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SM57-0902-01E

Contents

To ensure safety and optimal operating conditions of the


vehicle, carry out regular inspections according to the
maintenance schedule(Section 2).
Sections 1 through 2 provide information on overall
vehicle; section 3, assembly and disassembly procedures
for external components, and section 4 describes
maintenance procedure for the engine, frame and
electrical systems.
To facilitate use of this manual, each page starts with
disassembly and system diagrams, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide.

Engine

This manual explains how to maintain procedure for the


SN125 manufactured by DAELIM MOTOR CO., LTD.

General

How to use this manual

Electrical

Frame

Contents of this manual and specifications are subject


to change without prior notice for improvement of
vehicle quality.
No part of this publication may be reproduced without
written permission of DAELIM Motor Co.,Ltd.,

Service Information

Inspections / Adjustments

External Parts

Lubrication System

EMS(Engine Management System)

Fuel System

Engine Removal / Installation

LH, Crank Case Cover


Continuously Variable
Transmission

A.C Generator / Starter Clutch

Cylinder Head / Valves

10

Cylinder Head / Piston

11

Transmission / Crank Shaft


Crank Case

12

Front Wheel / Front Fork


/ Steering

13

Rear Wheel / Suspension /


Rear Swing Arm

14

Brake System

15

Charging System

16

Ignition System

17

Starter System

18

Lights / Switches / Horn

19

Wiring diagram(Euro2,Euro3)

20

SERVICE INFORMATION

1. SERVICE INFORMATION
SERIAL NUMBER LOCATION 1-1
1-2
SPECIFICATIONS
1-4
TORQUE VALUES
1-5
STANDARD TORQUE VALUES
1-5
SYMBOLS/ABBREVIATIONS

WIRING DIAGRAM

GENERAL SAFETY

SERVICE RULES
CAUTION WHEN WIRING

1-6
1-10
1-10
1-14

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

1-1

SERVICE INFORMATION

1,910mm
750mm
1,090mm
1,360mm
755mm
126mm
130kg
277kg

60
2.00
2.25

7.1 (6.8 )
1.2
25
90mm
80
90/70
stroke SOHC

1.0
1.05

13.8

ATDC

"( )" MARKED CONTENTS APPLY TO EURO 2 ONLY

1-2

380

SERVICE INFORMATION

ITEM

SPECIFICATIONS

TYPE / VENTURI BORE


MODEL MARK
CHOKE TYPE
MAIN JET
PILOT SCREW INITIAL SETTING
FLOAT LEVEL
IDLE SPEED

CV type ( vacuum ) / '24.2 mm


CVK
Auto-bystarter
# 95
2
17 mm
1.700100 rpm

DRIVE TRAIN

CLUTCH TYPE
PRIMARY REDUCTION
SECONDARY REDUCTION

Automatic Transmission
3.000
2.786

ELECTRICAL
SYSTEM

IGNITION SYSTEM
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT ( HIGH / LOW )
POSITION LIGHT
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEAM PILOT
WINKER PILOT
METER LIGHTS
LICENSE LAMP

ECU (C.D.I)
Closed type (MF) 12V 10AH
CR8EH -9 (NGK)
0.8 - 0.9 mm
15A, 30A (15A)
Starter motor
12V 55W / 12V 55W
12V 5W
12V 10W4
12V 21 / 5W
LED
LED
LED
12V 5W

(CARBURETOR)

( )MARKED CONTENTS APPLY TO EURO2 ONLY

1-3

SERVICE INFORMATION

1-4

SERVICE INFORMATION

1-5

SERVICE INFORMATION

1-6

SERVICE INFORMATION

1-7

SERVICE INFORMATION

1-8

SERVICE INFORMATION

1-9

SERVICE INFORMATION

GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other workers action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.

SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or
recommended parts.

2. Before maintenance, remove deposit or dust from the


chasis.

3. Store the parts of each system discriminatively to install


each part in the right place.

4. After removing gasket, O-ring, piston pin clip and cotter


pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.

1-10

SERVICE INFORMATION
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.

6. Check necessary place and measure necessary data


during installation. When installing, return to the state
before removing.

7. Align the bolts to uniform the tightening points before


tightening them when you dont know the bolt length.

8. Bolts, nuts and pieces must be tightened from the bigger


diameter to the smaller one, from inside to outside and
diagonally with the specified torque.

9. Check to see if the rubber part is worn out when


removing it and replace it if necessary. Some rubber part
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.

10. Recommended grease must be applied to or filled in


the specified place.

11. Maintenance needed to use the specialized tools must


performed with the right tool.

12. Never reuse the ball bearing removed with the ball
applied pressure when removing press-fitted the
bearing.

1-11

SERVICE INFORMATION
13. Check the smooth rotation of inner or outer race of the
ball bearing by rotating it manually.
Replace the ball bearing having excessive axial/
longitudinal hanging.
Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball
bearing)
Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.

14. Pay attention to installation direction in case of the


single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way
that the face marked with manufacturer and size
should direct to the outer axle.
SINGLE-SEALED TYPE DOUBLE-SEALED TYPE

OPEN TYPE

15. When blowing the ball bearing with compressed air


after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.

MANUFACTURERS NAME, BEARING No.

16. Install the snap ring so that chamfered side directs to


the load-applied side. After installation, check the
proper installation by rotating the snap ring.
SNAP RING

CHAMFERED EDGE

17. Check each part for proper tightening and operation


after installation.

18. The brake fluid and coolant can damage the painted
plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.

19. Install the oil seal so that the manufacturer marked


surface directs outer surface.(direction not covered
with oil)
Pay attention not to bend or damage the lip
Apply the grease to the lip

20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.

CAVITY
MANUFACTURERS NAME
CLIP
FITTING

1-12

SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine
interior from the infiltration of dust.

22. Install the gasket mounted in the contact surface of


each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.

23. Pay attention not to bend the cable excessively.


Transformed or damaged cable may cause malfunction
or damage.

24. Install the boots with the installing groove by inserting


the boots into the groove.

BOOTS

1-13

SERVICE INFORMATION

CAUTION WHEN WIRING


Each cord must be connected depending on its color.
When connecting different cord, attach color tube
around the connector. Connect the coupler to the
connector with same color and same pin number.
Identify the two-colored cord by main color first and
then striped color .

BLACK TUBE

WHITE
TUBE

When measuring voltage or resistance of the cord


terminal using tester, contact the tester plug behind of
the coupler. Pay attention not to open the cord terminal
and contact the tester plug from the front of the coupler
in case of water-proof coupler.
RED STRIPE

TESTER PLUG

WHITE
COUPLER.
WHITE

RED STRIPE

BLACK CORD

Recheck the condition of contact, securing and


continuity of each part after maintenance.
When connecting the battery, the plus terminal must be
connected first.
After connecting the terminal, apply the grease to the
terminal.

WHITE / RED CORD

When disconnecting the battery, the minus terminal


must be disconnected first.
Make sure that the tool such as spanner do not contact
with the frame.

Connect covers to the terminal after maintenance.

If the fuse is short-circuited, find out the cause and


repair. Replace with the fuse having the specified
capacity.

If there is rust in the terminal, remove the rust with sand


paper prior to connecting.

VALIDATION
OF CAPACITY!

1-14

REMOVE
THE
RUST!

SERVICE INFORMATION
Turn off the main switch before connecting/disconnecting.
Release the lock to disconnect the lock of the coupler.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.

When disconnecting the coupler, disconnect it while


holding the coupler body. Pull while holding the wire
harness cord and do not remove the coupler connection.

Insert the lock of the coupler until the lock is fully


secured.

Release the lock by inserting the coupler slightly and


then narrowing connection to remove the coupler.

Pay attention not to damage the vinyl cover of the


coupler.

Check to see if there is bended terminal and secure it to


avoid disconnecting.

If the wire harness coating is damaged, repair by


winding vinyl tape or replace it.
Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.

1-15

SERVICE INFORMATION
Insert the connector until the vinyl cover is fully inserted
into the terminal.
The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.

DRAINING HOLE

When removing T-start, broaden the groove of T-start


using the wiring driver and release the torque.
Connect the harness and the hose to T-start and then
insert until the groove is locked.
When removing T-start from the frame, replace it with
the new one.

WIRING DRIVER

GROOVE SIDE

Wire band must be secured firmly in the specified


location of the frame. In case of aluminium band, secure
the wire harness to the coated part.

Secure the wire harness firmly using the clamp.

In case of the weld clamp, do not clamp in the welded


part.

When clamping the wire harness, make sure that the


harness is not contacted with the shaft or rotating part.

When clamping the wire, pay attention not to contact


with hot part.

The wire harness must be routed without contacting


with the end of the lamp or any sharp edge.
The wire harness must be routed without contacting
with the end of the bolt or the piece.

1-16

SERVICE INFORMATION
In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape.

The wire must not hang down or be pulled excessively.

NOT TO
PULL!

If necessary, lock the wire harness properly.

When mounting parts, make sure that the wire harness


is not pressed by the parts.

Do not twist the wire harness.

Wire the wire harness not to be pulled or expanded


when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.

Prior to using the tester, please read the manual carefully and understand the contents.
When testing the resistance of the tester, the zero
adjustment must be performed before testing.

Do not drop or throw the parts especially semiconductor


contained parts because these parts may be damaged by
the impact of the drop.

Is this
measurement range or
configuration in accord
with the manual?

1-17

MEMO

INSPECTIONS/ADJUSTMENTS

2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1
MAINTENANCE SCHEDULE 2-3
FUEL LINE 2-4
THROTTLE GRIP OPERATION 2-4
AIR CLEANER 2-5
SPARK PLUG 2-5
VALVE CLEARANCE 2-6
CYLINDER COMPRESSION
RESSURE 2-6
CARBURETOR IDLE SPEED 2-7
TRANSMISSION OIL 2-7

ENGINE OIL 2-7


DRIVE BELT 2-7
BRAKE FLUID 2-8
BRAKE PAD 2-8
BRAKE SYSTEM 2-8
SIDE STAND 2-9
SUSPENSION 2-9
BOLTS, NUTS, FASTENERS 2-10
WHEELS/TIRES 2-10
STEERING STEM 2-10
LUBRICATION POINTS 2-11

2-1

INSPECTIONS/ADJUSTMENTS

2-2

INSPECTIONS/ADJUSTMENTS

2-3

INSPECTIONS/ADJUSTMENTS
FUEL
FUEL
TUBE
FUELTUBE
TUBE

FUEL
PUMP
FUEL
FUELPUMP
PUMP
FUEL
PUMP

THROTTLE
THROTTLEGRIP
GRIP
THROTTLE
GRIP
FREE
FREE
PLAY
FREEPLAY
PLAY

THROTTLE
THROTTLE
CABLE
THROTTLECABLE
CABLE

LOCK
NUT
LOCK
LOCKNUT
NUT

CARBURETOR
CARBURETOR
CARBURETOR

ADJUST
NUT
ADJUST
ADJUSTNUT
NUT
THROTTLECABLE
CABLE
THROTTLE
CABLE
THROTTLE

RUBBER
RUBBER
RUBBER
RUBBER

LOCK
LOCK
NUT
LOCK NUT
NUT

2-4

ADJUST
NUT
ADJUST
ADJUSTNUT
NUT
ADJUST
NUT

INSPECTIONS/ADJUSTMENTS
AIR
AIR
CLENER
AIRCLENER
CLENER

AIR
AIR
CLEANER
ELEMENT
AIRCLEANER
CLEANERELEMENT
ELEMENT
Check the element, if it is dirty or damaged replace it.

The air cleaner element made of dry process paper


filter.
Do not clean by compressed air blowing.

CHECK GAP,
DEPOSITS

0.8 ~ 0.9mm

Remove the spark plug maintenance cover.

CHECK WASHER
FOR DAMAGE
CHECK FOR
CRACKS

SPECIAL
BOLT
SPECIAL
SPECIALBOLT
BOLT
SPECIAL
BOLT

CYLINDER
CYLINDER
HEAD
COVER
CYLINDERHEAD
HEADCOVER
COVER

Hand-tighten the spark plug before using a wrench to


tighten to the specified torque.

SPARK
SPARK
PLUG
CAP
SPARKPLUG
PLUGCAP
CAP

2-5

INSPECTIONS/ADJUSTMENTS
TIMINCT
TIMINCT HOlLE
HOlLE CAP
CAP
TIMINCT
HOlLE
CAP

COOLING
COOLING
FAN
COOLING FAN
FAN

- Floor panel ass'y.


Loosen the 4 cylinder head bolts.
fan cover.
Remove the shroud B grommet of the timit hoile cap
on the RH. shroud.

ADJUST
WRENCH
ADJUST WRENCH
WRENCH
ADJUST
ADJUST
WRENCH

FEELER
FEELER
GAUGE
FEELER GAUGE
GAUGE

TAPPET
TAPPET
ADJUST
SCREW
TAPPET ADJUST
ADJUST SCREW
SCREW

SPARK
PLUG
CAP
SPARK
SPARK PLUG
PLUG CAP
CAP

CYLINDER
HEAD
CYLINDER
CYLINDER HEAD
HEAD

spark plug maintenance.

COMPRESSION
GAUGE
COMPRESSION
COMPRESSION GAUGE
GAUGE
COMPRESSION
GAUGE

CYLINDER
HEAD
CYLINDER
CYLINDER HEAD
HEAD
CYLINDER

2-6

INSPECTIONS/ADJUSTMENTS
PILOT
PILOT
SCREW
PILOTSCREW
SCREW

CARBURATOR IDLE SPEED


Erect the motorcycle on the mainstand.
Remove the rear fender, center cover.
Verify all engine adjustments satisfy specifications.
Make adjustment, If necessary.
Heat the engine to make accurate idling inspection and
adjustment.
Turn the throttle stop screw and make adjustments to
prescribed idling speed.
100RPM
IDLE SPEED : 1,700

THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW

Do not over adjustment the pilot screw. it could be


effect to starting. (refer to page 6-9)

TRANSMISSION OIL
INSPECTOIN
Remove the LH. crank case. (-> 8-2)
Remove the bolt and check the oil on oil check hole.
If the oil level is low(80W/90), add the oil.
Install oil check bolt.

OIL
CHECK
HOLE
OIL
OILCHECK
CHECKHOLE
HOLE
OIL
CHECK
HOLE

Make sure that the oil sealing washer is good


condition.
Erect the motorcycle on the main stand.

ENGINE OIL

OIL
OIL
SIGHT
GLASS
OILSIGHT
SIGHTGLASS
GLASS

INSPECTOIN
Start the engine and let it be warm fully.
Stop the engine. check the oil level line of the LH.
crank case cover oil sight glass.
It is good if the oil surface is between the lower level
line and upper that of the sight glass. If the oil level is
near the lower level line or below that, full to the
upper level line with the recommended oil.

UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER

DRAIN
DRAIN
PLUG
BOLT
DRAINPLUG
PLUGBOLT
BOLT
DRIVE
FACE
DRIVE
DRIVEFACE
FACE

TAPPET
ADJUSTING
HOLE
CAP
TAPPET
TAPPETADJUSTING
ADJUSTINGHOLE
HOLECAP
CAP
TAPPET
ADJUSTING
HOLE
CAP
DRIVE
BELT
DRIVE
DRIVEBELT
BELT
DRIVE
BELT

DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY

Erect the motorcycle on the main stand.

DRIVE BELT
Remove the LH. crankcase cover.
Check the drive belt for wear or damage.
Check schedule maintenance period, replace the new
drive belt if possible.

2-7

INSPECTIONS/ADJUSTMENTS

BRAKE FLUID

MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER

Check the oil level inside the front brake reservoir.


If the oil level is near the lower limit line, remove
the reservoir diaphrag mand fill DOT3 and DOT 4
brake fluid to the top limit line.
If the brake fluid reaches the lower limit line, check
the entire brake system for leaks.

CHECK
CHECK
GLASS
CHECKGLASS
GLASS

If the brake pad is worn severely brake fluid level


can be down.

BRAKE PAD
BRAKE PAD REPLACEMENT

ROD MARK

ROD MARK

BRAKE PAD

BRAKE PAD

DUBLE
DUBLE
BRAKE
HOSE
DUBLE BRAKE
BRAKE HOSE
HOSE

REAR
REAR
BRAKE
HOSE
REAR BRAKE
BRAKE HOSE
HOSE

Check the brake pads for wear.


If the rod mark on the pad reaches the brake
disc, replace the pads.

BRAKE SYSTEM
Check the front brake hose for cracks or damage.
If any leaks are found,replace immediately

FRONT
FRONT
CALLIPER
FRONT CALLIPER
CALLIPER

REAR
CALIPER
REAR
REAR CALIPER
CALIPER
REAR
CALIPER

FRONT
FRONT
BRAKE
HOSE
FRONT BRAKE
BRAKE HOSE
HOSE

BRAKE LEVER FREE PLAY

BRAKE
BRAKE
LEVER
BRAKE LEVER
LEVER

Check the free play after pulling the lever.


FREE
PLAY
FREE
FREEPLAY
PLAY
FREE
PLAY

2-8

FRONT:10~20mm
REAR:10~20mm

INSPECTIONS/ADJUSTMENTS
GREASE
GREASE
GREASE

SIDE
SIDE
STAND
SIDE STAND
STAND

SIDE
SIDE STAND
STAND SWITCH
SWITCH
SIDE
STAND
SWITCH

SIDE
SIDE
STAND
SIDE STAND
STAND

2-9

INSPECTIONS/ADJUSTMENTS

STANDARD PRESSURE

TIRE
TIRE
PRESSURE
GANGE
GAUGE
TIREPRESSURE
PRESSUREGANGE
GANGE

ITEM
FRONT WHEEL REAR WHEEL
DRIVER ONLY
2.00(29
2.00(29 psi)
1.78 psi)
DRIVER AND A PASSENGER
2.25(32
2.25(32 psi)
2.29 psi)

STEERING STEM

2-10

INSPECTIONS/ADJUSTMENTS

LUBRICATION POINTS
Use general grease unless specified here.
Apply oil or grease to the other sliding surfaces not shown here.

CONTROL CABLE LUBRICATION


Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning.
Change it when the cable lengthened.

RR. BRAKE LEVER PIVOT

THROTTLE GRIP

STEERING HEAD BEARING

WHEEL BEARING / SPEDOMETER GEAR


MAIN / SIDE STAND PIVOT

WHEEL BEARING

2-11

MEMO

EXTERNAL PARTS

SERVICE INFORMATION 3-1

SEAT SUPPORT PIPE 3-6

3-2
INNER BOX 3-3
FRONT COVER 3-3
FRONT FENDER3-4
FRONT UNDER COVER 3-4
SEAT3-5
REAR FENDER 3-5
REAR UPPER COVER 3-5
REAR UNDER COVER 3-5

CENTER COVER 3-6

MAINTENANCE PROCEDURE

3-7
FLOOR SIDE COVER 3-7
FLOOR PANEL 3-7
UNDER COVER 3-8
REAR WHEEL MUDGUARD 3-8
SPEEDOMETER 3-8
MUFFLER 3-9
TRUSS PIPE

3-1

EXTERNAL PARTS

MAINTENANCE PROCEDURE
NAME OF FRAME COVERS

This chart shows arrows connected in the order of disassembling covers.

3-2

INNER BOX

SEAT

CENTER COVER

UNDER COVER

FR. COVER

RR. FENDER

TRUSS PIPE

RR. WHEEL MUDGUARD

FR. FENDER

RR. UPPER COVER

FLOOR SIDE COVER

FR. WHEEL

RR. UNDER COVER

BATTERY COVER

FR. UNDER COVER

SEAT SUPPORT PIPE

FLOOR PANEL

EXTERNAL PARTS
FRONT
FRONT
COVER
FRONT COVER
COVER
INNER
INNER
BOX
INNER BOX
BOX

INNER BOX
REMOVAL / ASSEMBLY
Loosen the 6 tapping screws securing the
front side cover

FRONT
FRONT
SIDE
COVER
FRONT SIDE
SIDE COVER
COVER

TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW

Release the lock by turning the cap securing the


main key remove the cap.
Loosen the tapping screw securing inner box.
Remove the inner box.
Install in the reverse order of removal.

INNER
BOX
INNER
INNER BOX
BOX
INNER

TAPPING
TAPPING
SCREW
TAPPING SCREW
SCREW

HEAD
LIGHT
HEAD
HEAD LIGHT
LIGHT
HEAD

FRONT COVER
REMOVAL/ASSEMBLY
Loosen the 2 washer screw securing the
headlight case. Remove the headlight.

WASHER
WASHER
SCREW
WASHER SCREW
SCREW

Remove the speedometer cable, headlight


cable coupler (left and right)
HEAD
HEAD
LIGHT
CABLE
HEAD LIGHT
LIGHT CABLE
CABLE

Loosen the flange bolt securing the headlight


case.
Remove the case.

3-3

EXTERNAL PARTS

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER

Remove the speedometer cable and


speedometer.
Loosen the 6 tapping screw securing the front
side cover.

SPEEDOMETER
CABLE
SPEEDOMETER
SPEEDOMETER CABLE
CABLE

Loosen the 3 special screw securing the front


cover and remove the front cover.
Install in the reverse order of removal

SPECIAL
SPECIAL
SPECIAL
SPECIAL
SCREW
SCREW
SCREW

SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL

FRONT
FRONT
FENDER
FRONT FENDER
FENDER

FRONT FENDER
REMOVAL/ASSEMBLY
Loosen the 4 special screws (R/L).
Remove the wire grommet.
Remove the front fender.
Install in the reverse order of removal.

TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW

FRONT UNDER COVER


REMOVAL/ASSEMBLY
Loosen the 4 tapping screws (R/L) securing
the front of the floor panel.
Loosen the 2 flange bolts securing the front
under cover.
Loosen the 4 washer screws (R/L) securing
front of the floor side cover.

TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
FRONT
UNDER
COVER
FRONT
FRONT UNDER
UNDER COVER
COVER
FRONT

3-4

FLOOR
FLOOR
SIDE
COVER
FLOOR SIDE
SIDE COVER
COVER

EXTERNAL PARTS
Remove the front under cover.
Install in the reverse order of removal.

SEAT REMOVAL/ASSEMBLY
Release the seat lock at the back of seat.
Loosen the 2 flange nuts and remove the seat.
Install in the reverse order of removal.

SEAT
SEAT
SEAT

REAR FENDER
REMOVAL/ASSEMBLY

SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL

Loosen the 2 special bolts.


Loosen the 2 washer bolts and remove the rear
fender.
Remove the tail light cable.
Install in the reverse order of removal.

WASHER
WASHER
BOLT
WASHER BOLT
BOLT

REAR
FENDER
REAR
REAR FENDER
FENDER
REAR

REAR UPPER
UPPER COVER
COVER
REAR
REAR
UPPER
COVER

REAR UPPER COVER


REMOVAL/ASSEMBLY
Pull the behind of the rear upper cover to
remove it.
Install in the reverse order of removal.

3-5

EXTERNAL PARTS

REAR UNDER COVER


REMOVAL/ASSEMBLY

SPECIAL
SPECIAL
SCREW
SPECIAL SCREW
SCREW

Loosen the 4 special screw (R/L) securing the


rear under cover.
Remove it by opening the rear under cover.
Install in the reverse order of removal.
REAR
UNDER
COVER
REAR
REAR UNDER
UNDER COVER
COVER
REAR

SEAT
SEAT
SUPPORT
SEAT SUPPORT
SUPPORT

SEAT
SEAT
SEAT

UPPER
UPPER
COVER
HANDLE
HANDLE COVER

SEAT SUPPORT PIPE


REMOVAL/ASSEMBLY
Remove the rear upper cover.
Remove the rear fender.
the bar end cap B.

BAR
END
CAP
B
BAR
BAR END
END CAP
CAP B
B

Loosen the 4 flange bolts securing the seat


support.
Loosen the cap bolt securing the truss pipe and
remove the support pipe.
Install in the reverse order of removal.

FLANGE
BOLT
FLANGE
FLANGE BOLT
BOLT
FLANGE

CAP
BOLT
CAP
CAP BOLT
BOLT
CAP
BOLT

TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
TAPPING

FLANGE
BOLT
FLANGE
FLANGE BOLT
BOLT

CENTER COVER
REMOVAL/ASSEMBLY
Remove the rear upper and rear fender.
Remove the seat support pipe.
Loosen the 2 tapping screws and 2 flange bolts.
Remove the center cover.
Install in the reverse order of removal.

CENTER
CENTER
COVER
CENTER COVER
COVER

3-6

EXTERNAL PARTS

TRUSS PIPE
REMOVAL/ASSEMBLY
Remove the bar end cap B.
Loosen the flange bolt.
Loosen the 4 cap bolts.
Remove the truss pipe.
Install in the reverse order of removal.

FLOOR SIDE COVER


REMOVAL/ASSEMBLY
Loosen the 6 special screws LH., RH. in floor
side cover and loosen the 4 tapping screws
RH., LH.
Remove the floor side cover (R/L).
Install in the reverse order of removal.

TAPPING
TAPPING
SCREW
TAPPING SCREW
SCREW
TAPPING
FLOOR
SIDE
COVER
SPECIAL
SCREW
FLOOR SIDE
SIDE COVER
COVER
SPECIAL
SPECIAL SCREW
SCREW FLOOR
SPECIAL
SCREW
FLOOR
SIDE
COVER

FLOOR PANEL
REMOVAL/ASSEMBLY

BATTERY
COVER
BATTERY
BATTERY COVER
COVER

Remove the rear fender and upper cover.


Remove the support pipe.
Remove the truss pipe.

CENTER
COVER
CENTER
CENTER COVER
COVER
CENTER
FLOOR
PANEL
FLOOR
FLOOR PANEL
PANEL
FLOOR

FUEL
FUEL
CAP
NECK
FUEL CAP
CAP NECK
NECK
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT

Remove the center cover.


Remove the batery and loosen the flange bolt
securing under.
Remove the fuel cap neck.

3-7

EXTERNAL PARTS
Remove the inner box.
Remove the floor side cover.
Loosen the tapping screw securing the floor panel
and remove the floor panel.
Install in the reverse order of removal.

UNDER
UNDER
COVER
UNDER COVER
COVER

UNDER COVER
REMOVAL/ASSEMBLY
Remove the floor side cover.
Loosen the special screw (R/L) and remove
the under cover.
Install in the reverse order of removal.

SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL

WASHER
WASHER BOLT
BOLT
WASHER
BOLT

REAR WHEEL MUD GUARD


REMOVAL/ASSEMBLY
Loosen the air cleaner and 3 washer bolts
securing mud guard.
Remove the rear wheel mud guard.
Install in the reverse order of removal.

REAR
REAR
WHEEL
MUD
GUARD
REAR WHEEL
WHEEL MUD
MUD GUARD
GUARD

SPEEDO METER
REMOVAL/ASSEMBLY
Remove the headlight, speedometer coupler
and cable.
Remove the speedometer cable.

SPEEDOMETER
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
CABLE

3-8

EXTERNAL PARTS
Remove the inner box.
Loosen the 2 flange bolts securing the pilot
box.

FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT

Remove the speedometer cable.


Install in the reverse order of removal.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER

MUFFLER
REMOVAL/ASSEMBLY
Loosen the washer bolt securing the brake hose
clamp.
Loosen the 3 hex cap nut securing Ex. Pipe
comp.
Loosen the 2 flange bolt securing the muffler
comp.
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT

HEX
CAP
HEX
HEX CAP
CAP

Never performing the maintenance of the muffler


right after stopping the vehicle because the muffler
is extremely hot.

FLANGE
NUT
FLANGE
FLANGE NUT
NUT
FLANGE
NUT

Remove the Ex. muffler comp.

EX. PIPE
Loosen the 2 flange nuts securing the cylinder
comp.
Pull the Ex. pipe comp downward to remove it.
Install in the reverse order of removal.
Replace the packing when assemblying the muffler
and Ex. pipe comp.

3-9

MEMO

LUBRICATION SYSTEM

4-1
4-2
4-3
4-3
4-4

4-4
4-7
4-8

4-1

LUBRICATION SYSTEM

Inclusion of water.
Low or no oil pressure
Close oil valve relief.
Clogged oil strainer.
Worn and faulty oil pump.
Internal oil leaks.
Inadequate oil viscosity.
Shout of oil quantity.
Oil pump drivegear or sprocket it is not right.

4-2

LUBRICATION SYSTEM
OIL
OIL
SIGHT
GLASS
OILSIGHT
SIGHTGLASS
GLASS

UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
MIDDLE
MIDDLE
MIDDIE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER

Loosen the oil drain plug bolt and drain engine oil.
Tighten the oil drain plug bolt.
TORQUE VALVE : 1.4kgf m

OIL
OIL
DRAIN
PLUG
BOLT
OILDRAIN
DRAINPLUG
PLUGBOLT
BOLT

OIL
FILTER
SCREEN
SPRING
OIL
OILFILTER
FILTERSCREEN
SCREENSPRING
SPRING
OIL
FILTER
SCREEN
SPRING

TAPPER
TAPPER
ADJUST
HOLE
CAP
TAPPERADJUST
ADJUSTHOLE
HOLECAP
CAP

OILCOLLAR
COLLAR
OIL
OIL
COLLAR

OIL
FILTER
SCREEN
OIL
OIL FILTER
FILTER SCREEN
SCREEN

TAPPER
TAPPER
ADJUST
HOLE
CAP
TAPPERADJUST
ADJUSTHOLE
HOLECAP
CAP

ENGINE
OIL
REFUELING
ENGINE
ENGINEOIL
OILREFUELING
REFUELING
ENGINE
OIL
REFUELING

4-3

LUBRICATION SYSTEM
FLANGE
FLANGE
BOLTS
FLANGEBOLTS
BOLTS

OIL
FILTER
COVER
OIL
OILFILTER
FILTERCOVER
COVER

OIL
OIL
FILTER
ELEMENT
OILFILTER
FILTERELEMENT
ELEMENT
OIL
SEAL
OIL
OIL SEAL
SEAL

REDUCTION
GEAR
REDUCTION
REDUCTIONGEAR
GEAR
REDUCTION
GEAR
START
START
DRIVEN
GEAR
STARTDRIVEN
DRIVENGEAR
GEAR

OIL
OIL
PUMP
OILPUMP
PUMP

FLAT
FLAT
SCEWS
FLATSCEWS
SCEWS
OIL
OIL
PUMP
OILPUMP
PUMP

4-4

LUBRICATION SYSTEM
PLATE
PLATE
PLATE
PLATE

DRIVEN
DRIVEN
GEAR
DRIVENGEAR
GEAR
OUTER
ROTOR
OUTER
OUTER ROTOR
ROTOR
BODY
BODY
BODY

OIL
OIL
PUMP
SHAFT
OILPUMP
PUMPSHAFT
SHAFT

OIL PUMP DISASSEMBLY


Loosen the screw securing the oil pump plate.
Remove the oil pump body and the oil pump plate.
Clean the oil pump body, inner and outer rotors with
fresh cleaning oil.

INNER
INNER
ROTOR
INNERROTOR
ROTOR

PUMP
PUMP
BODY
PUMPBODY
BODY

FEELER GAUGE
GAUGE
FEELER
FEELER
GAUGE

4-5

LUBRICATION SYSTEM
OUTER
OUTER
ROTOR
OUTERROTOR
ROTOR
INNERROTOR
ROTOR
INNER
ROTOR
INNER

PUMPBODY
BODY
PUMP
PUMP
BODY

OIL
OIL
PUMP
SHAFT
OILPUMP
PUMPSHAFT
SHAFT

OILPUMP
OILPUMP
SHAFT
OILPUMPSHAFT
SHAFT

ROLLER
ROLLER
ROLLER

U
U
NUT
UNUT
NUT

DRIVEN
DRIVEN
GEAR
DRIVENGEAR
GEAR

OIL
OIL
PUMP
OILPUMP
PUMP

(
(

4-6

9-6)

9-5)
( 9-4)
( 9-2)
( 9-2)
( 14-6)
( 15-8)
3-9)

LUBRICATION SYSTEM

OIL
OIL
BOLT
OILBOLT
BOLT

OIL
OIL
RADIATOR
OILRADIATOR
RADIATOR

RADIATOR
RADIATOR
COVER
RADIATORCOVER
COVER

RADIATOR
RADIATOR
RUBBER
RADIATORRUBBER
RUBBER
RADIATOR COLLAR
COLLAR
RADIATOR
RADIATOR
COLLAR
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT

4-7

LUBRICATION SYSTEM
RADIATOR
RADIATOR
RADIATOR
RADIATOR

OIL
OIL
CHECK
BOLT
OILCHECK
CHECKBOLT
BOLT

( 8-2)

AC
AC
GENERATOR
CAP
ACGENERATOR
GENERATORCAP
CAP

4-8

8-2)

EMS(Engine Management System)

5. EMS(Engine Management System)


1. CAUTION WHEN REPAIRING THE EMS PARTS

5-2

2. THE COMPONENT PARTS OF THE EMS

5-3

3.TERMINAL ARRANGEMENT OF THE ECU

5-4

4. WIRING DIAGRAM OF THE ECU

5-4

5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp)

5-5

- Self diagnostic function

5-5

- Fail safe function

5-6

- How to check the fault code

5-7

- How to show the fault code

5-8

- How to read the fault code

5-8

- Fault code table

5-9

- How to remove the fault code

5-10

- EMS trouble shooting

5-10

6. ECU (Electronic Control Unit)

5-11

7. THROTTLE BODY

5-12

8. INJECTOR

5-16

9. MAPAT (Manifold Air pressure Sensor temperature sensor)

5-18

10. TPS (Throttle Position Sensor)

5-22

11. ETS (Engine Temperature Sensor)

5-25

12. ISA (Idle Speed Actuator)

5-28

13. O2(Oxygen) SENSOR

5-31

14. MIL

5-34

15. CKP (Crank Position sensor)

5-35

16. FUEL PUMP

5-39

17. HOW TO USE THE SCAN WHEN THE ECU IS INITIALIZED

5-42

18. HOW TO USE THE SCAN WHEN THE ISA PWM ADJUSTING

5-44

19. HOW TO USE SCAN WHEN THE IGNITION TIMING IS CHECK

5-45

20. HOW TO USE SCAN WHEN THE ENGINE REVOLUTION IS CHECKING

5-46

5-1

EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS.


If the fuse is short-circuited, findout the cause and repair.
Replace with the fuse having the specified capacity.
Do not use the electlic wires or others instead of the fuse.
Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop.

Do not touch the ECU terminal, because it may be damaged by the static.

The ignition key off when assembly and disassembly of the ECU coupler.
otherwise, it might be damage to ECU.

Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts

While engine operating, do not disassembly the battery terminal.


otherwise, it might cause damaged the EMS parts.

Use the specitied voltmeter and resistance meter.

5-2

EMS(Engine Management System)

2. THE COMPONENT PARTS OF THE EMS


EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.
1) INTAKE SYSTEM
As a system which controls and measures air to be necessary for combustion in engine, the intake system
is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air
cleaner and ISA(Idle Speed Actuator), etc.
In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means
that idle speed control system is installed in order to control small of quantity of air being necessary for
combustion.

2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to
injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division
pipe and injector.
The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter.
Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of
intake system.
Injector sprays fuel into the intake system by injection signals of ECU.

3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to
control proper spark time in cylinder, high-voltage system, and so forth.

4) CONTROL SYSTEM
Various sensors to move electric signals converted by checking the current engine status
Input interface which works various processes like regulating voltage levels, removal of noise, A/D
conversion, amplifying of inputted signals from above sensors.
Micro-computer which decides output value through various calculating, arithmetic and logic
processing.
Output interface to amplify the above output signals.
Actuator being mechanically worked by receiving the amplified output signals.

(Intake pressure sensor+Intake


temperature)

5-3

EMS(Engine Management System)

3. TERMINAL ARRANGEMENT OF THE ECU

Remarks
ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected.

4. WIRING DIAGRAM OF THE ECU

5-4

EMS(Engine Management System)

5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)


SELF-DIAGNOSTIC FUNCTION
The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation
normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL
(malfunction indicator lamp). It gives the rider that malfunction has occurred in the system.
However, the ECU takes fail-safe function, it enables to drive only temporary when that happen.
Normally, the MIL illuminates for 3 seconds, when the main key is turned on.
SPEEDOMETER

ODOMETER
DIRECTION
INDICATOR LAMP

HIGH BEAM
INDICATOR

MALFUNCTION INDICATOR LAMP

FUEL GAUGE

when the ignition key ON.

MIL
OFF

Able to engine start


Starting and driving are temporary

ON
Unable
Unable to engine start

Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs
fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.

Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump

The MIL on and blink(when this function detects a malfunction in the system)

MIL

ON

MIL on continuously, when the engine operating

Blink

MIL blinks, when the main key is turn on (engine is stop)

5-5

EMS(Engine Management System)


FAIL-SAFE FUNCTION
If the ECU checks something wrong , the vehicle can be driven by its fail safe function.
However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation
can be impossible.
MIL
on
INTAKE
INTAKE

: MIL on/off
: MIL on

If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.

intake
intake

INTAKE

INTAKE

The value of intake pressure is fixed as the


pressure just before when the intake pressure
sensor is out of order.
The value of intake temperature is fixed as a
temperature just before when the intake
pressure sensor is out of order.

! CAUTION

If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.

5-6

EMS(Engine Management System)


HOW TO CHECK THE FAULT CODE
There are two methods of checking the fault codes.
1) Use the MIL in the speedometer.
2) The diagnostic tool.
First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic
methods for each part)
Second) The diagnostic tool (refer to scan users manual.)
Turn off the ignition key
Disassemble the rh.side cover
The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.
(The coupler to check the malfunction of vehicle is placed in the rh.side cover)
Turn on the ignition key
Press the power button of diagnostic tool
Checks according to diagnostic procedure of diagnostic tool.

Coupler to check the malfunction diagnosis


Wire color to check the malfunction diagnosis
-P/W : PINK/WHITE
-P/Y : PINK/YELLOW
-B : BLACK
-G : GREEN

The diagnostic Tool.


The wireharness to check the ECU
This wireharness is connected with the ECU and main wireharness
It has two couplers to check the terminals.
First coupler) ECU no.1~20
Second coupler) ECU no.21~40
Arrangement of ECU PIN
First coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connected
Second coupler) ECU no.36,38 were not connected

The wireharness to check the ECU

5-7

EMS(Engine Management System)


HOW TO SHOW THE FAULT CODE
There are two methods to show the Fault codes.
First, the methods to show in engine operation
In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the
light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code,
stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be
verified.(refer to the fault code table)
Second,the ways of indication only turn on the ignition key.
When only ignition key is on and if the defect of each part brings out, the MIL keeps showing
the Fault code of defect part repeatedly in order to give defect information to driver.
! CAUTION

If the MILon when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started

HOW TO READ THE FAULT CODE


The fault codes are showed as 2 digits on the MIL of EMS.
Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed.
E.g. ) The Fault code of ISA

ON

OFF
1.5 sec

3 sec

1 flashing cycle : 0.5 sec

If many problems will happened in the EMS parts at the same time only one fault code is displayed by the
priority, however, the ECU is remembers all the fault codes.
After revise the code, remove the memorized fault code by the method of warm up.(5-10)
(Refer to remove the fault codes)
When the vehicle is checked using the diagnosis tool.
- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.

5-8

EMS(Engine Management System)


FAULT CODES TABLE

MIL INDICATION
(The number of blinks)

Fault
code no.

Priority
order

00

No failure

21

Injection valve failure(IV)

22

Idle speed actuator failure (ISA)

23

Electrical fuel pump failure (EFP)

12

Intake Manifold absolute pressure signal


failure (IMP)

13

Throttle position signal failure (TPS)

24

O2 sensor heater output failure (LSH)

14

Lambda signal failure (VLS)

15

Engine temperature signal failure (TENG)

16

Breathing air temperature signal failure


(TBA)

28

11

Malfunction indicate lamp failure (MIL)

Description

5-9

EMS(Engine Management System)


HOW TO REMOVE THE FAULT CODE
Remove the fault codes in two ways;
First) Full warm up
1. Starting the engine.
- The MIL blinks continuously because the ECU memorized the fault code yet.
2. Full warm up the engine (keep idling five minutes)
3. Turn off the ignition key after full warm up the engine
4. Turn on the ignition key again, and check whether the fault code is disappeared or not.
After full warm up, it is possible to check the fault code is removed with the ignition key on/off.
If many problems happened in the EMS parts at the same time, only one defect code will is displayed
by the priority order.
Even thought repair a fault and remove the memorized fault code, another fault code blinks.
at this time, revise the fault and remove the memorized fault code by the warm up.
Second) Malfunction diagnosis tool
(refer to the scan users manual)

EMS TROUBLE SHOOTING


Inspection before diagnosis
Inspection the following before malfunction diagnosis.
Quantity of engine oil and leakage
Quantity of fuel and leakage
Blocked of air cleaner
Condition of battery
Free play of throttle cable
Cutting of fuse
Leakage of emission gas
Connection of each coupler

5-10

EMS(Engine Management System)


SEAT
SEAT
SUPPORT
PIPE
SEAT SUPPORT
SUPPORT PIPE
PIPE
CENTER
CENTER
COVER
CENTER COVER
COVER

6. ECU
(ELECTRONIC CONTROL UNIT)
REMOVE
Remove the seat support pipe.
Remove the center cover.

! CAUTION

Before disassemble, the key is off.

Remove the ECU coupler.

Loosen the 4 flange bolts and remove the


ECU.

FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT

ECU
ECU
ECU

ASSEMBLY
Assembly is the reverse order of removal.
! CAUTION

Be sure to assemble the ECU ground wire.


(The color is green)

5-11

EMS(Engine Management System)

7. THROTTLE BODY

CENTER
CENTER
COVER
CENTER COVER
COVER

Remove the seat support pipe.


Remove the center cover.

Loosen the screw securing air cleaner connecting


tube band.
Remove the throttle body and air cleaner.

SCREW
SCREW
SCREW

Remove the gasoline in fuel tube.


Disconnect fuel tube securing inject cap.
Disconnect injector, MAPAT, throttle sensor, ISA
coupler.
Disconnect throttle cable.
Loosen the 2 flange bolts securing insulator and
remove the throttle body assy.

Remove the each component parts securing


throttle body and check.
! NOTE

Do not disconnect both the throttle adjust screw


and adjust nut.

5-12

EMS(Engine Management System)

DISCONNECT THE THROTTLE BODY


Disconnect fuel tank and air cleaner.
Remove the gasoline in fuel tube.
Disconnect fuel tube securing injector cap.
Disconnect TPS, ISA, MAPAT, injector coupler.
Disconnect throttle cable.
! CAUTION

THROTTLE
THROTTLE
BODY
THROTTLE BODY
BODY

INSULATOR
INSULATOR
INSULATOR
INSULATOR

THROTTLE
BODY
THROTTLE
THROTTLE BODY
BODY
THROTTLE
BODY

ISA
ISA
ISA
ISA

Do not disconnect both the throttle adjust screw


and adjust nut.

REMOVE
Loosen the throttle body 2 bolts securing the
insulator.
Disconnect the TPS (Throttle position sensor).
Disconnect the ISA(Idle speed actuator).
Disconnect the MAPAT.

TPS
TPS
TPS
! CAUTION

Do not disconnect the throttle valve.


MAPAT SENSOR
SENSOR
MAPAT
MAPAT
SENSOR

CHECKING THE THROTTLE BODY


Checking the TPS.
Checking the ISA.
Checking the MAPAT.

MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT

ISA
ISA
ISA

TPS
TPS
TPS
TPS

Checking the throttle shaft.


Checking the valve.
Assembly is the reverse order of removal.
Install the O-ring on the throttle body.

THROTLE
THROTLE
SHAFT
THROTLE SHAFT
SHAFT

THROTTLE
THROTTLE VALVE
VALVE
THROTTLE
VALVE

5-13

EMS(Engine Management System)


DISASSEMBLE THE INSULATOR
Disconnect injector cap bolt.
Disconnect injector and injector cap at the
same time from the insulator.
Disconnect injector and injector cap.

CHECKING THE INSULATOR


INJECTOR
INJECTOR
CAP
INJECTOR CAP
CAP

INJECTOR
INJECTOR
INJECTOR
INJECTOR

Check the O-ring.


Check the insulator inside.
Check the insulator cap inside.

ASSEMBLY OF THE INSULATOR


Assemble is the reverse order of removal.
Assemble the O-ring to insulator.
Install the insulator to the throttle body.
Torque : 1.0 kgf m

Remove the injector and check.

ASSEMBLY OF THE THROTTLE BODY


Assemble is the reverse order of removal.
Assemble the O-ring to the insulator.
! CAUTION

Replace the o-ring with new one.

Assemble the insulator to the throttle body.


Torque : 1.0 kgf m

INSTALLATION OF INSULATOR AND


THROTTLE BODY
Installation of insulator and throttle body in the
reverse order of removal.
Check the o-ring when the insulator assembly.
Assemble the insulator gasket.
! CAUTION

Replace the gasket with new one.

Install the assembled insulator and throttle


body to the cylinder head.
Torque : 1.2 kgf m

5-14

EMS(Engine Management System)


ADJUSTMENT OF THROTTLE CABLE
Assemble the throttle cable.
Adjust the free play of throttle grip.

INSPECTION OF SENSOR AND


ACTUATOR
Connect each sensor and the actuator coupler.
Check the ISA.
Check the TPS.
Check the MAPAT sensor.
! CAUTION

Be sure to the valve of TPS is whether the


standard valve after it became assembly.
Check the MAPAT sensor.

ADJUSTMENT OF IDLE SPEED


ACTUATOR (ISA)
A vehicle is assembled in the state which
engine operation is possible.
Loosen the maintenance cover and the adjustscrew is makes possible to adjust.
The coupler to check the malfunction of
vehicle is connected to the coupler of
diagnostic tool.
Turn on the ignition key.
Press the power-button of diagnostic tool.
The vehicle is warms up enough to adjust the
idling speed.
! CAUTION

The ECU is always initilized, before the engine


is starting.

The vehicle is warms up enough to adjust the


idling speed.

ENGINE TEMPERATURE : OVER 100


IDLE SPEED ACTUATOR : APROXIMATELY 20%
ISA
ISA
ISA
ISA

5-15

EMS(Engine Management System)

8. INJECTOR
REMOVE
INJECTOR
CAP
INJECTOR
INJECTOR CAP
CAP
INJECTOR
CAP

INJECTOR
INJECTOR
INJECTOR
INJECTOR

Turn off the ignition key.


Disconnect the injector coupler.
! CAUTION

Before disassemble, the key is off.

Loosen the injector cap bolt.

FLANGE BOLT
BOLT
FLANGE
FLANGE
BOLT

INJECTOR
INJECTOR
INJECTOR

Disconnect the injector.


!

NOTICE

Be sure to check the engine is cooling


because a little gasoline remains, It could be
still hot.
Be sure to inject the gasoline, after remove
the coupler from the ignition coil. It could be
damaged for the fire, sparked on the spark
plug.

ASSEMBLY
Assemble is the reverse order of removal.

5-16

EMS(Engine Management System)


CHECKING METHODS BY FAULT CODES
Checking of the Injector circuit
The fault code is displayed by MIL

Checking Circuit
ECU

INJECTOR

40 : INJECTOR control
39 : FUEL PUMP control

FUEL PUMP RELAY

Coupler terminal is based on wire harness.


Checking Procedure
1) Turn off the ignition key.
2) Check to see if the injector coupler has come loose or the wire is peeling off.
If there is no problem, measured the resistance of injector.
3)Disassemble the injector coupler and measure the resistance between injector terminals.
The resistance of injector : 14.50.7[ ], 20
Remarks : measuring unit for resistance : resistance R [ ]
4)If there is no problem, check the continuity between each terminal and ground.
The resistance between each terminal and ground : [ ]
If resistance value is not normal, replace injector with the new one.
5)If the resistance is normal, turns on the ignition key
- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.
6) Measure between the voltage of coupler.
Measuring terminal : BLACK/RED electric wire ~ ground
Measuring voltage : battery voltage 1.0[V]over
Remarks : Measuring unit of voltage : voltage [V]
7) If the measured voltage is normal,
Check the Blue/Yellow electric wire to see if they have been broken or have short-circuited
or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)
If there is no problem in the electric wires, ECU is broken
Replace the ECU with new one, it rechecks
8) If the measured voltage is not normal,
Check the Black/Red electric wire to see if they have been broken or have short-circuited.
Check the fuel pump relay.
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-17

EMS(Engine Management System)

MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT

TPS
TPS
TPS

9. MAPAT (Mainfold Air pressure sensor


Temperature sensor)
Located on the left-side of the throttle body.
! CAUTION

Before disassembly, the key is off.

REMOVE
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR TPS
TPS
TPS

Disconnect the MAPAT circuit sensor coupler.


Loosen the 2 MAPAT circuit sensor screws.

Disconnect the MAPAT sensor.

ASSEMBLY
Assembly is the reverse order of removal.

5-18

EMS(Engine Management System)


Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))s circuit
Fault code number is displayed by MIL
The Fault code of intake pressure sensor

The Fault code of intake temperature sensor

Checking circuit

MAPAT

ECU

3 : Intake
sensorpressure
ground
3 : pressure
Inhalation
26 : sensor
5V voltage
GROUND
27 : 26
IMP: 5V voltage
28 : TBA
27 : IMP 28 : TBA

Coupler terminal is based on the side of wire-harness

Checking Procedure
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input voltage of MAPATs coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
Remarks : Measuring unit of voltage : voltage [V]
If voltage value is not normal,
Check to see if the ECU coupler is loose or if there is a bad contact.
Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited
Remark : refer to (5-20) if the intake pressure sensor is broken
refer to (5-20) if the intake temperature sensor is broken
5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-19

EMS(Engine Management System)


Checking of the intake pressure sensor
1) If voltage value is normal, turn off the ignition key.
Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler
2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler.
Refer to how to assemble or disassemble the ECU ( 5-11 )
3) Turn on the ignition key. Start engine and operate idle.
4) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor.
Measuring terminal : ECU No. 27(P/L:PINK/BLUE)
~ ECU No.3(P/G : PINK/GREEN)
Measuring voltage : 0.1[V] ~ 4.8[V]
Remarks : Measuring unit of voltage : Voltage [V]
The voltage of air pressure;
20[kPa]: 0.719 ~ 0.859[V]
107[kPa]: 4.154 ~ 4.294[V]

WIRE
WIRE
HARNESS
WIRE HARNESS
HARNESS

5) If the measured voltage is not normal,


Check the P electric wire, P/G electric wire,
P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with the new one and it rechecks.
If measuring voltage is normal,
Check the P electric wire, P/G electric wire,
P/L electric wire to see if they have been broken or have
short- circuited if there is a bad contact.
badness of terminal No. 3, No. 26, No.27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.

5-20

EMS(Engine Management System)


Checking of the intake temperature sensor
1) If voltage value is normal, turn off ignition key.
2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.
Resistance of intake pressure sensor : 2000100[], 251
Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)
Remarks : Measuring value for resistance : Resistance[ ]
The Voltage of air pressure;
24 ~ 26[ ] : 1800~2200[ ]
99 ~ 101[ ] : 161~206[ ]
3) If measuring resistance is not normal,
Replace the MAPAT sensor with new one and it rechecks.
If the measured voltage is normal,
Check the P electric wire, P/G electric wire,
P/L electric wire to see if they have been broken or have
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No. 27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
4) Turn on the ignition key. Start the engine and idling.
5) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor
- Measuring terminal: ECU No.28(TBA)
~ ECU No.3(IMP GROUND)
- Measuring voltage: 0.1[V] ~ 4.9[V]
Remarks : Measuring unit of voltage : Voltage [V]
6) If the measured voltage is not normal,
Check the P electric wire, P/G electric wire,
P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with new one and it rechecks.
If the measured voltage is normal,
Check the P electric wire, P/G electric wire,
P/L electric wire to see if they have been broken or have
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No.28 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace ECU with the new one, it rechecks.
7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-21

EMS(Engine Management System)

10. TPS(Throttle position Sensor)


Located on the left side of throttle body.
! CAUTION

Before disassembly, the key is off.

TPS
TPS
TPS

REMOVE
Disconnect the TPS coupler.
Loosen 2 TPS screws.
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
SENSOR

Disconnect the TPS.

TPS
TPS
TPS

ASSEMBLY
Assembly is the reverse order of removal.

5-22

EMS(Engine Management System)


CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM
Fault code number is displayed by MIL

Checking circuit

TPS

ECU

4 : SENSOR GROUND
18 : 5V SUPPLY VOLTAGE
19 : TPS

The coupler terminal is based on the side of wire-harness

Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the IGNITION KEY.
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPSs coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit of voltage : voltage [V]
If voltage value is not normal,
Check to see if the ECU coupler is loose if there is bad contact.
Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been
broken or have short- circuited.
5) If the value of voltage is normal, turn off the ignition key.

5-23

EMS(Engine Management System)


Checking Procedure
6) Check continuty between the Sensor Ground Terminal of TPS and Earth.
The continuty TPS : 0[ ],201
Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH
Remarks : Measuring unit for resistance : Resistance R [ ]
7) If not problem, measure the resistance of TPS.
By turning round throttle grip, measure the resistance.
The resistance of TPS
If the throttle is totally closed : 0.9~1.6[k ],201
If the throttle is totally opened : 2.3~2.6[k ],201
Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Remarks : Measuring value of resistance : Resistance[k ]
8) If resistance and the continuty are not abnormal.
Adjust correctly the position of TPS
Replace the TPS with the new one and re-check.
9) If resistance and continuty are normal, connect the TPS coupler.
10) Turn on the ignition key.
11) Measure the TPS voltage of wire-harness to check the ECU.
Rotate the throttle lever, measure the voltage
Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Output voltage of TPS
-If the throttle is totally closed : 4.0~5.5[V]
-If the throttle is totally opened : 0.1~0.6 [V]
Remarks : Measuring unit for voltage : Voltage [V]
12) If the measured voltage is abnormal,
Replace the TPS with the new one, and re-check.
If the measured voltage is normal,
Check the GR/B electric wire, GR/L electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, and recheck.
13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

5-24

EMS(Engine Management System)


RH. SHROUD
SHROUD
RH.
RH.
SHROUD

11. ETS(Engine Temperature Sensor)


Situated at the back of the cylinder head.
Remove the RH. shroud.

! CAUTION

Before disassembly, the key is off.

REMOVE
Disconnect the ETS coupler.

Disconnect the ETS.

ASSEMBLY
Assembly is the reverse order of removal.

ETS
ETS
ETS

5-25

EMS(Engine Management System)


1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)
Fault code number is displayed by MIL

CHECKING CIRCUIT

ETS

ECU

4 : SENSOR GROUND
5V SUPPLY VOLTAGE
20 : ETS

Coupler terminal is based on the side of wire-harness

Checking Procedure
1) Turn off the ignition key .
2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input 5 voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Measure the terminal voltage of ETSs coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit for voltage : voltage [V]
If the voltage value is not normal,
Check to see if the ECU coupler is loose if there is bad contact.
Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been
broken or have short- circuited.
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS :1.6[k ]~10.6[k ],20 ~80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance R [k ]

5-26

EMS(Engine Management System)


6-1) If the measured value is not normal,
Replace the ETS with the new one, recheck.
If the measured value is normal,
Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if
the ECU coupler is a bad contact ( No.4, No. 20.)
If the electric wire is no problem, ECU is broken.
Replace ECU with the new one, recheck.
6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

Checking Procedure
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to ETS disassembly)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperatures change and testers value.
Characters of ETS

Temperature

Resistance value

20

10.6[k ]~14.4[k ]

80

1.35[k ]~1.65[k ]

110

0.57[k ]~0.69[k ]

Measuring unit of resistance : Resistance R [k ]


If the value of resistance is high or out of the standard value, replace the ETS with the new one.
! CAUTION

1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.
3) Install
Assembly is the reverse order of removal.
Tighten the ETS to the specified torque.
ETS torque : 3.0[kgf m]

5-27

EMS(Engine Management System)


ISA
ISA
ISA

INJECTOR
INJECTOR
INJECTOR

12. ISA(Idle Speed Actuator)


Located on the throttle body.
Remove the center cover.
! CAUTION

Before disassembly, the key is off.

REMOVE
Disconnect the ISA coupler.

ISA COUPLER
COUPLER
ISA
ISA
COUPLER

Loosen 2 ISA screws.


ISA
ISA
SCREW
ISA SCREW
SCREW

Remove the ISA.

ASSEMBLY
Assembly is the reverse order of removal.

5-28

EMS(Engine Management System)


1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.
Showing of defects codes by MIL

CHECKING CIRCUIT
ECU

ISA

FUEL PUMP RELAY

Coupler terminal is based on the side of the wire-harness

CHECK PROCEDURE
1) Turn off ignition key .
2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ],20
remarks : Measuring unit of resistance : Resistance R[ ]
ISA
ISA
ISA
ISA

4) If there is not problem, check about the level of electricity flow between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : [ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-28 )
remarks : Measuring unit for resistance : Resistance R[ ]

5-29

EMS(Engine Management System)


CHECK PROCEDURE
5) If the measured resistance and continuty is abnormal.
Replace ISA with the new one, and recheck.
6) If resistance and continuty is normal, connect the coupler of ISA.
7) Turn on ignition key
8) Measure ISA voltage of wire-harness to check ECU.
Measuring terminal : B/R electric wire ~ EARTH
Output voltage of ISA : Battery Voltage [V]
Remarks : Voltage measuring unit : Voltage [V]
If the measured voltage is normal,
Check the B/R electric wire, L/G electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, recheck.
If the measured voltage is abnormal,
Check the B/R electric wire, L/G electric wire, W/B electric wire to see if they have been
broken or have short- circuited.
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code.

5-30

EMS(Engine Management System)

13. O2(Oxygen) SENSOR


REMOVE
O2
O2 SENSOR
SENSOR COUPLER
COUPLER
O2
SENSOR
COUPLER

Located on the exhaust pipe.


Disconnect the RH. floor side cover.
Disconnect the O2 sensor coupler.
! CAUTION

Before disassembly, the key is off.

O2
SENSOR
O2
O2 SENSOR
SENSOR
O2
SENSOR

Remove the O2 sensor on the muffler.

Check the O2 sensor.


! CAUTION

Take precaution not to impact on the O2 sensor.

ASSEMBLY
O2
O2
SENSOR
O2 SENSOR
SENSOR

Assembly is the reverse order of removal.

5-31

EMS(Engine Management System)


1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT
Fault code number is displayed by MIL

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.

CHECKING CIRCUIT
OXYGEN SENSOR

ECU

Lamda

2 : LAMBDA SENSOR GROUND


12 : OXYGEN SENSOR SIGNAL
34 :: OXYGEN
34
OXYGENSENSOR
SENSORHEATER
GROUND

Coupler terminal is based on the side of Wire-Harness.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER


1) Turn off the ignition key.
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key
4) Measure input voltage of oxygen(O2)sensor coupler
Input voltage : Battery voltage[V]
Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler
(B/BR : BLACK/BROWN) ~ EARTH
Remarks : Measuring unit of Voltage : Voltage[V]

5-32

EMS(Engine Management System)


CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER
If the voltage value is abnormal,
Check to see if the ECU coupler is loose or if there is bad contact.
Check the B/B electric wire, G/W electric wire to see if they have been
broken or have short- circuited.
5) If the voltage value is normal, turn off the ignition key.
Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22
Measuring terminal (side of wire-harness) :
oxygen(O2)3 terminal of sensor coupler
Remarks : Measuring unit of Resistance : Resistance R[ ]
6) If the measured resistance is abnormal,
Replace the oxygen(O2)sensor with new one and recheck it.
If the measured resistance is normal,
Check the B/B electric wire, G/W electric wire to see if they have been
broken or have short- circuited.
If the electric wire is no problem, the ECU is broken.
Replace the ECU with new one, and recheck it.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL


1) Turn off the ignition key
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) The wire harness to check the ECU is connected to the ECU with a ECU coupler
Refer to the ECU assembly/disassembly (5-4)
4) Turn on the ignition key
5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.
Measuring terminal:
(V :VIOLET) ~ (V/B:VIOLET/BLACK)
Output voltage of oxygen(O2) sensor : 0.1~0.8[V]
Remark : measuring unit of voltage : voltage[V]
Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf m]
If the measured voltage is normal,
Check the V electric wire,
V/B electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal
No. 2, No. 12 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and recheck it.
If the measured voltage is abnormal,
Check the V electric wire, V/B electric wire, W/B electric wire to see if they have been
broken or have short- circuited.
6) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

5-33

EMS(Engine Management System)

14.CHECKING OF MIL
Fault code number is displayed by MIL

CHECKING CIRCUIT
ECU
24 : MALFUNCTION INDICATOR LAMP OUTPUT

MALFUNCTION INDICATOR LAMP(MIL)

CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
3) Turn on the ignition key.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the lamp.
But If the lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : (B) electric wire ~ (G)electric wire => Output voltage: battery voltage
Measuring terminal : (B/Y)electric wire ~ (G)electric wire => output voltage: 9V~15V
Remarks : measuring unit of voltage : voltage[V]
If the measured voltage is normal,
Check the R/Y electric wire, B electric wire, G electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.
If the measured voltage is abnormal,
Check the B/Y electric wire, B electric wire, G electric wire to see if they have been
broken or have short- circuited.
6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code.

5-34

EMS(Engine Management System)

15. CKP(Crank Position Sensor)


REMOVE
Remove the center cover.
Remove the ACG coupler.
Remove the CKP coupler.
CKP is located inside the RH. crank case
cover.
! CAUTION

Before disassembly, the key is off.

RH. SHROUD
SHROUD COMP
COMP
RH.
RH.
SHROUD
COMP

CRANK
CRANK
POSITION
SENSOR
CRANK POSITION
POSITION SENSOR
SENSOR

Remove the RH. shroud.


Remove the cooling fan.
Remove the fly wheel.

Remove the 3 screws securing ACG stator.


Remove the 2 screws securing CKP.

Check the ACG stator and position sensor.


Take precaution not to use the stator comp (18
terminal) like the carburetor type stator.

5-35

EMS(Engine Management System)


Check the fly wheel.
Fly wheel for the EMS system have 10 spots
on the fly wheel protrusion. It is different with
carburetor type.
Check the mark or contamination on the
protrusion.
! CAUTION

When replace the fly wheel, check the 10 spots


of protrusion part.

ASSEMBLY
Assembly is the reverse order of removal.

CHECKING OF CKP(Crank Position


Sensor)
MEASUREMENT RESISTANCE
Remove the seat.
Remove the LH. side cover.
Disconnect the ACG coupler and (L/G)
connector.
Measure the resistance between G and L.
STANDARD : 80~150(20)

MEASUREMENT PVA
Disconnect the ACG (L/G) connector.
Connect the (+)cord of PVA tester to the green
terminal or ground wire.
Connect the (-)cord of PVA tester to the blue
terminal.
Crank the engine with the starter motor and
measure the peak voltage of crank position
sensor coil.
HIGHEST VOLTAGE : 1.5V Over.
TOOL : PVA Multy tester.
Assembly is the reverse order of removal.

5-36

EMS(Engine Management System)

CHECK THE CIRCUIT OF CKP


Fault code number is displayed by MIL

CHECKING CIRCUIT

GREEN

BLUE

RED

BLUE

ECU PIN NUMBER


ECU
30 : CRANK
SIGNAL-A
30 :
_ A
22 :
_ B
22 : CRANK
SIGNAL-B

22

30

CHECK PROCEDURE
1) Turn ON ignition key.
2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.
When start up the ENGINE SINK ON change OFF to ON, its okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance.
- measuring resistance : 80 ~ 150[]

5-37

EMS(Engine Management System)


4) Check if crank signal A,B wires is breaks or not.
Remove the ECU, connect wire harness for inspection to wire harness of vehicle.
Check the wiring of crank signal A
- Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[]

Red
CKP_B
1

CKP_A
2

Check the wiring of crank signal B


- Measure terminal : No. 22 pin of wire harness for inspection - Blue wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[]

Blue
CKP_B
1

CKP_A
2

5) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

5-38

EMS(Engine Management System)

16. FUEL PUMP

FUEL
FILLER
CAP
FUEL
FUEL FILLER
FILLER CAP
CAP
FUEL
FILLER
CAP

REMOVE
Fuel pump is located inside the fuel tank.
Remove the fuel filler cap.
Remove the floor panel.

! CAUTION

Make sure that the key is off before assembly.

Remove the fuel hose.


Remove the fuel pump coupler.

FUEL
FUEL
TUBE
FUEL TUBE
TUBE

FUEL
PUMP
COUPLER
FUEL
FUEL PUMP
PUMP COUPLER
COUPLER
FUEL
PUMP
COUPLER

Loosen the 4 fuel pump setting place screws.


FUEL
FUEL
PUMP
SETTING
PLACE
FUEL PUMP
PUMP SETTING
SETTING PLACE
PLACE

SCREW
SCREW
SCREW

Remove the fuel pump.

5-39

EMS(Engine Management System)

FUEL PUMP

The terminal arrangement of the fuel pump


(The following color chart is the internal color of the fuel pump)

CONNECTOR WIRING

5-40

LOCATION

FUNCTION

COLOR

FUEL UNIT

YELLOW

FUEL UNIT2

GREEN

PUMP (+)

RED

GROUND

BLACK

EMS(Engine Management System)


Check the fuel pump.
Remove the fuel pump.
Measure the resistance between terminals.

The FLOAT position

Terminals resistance []

F : 140.5[mm]

40 5[]

1/2 : 83.5[mm]

220 5[]

E : 28.5[mm]

400 3[]

The float position is based on tank bottom plate.


Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)
wire of fuel unit terminal
Remark : measuring unit of resistance : resistance[]
If the measured resistance value is out of standard at float position, replace the fuel unit.



CHECK THE BLOW PRESSURE OF FUEL PUMP


- Blow pressure : 3.0 Bar
- After remove fuel tube from the injector, turn the ignition key ON/OFF 3
times, when the fuel come out about 100cc over, its Okay.
If under 100cc, check the fuel pump. Replace it if necessary.
(Be sure to the resistance of battery is over 12.6V)

ASSEMBLY
Assembly is the reverse order of removal.

5-41

EMS(Engine Management System)

17.HOW TO USE THE SCAN WHEN


ECU IS INITIALIZED
The coupler to check the malfunction of vehicle
is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnostic tool.
Press the enter button in the initial screen.
Press the enter in the vehicle diagnosis screen.

Press the enter button on the resetting ECU values.

If the enter-key is press than the ECU will reset.

Press the rest button on the following screen.

5-42

EMS(Engine Management System)


Press the enter button when it is ready

When the ECU was initialized. turn off the lgnition


key and then turn on the ignition key.

5-43

EMS(Engine Management System)

18.HOW TO USE THE SCAN WHEN


THE ISA PWM IS ADJUSTING
The coupler to check the malfunction of vehicle
is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the button at the vehicle diagnostic screen.

Press the enter button on the current data.

By looking the displayed figure on the ISA PWM,


adjust the throttle adjust screw.

5-44

EMS(Engine Management System)

19.HOW TO USE THE SCAN WHEN


THE IGNITION TIMING IS CHECKING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the enter button on the vehicle diagnosis screen.
Press the enter button on the current data.

To check the ignition angle

5-45

EMS(Engine Management System)

20.HOW TO USE THE SCAN WHEN


ENGINE REVOLUTION IS CHECKING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the enter button on the vehicle diagnosis screen.

Press the enter button on the current data.

Check the engine rpm on the engine speed

5-46

MEMO

MEMO

FUEL SYSTEM

6. FUEL SYSTEM
SERVICE INFORMATION 6-1
TROUBLESHOOTING 6-2
FUEL TANK 6-3
CARBURETOR 6-3

FLOAT CHAMBER/FLOAT/JET6-5
CARBURETOR INSULATOR 6-8
PILOT SCREW ADJUSTMENT 6-9
FUEL PUMP6-11

SERVICE INFORMATION
GENERAL SAFETY
!

WARNING

Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore,
the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas.
Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly
ventilated area.
!

CAUTION

Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions.
Pay particular attention to the position of O-ring. Replace with new ones when disassembled.
If it is desired to store a vehicle for a period longer than 1 month, drain gasoline out of the carburetor float chamber.
Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits, and idling may
become unstable.

SPECIFICATIONS
FUEL TANK CAPACITY : 7.2
RESERVE FUEL CAPACITY : 1.2

CARBURETOR SPECIFICATIONS
ITEM

VENTURI BORE
SETTING SERIES MARK

SPECIFCATUIONS
CV TYPE/ 24.2mm
CVK 166 (A)

MAIN JET No.

#95

FLOAT LEVEL

17mm

PILOT SCREW INITIAL OPENING

IDLING SPEED
THROTTLE GRIP FREE PLAY

1,700 100rpm
2-6mm

TOOL
FLOAT LEVEL GAUGE

6-1

FUEL SYSTEM

TROUBLESHOOTING
The vehicle does not start.

Air/Fuel mixture is extremely rich.

No gasoline in fuel tank.


Fuel is not coming out of carburetor.
Too much fuel is flowing into cylinder.
Air cleaner is blocked.
No spark emitted from spark plug.

Float valve is damaged.


Oil level is too high.
Air jet is blocked.
Auto bystarter is damaged.
Air cleaner is blocked.

Idle is unstable and engine turns off after starting.


Faulty idle adjustment.
Excessively lean or rich mixture.
Air cleaner is blocked.
Suction system is experiencing secondary intake of air.
Clogged fuel system.
Auto bystarter is damaged.
Ignition system is damaged.
Using low quality gasoline.
Air screw is adjusted improperly.
Carburetor is blocked.
Compression pressure is low.

Air/Fuel mixture is extremely lean


Fuel jet is blocked.
Bad ventilation of air in tank cap.
Fuel strainer screen is blocked.
Fuel tank is bent, creased or blocked.
Float valve is damaged.
Oil level is low.
Suction system is receiving secondary suction of air.
Fuel pump is incorrect flow of oil.

6-2

Back firing
Ignition system is damaged.
Mixture is too lean.

Mis-firing occurs when driving at high speeds.


Ignition system is damaged.
Mixture is too lean.
Insufficient power and high fuel consumption.
Air cleaner is blocked.
Ignition system is damaged.
Mixture is too lean.

FUEL SYSTEM

CRADLE
PIPE
CRADLE
CRADLEPIPE
PIPE
CRADLE
PIPE

CENTER
COVER
CENTER
CENTERCOVER
COVER
CENTER
COVER
FLOOR
FLOOR
PANEL
FLOORPANEL
PANEL

FUEL TANK
REMOVAL
!

WARNING

Gasoline is extremely flammable. Avoid fire during


work, and pay particular attention to electric sparks.
Furthermore, the evaporated (gasified) gasoline is highly
explosive. Work in a well-ventilated areas.

TRUSS
TRUSS
PIPE
COMP
TRUSSPIPE
PIPECOMP
COMP

SEATSUPPORT
SUPPORTPIPE
PIPE
SEAT
SUPPORT
PIPE
SEAT

FUELCAP
CAP
FUEL
CAP
FUEL
FLOOR
FLOOR
PANEL
FLOORPANEL
PANEL

SPECIAL
SPECIAL SCREW
SCREW
SPECIAL
SCREW

Release the seat lock by turning the main switch key to


open the seat.
Remove the following parts.
- Rear fender.
- Seat support pipe.
- Center cover.
- Truss pipe.
- Battery.
- Floor panel.
Remove the fuel unit wiry coupler.
Remove the fuel strainer tube.
Remove the flange nut.
Remove the fuel tank.
Install in the revers order removal.

FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE

FUEL
UNIT
FUEL
FUELUNIT
UNIT
FUEL
UNIT

CAUTION

After removing the fuel tank be sure to close


the fuel tank cap.
(Gasoline is extremely flemmable)

FUEL
TANK
FUEL
FUELTANK
TANK
FUEL
TANK

FUEL
STRAINER
TUBE
FUEL
FUELSTRAINER
STRAINERTUBE
TUBE
FUEL
STRAINER
TUBE

CARBURETOR

AIR
AIR
CLEANER
CONNECTING
BAND
AIRCLEANER
CLEANERCONNECTING
CONNECTINGBAND
BAND

REMOVAL
- Rear fender.
- Center cover.
- Air cleaner connecting tube band.

CARBURETOR
CARBURETOR
CARBURETOR

INSULATOR
INSULATOR
INSULATOR

6-3

FUEL SYSTEM

THROTTLE
CABLE
LOCK
NUT
THROTTLE
THROTTLECABLE
CABLELOCK
LOCKNUT
NUT
THROTTLE

TOP
TOP
SET
TOPSET
SET

Loosen the throttle cable lock nut and remove the


throttle cable from the carburetor.
Remove the fuel tube.
Remove the auto bystarter wiring.
Loosen the screw on the carburetor insulation band.
Remove the carburetor.

REMOVAL
Loosen the special pan screw on the carburetor top set.
Remove the top set.

SPECIAL
PAN
SCREW
SPECIAL
SPECIAL PAN
PAN SCREW
SCREW

COMPRESSION
COMPRESSION SPRING
SPRING

Remove the top set cover.


Remove the compression spring, vacuum piston comp.

Remove the spring seat, jet needle.


VACUUM
PISTON
COMP
VACUUM
VACUUMPISTON
PISTONCOMP
COMP
VACUUM

VALVE
PLATE
SET
VALVE
VALVEPLATE
PLATESET
SET
VALVE

6-4

FUEL SYSTEM

VACUUM
VACUUM
PISTON
VACUUMPISTON
PISTON

JET
JET
NEEDLE
JETNEEDLE
NEEDLE

INSPECTION
Check the needlejet for wear and replace if necessary.
Check the vacuum piston for damage and replace if
necessary.
Check the diaphragm for damage pin holes, wrinkles
and bends and replace if necessary.
!

NOTE

Check the diaphragm adequately for crack in


the wrinkle area and bend area.

VALVE
VALVE
PLATE
SET
VALVEPLATE
PLATESET
SET

FLOAT CHAMBER / FLOAT /


JET
DISASSEMBLY
Loosen the 4 screws securing float chamber set.

PAN
PAN
PAN
SCREW
SCREW
SCREW
SCREW

FLOAT
CHAMBER
SET
FLOAT
FLOATCHAMBER
CHAMBERSET
SET
FLOAT
CHAMBER
SET

FLOAT
VALVE
SET
FLOAT
FLOATVALVE
VALVESET
SET
FLOAT
VALVE
SET

ARM
ARM
PIN
ARMPIN
PIN
FLOAT
FLOAT
COMP
FLOATCOMP
COMP

Remove the float pin, float and float valve


!

CAUTION

Do not damage the jets. because it made of


soft material and also do not use the wire
when cleaning the air and fuel passage.
Otherwise it will damage to the carburetor
body, eventually it will be effect the engine.
Namely, it is cause of bad condition of engine.

FLOAT
FLOAT VALVE
VALVE SET
SET
FLOAT
VALVE
SET
MAIN
MAIN JET
JET
MAIN
JET

SLOW
JET
SLOW
SLOWJET
JET
SLOW

Check the float valve and valve seat for scores,


scratches, clogging and damage replace if necessary.
Check the float valve operation.

6-5

FUEL SYSTEM
Remove the main jet, needle jet holder, needle jet, slow
jet, screw set, diaphragm comp, compression spring.

CARBURETOR BODY

NOTE

Turn in the pilot jet and record the number of


turns it takes before it seats lightly.
Do not force the pilot screw against its seat;
The seat will be damaged.

Clean the jet and hole of carburetor body with blow the
compressed air.

TOP SET
FLOAT
VALVE SET

COMPRESSION SPRING

FLOAT COMP
AUTO BYSTARTER SET
NEDDLE JET COMP

SCREW SET

VACUUM PISTON COMP


FLOAT CHAMBER SET

DIAPHRAGM COMP

NEEDLE JET HOLDER


MAIN JET #95

6-6

SLOW JET

FUEL SYSTEM
ASSEMBLY

SCREW
SCREW
SET
SCREWSET
SET

Install the needle jet, needle jet holder, main jet and
slow jet.
Tighten the pilot jet until it seat lightly, then turn it out
as much as number recorded during removal.
Install the pilot jet rubber.

Install the float valve set, float comp, float pin.


Measure the float level with the float valve gauge.
FLOAT LEVEL : 13 mm
TOOL : FLOAT COMP LEVEL GAUGE

Install the float chamber set.


Install the stay plate set and 4 pan screws.
!
FLOAT
FLOAT
CHAMBER
SET
FLOATCHAMBER
CHAMBERSET
SET

NOTE

Be sure to replace the float chamber body O-ring


with the new one.

Install the valve plate set, compression spring in the


vacuum piston comp.
TOP
SET
TOP
TOPSET
SET

NOTE

Install the jet needle aligned with the grooves.


Install the diaphragm cover with its cutout aligned with
the cover.
Place the top set on the spring.
Tighten the 2 special pan screws.

6-7

FUEL SYSTEM

NOTE

Be careful not to pinch the diaphragm, and to


keep the spring straight.

COMPRESS
STRAIGHT

Install the drain tube and air-hose.

THROTTLE
CABLE
THROTTLE
THROTTLECABLE
CABLE
THROTTLE
CABLE

CABURETOR INSTALLATION
Install the carburetor to the carburetor insulator.
Tighten the carburetor insulator band screw.
Install the fuel tube to the carburetor.
Intall the wiring coupler of the auto bystarter.
Install the throttle cable to the carburetor.
Intall the air cleaner.
Install the center cover.

NOTE

After adjusting the carburetor, check the


throttle grip free play.
AIRCLEANER
CLEANERCONNECTING
CONNECTINGTUBE
TUBEBAND
BAND
AIR
CLEANER
CONNECTING
TUBE
BAND
AIR

CABURETOR INSULATOR
REMOVAL

FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT

Remove
- Center cover.
- Air cleaner.
- Carburetor.
Remmove the fuel pump negative pressure tube.
Loosen the carburetor insulator 2 setting nuts.
Remove the carburetor insulator.
Remove the carburetor insulator band.
Install the reverse order of removal.
INSULATOR
INSULATOR
INSULATOR
INSULATOR

6-8

FUEL SYSTEM

O-RING
O-RING
O-RING

INSPECTION
Check the carburetor insulator O-ring for wear or
damage.
Install in the reverse order of removal.

PILOT SCREW ADJUSTMENT


THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
THROTTLE
STOP
SCREW

PILOT
PILOT
SCREW
PILOTSCREW
SCREW

USING THE EMISSION ANALYZER (CO,HC)


Open the seat and remove the center cover.
Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM

MUFFLER
MUFFLER
MUFFLER

EMISSION
ANALYZER
EMISSION
EMISSIONANALYZER
ANALYZER
EMISSION
ANALYZER

NOTE

Before adjustment the pilot screw, check the


following items.
- Fuel system electrical system for troubling.
- Do not force the pilot screw against its seat ;
The seat will be damaged.
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
- Emission analyzer for correction.
Exhaust gas contains poisonous substance.
Do not adjusting for a long period of time in a
closed, or poorly ventilated area.
Extend the hose (60Cm) at the tail pipe, and insert the
probe of the emission analyzer to the tail pipe, and
adjust the pilot screw with a , the Co to became
3~4%.
Adjust by the throttle stop screw, repeat steps and
until accord the idle rpm (1,800rpm) and the Co
(3~4%).

THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW

6-9

FUEL SYSTEM
When idling, check to see if the rotation is smoothly
and to return is nomal.
Install the center cover.

ACCELERATION
ACCELERATION
ACCELERATION

PILOT
SCREW
PILOT
PILOTSCREW
SCREW
PILOT
SCREW

THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW

CAUTION

If the engine cannot be adjusted by turning the


pilot screw within a turn, check for other
engine problems.

EMISSION ANALYZER IS NOT EXIST


Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM

ACCELERATION
ACCELERATION
ACCELERATION

PILOT
PILOT
SCREW
PILOTSCREW
SCREW

6-10

THROTTLE
THROTTLE
STOP
SCREW
THROTTLESTOP
STOPSCREW
SCREW

NOTE

Before adjustment the pilot screw, check the


following items.
- Fuel system electrical system for troubling.
- Do not force the pilot screw against its seat ;
The seat will be damaged.
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
When idling, check to see if the rotation is smoothly
and to return is normal.
Turn the throttle stop screw until the 1,000RPM, and
check the stopping of engine.
If the engine is stop, adjust the pilot screw with a ,
and repeat step and .

FUEL SYSTEM
!

ACCELERATION
ACCELERATION
ACCELERATION
ACCELERATION

CAUTION

If the engine cannot be adjusted by turning the


pilot screw within a turn, check for other
engine problems.
After the final test of the starting and driving, readjust
if necessary.

FUEL PUMP
REMOVE
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT

- Center cover.
- Inlet, outlet, vacuum tube.
- 2 bolts securing the fuel pump.
- Fuel pump.

FUEL
FUELPUMP
PUMP
FUEL
PUMP

FUEL
FUEL
PUMP
FUELPUMP
PUMP

DISASSEMBLY
Loosen the 4 screws securing the fuel pump.

Remove the fuel pump.


Check the diaphragm A and B of fuel pump for
damage.

6-11

FUEL SYSTEM
Check the gaskets.

Check the suction valve, outlet valve and relief valve


for damage and crack.

Install in the reverse order of removal.

FUEL
PUMP
FUEL
FUELPUMP
PUMP
FUEL
PUMP
!

NOTE

After install the fuel pump, check the blowing


quantity of fuel in the outlet tube.

6-12

ENGINE REMOVAL/INSTALLATION

7. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 7-1
ENGINE REMOVAL/INSTALLATION7-2

SERVICE INFORMATION
GENERAL SAFETY
NOTE
Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness.
Attach tape to the frame to protect it during the engine removal or installation.
The following works can be carried out without removing the engine from the vehicle body.
-TRANSMISSION (SECTION 12)
-STARTING CLUTCH (SECTION 9)
-OIL PUMP (SECTION 4)
-A.C. GENERATOR (SECTION 9)
-START MOTOR (SECTION 18)
-CONTINUOUSLY VARIABLE TRANSMISSION (SECTION 8)
-CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 10,11)
-EX. MUFFLER (SECTION 3)
-CARBURETOR (SECTION 6)
-REAR SWING ARM (SECTION 14)
Items to be worked after removing engine.
-CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING
Engine oil capacity : 1.1 - When disassembled.

TORQUE VALUES :
ENGINE HANGER BOLT (FRONT) : 2.7fm
(REAR) : 3.5fm

7-1

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL
Drain the engine oil.
Release the seat lock by turning the main switch key to
open the seat.
Remove the following parts.
- Rear under cover.
- Air cleaner (2-5)
- Carburetor (6-3)
Disconnect the ACG coupler and connector wiring
connected to the ACG, disconnect the starter motor
wiring cable.
Disconnect the high-tension cord from the engine.
Remove the bleeder tube from the cylider hesd cover.

DRAIN
DRAINPLUG
PLUGBOLT
BOLT
DRAIN
PLUG
BOLT
BRAKE
BRAKE
HOSE
BRAKEHOSE
HOSE

MUDGUARD
MUDGUARD
MUDGUARD
MUDGUARD

MUFFLER
MUFFLER
MUFFLER
MUFFLER

FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
REAR
REAR
WHEEL
REARWHEEL
WHEEL

RADIATER
HOSE
RADIATER
RADIATERHOSE
HOSE
RADIATER
HOSE

7-2

Remove
- Muffler
- Rear brake caliper
- Swing arm
- Rear wheel mudguard

Loosen the U nut.


Remove the rear wheel.

Remove the RH. shroud.


Remove the RH. radiater hose.

ENGINE REMOVAL/INSTALLATION
Loosen the rear cushion under bolt.

REAR
CUSHION
REAR
REARCUSHION
CUSHION
REAR
CUSHION

REAR
REAR
CUSHION
UNDER
BOLT
REARCUSHION
CUSHIONUNDER
UNDERBOLT
BOLT
SECONDARY
SECONDARY
SECONDARY
SECONDARY
AIR
FILTER
AIR
AIRFILTER
FILTER
AIR
FILTER

Remove the SAI tube from the secondary air filter


assembly.
Loosen the 10mm U nut from the engine hanger.
Lifting the frame back side and remove the flange bolt
securing engine hanger and disassemble the frame and
engine.

ISA
ISA
TUBE
ISATUBE
TUBE

ENGINE INSTALLATION
Install in the reverse order of removal.
!

ENGINE
ENGINE
HANGER
PLATE
ENGINEHANGER
HANGERPLATE
PLATE

NOTE

Take precautions not to damage wiring and


cable.
Take precautions not to damage the thread part
of bolts.
Arrange the cable tube and wring in the right
positions.
TORQUE :
ENGINE HANGER NUT (FRONT) : 4.5fm
(REAR) : 4.5fm

Check the following after the engine is installed.


- Engine oil
- Electric systems

7-3

LH.CRANKCASECOVER/CONTINUOUSLYVARIABLETRANSMISSION

LH. CRANK CASE COVER

8-0

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

8. LH. CRANKCASE
/CONTINUOUSLY VARIABLE TRANSMISSION
SERVICE INFORMATION8-1
TROUBLESHOOTING 8-1
LH. CRANK CASE COVER 8-2
DRIVE BELT 8-3

MOVABLE DRIVE FACE8-5


CLUTCH/DRIVEN PULLEY ASSEMBLY8-8
DRIVEN FACE INSPECTION 8-10
DRIVE PULLEY INSTALLATION8-13

SERVICE INFORMATION
GENERAL SAFETY
Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil
contact.
Do not operate starter motor while the LH. crank case front cover is removed.
!

NOTE

Take precautions not ot apply the grease oil to the movable drive face or weight roller.

SPECIFICATIONS
ITEM

STANDARD

SERVICE LIMIT

MOVABLE DRIVE FACE BUSHING INNER DIAMETER

24.000-24.013mm

24.05mm

DRIVE FACE BOSS OUTER DIAMETER

23.980-23.993mm

23.96mm

DRIVE BELT WIDTH

22mm

20.5mm

WEIGHT ROLLER OUTER DIAMETER

19.95-20.02mm

19.50mm

CLUTCH OUTER AND INNER DIAMETER

125.0-125.2mm

125.5mm

DRIVEN FACE SPRING PLAY

140mm

135mm

DRIVEN FACE OUTER DIAMETER

33.965-33.985mm

33.785mm

DRIVEN FACE INNER DIAMETER

34.000-34.025mm

34.060mm

TROUBLESHOOTING
Engine starts but motorcycle does not work.
Drive belt worn.
Ramp plate damaged.
Clutch shoe worn or damaged.
Movable driven face spring cut.

Vehicle unable to run at the maximum speed,


or lack of output
Drive belt worn.
Defective movable driven face spring.
Weight roller worn.
Pulley face contaminated.

Engine stops, or the vehicle runs suddenly,


after starting.
Clutch shoe spring cut.

8-1

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

LH. CRANKCASE COVER

B-STAY
B-STAY
B-STAY
B-STAY

DISASSEMBLY
AIR
AIR
CLEANER
AIRCLEANER
CLEANER

Remove the air cleaner and flange bolt securing B stay.


Remove the flange bolts securing LH. crankcase.

LH.
CRANK
CASE
COVER
LH.
LH.CRANK
CRANKCASE
CASECOVER
COVER
LH.
COVER
GASKET
LH.
LH.COVER
COVERGASKET
GASKET
LH.

DRIVE
FACE
DRIVE
DRIVEFACE
FACE
DRIVE

Remove the LH. crankcase cover.


Remove the gasket and dowel pin.

INSTALLATION
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY

Install the new gasket and dowel pin after removing the
gasket of the crankcase surface.
!

NOTE

Tighten the bolts diagonally with specified


tightening torque.
Be sure to replace a new gasket and dowel pin.

Install the LH. crankcase cover.


Install the air cleaner and B stay and tighten the flange
bolt.

8-2

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

DRIVE
FACE
HOLDER
DRIVE
DRIVEFACE
FACEHOLDER
HOLDER
DRIVE
FACE
HOLDER

DRIVE
FACE
DRIVE
DRIVEFACE
FACE
DRIVE
FACE

DRIVE BELT
REMOVAL
Remove the LH. crankcase cover.
Loosen the drive face setting flange nut 12mm using
the drive face holder and remove the drive face.
TOOL : DRIVE FACE HOLDER

Loosen the clutch outer setting nut using the universal


holder.

DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY

TOOL : UNIVERSAL HOLDER

Enlarge the driven pulley belt groove with the drive


belt in place as photo.

DRIVE BELT

CAUTION

Squeeze the drive belt into the pulley groove as


shown so that it slackens enough to remove the
driven pulley from the drive shaft.

DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY

DRIVEN
PULLEY
DRIVEN
DRIVENPULLEY
PULLEY
DRIVEN
PULLEY

Remove the driven pulley sub assembly with the drive


belt in place.
Remove the drive belt from the driven pulley sub assy.

8-3

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


DRIVE BELT INSPECTION
Check the drive belt for cracks, pry separation and
wear, replace as necessary.
Measure the width of the drive belt as shown.

COG

WIDTH

SERVICE LIMIT : 20.5mm


!

NOTE

Use only a genuine DAELIM replacement drive belt.


Do not get oil or grease on the drive belt or pulley
faces. Clean off any grease or oil before reinstalling.

DRIVE BELT INSTALLATION


DRIVEN PULLEY SUB ASSY

Turn the pulley clockwise and spread the face apart


while installing the drive belt and install the drive belt
to the driven pulley assy.

Install the driven pulley sub assy on the drive belt.


Install the drive belt to the movable drive face apart.

DRIVE
DRIVE
BELT
DRIVEBELT
BELT

DRIVEN
PULLEY
DRIVEN
DRIVEN PULLEY
PULLEY

Temporarity install the driven pulley and flange nut.


Hold the clutch outer using the universal holder and
tighten the flange nut with the specified torque.

NOTE

Do not rotate the movable drive face to became


the original position until the driven pulley to
be installed completely to the drive shaft.

8-4

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

FLANGE
NUT
FLANGE
FLANGENUT
NUT

Install the drive face to the LH. crank shaft.


Install the rear axel collar and temporaily install the
flange nut.
Tighten the flange nut to the specified torque using the
drive face holder.
m
TORQUE VALVE : 7.0~8.0kgf
m
TORQUE VALVE : 5.0~6.0kgf
TOOL : DRIVE FACE HOLDER
UNIVERSAL HOLDER

CAUTION

When installing the drive face match it when


the LH. crank shaft serration accurately.

MOVABLE DRIVE FACE


MOVABLE
MOVABLE
DRIVE
FACE
MOVABLEDRIVE
DRIVEFACE
FACE

REMOVAL
Remove the LH. crank case cover.
Hold the drive face holder on drive face.
Remove the drive face nut, rear axel collar, drive face.

DRIVEFACE
FACEBOSS
BOSS
DRIVE
DRIVE
FACE
BOSS

TOOL : DRIVE FACE HOLDER


Remove the movable drive face and drive face boss.

Remove the ramp plate, weight rollers and oil seal


from movable drive face.

SLIDE
SLIDE
PIECE
SLIDEPIECE
PIECE

FACE
FACE
BOSS
FACEBOSS
BOSS

RAMP
RAMP
PLATE
RAMPPLATE
PLATE

MOVABLEDRY
DRY WEIGHT
MOVABLE
MOVABLE
DRY
WEIGHT ROLLER
ROLLER
WEIGHT
ROLLER
FACE COMP
COMP
FACE
FACE
COMP

8-5

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


MOVABLE DRIVE FACE INSPECTION
WEIGHT ROLLER

Check the rollers for wear or damage.


Measure the O.D. of each roller.
SERVICE LIMIT : 19.5mm
Measure the abnormal wear.
SERVICE LIMIT : LESS THAN 2.0mm

Check the drive face boss for wear or damage and


replace as necessary.
Measure the O.D. of the drive face boss. Replace the
boss if the service limit is exceeded.

MOVABLE DRIVE FACE

BOSS

SERVICE LIMIT : LESS THAN 23.960mm


Measure the I.D. of the drive face . Replace it if the
service limit is exceeded.
Movable drive face inner diameter.
SERVICE LIMIT : LESS THAN 24.05mm

RAMP
PLATE
RAMP
RAMPPLATE
PLATE

GREASE
GREASE
GREASE

MOVABLE DRIVE FACE INSTALLATION


Install the weight roller on the movable drive face.
Apply the inside of the movable drive face with the
specified amount of grease.
SPECIFIED GREASE : ALVANIA EP2
GREASE APPLICATION : 0.5~1.5 g
Install the movable drive face boss.

OIL
SEAL
OIL
OIL SEAL
SEAL
!
WEIGHT
ROLLER
WEIGHT
WEIGHT ROLLER
ROLLER

MOVABLE
DRIVE
FACE
MOVABLE
MOVABLEDRIVE
DRIVEFACE
FACE
MOVABLE
DRIVE
FACE

8-6

NOTE

Do not get the grease on the drive face. Remove


any misplaced grease with a degreasing agent.
Use only the specified grease in the specified amount.
Install the movable drive face boss and movable drive
face to the LH. crank shaft.

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


Install the drive belt into the movable drive face.

MOVABLE
DRIVE
FACE
MOVABLE
MOVABLE DRIVE
DRIVE FACE
FACE

Install the drive face in to the LH. crank shaft, and


install the rear axcel collar.

DRIVE
DRIVE
FACE
DRIVEFACE
FACE
REAR
AXCEL
COLLAR
REAR
REARAXCEL
AXCELCOLLAR
COLLAR
REAR

Tighten the flange nut into the drive face.


FLANGENUT
NUT
FLANGE
FLANGE
NUT

Tighten the nut to the specified torque using the drive


face holder.
m
TORQUE VALVE : 7.0~8.0kgf
TOOL : DRIVE FACE HOLDER
!

NOTE

Tighten the drive face nut to the specified


torque.
Install the LH. crankcase cover.

8-7

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION

DRIVEN PULLEY
REMOVAL
Remove the LH. crankcase cover.
Remove the drive face.
Hold the clutch outer using the universal holder and
remove the 12mm flange nut, then remove the driven
pulley.
TOOL : DRIVE FACE HOLDER
UNIVERSAL HOLDER

Remove the driven pulley sub assembly from the drive


shaft.
Remove the drive belt.

DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY

DISASSEMBLY

LOCK NUT WRENCH

Remove the special nut.

LOCK NUT

TOOL : CLUTCH SPRING NUT


LOCK NUT WRENCH

CLUTCH SPRING COMPRESSOR

DRIVEN
FACE
COMP
DRIVEN
DRIVENFACE
FACECOMP
COMP
DRIVEN

DRIVEN
DRIVEN
FACE
SPRING
DRIVENFACE
FACESPRING
SPRING

SPRINGGUIDE
GUIDE
SPRING
GUIDE
SPRING
DRIVE
PLATE
DRIVE
DRIVEPLATE
PLATE
DRIVE
PLATE

8-8

Remove the drive plate, driven face spring and driven


face spring guide.

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


Remove the seal collar from the driven pulley.

SEAL COLLAR

MOVABLE DRIVEN FACE

GUIDE ROLLER PIN


GUIDE PIN

Remove the guide pins and guide pin rollers and the
movable driven face.
Remove the O-ring from movable driven face.

GUIDE ROLLER

DRIVEN FACE

GUIDE PIN

Remove the oil seal from the movable driven face.


MOVABLE DRIVEN FACE

OIL SEAL

O-RING
GUIDE PIN

OIL SEAL

Remove the movable driven face.

O-RING

8-9

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


DRIVEN PULLEY INSPECTION
DRIVEN FACE BEARING INSPECTION
Check the each parts.
Check the driven face needle bearing(inner) for
damage or excessive play and replace as necessary.
Turn the inner race of the ball bearing with your finger.
Check that the bearing turns smoothly and quietly, and
that the bearing outer race fits securely.
Replace the bearing (8-11).
INNER NEEDLE BEARING
OUTER BALL BEARING

MOVABLE DRIVEN FACE SPRING INSPECTION


MOVABLE DRIVEN FACE SPRING

Measure the free length of the driven pulley spring and


replace if the service limit is exceeded.
SERVICE LIMIT : 135mm
TOOL : VERNIER CALIPER

FREE
LENGTH

CLUTCH OUTER
Measure the I.D. at shoe contact surface of the clutch
outer. Replace the outer if the service limit is exceeded.

VERNIER
CALIPER

SERVICE LIMIT : 125.5mm

CLUTCH OUTER

CLUTCH SHOE INSPECTION


Check the clutch shoe for wear or damage.
Measure the thickness of each shoe.
SERVICE LIMIT : 2.0mm

CLUTCH SHOE

8-10

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


Check the following;
- Movable driven face for damage or excessive wear.
- Guide pin groove for damage or deformation.
Replace damaged or worn parts as necessary.
Measure the I.D. of the movable driven face; replace if
the service limit is exceeded.
SERVICE LIMIT : 34.060mm

GUIDE GROOVE

MOVABLE DRIVEN FACE

Check the driven face for damage or excessive wear;


replace as necessary.
Measure the O.D. of the driven face; replace if the
service limit is exceeded.

DRIVE FACE

SERVICE LIMIT : 33.785mm

DRIVEN FACE BEARING REPLACEMENT


Remove the inner bearing.
Remove the snap ring then drive out the outer bearing
toward the inner bearing side.
Drive a new outer bearing into place with the sealed
end toward the outside. Install the snap ring securely.
Apply the specified amount of specified grease as
shown.

OUTER BEARING

GREASE APPLICATION : 9.0~9.5 g

INNER BEARING
SNAP RING

INNER REARING

Install in a new inner bearing.


SEALED SIDE

SPECIFIED
GREASE

SNAP RING

INNER NEEDLE
BEARING

TOOLS : BEARING DRIVEN ATTACHMENT


DRIVE PILOT
!

NOTE

Install the cir-clip fimly to the groove.


Install the inner-bearing using a hydraulic press.

OUTER BEARING

8-11

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


DRIVEN FACE / MOVABLE DRIVEN FACE
OIL SEAL

Install new oil seal and O-ring on the movable driven


pulley face.

O-RING

MOVABLE DRIVEN FACE

GUIDE ROLLER PIN


GUIDE PIN

Install the movable face on the driven pulley face.


Install the guide rollers and guide pins.

GUIDE ROLLER

GUIDE PIN

DRIVEN FACE

Install the seal collar.


SEAL COLLAR

LOCK NUT WRENCH

DRIVEN PULLEY SUB ASSY


Install the spring guide, driven face, drive plate assy.
Compress the assembly by turning the tool handle until
the special nut can be installed.
Clamp the clutch spring compressor in a vise and
tighten the lock nut to the specified torque using the
lock nut wrench.
m
TORQUE VALVE : 5.5kgf
Remove the spring compressor.

CLUTCH SPRING COMPRESSOR

8-12

TOOL : CLUTCH SPRING COMPRESSOR


LOCK NUT WRENCH

LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION


CLUTCH/DRIVEN PULLEY INSTALLATION
Turning the driven pulley assy rightside, extend the
belt assemble groove maximum.
Install the drive belt into driven pulley sub assy, install
the drive shaft.

Install the drive belt into movable drive face..


DRIVEN
PULLEY
DRIVEN
DRIVEN
PULLEY

DRIVEN
PULLEY
fifi
fifi
PULLEY
fifi
fifi
fifi
fifi

DRIVE
DRIVE BELT
BELT
DRIVE
BELT

DRIVE
DRIVE
FACE
DRIVEFACE
FACE

Install the drive face, rear axcel collar drive pulley nut.
Tighten to the specified torque using drive face holder.
m
TORQUE VALVE : 7.0~8.0kgf
TOOL : DRIVE FACE HOLDER

DRIVEN
DRIVEN PULLEY
PULLEY
DRIVEN
PULLEY

Install the clutch onter into driven pulley sub assy and
flange nut.
Hold the clutch outer using drive universal holder,
install the flange nut to the specified torque.
m
TORQUE VALVE : 5.5kgf
TOOL : UNIVERSAL HOLDER
Install the LH. crank case cover, and tighten the flange
bolt.

8-13

A.C GENERATOR / STARTER CLUTCH

STARTER
COMP
@
FLY
WHEEL
@
COOLING
FAN

9-0

SAIsai@@
LID VALVE

A.C GENERATOR / STARTER CLUTCH

9
9
9
9

9
9
9

16.

9-1

A.C GENERATOR / STARTER CLUTCH

SHROUD
RH.
RH.
SHROUD
RH.SHROUD
SHROUD
SAI
TUBE
SAI
SAITUBE
TUBE
SAI
TUBE

REMOVAL
Remove the following parts.
- RR. Inner
- SAI Tube
- RH. / LH. Pillion step holder
- Muffler comp

SETTING
SETTING
SCREW
SETTINGSCREW
SCREW

Loosen the RH. shroud 4 flange bolts and 4 tapping


screws.
Remove the RH. shroud.
Loosen the LH. shroud setting screw.
Remove the LH. shroud.
Install in the reverse order of removal.

LH.
SHROUD
LH.
LH.SHROUD
SHROUD
LH.
SHROUD
SAI
SAI
TUBE
SAITUBE
TUBE

A.C GENERATOR
REMOVAL
Loosen the rear cushion under cover.
Loosen the 3 bolts securing RH. shroud.
Remove the SAI.
Remove the shroud.

SAI
SAI
REED
VALVE
SAIREED
REEDVALVE
VALVE
COOLING
COOLING
FAN
COOLINGFAN
FAN

Loosen the 3 cooling fan bolts.


Remove the A.C.G. wiring from the A.C.G. wiring
setting clamp securing the engine and frame.

FLYWHEEL
FLYWHEEL
COMP
FLYWHEELCOMP
COMP

9-2

A.C GENERATOR / STARTER CLUTCH

FLYWHEEL
FLYWHEEL
FLYWHEEL

DRIVE
DRIVE
FACE
DRIVEFACE
FACE

Install the universal holder on the flywheel.


If the universal holder connot be used, remove the LH.
crankcase cover at the left side of the crankshaft, and
hold the drive face with the drive face holer.

Loosen the flange nut securing the fly wheel, and


remove the flywheel using the A.C.G rotor puller.
! CAUTION

A.C.G
A.C.G
ROTOR
PULLER
A.C.GROTOR
ROTORPULLER
PULLER

Insert the puller shaft and remove the flywheel


after inserting the A.C.G rotor puller and
securing it with spanner.
The flywheel may easily removed if you rotate
the puller while tapping the puller shaft with
metal hammer.
Always use a holder and a puller to remove the
flywheel. Do not try to remove the flywheel by
hammering directly on it. The crankshaft or
components could be damaged.
After removing the flywheel, check the
woodruff key for damage and wear.

A.C.GCOUPLER
COUPLER
A.C.G
A.C.G
COUPLER

STARTER
COMP
STARTER
STARTERCOMP
COMP
STARTER

Disconnect the A.C.G wire coupler.


TOOL : A.C.G ROTOR PULLER
UNIVERSAL HOLDER
DRIVE FACE HOLDER

Loosen the fan screw securing the starter comp and


remove the starter comp on the RH.crankcase cover.

RH.
CRANK
CASE
COVER
RH.
RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.

9-3

A.C GENERATOR / STARTER CLUTCH


A.C GENERATOR INSTALLTION
STARTER
STARTER
COMP
STARTERCOMP
COMP

SAI
TUBE
SAI
SAITUBE
TUBE
SAI

Install the stator to the RH. Crankcase cover.


Clean the tapered portion of the crankshaft.
Clean the inside part of the flywheel.
Check the woodruff key, install the flywheel by
aligning the groove with the woodruff key.

Temporarily install the flywheel nut, hold the flywheel


with the universal holder, or remove the LH. crankcase
cover and tighten the flywheel nut with the specified
torque.
TORQUE VALVE : 5.0~6.0kgf m
TOOL : UNIVERSAL HOLDER
Hold the drive face with drive face holder and install
the cooling fan.
Install the LH. crankcase cover.
TORQUE : 0.8~1.2kgf m
Install the RH. Shroud.
Connect the A.C.G wiring coupler and connector to the
wire harness, and install the wiring with the clamp.
Install rear under cover.
Install the muffler.

SAI
REED
VALVE
SAI
SAIREED
REEDVALVE
VALVE
SAI
COOLING
COOLING
FAN
COOLINGFAN
FAN

SAI
PIPE
SAI
SAI PIPE
PIPE

RH. CRANKCASE COVER

RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.
RH.
CRANK
CASE
COVER

9-4

Remove the following parts.


- Rear under cover.
- Ex. Muffler.
- Rear swing arm.
- RH shroud.
- Cooling fan.
- A.C.G starter comp.
- SAI reed valve.
Loosen the flange bolt securing the RH. Crankcase
cover.
Remove the RH crankcase cover.

A.C GENERATOR / STARTER CLUTCH


Remove the RH. Crankcase cover gasket and dowelpin.
REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR

STARTINGCLUTCH
CLUTCH
STARTING
CLUTCH
STARTING

GASKET
GASKET
GASKET
DOWEL
DOWEL
PIN
DOWELPIN
PIN
OIL
PUMP
OIL
OILPUMP
PUMP
OIL
PUMP

OIL
OIL
SEAL
OILSEAL
SEAL

RH.
CRANK
CASE
COVER
RH.
RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.
CRANK
CASE
COVER

REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR

SHAFT
SHAFT
SHAFT
STARTER
REDUCTION
GEAR
STARTER
STARTERREDUCTION
REDUCTIONGEAR
GEAR
STARTER
REDUCTION
GEAR

9-5

A.C GENERATOR / STARTER CLUTCH


STARTER REDUCTION GEAR
INSTALLATION
REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR

Install the starter reduction gear and shaft.


Remove the gasket residues from the RH. Crankcase.

GASKET
GASKET
GASKET
GASKET

DOWELPIN
PIN
DOWEL
DOWEL
PIN

Install a new gasket and dowel pin.


Tighten the RH. Crankcase cover with flang bolts.
Install the following parts.
- A.C.Generator
- Cooling fan
- RH. Shroud
- Rear swing arm
- Rear caliper
- EX. Muffler
- Rear under cover
- Pillion step holder

STARTER CLUTCH
REMOVAL
Remove the following parts.
- Rear under cover
- EX. Muffler
- Rear swing arm
- RH. Crankcase cover

RHCRANK
CRANKCASE
CASECOVER
COVER
RH
RH
CRANK
CASE
COVER

Loosen the starter clutch lock nut with a special socket.


STARTING
STARTING
CLUTCH
STARTINGCLUTCH
CLUTCH

SPECIAL
SOCKET
SPECIAL
SPECIALSOCKET
SOCKET
SPECIAL
SOCKET

9-6

TORQUE VALVE : 9.5kgf m


TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER

A.C GENERATOR / STARTER CLUTCH


Remove the thrust washer.
Remove the starter driven gear and starter clutch.

THRUST
THRUST WASHER
WASHER
THRUST
WASHER
LOCK
LOCK
NUT
LOCKNUT
NUT

OIL
OIL
PUMP
DRIVE
GEAR
OILPUMP
PUMPDRIVE
DRIVEGEAR
GEAR

Check the starter driven gear and starter clutch for


proper operation.
Remove the starter clutch.

OIL
OIL
PUMP
OILPUMP
PUMP

STARTER CLUTCH INSPECTION


NEEDLE
NEEDLE
BEARING
NEEDLEBEARING
BEARING

Check the starting clutch assembly for proper


operation.
Remove the starter driven gear, needle bearing and
starter oneway clutch set from the starter clutch
assembly.

STARTER
ONEWAY
CLUTCH
SET
STARTER
STARTERONEWAY
ONEWAYCLUTCH
CLUTCHSET
SET
STARTER
ONEWAY
CLUTCH
SET
STARTER
STARTER
DRIVEN
DRIVEN
GEAR
GEAR
STARTER DRIVEN GEAR

Check the starter driven gear for wear or damage.


Measure the inner diameter of the starter driven gear.
AAA

SERVICE LIMT : A : 32.10 mm


B : 39.53 mm

BB
BB

9-7

A.C GENERATOR / STARTER CLUTCH

STARTER
STARTER
ONEWAY
CLUTCH
SET
STARTERONEWAY
ONEWAYCLUTCH
CLUTCHSET
SET

THRUST
WASHER
THRUST
THRUST WASHER
WASHER
LOCK
LOCK
NUT
LOCKNUT
NUT

Hold the drive face with the drive face holder.


Tighten the lock nut with specified torque.
TORQUE VALVE : 9.5kgf m
TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER
SPECIAL
SPECIAL
SOCKET
SPECIALSOCKET
SOCKET

Install the following parts.


- RH. Crankcase cover
- A.C Generator
- Cooling fan
- RH. Shroud
- Rear swing arm
- Rear caliper
- EX. Muffler
- Rear under cover
- Pillion step holder

RH.
RH. CRANK
CRANK CASE
CASE COVER
COVER
RH.
CRANK
CASE
COVER

9-8

MEMO

CYLINDER HEAD / VALVES

FLANGE NUT

IN VALVE ROCKER ARM

CAM SHAFT HORDER


EX. VALVE ROCKER ARM
CAM SHAFT COMP

EX. VALVE
INLET VALVE

CARBURETOR INSULATOR

CYLINDER HEAD COMP


SAI PIPE
CYLINDER HEAD GASKET

10-0

CYLINDER HEAD / VALVES

10. CYLINDER HEAD / VALVES


SERVICE INFORMATION 10-1
TROUBLESHOOTING 10-2
CAMSHAFT 10-3
CYLINDER HEAD 10-5
VALVE SPRINGS 10-6

VALVES 10-6
VALVE GUIDES 10-7
VALVE SEATS 10-8
CYLINDER HEAD ASSEMBLY10-12
CAMSHAFT ASSEMBLY10-13

SERVICE INFORMATION
GENERAL SAFETY
The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed
from the frame to maintain the cylinder head.
The oil of camshaft oil is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder
head.

SPECIFICATIONS
Unit : mm

ITEM

ROCKER ARM
CAMSHAFT

STANDARD VALUE

ROCKER ARM INNER DIAMETER

12.016 - 12.034

12.060

ROCKER ARM SHAFT OUTER DIAMETER

11.982 - 12.000

11.950

IN

33.835 - 33.995

33.625

EX

33.984 - 34.144
-

33.765
-

IN

37.21

36.90

EX

37.21

36.90

IN

4.972 - 4.984

4.920

EX

4.952 - 4.964

4.900

VALVE GUIDE INNER DIAMETER

IN,EX

5.000 - 5.012

5.030

CLEARANCE BETWEEN
STEM AND GUIDE

IN

0.016 - 0.040

0.090

EX

0.036 - 0.060

0.120

0.8 - 1.0

1.4

CAM HEIGHT

CYLINDER HEAD WARPAGE


VALVE SPRING FREE LENGTH

VALVE
VALVE GUIDE

SERVICE LIMIT

VALVE STEM OUTER DIAMETER

VALVE SEAT WIDTH

TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT
SPARK PLUG
CAMSHAFT HOLDER 8mm NUT
CAM CHAIN TENSIONER MOUNTING BOLT
CAM CHAIN TENSIONER SEALING SCREW
CYLINDER HEAD COVER BOLT
CYLINDER HEAD BOLT
TAPPET ADJUST NUT

1.0 kgfm
1.2 kgfm
2.0 kgfm
1.2 kgfm
0.4 kgfm
0.9kgfm
1.1 kgfm
0.8 kgfm

10-1

10

CYLINDER HEAD / VALVES


TOOLS
VALVE GUIDE REAMER
VALVE GUIDE DRIVER
VALVE SPRING COMPRESSOR
VALVE SEAT CUTTER
SEAT CUTTER IN 37(21.5mm)
EX 37(18.5mm)
IN 45(22.0mm)
EX 45(22.0mm)
IN 55(20.0mm)
EX 55(20.0mm)

TROUBLESHOOTING
Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,
or by tracing noises to the top-end with a sounding rod or stethoscope.

Low comperssion

Rough idle

Valves
-Incorrect valve adjustment (see section 3)
-Burned or bent valves
-Incorrect valve timing
-Broken valve spring
-Uneven valve seating

Low cylinder compression

Cylinder head
-Leaking or damage head gasket
-Warped or cracked cylinder head
Cylinder, piston (see section 11)

Excessive white smoke


Worn valve guide or valve stem
Damaged valve stem seal
Worn or damaged piston ring

10-2

Compression too high


Excessive carbon build-up on piston or combustion
chamber

Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Worn rocker arm and / or shaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
Damaged cylinder head gasket
Incorrect spark plug installation

CYLINDER HEAD / VALVES

CAMSHAFT
REMOVAL

SPECIALBOLTS
BOLTS
SPECIAL
SPECIAL
BOLTS
CYLINDERHEAD
HEADCOVER
COVER
CYLINDER
HEAD
COVER
CYLINDER

Remove the following parts.


- Rear fender
- Seat support pipe
- Center cover
- Truss pipe
- Floor panel
Loosen the special bolt securing the cylinder head
cover and remove the cover.

Turn the crankshaft to the left, and align theTmark


of the flywheel with the index mark of the RH.
crankcase cover.
Verify that the piston is located at the top dead center.
(Make all camshaft lobes face downward.)
If all camshaft lobes face upward, rotate the crankshaft
to the left for 1 turn (360
), and align theT mark
with the index mark once again.
T-MARK
T-MARK
T-MARK

Loosen the pan screw of the cam chain, remove the


tensioner flange bolts and tensioner lifter.

FAN
SCREW
FAN
FANSCREW
SCREW
FAN

TENSIONER
TENSIONER
LIFT
TENSIONERLIFT
LIFT

Loosen the 4 camshaft holder 8mm nuts.


Remove the camshaft holder from the cylinder head.

FLANGENUT
FLANGENUT
FLANGENUT

CAM
SHAFT
HOLDER
CAM
CAMSHAFT
SHAFTHOLDER
HOLDER
CAM
SHAFT
HOLDER

10-3

CYLINDER HEAD / VALVES

Remove the cam chain from the camshaft.

! NOTE

Take precautions not to allow the cam chain to drop


into the crankcase.

Remove the camshaft.


CAM
CAM
SHAFT
CAMSHAFT
SHAFT

Insert the 6mm bolt into the rocker arm shaft, and
pulling bolts to remove the rocker arm shaft.
Remove the rocker arm.
Remove the other side rocker arm shaft and rocker arm
in the same sequence.

ROCKER
ARM
SHAFT
ROCKER
ROCKERARM
ARMSHAFT
SHAFT

CAMSHAFT INSPECTION
Check the rocker arm and rocker arm shaft for wear or
damage.
Measure the inner diameter of the rocker arm.
SERVICE LIMIT : 12.060 mm
INNER
INNER
DIAMETER
INNERDIAMETER
DIAMETER

Measure the outer diameter of the rocker arm shaft.


SERVICE LIMIT : 11.950 mm

OUTER
DIAMETER
OUTER
OUTERDIAMETER
DIAMETER
OUTER
DIAMETER

MICRO
MICROMETER
METER
MICRO
METER

Check the cam lobes of the camshaft for wear or


damage.
Measure the height of the cam lobe.
SERVICE LIMIT : IN : 33.625 mm
EX: 33.765 mm

CAM
SHAFT
CAM
CAMSHAFT
SHAFT
CAM
SHAFT

10-4

CYLINDER HEAD / VALVES

Manually turn the camshaft bearing outer race, and


check if it turns smoothly.
Check the bearing for wear or damage.
! CAUTION

Be sure to check the valve clearance.

CAMSHAFT
BEARING
CAMSHAFT
CAMSHAFTBEARING
BEARING

CYLINDER HEAD
CYLINDER
CYLINDER
HEAD
CYLINDERHEAD
HEAD

FLANGE
FLANGE
FLANGE
BOLTS
BOLTS
BOLTS

Remove the following parts.


- Rear fender
- Seat support pipe
- Center cover
- Truss pipe
- Floor panel
- RH. LH. shroud
- Cylinder head cover
- Cam shaft
- EX. Pipe
- Cylinder head
Remove the cylinder head gasket, dowel pin and
camchain guide from the cylinder.

CYLINDER
CYLINDER
HEAD
GASKET
CYLINDERHEAD
HEADGASKET
GASKET

CAMCHAIN
CAMCHAIN
CAMCHAIN
CAMCHAIN
CYLINDERHEAD
HEAD
CYLINDER
CYLINDER
HEAD

DISASSEMBLY
SPARK
PLUG
SPARK
SPARKPLUG
PLUG
SPARK
PLUG

Remove the carburetor insulator.


Remove the spark plug from the cylinder head.

10-5

CYLINDER HEAD / VALVES

Remove the valve spring, valve cotter, retainer, spring


and valve. Using the valve spring compressor.
TOOL : VALVE SPRING COMPRESSOR
! NOTE

To prevent the loss of tension, do not compress the


valve spring more than necessary.
Mark the disassembled parts so that they can be
reassembled into the original position later.

VALVE
SPRING
VALVE
VALVESPRING
SPRING

VALVE
SPRING
COMPRESSOR
VALVE
VALVESPRING
SPRINGCOMPRESSOR
COMPRESSOR

CYLINDER HEAD INSPECTION


Remove the carbon deposits from the inside of the
combustions chamber.
! NOTE

Take precautions not to damage the cylinder head


gasket attachment.
Check the spark plug assembling hole and the valve
seat for cracks.
Using a square and a feeler gauge, check the cylinder
head distortion.

FEELER
FEELERGAUGE
GAUGE
FEELER
GAUGE

SERVICE LIMIT : 0.1 mm

VALVE SPRINGS

VALVESPRING
SPRING
VALVE
VALVE
SPRING

Measure the free length of the inner and outer valve


springs.
SERVICE LIMIT : 36.90 mm
! NOTE

Replace the valve spring with new one if the length of


any one is less than the service limit.

VALVE
VALVE
VALVE

VALVES
Inspect each valve for bending, burning, scratches or
abnormal wear.
Insert the valves in their original positions in the
cylinder head.
Check that each valve moves up and down smothly,
without binding.
Measure and record the valve stem outer diameter in
three places along the valve guide sliding area.
SERVICE LIMIT : IN : 4.920 mm
EX: 4.900 mm

Replace the valve with a new one if the service limit is


exceeded.

10-6

CYLINDER HEAD / VALVES

VALVE
GUIDE
REAMER
VALVE
VALVEGUIDE
GUIDEREAMER
REAMER
VALVE
GUIDE
REAMER

VALVE GUIDES
INSPECTION
Insert the valve guide reamer from the combustion
chamber side and ream the guide to remove any carbon
build-up before measuring the guide.
! NOTE

Take care not to tilt or lean the reamer in the guide


while reaming.
Rotate the reamer clockwise, never counterclockwise
when inserting and removing.
VALVE
VALVE
GUIDE
VALVEGUIDE
GUIDE

TOOL : VALVE GUIDE REAMER

Measure and record each valve guide inner diameter.


SERVICE LIMIT : 5.030 mm

Measure the guide-to-stem clearance with a dial


indicator while rocking the stem in the direction of
normal thrust.
SERVICE LIMIT : IN : 0.090 mm
EX: 0.120 mm

Measure the inner diameter of the new valve guide. If


the clearance is not within the service limit, replace the
valve.

VALVE
VALVE
GUIDE
DRIVER
VALVEGUIDE
GUIDEDRIVER
DRIVER

REPLACEMENT
Heat the cylinder head to 130
C - 140
C (275
F - 290
F).
Support the cylinder head and drive the old guides out
of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER
! NOTE

Avoid damaging the head when driving the valve


giude out.
! CAUTION

Do not heat the cylinder head beyond 150


C (300
F).
Use temperature indicator sticks, available from
welding supply stores, to be sure the cylinder head is
heated to the proper temperature.
Using a torch to heat the cylinder head may cause
warping.
Wear insulated gloves to avoid burns when handling
the heated cylinder head.
Refinish the valve seats whenever the valve guides are
replaced to prevent uneven seating.

10-7

CYLINDER HEAD / VALVES

VALVE
GUIDE
VALVE
VALVEGUIDE
GUIDE
VALVE
GUIDE

Apply oil to a new O-ring and install it onto a new


valve guide.
Drive the new guide in from the camshaft side of the
cylinder head while the cylinder head is still heated.
TOOL : VALVE GUIDE DRIVER

When reaming new valve guides, insert the valve guide


reamer from the combustion chamber side.
! NOTE

Take care not to tilt or lean the reamer in the guide


while reaming.
Otherwise, the valve is installed slanted, that causes oil
leaks from the stem seal and improper valve seat
contact and results in the valve seat refacing not able
to be performed.
Use cutting oil on the reamer during this operation.
Rotate the reamer clockwise, never counterclockwise
when inserting and removing.
TOOL : VALVE GUIDE DRIVER

Reface the valve seats and clean the cylinder head


thoroughly to remove any metal particles.

VALVE SEATS
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to each valve
face.

VALVE
VALVE
VALVE

10-8

CYLINDER HEAD / VALVES

VALVE
VALVE
SEAT
VALVESEAT
SEAT

Remove the valve and inspect the valve seat face.


The valve seat contact should be within the specified
width and evenly all around the circumference.
If the valve seat width is not within specification,
reface the valve seat.
! NOTE

Valve faces and stem tips cannot be ground. If a valve


face or stem tip is rough, worn unevenly, or contacts
the seat improperly, the valve must be replaced.
Measure the valve seat width.STANDARD VALUE : 0.8
-1.0 mm
SERVICE LIMIT : 1.4 mm

VALVE SEAT REFACING


Reface the worn valve seat by using valve seat cutters
and grinders.
45

! NOTE

55

Follow the refacer manufactuers operating instructions.


Reface the valve seat whenever the valve guide has been
replaced.
Be careful not to grind the seat more than necessary.

37

Using a 45 degree cutter, remove any roughness or


irregularities from the seat.
ROUGHNESS

Using a 37 degree cutter, remove of the existing


valve seat material.

37

10-9

CYLINDER HEAD / VALVES

Using a 55 degree cutter, remove the bottom of the


old seat.

55

Using a 45 degree cutter, cut the seat to the proper


width.
SEAT WIDTH

45

If the contact area is too high on the valve, the seat


must be lowered using a 37 degree flat cutter.
Refinish the seat to specifications, using a 45 degree
finish cutter.
CONTACT TOO HIGH

37

If the contact area is too low on the valve, the seat must
be raised using a 55 degree inner cutter.
Refinish the seat to specifications, using a 45 degree
finish cutter.

CONTACT TOO LOW

55

10-10

CYLINDER HEAD / VALVES

After cutting the valve seat, apply lapping compound to


the valve face, and insert the valve with a valve guide
reamer.
! NOTE

Do not excessively press and turn the valve to set it as it


may cause damage. Gently strike and set the valve.

The seat surface may become worn on one side if the


valve is set in the same position. Turn the valve slightly
when setting it.
Take precautions not to allow compound to get into the
clearance between the stem and guide while the valve is
being set.

CYLINDER
CYLINDER
CYLINDER
STEM
SEAL
STEM
STEMSEAL
SEAL

IN/EX VALVE ASSEMBLY

VALVE
VALVE
VALVE
SPRING
SPRING
SPRING
RETAINER
RETAINER
RETAINER
RETAINER
COTTER
COTTER
COTTER

Install the valve spring and new stem seals.


Lubricate each valve stem with molybdenum disulfide
grease and insert the valve into the valve guide.
Check the valve moves up and down smoothly.

For valve spring with varying pitch, install the valve


springs with the narrow pitch end facing down.

NARROW PITCH

Install the spring retainers.


Compress the valve springs with the valve spring
compressor and install the valve cotters.
! CAUTION

Compressing the valve spring more than necessary


when installing the valve cotters may cause loss of
valve spring tension.
TOOL : VALVE SPRING COMPRESSOR
VALVE
SPRING
COMPRESSOR
VALVE
VALVESPRING
SPRINGCOMPRESSOR
COMPRESSOR
VALVE
SPRING
COMPRESSOR

10-11

CYLINDER HEAD / VALVES

Tap the valve stems gently with a soft hammer to


firmly seat the cotters.
! CAUTION

Take necessary precautions not to damage the valve.

VALVE
VALVE
SPRING
VALVESPRING
SPRING

CYLINDER
CYLINDER
HEAD
CYLINDERHEAD
HEAD

Apply engine oil to the new O-ring, and assemble it to


the carburetor insulator groove.
Tighten the carburetor insulator with mounting bolts.
Install the cam chain tensioner, and assemble pilot.
TORQUE : 1.0 kgf m

Install the spark plug.


TORQUE : 1.2 kgf m

CYLINDER
CYLINDER
CYLINDER

GASKET
GASKET
GASKET

CYLINDER HEAD ASSEMBLY


Clean any gasket material from the cylinder mating surface.
Install the cam chain guide to the cylinder.
Install the dowel pins and new gasket.

DOWEL
PIN
DOWEL
DOWEL PIN
PIN

CAM
CAM
CHAIN
CAMCHAIN
CHAIN
CYLINDER
HEAD
CYLINDER
CYLINDERHEAD
HEAD
CYLINDER

10-12

Install the cylinder head.

CYLINDER HEAD / VALVES

CAMSHAFT ASSEMBLY
EX.
VALVE
ROCKER
ARM
EX.
EX.VALVE
VALVEROCKER
ROCKERARM
ARM
EX.
VALVE
ROCKER
ARM
IN.
IN.
VALVE
ROCKER
ARM
IN.VALVE
VALVEROCKER
ROCKERARM
ARM

Apply engine oil to the rocker arm shaft, and assemble


the rocker arm to the camshaft holder.

EX.
ROCKER
ARM
SHAFT
IN.
ROCKER
ARM
SHAFT
EX.
IN.
EX.ROCKER
ROCKERARM
ARMSHAFT
SHAFT
IN.ROCKER
ROCKERARM
ARMSHAFT
SHAFT
EX.
ROCKER
ARM
SHAFT
CAM
SHAFT
HOLDER
CAM
SHAFT
HOLDER
CAM SHAFT HOLDER

CAM
CAM SHAFT
SHAFT HOLDER
HOLDER
CAM
SHAFT
HOLDER

CAM
SHAFT
CAM
CAMSHAFT
SHAFT

CAM
CAM
CHAIN
CAMCHAIN
CHAIN

Tighten the rocker arm shaft with 6mm bolts, and align
the bolt hole of the camshaft holder with the fitting side
of the rocker arm shaft.

Check the camshaft assembly for abnormal condition,


and place it on the cylinder head.
Put the cam chain and cam sprocket on the cam
sprocket.

Slowly rotate the crankshaft counterclockwise, and


align theTmark of the flywheel with the index mark
of the RH. crank case cover.
! CAUTION

Take precautions not to allow the cam chain to come


T-MARK
T-MARK
T-MARK
T-MARK

off the camshaft timing gear while turning the


camshaft.

10-13

CYLINDER HEAD / VALVES

Apply engine oil to the camshaft, and install it on the


cylinder head with the cam thread facing downward.
Assemble the cam chain and cam sprocket after
matching the cam sprocket timing mark in parallel with
the top of the cylinder head.

CAM
CAM
SHAFT
CAMSHAFT
SHAFT

TIMING
MARK
TIMING
TIMINGMARK
MARK

CAM
CAM
SHAFT
HOLDER
CAMSHAFT
SHAFTHOLDER
HOLDER

Install the dowl pins on the cylinder head.


Install the cam shaft holder.
! CAUTION

The hole of the camshaft holder and the fitting section


of the rocker arm shaft fit section must be in alignment.

Of IN and EX, the shorter rocker arm should be


installed on the IN side.

Install the cam cover plate.


Apply engine oil to the threaded part; install the
camshaft holder nut and bolts, and tighten them driving
with 2 - 3 times.
TORQUE VALUE : 2.0 kgf m

Remove the pan screws and seals from the cam chain
tensioner lifter.
Rotate the tensioner shaft clockwise with a small
driver, and insert the shaft into the body completely.
! CAUTION

If the cam chain tensioner lifter is dropped, the shaft


will advance by the spring force.

10-14

CYLINDER HEAD / VALVES

HARDCLIP
HARDCLIP
HARDCLIP

TENSIONER
TENSIONER
LIFTER
TENSIONERLIFTER
LIFTER

Fix the tensioner shaft with a hard clip.


Assemble a new gasket to the tensioner lifter, and
install the tensioner lifter on the cylinder.
Tighten the tensioner mounting bolts.
TORQUE VALUE : 1.2 kgf m

Remove the tensioner shaft clip from the tensioner


lifter. Assemble the O-ring and pan screws to the
tensioner lifter.
TORQUE VALUE : 0.4 kgf m
FAN
FAN
SCREW
FANSCREW
SCREW

Fill clean engine oil into the operating parts of the


cylinder head.
Adjust the valve clearance.
VALVE CLEARANCE : INHALE 0.12 0.02mm
EXHALE 0.12 0.02mm

FEELER
GAUGE
FEELER
FEELERGAUGE
GAUGE
FEELER
GAUGE

Remove oil from the cylinder head cover grooves, and


accurately assemble the gasket to the cover.
Install the cylinder head cover.
Tighten the cylinder head cover bolts.
TORQUE VALUE : 0.9 kgf m

Install the carburetor insulator..


Install in the reverse order of removal.

SPARK
SPARK
PLUG
CAP
SPARKPLUG
PLUGCAP
CAP

10-15

CYLINDER / PISTON

CYLINDER

TOP RING
SECOND RING
OIL RING
CYLINDER GASKET

PISTON

11-0

CYLINDER / PISTON

11. CYLINDER / PISTON


SERVICE INFORMATION 11-1
TROUBLESHOOTING 11-1
CYLINDER 11-2

PISTON / PISTON RING 11-3


CYLINDER INSTALLATION 11-6

SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
Take care not to damage the cylinder wall and piston.
Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.

SPECIFICATIONS
Unit : mm

ITEM

STANDARD VALUE

SERVICE LIMIT

INNER DIAMETER

56.000 - 56.010 mm

56.100 mm

TAPER

0.050 mm

OUT-OF-ROUND

0.005 mm

HEAD CONTACT WARPAGE

0.020 mm

PISTON SKIRT OUTER DIAMETER

55.925 - 55.945 mm

55.825 mm

PISTON PIN HOLE INNER DIAMETER

15.002 - 15.008 mm

15.040 mm

PISTON PIN OUTER DIAMETER

14.994 - 15.000 mm

14.960 mm

PISTON-TO-PISTON PIN CLEARANCE

0.002 - 0.014 mm

0.020 mm

TOP

0.040 - 0.067 mm

0.110 mm

SECOND

0.025 - 0.052 mm

0.080 mm

TOP / SECOND

0.10 - 0.25 mm

0.50 mm

OIL RING (SIDE RAIL)

0.20 - 0.70 mm

1.10 mm

CYLINDER-TO-PISTON CLEARANCE

0.055 - 0.090 mm

0.200 mm

CONNECTING ROD SMALL END INNER DIAMETER

15.010 - 15.028 mm

15.060 mm

GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN

0.010 - 0.034 mm

0.040 mm

CYLINDER

PISTON,
PISTON PIN,
PISTON RING

PISTON RING-TOGROOVE CLEARANCE


PISTON RING
JOINT GAP

TROUBLESHOOTING
Comperssion too low

Overheating

Worn piston
Worn, damaged piston ring
Worn cylinder

Excessive carbon build-up on top of piston

Abnormal noise
Excessive smoke
Worn cylinder, piston or piston rings
Improper installation of piston ring
Scored or scratched piston or cylinder wall

Worn cylinder and piston


Worn connecting rod small end bearing or piston pin
Damaged piston ring
Excessive carbon build-up on top of piston

11-1

11

CYLINDER / PISTON

CYLINDER

CYLINDER
CYLINDER
CYLINDER

REMOVAL
Remove EX. pipe.
Remove the cylinder head cover.
Remove the cam shaft.
Remove cylinder head.
Remove the cam chain guide from the cylinder.
Remove cylinder

CAM
CAM
CHAIN
GUIDE
CAMCHAIN
CHAINGUIDE
GUIDE

Remove the gasket and dowel pin. Carefully remove


any adhering gasket material from the cylinder / head
mating surface. Do not scratch the surface.
! NOTE

Take care not to damage the cylinder mating surface.


CYLINDER
GASKET
CYLINDER
CYLINDERGASKET
GASKET

PISTON
PISTON
PISTON
PISTON

WEAR INSPECTION
CYLINDER
GAUGE
CYLINDER GAUGE

Inspect the cylinder wall for scratches and wear.


Measure and record the cylinder inner diameter at three
levels in both an X and Y axis.
Take the maximum reading to determine the cylinder
wear.
SERVICE LIMIT : 56.100 mm

Measure the piston outer diameter.


Calculate the piston-to-cylinder clearance. Take the
maximum reading to determine the clearance.
SERVICE LIMIT : 0.2 mm

TOP
TOP

MIDDLE
MIDDLE

BOTTOM
BOTTOM

11-2

Calculate the cylinder for out-of-round at three levels in


an X and Y axis. Take the maximum reading to
determine the out-of-round.
Calculate the cylinder for taper at three levels in an X
and Y axis. Take the maximum reading to determine
the taper.
If any of the cylinder measurements exceed the service
limits, replace the cylinder.
SERVICE LIMIT : OUT-OF-ROUND : 0.005 mm
TAPER : 0.05 mm

CYLINDER / PISTON
WARPAGE INSPECTION
Check the cylinder for warpage by placing a straight
edge and feeler gauge across the stud holes. Replace
the cylinder if the service limit is exceeded.
SERVICE LIMIT : 0.02 mm
! NOTE

Any clearance between the cylinder and head due to


damage or warpage will result in compression leaks
and reduced performance.

FEELER
FEELER
GAUGE
FEELERGAUGE
GAUGE

PISTON
PISTON
PISTON
PISTON

PISTON / PISTON RING


REMOVAL
! NOTE

Place a clean shop towel over the crankcase to prevent


the possibility of the clip falling into the crankcase.

PISTON
PISTON
PIN
CLIP
PISTONPIN
PINCLIP
CLIP

Remove the piston pin clip using a pair of pliers.


Press the piston pin out of the piston.

! NOTE

Do not damage or scratch the piston.


Do not apply side force to the connecting rod.
Do not let the clip fall into the crankcase.

INSPECTION
Clean carbon deposits from the piston.
Inspect the piston rings for movement by pressing the
rings. The rings should be able to move in its groove
without catching.
Spread each piston ring and remove it by lifting it up at
a point just opposite the gap.
! NOTE

Do not damage to the piston by piston ring when


PISTON
RING
PISTON RING

removing.
Measure the clearance between the piston ring and
piston grooves.
SERVICE LIMIT : TOP : 0.110 mm
SECOND : 0.080 mm
OIL RING : 0.280 mm

Inspect the piston for wear or damage.

11-3

CYLINDER / PISTON

11-4

CYLINDER / PISTON

MARK
R

TOP RING

SECOND RING
SIDE RAIL
OIL
SPACER
20mm

RING

SIDE RAIL

PISTON

TOP RING

SECOND RING

CRANK
SHAFT
CONNECTING
ROD
CRANK
CRANKSHAFT
SHAFTCONNECTING
CONNECTINGROD
ROD
CRANK

11-5

CYLINDER / PISTON

CYLINDER
CYLINDER
GASKET
CYLINDERGASKET
GASKET

PISTON
PISTON
PISTON

DOWEL
DOWEL
PIN
DOWELPIN
PIN

PIN
PIN
CLIP
PINCLIP
CLIP

CYLINDER
CYLINDER
CYLINDER

( 10-12)
( 10-13)
( 10-5)
( 3-9)
( 7-3)

11-6

MEMO

TRANSMISSION/CRANKSHAFT/CRANK CASE

12-0

TRANSMISSION/CRANKSHAFT/CRANKCASE

12
12-1
12-2
12-3
12-6

12-7
12-8
12-9
12-10

( SECTION 4-4)
( SECTION 7)
( SECTION 10 AND 11)
( SECTION 9)
( SECTION 8)
( SECTION 8)

( SECTION 12)

12

12-1

TRANSMISSION/CRANKSHAFT/CRANK CASE
TORQUE VALUE
CRANK CASE BOLT 1.0kg-m

TOOLS
-UNIVERSAL BEARING PULLER
-BEARING REMOVER SET
-REMOVER ASSEMBLY
-REMOVER SHAFT
-REMOVER HEAD
-SLIDING WEIGHT
-ASSEMBLY SHAFT

TROUBLESHOOTING
Engine Noise
Connecting rod big and small ends loose.
Crank pin bearing loose.

Engine started but unable to move out


Transmission damage.
Transmission seized.

Noise during operation


Gear worn, overheated, or cranked.
Bearing worn.

Oil leaks
Excessive oil level.
Oil seal worn or damaged.

12-2

TRANSMISSION/CRANKSHAFT/CRANK CASE

8-2
8
3-9
14-6
15-8
14-3
TRANSMISSION
COVER
TRANSMISSION
TRANSMISSIONCOVER
COVER
TRANSMISSION
COVER

COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER

SPECIAL
SPECIAL
BOLT
SPECIALBOLT
BOLT

FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT

DRIVESHAFT
SHAFT
DRIVE
DRIVE
SHAFT

TRANSMISSION
COVER
TRANSMISSION
TRANSMISSIONCOVER
COVER
TRANSMISSION
COVER

OIL
SEAL
OIL
OILSEAL
SEAL
OIL
SEAL

12-3

TRANSMISSION/CRANKSHAFT/CRANK CASE

FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT

COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER

DRIVE SHAFT

FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT

COUNTER
COUNTER
SHAFT
COUNTERSHAFT
SHAFT

12-4

TRANSMISSION/CRANKSHAFT/CRANK CASE

NEEDLE
NEEDLE
BEARING
NEEDLEBEARING
BEARING

BALL
BEARING
BALL
BALL BEARING
BEARING

OUTER
OUTER
DRIVER
OUTERDRIVER
DRIVER

OUTER
OUTER
HANDLE
OUTERHANDLE
HANDLE

DRIVER
DRIVER
PILOT
DRIVERPILOT
PILOT

CRANK
ASSEMBLY
COLLAR
CRANK
CRANKASSEMBLY
ASSEMBLYCOLLAR
COLLAR
CRANK

Install the bearing to the case with special tools.

CRANK
ASSEMBLY
SHAFT
CRANK
CRANKASSEMBLY
ASSEMBLYSHAFT
SHAFT
CRANK

TOOL : DRIVE HANDLE A


OUTER DRIVER
DRIVER PILOT

FINAL
FINAL SHAFT
SHAFT
FINAL
SHAFT

COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER
SHAFT

12-5

TRANSMISSION/CRANKSHAFT/CRANK CASE

Replace the new oil seal on the transmission


cover.
Insrall the transmission cover.

MISSIONCOVER
COVER
MISSION
MISSION
COVER

ENGINE
ENGINE
ENGINE
ENGINE

Loosen the 8 RH./LH. crankcase setting bolt.


Remove the transmission bleeder tube.
Remove the RH./LH. radiator hose from the RH.
crankcase.

FLANGE
FLANGE
BOLTS
FLANGEBOLTS
BOLTS

12-6

TRANSMISSION/CRANKSHAFT/CRANK CASE

RH.
RH.
CRANK
CASE
RH.CRANK
CRANKCASE
CASE

LH.
LH.
CRANK
CASE
LH.CRANK
CRANKCASE
CASE

CRANK
CRANK
SHAFT
CRANKSHAFT
SHAFT

GASKET
GASKET
GASKET
GASKET

DOWEL
DOWEL
PIN
DOWELPIN
PIN

CRANK
CRANK
BEARING
CRANKBEARING
BEARING

RH.
RH.
CRANK
CASE
RH.CRANK
CRANKCASE
CASE

UNIVERSAL REARING PULLER

12-7

TRANSMISSION/CRANKSHAFT/CRANK CASE

DIAL GAUGE

MEASURING POINT

FILLER GAUGE

DIAL GAUGE

Y
X

OIL
OIL SEAL
SEAL

LH.
CRANK
CASE
LH.
LH.CRANK
CRANKCASE
CASE
LH.
BEARING
BEARING
BEARING

OIL
OIL SEAL
SEAL
OIL
SEAL

12-8

TRANSMISSION/CRANKSHAFT/CRANK CASE

BEARING
BEARING
REMOVER
SET
BEARINGREMOVER
REMOVERSET
SET

DRIVER
DRIVER
HANDLE
DRIVERHANDLE
HANDLEAAA

OUTER
DRIVER
OUTER
OUTERDRIVER
DRIVER
OUTER

DRIVERPILOT
PILOT
DRIVER
DRIVER
PILOT

DRIVER
DRIVER
HANDLE
DRIVERHANDLE
HANDLEAAA

TOOL : CRANK SHAFT ASSEMBLER

CRANK
SHAFT
ASSEMBLY
CRANK
CRANKSHAFT
SHAFTASSEMBLY
ASSEMBLY
CRANK

12-9

TRANSMISSION/CRANKSHAFT/CRANK CASE

DOWEL
DOWEL
PIN
DOWELPIN
PIN
CRANK
CRANK
SHAFT
CRANKSHAFT
SHAFT

LH.
LH.
CRANKCASE
LH.CRANKCASE
CRANKCASE

Install the crankcase.


Install the engine on the frame. (

12-10

7-3)

MEMO

FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE

STEERING STEM

FRONT FORK

FRONT DISK

FRONT WHEEL

FRONT TIRE

13-0

FRONT WHEEL/FRONT FORK/STEERING

13. FRONT WHEEL/FRONT FORK/STEERING


SERVICE INFORMATION13-1
TROUBLESHOOTING 13-2
STEERING HANDLE 13-3
FRONT WHEEL 13-4
FRONT WHEEL BEARING 13-5

SPEEDOMETER GEAR13-6
FRONT WHEEL INSTALLATION13-7
FRONT FORK 13-7
STEERING STEM 13-12

SERVICE INFORMATION
GENERAL SAFETY
!

CAUTION

Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged.
Place a jack underneath the engine to support the 2-wheeled vehicle.

SPECIFICATIONS
ITEM

STANDARD VALUE (mm)

SERVICE LIMIT (mm)

0.2

RADICAL

2.0

AXIAL

2.0

AXLE SHAFIT DEFLECTION


FRONT WHEEL RIM DEFLECTION

FRONT CUSHION SPRING FREE LENGTH

266.3

13

TORQUE VALUES
STEERING STEM LOCK NUT
STEERING TOP CONE RACE
FRONT CUSHION BOLT
FRONT AXLE NUT
BRAKE CALIPER BOLT

7.84~11.76 fm
0.49~1.27 fm
1.98~2.45 fm
4.41~4.9 fm
2.45~3.43 fm

13-1

FRONT WHEEL/FRONT FORK/STEERING

TROUBLESHOOTING
Hard steering
Steering top cornice too tight.
Damaged steering stem steel ball.
Faulty steering ball race, cone race.
Insufficient tire pressure.
Tire is worn.

Steers to one side or does not track straight


Bent front fork.
Bent front axle.
Bent frame.
Tire is worn or modification.
Worn wheel bearing.

Front wheel wobbling


Bent rim.
Faulty wheel bearing.

Hard to rotate the wheel.


Faulty wheel bearing.

Soft suspension
Weak fork spring.

Front cushion noise


Loose front fork fasteners.

13-2

FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE

MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER
MASTER
CYLINDER

REMOVAL
Loosen the bolts securing the front and rear break
master cylinder.

MASTERCYLINDER
CYLINDER
MASTER
MASTER
CYLINDER
HOLDER
HOLDER
HOLDER
HOLDER
INNER
BOX
INNER
INNERBOX
BOX

LH.HANDLE
HANDLEGRIP
GRIP
LH.
HANDLE
GRIP
LH.

RH.
HANDLE
GRIP
RH.
RH.HANDLE
HANDLEGRIP
GRIP

Disconnect the throttle cable from the throttle grip.

Remove the handle grip from the handlebar.


HANDLE
HANDLE
GRIP
HANDLEGRIP
GRIP

HEX
SOCKET
BOLTS
HEX
HEXSOCKET
SOCKETBOLTS
BOLTS
HEX
SOCKET
BOLTS

Remove the cap on the handle upper holder.


Loosen the hexbolt securing handle bar and remove the
steering handle comp.

HANDLE
HANDLE UPPER
UPPER HOLDER
HOLDER
HANDLE
UPPER
HOLDER

13-3

FRONT WHEEL/FRONT FORK/STEERING

STEERING
HANDLE
STEERING
STEERINGHANDLE
HANDLE
STEERING

INSTALLATION
Align the line of the steering handle to the handle under
holder.
Install the handle upper holder using the hexbolt, to the
specified torgue.
TORQUE : 3.92 - 4.9fm

HANDLE
HANDLE
UNDER
HOLDER
HANDLEUNDER
UNDERHOLDER
HOLDER

NOTE

Adjust the throttle grip free play to the


specified range of 2-6mm.
Install in the reverse order of removal.

HANDLE
HANDLE UPPER
UPPER HOLDER
HOLDER
HANDLE
UPPER
HOLDER

FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT

FRONT
FRONT
CALIPER
FRONTCALIPER
CALIPER

FRONT WHEEL
REMOVAL
Jack the motorcycle front wheel off the ground.
Loosen the flange bolt securing the front caliper to
remove the caliper.
Loosen the axle nut, speedometer cable setting screw
and remove the wheel.

DIAL
GAUGE
DIAL
DIALGAUGE
GAUGE
DIAL
GAUGE

FRONT
AXLE
FRONT
FRONTAXLE
AXLE

INSPECTION
AXLE RUNOUT
Set the axle in V blocks and measure the runout using a
dial gauge.
The actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT : 0.2mm replace if over

13-4

FRONT WHEEL/FRONT FORK/STEERING

ROTATION
ROTATION
ROTATION

BEARING
BEARING
REMOVER
HEAD
BEARINGREMOVER
REMOVERHEAD
HEAD

DRIVER
HANDLE
DRIVER
DRIVERHANDLE
HANDLEAAA
DRIVER

13-5

FRONT WHEEL/FRONT FORK/STEERING

SPEEDOMETER GEAR
GEAR
GEAR
WASHER
GEARWASHER
WASHER

INSPECTION
Remove the speedometer gear from the speedometer
gear box.
Apply grease to the speedometer gear unit and install.

SPEEDOMETER
GEAR
BOX
SPEEDOMETER
SPEEDOMETERGEAR
GEARBOX
BOX
SPEEDOMETER
GEAR
BOX

SPEEDOMETER
GEAR
SPEEDOMETER
SPEEDOMETERGEAR
GEAR
SPEEDOMETER
GEAR

ASSEMBLY
DUST
SEAL
DUST
DUSTSEAL
SEAL
DUST
SEAL

Apply grease to left side dust seal rim.


Install the left side dust seal.
Install the brake disk.
Install disk bolts.
TORQUE VALUE : 4.0 ~4.5 kgfm

BEARING
BEARING
BEARING

Install the front wheel side collar.

FRONT
FRONT
WHEEL
SIDE
COLLAR
FRONTWHEEL
WHEELSIDE
SIDECOLLAR
COLLAR

Install the speedometer gear unit by aligning its


retaining pawl with the hub cutout.

GEARBOX
BOXRETAINER
RETAINER
GEAR
GEAR
BOX
RETAINER

13-6

FRONT WHEEL/FRONT FORK/STEERING

Apply grease to the dust seal rim.


Install the dust seal, and align the tangs of the
speedometer gear retainer with the gear groove to
assemble the speedometer gear box.

GEAR
BOX
RETAINER
GEAR
GEARBOX
BOXRETAINER
RETAINER
GEAR
BOX
RETAINER

SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX

PART
PART

FRONT WHEEL INSTALLATION


Insert the front wheel between the front forks.
Insert the disk, taking precautions not to damage the
pad, and assemble the wheel.
Align the slots of the speedometer gear with the tangs
of the RH. fork slider.
Insert the front axle into the speedometer gear box and
the wheel hub.

SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX

Install the axle nut.


Install the speedometer cable, and tighten with screws.
Place the front wheel on the ground, and tighten the
axle nut to the specified torque.
TORQUE VALUE : 5.0-7.0 kgfm

AXLE
AXLE
NUT
AXLENUT
NUT
FRONT
FRONT
CALIPER
FRONTCALIPER
CALIPER

FRONT FORK
REMOVAL
Remove the following parts.
-Front brake caliper
-Front fender
-Front wheel

FRONT
FRONT
WHEEL
AXLE
FRONTWHEEL
WHEELAXLE
AXLE

13-7

FRONT WHEEL/FRONT FORK/STEERING

When removing the front fork, loosen the flange bolt


lightly.
STEERINGSTEM
STEMCOMP
COMP
STEERING
STEM
COMP
STEERING

NOTE

Support the vehicle securely under the engine not


to turn over it.
Loosen the flange bolt, but do not remove it.
Loosen the 4 setting bolts securing the RH./LH. front
fork, remove the RH./LH. front fork.
After removal of RH. front fork, loosen the flange bolt
and remove the front brake hose clamp A.

FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
FRONT
FRONT
FORK
BOLT
FRONTFORK
FORKBOLT
BOLT

DISASSEMBLY
Remove the fork pipe bolt.

!
FRONT
FRONT
FORK
PIPE
FRONTFORK
FORKPIPE
PIPE

SOCKETBOLT
BOLT
SOCKET
SOCKET
BOLT

NOTE

If the screw is completely loosened, the fork tube


cap bolt may spring out by the force fo the spring.
Take due precautions.
Remove the fork spring, and expand and release
the fork pipe several times to drain fork oil.
Wrap the bottom case with a piece of cloth, and
remove the socket bolt.

NOTE

If the socket bolt turns idle, but cannot be


removed, temporarily assemble the spring and
the fork tube cap bolt first.
Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.

13-8

FRONT WHEEL/FRONT FORK/STEERING

Remove the dust seal.

DUST
SEAL
DUST
DUSTSEAL
SEAL
DUST
SEAL
OIL
OIL
SEAL
STOP
RING
OILSEAL
SEALSTOP
STOPRING
RING

Remove the oil seal stop ring.


! NOTE

Take precaution not to damage the interior and


exterior rim of the bottom case.

Remove the fork pipe from the bottom case.


Remove the cution spring, pipe seat and oil lock piece
from the fork pipe.
BOTTOM
BOTTOM
CASE
BOTTOMCASE
CASE

FORK
FORK
BOLT
FORKBOLT
BOLT

FRONT
CUSHION
SPRING
FRONT
FRONTCUSHION
CUSHIONSPRING
SPRING
PIPESEAT
SEAT
PIPE
PIPE
SEAT

Check and inspect the each parts.

FORK
FORK
PIPE
FORKPIPE
PIPE

RESOUND
SPRING
RESOUND
RESOUNDSPRING
SPRING
RESOUND

BOTTOM
BOTTOM
CASE
BOTTOMCASE
CASE

OIL
OIL
LOCK
PIECE
OILLOCK
LOCKPIECE
PIECE

SOCKET
SOCKET BOLT
BOLT
SOCKET
BOLT

13-9

FRONT WHEEL/FRONT FORK/STEERING


FRONT FORK INSPECTION
Place the fork spring on a level place, and measure the
free length.
If the free length deviates from the service limit,
replace the springs with new ones.
Check components for damage or abnormal wear.
Replace defective parts with new ones.
SERVICE LIMIT : FORK SPRING : 266.3mm
FRONT
FRONT
FORK
SPRING
FRONTFORK
FORKSPRING
SPRING

FORK
PIPE
FORK
FORKPIPE
PIPE
FORK
PIPE

Set the fork pipe on a V-blocks, and measure fork pipe


deflection by rotating with a dial gauge.
SERVICE LIMIT : Replace if the deflection is greater
than 0.2mm

Check the slider bush contact face.


If the slider bush is extensively damaged, replace the
bottom case.

OIL
SEAL
STOP
RING
OIL
OILSEAL
SEALSTOP
STOPRING
RING
OIL
SEAL
STOP
RING

FRONT FORK ASSEMBLY


Wash parts with clean oil prior to assembling.
Assemble the rebound spring and the fork piston to the
fork tube.
Assemble the fork pipe to the bottom case.

Wrap the bottom case with a piece of cloth, and fix it to


the vise.
Apply screw locking agent to the socket bolt thread,
and assemble the socket bolt to the fork piston.
TORQUE VALUE : 2.0kgfm
!

NOTE
When a vise is used to hold the bottom case, do not
insert the case itself but insert the bracket.

13-10

FRONT WHEEL/FRONT FORK/STEERING


Apply ATF to a new oil seal.
Assemble the oil seal to the bottom case.
Insert the oil seal with special tools until the attachment
groove of the bottom case set ring is exposed.

FORK SEAL DRIVER

TOOLS : FORK SEAL DRIVER


FORK SEAL DRIVER BODY

DUST
DUST
SEAL
DUSTSEAL
SEAL

Install the oil seal stopper ring.


Accurately assemble the oil seal stop ring to the bottom
case.

Install the dust seal.


Fill a prescribed amount of automatic transmission
fluid(ATF) into the fork tube.
CAPACITY : 90cc
FORK OIL

OIL LEVEL

Slowly press the fork tube 2-3 times to discharge air.

Assemble the springs to the fork pipe.


!

NOTE

Install the spring with the smaller pitch side facing


downward.

13-11

FRONT WHEEL/FRONT FORK/STEERING

Assemble the fork bolt to the fork pipe.


FORK
PIPE
BOLT
FORK
FORKPIPE
PIPEBOLT
BOLT

ASSEMBLY
STEERING
STEERING
STEM
STEERINGSTEM
STEM

Align the part of groove with the setting bolt


connection.
Tighten the front fork setting bolt to the specified
torque.
TORQUE VALUE : 7.5 kgfm

FRONT
FRONT
FORK
FRONTFORK
FORK

FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT

STEERING STEM

HANDLE
POST
COMP
HANDLE
HANDLEPOST
POSTCOMP
COMP
HANDLE

REMOVAL
Remove the following parts.
- Handle cover
- Rear handle cover
- Front cover
- Handle bar
- Front wheel
FLANGE
BOLT
FLANGE
U-NUT
FLANGEBOLT
BOLT
FLANGE
BOLT
U-NUT
U-NUT
U-NUT
SETTING
SETTING
HANDLE
COLLAR
SETTINGHANDLE
HANDLECOLLAR
COLLAR

STEERING
STEM
SOCKET
STEERING
STEERINGSTEM
STEMSOCKET
SOCKET

NOTE

Be careful not to turn over the vehicle.

Remove the steering stem lock nut with steering stem


lock nut socket.
Remove the steering top nut with steering stem socket.

STEERING
STEERING
STEM
LOCK
NUT
STEERINGSTEM
STEMLOCK
LOCKNUT
NUT

13-12

FRONT WHEEL/FRONT FORK/STEERING

STEERING
STEERING
STEM
COMP
STEERINGSTEM
STEMCOMP
COMP

Remove the front fork.


Check the steel ball, cone race and ball race for damage
and wear if possible, replace it.
Check the bottom cone race for wear and damage.

STEERING
UNDER
BALL
ASS
STEERING
STEERINGUNDER
UNDERBALL
BALLASS
ASS YYY

STEERING
UNDER
BALL
ASS
STEERING
STEERINGUNDER
UNDERBALL
BALLASS
ASS YYY
STEERING
UNDER
BALL
ASS

Remove the steering top ball race from the head pipe.
Remove the steering bottom ball race.
Check the ball race for wear and damage, if necessary,
replace it.

INSTALLATION
Install the steering head dust seal washer and dust seal
onto the steering stem.
Press in the steering bottom cone race using the
steering stem driver.
Install the under ball assy into the steering stem.
TOOL : STEERING STEM DRIVER

STEERING
TOP
THREAD
NUT
STEERING
STEERINGTOP
TOPTHREAD
THREADNUT
NUT
STEERING
TOP
THREAD
NUT

Insert the steering stem into the head pipe.


Install the steering upper ball assy into the steering
stem.
Install the top cone race and steering top thread onto
the steering head.
Tighten the top thread to specified torque, then loosen
the top thread turn.
TORQUE VALUE : 0.15~0.25 kgfm

Recheck that the steering stem moves smoothly


without play or binding.
Tighten the steering stem lock nut temporarily.
TOOLS : STEERING STEM LOCK NUT SOCKET
STEERING STEM SOCKET

Install the following parts


-Front fork
-Front wheel
-Steering handle
-Inner box

13-13

REAR WHEEL/SUSPENSION/REAR SWING ARM

14-0

REAR WHEEL/SUSPENSION/REAR SWING ARM

14. REAR WHEEL / SUSPENSION / REAR SWING ARM


SERVICE INFORMATION 14-1

14-5
REAR CUSHION

TROUBLESHOOTING 14-2

14-6
REAR SWING ARM

REAR WHEEL 14-3

SERVICE INFORMATION
!

CAUTION

Use the specified tire lever and rim protector to remove or assemble tires to protect the rim from being damage.

SPECIFICATIONS
ITEM

REAR WHEEL RIM RUN OUT


REAR CUSHION SPRING FREE LENGTH

STANDARD VALUE

SERVICE LIMIT

2.0 mm

219 mm

215 mm

TORQUE VALUES :
REAR CUSHION UPPER BOLT
REAR CUSHION UNDER BOLT
REAR CUSHION ROD LOCK NUT
REAR AXLE NUT

3.5~4.5fm
3.5~4.5fm
3.0~4.5fm
6.0~8.0fm

14

14-1

REAR WHEEL/SUSPENSION/REAR SWING ARM

TROUBLESHOOTING
Wobble or vibration in motorcycle
Bent wheel tire
Faulty tire
Axle not tightened properly
Insufficient air in tire
Wheel out of balance

Soft suspension
Weak springs
Rear damper improperly adjusted, oil leakage

Hard suspension
Rear damper improperly adjusted
Bent shock absorber rod

Suspension noise
Loose fasteners
Worn shock

14-2

REAR WHEEL/SUSPENSION/REAR SWING ARM

REAR WHEEL
REMOVAL
Support the motorcycle on the main stand.
Remove the muffler.

MUFFLER
MUFFLER
MUFFLER

Remove the rear brake caliper assembly with brake hose


from the rear swing arm.
Loosen the rear axle nut.
Remove the rear swing arm.

REAR
SWING
ARM
REAR
REARSWING
SWINGARM
ARM
REAR
SWING
ARM

Remove the rear wheel inside collar.

REAR
REARWHEEL
WHEELINSIDE
INSIDECOLLAR
COLLAR
REAR
WHEEL
INSIDE
COLLAR

Remove the rear wheel.


REAR
WHEEL
REAR
REARWHEEL
WHEEL
REAR
WHEEL

REAR
BRAKE
DISK
REAR
REARBRAKE
BRAKEDISK
DISK
REAR
BRAKE
DISK

14-3

REAR WHEEL/SUSPENSION/REAR SWING ARM

DIAL
DIAL
GAUGE
DIALGAUGE
GAUGE

FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT

REAR
REAR
WHEEL
REARWHEEL
WHEEL

( 14-6)

REAR
REAR
WHEEL
INSIDE
COLLAR
REARWHEEL
WHEELINSIDE
INSIDECOLLAR
COLLAR

REAR
REAR
SWING
ARM
REARSWING
SWINGARM
ARM

Install the EX. muffler.

14-4

REAR WHEEL/SUSPENSION/REAR SWING ARM

REAR CUSHION

REAR
REAR
CUSHION
REARCUSHION
CUSHION

REMOVAL
UNDER
UNDER
UNDER

Remove the upper bolt.


Remove the lower bolt.
Remove the rear cushion.

BOLTS
BOLTS
BOLTS

ATTACHMENT
ATTACHMENT
ATTACHMENT

DISASSEMBLY
Install the compressor attachment as shown in the
figure.
Install the cushion on the cushion compressor, and
compress the spring.
TOOL : REAR CHUSION COMPRESSOR
ATTACHMENT
REAR CHUSION COMPRESSOR

REAR
CUSHION
COMPRESSOR
REAR
REARCUSHION
CUSHIONCOMPRESSOR
COMPRESSOR
REAR
CUSHION
COMPRESSOR

ATTACHMENT
ATTACHMENT
ATTACHMENT

Fix the upper metal and loosen the hex nut.


Remove the upper metal.
Remove the hex nut, upper metal, stopper rubber and
the spring from the rear damper comp.

UPPER
UPPER
METAL
UPPERMETAL
METAL

INSPECTION
REAR
REAR
CUSHION
SPRING
REARCUSHION
CUSHIONSPRING
SPRING

Measure the rear cushion spring free length.


Check the damper rod for deflection or damage.
SERVICE LIMIT : 215mm

FREE
FREE
LENGTH
FREELENGTH
LENGTH

14-5

REAR WHEEL/SUSPENSION/REAR SWING ARM


INSTALLATION
Install the spring, stopper rubber to the damper comp.
Apply thread locking agent to the hex nut, and install
the rear cushion compressor attachment on the damper
rod.
Fix the upper metal, and tighten the hex nut.
TORQUE VALVE : 3.0~4.5kgf m
TOOLS : REAR CHUSION COMPRESSOR ATTACHMENT
REAR CHUSION COMPRESSOR
!

NOTE

Install the spring with the smaller pitch side


facing downward.
Install the rear cushion.
Tighten the top and bottom of the cushion with bolts.
TORQUE VALVE : UPPER SIDE : 3.5~4.5kgf m
LOWER SIDE : 3.5~4.5kgf m

REAR SWING ARM

REAR
BRAKE
CALIPER
REAR
REARBRAKE
BRAKECALIPER
CALIPER

REMOVAL
Remove the EX. Muffler.

REAR
REAR
SWING
ARM
REARSWING
SWINGARM
ARM

Remove the rear brake caliper.


Loosen the rear axle U-nut.
Remove the rear swing arm.

14-6

REAR WHEEL/SUSPENSION/REAR SWING ARM

DISASSEMBLY
Disassemble the rear wheel outside collar from the rear
swing arm.
Disassemble the oil seal (28 x 42 x 7) and radial ball
bearing (6302UU).

OIL
OIL
SEAL
OILSEAL
SEAL

OUTSIDE
OUTSIDE
COLLAR
OUTSIDECOLLAR
COLLAR

INSTALLATION
REAR
SWING
ARM
REAR
REARSWING
SWINGARM
ARM
REAR
SWING
ARM

Install in the reverse order of removal.


Install the rear swing arm to the rear wheel axle bolt.
Tighten the rear wheel axle nut.
TORQUE VALUE : 6.0~8.0 kgfm

Install the rear caliper.


Install the muffler.

14-7

MEMO

MEMO

BRAKE SYSTEM

15-0

BRAKE SYSTEM

15. BRAKE SYSTEM


SERVICE INFORMATION15-1
TROUBLESHOOTING15-2
BRAKE FLUID 15-3
FRONTBRAKEPADREPLACEMENT15-5
REAR BRAKE PAD 15-6

FRONT BRAKE CALIPER 15-6


REAR BRAKE CALIPER 15-8
MASTER CYLINDER15-11
BRAKE DISK 15-13

SERVICE INFORMATION
GENERAL SAFETY
Do not allow foreign material to enter the system when replenishing brake fluid.
To prevent chemical changes, do not mix different types of brake fluid.
Do not use the old brake fluid again.
Brake fluid can cause damage to painted, plastic, and rubber surfaces. Take precaution not to allow parts to be
contaminated by the brake fluid.
Do not reuse sealing washers.
Clean the disassembled parts with brake fluid, and check for any clogged passage with compressed air.
Bleed the brake hose after removing it.
Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking
performance, if contaminated, replace the pad with a new one and clean the disk.

SPECIFICATIONS
ITEM

STANDARD

SERVICE LIMIT

FRONT BRAKE CALIPER PISTON A O.D

33.928-33.878mm

33.848mm

FRONT BRAKE CALIPER CYLINDER A I.D

33.96-34.01mm

34.01mm

FRONT BRAKE CALIPER PISTON B O.D

25.33-25.37mm

25.30mm

FRONT BRAKE CALIPER CYLINDER B I.D

25.41-25.46mm

25.46mm

REAR BRAKE DISK THICKNESS

4.0mm

3.0mm

REAR BRAKE DISK RUNOUT

3.0mm

REAR BRAKE MASTER CYLINDER I.D

13.5mm

13.543mm

REAR BRAKE MASTER CYLINDER PISTON O.D

13.5mm

13.378mm

REAR CALIPER CYLINDER I.D

34.0mm

34.039mm

REAR CALIPER PISTON O.D

34.0mm

33.914mm

15

15-1

BRAKE SYSTEM

TROUBLESHOOTING
Brake lever / pedal soft or spongy

Brake lever / pedal hard

Air bubbles in the hydraulic system.


Leaking hydraulic system.
Contaminated brake pad / disk .
Worn caliper piston seal.
Worn master cylinder piston seal.
Worn brake pad.
Contaminated caliper.
Caliper not sliding properly.
Worn brake pad / disk.
Low fluid level.
Clogged fluid passage.
Warped / deformed brake disk.
Sticking / worn caliper piston.
Sticking / worn master cylinder piston.
Worn brake disk.
Contaminated master cylinder.
Bent brake lever / pedal.

Clogged / restricted brake system.


Sticking / worn caliper piston.
Caliper not sliding properly.
Clogged / restricted fluid passage.
Worn caliper piston seal.
Sticking / worn master cylinder piston.
Bent brake lever / pedal.

Brakes grab or pull to one side


Contaminated brake pad / disk.
Misaligned wheel.
Clogged / restricted brake hose.
Warped / deformed brake disk.
Caliper not sliding properly.
Clogged / restricted brake hose joint.

Brakes drag
Contaminated brake pad / disk.
Misaligned wheel.
Worn brake pad / disk
Warped / deformed brake disk.
Caliper not sliding properly.
Hydraulic system contaminated with dust.

15-2

BRAKE SYSTEM

BRAKE FLUID

MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER
MASTER
CYLINDER

! CAUTION

A contaminate disk or pad reduces braking


power. Do not allow the disk or pad to be
contaminated by oil.
Replace contaminated pads, and remove
pollutants from the disk completely.
Check the brake fluid level often and replenish
new fluid as required.
Do not spill fluid on painted, plastic or rubber
parts.
FR.
FR.
BRAKE
BREEDER
VALVE
FR.BRAKE
BRAKEBREEDER
BREEDERVALVE
VALVE

FR.
FR.
BRAKE
MASTER
CYLINDER
FR.BRAKE
BRAKEMASTER
MASTERCYLINDER
CYLINDER

Remover the fluid maintenance lid.


Remove the oil cup cap, diaphragm plate, and
diaphragm from the master cylinder.
Connect the bleeder hose to the bleeder valve. Loosen
the bleeder valve, and pump the brake lever repeatedly.
When there is no more fluid flowing out of the bleeder
valve. Stop pumping the brake lever.

CALIPER
CALIPER
CALIPER
BREEDER
BREEDER
VALVE
BREEDERVALVE
VALVE
FRONT
FRONT
BRAKE
LEVER
FRONTBRAKE
BRAKELEVER
LEVER

FRONT BRAKE AIR BLEEDING


<When the brake bleeder is available>

BRAKE BREEDER

Fill the reservoir with DOT 3 or 4 brake fluid up to the


upper level.
! CAUTION

To prevent chemical changed.Do not use


different type of brake fluid.
Connect the recommended brake bleeder to the bleeder
valve.
Loosen the bleeder valve while pumping the brake
lever.
Repeat this operation until the brake fluid flows out of
the brake bleeder.
Add brake fluid.
BRAKE
BRAKE
FLUID
BRAKEFLUID
FLUID

! NOTE

Check the fluid level often and replenish fluid


if the amount of fluid is reduced to the lower
level.
Read the users manual carefully prior to
disassembling or using the brake bleeder.
Protect the bleeder valve with tape to prevent
air from entering the bleeder valve.
Repeat the above procedures until no air bubbles
appear in the bleeder hose.
Squeeze the bleeder valve and operate the brake lever
to check the ingress of air.

15-3

BRAKE SYSTEM
BREEDERVALVE
VALVE
BREEDER
BREEDER
VALVE

BREEDER
BREEDER
HOSE
BREEDERHOSE
HOSE

<When the brake bleeder is not available>


Fill the brake fluid up to the upper limit line.
Connect the transparent bleeder hose to the bleeder
valve and place the other end of the hose in a container.
Squeeze the brake lever, then open the bleeder
valve 1/2 turn, and close the valve.
! NOTE

Do not release the brake lever until the bleeder valve


has been closed.

FR.
BRAKE
LEVER
FR.
FR.BRAKE
BRAKELEVER
LEVER
FR.
BRAKE
LEVER

Release the brake lever slowly and wait several


seconds after it reaches the end of its travel.
Repeat the above steps and until bubbles
cease to appear in the fluid at the end of the hose.
Check the fluid level often, and add fluid if the fluid
level is near the lower level.
If no air leaks out of the bleeder hose, operate the brake
lever to check the presence of air.
Tighten the bleeder valve.
TORQUE VALUE : 0.4~0.7 kgfm

DIAPHRAGM
PLATE
DIAPHRAGM
DIAPHRAGMPLATE
PLATE
DIAPHRAGM
PLATE

Be sure that the brake fluid is up to the upper level of


the master cylinder and refill if necessary
Reinstall the diaphragm, diaphragm plate and oil cup
cap.
TORQUE VALUE : 1.0 kgfm

REAR BRAKE BLEEDLING (INTERLOCK)


RR.
RR.
BRAKE
BREEDER
VALVE
RR.BRAKE
BRAKEBREEDER
BREEDERVALVE
VALVE
REARCALIPER
CALIPER
REAR
REAR
CALIPER

The rear brake is apply to interlocking system, when


squeezing the right side brake lever, the front and rear
brake works at once.
Fill the brake fluid up to the upper limit line.
Connect the breeder hose to the breeder valve on
the rear caliper and bleed air.

BREEDER
BREEDER HOSE
HOSE
BREEDER
HOSE

15-4

BRAKE SYSTEM
If no air leaks out of the breeder hose after operate
the brake lever, stop pumping it.

RR.
RR.BRAKE
BRAKELEVER
LEVER
RR.
BRAKE
LEVER

FR.
FR.
BREEDER
VALVE
FR.BREEDER
BREEDERVALVE
VALVE

FR.
FR.
BRAKE
HOSE
FR.BRAKE
BRAKEHOSE
HOSE

HANGER
HANGER
PIN
HANGERPIN
PIN

Connect the breeder hose to the breeder valve on


the front caliper and bleed air.
Fill the brake fluid up to the upper limit line and
install the diaphragm, plate and oil cup cap.
Install the fluid maintenance lid.

FRONT BRAKE PAD


REPLACEMENT

FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT

Loosen the hanger pin on the front caliper.


! NOTE

When replacing brake pads, replace whole set.


Do not remove the brake hose when replacing brake
pads.

BRAKE
PAD
BRAKE
BRAKEPAD
PAD

Remove the brake caliper from the front fork.


Loosen the hanger pin from the brake pad.
Install the hanger pin to the new brake pads.
Install the brake caliper to the front fork.

15-5

BRAKE SYSTEM
RR.
CALIPER
RR.
RR.CALIPER
CALIPER

LOCK
PLATE
LOCK
LOCKPLATE
PLATE

REAR BRAKE PAD


REPLACEMENT
Flatten the lock plate pawl and loosen the hanger pin.
! NOTE

When replacing brake pads, replace whole set.


Do not remove the brake hose when replacing brake
HANGER
HANGER
PIN
HANGERPIN
PIN

PAD
PAD
SPRING
PADSPRING
SPRING

RR.
RR.
BRAKE
PAD
RR.BRAKE
BRAKEPAD
PAD

FR.
FR.
CALIPER
FR.CALIPER
CALIPER

pads.
Loosen the rear brake bolt and remove the brake
caliper.
Loosen the new brake pad, lock plate, hanger pin and
replace the pads.
Install in the revers order of removal.

FRONT BRAKE CALIPER


REMOVAL
Drain the brake fluid.
Loosen the oil bolt securing the brake hose.
Loosen the 2 bolts securing the caliper.

! NOTE

Avoid spilling fluid on painted, plastic or rubber parts.

! CAUTION

Keep oil off the brake disk or pad, because the


contaminated brake disk or pads reduce the braking
performance if contaminated. Replace the pad with a
new one and clean the disk.

15-6

BRAKE SYSTEM
DISASSEMBLY
AIR
AIR
GUN
AIRGUN
GUN

Remove the pad spring, pad comp, caliper bracket,


boot from the caliper body.
Wrap the caliper with a piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
Remove the piston from the caliper while blowing the
low-pressure air in the opening of the brake hose.

PISTON
PISTON
PISTON
PISTON

! CAUTION

PISTON
SEAL
PISTON
PISTONSEAL
SEAL
PISTON
DUST
DUST
SEAL
DUSTSEAL
SEAL

Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.
Disassemble the piston seal and the dust seal.
! NOTE

Pay attention not to damage the inner sunface of the


caliper.
Clean the piston and inside of the caliper with the brake
fluid.
CALIPER
BODY
CALIPER
CALIPERBODY
BODY
CALIPER

INSPECTION
Check the caliper cylinder bore for scoring, scratches,
or other damage.
Measure the caliper cylinder I.D.
SERVICE LIMIT : CYLINDER I.D.A : 34.01mm
CYLINDER I.D.B : 25.46mm

Check the caliper piston outer diameter part for


scratches or other damage.
Measure the piston outer diameter.
SERVICE LIMIT : PISTON O.D.A : 33.848MM
PISTON I.D.B : 25.30MM

PISTON
PISTON
PISTON
PISTON

15-7

BRAKE SYSTEM
HANGER
PIN
HANGER
HANGERPIN
PIN

LHCALIPER
CALIPERBODY
BODY
LH
CALIPER
BODY
LH

RH
RH
CALIPER
BODY
RHCALIPER
CALIPERBODY
BODY
PISTON
PISTONA
A
PISTON
A

PISTON
AA
PISTON
PISTONAA
PISTON

BRAKE
BRAKE
PAD
BRAKEPAD
PAD

ASSEMBLY
Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper.
Install the piston in the caliper with the groove side of
the piston facing the pad.

PISTON
PISTON
PISTONBB
B
PAD
SPRING
PAD
PADSPRING
SPRING
PAD
SPRING
SOCKET
SOCKET
BOLT
SOCKETBOLT
BOLT

Install the RH./LH. caliper body.


Install the socket bolt.
Install pad spring to the caliper.
Install caliper hanger pin bolt to the pad comp and
caliper bracket to the caliper body.
Install the brake pad to the caliper.

INSTALLATION
FR.
FR.CALIPER
CALIPER
FR.
CALIPER

Install the brake caliper to the from fork, and front axle.
Install the caliper to the specified torgue.
TORQUE VALUE : 3.0 kgfm

Install the brake hose to the caliper body with the new
2 oil bolts washer and oil bolts.
Install the oil bolt to the specified torgue.
TORQUE VALUE : 3.4 kgfm

Fill the brake fluid, and bleed air.


RR.
RR.
BRAKE
HOSE
RR.BRAKE
BRAKEHOSE
HOSE

REAR BRAKE CALIPER


REMOVAL
Loosen the rear brake hose bolt and remove the brake
hose.
Loosen the 2 bolts and remove the rear brake caliper.

RR.
RR.
CALIPER
RR.CALIPER
CALIPER

15-8

BRAKE SYSTEM
DISASSEMBLY

AIR
AIR GUN
GUN
AIR
GUN

Remove the rear brake caliper.


Check the caliper assembly.
Remove the pad spring, slide pin, caliper bracket and
boot from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
PISTON
PISTON
PISTON

DUST
DUST
SEAL
DUSTSEAL
SEAL

Wrap the caliper with a piece cloth to avoid piston and


brake fluid leakage and facing the piston downward.
Remove the piston from the caliper, while blowing the
low-pressure air in the opening of the brake hose.
! CAUTION

Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.

Disassemble the piston seal and the dust seal.


Clean the piston and inside of the caliper with the brake
fluid.
CALIPER
CALIPER
BODY
CALIPERBODY
BODY

PISTON
PISTON
PISTON
PISTON

INSPECTION
Check the caliper cylinder bore for scoring scratches or
other damage.
Measure the caliper cylinder I.D
CYLINDER I.D.B : 25.07mm

Check the caliper piston outer diameter part for


scratches or other damage.
Measure the piston outer diameter .
SERVICE LIMIT : 24.8mm

15-9

BRAKE SYSTEM
CALIPER
CALIPER
CALIPER
CALIPER
COMP
COMP
COMP
COMP

RH.SIM(DC)
RH.SIM(DC)
RH.SIM(DC)

LOCKPLATE
PLATE
LOCK
PLATE
LOCK
HANGER
HANGER
HANGER
PIN
PIN
PIN

PISTON
PISTON
PISTON
SEAL
SEAL
SEAL
SEAL

ASSEMBLY
Clean the piston seal and dust seal with the brake fluid
and install them into the grooved side of the caliper
with the grooved side toward the pad.

PAD
PAD
PAD

CALIPER
CALIPER
CALIPER
BRACKET
BRACKET
BRACKET
DUST
DUST
SEAL
DUSTSEAL
SEAL

PISTON
PISTON
PISTON
PISTON

PAD
PAD
SPRING
PADSPRING
SPRING

Coat the cyliton grease to the boot.


Connect the boot to the piston of the caliper.

DUST
PLUG
DUST
DUSTPLUG
PLUG

INSTALLATION
Tighten the caliper hanger pin bolt, and install the
caliper bracket in the caliper.
Install the rear brake hose in the caliper.

RR.
RR. BRAKE
BRAKE HOSE
HOSE
RR.
BRAKE
HOSE

15-10

BRAKE SYSTEM

MASTER CYLINDER
MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER

REMOVAL
Drain the front rear brake fluid.
Remove the front rear stop switch.
Loosen the brake hose oil bolt.
Loosen the master cylinder holder bolt.
Remove the master cylinder.

! CAUTION

BRAKE
BRAKE
LEVER
BRAKELEVER
LEVER

PIVOT
PIVOT
BOLT
PIVOTBOLT
BOLT

Brake fluid causes damage to the painted, plastic or


rubber parts. Do not spill fluid on these parts.

If contaminated, gently wipe off the fluid with a piece


of cloth or wash in water. Close hose joints properly to
prevent leakage of brake fluid.
Clean the disassembled parts with brake fluid, and use
compressed air to verify each passage is not clogged.
Do not allow the disassembled parts to be
contaminated by waste material or dust.

MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER

DISASSEMBLY
Remove the front / rear stop switches.
Remove the piston boot, cir clip from the master
cylinder.
TOOL : SNAP RING PLIERS

Remove the washer piston spring from the master


cylinder.
Clean the master cylinder, reserve, master piston with
the recommended brake fluid.

MASTER
MASTER
CYLINDER
SET
MASTERCYLINDER
CYLINDERSET
SET
STOP
STOP
SW
STOPSW
SW
LEVER
LEVER
LEVER

BOOT
BOOT
BOOT
BOOT

CIR
CLIP
CIR
CIRCLIP
CLIP

MASTER
MASTER
CYLINDER
BODY
MASTERCYLINDER
CYLINDERBODY
BODY

15-11

BRAKE SYSTEM
INSPECTION

PISTON
PISTON
PISTON

Check the piston periphery for scores, scratches or


nicks replace if necessary.
Check the primary and secondary cups for wear.

SECONDARY
SECONDARY
CUP
SECONDARYCUP
CUP

PRIMARY
CUP
PRIMARY
PRIMARYCUP
CUP

! NOTE

If there is any leak of fluid, when installing


new piston, it may indicate the side wear of the
cylinder by the direction of the piston
contacting face. In this case, the master
cylinder must be replaced also.
Check the master cylinder for scores, scratches or nicks
and replace if necessary.

OIL CUP CAP

DIAPHRAGM
PLATE

BOOT
CIR CLIP

DIAPHRAGM

SPRING

WASHER
MASTER
CYLINDER BODY

LEVER

ASSEMBLY
! CAUTION

Replace the piston, spring, cups and snap ring


as a set.
Be sure that each part is free from dust or dirt
before reassembly.
When cleaning with the brake fluid, use the
specified brake fluid.

STOP SW

Apply the recommendatory brake fluid to the cup,


cylinder and inside of cylinder, and install the spring,
primary cup, piston.
! CAUTION

When installing the cups, do not allow to close


the cup ends.
Install the spring with its smaller direction of
coil ends toward the piston.
Install the side of primary cup toward the
spring.
Install the cir clip to the master cylinder groove firmly.
TOOL : SNAP RING PLIERS

Install the boot to the master cylinder.

15-12

BRAKE SYSTEM
INSTALLATION
Install the front rear master cylinder to the handle.
! NOTE

BRAKE
BRAKE
HOSE
OIL
BOLT
BRAKEHOSE
HOSEOIL
OILBOLT
BOLT

Install the holder with its UP mark facing


upwards, and align the holder joint with the
punch mark on the handle bar.
Tighten the holder upper bolt first.

Install the brake hose to the master cylinder with 2 new


sealing washers and the hose bolt.
TORQUE VALUE : 2.5~3.5 kgfm

Loosen the 2 flat screws, remove the oil cup cap,


diaphragm plate and diaphragm.
Fill the brake fluid, and bleed air.
Install the diaphragm, diaphragm plate and the oil cup
cap, tighten the 2 flat screws.

BRAKE DISK
INSPECTION
Measure the brake disk for the thickness.
SERVICE LIMIT : 3.0mm
TOOL : MICRO METER

RR.
RR.
BRAKE
DISK
RR.BRAKE
BRAKEDISK
DISK
FR.
BRAKE
DISK
FR.
FR.BRAKE
BRAKEDISK
DISK
FR.

Check the brake disk for wobbles.

FR.
FR.
BRAKE
DISK
FR.BRAKE
BRAKEDISK
DISK

SERVICE LIMIT : 0.02MM


TOOL : DIAL GAUGE

RR.
BRAKE
DISK
RR.
RR.BRAKE
BRAKEDISK
DISK
RR.

15-13

CHARGING SYSTEM

15A

16-0

CHARGING SYSTEM

16. CHARGING SYSTEM


SERVICE INFORMATION16-1
TROUBLESHOOTING 16-2
BATTERY 16-3

CHARGING SYSTEM INSPECTION 16-4


A.C. GENERATOR INSPECTION16-5
REGULATOR RECTIFIER INSPECTION 16-5

SERVICE INFORMATION
! WARNING

Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.
!

CAUTION

This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
When charging the battery, remove the battery from the frame and do not open stopper.
There is the possibility of damaging the regulator/rectifier, etc. if the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that the
battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss in
battery strength.
It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
For information on generator disassembly, refer to section 9.

16
SPECIFICATIONS
ITEM

BATTERY
A.C.GENERATOR
REGULATOR /
RECTIFIER

STANDARD VALUES

Capacity

12V - 10AH (MF)

Terminal-to-terminal voltage (When fully charged)

13.0 - 13.2V

Charging coil resistance value ( 20


C)

0.1 - 1.0

rpm at charging start

1,500rpm

Regulator voltage

14.5 0.5V

TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER

16-1

CHARGING SYSTEM

TROUBLESHOOTING
No power (Key turned on)

Low power (Engine running)

Dead battery.
-Low fluid level.
-Low specific gravity.
-Charging system failure.
Disconnected battery cable.
Main fuse burned out.
Faulty ignition switch.

Battery undercharged.
Battery is failing.
Charging system failure.

Low power (Key turned on)


Battery undercharged.
-Low fluid level.
-Low specific gravity.
Charging system failure.
Loose battery connection.

Intermittent power
Loose battery connection.
Loose charging system connection.
Loose starting system connection.
Loose connection or short circuit in ignition system.
Loose connection or short circuit in lighting system.

Charging system failure


Loose, broken or shorted wire or connection.
Faulty regulator rectifier.
Faulty A.C generator.

CHARGING SYSTEM
Measure battery current leakage.

INCORRECT

CORRECT

Inspect the charging voltage.


UNDER 14V

Check the voltage between the battery line and


ground wire of regulator rectifier.

Check the regulator rectifier.


CORRECT

OVER 15V
14~15V

ABNORMAL

Shorted harness wire.


Faulty ignition switch.

INCORRECT

Faulty regulator rectifier.


Battery is failing

Open circuit in wire harness.


Poorly connected coupler.

NORMAL

Check the resistance of the charging coil at


the charging coil line of regulator rectifier
coupler.

INCORRECT

Check the charging coil of theA.C


generator.
NORMAL

Poorly connected A.C generator coupler.


ABNORMAL

CORRECT

Check the regulator rectifier.

Faulty charging coil.


ABNORMAL

Faulty regulator rectifier.

NORMAL

Faulty battery.

16-2

CHARGING SYSTEM
BATTERY
COVER
BATTERY
BATTERYCOVER
COVER
BATTERY
COVER

BATTERY
REMOVAL
Loosen the screws securing the battery cover and
remove the battery cover.

SCREW
SCREW
SCREW

CABLE
CABLE
CABLE

BATTERY
BATTERY
BATTERY

CABLE
CABLE
CABLE

Remove the battery.


Disconnect the negative battery cable first, and
then disconnect the positive cable.
The installation sequence is the reverse of removal.

BATTERY (OPEN-CIRCUIT VOLTAGE) INSPECTION


Remove the battery cable.
Disconnect the battery terminals from the battery.
Measure the voltage between the battery terminals.
FULLY CHARGED : 13.0-13.2V
INSUFFICIENTLY CHARGED : UNDER 12.3V
TOOL : DIGITAL TESTER
! NOTE

Use a voltmeter that will accurately indicate 0.1V


difference.
When measuring the battery volate after driving, leave
it for at least 30 minutes, or the accurate results cannot
be obtained because the battery voltage fluctuates just
driving.
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the charger negative (-) cable to the battery
negative (-) terminal.
! NOTE

The rapid charging could be possible to reduce the


battery life and cause of damage.

Avoid the rapid charging except emergency.


Be sure to the battery charging is not allow to exceed
the specified changing time and current.

16-3

CHARGING SYSTEM

CHARGING SYSTEM INSPECTION


LEAK TEST
Trun off the ignition switch, and disconnect the ground
(-) cable from the battery.
Connect an ampere meter between negative (-) terminal
and ground cable.
With the ignition switch off, measure the leakage current.
LEAK CURRENT : Not to allow to exceed 0.5A
TOOL : DIGITAL TESTER
! NOTE

When measuring current using a tester, set it to a large


AMPERE METER

BATTERY TERMINAL

range, and then bring it down the range to an


appropriate level.
Current flow larger than the range selected may blow
out the fuse in the tester.
While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.

EARTH CABLE

CHARGING VOLTAGE INSPECTION


! NOTE

Be sure that the battery is fully charged before


performing this test.
The amount of current flow may change abruptly if not
sufficiently charged. Use a battery whose voltage
between its terminals is 13.0 13.2V
If the brobes are connected in reverse order, the
registered current flow direction when charging and
discharging the battery will be reversed as well.
After warming up the engine, replace the battery with a
fully charged battery.
Connect a tester between the battery terminals.
Connect a RPM tester to the high-tension cord.
Start the engine, gradually increase the engine speed
and measure the charging voltage and charging current.
CHARGING CURRENT : 0~0.5A / 5,000rpm
CONTROL VOLTAGE : 14.50.5V / 5,000rpm
TOOLS : RPM TESTER, DIGITAL TESTER
MAIN FUSE
TERMINAL

! NOTE

Take precaution not to control the tester or wiring


MAIN FUSE

when flowing the current.


It can cause the damage for the other parts by
overflowing the current.
Install in the reverse order of removal.

16-4

CHARGING SYSTEM

A.C GENERATOR INSPECTION


AC
AC
GENERATOR
COUPLER
ACGENERATOR
GENERATORCOUPLER
COUPLER
! NOTE

This test can be made without removing the stator


from the engine. Disconnect the wellow wire from the
auto bystarter.
Release the rear under cover.
Disconnect the A.C generator connector.

AC
GENERATOR
COUPLER
AC
ACGENERATOR
GENERATORCOUPLER
COUPLER

MAGNETIC
MAGNETIC
SW.
MAGNETICSW.
SW.

WINKER
WINKER
RELAY
WINKERRELAY
RELAY

Measure the resistance between the yellow wires.


Replace the stator if resistance value is high or there is
continuity between each yellow wire and ground.
Resistance : yellow~yellow 0.6~1.6

REGULATOR RECTIFIER
INSPECTION
Remove the center cover.
Remove the regulator rectifier coupler.
Measure each terminal.

EURO 2
IGNITION
IGNITION COIL
COIL
IGNITION
COIL

CDIUNIT
UNIT
CDI
CDI
UNIT

REGULATOR
REGULATOR
RECTIFIER
REGULATORRECTIFIER
RECTIFIER

REGULATOR
RECTIFIER
REGULATOR
REGULATORRECTIFIER
RECTIFIER
REGULATOR

R
B
Y
Y
Y
G

B
0-5

1-4

1-4

1-4
25-40k

Y
1-3

Y
1-3

EURO 3
Tester

Tester

R
G
Y
Y
Y

R
28~36

G
28~36

Y
1-3

Unit :
G
1-4
25-40k
1-4
1-4
1-4

Unit : , (20)
Y
Y

Replace the regulator rectifier unit if the resistance


value between the terminals is abnormal.

16-5

IGNITION SYSTEM

IGNITION SYSYTEM

BATTERY
(12V 10AH)

UNIT

HEADLIGHT RELAY

G/B
B/Y
G
B/Y

FUSE
(15A)

B/W
P
B

PULSE
GENERATOR

SPARK
PLUG

17-0

IGNITION
COIL

MAIN
SW

B/Y
AC.
GENERATOR

SIDE STAND
SWITCH

IGNITION SYSTEM

17. IGNITION SYSTEM


SERVICE INFORMATION 17-1
TROUBLESHOOTING 17-2
CDI UNIT 17-3
PULSE GENERATOR INSPECTION 17-3

IGNITION COIL INSPECTION 17-4


IGNITION TIMING INSPECTION 17-5
SIDE STAND IGNITION CUT-OFF
SWITCH 17-5

SERVICE INFORMATION
GENERAL SAFETY
Follow the steps described in the troubleshooting flow chart when servicing the ignition system.
The CDI unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing.
Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (SECTION 20)

SPECIFICATIONS
ITEM

STANDARD VALUE

PRIMARY COIL
IGNITION COIL
RESISTANCE VALUE 20

SPARK PLUG GAP

WITH PLUG CAP

7.3 ~ 11.0

WITHOUT PLUG CAP

3.6 ~ 4.6

SECONDARY COIL

PULSE GENERATOR COIL RESISTANCE VALUE


SPARK PLUG

0.1 ~ 0.2

90 ~150
NGK CR8EH-9
0.8~0.9mm

17

TOOLS
DIGITAL TESTER
PVA MULTI-TESTER
DC-CDI TESTER

17-1

IGNITION SYSTEM

TROUBLESHOOTING
No spark at plug.
UNUSUAL CONDITION

IGNITION COIL PRIMARY VOLTAGE


PULSE GENERATOR
EXCITE COIL

17-2

PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)

Low peak voltage.

1. The multitester impedance is too low.


2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
3. The sample timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in ignition system.
5. Faulty ignition system control circuit such as side stand switch.
6. Faulty ignition coil.
7. Faulty CDI unit (in case when above No. 1~6 are normal).

No peak voltage.

1. Incorrect peak voltage adaptor connections.


2. Faulty ignition switch.
3. Loose or poorly connected CDI unit connector.
4. Open circuit or poor connection in ground cord of the CDI unit.
5. Faulty ignition system control circuit such as side stand switch.
6. Faulty peak voltage adaptor.
7. Faulty CDI unit (in case when above No. 1~6 are normal).

Peak voltage is normal, but no spark


jumps at plug.

1. Faulty spark plug or leaking ignition coil secondary current ampere.


2. Faulty ignition coil.

Low peak voltage.

1. The multitester impedance is too low.


2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
3. The sample timing of the tester and measured pulse were not
synchronized.(System is normal if measured voltage is over the
standard voltage at least once.)

No peak voltage.

1. Faulty peak voltage adaptor.

Low peak voltage.

1. The multitester impedance is too low.


2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
3. The sample timing of the tester and measured pulse were not
synchronized.(System is normal if measured voltage is over the
standard voltage at least once.)

No peak voltage.

1. Faulty peak voltage adaptor.

IGNITION SYSTEM
CDI
CDI
UNIT
CDIUNIT
UNIT

CDI UNIT INSPECTION (EURO2)


CDI IGNITION CIRCUIT INSPECTION
! NOTE

Follow the steps described in the troubleshooting flow


chart when servicing the ignition system.
Release the seat lock with the main key.
Remove the rear under cover.
Disconnect the coupler from the CDI unit, and check the
ignition system circuits from the wiring coupler side.
Inspection Items
CDI
CDI
UNIT
CDIUNIT
UNIT

ITEM

INSPECTION

MAIN
SWITCH

Check that there is battery voltage between


main switch wire (black) and ground wire
when the ignition is ON

Check that the resistance of coil (between blue /


PULSE
yellow and green) is within the specified range.
GENERATOR
( 90~150) (20)
Check that the resistance of coil (between black
IGNITION COIL
(PRIMARY COIL) / yellow and green) is within the specified range.
( 0.1~0.2) (20)
GROUND WIRE Check continuity between ground and frame.
If there are a normality in the diagonosis above, and if
there is no spark at plug, check the CDI unit and
ignition coil by using a CDI tester.
TOOLS : CDI TESTER
DIGITAL TESTER
! NOTE

Read tester manual carefully prior to using the tester.


Replace the CDI unit if faulty.
Install in the reverse order of removal.

PULSE GENERATOR INSPECTION


RESISTANCE MEASUREMENT
PULSE
PULSE
CORD
PULSECORD
CORD

Release the seat lock with the main key.


Remove the rear under cover.
Disconnect the A.C generator 4P coupler and the blue /
yellow wire connector.
Measure the resistance between the green and blue / yellow.
STANDARD VALUE : 90~150 (20)

PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire connector.
Connect the peak voltage adaptor probes to the pulse
generator wire terminal of the wire harness side
connector and ground.
Crank the engine with the kick starter or starter motor
and measure the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V
TOOL : PVA MULTI TESTER

Install in the reverse order of removal.

17-3

IGNITION SYSTEM

IGNITION COIL INSPECTION


Remove the rear under cover.
Remove the primary wire.
! NOTE

Since the resistance value of the primary coil is


inherently very small, it is difficult to distinguish it
from a shorted wire..
IGNITION
IGNITION
COIL
IGNITIONCOIL
COIL

Measure the resistance between the two terminals of


the ignition primary coil.
If the resistance value is within the specified range the
coil is good.
If resistance is (infinite), replace the coil with a new
one.

SPARK
PLUG
CAP
SPARK
SPARKPLUG
PLUGCAP
CAP
SPARK
PLUG
CAP

STANDARD VALUE : 0.1~0.2

With the spark plug cap on, measure the resistance


between the primary coil terminal and the spark plug
cap.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.

IGNITION
COIL
IGNITION
IGNITIONCOIL
COIL
IGNITION

STANDARD VALUE : 7.3~11.0

Without the spark plug cap, measure the resistance


between the primary coil terminal and high-tension
code.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (infinite), replace the coil with
new one.
STANDARD VALUE : 3.6~4.6

IGNITION
IGNITION
COIL
IGNITIONCOIL
COIL

FAN
FAN
SCREW
FANSCREW
SCREW

IGNITION
COIL
IGNITION
IGNITION COIL
COIL

17-4

REPLACEMENT
Remove the high-tension cord from the plug, remove
the plug cap.
Remove the wire from the ignition coil.
Remove the primary wire from the ignition coil.
Loosen the ignition coil fixing bolt securing the frame,
Remove the ignition coil.
Install in the reverse order of removal.

IGNITION SYSTEM
RH
RH
SHROUD
RHSHROUD
SHROUD

IGNITION TIMING INSPECTION


! NOTE

As the system uses the CDI unit, the ignition timing


need not be adjusted, Check the ignition system if the
ignition timing is incorrect.
Warm up the engine.
! NOTE

TIMINGHOLE
HOLE
TIMING
TIMING
HOLE

Read the instruction for timing light operation.


Connect the timing light to the high-tension cord.
Start the engine and let it idle.
TIMING
TIMING
LIGHT
TIMINGLIGHT
LIGHT

IDLE SPEED : 15
BTDC 1,600rpm

The ignition timing is correct if the F mark aligns


with the index mark on the case.
Increase the engine speed by turning the throttle stop
screw and make sure the F mark begins to move
counterclockwise when the engine speed at
approximately 4,000 rpm.
Install in the reverse order of removal.

SIDE
SIDE STAND
STAND SWITCH
SWITCH
SIDE
STAND
SWITCH

SIDE STAND IGNITION CUTOFF SWITCH


INSPECTION
Remove the coupler of the side stand switch linked to
the wire.

SIDESTAND
STANDDOWN
DOWN
SIDE
SIDE
STAND
DOWN

SIDESTAND
STANDSWITCH
SWITCH
SIDE
SIDE
STAND
SWITCH

SIDE
SIDE
STAND
UP
SIDESTAND
STANDUP
UP

Check for continuity between the terminal as shown


below;

ITEM

TERMINAL

SPECIFICATION

ON
(Side stand is
lowered)

GREEN AND
BLACK/WHITE

NO
CONTINUITY

OFF
(Side stand is
retracted)

GREEN AND
BLACK/WHITE

CONTINUITY

17-5

STARTER SYSTEM

STARTER SYSTEM
STARTER
RELAY

CABLE

CABLE

G/Y
G/Y

STOP LAMP
Y/R

FRONT
STOP
SWITCH

REAR
STOP
SWITCH

STARTER
SWITCH
G

MAIN
SWITCH

FUSE

BATTERY
(12V 10AH

18-0

STARTER
MOTOR

STARTER SYSTEM

18. STARTER SYSTEM


SERVICE INFORMATION 18-1
TROUBLESHOOTING 18-2

STARTER MOTOR 18-3


STARTER MAGNETIC SWITCH 18-6

SERVICE INFORMATION
GENERAL SAFETY
! WARNING

Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.
The starter motor can be maintained without removing the engine from the vehicle.
A weak battery may be unable to turn the starter motor quickly enough, or, supply adequate ignition current.
The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over.
The engine may not be turned over if the stop switch is faulty.

SPECIFICATION
ITEM

STANDARD VALUE

SERVICE LIMIT

STARTER MOTOR BRUSH LENGTH

10.2 mm

5 mm

TOOLS
DIGITAL TESTER
VERNIER CALIPER

18

18-1

STARTER SYSTEM

TROUBLESHOOTING
Starter motor will not turn.
Check for a blown main fuse before servicing.
Check that the stop light is correctly adjusted.
Check that the side stand is positioned in the condition under which the engine can be started.

With the ignition switchONand squeeze


the brake lever, check for
a click sound
from starter magnetic switch. (17-6)

CLICKS

Connect the starter motor (+) terminal to the


battery positive terminal. (Because a large
amount of current flows, do not use thin
wires). (17-3)
Starter motor does not turn.

NO CLICK.
Starter motor turns.
Faulty starter motor.
Disconnect starter magnetic switch coupler,
and check the starter magnetic switch coil
ground wire. (17-6)

Loose or disconnected
wire or cable.
NO CONTINUITY.

CONTINUITY.
Connect the starter magnetic switch coupler.
Measure the starter magnetic voltage at the
starter magnetic switch coupler. (17-6)

NO VOLTAGE.

VOLTAGE MEASURED.
Check the starter magnetic switch operation.
(17-7)

NORMAL

ABNORMAL

Starter motor turns slowly.


Low specific gravity in battery. (or dead battery)
Poorly connected battery terminal cable.
Poorly connected starter motor cable.
Faulty starter motor.
Poorly connected battery ground cable.
Damaged or worn brush.

Starter motor and engine turns, but engine does not start.
Faulty ignition system.
Engine problems.

Starter motor turns, but engine does not turn over.


Starter motor is running backwards.
-Brushes assembled improperly.
-Case assembled improperly.
-Terminals connected improperly.
Faulty starter clutch.
Damaged starter gear.

18-2

Faulty starter switch.


Faulty side stand switch.
Loose or poor contact at connector.
Open circuit in wire harness.

Faulty ignition switch or starter switch.


Loose or poor contact at connector.
Open circuit in wire harness.
Faulty brake stop switch.
Loose or poor contact at starter magnetic
switch coupler.
Faulty starter magnetic switch.

STARTER SYSTEM

STARTER MOTOR

STARTER
MOTOR
STARTER
STARTERMOTOR
MOTOR
STARTERMOTOR
MOTORCABLE
CABLE
STARTER
STARTER
MOTOR
CABLE

REMOVAL
Remove the starter motor cable from the starter
magnetic switch.
Loosen the 2 flange bolts securing the engine case,
remove the battery earth cable and starter motor.
Install in the reverse order of removal.
! NOTE

FLANGE
FLANGE BOLT
BOLT
FLANGE
BOLT

Always turn the ignition switch OFF before servicing


STARTER
STARTER
MOTOR
STARTERMOTOR
MOTOR
SETTING
SETTING
BOLT
SETTINGBOLT
BOLT

the starter motor. The motor could suddenly start,


causing serious injury.
Accurately tighten the battery earth cable.

DISASSEMBLY
Remove the starter motor cable.
Before disassembling the starter motor mark the
position of the case and cover so the starter can be
assembled correctly later.
Loosen the starter motor case bolts and remove the
motor cover.
ASSEMBLY
ASSEMBLY
MARK
ASSEMBLYMARK
MARK

INSPECTION
RR.
BRACKET
RR.
RR.BRACKET
BRACKET
CORD
CORD
TERMINAL
CORDTERMINAL
TERMINAL

Check for continuity of the starter motor case.


-Between cord terminal and bracket: normal
if no continuity.
-Between cord terminal and brush : normal if there is
continuity.
If abnormal, replace with a new one.

BRUSH
BRUSH
BRUSH

BRUSHHODER
HODERSET
SET
BRUSH
HODER
SET
BRUSH
BRUSH
BRUSH
HODER
BRUSHHODER
HODER

BRUSH
HODER
BRUSH
BRUSH HODER
HODER

Loosen the brush terminal setting nut, remove the


brush holder set.
Check for continuity between and terminals
of the brush holder.
If there is continuity, replace with a new one.

18-3

STARTER SYSTEM
Remove the brush spring, and then remove the brush.
Measure the brush length. Replace the brush if it is
worn beyond the service limit.

BRUSH
BRUSH
BRUSH

SERVICE LIMIT : 5 mm
TOOL : VERNIER CALIPER
! NOTE

If replacement, replace with a brush holder set.

Check the commutator for :


-Damage or abnormal wear. Replace with a new
one.
-Discoloration of the commutator bar. Replace with
a new one.
-Metallic debris between commutator bars. Clean it
off.

COMMUTATOR
COMMUTATOR
COMMUTATOR
COMMUTATOR

Check for continuity between pairs of commutator


bars.
Make a continuity check between individual
commutator bars and the armature shaft.
There should be no continuity.

OIL
SEAL
OIL
OILSEAL
SEAL
OIL

NEEDLE
NEEDLE BEARING
BEARING
NEEDLE
BEARING

18-4

Check the needle bearing and oil seal.


-Do not rotate smoothly. Replace with a new one.
-Damage oil seal. Replace with a new one.

STARTER SYSTEM
STARTER MOTOR ASSEMBLY
BRUSH
HOLDER
SET
BRUSH
BRUSH HOLDER
HOLDER SET
SET

Install the brush and brush spring to the brush hold set.
Insert the brush terminal into the rear bracket, and
install the terminal set and flange nut.
Align the brush holder set with the rear bracket
groove, and install the brush holder set.
Apply grease to both ends of the armature shaft, and
install the 2 washers.
Push and hold the brush inside the rear bracket, and
insert the armature into the rear bracket groove.

RR.
RR.
BRACKET
RR.BRACKET
BRACKET

Align the yoke with the rear bracket mark, and install
the yoke to the amature.

! CAUTION

The sliding surfaces of the brushes can be damaged if

RR.
RR.
BRACKET
RR.BRACKET
BRACKET

they are not installed properly.


When inserting the armature into the case, hold the
armature tightly to keep the magnet from pulling the
armature against the case.

Align the front bracket with the yoke mark, and install
the front bracket.
Tighten the 2 set bolts.

MARK
MARK
MARK
MARK
FR.
FR.
BRACKET
FR.BRACKET
BRACKET

YOKE
YOKE
YOKE

RR.
RR.
BRACKET
RR.BRACKET
BRACKET

! CAUTION

When installing the cover, take care to prevent


damaging the oil seal lip with the shaft.
Overtightening the starter motor cable terminal nuts
may cause the inside the starter motor, resulting in
serious damage to the inner connectors.
SETTING
BOLT
SETTING
SETTING BOLT
BOLT
SETTING

18-5

STARTER SYSTEM
STARTER
STARTER
MAGNETIC
SWITCH
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH

STARTER MAGNETIC SWITCH


REMOVAL
Remove the center cover and battery cover.
Remove the battery (+) cable from the starter magnetic
switch terminal.
Remove the starter motor cable from the starter
magnetic switch terminal.
Disconnect the yellow / red connector and green /
yellow connector from the wire harness.
Remove the starter magnetic switch from the switch
setting bracket securing the frame.
Install in the reverse order of removal.

STARTER
STARTER
MAGNETIC
SWITCH
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH

INSPECTION
Check if the starter magnetic switch clicks when it is
turned ON.
-Clicks Poorly connected battery terminal and
motor terminal of the switch. (Check
the starter magnetic switch)
-No clicks No starter magnetic switch input
voltage. (Faulty relay ground line and
starter magnetic switch)

STARTER
MAGNETIC
SWITCH
STARTER
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH
STARTER
MAGNETIC
SWITCH

Starter magnetic switch voltage


Measure the voltage between the yellow / red wire (+)
and ground at the starter magnetic switch connector.
If battery voltage appears only when the starter switch
is pressed, it is normal.

Starter magnetic switch ground line


Disconnect the wire connector from the starter
magnetic switch and check for continuity between the
ground wire (green / yellow) and ground.

18-6

STARTER SYSTEM
OPERATION CHECK
Disconnect the magnetic switch wire connector.
Apply battery voltage between terminals, when the
yellow / red wire is connected to the positive (+)
battery terminal and the green / yellow wire to the
negative (-) battery terminal.
If there is continuity between battery and motor
terminal, it is normal.
Install in the reverse order of removal.

18-7

MEMO

LIGHTS/SWITCHES/HORN

19. LIGHTS/SWITCHES/HORN
SERVICE INFORMATION 19-1
TROUBLESHOOTING19-1
HEADLIGHT 19-2
FRONT WINKER 19-2
REAR TAIL LIGHT 19-3
REAR WINKER 19-3

SPEEDOMETER 19-3
MAIN SWITCH 19-4
HANDLE BAR SWITCH 19-4
HORN SWITCH 19-5
FRONT/REAR STOP SWITCH 19-5
FUEL GAUGE19-6

SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.

TROUBLESHOOTING
Light not turned on when the main switch is ON

Fuel meter indicator malfunctioning

Faulty light bulb


Faulty switch
Faulty or disconnected wiring
Fuse cut
Battery discharged

Coupler separated.
Harness disconnected.
Float operation malfuction.
Fuel unit damaged.

Dim headlight

Coupler loose.
Fuel unit damaged.
Meter damaged.

Battery discharged
Wiring and switch resistance high

Fuel meter needle unstable

Headlight Hi-Low bean cannot be charged

19

Faulty light bulb


Faulty dimmer switch

19-1

LIGHTS/SWITCHES/HORN

HEADLIGHT BULB
REMOVAL
Loosen the washer screw securing the headlight.
Disconnect the headlight wiring.
Install in the reverse order of removal.

HEAD
HEAD
LIGHT
HEADLIGHT
LIGHT

BULB REPLACEMENT
WASHER
WASHER
SCREW
WASHERSCREW
SCREW

Pull off the headlight socket.


Replace with a new bulb.
Install in the reverse order of removal.
HEAD
HEAD
LIGHT
SOCKET
HEADLIGHT
LIGHTSOCKET
SOCKET

! NOTE

When replacing the bulb, be sure not to put


finger and contaminated gloves prints on the
headlight bulb, as they may create hot spots on
the bulb and cause is to fail.
Note the following when replacing the bulb.
- Do not replace while the headlight is ON.
after it is turned OFF, be sure to let it cool
down before servicing.
- Wear clean gloves while replacing the bulb.
Do not put finger prints on the headlight bulb.
- If you touch the bulb with your bare hands,
clean it with a cloth moistened with alcohol
and clean it with a clean cloth again.
- Be sure to install the rubber cover after
replacing the bulb.

HEAD
LIGHT
BULB
HEAD
HEADLIGHT
LIGHTBULB
BULB
HEAD

FRONT WINKER
BULBS REPLACEMENT
Press the lock on the side of the winker base.
Remove the winker lens.
Remove the bulb from the socket and replace with a
new bulb.
! NOTE

WINKER
BULB
WINKER
WINKERBULB
BULB
WINKER
FRONT
FRONT
WINKER
FRONTWINKER
WINKER

Pay attention not to damage the lens.


Do not apply excessive force when removing
the lens.
Install in the reverse order of removal.

19-2

LIGHTS/SWITCHES/HORN

REAR TAIL LIGHT

REAR
WINKER
REAR
REARWINKER
WINKER

ASSEMBLY REPLACEMENT
Remove the rear upper cover.
Loosen the 2 screws securing the rear tail light.
Remove the coupler link to the tail light.
The tail light is LED light so, replace it with assembly
parts.
Install in the reverse order of removal.
! NOTE

TAIL
TAIL
STOP
BULB
TAIL&&&STOP
STOPBULB
BULB

REAR
REAR WINKER
WINKER
REAR
WINKER

Pay attention not to damage the lens.


Do not apply excessive force when removing
the lens.
Check the installation of the tail light and lens
seal accurately.

REAR WINKER
BULB REPLACEMENT
Press the lock on the side of the winker base and
remove the rear winker cover.
Remove the winker lens.
Remove the bulb from the socket and replace with a
new bulb.
Install in the reverse order of removal.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER

SPEEDOMETER
REMOVAL
Remove the inner box.
Remove the headlight.
Remove the wiring coupler and speedometer cable.
Loosen the flange bolt securing the pilot box on the
inner box and remove the speedometer set.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
PILOT
PILOT
BOX
PILOTBOX
BOX

Loosen the bolt securing the pilot box from the


speedometer set and remove the speedometer assembly.
Install in the reverse order of removal.

19-3

LIGHTS/SWITCHES/HORN
MAINSWITCH
SWITCH
MAIN
MAIN
SWITCH

MAIN SWITCH
REMOVAL
Remove the front cover.
Disconnect the ignition switch wire couplers.

MAIN
MAIN
SWITCH
TERMINAL
MAINSWITCH
SWITCHTERMINAL
TERMINAL

Check for continuity between the wire terminal.


RED

BLACK

OFF
ON

PASSINGSWITCH
SWITCH
PASSING
SWITCH
PASSING

HANDLE BAR SWITCH


Disconnect the connector of handle switch.
Check for continuity between terminals.

PASSING SWITCH
BAT2

HI

RED

BLACK

HI
COLOR
DIMMER
DIMMER
SWITCH
DIMMERSWITCH
SWITCH

WINKER
WINKER SWITCH
SWITCH
WINKER
SWITCH

WINKER SWITCH
W

GRAY

SKY BLUE

ORANGE

BAT4

HI

LO

BROWN/WHITE

BLUE

WHITE

R
N
L
COLOR

DIMMER SWITCH
HI
HORN
HORN SWITCH
SWITCH
HORN
SWITCH

(N)
LO
COLOR

19-4

LIGHTS/SWITCHES/HORN
HEADLIGHT SWITCH
HEADLIGHT
HEADLIGHT
SWITCH
HEADLIGHTSWITCH
SWITCH

BAT2

TL

HL

Br/L

Br

OFF
P
H
COLOR

STARTER SWITCH
STARTER
STARTER
SWITCH
STARTERSWITCH
SWITCH

ST

YELLOW / RED

GREEN

FREE
PUSH
COLOR

HORN
Remove the wire connector from the horn.
Connect the horn terminal with 12V battery.
Normal if it sounds.

HORN SWITCH
HO

BAT2

LIGHT GREEN

BLACK

FREE
PUSH

HORN
HORN
HORN

COLOR
FRONT
STOP
SWITCH
FRONT
FRONT STOP
STOP SWITCH
SWITCH

FRONT / REAR STOP SWITCH


INSPECTION
Remove the front handle cover.
Check for continuity between the black and green /
yellow wire terminals inside the speedometer assembly.
-When the brake lever is pulled - CONTINUITY.
-When the brake lever is released - NO CONTINUITY.

REAR
STOP
SWITCH
REAR
REARSTOP
STOPSWITCH
SWITCH
REAR

19-5

LIGHTS/SWITCHES/HORN
FUEL
FUEL
TANK
FUELTANK
TANK

FUEL GAUGE
Remove the floor panel.
Remove the unit set cap, and remove the fuel gauge.

UNIT
UNIT
SET
CAP
UNITSET
SETCAP
CAP

Take precaution not to damage the wire.


Check the base packing for damage.

FUEL
GAUGE
FUEL
FUELGAUGE
GAUGE
FUEL

BASE
BASE
PACKING
BASEPACKING
PACKING

Inspect the fuel gauge.

FUEL GAUGE
FUEL

THERMISTER

ETC

OFF
1.2 L

FUEL CHECK
COLOR

19-6

YELLOW/WHITE

GREEN

MEMO

MEMO

WIRING DIAGRAM

20-1. WIRING DIAGRAM (EURO-2)

WIRING DIAGRAM

20-2. WIRING DIAGRAM (EURO-3)

SERVICE MANUAL
2009. 02 PRINTED
2009. 02 PUBLICATION

COPY PROHIBIT

SM57-0902-01E