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SF50 Service Manual Hyosung Motors
SF50 Service Manual Hyosung Motors
SERVICE MANUAL
SERVICE MANUAL
99000-91310
GROUP INDEX
FOREWORD
PERIODIC MAINTENANCE
ENGINE
FUEL SYSTEM
4
5
CHASSIS
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ELECTRICAL SYSTEM
SERVICING INFORMATION
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GENERAL INFORMATION
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COMPONENT PARTS
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and
meaning associated with them respectively.
DEFINITION
SYMBOL
DEFINITION
Apply THREAD LOCK1324.
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Apply BOND1215.
SYMBOL
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GENERAL INFORMATION
1
CONTENTS
1-1
GENERAL PRECAUTIONS
1-1
1-3
1-3
BREAK-IN PROCEDURES
1-4
EXTERIOR ILLUSTRATION
1-5
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SPECIFICATIONS
INFORMATION LABELS
1-6
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NOTE:
Indicates special information to make maintenance easier or instructions cleaner.
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GENERAL PRECAUTIONS
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Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
WARNING
Proper service and repair procedures are important for the safety of the service machanic and the safety
and reliability of the vehicle.
When 2 or more persons work together, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in is wellventilated
and that you follow all off the material manufacturers instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for
leaks.
CAUTION
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If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean, and also lubricated when specified.
When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
When removing the battery, disconnect the negative cable first and then positive cable. When reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the
positive terminal.
When performing service to electrical parts, if the service procedures do not require use of battery power, diconnect the negative cable at the battery.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and
certain other parts as specified, be sure to replace them with new ones. Also, before installing these new
parts, be sure to remove any left over material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
Do not use self-locking nuts a few times over.
Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil
if a thread is smeared with them.
After reassembly, check parts for tightness and operation.
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To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
To protect Earths natural resouces, properly dispose of used vehicles and parts.
LEFT SIDE
RIGHT SIDE
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The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame under the
footboard. The engine serial number is located on the up side of the crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.
TRANSMISSION OIL
Make sure that the transmission oil you use comes under API
classification of SH, SG or SF and that its viscosity rating
is SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motor
oil is not available, select an alternate according to the right chart.
ENGINE OIL
Specification and classification: APOLLOIL BIKE-K, HYPOL HS
BRAKE FLUID
Specification and classification: DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
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BREAK-IN PROCEDURES
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During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts toBREAK-INbefore subjecting the engine to maximum
stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its
early life. The general rules are as follows:
Keep to these break-in engine speed limits:
Up to 1,000km(600miles): Less than 1/2 throttle.
Upon reaching an odometer reading of 1,000 km you can subject the motorcycle to full throttle operation.
Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
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740
125
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990
1,110
320
350
635
EXTERIOR ILLUSTRATION
1,270
1,825
135
Tail/Brake lamp
710
535
690
(Front) Turnsignal
lamp
600
Rear reflector
(Rear) Turnsignal
lamp
Head lamp
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Dry mass
ENGINE
Two-stroke, forced air cooled
1
41 mm (1.6 in)
37.4 mm (1.5 in)
49 (3.0 cu.in)
SIDE DRAFT VARIABLE VENTURI (PISTON)
Wet filter type
Kick/self starter
7.4 : 1
Reed valve
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Type
Number of cylinder
Bore
Stroke
Piston displacement
Carburetor
Air cleaner
Starter system
Corrected compression ratio
Intake system
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TRANSMISSION
Front suspension
Rear suspension
Caster
Trail
Steering angle
Front tire size
Rear tire size
Front brake
Rear brake
CHASSIS
Clutch
Reduction ratio
Drive system
Telescopic type
Coil spring type
25
75mm (2.95in)
45(right & left)
110/70-12 47J
120/70-12 51J
Disc
Drum
ELECTRICAL
CDItype
20B.T.D.C. at 1,000 rpm
BR8HSA
12V 3Ah/10HR
Magneto
10A
15W2
10W4
5/10W
1.7W2
1.7W
1.7W
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Ignition type
Ignition timing
Spark plug
Battery
Generator
Fuse
Headlamp
Turn signal lamp
Tail/Brake lamp
Speedometer lamp
Oil level indicator lamp
Turn signal indicator lamp
CAPACITIES
4.8
1.0
110cc (Replace)
130cc (Overhaul)
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Fuel tank
Engine oil tank
Transmission oil
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NOTE:
The specifications are subject to change without notice.
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE
2- 1
MAINTENANCE PROCEDURES
2- 3
2- 3
2- 4
2- 4
SPARK PLUG
2- 4
FUEL LINE
AIR CLEANER ELEMENT
THROTTLE CABLE PLAY
TIRES
STEERING
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TRANSMISSION OIL
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OIL PUMP
BRAKES
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BATTERY
FRONT SUSPENSION
2- 5
2- 5
2- 6
2- 7
2- 7
2- 8
2- 8
2-10
2-11
2-11
REAR SUSPENSION
2-12
2-12
Every 8,000 km
page
Battery
Inspect
Inspect
2-3
Inspect
Inspect
2-4
Clean
2-4
Clean
Replace
2-4
Inspect
Item
Clean
Inspect
Fuel line
Inspect
Inspect
2-6
Inspect
Inspect
2-7
Inspect
Inspect
2-7
Inspect
Inspect
2-8
Initial 1,000 km
Every 4,000 km
Every 8,000 km
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Inspect
Inspect
2-9
Inspect
Inspect
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Oil pump
Transmission oil
2-5
2-5
CHASSIS
Interval
Item
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Initial 1,000 km
Interval
Brakes
Brake hose
Inspect
Inspect
2-9
2-9
Tires
Inspect
Inspect
2-10
Steering
Inspect
Inspect
2-11
Front suspension
Inspect
Inspect
2-11
Rear suspension
Inspect
Inspect
2-12
Inspect
Inspect
2-12
LUBRICATION CHART
The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is
calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.
Interval
Every 8,000 km
Motor oil
Throttle grip
Grease
Brake cable
Motor oil
Speedometer cable
Grease
Grease
Brake cam
Grease
Item
Throttle cable
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WARNING
Be careful not to apply too much grease into the brake cam. If grease is on the linings, brake slippage will
result.
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Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has
been operated under wet or rainy conditions.
Before lubricating each part, clean off rusty sports and wipe off grease, oil, dirt or grime.
MAINTENANCE PROCEDURE
This section describes the service procedures for
each section of the periodic maintenance.
BATTERY
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
Bettery voltage
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Standard charge
0.4A5~10 Hours
Fast charge
4A30 Minutes
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CAUTION
Recharge
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W h e n r e c h a r g i n g t h e b a t t e r y r e m o v e
the battery from motorcycle.
Otherwise, regulator/rectifier unit
should be an obstacle.
W h e n r e c h a r g i n g t h e b a t t e r y , d o n o t
remove the caps.
When recharging the battery, above the
charge electric current and time should
be kept as 12V.
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NOTE:
Remove carbon Every 8,000km.
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SPARK PLUG
NOTE:
Inspect Initial 1,000km and Every 4,000km,
Replace every 8,000km.
Neglecting the spark pulg maintenance eventually leads to
difficult starting and poor performance. If the spark plug is
used for a long period, the electrode gradually burns away
and carbon builds up along the inside part. In accordance
with the Periodic Inspection Chart, the plug should be
removed for inspection, cleaning and to reset the gap.
Carbon deposits on the spark plug will prevent good
sparking and cause misfiring. Clean the deposits off
periodically.
Carbon
0.6 ~ 0.7 mm
Standard
BR8HSA
CAUTION
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FUEL LINE
NOTE:
Inspect Initial 1,000 km and Every 4,000 km,
Replace every four years.
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Inside
CAUTION
Non-flammable
cleaning solvent
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Hyosung
genuine oil
0.5 ~ 1.0 mm
Fixing
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OIL PUMP
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NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
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The engine oil is fed by the oil pump to the engine. The
amount of oil fed to it is regulated by engine speed and
oil pump control lever which is controlled by amount of
throttle opening.
Check the oil pump in the following manner to confirm
correct operation for throttle valve full closing position.
Fix the throttle grip. (The early idling condition)
Check whether the mark on the oil pump control
lever is aligned with the index mark when the
throttle grip is fixed as above.
If the marks are not aligned, loosen lock nuts and
turn the adjuster in or out to align the marks.
After aligning the marks, tighten the lock nuts .
CAUTION
TRANSMISSION OIL
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
Inspect transmission oil periodically following procedure
below.
Remove the low leg shield.
Remove the clutch cover.(Refer to page 3-6)
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BRAKES
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NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
Replace the hose Every four years.
Replace the brake fluid Every two years.
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Middle line
DOT4
WARNING
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joints
for leakage before riding.
BRAKE PADS
Wearing condition of brake pads can be checked by
observing the limit line marked on the pad. When the
wear exceeds the limit mark, replace the pads with new
ones.
BRAKE LAMP SWITCH
For the brake lamp come on after the brake lever is
pulled, adjust the brake lamp switch.
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Do original position
Turning
Turning
Turning
15~25 mm
WARNING
REAR BRAKE
Adjust by turning the adjusting nut so that the play
is 15~25 mm as shown in the illustration.
Range
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Front
Index mark
Brake lining wear limit
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Index mark
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Front
Play
is
had
little
Adjuster
nut
Play
is had
much
TIRES
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
TIRE PRESSURE
If the tire pressure is too high, the motorcycle will tend to
ride stiffly and have poor traction. Conversely, if the tire
pressure is too low, stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
roadability and to prolong tire life.
CAUTION
SOLO RIDING
DUAL RIDING
kpa
kg/
kpa
kg/
FRONT
123
1.25
172
1.75
REAR
196
2.00
221
2.25
REAR
1.6 mm
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FRONT
NORMAL RIDING
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COLD INFLATION
TIRE PRESSURE
STEERING
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
FRONT SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
Inspect the front shock absorber for oil leakage or other
damage, and replace the defective parts, if necessary.
OVER
NORMAL
SHORT
REAR SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
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NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
Inspect the rear shock absorber for oil leak and the
mounting rubbers including engine mountings for wear
and damage. Replace the defective part if necessary.
These bolts and nuts listed below are important safety parts. They must be loosened first and retightened, to the specified
torque with a torque wrench.
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ENGINE
CONTENTS
3- 1
3- 1
ENGINE REMOUNTING
3- 3
ENGINE DISASSEMBLY
3- 4
3-14
3-14
BEARINGS
OIL SEALS
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CRANKSHAFT
3-14
3-15
3-15
CYLINDER HEAD
3-18
CYLINDER
PISTON
OIL SEALS
BEARINGS
BUSHINGS
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ENGINE REASSEMBLY
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REED VALVE
3-19
3-19
3-22
3-22
3-22
3-23
3-23
3-24
CRANKCASE
3-25
CENTER STAND
3-26
3-27
TRANSMISSION
3-29
3-31
3-32
MOVABLE DRIVE
3-36
KICK STARTER
3-38
PISTON
3-40
3-42
MAGNETO
3-43
MUFFLER
3-45
CRANKSHAFT
3-1 ENGINE
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Disconnect the oil pump cable and the thermoelement lead coupler .
Disconnect the throttle cable. (Refer to page 4-2)
ENGINE 3-2
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3-3 ENGINE
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UPmark
8mm
Damper
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Front side
10mm
ENGINE REMOUNTING
ENGINE 3-4
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ENGINE DISASSEMBLY
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MUFFLER
Remove the muffler by removing the nuts.
MAGNETO
Remove the cooling fan.
Remove the magneto rotor nut with the special
tool.
Rotor holder : 09930-40113
3-5 ENGINE
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REED VALVE
Remove the intake pipe with reed valve .
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OIL PUMP
Remove the oil pump .
Remove the oil pump driven gear .
CYLINDER
Remove the cylinder cowling.
Remove the cylinder head and cylinder .
ENGINE 3-6
PISTON
Place a cloth beneath the piston and remove the piston circlip with a long nose pliers.
Remove the piston pin and piston .
Remove the piston pin bearing .
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KICK STARTER
Remove the kick starter lever .
Remove the clutch cover .
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3-7 ENGINE
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ENGINE 3-8
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CAUTION
3-9 ENGINE
CAUTION
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CAUTION
TRANSMISSION
Drain transmission oil.
Remove the gear box cover .
Remove the driveshaft .
ENGINE 3-10
Remove the oil seal from the gear box cover with
the special tool.
Oil seal remover : 09913-50121
CAUTION
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CAUTION
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3-11 ENGINE
WHEEL, BRAKE
Remove the rear axle nut and washer .
Remove the rear wheel .
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ENGINE 3-12
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CENTER STAND
Remove the return spring .
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CRANKCASE
Remove the crankcase securing screws.
CAUTION
3-13 ENGINE
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ENGINE 3-14
Bushing
Front side
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Rear side
Bushing
Crankcase
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Crankcase
BEARINGS
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ENGINE COMPONENTS
INSPECTION AND SERVICING
OIL SEAL
Damage to the lip of the oil seal may result in leakage of
the fuel-air mixture or oil. Inspect for damage and be
sure to replace the damaged seal if found.
Bushing
3-15 ENGINE
CRANKSHAFT
CRANKSHAFT RUNOUT
Support crankshaft byVblocks, with the dial gauge
rigged to read the runout as shown.
Crankshaft runout
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ENGINE 3-16
1. CLUTCH-IN INSPECTION
Warm up the motorcycle to normal operating temperature.
Remove the right frame side cover.
Connect an engine tachometer to the engine.
Seated on the motorcycle with the motorcycle on level
ground, increase the engine RPMs slowly and note the
RPM at which the motorcycle begins to move forward.
Engine tachometer : 09900-26006
Standard
3,600 rpm
Tolerance
200 rpm
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Clutch-in RPM
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CAUTION
Tolerance
200 rpm
Standard
3-17 ENGINE
CAUTION
DRIVE V-BELT
Remove the drive V-belt and check for cracks, wear and
separation. Measure the drive V-belt width with a vernier
calipers. Replace it if the drive V-belt width is less than
the service limit or any defect has been found.
Drive V-belt width
CAUTION
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DRIVE FACE
Inspect the V-belt contact surface of the drive faces for
wear, scratches or any abnormality. If there is something unusual, replace the drive face with a new one.
ENGINE 3-18
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CYLINDER HEAD
Decarbon the combustion chamber.
Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a
clearance reading at several places.
Thickness gauge : 09900-20806
Cylinder head distortion
3-19 ENGINE
CYLINDER
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Cylinder bore
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The wear of the cylinder wall is determined from diameter reading taken at 20 mm from the top of the cylinder
with a cylinder gauge. If the wear thus determined
exceeds the limit indicated below, rework the bore to the
next oversize by using a boring machine or replace the
cylinder with a new one.
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PISTON
CYLINDER TO PISTON CLEARANCE
Cylinder-to-piston clearance is the difference between
piston diameter and cylinder bore diameter. Be sure to
take the maked diameter at right angles to the piston
pin. The value of elevation is prescribed to be 15 mm
from the skirt end.
Micrometer(25~50 mm) : 09900-20202
Piston diameter
ENGINE 3-20
As a result of the above measurement, if the piston-tocylinder clearance exceeds the following limit, overhaul
the cylinder and use an oversize piston, or replace both
cylinder and piston. The measurement for the bore
diameter should be taken in the intake-to-exhaust port
direction and at 20mm from the cylinder top surface.
Serivice limit
Cylinder bore
41.005~41.020 mm 41.070 mm
Piston diameter
40.935~40.950 mm 40.885 mm
0.120 mm
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DE-CARBONING
De-carbon the piston and piston ring grooves, as illustrated. After cleaning the grooves, fit the rings and rotate
them in their respective grooves to be sure that they
move smoothly.
Carbon in groove is liable to cause the piston ring to get
stuck in the groove, and this condition will lead to
reduced engine power output.
A piston whose sliding surface is badly grooved or
scuffed due to overheating must be replaced. Shallow
grooves or minor scuff can be removed by grinding with
emery paper of about # 400.
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Standard
3-21 ENGINE
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Service Limit
0.75 mm
PISTON RINGS
Check each ring for end gap, reading the gap with a
thickness gauge shown in the illustration. If the end gap
is found to exceed the limit, indicated below, replace it
with a new one.
The end gap of each ring is to be measured with the
ring fitted squarely into the cylinder bore and held at the
least worn part near the cylinder bottom, as shown in
the illustration.
Service limit
1st
3.2 mm
2nd
3.1 mm
Fix the piston ring in the piston ring groove, measure the
ring side clearance with the thickness gauge while
matching the sliding surfaces of piston and ring.
Piston ring-ring groove clearance
Standard
1st
0.02~0.06 mm
2nd
0.02~0.06 mm
ENGINE 3-22
REED VALVE
When reinstalling the reed valve and stopper plate to
the body, align the both cut on the reed valve and stopper plate.
Apply THREAD LOCK 1324 to the stopper plate
securing screws.
Thread Lock1324
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ENGINE REASSEMBLY
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OIL SEALS
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ell
S h
A valnia
3
I ndustrial e
purpos
M ulti-
ase
G re
3-23 ENGINE
BEARINGS
Install new bearings with the special tool.
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BUSHINGS
NOTE:
Knurled end should face inside. Protrusion and
should be in the same dimension.
ENGINE 3-24
Bushing
Bushing
Crankcase
Crankcase
CRANKSHAFT
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Crank shaft
Crankcase RH
Oil seal
Oil seal
Oil pump drive gear
Oil pump driven gear
Oil seal
Standard 35.00.1 mm
3-25 ENGINE
BOND1215
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CRANKCASE
NOTE:
Align the oil seal with edge of the crankcase as
shown in the illustration.
Bearing installer : 09913-85210
ENGINE 3-26
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CENTER STAND
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3-27 ENGINE
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Brake
cam
ENGINE 3-28
Slit
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CAUTION
Super GreaseA
3-29 ENGINE
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TRANSMISSION
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Thrust
Center
Circlip
Rounded coner
ENGINE 3-30
Super GreaseA
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Oil seal
Align face
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3-31 ENGINE
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ENGINE 3-32
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3-33 ENGINE
CAUTION
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Thrust
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Rounded coner
CAUTION
Oil seal
Super GreaseA
Insert up to contact
to the stopper.
ENGINE 3-34
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Super GreaseA
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Pin
Spacer
CAUTION
3-35 ENGINE
CAUTION
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ENGINE 3-36
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MOVABLE DRIVE
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3-37 ENGINE
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CAUTION
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Super GreaseA
Install the spring and spacer .
ENGINE 3-38
Replace
110
Overhaul
130
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KICK STARTER
3-39 ENGINE
Super GreaseA
Position the kick starter shaft return spring and hook
the spring end on the crankcase cover boss .
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CAUTION
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ENGINE 3-40
CAUTION
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PISTON
Locating pin
CORRECT
INCORRECT
3-41 ENGINE
Apply engine oil on the piston pin and install the piston to the conrod.
CAUTION
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Inside Outside
ENGINE 3-42
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Super GreaseA
3-43 ENGINE
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MAGNETO
ENGINE 3-44
Thread Lock1324
Rotor holder : 09930-40113
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3-45 ENGINE
MUFFLER
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FUEL SYSTEM
CONTENTS
4- 1
CARBURETOR
REMOVAL
4- 1
DISASSEMBLY
4- 2
INSPECTION
4- 4
4- 5
FUEL TANK
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REMOVAL
CLEANING
REMOUNTING
OIL PUMP
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FUEL PUMP
4- 7
4- 7
4- 8
4- 8
4- 8
4- 9
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CARBURETOR
REMOVAL
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DISASSEMBLY
Remove the thermoelement assembly.
CAUTION
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INSPECTION
Foreign matter
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Install the air vent hose , oil hose and fuel hose .
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FUEL TANK
REMOVAL
Remove the low leg shield .
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CLEANING
Dust from the fuel tank tends to bulid up in the fuel filter
which, when the fuel filter has been neglected for a long
period, inhibits the flow of fuel.
Remove the dust from, the fuel filter using compressed air.
REMOUNTING
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OIL PUMP
AIR BLEEDING
Whenever evidence is noted of some air having leaked
into the oil pipe from the oil tank in a machine brought in
for servicing, or if the oil pump has to be removed for
servicing, be sure to carry out an air bleeding operating
with the oil pump in place before returning the machine
to the user.
To bleed air, hold the machine in standstill condition.
Loosen the air bleeding screw to let out air and after
making sure that the trapped air has all been bled, tighten the air bleeding screw completely.
Engine oil
discharge amount
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CAUTION
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FUEL PUMP
REPLACE
Remove the rear shock absorber, and support the
center stand by a 70 mm wooden block.
Open the seat, and remove the trunk by loosing the
four nuts.
Remove the one lock nut of fuel pump.
Disconnect the inlet hose.
CAUTION
ELECTRICAL SYSTEM
CONTENTS
ELECTRICAL PARTS
5- 1
IGNITION/CHARGING SYSTEM
5- 2
5- 2
STATOR COILS
5- 3
REGULATOR/RECTIFIER
5- 4
IGNITION COIL
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STARTER SYSTEM
5- 4
5- 5
5- 6
5- 7
5- 8
5- 9
5-10
BATTERY
5-11
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SWITCHES INSPECTION
ELECTRICAL PARTS
Ignition coil
Thermolement assembly
Fuel level gauge
Oil level gauge
Rear brake
cable
Wiring
harness
Speedometer
cable
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Brake
hose
Head Lamp
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Regulator
IGNITION/CHARGING SYSTEM
Stator
lgnition
coil
Regulator/Rectifier
CDI
unit
Spark
plug
Lighting
switch
T/L
M/L
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Engine stop
switch
H/L
Battery
12V 3AH
(MF)
12V
12V
5W 1.7W2
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12V
15W2
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IGNITION COIL
Over 8 mm
Yellow
Red(+)
Spark
Black
Black(-)
0.19 ~ 0.24
Secondary
5.4 ~ 6.6
B/R
C.D.I. UNIT
Using the pocket tester (R 1 range), measure the
resistance between the lead wire in the following table.
Pocket tester : 09900-25002
Unit :
Ground
Plug cap
B/R
B/W
Br
7~10
3~4
7~10
5~7
W/BL 14~18
B/R
3~5
B/W 7~11
3~4.5
W 12~16
6~8
25~35
Br 10~14
5~7
1.2~2.5
B/Y
3~4.5 1.2~2.5
27~37
5~8
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B/Y
W/BL
B/W
Probe of tester to :
B/Y
Probe of tester to :
STATOR COILS
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Standard resistance
(Black)
Y/W
Ground
W/R
Ground
B/R
Ground
Exciting coil
220 ~ 260
Br
Pick-up coil
90 ~ 110
(Red)
W/BL
B/R
Br
502~ 260
50 ~ 230
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10 ~ 100
Unit :
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REGULATOR/RECTIFIER
STARTER SYSTEM
The starter system is shown in the diagram below: namely, the starting motor, starter relay, starter switch and battery.
Depressing the starter switch (on the right handlebar switch box) while squeezing the front or rear brake lever energizes
the relay, causing the contact points to close which connects the starting motor to the battery.
Starter relay
R
R/W
Fuse
Y/G
IG switch
Starter switch
Point
Brake switch
Battery
W/B
Starter
motor
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CARBON BRUSHES
When the brushes are worn, the motor will be unable to
procedure sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically inspect the
length of the brushes and replace them when they are
too short or chipping.
Carbon brushes wear
Service limit 4 mm
COMMUTATOR
If the commutator surface is dirty, starting performance
will decrease. Polish the commutator with #400 or similar fine emery paper when it is dirty. After polishing wipe
the commutator with a clean dry cloth.
Measure the commutator under cut .
Commutator under cut
Service limit 4 mm
Segment
ARMATURE COIL
Using the pocket tester, check the coil for open and
ground by placing probe pins on each commutator segment and rotor core (to test for ground)and on any two
segments at various places (to test for open), with the
brushes lifted off the commutator surface.
If the coil is found to be open-circuited or grounded,
replace the armature. Continuous use of a defective
armature will cause the starting motor to suddenly fail.
Pocket tester : 09900-25002
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B/W
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Y/B
Fuel tank
Resistance
1/2
38
90
E(Empty)
-6
10
1/2
+ 10
0
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F(Full)
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IG switch
Battery
Switch
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THERMOELEMENT
B/R
R
Y/W R/W
Battary
Regurator/Rectifier
PTC
Magneto
INSPECTION
Disconnect the thermoelement coupler .
Connect the thermoelement coupler to a 12V battery and touch the thermoelement to check the
temperature being raised.
The thermoelement should become heated to a
temperature more than that of human body within
five minutes. If not, replace with new one.
CAUTION
SWITCHES INSPECTION
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STARTER SWITCH
ON
W/B
Y/G
OFF
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W/B
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OFF
Black
Blue
Green
Gray
Light blue
Light green
Orange
Red
White
Yellow
Black with Red tracer
Black with White tracer
White with Black tracer
Yellow with White tracer
Yellow with Green tracer
Blue with White tracer
Lg
L
Sb
WIRE COLOR
B
L
G
Gr
Sb
Lg
O
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W
Y
B/R
B/W
W/B
Y/W
Y/G
L/W
ON
HORN SWITCH
ON
B/W
OFF
IGNITION SWITCH
B/W
B/R
LOCK
OFF
LIGHTING SWITCH
ON
OFF
Gr
Y/W
ON
C
L/W
BATTERY
BATTERY
YT4L-BS
Type
Capacity
12V, 3AH/10HR
1.32(at 20)
Filter
Cap
Safety valve
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INITIAL CHARGING
FILLING ELECTROLYTE
Remove the aluminum tape sealing the battery
electrolyte filler holes .
Pole plate
Pole plate
Separator
(fiberglass plate)
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Make sure air bubbles are coming up each electrolyte container, and leave in this position for about
more than 20 minutes.
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NOTE:
If no air bubbles are coming up from a filler port, tap the
bottom of the two or three times.
Never remove the container from the battery.
(at 25)
seconds
NOTE:
Initial charging for a new battery is recommended if two
years have elapsed since the date of manufacture.
(Minutes)
Time
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RECHARGING OPERATION
Fast
Standard
Voltage
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(at 0~40)
Voltage
NOTE:
When a battery is left for a long term without using, it is
subject to discharge. When the motorcycle is not used
for more than 1 month(especially during the winter season), recharge the battery once a month at least.
(Minutes)
Time
WARNING
CHASSIS
CONTENTS
6- 1
FRONT BRAKE
6- 7
FRONT FORK
6-14
STEERING
6-18
6-22
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FRONT WHEEL
6-1 CHASSIS
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FRONT WHEEL
Do not operate the front brake lever while dismounting the caliper.
CHASSIS 6-2
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6-3 CHASSIS
Drive out the both bearing with the special tool in the following procedures.
Insert the adapter into the bearing.
After inserting the wedge bar from the opposit side,
lock the wedge bar in the slit of the adapter.
Drive out the bearing by knocking the wedge bar.
Wheel bearing remover : 09941-50111
CAUTION
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INSPECTION
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WHEEL RIM
Make sure that the wheel rim runout does not exceed
the service limit when checked as shown.
An excessive runout is usually due to worn or loose
wheel bearings and can be reduced by replacing the
bearings. If bearing replacement fails to reduce the
runout, replace the wheel.
Wheel rim runout
(Axle and Radial)
TIRE
Inspect the tires for wear and damage, and check the
tire tread depth as shown. Replace a badly worn or damaged tire. A tire with its tread worn down to the limit(in
terms of tread depth)must be replaced.
CHASSIS 6-4
Tire depth
service limit
Front
1.6 mm
Rear
1.6 mm
Check the tire pressure, and examine the value for evidence of air leakage.
Normal riding
TIRE PRESSURE
Cold inflation
Solo riding
Dual riding
kg/
kPa
kg/
kPa
Front
1.25
123
1.75
172
Rear
2.00
196
2.25
221
I ndustrial e
purpos
M ulti-
ase
G re
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Super GreaseA
ell
S h
A valnia
WHEEL BEARING
Apply SUPER GREASEAto the bearings before
installing.
CAUTION
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Right side
Left side
Bearing(R)
Bearing(L)
Clearance
Spacer
Bearing(L)
6-5 CHASSIS
OIL SEAL
Install the oil seal with the special tool.
Oil seal installer : 09923-55131
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DISC PLATE
Install the disc plate and tighten them to the specified
torque.
CHASSIS 6-6
CAUTION
FRONT WHEEL
Tighten the front axle nut to the specified torque.
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6-7 CHASSIS
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FRONT BRAKE
Do not operate the front brake lever while dismounting the caliper.
CHASSIS 6-8
CAUTION
Replace the brake pads as a set, otherwise braking performance will be adversely affected.
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Never re-use the brake fluid left over from the last
servicing and stored long periods.
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6-9 CHASSIS
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CALIPER INSPECTION
CHASSIS 6-10
CALIPER REASSEMBLY
Silicone Grease
SPECIFIED TORQUE
Nm
kgm
18 ~ 28
1.8 ~ 2.8
20 ~ 25
2.0 ~ 2.5
WARNING
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Item
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6-11 CHASSIS
Disc runout
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CAUTION
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CHASSIS 6-12
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6-13 CHASSIS
CAUTION
Circlip
spring
Piston
Primary cap
Second cap
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Boot
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Master cylinder
Upside
Clearance
CHASSIS 6-14
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FRONT FORK
Do not operate the front brake lever while dismounting the caliper.
6-15 CHASSIS
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Loosen the front fork bolt, then draw out the fork
spring.
Loosen the front fork lower clamp bolts.
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CHASSIS 6-16
INSPECTION
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CAUTION
6-17 CHASSIS
FORK SPRING
Measure the fork spring free length.
Fork spring free length
Standard 290.9 mm
290.9
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Thread Lock1324
Bond1215
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FORK OIL
For the fork oil, be sure to use a front fork oil whose
viscosity rating meets specification below.
Fork oil type
Capacity
TELLUS # 37
50 cc(One side)
CUSHION SPRING
When installing the front fork spring, the close end
should position upside.
Up side
CHASSIS 6-18
STEERING
REMOVAL AND DISASSEMBLY
Remove the handlebar cover.
Remove the handlebar by removing the clamp bolt
and set bolt .
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CAUTION
6-19 CHASSIS
22 pcs
Lower
25 pcs
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INSPECTION
CHASSIS 6-20
INNER RACE
Press in the upper and lower inner races with the special tool.
Steering race installer : 09941-34513
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Super GreaseA
Lower
25 pcs
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Upper
STEEL BALL
Apply SUPER GREASE A when installing the
upper and lower steel balls.
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CAUTION
6-21 CHASSIS
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CHASSIS 6-22
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6-23 CHASSIS
INSPECTION
REAR BRAKE DRUM
Measure the brake drum I.D. to determine the extent of
wear and, if the limit is exceeded by the wear noted,
replace the drum. The value of this limit is indicated
inside the drum.
Rear brake drum I.D
BRAKE SHOE
Using a vernier calipers, measure the brake shoe outside diameter at the place as shown in the photo. If the
measurement is less than the limit, replace the brake
shoe.
CAUTION
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WHEEL
Refer to page 6-3.
TIRE
Refer to page 6-4.
Service limit 96 mm
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CAUTION
Front
Punch mark
Slit
Front
CHASSIS 6-24
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SERVICING INFORMATION
CONTENTS
7- 1
SPECIAL TOOLS
7- 6
TIGHTENING TORQUE
7-10
SERVICE DATA
7-12
7-18
WIRING DIAGRAM
7-20
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TROUBLESHOOTING
TROUBLESHOOTING
ENGINE
Complaint
Remedy
Replace.
Refair or replace.
Refair or replace.
Replace.
Tighten.
Replace.
Replace.
Clean and dry.
Replace.
Replace.
Replace.
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Clean.
Clean or replace.
Replace.
Clean or replace.
Noisy engine.
Replace.
Clean.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Slipping clutch
Replace.
Replace.
Engine idles
poorly.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Clean or adjust.
Replace.
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Engine stalls
easily.
Clean.
Replace.
Clean.
Clean.
Clean.
Complaint
Engine runs
poorly in highspeed range.
Remedy
Replace.
Replace.
Adjust.
Replace.
Dirty or heavy
exhaust smoke.
Engine lacks
power.
Replace.
Replace.
Replace.
Adjust or replace.
Clean.
Adjust or replace.
Clean.
Clean or replace.
Retighten or replace.
Replace.
Replace.
Replace.
Replace.
Engine overheats.
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Trouble with
starting.
Complaint
CARBURETOR
Replace.
Adjust or replace.
Clean
Clean, and replace.
Clean.
Clean.
Replace or clean.
Adjust or replace.
Retighten or replace.
Change.
Change.
Clean or replace.
Remedy
Clean.
Check starter body and carburetor
for tightness, and replace gasket.
Check and replace.
Check and replace.
Idling or low-speed
trouble.
Replace.
Replace.
Check and adjust.
Clean.
Adjust or replace.
ELECTRICAL
Complaint
Remedy
Replace.
Replace.
Replace.
Connect/tighten.
Adjust carburetor.
Adjust carburetor.
Change.
Clean.
Replace by hot type plug.
Replace.
Spark plug
electrodes overheat
or burn.
Magneto charge,
but charging rate is
below the specifications.
Repair, or retighten.
Magneto
overcharges
Ustable charging.
Repair or replace.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace or repair.
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Starter button is
not effective.
No sparking or
poor sparking.
Replace.
Replace.
Replace the battery.
Replace.
Replace.
BATTERY
Complaint
Battery runs down
quickly.
Remedy
Check the magneto and regulator/rectifier circuit connections, and make
necessary adjustments to obtain specified charging operation.
Replace the battery, and correct
the charging system.
Replace the battery.
Replace the battery.
Reversed battery
polarity.
1. The battery has been connected the wrong way round in the
system, so that it is being charged in the reverse direction.
Battery discharges
too rapidly.
Clean.
Replace.
CHASSIS
Complaint
Remedy
Adjust.
Replace.
Replace.
Adjust.
Wobbly handle.
Replace.
Replace.
Replace.
Replace.
Replace.
Retighten.
Retighten.
Replace.
Tighten.
Front suspension
too soft.
1. Weakened springs.
2. Oil leakage of shock absorber.
Replace.
Replace.
Front suspension
too stiff.
Noisy front
suspension.
Rear suspension
too soft.
1. Weakened spring.
2. Oil leakage of rear shock absorber.
Noisy rear
suspension.
Complaint
Insufficient brake
power.
Brake squeaking.
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Refill.
Replace.
Refill.
Retighten.
Replace.
Replace.
Replace.
Replace.
Retighten.
Replace.
Replace.
Retighten.
Replace.
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BRAKES
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Handling feels
too heavy.
Remedy
Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replace.
Replace.
Replace.
Adjust.
Complaint
Excessive brake
lever stroke.
Remedy
Bleed air.
Replenish fluid to normal lever;bleed
air.
Replace with correct fluid.
Replace.
Replace.
Leakage of brake
fluid.
Brake drags.
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SPECIAL TOOLS
Part NumberPart NameDescription
Special tools
09900-00401
Ltype hexagon wrench set
09900-00410
Hexagon wrench set
09900-20508
Cylinder gauge set
(1/100mm, 40-80mm)
09900-05108
09900-20602
Dial gauge
(1/100mm, 1mm)
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09900-06107
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09900-20605
Dial calipers
(1/100mm, 10-34mm)
Measure width of conrod big-end
09900-20606
Dial gauge
(1/100mm, 10mm)
Measure run-out of wheel
09900-09003
09900-20701
Magnetic stand
09900-20102
09900-20806
Vernier calipers
Thickness gauge
Measure thickness
09900-20202
Micrometer
(1/100mm, 25-50mm)
09900-21304
09900-20203
Micrometer
(1/100mm, 50-75mm)
09900-21602
Special tools
V-block set
Special tools
09900-22301
09913-60710
Plastic gauge
Bearing remover
09900-22401
Small bore gauge
(10-18mm)
09913-75520
09900-25002
09913-75821
Bearing installer
Bearing installer
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Pocket tester
09900-28107
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Electro tester
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Tachometer
09910-20115
09915-63310
Conrod holder
09910-32812
09915-64510
Crankshaft installer
Compression gauge
09913-14541
09916-84511
Tweezers
09913-50121
09920-13120
Crankcase separater
Seprate to crankcase
Special tools
Special tools
09921-20200
09930-30163
Rotor remover
Attached to the top of sliding shaft when removing rotor
09930-32420
Rotor holder
09922-55131
09930-40113
09921-20210
Rotor holder
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Bearing installer
Used to drive bearing in
09923-73210
09940-10122
Clamp wrench
09923-74510
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09924-84521
09940-34561
Bearing installer
09925-98221
09940-50113
Bearing installer
09930-10121
09941-34513
Bearing installer
09930-30102
09941-50110
Special tools
09951-76010
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Bearing installer
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Special tools
TIGHTENING TORQUE
ENGINE
Nm
kgm
35 ~ 45
3.5 ~ 4.5
18 ~ 28
1.8 ~ 2.8
8 ~ 12
0.8 ~ 1.2
Spark plug
25 ~ 30
2.5 ~ 3.0
8 ~ 12
0.8 ~ 1.2
40 ~ 60
4.0 ~ 6.0
ITEM
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48 ~ 72
4.8 ~ 7.2
9 ~ 15
0.9 ~ 1.5
9 ~ 15
0.9 ~ 1.5
3~5
0.3 ~ 0.5
40 ~ 60
4.0 ~ 6.0
40 ~ 60
4.0 ~ 6.0
40 ~ 60
4.0 ~ 6.0
8 ~ 12
0.8 ~ 1.2
CHASSIS
ITEM
Nm
kgm
6~9
0.6 ~ 0.9
22 ~ 35
2.2 ~ 3.5
60 ~ 90
6.0 ~ 9.0
60 ~ 100
6.0 ~ 10.0
18 ~ 28
1.8 ~ 2.8
8 ~ 12
0.8 ~ 1.2
6~9
0.6 ~ 0.9
18 ~ 28
1.8 ~ 2.8
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2.0 ~ 2.5
33 ~ 52
3.3 ~ 5.2
35 ~ 55
3.5 ~ 5.5
22 ~ 28
2.2 ~ 2.8
48 ~ 52
4.8 ~ 5.2
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20 ~ 25
Bolt Diameter
(mm)
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For other bolts and nuts whos torque is not listed, refer to this chart :
7marked bolt
kgm
Nm
kgm
1.0 ~ 2.0
0.1 ~ 0.2
1.5 ~ 3.0
0.15 ~ 0.3
2.0 ~ 4.0
0.2 ~ 0.4
3.0 ~ 6.0
0.3 ~ 0.6
4.0 ~ 7.0
0.4 ~ 0.7
8.0 ~ 12.0
0.8 ~ 1.2
10.0 ~ 16.0
1.0 ~ 1.6
18.0 ~ 28.0
1.8 ~ 2.8
10
22.0 ~ 35.0
2.2 ~ 3.5
40.0 ~ 60.0
4.0 ~ 6.0
12
35.0 ~ 55.0
3.5 ~ 5.5
70.0 ~ 100.0
7.0 ~ 10.0
14
50.0 ~ 80.0
5.0 ~ 8.0
110.0 ~ 160.0
11.0 ~ 16.0
16
80.0 ~ 130.0
8.0 ~ 13.0
170.0 ~ 250.0
17.0 ~ 25.0
18
130.0 ~ 190.0
13.0 ~ 19.0
200.0 ~ 280.0
20.0 ~ 28.0
Nm
SERVICE DATA
CYLINDER + PISTON + PISTON RING
Unit : mm
ITEM
STANDARD
LIMIT
0.065 ~ 0.075
0.120
Cylinder bore
41.005 ~ 41.020
41.07
Piston diam.
40.935 ~ 40.950
Measure at 15mm from the skirt end
40.885
Cylinder distortion
0.1
0.1
Approx. 4.5
2nd
Approx. 4.3
3.1
1st
0.10 ~ 0.25
0.75
0.10 ~ 0.25
0.75
2nd
0.02 ~ 0.06
1st
0.02 ~ 0.06
2nd
Piston pin bore I.D
10.002 ~ 10.010
10.030
9.995 ~ 10.000
9.980
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3.2
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ITEM
CONROD + CRANKSHAFT
Unit : mm
STANDARD
LIMIT
14.003 ~ 14.011
14.047
3.0
35 0.1
0.08
OIL PUMP
Unit : mm
ITEM
STANDARD
30.000(30/1)
CLUTCH
Unit : mm
STANDARD
LIMIT
110.00 ~ 110.15
110.35
3.0
2.0
6,000 200rpm
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Clutch in rpm
ITEM
TRANSMISSION
ITEM
STANDARD
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LIMIT
12.0
2.997 ~ 0.813
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Gear ratios
Unit : mm
V-belt width
V-belt thickness
16.5 0.6
15.3
8.0 0.6
143.8
135 ~ 153
CARBURETOR
Unit : mm
ITEM
SPECIFICATION
Carburetor type
VM14
14
HG 266
Idle rpm
1,800 50 rpm
Fuel level
24.5
(M.J.)
55
(M.A.J.)
1.0
Jet needle
(J.N.)
3E17-3
Needle jet
(N.J.)
I.D. No.
Pilot jet
(P.J.)
Throttle valve
(T.V.)
By-pass
(B.P.)
Valve seat
(V.S.)
Stater jet
(G.S.)
Pilot screw
(P.S.)
Pilot outlet
(P.O.)
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25
3.0
2.4 0.05
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Main jet
25
0.8
0.5 ~ 1.0
ELECTRICAL
Unit : mm
ITEM
SPECIFICATION
Ignition timing
Spark plug
Type
BR8HSA
Gap
0.6 ~ 0.7
Over 8 mm
Spark performance
Primary
0.19 ~ 0.24
Secondary
5.4 ~ 6.6
Lighting coil
0.54 ~ 0.80
Y/W-Ground
Charging coil
0.69 ~ 1.03
W/R-Ground
Exciting coil
220 ~ 260
B/R-Ground
Pick-up coil
90 ~ 110
Br-W
PY
YT4L-BS
RI
Capacity
12V, 3AH
1.32 at 20 (68)
10 A
Fuse
WATTAGE
H
TE
Regulated voltage
Battery
NOTE
ITEM
Head lamp bulb
Unit : W
SPECIFICATION
15W 2
5 / 10W
10W 4
1.7W / 17W
1.7W 2
BRAKE+WHEEL
Unit : mm
ITEM
LIMIT
STANDARD
Front
5 ~ 20
Rear
15 ~ 25
Rear
100
100.7
Rear
99.2
96
Front
4.0 0.2
3.5
Front
Front
11.000 ~ 11.043
11.055
Front
10.957 ~ 10.984
10.945
Front
30.230 ~ 30.306
30.315
Front
30.150 ~ 30.200
30.140
Axial
Radial
Front
0.30
H
TE
Front
110/70-12 47J
Rear
120/70-12 51J
RI
Tire size
Front
PY
Rear
3.0
3.0
0.25
1.6
1.6
SUSPENSION
Unit: mm
STANDARD
ITEM
Front fork stroke
LIMIT
75
290.9
TELLUS # 37
50 cc
66
TIRE PRESSURE
FRONT
123
REAR
196
DUAL RIDING
kg/
kPa
kg/
1.25
172
1.75
2.00
221
2.25
RI
kPa
H
TE
SOLO RIDING
COLD INFLATION
TIRE PRESSURE
FUEL + OIL
PY
ITEM
SPECIFICATION
1.0
1.0 ~ 1.2
(at 3,000 rpm for 5 minutes)
4.8
APOLLOIL BIKE-K, HYPOL HS
Fuel type
110
Overhaul
130
NOTE
DOT 4
I.D 60/Hr
F.O 100/Hr
REAR BRAKE
Rear turnsignal L
Rear turnsignal
R/L
H
TE
Switch thermo
Battery cover
Fuse case
09407-22402
PY
RI
Rear turnsignal R
09407-22402
Lamp assy, Tail & Stop
Rear turnsignal R/L
Starter relay
Ignition coil
Rear brake
cable
Brake cable
09407-22402
Starter motor
magneto
Clamp
Engine earth
Rear brake
cable
Throttle cable
Front
VIEW B
Harness
Harness
Frame
P.T.C
Frame earth
VIEW D
Starter motor
Starter motor
Switch thermo
Clamp
G
D
Fuel tank
Speedometer
cable
Harness
Head lamp
H
TE
Harness
Steering lock
Speedometer cable
Front
Starter motor
magneto
Ignition coil
RI
Engine earth
Helmet box
PY
Fuse case
Battery, ,
Oil level gauge
Rear fender
Shield leg lower rear
09407-22402
CABLE
VIEW C
Harness
Throttle cable
Brake cable
Brake
hose
Rear brake
cable
Throttle cable
Regulator
Regulator
Front turnsignal RH/LH
Head lamp
Horn
CDI unit
Turnsignal relay
Clamp
Harness
Head lmap
Lamp
Rear combination
Rear turnsignal
Front turnsignal
Oil pilot lamp
turnsignal pilot lamp
Illumination
DEST
Tail
Stop
Front turnsignal LH
Head lamp
Front turnsignal RH
5
10
152
10
10
1.7
1.7
1.72
Speedometer
Turnsignal
B
Br
G
Gr
L
: Black
: Brown
: Green
: Gray
: Blue
Lg
O
R
Sb
W
Ignition switch
Horn
: Light green
: Orange
: Red
: Light blue
: White
Y
BG
BW
BR
LW
Oil gauge
Spark plug
: Yellow
: Black with Green tracer
: Black with White tracer
: Black with Red tracer
: Blue with White tracer
C.D.I unit
Regulator
RB
RW
WB
WR
YB
Battery
Engine earth
Rear turnsignal LH
Rear turnsignal RH
Carburetor, Heater
Thermo switch
P.T.C
Starter motor
H
TE
Fuel gauge
Frame earth
RI
Turnsignal relay
PY
WIRE COLOR
Handle switch LH
Horn
Lighting
Handle switch RH
Starter
WIRING DIAGRAM
D
H
TE
Prepared by
RI
PY