4.3 ENGINE OIL LEVEL Place the engine on the level plane.

Check the oil level with the oil level gauge, but do not screw it in when making this check.

Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge.

LOWER LEVEL

UPPER LEVEL

4.4 ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. NOTE: drain the oil while the engine is warm to ensure complete draining.
OIL DRAIN

Remove the oil filter cap, spring and oil filter screen.

OIL FILTER SCREEN

OIL FILTER

Install the oil drain bolt with sealing washer. TORQUE: 20~30 n-m (2.0~3.0 kg-m)

Fill the crankcase with recommended oil. ENGINE OIL CAPACITY: 1.2 liter at draining. Install the oil filter cap. Install the oil level gauge. Start the engine and let it idling for 2 or 3 minutes. Stop the engine and check that the oil level at the upper line on the gauge. Make sure there are no oil leaks.
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OIL DRAIN

OIL FILTER CAP

4.5 OIL PUMP REMOVAL Remove the fan cover ass’y.

FAN COVER ASS’Y

Remove the cooling fan composition.

COOLING FAN COMPOSITION

Remove the A.C.G generator ass’y.

Remove the left crankcase cover.

2

Remove the oil pump chain and oil pump driven sprocket.Remove the starting clutch outer and gear ass’y. Remove the flange bolts and oil separator. Remove the oil pump ass’y. 3 .

Disassemble the oil pump.12 mm. 4 . SERVICE LIMMIT: 0. Remove the oil pump shaft and measure the pump and clearance.2 mm. INSPECTION Measure the oil pump rotor-to-body clearance. SERVICE LIMMIT: 0. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump rotor tip clearance.

4. 5 .5 OIL PUMP ASS’Y / INSTALLATION Install the outer rotor. Install the oil pump ass’y Install the oil pump driven sprocket and oil pump chain. inner rotor and oil pump shaft onto the body. NOTE: Pour a drop of clean engine oil inside the oil pump.

G generator ass’y 6 . Install the A. dowel pins and right crankcase cover. Install the new gasket.C. Install the starting clutch outer and gear ass’y.Install the oil separator.

Install cooling fan composition Install fan cover 7 .

000-5.0 4. O-ring and dowel pins are in place. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case.90 5.D.10 1. camshaft and the other parts.10 9.8 IN EX IN EX IN EX IN/EX IN EX IN EX Valve stem O. SPECIFICATIONS ITEM Cylinder compression Cam lobe height Rocker arm I.9~1.1 SERVICE INFORMATION 5.1 4.4 kg-m) 9~12 n-m (0.3 35.057 1.2 kg-m) 8 .8~12 kg-m) 20~24 n-m (2. 0 1.D.90 4.91 31.975-4.2 34.012 0.5.3 CAMSHAFT ASS’Y REMOVAL 5.580 26. 08 0. Rocker arm shaft O. Before installing the cylinder head be sure the orifice is not clogged and the gasket.2 TROUBLESHOOTING 5.0~2.018 9.000-10.987 32.0 SERVICE LIMIT --------26.30 0.972-9.D.D. valves. Valve guide I. CYLINDER HEAD / VALVES 5.030-0.420 10.970 5.955-4. Valve spring free length STANDARD 12±0.4 CYLINDER HEAD REMOVAL 5.990 4.5 kg/cm2 26.180 26.010-0.1 SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head.5 CYLINDER HEAD INSTALLATION 5.020 10. Stem-to-guide clearance Valve seat width TORQUE VALUES Cylinder head bolts Camshaft holder flange nuts Tappet adjusting nut 8~12 n-m (0. The engine must be removed from the frame to service cylinder head.037 0. 8 1.

These problems can be diagnosed by a compression test. Weak valve spring. Worn or damaged valve seats. Warped or cracked cylinder head. Low compression valve Incorrect valve adjustment. Worn or damaged cam chain tensioner. Excessive smoke Damaged valve stem seal. Worn or damaged rocker arm or camshaft. Burned or bent valve. Incorrect valve timing.5.2 TROUBLE SHOOTING Engine top-end problems usually affect engine performance. or by tracing engine noise to the top end with a sounding rod or stethoscope. 9 . Worn cam sprocket teeth. Cylinder head Leaking or damaged head gasket. Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring. Worn or damaged cam chain. Faulty cylinder or piston rings.

Relax the cam chain adjuster screw. Remove the inlet pipe ass’y. 10 .5. Remove the cylinder head cover. Remove the shroud compositions.3 CAM SHAFT ASS’Y REMOVAL Remove the rubber tube of gas waste recovery. Remove the air cleaner and carburetor.

18 mm EX 26. INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage.Remove the screw and O-ring and tighten the cam chain-adjusting bolt with clockwise direction. Relax the camshaft gear from cam chain and remove the camshaft.02 mm 11 . SERVICE LIMIT: IN 26. Remove the nuts and washers Remove the camshaft holder and dowel pins.

Pull on the bolt to remove the shafts and rocker arms.91 mm 12 .10 mm Measure the O.D. of each rocker arm shaft. Screw a 5 mm bolt into the rocker arm shaft threaded end. of each rocker arm. Measure the I. SERVICE LIMIT: 10. rocker arms and rocker arm shafts for wear or damage.D. SERVICE LIMIT: 9. Inspect the camshaft holder.Inspect the camshaft and bearings for wear or damage and replace them if necessary.

4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head.5. Remove the cam chain guide. 13 . spring retainers and valve springs with a valve spring compressor. CYLINDER HEAD DISASSEMBLY Remove the valve cotters. Remove the cylinder head gasket and dowel pins.

1 mm Inspect each valve for turning. Measure the cylinder head diagonally for warp with a straight edge and feeler gauge. Measure the free length of the inner and outer valve springs. burning. 14 . SERVICE LIMITS: Inner 31. scratches or abnormal stems wear.INSPECTION Clean off all carbon deposits from the combustion and check the spark plug hole and valve area for cracks. Check the valve movement in the guide.2 mm Outer 34.

If the valve guide is replaced. SERVICE LIMITS: IN / EX 5. If so. INSTALLATION Install the new gasket and dowel pins.30 mm Calculate the stem-to-guide clearance. determine if a new guide with standard dimensions would bring the clearance within tolerance.D. don’t compress the valve springs more than necessary.Measure and record each valve stem O.D.08 mm EX 0. replace guides as necessary and ream to fit. NOTE: To prevent loss of tension. Install the valve springs. Insert the valves into the guides. SERVICE LIMITS: IN 0. the valve seat must be refaced. CYLINDER HEAD ASS’Y Lubricate each valve stem with oil. 15 .90 mm Measure and record the valve guide I.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits. SERVICE LIMITS: 4. retainers and the cotters.

Install the cam chain guide. Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter-clockwise. 16 . Install the cylinder head. CAMSHAFT ASS’Y INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.

Torque: 20 n-m (2.Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole towards the front. Tighten the washers and nuts.0 kg-m) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge. STANDARD VALVE: 0. Install the dowel pins and camshaft holder. 17 .08 mm Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw.

CYLINDER HEAD COVER 18 .Install the cylinder head cover.

5 CYLINDER INSTALLATION 6.400-57.5 ---------0.1025 15. Piston pin bore Piston pin O.50 0.1 15. SPECIFICATION ITEM Cylinder I.6. Taper Out of round Warp across top Piston Piston pin Piston rings Piston O.2 kg-m) 19 .010-15.D.8~1.06 TORQUE VALUES Cylinder head bolts Camshaft holder flange nuts Tappet adjusting nut 8~12 n-m (0.10 0.410 ---------------------------57.1 SERVICE INFORMATION 6. CYLINDER AND PISTON 6.008 14.028 SERVICE LIMIT 57.10 0.015-0.0~2.014 0.02 0. TOP/SEC OIL STANDARD 57.050 0.2-0.D.10 56.04 14.000 0.015-0.960 0.3075-57.D.D.500 15.4 kg-m) 9~12 n-m (0.3095 15.12 0.2 kg-m) 20~24 n-m (2.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case.002-0. Before installing the cylinder head be sure the orifice is not clogged and the gasket.0005-0. O-ring and dowel pins are in place.3 CYLINDER REMOVAL 6.10-0.050 0.994-15.7 0.12 0.002-15.25 0.9~1. Piston-to-pin clearance Piston ring TOP SECOND Groove Clearance Piston ring end gap Cylinder-to-piston clearance Connecting rod small end I.2 TROUBLESHOOTING 6.4 PISTON REMOVAL 6.

Improper installation of piston rings Scored or scratched piston or cylinder wall. Damaged valve stem seal. Excessive carbon build-up.6.2 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings. Knocking or abnormal noise Worn piston and cylinder. piston. 20 . or piston rings. Overheating Excessive carbon build-up on piston or combustion chamber wall. Excessive smoke Worn cylinder.

Remove the cylinder.6.3 CYLINDER REMOVAL Remove the cylinder head. NOTE: Be carefully not to damage the gasket surface. Remove the cylinder gasket and dowel pins. Clean off any gasket materials from the cylinder surface. 21 .

22 . Spread each piston ring and remove it by lifting up at a point opposite the gap. Remove the piston. INSPECTION Inspect the cylinder walls for scratches or wear. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase.6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin from the piston.

at three levels in both an X and Y axis. Take the maximum reading to determine the out-of-round.D.12 mm 23 . Take the maximum reading to the cylinder wear.12 mm SECOND 0. SERVICE LIMITS: 0.10 mm PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance.10 mm Calculate cylinder taper at three levels in an X and Y-axis. SERVICE LIMITS: 0.Measure and record the cylinder I. SERVICE LIMITS: 0. SERVICE LIMITS: TOP 0.10 mm Inspect the top of the cylinder for warp.

04 mm 24 .5 mm Measure the piston pin O. Insert each piston ring into the cylinder and measure the ring end gap. SERVICE LIMIT: 15.Inspect the piston for wear or damage.D. SERVICE LIMIT: 14.D.5 mm SECOND 0. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder.960 mm Measure the piston pin O. SERVICE LIMITS: TOP 0.

02 mm Measure the connecting rod small end I. SERVICE LIMITS: 15. Space the piston ring end gaps 120 degrees apart. 25 .06 mm 6. NOTE: Don’t interchange the top and second rings. Avoid piston and piston ring damage during installation. SERVICE LIMITS: 0.Calculate the piston-to-piston pin clearance.D.5 PISTON & PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston ring with the marks facing up.

26 . NOTE: Be carefully not to damage the gasket surface. Do not align the piston pin clip end gap with the piston cutout. 6.PISTON INSTALLATION Install the piston with it’s “IN” mark on the intake calve. Install the dowel pins a new gasket. NOTE: do not allow the clip to fall into the crankcase. Install the piston pin with new pin clips.6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface.

NOTE: Avoid piston rings damage cylinder bore during installation. Install the cylinder head. 27 .Coat the cylinder bore and piston rings with engine oil and install the cylinder. Do not allow the cam chain fall into the crankcase.

1 SERVUCE INFORMATION 7.D.098 23.40 28.2 168.6 C.8-125.03 24.D.T ASSEMBLY 7.92 125.0 24.0 Clutch weight lining thickness -------------- TORQUE VALUES Clutch outer nut Drive face nut 55 N-m (5. Drive face boss O.09 23. Movable drive face I.0 17.1 SERVICE INFORMATION If the drain tube ass’y fills with water.V.98 124. Clutch outer I.D.06-24.8-20. TRANSMISSION & KICK STARTER 7.5 1.5 kg-m) 55 N-m (5.4 SERVICE LIMIT (mm) 19.7.5 kg-m) 28 .5 KICK STARTER ASSEMBLY 7.T DISASSEMBLY 7.D. Driven face spring length STANDARD (mm) 19.4-169.5 164.V.96-23.4 KICK STARTER DISASSEMBLY 7.2 17.3 C.D.98-28.9-18.1 27. Drive face collar I. SPECIFICATIONS ITEM Driven the width Weight roller O.2 TROUBLE SHOOTING 7. the tube should be drained.

7. Worn weight roller.2 TROUBLE SHOOTING Engine starts but can’t travel Worn driven belt. Low engine power Worn driven belt. 29 . Damaged driven face spring. Worn clutch lining. Dirty driven face.

Clean off any gasket material from L crankcase surface.T DISASSEMBLY LH CRANKCASE COVER REMOVAL Relax the band screw and remove the C.T inlet duct.T INLET DUCT Remove the bolts and LH crankcase cover.V.3 C. LH CRANKCASE COVER Remove the gasket and dowel pins.V.V. C. GASKET DOWEL PINS LH CRANKCASE SURFACE 30 .7.

C. FLANGE NUT DRIVE FACE Relax the flange nut. Remove the drive pulley assy and driven belt. 31 . and remove the drive face.T REMOVAL Relax the flange nut. DRIVE FACE BOSS MOVABLE DRIVEN FACE Remove the ramp plate and weight roller set.V. FLANGE NUT FLANGE BELT DRIVE PULLEY Remove the drive face boss and movable driven face ass’y.

Relax the special nut and remove the driven plate composition and driven face spring. SERVICE LIMIT:28.03mm Inspect the drive face collar for wear or damage. of drive face collar. INSPECTION Inspect the driven belt for wear.D.0 mm Inspect the weight roller for wear or damage and replace them if necessary. of movable driven face. Measure the O.D. Measure the I.098 mm 32 . SERVICE LIMIT:19. of weight rollers. tears or damage. SERVICE LIMIT:17.D. Measure the width of driven belt. SERVICE LIMIT:24.40 mm Measure the I.

of clutch outer. SERVICE LIMIT:125. SERVICE LIMIT:1. Measure the thickness of clutch weight lining. Measure the I. Measure the O.D.D.0 mm 33 .5mm Measure the length of driven face spring.Inspect the drive face boss for wear or damage. of drive face boss. SERVICE LIMIT:164.92 mm Inspect the clutch outer for wear or damage. SERVICE LIMIT:23.5 mm Inspect the clutch weight set for wear or damage.

Inspect the driven face ass’y and replace them if necessary. CIRCLIP Remove the kick-starter spindle ass’y. 7. EX. Circle-clip and washer from kick starter spindle composition.4 KICK STARTER DISASSEMBLY Remove the LH crankcase cover. STARTER SPINDLE ASS’Y STARTER IDLE GEAR ASS’Y 34 . Remove the Kick starter. Remove the kick-starter idle gear ass’y Remove the kick spindle bush. KICK STARTER LH CRANKCASE COVER Remove the ex.

KICK DRIVEN SPRING 35 . KICK SPINDLE BUSH KICK RETURN SPRING Inspect the kick driven gear and spring for wear or damage. Inspect the kick-starter return spring for fatigue or damage. Inspect the kick-starter spindle bush for wear of damage.INSPECTION Inspect the kick-starter spindle composition for wear or damage.

Assemble the movable drive face. spring and driven plate.6 C.5 KICK-STARTER ASSEMBLY Install the kick driven gear and spring. 36 . KICK STARTER 7. Install the kick spindle bush. return spring and spindle ass’y.V.7.T ASSEMBLY Assemble the driven face ass’y. weight roller set and drive face. Install the kick-starter.

GASKET 37 DOWEL PIN . FLANGE NUT DRIVEN BELT DRIVE PULLEY Install the dowel pins and gasket.Install the movable drive face ass’y and boss. FLANGE NUT DRIVE FACE Install the driven belt and driven pulley ass’y. DRIVE FACE BOSS MOVABLE DRIVEN FACE Install the drive face and kick starter ratchet.

LH CRANKCASE COVER Install the air cleaner case and C. 38 .T ducts.Install the LH crankcase cover.V.

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