280~320
280~320
400~500
80~120
80~120
80~120
80~120
40~50
40~70
Q'TY
THREAD DIA(mm)
TORQUE(kgf・cm)
1
1
1
3
4
4
1
1
4
1
2
2
4
2
2
14
14
14
10
10
8
22
22
10
8
8
12
8
8
6
600~800
1000~1200
800~1000
400~550
450~550
180~ 250
600~900
400~500
300~400
150~200
400~550
400~500
270~330
200~250
100~140
FRAME
TIGHTEN LOCATION
Front wheel axle nut
Rear wheel axle nut
Rear fork pivot nut
Engine upper hanger nut
Engine front hanger nut
Handle pipe upper holder bolt
Steering stem nut
Front fork nut
Rear shock absorber
Rear brake torque link
Front fork top bridge
Front fork bottom bridge
Final drive sprocket
Seat bolt
Drive sprocket bolt
STANDARD TORQUE
TYPE
5 mm bolt, nut
6 mm bolt, nut
8 mm bolt, nut
10 mm bolt, nut
12 mm bolt, nut
TORQUE(kgf·cm)
45~60
80~120
180~250
300~400
500~600
TYPE
5 mm bolt
6 mm bolt
6 mm flange bolt, nut
8 mm flange bolt, nut
10 mm flange bolt, nut
TORQUE(kgf·cm)
35~50
70~110
100~140
240~300
350~450
1-3
1.GENERAL INFORMATION
Torque specifications listed below for respective locations.
TROUBLE SHOOTING
A. HARD START OR CANNOT START
symptom
inspection adjustment
loosen carburetor drain
screw, check inner side for
gasoline
cause
no gasoline in the tank
fuel tube between gasoline tank and
carburetor clogged.
enough gasoline supplied
for carbuertor
no gasoline supplied
for carburetor
remove spark plug,insert it
into plug cap, check the
spark by touching engine
grid
spark plug jump
spark weak or no spark
test cylinder
compression
float chamber fuel tube clogged
gasoline cover air hole clogged
fuel filter clogged
fuel filter screen clogged
gasoline auto fuel cup faulty
spark plug faulty
fouled spark plug
CDI unit fualty
pulse coil faulty
high voltage coil cable open or
short
high voltage coil open or short
main switch faulty
A.C.G. faulty
normal compression
pressure too low or no
pressure
follow the starter
keypoints to re-start
engine dose not fire
engine knocks, but no
starting
remove and check the
spark plug again
Battery faulty
valve too tight, no gap
valve seat faulty
cylinder, piston, piston ring
faulty
cylinder gasket leak
valve burnt out
valve timing faulty
crankcase leak when wmpress
Fuel tube clogged
muffler clogged
auto air cut poor action
inlet duct has air in
ignition timing incorrect
carburetor fuel adjusting
screw set faulty
air cleaner clogged
spark plug dry
start engine with choke closed
1-4
spark plug wet
carburetor fuel level too high
auto air cut poor action
throttle excessively
1.GENERAL INFORMATION
B. ROTATION ROUGH (LACKS POWER)
symptom
inspection adjustment
start engine and slightly
apply fuel
engine speed up
engine speed can't up
adjust ignition timing use
timing tester
ignition timing
correct
ignition timing
incorrect
cause
air cleaner clogged
fuel tube clogged
air hole on the fuel tank cap blocked
exhaust tube clogged
auto air cut faulty
carburetor vacuum diaphragm worn
auto fuel cup faulty
faulty CDI unit
faulty A.C.Generator
valve adjuster poor
valve clearance
correct
valve coearance
incorrect
valve clearance misadjustment
valve seat worn
compression pressure check
compression normal
pressure to low
carburetor block check
no clogged
block
fualty valve seat
cylinder, piston worn
gasket leak
valve timing incorrect
piston ring worn
remove and clean
remove spark plug
no fouled
discolored
dirt and color change
remove dirt
spark plug improper heat range
spark plug clearance misadjustment
check crankcase oil level
for too much or dirt
oil lever normal
oil too much
check cylinder head
lubrication
normal
abnormal
engine too hot
no overheating
overheated
high speed
continue working
no knock shock
knocks
too much oil
too little oil
oil no replacement
oil tube clogged
lean projection from oil pump
piston, cylinder worn
lean mixture
poor gasoline
carbon in burning chamber too much
ignition timing too early (C.D.I. faulty)
clutch slip
carbon in burning chamber too much
poor gasoline
clutch slip
lean mixture
ignition timing too early(C.D.I.faulty)
1-5
1.GENERAL INFORMATION
C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED)
symptom
inspection adjustment
cause
ignition timing
adjustment
normal
abnormal
faulty CDI unit
faulty A.C.Generator
valve gap adjust faulty
adjust carburetor fuel
adjusting screw
adjust OK
adjust faulty
lean mixture(loosen screw)
rich mixture(tighten screw)
carburetor gasket
has air inlet
no air inlet
has air inlet
insulator plate gasket poor
carburetor locking nut loose
insulator plate gasket torn
vacuum tube crack
Remove spark plug,insert to the
plugcap, check spark by toucning
engine irongrid.
sparking well
poor sparking
poor or dirty spark plug
faulty CDI unit
faulty A.C.Genertor
poor ignition coil
spark plug cable open or short
poor main switch
vacuum tube damaged
good
no good
air inlet duct clogged, damaged
1-6
1.GENERAL INFORMATION
D. ROTATION ROUGH (HIGH SPEED)
symptom
cause
inspection adjustment
ignition timing
adjustment
normal
abnormal
faulty CDI unit
faulty pulse generator
valve clearance
adjustment
normal
abnormal
poor adjustment
valve seat faulty
check auto fuel
cup for fuel
supplied.
normal
abnormal
too little fuel in the fuel tank
fuel tube, fuel filter clogged
air hole on the fuel tank colgs
auto fuel cup faulty
carburetor blocked
no blocked
blocked
clean
valve timing
adjusting
inspection
timing correct
timing incorrect
cam sprocket aligning marks incorrect
check valve spring
good
spring broken
loose elasticity
faulty spring
1-7
1.GENERAL INFORMATION
E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE)
inspection adjustment
symptom
cause
measure battery voltage.
and then start engine
battery voltage
can't rise
battery voltage rise to
normal value,after
engine stops, the voltage
return to original.
reach battery life
faulty battery
check voltage regulator
rectifier coupler
normal
coupler poor contact
red wire open
abnormal
check the voltage between
voltage red wire
and frame body(grounding)
with mult-meter(+).(-)
terminals.
hsa voltage
voltage adjuster
white wire open
no voltage
measure the resistance of
AC generator coil
coil faulty
connector.poor contact
AC generator white wire open
abnormal
normal
faulty battery
poor charge (over charge)
after engine starter, measure the
voltage between voltage regulaton
/rectifier red (+) wire and
green (-) wire connected with
frame body.
voltage over
normal
voltage normal
check voltage regulator/
rectifier coupler for poor
contact.
normal
poor contact
measure the resistance of
voltage adjuster unit
can't meet
specification
1-8
Coupler poor contact.
green wire poor
grounding
faulty voltage
regulator/rectifier
1.GENERAL INFORMATION
F.SPARK PLUG NO SPARK
Inspection adjustment
symptom
cause
replace with new spark plug
and test again.
spark wear of
no spark
spark strong
original spark plug
faulty
Check spark cap and high
voltage cable for slack
no slack
slack
spark plug cap
slack
check CDI unit plug for slack
normal
abnormal
plug poor contact
Check the resistance
between the wires.
terminals of CDI unit.
normal
abnormal
Check related portions
normal
fualty main switch.
faulty trigger
magntic coil
poor pulse coil
poor IGN coil
abnormal
use CDI tester for CDI unit
normal
abnormal
control cable open
connector.socket
poor contact
faulty CDI unit
use CDI tester to check
ignition voltage coil
abnormal
faulty IGN coil
1-9
2.INSPECTION/ADJUSTMENT
ENGINE
MAINTENANCE SCHEDULE ..................2-2
SERVICE INFORMATION.........................2-3
ENGINE OIL/OIL FILTER...........................2-4
SPARK PLUG ............................................2-5
COMPRESSION TEST .............................2-6
VALVE CLEARANCE...............................2-7
IGNITION TIMING........................................2-8
CAM CHAIN TENSION ADJUSTMENT ..2-9
THROTTLE GRIP ADJUSTMENT............2-10
IDLING SPEED ADJUSTMENT...............2-11
FRAME
AIR CLEANER........................................2-12
CLUTCH ADJUSTMENT ......................2-12
BRAKE ADJUSTMENT.........................2-13
DRIVE CHAIN ADJUSTMENT .............2-14
WHEELS/RIM .........................................2-15
SUSPENSION ........................................2-16
STEERING ..............................................2-17
BATTERY................................................2-17
HEAD LIGHT AIM...................................2-18
STOPLIGHT SWITCH............................2-18
2-1
2.INSPECTION/ADJUSTMENT
MAINTENANCE SCHEDULE
Item
Check Items
Maintenance
kilometer
Maintenance
Interval
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
NEW
1 Month
3 Months
6 Months
1 Year
C
1
Air cleaner
I
R
2
Gasoline filter
I
3
Oil filter
C
Replacement for every 5000KM
4
Oil filter screen
C
Cleaning for every 5000km
5
Engine Oil
R
Replacement for every 5000KM
6
Wheels tires
I
I
7
Battery
I
I
8
Brake and operation free play
I
I
9
Steering stem bearing
C
R
C
R
I
10
FR./RR. Cushion
I
11
Screws/nuts
I
12
Spark plug
I
R
13
Clutch
I
I
14
Frame of lubrication
15
Exhaust muffler
I
I
16
Carburetor
I
I
17
Ignition timing
I
I
18
Emission
I
I
19
Idle speed
I
I
20
Gasoline system
I
I
21
Throttle cable
I
I
22
Engine bolt torque
I
I
23
Deposit of exhaust outlet
24
Cylinder head/cylinder
Piston exhaust system deposit
25
Cam chain
I
26
Valve clearance
I
I
27
Light/electrical appliance/Meter
I
I
28
Side stand﹠Spring
I
I
I
L
I
I
I
I
The table is refered to the driving distance about 1000km per month
I-inspection, cleaning, adjustment or replacement (if necessary)R-replacement
C-leaning L-lubrication
REMARK: Ridden in unusually dusty areas, require more frequently air filter element cleaning.
2-2
R
2.INSPECTION/ADJUSTMENT
SERVICE INFORMATION
SPECIFICATLON
ENGINE
Oil capacity
Spark plug gap
Spark plug gap
Valve clearance IN
EX
Cylinder compression
FRAME
1.1~1.5 liter
A6RTC
0.6-0.7mm
0.08mm
0.10mm
12.5kg/c ㎡±2kg/c ㎡
Clutch lever free play
Drive chain stack
Front brake lever free play
Rear brake pedal free play
Throttle grip free play
10-20mm
10-20mm
10-20mm
20-30mm
2-6mm
SPECIAL TOOL
Valve clearance adjuster
TORQUE VALVES
Right crankcase cover
Front fork top bridge bolt
Front fork bottom bridge bolt
Rear wheel axle nut
Rear shock absorber nut
Rear fork pivot bolt
80-120 kgf・cm
100-140 kgf・cm
200-250 kgf・cm
400-550 kgf・cm
300-400 kgf・cm
350-450 kgf・cm
2-3
2.INSPECTION/ADJUSTMENT
OIL/OIL FILTER
OIL LEVEL CHECK
Start and warm up the engine for few minutes,then
stop the engine.
Check the oil level with oil level gauge after a few
minutes.
If the oil level is near the lower mark,fill the crankcase
to the upper level mark with the recommended grade
oil.
OIL FILTER SCREEN COVER
OIL REPLACEMENT
NOTE:
Drain the engine oil while the engine is warm.
Remove the oil filter screen cover, and drain the
engine oil.
NOTE :
Make sure that the oil filter screen cover O-ring
is in good condition.
Fill the crankcase up to the upper level mark on the oil
level gauge with the recommended oil:15W-40
API:SH/CD
2-4
2.INSPECTION/ADJUSTMENT
OIL FILTER SCREEN CLEANING
Remove the oil filter cap, oil filter screen and drain the
engine oil.
Operate the kick starter several times to drain residual
oil completely.
Clean the oil filter screen with compressed air.
Install the oil filter screen, spring and screen cap.
Fill the crankcase with the recommended oil.
OIL CAPACITY:0.9L
OIL FILTER SCREEN
COVER
SPARK PLUG
Disconnect the spark plug cap and remove the spark
plug .
Visually inspect the spark plug electrodes for wear.
The center electrode should have square edges and
side electrode should have a constant thickness.
Discard the spark plug if there is apparent wear or if
the insulator is cracked and/or chipped .If the spark
plug deposits can be removed by sandblasting or wire
brushing,the spark plug can be reused.
Inspect the gap with a feeler gauge and adjust by
bending the side electrode.
Standard gap:0.6-0.7mm
NOTE:
To install turn finger tight then tighten with a spark
plug wrench.
2-5
2.INSPECTION/ADJUSTMENT
COMPRESSION TEST
Warm up the engine.
Stop the engine .Remove spark plug .Insert the
compression gauge.
Push in the choke lever .Open the throttle grip fully.
Electrical start engine several times.
NOTE:
Ÿ Watch for compression leaking at the gauge
connection.
Ÿ Crank the engine until the gauge reading stops
rising .The maximum reading is usually reached
in several times.
Compression:9.5kg/c ㎡±1kg/c ㎡
Low compression can be caused by:
Ÿ Improper calve adjustment.
Ÿ Valve leakage .
Ÿ Blown cylinder head gasket.
Ÿ Worn piston rings or cylinder.
Ÿ Worn piston.
High compression can be caused by:
Ÿ Carbon deposits in combustion chamber or on
piston head.
2-6
ELECTRICAL
START ENGINE
2.INSPECTION/ADJUSTMENT
VALVE CLEARANCE
ALIGN
MARK
NOTE:
Inspect and adjust the valve clearance while the
engine is cold.
Remove the timing inspection hole cap and crankshaft
hole cap.
Rotate the generator rotor counterclockwise and align
the “T”mark on the generator rotor with the index mark
in the left crankcase
(piston must be at T.D.C.of the compression
stroke).
ALIGN
MARK
Inspect the intake and exhaust valve clearance by
inserting a feeler gauge between the adjusting screw
and valve stem,valve clearance:
Intake:
0.05mm
Exhaust:
0.10mm
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag in the feeler
gauge.
ADJUSTING
SCREW
NOTE:
Inspect the valve clearance again after tightened the
lock nut.
LOCK NUT
2-7
2.INSPECTION/ADJUSTMENT
Install the valve adjuster caps and generator cap.
NOTE:
Check the O-ring for damage and spread oil before
installing the caps.
O-RING
IGNITION TIMING
The C.D.I.ignition timing is not adjustable.
If the ignition timing is not correct ,check the C.D.I.unit
and A.C.generator and replace any faulty parts.
Use the standard tester to check the ignition timing.
Spark plug inspection and adjustment.
Replace the coil if there is no sparks at plug.
IGNITION TIMING INSPECTION
Remove the generator cover and check the ignition
timing with a timing light.
Timing is correct if the index mark aligns with the
“F”mark within ±3°at 1500rpm.
Ignition timing :10°BTDC/1500rpm.
Ignition coil continuity test :
Check the resistance of the primary coil
and secondary coil.
1.Primary coil
0.31±0.03Ω
2.Secondary coil
4.0±0.4kΩ
2-8
2.INSPECTION/ADJUSTMENT
Inspect the C.D.I unit with C.D.I tester.
Replace the faulty C.D.I unit.
SWITCH
1. OFF
2. P
3. EXT
4. ONI
5. ONZ
C.D.I. normal
no sparks
no sparks
no sparks
sparks
sparks
C.D.I faulty
------------sparks
no sparks
no sparks
CAM CHAIN TENSIONER
ADJUESTER
CAM CHAIN TENSIONER
ADJUESTER
The cam chain tension is kept by the tensioner
push rod that is compressed by the spring.
CAUTION:
If remove any parts that is related with the cam
chain ,remove the cam chain tensioner adjuester
first.
2-9
2.INSPECTION/ADJUSTMENT
CARBURETOR
THROTTLE GRIP FREE PLAY
Check throttle grip free play.
Free play:2-6mm
THROTTLE GRIP ADJUSTMENT
Loosen the lock nut and turn the adjuster to adjust.
ADJUSTER NUT
2-10
2.INSPECTION/ADJUSTMENT
IDLING SPEED ADJUSTMENT
Warm up the engine.
Turn the stop screw to obtain the idling speed of
1100rpm.
Turn the air screw to the maximum speed,then turn
the stop screw to obtain the specified idling speed.
Idling speed:1500±100 rpm.
NOTE:
Turn the air screw clockwise for making fuel –air
mixture lean.
Turn counterclockwise for rich.
STOP SCREW
AIR SCREW
2-11
2.INSPECTION/ADJUSTMENT
AIR CLEANER
Remove the left side cover.
Remove the air cleaner cover.
Remove the air cleaner element.
NOTE:
Clean the cleaner element periodically.(Refer to
maintenance schedule.)
SCREWS
Assemble air cleaner element in reverse order of
disassemble.
AIR CLEANER
ELEMENT
CLUTCH ADJUSTMENT
CLUTCH LEVER FREE PLAY
Measure the clutch free play at the tip of the clutch
lever.
Free play :10-20mm
2-12
2.INSPECTION/ADJUSTMENT
FREE PLAY ADJUSTMENT
Loosen the lock nut and turn the adjuster.
Turn the adjuster ,clockwise for decreasing the free
play ,counterclockwise for increasing the free play.
.
LOCK NUT
ADJUSTER NUT
BRAKE ADJUSTMENT
FRONT BRAKE LEVER FREE PLAY
Measure the brake free play at the tip of the brake
lever.
Free play:10-20mm
10~20mm
BRAKE PAD WEAR INSPECTION
Check for brake pad wear by operating the bake lever.
Check the brake pads for wear by looking through the
slot indicated by the arrow cast on the caliper
assembly.
Replace the brake pads if the wear line on the pads
reaches the edge of the brake disc.
2-13
2.INSPECTION/ADJUSTMENT
REAR BRAKE PEDAL FREE PLAY
Measure the brake pedal free play before the brake
start to engage.
Free play :20-30mm
20~30mm
REAR BRAKE PEDAL
ADJUSTMENT
Turn the brake adjuster nut clockwise to decrease the
free play and counterclockwise to increase the play.
CAUTION:
The adjuster nuts indentation should seat against
the brake arm pin properly.
ADJUSTING NUTS
DRIVE CHAIN ADJUSTMENT
Place the motorcycle on its main stand and shift the
transmission into neutral.
Remove chain cap and check the drive chain slack by
moving up and down with the fingers.
Chain slack:10-20mm
10~20m
m
2-14
2.INSPECTION/ADJUSTMENT
Loose the rear wheel axle nut for adjusting.
Turn the adjusting nuts on both adjusters as
necessary.
ADJUSTING NUTS
CAUTION:
Tighten the axle nut.
TORQUE:1000-1200 kgf・ cm
Recheck the drive chain slack and free wheel rotation.
Lubricate the drive chain with chain lubricant.
WHEEL/RIM
Stand the motorcycle,check the tires for cuts,imbedded
nails,or other sharp objects.
Check the tire pressure.
One rider
Cold tire
Two riders
pressure
Max.load
Tire size
Min. depth of tread
Front 2.25 kg/c ㎡
Rear 2.50 kg/c ㎡
Front 2.50 kg/c ㎡
Rear 2.50 kg/c ㎡
120kg
Front 2.75-18
Rear 90/90-15
Front
1.5mm
Rear
2.0mm
2-15
2.INSPECTION/ADJUSTMENT
SUSPENSION
FRONT SUSPENSION
Check the action of the front forks by compressing
them several times with the front brake applied .
If there are abnormal noises or rattles ,check all the
fasteners and tighten them to the specified torque.
TORQUE:
Front fork top bridge bolt :100-140 kgf・cm
Frint fork bottom bridge bolt :240-300 kgf・cm
Axle nut:600-800 kgf・cm
REAR SUSPENSION
Check for abnormal noises and leaks by compressing
the rear suspension several times.
Check the rear suspension nut for loosing
Torque:300-400 kgf・cm
Move the rear wheel side ways with force to see if the
swing arm bushings are worn.
Rear fork torque:800-1000 kgf・cm
2-16
2.INSPECTION/ADJUSTMENT
STEERING
Raise the front wheel off the ground and check that
the handlebar rotates freely.If the handlebar moves
unevenly ,binds or has vertical movement,adjust the
steering head nut.
BATTERY
Inspect the battery fluid level ,if the fluid level nears
the lower level mark,fill with distilled water to the upper
level mark .
Clean the battery terminals with warm water.
Check the specific gravity of the battery
electrolyte.(13-3)
NOTE
:
Do not overfill. Add only distilled water.
Tap water will shorten the service life of the
battery.
WARNING:
Keep the electrolyte away from eyes ,skin and
clothes. If touched it ,wash them with clean
water quickly.
2-17
2.INSPECTION/ADJUSTMENT
HEADLIGHT AIM
Adjust vertically by turning headlight up and down with
the headlight bolts loosening.
Fasten the bolts after adjustment.
ADJUST NUTS
STOPLIGHT SWITCH
STOPLIGHT SWITCH
The stoplight should come on when the brake pedal is
depressed 20mm from the standard pedal position.If
the action is abmormal, adjust by turning the stoplight
switch adjusting nut.
ADJUSTING NUT
2-18
3.LUBRICATION SYSTEM
CAM SHAFT
OIL LINE OF
CAM SHAFT
PISTON
MAIN SHAFT
OIL ORIFICE OF
CRANKSHAFT
OIL PUMP
COUNTER SHAFT
OIL FILTER
3-0
3.LUBRICATION SYSTEM
TROUBLE SHOOTING...........................3-1
SERVICE INFORMATION..................... 3-1
TROUBLE SHOOTING
OIL LEVEL TOO LOW
1. Natural consumption
2. Oil leaks
3. Worn piston rings
OIL CONTAMINATION
1. Oil not changed often enough
2. Faulty cylinder head gasket
OIL PRESSURE TOO LOW
1. Oil filter clogged
2. Oil pump damaged
OIL PRESSURE TOO HIGH
1. Oil filter or line clogged
2. Oil not recommended
NO OIL PRESSURE
1. Oil level too Iow
2. Oil pump damaged
SERVICE INFORMATION
NOTICE:
Inspection and service of oil pump can be serviced
with the engine installed on the frame.
Oil pump service --- 7-9
Oil filter cleaning --- 2-4 ~ 2-5
SPECIFICATIONS
Oil capacity
Oil recommended
Oil pump delivery
3-1
0.85~0.90 liter
SAE 15W-40 API:SH/CD
3.5 liter above / min. / 4600rpm
4.ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION......................4-1
ENGINE REMOVAL................................4-2
ENGINE INSTALLATION.......................4-4
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The following parts can be serviced with the engine installed on the frame:
Ÿ Generator
Ÿ Clutch
Ÿ Oil pump
Ÿ Cam shaft / Rocker arm
Ÿ Shift spindle
Ÿ Cam chain tensioner
Ÿ Kick starter arm
The following parts must be serviced with the engine removed off the frame:
Ÿ Cylinder head
Ÿ Cylinder
Ÿ Piston
Ÿ Crankshaft
Ÿ Transmission
Ÿ Kick starter shift
During removal and installation, jack or adjustable support is required to maneuver the engine.
TORQUE VALUES
Engine hanger 10mm bolt / nut
Drain bolt
Gearshift pedal bolt
Kick starter pedal bolt
450-550 kgf・cm
300-500 kgf・cm
80-120 kgf・cm
80-120 kgf・cm
4-1
4.ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil.
Turn the fuel cock to “OFF” and disconnect the fuel
tubes and all connect tubes.
Remove the right and left side covers.
Remove the gear change pedal and left crank case
rear cover.
LEFT CRANKCASE RR.COVER
GEAR CHANGE PEDAL
Disconnect the A.C. generator wire of the connector
and remove the generator wire.
Remove the wire clamp screw and clamp.
A.C. GENERATOR WIRE
4-2
4.ENGINE REMOVAL/INSTALLATION
Remove the clutch cable.
Remove the spark plug cap.
Remove the muffler.
CLUTCH CABLE
Loosen carburetor clip.
Separate the carburetor pipe and the cylinder head by
removing the attaching bolts.
Remove the crankcase breather tube.
CLIP
BREATHER TUBE
ADJUSTING NUT
Loosen the rear wheel axle nut.
Loosen the drive chain adjusting nut and push the rear
wheel forward.
Remove the drive chain clip, and remove the drive
chain.
WHEEL AXLE NUT
4-3
4.ENGINE REMOVAL/INSTALLATION
Remove the front engine hanger bolt.
NOTE:
Places jack or padded block under the engine before
removing the front engine hanger.
Disconnect the starter motor wire.
FRONT ENGINE HANGER
BOLT
BOLTS
Remove the 10mm bolts of the rear engine hanger.
Remove the engine.
NOTE:
Prevent damage to wire harnesses and cables during
operation.
ENGINE INSTALLATION
Follow the reverse procedure of removal to install the
engine.
Notice the following items during installation:
Ÿ Route all wire harnesses and cables properly.
Ÿ Adjust the throttle grip free play (P2-10)
Ÿ Adjust the clutch lever free play (P2-12)
Ÿ Adjust the drive chain slack (P2-14)
Ÿ Fill the crankcase with the recommended grade oil
to the proper level.
SAE 15W-40 APl: SH / CD
4-4
5. CYLINDER HEAD/ VALVE
TROUBLE SHOOTING ...........................5-1
SERVICE INFORMATION......................5-2
CAM SHAFT REMOVAL .......................5-3
CYLINDER HEAD/ROCKER ARM REMOVAL .......5-4
CYLINDER HEAD DISASSEMBLY......5-6
VALVE/VALVE GUIDE INSPECTION ...........5-7
VALVE GUIDE REPLACEMENT .........5-8
VALVE SEAT INSPECTION/REFACING ......5-9
VALVE SEAT GRINDING ......................5-10
CYLINDER HEAD ASSEMBLY.............5-13
CYLINDER HEAD INSTALLATION.......5-14
CAM SHAFT INSTALLATION...............5-15
TROUBLE SHOOTING
LOW COMPRESSION
1. Valve
Incorrect valve clearance
Burned or bent valves
Incorrect valve timing
Broken valve spring
2. Cylinder head
Leaking or damaged head gasket
Warped or cranked cylinder head
HIGH COMPRESSION
1. Excessive carbon buildup on piston or combustion chamber.
ABNORMAL NOISE
I. Incorrect valve clearance
2. Broken valve spring
3. Worn rocker arm or camshaft
4. Loose or worn cam chain
5. Worn cam chain tensioner
6. Worn cam sprocket teeth
5-1
5.INSPECTION/ADJUSTMENT
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Camshaft, rocker arm shaft and rocker arm can be serviced with the
engine installed on the frame.
Camshaft lubrication oil is fed to the cylinder head through an oil
control orifice in the engine case.
Be sure this orifice is not clogged and the O-ring and dowel pins are in
place before installing the cylinder head.
During assembly, apply molybdenum disulfide grease to the camshaft
bearings, and pour clean engine oil into the cylinder head.
TORQUE VALUES
Cylinder head bolt
Cylinder 6mm bolt
Cam sprocket
280-300 kgf・cm
140 -180 kgf・cm
80-120 kgf・cm
SPEClFICATIONS
ITEM
STANDARD SERVICE
LIMIT
IN
32.382mm
31.25mm below
EX
31.987mm
30.87mmbelow
Cam lift
Camshaft
Runout
0.02mm
Rocker arm I.D.
I.D.
12.000~12.018mm
12.018mm above
Rocker arm shaft
O.D.
11.966~11.984 mm
11.966mm below
39.95~40.55mm
39mm below
Free length
Valve
spring
→36.21mm
→29.21mm
Stall length
(IN)0.06±0.02mm
(EX)0.10±0.02mm
Valve clearance
O.D.
Valve
guide
Guide I.D.
Stem to guide
Clearance
Valve seat width
5-2
18.17±1.82kgf
57±4.28 kgf
IN
5.450~5.465mm
5.42mm
EX
5.430~5.455mm
5.40mm
IN
5.475~5.485mm
5.50mm
EX
5.475~5.485mm
5.50mm
IN
0.010~0.035mm
0.08mm
EX
0.03~0.055mm
0.10mm
1.45~1.15mm
1.6mm
5. CYLINDER HEAD/ VALVE
CAMSHAFT REMOVAL
NOTE:
The camshaft, rocker arm and rocker arm shaft can
be serviced with the engine installed on the frame.
Remove the cam sprocket cover.
CAM SPROCKET
COVER
Remove the crankshaft hole cap and the timing
inspection hole cap.
Rotate the generator rotor counterclockwise and
locate the piston at the T.D.C. of the compressing
stroke.
Remove the cam sprocket bolts and remove the cam
sprocket.
NOTE:
Take care not to drop then bolt into the
crankcase.
INDEX MARK
“O” MARK
Suspend the cam chain with a wire to prevent it from
falling into the crankcase.
Remove the camshaft.
5-3
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD
CAM CHAIN TENSIONER BOLT
REMOVAL
Remove the cam chain tensioner bolt.
Remove the 8mm bolt.
Remove the 4 cylinder head nuts.
Remove the dowel pins.
Remove cam chain tensioner.
Remove the cylinder head.
8mm BOLT
Remove the rocker arm shaft.
Remove the rocker arms.
5-4
5. CYLINDER HEAD/ VALVE
CAMSHAFT INSPECTION
Inspect the cams of the camshaft for wear.
Service limit:
Inlet: 31.25mm
Exhaust: 30.87mm
ROCKER ARM INSPECTION
Inspect the rocker arm I.D. and the rocker arm for wear,
damage or clogged oil holes.
Rocker arm I.D.
Service limit: φ12.018mm
ROCKER ARM SHAFT INSPECTION
Inspect rocker arm shaft for wear or damage.
Rocker arm shaft O.D.
Service limit :φ11.966mm
5-5
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD DISASSEMBIY
Remove carbon deposits from the combustion
chamber. Remove valve spring and valve spring and
valve with a valve spring compressor.
VALVE
SPRING RETAINER
VALVE COTTER
CYLINDER HEAD INSPECTION
Remove gasket from cylinder head with a scraper.
Check the cylinder head for crack.
Check the cylinder head for warpage with a straight
edge and a feeler gauge.
Service limit: 0.10mm
VALVE SPRING INSPECTION
Measure the free length of the inner and outer valve
spring.
Service limit: 39mm below
5-6
5. CYLINDER HEAD/ VALVE
VALVE/VALVE GUIDE
INSPECTION
Inspect valves for scratches, burning or wear.
Check the valve movement in the guide.
Measure the valve stem O.D.
Service limit:
Intake: ∮5.42mm
Exhaust:∮5.40mm
NOTE:
Remove any carbon buildup before checking the
valve guide I.D.
Guide I.D. service limit
Intake: ∮5.50mm
Exhaust : ∮5.50mm
Measure the valve guide I.D. and calculate the stem to
guide clearance.
Service limit:
Intake: 0.08mm
Exhaust: 0.10mm
If the stem to guide clearance exceeds the service limit,
replace the valve or guide to fit.
NOTE:
The guide must be reamed when replacing a new
one.
5-7
5.INSPECTION/ADJUSTMENT
VALVE GUIDE
REPLACEMENT
Drive out the valve guide from the combustion
chamber side with a 5mm valve guide remover.
NOTE:
When driving out the valve guide, do not damage
the cylinder head.
Install the new valve guide from the top of the cylinder
head, and ream it with a reamer, then clean the
cylinder head.
5-8
VALVE GUODE REMOVER
5. CYLINDER HEAD/ VALVE
VALVE SEAT INSPECTION/ REFACING
Clean intake and exhaust valves to remove carbon
deposits.
Apply a light coating of prussian blue to each valve
face.
Insert each valve into the guide and rotate them two
cycles.
Remove the valve and inspect the face.
CAUTION:
If the valve face is burned or damaged or unevenly,
replace the valve.
CONTACT AREA
VALVE SEAT
Inspect the valve seat.
If the seat is too wide or too narrow, the seat must be
refinished.
SERVICE LIMIT
1.5mm
SERVICE LIMIT
1.8mm
5-9
5.INSPECTION/ADJUSTMENT
VALVE SEAT GRINDING
60°
NOTE:
Follow the instructions described in the cutter
instruction manual.
32°
45°
Remove any roughness from the seat by applying 4~5
kg pressure, turning the cutter left and right.
4~5kg
NOTE:
Add engine oil to the face when operating.
CUTTER
CUTTER HOLDER
TURN RIGHT AND LEFT
Using a 45 degree cutter,remove any roughness from
the seat.
ROUGHNESS
45°
VALVE SEAT
5-10
5. CYLINDER HEAD/ VALVE
Using a 32 degree cutter, remove 1/4 of the existing
valve seat material.
32o CUTTER
VALVE SEAT
Remove the bottom 1/4 of the old seat by using a 60
degree cutter.
60o CUTTER
Finish the seat to the proper width by using a 45
degree cutter.
45o CUTTER
5-11
5.INSPECTION/ADJUSTMENT
If the contact area is too high on the valve,the seat
must be lowered using a 37.5 degree cutter, then
finish with a 45 degree cutter.
CUT TOP END
CONTACT AREA
TOO HIGH
If the contact area is too low on the valve,the seat
must be raised using a 63.5 degree cutter, then finish
with a 45 degree cutter.
CONTACT AREA TOO LOW
CUT BOTTOM END
63.5 o
After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.
5-12
5. CYLINDER HEAD/ VALVE
VALVE
CYLINDER HEAD ASSEMBLY
Compress the valve springs with a valve spring
compressor and install the valve cotters into the valve
retainer.
CAUTION:
Do not compress the valve spring more than
necessary.
SPRING RETAINER
VALVE COTTER
NOTE:
Install a new valve stem seal when assembling.
Lubricate each valve stem with the engine oil then
insert them into the guides.
Install the valve spring and retainers.
NOTE:
Install the valve springs with the tightly wound coils
facing the cylinder head.
Tap the valve stems gently with a plastic hammer to
firmly seat the cotters.
5-13
5.INSPECTION/ADJUSTMENT
CYLINDER HEAD INSTALLATION
CAMSHAFT AND CAMSPROCKET
ASSEMBLY
ROCKER ARM
NOTE:
Rocker arms must be installed at the right position.
Clean the cylinder head gasket surface of any gasket
material.
Install the new gasket, O-ring and dowel pins and
chain guide.
NOTE:
Do not allow dust and dirt to enter the cylinder.
TENSIONER BOLT
Install the cylinder head.
NOTE:
Support the cam chain to keep it from falling into the
crankcase.
Install the cam chain tensioner set and bolt and
washer.
Install dowel pins.
8mm BOLT
5-14
5. CYLINDER HEAD/ VALVE
CAM SHAFT
INSTALLATION
Rotate the generator rotor and align the "T" mark with
the index mark.
Install the camshaft comp.
When intalling camshaft set, please take care that.The
line on the camsprocket should be in parallel with the
surface of cylinder head.(The IN/EX cam should be
faced down).
Install the camshaft holder.
Install the cylinder head nuts.
TORQUE:280 ~ 300 kgf・cm
CAUTION:
The cap nut of the four holder nuts must be installed
at the left-front side.
“O” MARK
INDEX MARK
Install the 6mm bolts.
Install the cam chain chain tensioner.
Install the auto-tensioner. (Lock the spring cap bolt
first.)
Release the auto-tensioner lock bolt.
Adjust the valve clearance.(2-7)
Install the cylinder head cover.
Install the R/L cylinder head side cover.
Install the 6mm special bolts.
NOTE:
If the cylinder head side cover gasket is damaged or
broken, replace with a new one.
5-15
6. CYLINDER/PISTON
TROUBLE SHOOTING ...........................6-1
SERVICE INFORMATION......................6-1
CYLINDER REMOVAL...........................6-2
PISTON REMOVAL ................................6-3
PISTON/PISTON RING INSPECTION ............6-3
PISTON RING INSTALLATION................6-5
PISTON INSTALLATION ..........................6-6
CYLINDER INSTALLATION .....................6-6
TROUBLE SHOOTING
LOW COMPRESSION
1. Worn cylinder or piston rings.
EXCESSIVE SMOKE
1. Worn cylinder,piston or piston rings.
2. Improper installation of piston rings.
3. Scored or scratched piston or cylinder
wall.
OVERHEATING
1. Excessive carbon build-up on piston or
combustion chamber wall.
KNOCKING OR ABNORMAL NOISE
1. Worn piston or cylinder.
2. Excessive carbon build-up
SERVICE INFORNATION
GENERAL STRUCTIONS
XS125-K
ITEM
STANDARD CERVICE
LIMIT
56.495~56.515mm
56.52mm
Runout
0.05mm
0.05mm
Taper
0.05mm
0.05mm
Top
0.025~0.055mm
0.060mm
Second
0.015~0.040mm
0.045mm
Top
0.10~0.30mm
0.5mm
Second
0.10~0.30mm
0.5mm
Oil ring
0.30~0.90mm
Cylinder I.D.
Cylinder
Piston ring to
ring groove
clearance
Piston ring
End gap
Piston
rings
groove
clearance
Piston O.D.
56.485~56.505mm
56.48mm
Piston pin bore
15.002~15.008mm
15.05mm
Connecting rod small end I.D.
15.016~15.034mm
15.07mm
Piston pin O.D.
14.994~15.000mm
14.994mm
Top
0.97~0.99mm
1.460mm
Second
0.97~0.99mm
1.460mm
0.005~0.015mm
0.11mm
Piston ring
thickness
Cylinder to piston clearnace
6-1
6.CYLINDER/PISTON
CYLINDER REMOVAL
Remove the cylinder head.
Remove the dowel pins and gasket.
Remove the cylinder.
NOTE:
Avoid the dowel pins falling into the crankcase
during removing the cylinder.
Remove the dowel pins and gasket.
Clean the cylinder gasket surface of any gasket
material.
NOTE:
Avoid damaging the cylinder gasket surface during
this operation.
CYLINDER INSPECTION
Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D.
NOTE:
According to the right picture measure the cylinder
runout.
Service limit:
ITEM
Runout
Taper
I.D.
6-2
XS125-K
0.05mm
0.05mm
56.52mm
6. CYLINDER/PISTON
PISTON REMOVAL
Remove the piston pin clip with pliers.
Press the piston pin out of piston, remove the piston.
NOTE:
Avoid the clip falling into the crankcase.
PISTON / PISTON RING
INSPECTION
Measure the piston ring-to-ring groove clearance.
Service limit .
Top ring: 0.13mm
Second ring: 0.12mm
Remove the piston rings.
Inspect the piston for damage or cracks.
Inspect the piston groove for wear.
Insert each piston ring into the cylinder and measure
the ring end gap.
Top / Second ring : 0.5mm
6-3
6.CYLINDER/PISTON
Measure the piston O.D. at the skirt.
Service limit: 56.48mm
NOTE:
Measure the piston O.D. at a point from the bottom.
Calculate the piston-to-cylinder clearance.
Service limit:0.11mm
Measure the piston pin bore I.D.
Service limit:15.05mm
Measure the piston pin O.D.
Service limit:14.994mm
Measure the top/second ring thickness.
Service limit: 1.460mm
6-4
6. CYLINDER/PISTON
PISTON RING INSTALLATION
Install the piston rings.
TOP RING
NOTE:
SECOND
RING
Ÿ Avoid piston and piston ring damage during
installation.
Ÿ All rings should be installed with the markings
facing up.
Ÿ After installation, the piston rings should be
free to rotate in the grooves.
OIL RING
Space the piston ring end gaps 120 degree apart.
TOP RING
SECOND RING
OIL RING
6-5
6.CYLINDER/PISTON
PISTON INSTALLATION
Install the piston, piston pin and piston pin clip.
NOTE:
Ÿ Position the "IN" mark on the piston to the
carburetor side.
Ÿ Do not let the piston pin clip fall into the crankcase.
NOTE:
Ÿ
Ÿ
PISTON PIN CLIP
Use new piston pin clip whenever disassembling.
Do not align the piston pin clip end gap with the
piston cutout.
END GAP
CUTOUT
CYLINDER INSTALLATION
Install the cylinder gasket and dowel pins.
Clean the cylinder gasket surface of any gasket
material.
NOTE:
Avoid damaging the cylinder gasket surface during
this operation.
Install the cylinder.
NOTE:
Avoid piston and piston rings damage during
installation.
Install the cylinder gasket and dowel pins.
Install the cylinder head.(5-8)
NOTE:
Coat the cylinder and piston with the engine oil before
installing the cylinder.
6-6
7.CLUTCH/OIL PUMP/GEAR SHIFT
TROUBLE SHOOTING ...........................7-1
SERVICE INFORMATION......................7-1
RIGHT CRANKCASE COVER REMOVAL ...7-2
CLUTCH...................................................7-2
OIL PUMP ................................................7-7
GEARSHIFT LINKAGE...........................7-9
RIGHT CRANKCASE COVER INSTALLATION ......7-11
TROUBLE SHOOTING
Faulty clutch operation can be corrected by adjusting the clutch lever free play.
CLUTCH SPINS WHEN ACCELERATING
HARD SHIFTING
1. No free play
2. Discs worn
3. Spring weak
1. Stopper plate bent
2. Improper clutch adjustment
CLUTCH DISENGAGED ( MOTORCYCLE
CREEPS )
1. Return spring broken or weak
2. Shift spindle bent
1. Too much free play
2. Plates warped
JUMPS OUT OF GEAR
EXCESSIVE LEVER PRESSURE
LOW OIL PRESSURE
1. Clutch cable kicked, damaged or dirty
2. Lifter mechanism damaged
1. Oil pump drive gear worn
2. Faulty oil pump
GEARSHIFT PEDAL WON'T RETURN
1. Stopper arm spring broken
SERVICE INFORMATION
GENERAL INSTRUCTION
This section covers removal, installation and servicing
of the clutch, oil pump, filter and gearshift linkage. All
these operations can be accomplished with the engine
in the frame.
COMMON TOOLS
22mm wrench socket
Air wrench
TORQUE VALUES
Right crankcase cover
Kick starter pedal
Step bar
80 ~ 120 kgf・cm
100 ~ 150 kgf・cm
180 ~ 200 kgf・cm
SPECIFICATIONS
ITEM
Leve
Free play
Spring free length
STANDARD SERVICE
LIMIT
10~20mm
------------
30.6mm
28.6mm
3.0mm
2.8mm
-------
0.2mm
0.30mm
0.35mm
0.25~0.31mm
0.40mm
0~0.06mm
0.11mm
Clutch
Friction plate thickness
Clutch plate warpage
Tip clearance
Oil pump
Rotor-to-body clearance
End clearance
7-1
7.CLUTCH/OIL PUMP/GEAR SHIFT
RIGHT CRANKCASE COVER
REMOVAL
Drain oil from the engine.
Disconnect the clutch cable.
Remove the kick starter arm.
Remove the right crankcase cover.
CLUTCH CABLE
CLUTCH
CLUTCH REMOVAL
Remove the clutch lifter rod.
Remove the oil filter rotor cover.
LIFTER ROD
Remove the 16mm lock nut with a lock nut wrench.
Remove the oil filter rotor.
OIL FILTER ROTOR
7-2
FILTER ROTOR COVER
7.CLUTCH/OIL PUMP/GEAR SHIFT
Remove the bearing, clutch bolt, clutch lifter plate and
clutch spring.
CLUTCH BOLT
CLUTCH LIFTER PLATE
CLUTCH SPRING INSPECTION
Measure the clutch springs free length.
Service limit: 28.6mm
Remove the 20mm set ring.
SET RING
Remove the clutch center, disks, plates and pressure
plate.
7-3
7.CLUTCH/OIL PUMP/GEAR SHIFT
CLUTCH CENTER
CLUTCH OUTER
CLUTCH PLATE
CLUTCH PRESSURE
CLUTCH FRICTION DISC
INSPECTION
Replace the clutch disks if they have any score or
discoloration.
Measure the clutch friction disk thickness.
SERVICE LIMIT: 2.8mm
CLUTCH PLATE INSPECTION
Check the plates for warpage on a surface plate using
a feeler gauge.
Service limit: 0.2mm
7-4
7.CLUTCH/OIL PUMP/GEAR SHIFT
Remove the 20 mm washer and clutch outer.
20mm WASHER
CLUTCH OUTER INSPECTION
Check the clutch outer for cracks or indentation.
CLUTCH OUTER INSTALLATION
WASHER
Install the clutch outer, 20mm washer on the main
shaft.
NOTE:
When installing the washer, it should fit with the
main shaft groove.
Install the clutch pressure plate, friction discs, clutch
plates and clutch center.
7-5
7.CLUTCH/OIL PUMP/GEAR SHIFT
Install and tighten the 20mm set ring.
LOCK NUT
BEARING
Install the clutch springs, lifter plate and tighten the
bolts.
Install the bearing.
NOTE:
Tighten the bolts in a crisscross pattern in two or
three steps.
TORQUE :80-120 kgf・cm
CLUTCH LIFTER PLATE
Install the oil filter rotor.
Install the lock washer and 16mm lock nut.
Tighten the 16mm lock nut.
TORQUE :400-500 kgf・cm
Install the filter rotor cover.
Check the oil through for a smooth operation without
binding.
Install the lifter rod.
Install the dowel pins and a new gasket.
Install the right crankcase cover
Connect the clutch cable.
Install the exhaust muffler and step bar.
Fill the crankcase with the recommended oil
Adjust the clutch lever free play.
Dowel pin
LIFTER ROD
7-6
FILTER ROTOR COVER
7.CLUTCH/OIL PUMP/GEAR SHIFT
OIL PUMP
OIL PUMP
OIL PUMP REMOVAL
Remove the right crankcase cove.
Remove the oil filter rotor.
Remove the oil pump cover.
OIL PUMP DRIVE GEAR
Remove the oil pump drive gear.
Remove the 6 mm screws and oil pump.
6mm SCREWS
OIL PUMP DISASSEMBLY
OIL PUMP PLATE
Remove the oil pump plate.
OIL PUMP INSPECTION
Measure the inner rotor-to-outer rotor clearance.
SERVICE LIMIT: 0.35mm
7-7
7.CLUTCH/OIL PUMP/GEAR SHIFT
Measure the outer rotor-to-body clearance.
Service limit: 0.40mm
Measure the rotor-to-cover clearance.
NOTE:
Measure the clearance with the gasket installed.
Service limit: 0.11mm
OIL PUMP ASSEMBLY
DRIVE SHAFT
DRIVE GEAR
Install the oil pump drive gear and gear shaft on the
pump body.
Install the oil pump cover.
NOTE:
Align the cutout in inner rotor with the cutout on the
shaft.
OIL PUMP COVER
Check the oil pump for rotating freely.
7-8
OIL PUMP BODY
7.CLUTCH/OIL PUMP/GEAR SHIFT
OIL PUMP INSTALLATION
O-RING
Install new O-rings.
Install the oil pump to the right crankcase.
OIL PUMP
GEARSHIFT LINKAGE
GEARSHIFT LINKAGE DISASSEMBLY
Remove the clutch.
Remove the gearshift pedal.
Remove the gearshift spindle.
GEARSHIFT SPINDLE
7-9
7.CLUTCH/OIL PUMP/GEAR SHIFT
Remove the gearshift drum stopper arm.
Remove the gearshift cam.
Check each part for wear or damage.
GEARSHIFT CAM
GEARSHIFT DRUM
STOPPER ARM
GEARSHIFT SPINDLE
4MM ROLLER
GEARSHIFT LINKAGE ASSEMBLY
Install the four 4mm roller.
Align the hole of the gearshift cam with the roller, then
install the gearshift cam.
GEARSHIFT CAM
Install the gearshift drum stopper.
NOTE
After installation, check the drum stopper
operation.
7-10
GEARSHIFT CAM
GEARSHIFT DRUM
STOPPER
7.CLUTCH/OIL PUMP/GEAR SHIFT
Install the gearshift spindle.
CLUTCH
DRIVE GEAR
NOTE :
Align the gearshift return spring on the projection
of the crankcase.
Check the gearshift linkage for smooth operation.
Install the clutch, oil pump and oil filter rotor.
OIL PUMP
RIGHT CRANKCASE COVER
INSTALLATION
Install the dowel pins and a new gasket.
Install the right crankcase cover and tighten the
screws.
Connect the clutch cable.
Install the kick starter pedal.
Fill the crankcase with the recommended oil.
Adjust the clutch lever free play.
7-11
8. A.C.GENERATOR
SERVIE INFORMATION .......................8-1
LEFT CRANKCASE COVER REMOVAL ................8-2
FLYWHEEL REMOVAL........................8-2
FLYWHEEL INSTALLATION ..............8-3
LEFT CRANKCASE COVER INSTALLATION .........8-3
STARTER MOTOR REMOVAL ...........8-4
STARTER DRIVEN GEAR REMOVAL ........8-4
STARTER MOTOR GEAR SET ..........8-4
SERVIE INFORMATION
GENERAL INSTRUCTION
This section covers removal and installation of the AC generator and starter motor.
These operation can be done with the engine installed in the frame.
Special tool
Rotor puller
TORQUE VALVE
Flywheel bolt
260~320kgf.cm
8-1
8. A.C.GENERATOR
LEFT CRANKCASE COVER
REMOVAL
LEFT CRANKCASE
COVER
LEFT CRANKCASE
REAR COVER
Remove the gearshift pedal.
Remove the left crankcase rear cover.
Disconnect the AC generator and pulse generator wire
connector.
Remove the left crankcase cover.
NOTE:
Generator stator is in the left crankcase cover, it can
be removed by removing the attaching screws.
GEARSHIFT PEDAL
FLYWHEEL REMOVAL
Remove the flywheel bolt.
FLYWHEEL SETTING BOLT
Remove the flywheel with the rotor puller.
8-2
8. A.C.GENERATOR
STATOR COIL INSPECTION
NOTE :
This inspection can be made with the stator in the
frame.
Check the starter for continuity.
Continuity should exist between:
Yellow and pink,
Black/red and ground,
Blue/white and green/white
Pink,yellow,blue/white and green/white should not
continue with the ground.
Yellow and green.
Replace the stator and pulse generator assembly if
necessary.
FLYWHEEL INSTALLATION
Reverse the procedure of removal to assembly.
NOTE :
Ÿ
Check wire for security in its place.
Ÿ Do not interfere the wire with the flywheel.
Install and tighten the flywheel.
TORQUE: 400~500 kgf· ・cm
FYL WHEEL BOLT
LEFT CRANKCASE
COVER INSTALLATION
GENERATOR WIRE
CONNECTORS
Install the left crankcase cover (with stator coil)
Connect the generator wire connectors.
Route the neutral switch wire through the groove in
the left crankcase cover.
Install the left crankcase rear cover.
Install the gearshift pedal.
8-3
8. A.C.GENERATOR
STARTER MOTOR REMOVAL
BOLTS
Disconnect the starter motor wire from the motor..
Remove the starter motor by removing the bolts.
ELECTRIC CONNECTOR
STARTER DRIVEN GEAR REMOVAL
Remove the left crankcase cover .
Remove the flywheel.
Remove the starter driven gear.
STARTER DRIVEN GEAR
STARTER MOTOR GEAR SET
STARTER MOTOR
STARTER DRIVEN GEAR
1. Starter driven gear
2 Starter reduce gear
3 Starter motor
Install the starter motor and gear in the reverse order
of removal.
8-4
STARTER REDUCE GEAR
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
TROUBLE SHOOTING ...........................9-1
SERVICE INFORMATION......................9-2
CRANKCASE SEPARATION ...............9-2
CRANKSHAFT REMOVAL ...................9-3
TRANSMISSION DISASSEMBLY.........9-5
TRANSMISSION ASSEMBLY...............9-8
KICK STARTER DISASSEMBLY.........9-10
CRANKCASE ASSEMBLY...................9-11
TROUBLE SHOOTING
HARD TO SHIFT
CRANKSHAFT NOISE
1. Shift fork bent
2. Shift fork shaft bent
1. Worn connecting rod big end bearing
2. Bent connecting rod
3. Worn crankshaft bearing
TRANSMISSION JUMPS OUT OF GEAR
GEAR NOISE
1. Gear dogs worn
2. Shift fork bent or damaged
3. Shift fork shaft bent
1. Worn transmission gears
2. Worn spline shafts
SERVICE INFORMATION
GENERAL INSTRUCTION
Transmission and crankshaft repairs require crankcase separation.
Remove the following parts before separating the crankcase:
Engine removal
Cylinder head removal
Cylinder / Piston removal
Clutch / oil pump / Gearshift linkage removal
Left crankcase cover removal
Flywheel removal
4-2
5-2
6-2
7-2
8-2
8-2
SPECIAL TOOLS
Bearing driver
Bearing driver pilot
SPECIFICATIONS
ITEM
STANDARD SERVICE
LIMIT
12.000~12.018mm
12.05mm
4.925~5.000mm
4.80mm
11.976~11.994mm
11.9mm
0.030mm below
0.050mm
15.016~15.034mm
15.08mm
Axial
0.10~0.30mm
0.6mm
radial
0.000~0.008mm
0.030mm
I.D.
Gearshift fork
Claw thickness
Shift fork shaft
O.D.
Runout
Connecting rod small End I.D.
Crankshaft
Connecting rod big
End side clearance
9-1
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
CRANKCASE SEPARATION
Remove the right crankcover and interial parts.
(7-3~ 7-13)
Remove left cover and interial parts.
9-2
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Remove the left crankcover all 6mm attaching bolts.
Separate the left crankcase from the right crankcase.
Remove the gasket and dowel pins.
CRANKSHAFT REMOVAL
CRANKCASE
Remove the left crankcase.
Remove the crankshaft.
CRANKSHAFT INSPECTION
Measure the connecting rod big end side clearance
with a feeler gauge.
Service limit: 0.60mm
Measure the connecting rod big end radial clearance.
Service limit:0.05mm
CRANKCASE
9-3
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Support the crankshaft bearings on a V-block and
measure the runout using a gauge.
NOTE:
Coat the bearing and connecting rod big end with
engine oil before installation.
Service limit: 0.050mm
Measure the connecting rod small end I.D.
Connecting rod small end I.D.
Service limit: ∮15.08mm
FREE PLAY
CRANKSHAFT BEARING
INSPECTION
Spin the crankshaft bearing by hand and check for
play. The bearing must be replaced if it is noisy or
has excessive play.
FREE PLAY
AXIAL
9-4
RADIAL
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
SHIFT FORK
SHAFT
TRANSMISSION
DISASSEMBLY
Remove the crankshaft.
Remove the shift fork shaft.
Remove the shift drum.
Remove the shift forks.
COUNTER
SHAFT
MAIN SHAFT
SHIFT DRUM
SHIFT FORK SHAFT
SHIFT DRUM
SHIFT FORK
SHIFT FORK AND SHIFT FORK
SHAFT INSPECTION
Check the shift fork for wear, bending or damage.
Measure the shift fork I.D.
Service limit: 12.05mm
CHECK FOR WEAR
OR DAMAGE
Measure each shift fork claw thickness.
Service limit: 4.80mm
9-5
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Measure the shift fork shaft O.D.
Service limit: 11.976mm
SHIFT DRUM INSPECTION
Check the gearshift drum for wear or damage.
Disassemble the transmission gears.
Check each gear for wear or damage and replace if
necessary.
Check the crankcase oil orifice for clogged, blowing
through with compressing air if necessary.
9-6
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Check the crankcase bearings, replace them if they
have excessive free play or noisy.
FREE PLAY
FREE PLAY
AXIAL
RADIAL
BEARING INSTALLATION
Install the bearings into the left, right crankcase with
special tools.
NOTE:
Install the bearing horizontally, to prevent bearing
damage.
9-7
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
TRANSMISSION ASSEMBLY
NOTE:
Before assembling,coat each gears with engine oil.
C1
C3
Counter shaft
C4
C5
C2
Main shaft
Driver sprocket
M3
M4
M5
Assemble the gears of the countershaft and mainshaft.
NOTE:
Seat the snap ring in the ring groove properly.
9-8
M2
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
Install the crankshaft assemblies in the right
crankcase.
Install the mainshaft and countershaft assemblies in
the right crankcase.
CRANKSHAFT
NOTE:
Keep the thrust washers in place during installation.
MAINSHAFT
Install the mainshaft, countershaft and shift forks.
SHIFT FORK
Install the gearshift drum.
Install the shift fork shaft.
NOTE:
Engage the shift fork guide pin with the drum
groove by raising the shift fork.
After assembling, check each part for moving
freely.
SHIFT FORK SHAFT
GEARSHIFT DRUM
9-9
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
KICK STARTER DISASSEMBLY
Remove the kick starter spindle assembly.
KICK STARTER SPINDLE
Remove the kick starter spindle from the engine.
Remove the thrust washer and drive ratchet.
Measure the I.D. of the pinion.
Service limit:24.96mm
Measure the pinion sliding O.D. of the spindle.
Service limit:24.80mm
9-10
9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER
KICK STARTER ASSEMBLY
Reverse the operation of diassembly for
assembing.
CRANK CASE ASSEMBLY
Install the gasket and dowel pins.
Install the left crankcase on the right crankcase.
NOTE:
Make sure that the gasket is in place.
9-11
10. CARBURETOR
TROUBLE SHOOTING ...........................10-1
SERVICE INFORMATION......................10-1
CARBURETOR REMOVAL...................10-2
THROTTLE VALVE DISASSEMBLY...10-2
FLOAT/FLOAT VALVE/JETS DISASSEMBLY 10-3
FLOAT/FLOAT VALVE/JETS ASSEMBLY ......10-5
FLOAT/LEVEL ADJUSTMENT.............10-5
THROTTLE VALVE ASSEMBLY..........10-5
CARBURETOR INSTALLATION...........10-6
TROUBLE HOOTING
ENGINE CRANKS BUT NOT START
1. No fuel in the fuel tank
2. No fuel in the carburetor
3. Too much fuel in the combustion chamber
4. No spark at the spark plug ( ignition malfunction )
5. Air cleaner clogged
ENGINE IDLE ROUGHLY
1. Idling speed incorrect
2. Ignition malfunction
3. Low compression
4. Rich mixture
5. Lean mixture
6. Air cleaner clogged
7. Air leaking into intake pipe
8. Fuel contaminated
LEAN MIXTURE
1. Carburetor jets clogged
2. Float chamber vent clogged
3. Fuel filter clogged
4. Fuel line restricted
5. Float level too Iow
6. Float valve faulty
RICH MIXTURE
1. Choke stuck closed
2. Float valve faulty
3. Float level too high
SERVICE INFORMATION
GENERAL INSTRUCTIONS
locations of the jets and place them individually.
Take cautions when dealing this operation.
Always work in a well-ventilated area and away from
sparks or open flames. When assembling, note the
SPECIAL TOOL
Float gauge
10-1
10. CARBURETOR
CARBURETOR REMOVAL
Disconnect the fuel line.
Disconnect the all connect tubes.
Drain fuel from the carburetor.
WARNING:
Keep away from flames or sparks. Wipe up spilled
gasoline at once.
CARBURETOR
Loosen the carburetor band.
BAND
NEEDLE SPRING
THROTTLE VALVE DISASSEMBLY
THROTTLE CABLE
Disconnect the throttle cable.
Remove the needle spring.
Remove the needle.
Check the needle and throttle valve for wear or
damage.
NEEDLE
10-2
10. CARBURETOR
Remove the carburetor assembly.
FLOAT/FLOAT VALVE/JETS
DISASSEMBLE
Remove the float chamber body.
WARNING:
Pour the float chamber gasoline into the tank
Pull out the float pin, remove the float and
float valve.
FLOAT PIN
FLOAT VALVE INSPECTION
inspect the float valve surface for wear or
damage.
WEAR OR DAMAGE
FLOAT VALVE
10-3
10. CARBURETOR
Remove the main jet, needle jet and needle
jet holder.
NOTE:
Avoid damage to the jets.
MAIN JET
NEEDLE JET
NEEDLE JET HOLDER
AIR SCREW
Remove the air screw.
NOTE:
Before removeing air screw, record the number of
relations until it rests lightly so it can be returned to
its original position.
Check each part for damage.
Blow open all body openings with compressed air.
10-4
10. CARBURETOR
FLOAT /FLOAT VALVE/
JETS ASSEMBLY
Install the stop screw, air screw, main jet,
needle jet and needle jet holder.
NOTE:
Do not damage jets at the time of assembly.
MAIN JET
FLOAT LEVEL
ADJUSTMENT
24mm
If the float level is too high or too Iow,bend the float
arm for adjusting.
Float level: 24mm
THROTTLE VALVE
ASSEMBLY
lnstall the jet needle in the valve and secure it with the
clip retainer.
10-5
10. CARBURETOR
Connect the throttle cable.
NOTE:
Route the throttle cable end through the adjuster
and the carburetor top. Make sure that the throttle
cable is pulled tightly.
NOTE:
When installing the throttle valve, align the throttle
vale groove with the pilot screw.
Throttle stop screw
CARBURETOR
INSTALLATION
Installation is essentially in the reverse odrer of
removal.
After Installation ,adjust:
Throttle grip free play (2-10).
Idling speed (2-11).
AIR SCREW
10-6
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
TROUBLE SHOOTING ...........................11-1
SERVICE INFORMATION......................11-1
HEADLIGHT.............................................11-2
METER.....................................................11-3
TROUBLE SHOOTING
FRONT WHEEL WOBBLING
HANDLE BAR .........................................11-3
FRONT WHEEL ......................................11-4
FRONT FORK..........................................11-7
STEERING STEM...................................11-8
SOFT SUSPENSION
1. Axle not tightened properly
2.Worn front wheel bearing
3. Distorted rim
1. Weak rear fork spring
2. Insufficient fluid in the front forks
HARD STEERING
HARD SUSPENSION
1. Steering stem nut too tight
2. Faulty steering stem bearing
3. Insufficient tire pressure
1. Bent front fork
2. Too much fluid in the front forks
STEERS TO ONE SIDE
FRONT SUSPENSION NOISE
1. Bent front axle
2. Bent front fork
3. Faulty front wheel
4. Misadjusted shock absorber
1. Bent front fork
2. Insufficient fluid in the front fork
3. Loose front fork fasteners
SERVICE INFORMATION
GENERAL INSTRUCTIONS
This section covers the removal, inspection and
installation of the front wheel, front fork and steering.
Before removing the front wheel, place a block under
the engine.
TORQUE VALUES
Front wheel axle nut
Handlebar upper holder
Steering stem nut
Front fork top bridge
Front fork bottom bridge
600 ~
100 ~
600 ~
400 ~
400 ~
800 kgf・cm
140 kgf・cm
800 kgf・cm
550 kgf・cm
550 kgf・cm
SPECIFICATIONS
STANDARD SERVICE
LIMIT
…………………
2.0mm
Axial
…………………
2.0mm
Radial
…………………
2.0mm
Axle runout
Rim runout
11-1
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
HEADLIGHT
screw
HEADLIGHT REMOVAL
Remove the headlight screw.
Remove the headlight case.
Disconnect the wire connector.
HEADLIGHT WIRING
Route the wires through the headlight
Connect the wires Color-to-color.
HEADLIGHT INSTALLATION
Install the headlight.
Install the headlight case aligning the mark to the
holder, tighten the bolts.
bolt
11-2
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
METER
METER REMOVAL
Remove the headlight case .
Disconnect each wire and connector.
Disconnect the meter cables.
Remove the setting screws.
Remove the meter.
setting screws
HANDLEBAR
HANDLEBAR REMOVAL
Remove the wire harness.
Remove the light switch and throttle cable, remove the
turn signal switch assembly.
Remove the handlebar upper holder bolts.
Disconnect the front brake and clutch cable from the
lever.
Remove the handlebar holders and take off the
handlebar.
HANDLE BAR INSTALLATION
Connect the front brake and clutch cable to the lever.
Install the handlebar on the lower holder.
NOTE:
Align the punch marks on the handlebar with the top
of the handlebar lower holder.
Install the handlebar holders.
NOTE:
Tighten the forward bolts to the specified torque first,
then tighten the rear bolts to the same torque.
TORQUE:100~140 kg-m
Install the light switch and throttle grip.
11-3
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
NOTE:
Coat the throttle grip hole with grease.
Install the winker switch assembly.
NOTE:
Align the punch mark on the handlebar with the split
in the housing.
FRONT WHEEL
FRONT WHEEL REMOVAL
Raise the front wheel off the ground by placing a block
under the engine.
Disconnect the speedometer cable and front brake
cable.
Remove the axle nut.
Pull out the axle, remove the front wheel.
FRONT WHEEL AXLE
SHAFT INSPECTION
Place the axle on V-blocks and measure the runout,
the actual runout is 1/2 of the total indicator reading.
Service limit: 0.2mm under
WHEEL BEARING INSPECTION
Shake the bearing back and forth and spin it by hand,
replace the bearing with a new one if it is noisy or has
excessive play.
11-4
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
FRONT BRAKE
FRONT BRAKE DISC INSPECTION (DISC
BRAKE)
Replace the brake pads if the wear indicator mark is
pointed.
Measure the brake disc thickness.
Service limit: 3.5mm
FRONT BRAKE DISASSEMBLY
Remove the caliper by removing the two caliper
mounting bolts.
Remove the pad guide bolts.
Remove the brake pads.
CAUTION:
Do not operate the brake lever after the caliper
removal to avoid brake pads sticky.
FRONT BRAKE ASSEMBLY
Reverse the procedures of disassembly to install the
brake pads.
Tighten the brake pad guide bolts.
FRONT BRAKE LINING INSPECTION
(DRUM BRAKE)
Measure the brake lining thickness.
Service limit: 2.0mm
11-5
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
BRAKE SHOES
FRONT BRAKE PANEL INSPECTION
Remove the brake shoes and springs.
Remove the brake arm and brake cam.
Remove the speedmeter drive gear and dust seal.
BRAKE CAM
FRONT BRAKE PANEL ASSEMBLY
Install a new dust seal.
Apply grease to the speedometer gear and install the
gear.
Apply grease to the sliding surfaces of the brake cam
and shoes as shown in the figure above.
Install the brake cam and brake arm aligning the
punch mark on the brake arm with the panch mark on
the cam.
Install the brake shoes and springs.
FRONT WHEEL RIM INSPECTION
Check the wheel rim runout by placing the wheel on
the turning stand.
Service limit:
Axial: 2.0mm under
Radial: 2.0mm under
FRONT WHEEL ASSEMBLY
Apply grease to the wheel bearings.
Install the right bearing and center collar.
Install the left bearing and dust seal.
Install the side collar.
NOTE:
Install the bearing with the sealed end facing
the outside.
11-6
BRAKE ARM
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
FRONT WHEEL
INSTALLATION
Install the front wheel.
Install the axle shaft from the right side.
Tighten the axle nut.
TORQUE: 600-800 kgf・cm
Connect the speedometer cable.
FRONT FORK
FRONT FORK REMOVAL
Remove the front wheel.
Remove the brake caliper bolts.
Remove the front fender.
BOLTS
Remove the fork top bridge bolts.
TOP BRIDGE BOLTS
Loosen the fork bottom bridge, remove the
front shock absorber assembly.
BOTTOM BRIDGE BOLTS
11-7
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
If the front fork is too soft or too hard, refill
or drain the shock absorber fluid.
Shock absorber fluid:
CUSHION OIL
Standard capacity :160c.c
FRONT FORK
INSTALLATION
Install the front fork from the bottom.
NOTE:
Turn the front fork left and right by hand while
installing.
Tighten the fork top bridge bolts.
TORQUE: 400-550 kgf・cm
Tighten the fork bottom bridge bolts.
TORQUE: 400-550 kgf・cm
Install the front fender.
Install the front wheel.
STEERING STEM
FRONT FORK TOP REMOVAL
Remove the handlebar.
Remove the headlight and meter assembly.
Remove the front fork.
Remove the steering stem nut and washer.
11-8
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
STEERING STEM DISASSEMBLY
Remove the front fork top bridge bolts.
NOTE:
Do not let the steel balls fall.
Remove the steel balls cone brace,steering stem and
steel balls.
Check the top and bottom cone races and steel balls
for wear or damage and replace if necessary.
STEERING STEM ASSEMBLY
STEEL
BALLS
STEEL
BALLS
TOP CONE
BRACE
STEERING
STEM
STEERING
LOCK
BOTTOM
CONE BRACE
DRIVE IN
DRIVE OUT
Install the steel balls cone race.
DRIVER
DRIVER HOLDER
11-9
11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK
Grease the steel balls and cone races, install the
steering stem.
Install the steering top nut and tighten it until snug
against the upper cone race.
Back the op nut out 1/8 turn to let steering stem be
able to rotor freely.
Install the front fork top bridge.
Install the front fork.
Tighten the front fork bottom bridge bolts.
TORQUE: 400-550 kgf・cm
TOP BRIDGE BOLT
FRONT FORK
TOP BRIDGE
Tighten the steering stem nut.
TORQUE: 600-800 kgf・cm
Tighten the front fork top bridge bolts.
TORQUE: 400-550 kgf・cm
Install the handlebar, meter, headlight and front wheel.
11-10
12. REAR WHEEL/REAR SUSPENSION
TROUBLE SHOOTING ...........................12-1
SERVICE INFORMATION......................12-1
REAR WHEEL.........................................12-2
REAR BRAKE PANEL...........................12-5
SHOCK ABSORBER .............................12-6
REAR FORK ............................................12-8
REAR BRAKE PEDAL...........................12-9
TROUBLE SHOOTING
HARD SUSPENSION
WOBBLE OR VIBRATION IN
MOTORCYCLE
1. Bent damper shaft
2. Faulty shock absorber stopper rubber
1. Loose rear wheel bearing
2. Distorted rim
3. Tire pressure too high
4. Loose axle nut
SUSPENSION NOISE
1. Loose fasteners
2. Faulty shock absorber stopper rubber
3. Damper leaking
4. Damper and spring binding
SOFT SUSPENSION
1. Weak spring
2. Shock absorber faulty or too soft
POOR BRAKE PERFORMANCE
1. Improper brake adjustment
2. Brake linings oily or worn
3. Worn brake drum
4. Brake arm serrations improperly engaged
SERVICE INFORMATION
TORQUE VALUES
Rear wheel axle nut
Rear fork pivot bolt nut
Rear brake torque link nut
Shock absorber nut
Final driven sprocket
Drive sprocket bolt
1000 ~ 1200 kgf・cm
800 ~ l000 kgf・cm
150 ~ 200 kgf・cm
300 ~ 400 kgf・cm
270 ~330 kgf・cm
100 ~ 140 kgf・cm
SPECIFICATIONS
ITEM
STANDARD SERVICE
LIMIT
Rear axle runout
0~0.01mm
0.2mm
Axial
………
2.0mm
Radial
………
2.0mm
Brake drum I.D
150mm
152mm
Brake lining thickness
4.3mm
2.0mm
Shook absorber spring free length
195.3mm
183mm
Rear fork bushing clearance
0.2~0.3mm
0.5mm
Rim runout
12-1
12. REAR WHEEL/REAR SUSPENSION
REAR WHEEL
REAR WHEEL REMOVAL
Raise the rear wheel off the ground on the main
stand.
Remove the exhaust muffler.
Disconnect the brake rod from the brake arm.
Disconnect the brake torque link from the brake
panel.
Remove the axle nut and loose the chain adjusting
nut. Pull out the axle shaft and remove the drive chain
from the drive sprocket, then remove the rear wheel.
AXLE INSPECTION
Set the axle in the V-blocks and measure the runout.
The actual runout is 1/2 of the total indicator reading.
service limit: 0.2mm under
12-2
ADJUSTING NUT
12. REAR WHEEL/REAR SUSPENSION
BEARING FREE PLAY INSPECTION
Shake the bearing back and forth and spin it by hand,
replace it with a new one if it is noisy or has excessive
free play.
WHEEL RIM RUNOUT INSPECTION
Check the rim runout by placing the wheel in a turning
stand. Turn the wheel by hand and read the runout
using a dial indicator gauge.
TORQUE: 25-50 kgf・cm
Runout:
Axial:
2.0mm under
Radial: 2.0mm under
FINAL DRIVEN SPROCKET
INSPECTION
Check the condition of the final driven sprocket teeth.
Replace the sprocket if it is worn.
NOTE:
The drive chain and drive sprocket must be also
inspected for wear.
GOOD
NOT GOOD
DAMPER RUBBER INSPECTION
Check the damper rubbers for wear or damage and
replace if necessary.
12-3
12. REAR WHEEL/REAR SUSPENSION
FINAL DRIVEN SPROCKET ASSEMBLY
Install the drive sprocket and new lock plates on the
driven flange and tighten them with the bolts and
nuts.
TORQUE:240~300 kg f・cm
Bend up the lock plate tabs against the nuts.
Install the driven flange on the wheel hub.
12-4
12. REAR WHEEL/REAR SUSPENSION
Measure the brake drum I.D.
Service limit: ∮152mm
REAR BRAKE PANEL
BRAKE ARM
BRAKE CAM
NOTE:
Grease the place as figure.
BRAKE
SHOE
BRAKE SHOE INSPECTION
Measure the lining thickness.
Service limit: 2.0mm
BRAKE SHOE REPLACEMENT
Separate the brake shoes with the brake cam.
Remove the brake shoes and springs.
Grease the brake cam.
Install the new brake shoes.
WARNING:
Contaminated brake lining reduces stopping power.
Keep grease off the lining.
12-5
12. REAR WHEEL/REAR SUSPENSION
Install the hold arm.
Install the brake linkage.
Adjust the drive chain tension (2-13).
Drive chain slack: 10 ~ 20mm
Tighten the chain tension adjusters.
Tighten the axle nut.
TORQUE: 1000~1200 kg f・cm
Apply engine oil to the drive chain.
Install the step bar and the muffler.
ADJUSTING NUT
SHOCK ABSORBER
SHOCK ABSORBER REMOVAL
Remove the left and right shock absorber assembly.
SHOCK ABSORBER DISASSEMBLY
Compress the shock absorber spring with a shock
absorber compressor.
Loosen the lock nut, remove the upper holder.
12-6
HOLDER
12. REAR WHEEL/REAR SUSPENSION
SPRING COMPRESSOR
Remove the spring and rubber.
SHOCK ABSORBER SPRING
INSPECTION
Measure the shock absorber spring free length.
Service limit: 183mm
Check the shock absorber for noisy or leaks.
SHOCK ABSORBER ASSEMBLY
NOTE:
HOLDER
Install the spring with the tightly wound coils at
the top.
TORQUE: 150-250kgf・cm
SPRING COMPRESSOR
SHOCK ABSORBER INSTALLATION
Tighten the shock absorber upper and lower
mounting nuts.
TORQUE: 300-400 kgf・cm
Check the shock absorber operation.
NOTE:
Ÿ Adjust the right and left absorber to the same
scales.
Ÿ The standard position is "1".
12-7
12. REAR WHEEL/REAR SUSPENSION
REAR FORK
REAR FORK REMOVAL
Remove the muffler.
Remove the rear wheel (12-3).
Remove the rear shock absorber (12-9).
Remove the drive chain cover.
Remove the rear fork mounting bolts.
REAR FORK
REAR FORK DISASSEMBLY/ASSEMBLY
NOTE:
BUSH
Drive the bushings out with a soft hammer, making
sure that they are not damaged. Lubricate with
grease after installation.
CHAIN ADJUSTER
PIVOT BOLT
REAR FORK INSPECTION
Inspect the pivot bushing for cracks or damage.
Check each part for wear or damage.
12-8
12. REAR WHEEL/REAR SUSPENSION
REAR FORK INSTALLATION
Install the rear fork.
TORQUE: 800~1000 kgf・cm
Install the rear shock absorber and rear wheel.
Install the muffler.
REAR BRAKE PEDAL
Remove the muffler.
Remove the brake linkage rod.
Remove the brake light switch spring.
Remove the brake return spring.
Adjust the rear brake after installation.
ADJUSTING BOLT
NOTE :
Do not forget to install the brake light switch spring.
12-9
13. BATTERY/CHARGING SYSTEM
TROUBLE SHOOTING ...........................13-1
SERVICE INFORMATION......................13-2
BATTERY.................................................13-3
CHARGING SYSTEM.............................13-4
TROUBLE SHOOTING
NO POWER --- KEY TURNED ON
1. Dead battery
-- Battery electrolyte evaporated
-- Battery not charged
-- Charging system failure
2. Disconnected battery cable
3. Main fuse burned out
4. Faulty ignition switch
LOW POWER --- KEY TURNED ON
1. Weak battery
-- Low battery electrolyte level
-- Charging system failure
2. Loose battery connection
LOW POWER --- ENGINE RUNNING
1. Battery undercharged
-- One or more dead cells
-- Low battery electrolyte level
2. Charging system failure
3. Generator failure
4. Faulty voltage regulator
5. Faulty ignition coil
6. C.D.I. UNIT failure
INTERMITTENT POWER
1. Loose battery connection
2. Loose charging system connection
3. Loose connection or short circuit in ignition system
4. Loose connection or short circuit in light system
13-1
13. BATTERY/CHARGING SYSTEM
CHARGING SYSTEM FAILURE
1. Loose broken or shorted wire
2. Faulty voltage regulator
3. Faulty generator
4. Battery undercharged
SERVICE INFORMATION
GENERAL INSTRUCTIONS
1. Battery acid level should be checked and refill with distilled water when necessary.
2. When charging the battery, quick-charging should only be done in an emergency; slow charging is preferred.
3. Remove the battery from the motorcycle for charging whenever possible. If battery must be charged on the
motorcycle, keep away from flames or sparks.
4. The parts of charging system can be tested on the motorcycle.
5.Refer to section 8 for generator removal and installation.
SPECIFICATIONS
Battery
Capacity
Electrolyte specific gravity
Charging current
12 & 8AH
1.260-1.280 (2000/68~F)
0.9A
A.C. generator
Charging output
Charging rpm
Rectifier
150W/5,000rpm
1,000 max. (Day)
2,500 max. (Night)
Three-way full wave
Fuse
15A
13-2
13. BATTERY/CHARGING SYSTEM
BATTERY
BATTERY REMOVAL AND
INSTALLATION
Remove the right side cover.
Disconnect the battery negative cable first, then the
battery positive cable.
Disconnect the battery band, remove the battery.
BATTERY INSTALLATION
Put the battery on the battery rack.
Install the battery band.
Connect the battery positive cable first, then the
battery negative cable.
Install the right side cover.
SPECIFIC GRAVITY TEST
Test each cell by using a hydrometer.
SPECIFIC GRAVITY :
1.260-1.280
Fully charged
1.220 or below
Undercharged
(20℃/68 °F )
NOTE ~
•
•
•
•
The battery must be recharged if the specific
gravity is below 1.23.
The specific gravity varies with the temperature as
shown in the accompanying table.
Replace the battery if sulfating is evident.
The battery must be replaced if there are pastes
on the bottom of each cell.
WARNING:
The battery electrolyte contains sulfuric acid.
Protect your skin, eyes and clothing. Note the
followings:
1. In case of contact, flush thoroughly with water.
2. In case of drinking, drink mass of water or milk,
and eat the white of an egg or drink vegetable oil.
3. Cover the eyes when operating at short distance,
in case of contact, flush thoroughly with water and
spread of eye-ointment.
4. Keep flames and sparks away from a charging
battery.
5.Place the charging battery in a ventilate area.
13-3
13. BATTERY/CHARGING SYSTEM
Connect the charger positive(+) cable to the battery
positive (+) terminal, negative (-) cable to the battery
negative (-) terminal.
Charge the battery until the specific gravity of the
electrolyte is 1.260-1.280 (20℃/68℉ )
Charging current: 0.7A max.
WARNING:
Before charging a battery, remove the cap from
each cell.
Keep flames and sparks away from a charging
battery.
Connect the cables first, then turn on the power.
Discontinue charging if the electrolyte temperature
exceeds 45 ℃ (113℉).
CAUTION:
Quick-charging only be done in an emergency;
slow-charging is preferred.
After installed the battery, coat the terminals with clean
grease to keep from oxidation.
CAUTION:
Route the breather tube as shown on the battery
caution label.
CHARGING SYSTEM
PERFORMANCE TEST
VOLTMETER
Warm up the engine before taking readings.
Connect a voltmeter and an ammeter to check
charging output.
NOTE:
Use a fully charged battery to check the charging
system output.
BATTERY
13-4
AMMETER
13. BATTERY/CHARGING SYSTEM
STATOR COILS TEST
NOTE:
This test can be made with the stator on the frame.
Disconnect and measure the A.C. generator
connectors with a multi-meter.
Conductivity should exit between :
Pink- yellow,blue/white-green/white,black/red-ground.
Pink,yellow,blue/white,green/white should not conduct
electricity with ground.
RECTIFIER
RECTIFIER
Disconnect the rectifier connector and check its
performance.
WARNING:
Do not use high voltage power, especially the
ohmmeter, or the rectifier will be burnt out.
(-)
RED
(+)
RED
GREEN
YELLOW
PINK
BLACK
∞
∞
∞
∞
√
√
√
∞
∞
GREEN
√
YELLOW
√
∞
PINK
√
∞
∞
BLACK
√
∞
∞
∞
∞
Rectifier is normal if there is continuity only in the direction shown.Replace the rectifier if there is continuty in
reverse direction.
13-5
14. IGNITION SYSTEM
TROUBLE SHOOTING ...........................14-1
SERVICE INFORMATION......................14-2
IGNITION COIL ...........................................14-3
TROUBLE SHOOTING
ENGINE CRANKS BUT NOT START
Green/white
1. No sparks at the spark plug
2. Improper ignition timing
3. Faulty plug
Blue/white
Black/ yellow
NO SPARKS AT THE SPARK PLUG
1. No current in primary circuit
2. High tension cord broken
3. Faulty ignition coil
4. Faulty A.C. generator
5. Faulty C.D.I. unit
C.D.I.
Green
ENGINE RUNS BUT ROUGHLY
1. Primary circuit
-- C.D.I. unit failure
-- Faulty A.C. generator
-- Faulty ignition coil
-- Loose wires
-- Poorly contacted switch terminals
2. Secondary circuit
-- Faulty,spark plug
-- Faulty high tension cord
-- Faulty ignition coil
3. Ignition timing
-- Faulty A.C. generator
-- Faulty C.D.I. unit
Black/red
Black/white
14-1
14. IGNITION SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTION
This section contains the ignition system.
Be sure that the battery is fully charged before
diagnosing troubles in the ignition system.
Also refer to the following pages:
Spark plug
2-5
Ignition timing adjustment
2-8
SPECIFICATIONS
Spark plug:
Spark plug gap:
Ignition timing :Initial
Full advance
14-2
D7RC
0.6~0.7mm(0.024-0.028in)
15°±2°/1500rpm
29.5°±2°/4000rpm
14. IGNITION SYSTEM
IGNITION COIL
IGNITION COIL
IGNITION COIL REMOVAL
Remove the seat.
Remove the fuel tank.
Remove the spark plug cap.
Disconnect all wires to the ignition coil.
Remove the ignition coil.
IGNITION COIL TEST
Check the ignition coil output using a tripolar tester.
NOTE:
Follow the instructions described in the user
manual.
Check the primary circuit, it is normal if there is
conductivity when connecting a ohmmeter.
PRIMARY COIL
0.31±0.03KΩ
SECONDARY COIL
4.0±0.4KΩ
14-3
15. SWITCHES/HORN
TROUBLE SHOOTING ...........................15-1
SERVICE INFORMATION......................15-2
MAIN/DIMMER SWITCH ........................15-3
WINKER/HORN SWITCH.......................15-3
HEADLIGHT SWITCH ............................15-3
HEADLIGHT SWITCH ............................15-3
START/HAZARD SWITCH.....................15-3
FRONT/REAR BRAKELIGHT SWTICH........15-4
HORN SWTICH .......................................15-4
TROUBLE SHOOTING
NO LIGHTS COME ON WHEN IGNITION
SWITCH IS TURNED ON:
1. Battery low
2. Wiring loose or blown
3. Fuse blown
4. Open or shorted wiring
5. Faulty combination switch
6. Bulb at fault or burned out
ALL LIGHTS COME ON BUT DIMLY WHEN
IGNITION SWITCH IS TURNED ON:
1. Battery low
2. Wiring or switch has excessive resistance
HEADLIGHT BEAMS DO NOT SHIFT WHEN
HIGH-LOW SWITCH IS OPERATED:
1. Faulty dimmer switch
2. Faulty headlight switch
15-1
15. SWITCHES/HORN
SERVICE INFORMATION
GENERAL INSTRUCTIONS
All electrical wires are color-coded. Check the color before connecting wires.
All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when
reconnecting.
A conductivity check can usually be made without removing the part from the motorcycle by simply
disconnecting the wires and connecting a galvanometer or voltmeter to the terminals or connections.
SPECIFICATIONS
Headlight
Winker light
Tail / Stop light
Speedometer light
Neutral pilot
Winker indicator
High beam pilot
15-2
12V
12V
12V
12V
12V
12V
12V
35/35W
10W
5W/21W
3.4W x 2
3.4W
3.4W
1.7W
15. SWITCHES/HORN
MAIN SWITCH
WIRE COLOR
DIMMER SWITCH
BLACK/
WIRE COLOR
BROWN/
GREEN
RED
BLACK
G
R
B
WHITE
RED
Br
B/W
Br/R
○
○
○
○
○
○
○
BLUE
L
BROWN/WHITE
○
○
Br/W
SWITCH POSITION
SWITCH POSITION
P
WHITE
W
BROWN
○
○
○
○
○
WINKER SWITCH
HORN SWITCH
WIRE COLOR
WIRE COLOR
SKY BLUE
SB
GRAY
Gr
ORANGE
O
G
LIGHT GREEN
LG
○
○
GREEN
SWITCH POSITION
SWITCH POSITION
○
○
○
●
○
●
LIGHT SWITCH
WIRE COLOR
BLACK
B
BROWN
Br
BROWN/WHITE
Br/W
○
○
○
○
○
SWITCH POSITION
●
START SWTICH
HAZARD SWITCH
WIRE COLOR
WIRE COLOR
YELLOW/RED
Y/R
BLACK
B
ORANGE
O
○
○
SWITCH POSITION
SWITCH POSITION
○
●
GRAY
Gr
○
SKY
BLUE
SB
●
15-3
15. SWITCHES/HORN
FRONT BRAKELIGHT SWITCH
Check that the front brakelight switch for conductivity
between the BLACK and GREEN/YELLOW wires. The
switch is normal if there is conductivity with the front
brake applied.
STOP SWITCH
REAR BRAKELIGHT SWITCH
The switch is normal if there is conductivity with the
rear brake applied.
HORN
ADJUSTING SCREW
Connect the horn to a 12V battery for testing its
performance. Adjust tile horn if the noise is not loud
enough.
BATTERY
ATTACHING NUT
15-4
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