NEX 115 Manual de Serviços (Ingles) UH110S PDF

NEX115
NEX115
HAOJUE HOLDING CO.,LTD.
Add:No.5 Jiangdabei Road, Jiangmen City, Guangdong Province, P.R China
Tel :(0750) 3288999 Fax:(0750) 3288333 Postcode:529000
S E R V I C E
M A N U A L
99500H5716UH000
Prepared by Haojue Holding
June, 2019
Printed in China
维修说明书
维修说明书
FOREWORD GROUP INDEX
This manual contains an introductory description on the
NEX115 and procedures for its inspection service and
overhaul of its main components. Other information
considered as generally known is not included.
Read the GENERAL INFORMATION section to familia-
GENERAL INFORMATION 1
rize yourself with the motorcycle and its maintenance.
Use this section as well as other sections to use as a
guide for proper inspection and service.
This manual will help you know the motorcycle better so
that you can assure your customers of fast and reliable
PERIODIC MAINTENANCE 2
service.
8
This manual has been prepared on the basis of the
latest specifications at the time of publication. If
modifications have been made since then, differ-
ENGINE
3
ences may exist between the content of this manual
and the actual motorcycle.
Illustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual motorcycle
FI SYSTEM DIAGNOSIS 4
exactly in detail.
This manual is written for persons who have enough
knowledge, skills and tools, including special tools,
FUEL SYSTEM AND
for servicing Haojue motorcycles. If you do not have
the proper knowledge and tools, ask your
authorized Haojue motorcycle dealer to help you.
THROTTLE BODY 5
WARNING
Improper repair may result in injury to the

CHASSIS 6
mechanic and may render the motorcycle unsafe
for the rider and passenger.
CAUTION
ELECTRICAL SYSTEM 7
Inexperienced mechanics or mechanics without
proper tools, not to able to properly perform the
services described in this manual. SERVICING INFORMATION 8
HAOJUE HOLDING.,LTD
JUNE, 2019
9
(The 1st Edition)
HAOJUE HOLDING., LTD . 2019 WIRING DIAGRAM
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1.The text of this manual is divided into sections.
2.The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown as at the right will allow you to
find the first page of the section easily.
4.The contents are listed on the first page of each section
to help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instruction and tightening torque,
lubricating points and locking points, are provided.
EX: Front wheel

1 Front axle
2 Speedometer gearbox
3 Seal ring
4 Bearing
5 Spacer
6 Front tire
7 Front wheel rim
8 Oil seal
9 Front brake disc
10 Collar
A Front axle nut
B Brake disc bolt
ITEM N•m Kgf•m
A 40-48 4.0-4.8
B 18-28 1.8-2.8
SYMBOL
The following symbols are instructions and necessary information for maintenance.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply THREAD LOCK “1360"
Data beside it indicates specified
99000-32130
torque.
Apply oil. Use engine oil unless

OIL
otherwise specified. Apply or use the absorber oil
Apply SUPER GREASE “A”

Apply or use the brake fluid
99000-25010
Apply MOLY PASTE

Measure in voltage
99000-25140
Apply sealant “1215”

Measure in resistance
99000-31110
Apply sealant “1207B”

Measure in continuity test range
99000-31140

99000-32050 Use special tool

99000-32030 The data of maintenance
WIRE COLOR
B ............. Black Gr ............. Grown R ............. Red
Bl ............. Blue Lbl............. Light blue V ............. Violet
Br ............. Brown Lg ............. Light green W ............. White
Dg ............. Deep green O ............. Orange Y ............. Yellow
G ............. Green P ............. Pink
B/Bl ............. Black with Blue tracer O/Bl ............. Orange with Blue tracer
B/Br ............. Black with Brown tracer O/W ............. Orange with White tracer
B/G ............. Black with Green tracer O/Y ............. Orange with Yellow tracer
B/R ............. Black with Red tracer R/B ............. Red with Black tracer
B/W ............. Black with White tracer R/Y ............. Red with Yellow tracer
B/Y ............. Black with Yellow tracer W/B ............. White with Black tracer
Bl/W ............. Blue with White tracer W/R ............. White with Red tracer
Bl/Y ............. Black with Yellow tracer Y/G ............. Yellow with Green tracer
Br/Y ............. Brown with Yellow tracer Y/R ............. Yellow with Red tracer
G/Y ............. Green with Yellow tracer Y/W ............. Yellow with White tracer
O/B ............. Orange with Black tracer
GENERAL INFORMATION
1
1
CONTENTS
WARNING/CAUTION/NOTE 1-1
GENERAL PRECAUTIONS 1-1
SERIAL NUMBER LOCATION 1-2
FUEL AND OIL RECOMMENDATION 1-2
BREAK-IN PROCEDURE 1-2
SPECIFICATIONS 1-4
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the
symbol and the words WARNING,CAUTION and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and the cautions contained in this manual cannot possibly cover
all potential hazards relating to the servicing, or lack of servicing of the motorcycle. In addition to the
WARNING and CAUTION stated, you must use good judgment and basic mechanical safety principles. If
you are unsure about how to perform a particular service operation, ask a more experienced technician for
advice.
GENERAL PRECAUTION
WARNING
Proper service and repair procedures are important for the safety of the service technician and the
safety and reliability of the motorcycle.
When 2 or more persons work together, pay attention to safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor.
When working with the toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer's instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust
system during or for a while after engine operation.
After servicing fuel, oil, exhaust or brake system, check all lines and
fittings related to the system for leakage.
1-1
GENERAL INFORMATION
If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they
may be reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean. Lubricate them when specified.Use the
specified lubricant, bonds or sealant.
When removing the battery, disconnect the negative cable first and then the positive cable. When
reconnecting the battery, connect the positive cable first and then the negative cable, and replace
the terminal cover on the positive terminal.
When performing service to electrical parts, if the service procedures not require use of battery
power, disconnect the negative battery cable.
When tightening the cylinder head, case bolts and nuts, tighten the larger sizes first. Always tighten
the bolts and nuts from the inside working out, in a crisscross manner.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts,
cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones.
Also, before installing these new parts, be sure to remove any left over material from the mating
surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread
is smeared with them.
After reassembling, check parts for tightness and proper operation.
NOTE:
To protect the environment, do not unlawfully dispose of used motor oil and all other fluids: batteries
and tires.
To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.
1-2
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the frame. The engine serial
number is located on the left side of the crankcase. These numbers are required especially for registering the
motorcycle and ordering spare parts.
FUEL AND OIL RECOMMENDATIONS

FUEL
Use unleaded gasoline of grade 89 octane (Research Method) or higher. Ethanol gasoline E10.
Use non-unleaded gasoline and low quality engine oil will shorten the spark plug and muffler
accelerant life. Dirty gasoline will clog the fuel hose. Do not overfill the gasoline.
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer service
life of your motorcycle. Use only oils which are rated SJ or SL the Engine oil
API service classification.
The recommended viscosity is SAE 10W-40. In winter of northen
cold area 5W-30 should be used, If an SAE 10W-40 or 5W-30
motor oil is not available, select an alternative according to the
right chart.
If driving under high-speed or high load condition frequently,
Haojue synthetic engine oil is recommend.
BREAK-IN PROCEDURE
The correct ”BREAK-IN” extends the engine life and maximums the engine performance. The general
rules are as follows:
The throttle must not be opened to the full during the new motorcycle's break-in period. Throttle opening
should be limited to less than 3/4 of its maximum, while violent acceleration should be avoided.
Do not maintain constant engine gear and speed for an extended time period during any portion of the
break-in. Try to vary the throttle position. During the period of break-in, increase the throttle opening
properly to enable break-in fully.
When engine is running at constant low speed (low load), parts will wear rapidly leads to bad brake-in.
1-3
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 1910 mm
Overall width 710 mm
Overall height 1100mm
Wheelbase 1230 mm
Ground clearance 141 mm
Curb weight 102 kg
ENGINE
Type Single cylinder, vertical, air-cooled, four stroke
Number of cylinders 1
Bore 51 mm
Stroke 55.6 mm
Piston displacement 1 14 ml
Compression ratio 9.0: 1
Fuel supply Fuel injection
Air cleaner Oiled paper filter
Starter system Electric starter
Lubrication system Wet sump
TRANSMISSION
Clutch Wet multi-plate type
Transmission 5-speed constant mesh
Primary reduction ratio 4.059
Final reduction ratio 2.571
Gear ratios, Low 2.615
2nd 1.941
3rd 1.556
4th 1.136
Top 0.917
Drive chain KMC 420SB 102 links
1-4
GENERAL INFORMATION
ELECTRIC
Ignition type Electronic ignition (CDI)
Spark plug CPR6EA
Battery 12V 5Ah
Fuse 10 A/15A/20A
Headlamp 12V 35W/35W
Tail light / brake light 12V 5W/21W
Turn signal light 12V 10W
Position light 12V 5W
License light 12V 5W
CHASSIS
Front suspension Telescopic, coil spring, oil damped
Rear suspension Swing arm type, oil dampened, 5-way adjustable
Steering angle 42°
Caster 26.5°
Trail 70 mm
Turning diameter 4000 mm
Front brake Disc brake/Brake lever
Rear brake Disc brake/Brake pedal/CBS
Front tire size 7 0/90-17 38P
Rear tire size 80/90-17 50P
Front absorber stroke 90 mm
CAPACITIES
Fuel tank 4.1 L
Engine oil, oil change 800 ml
Overhaul 1 000 ml
Front absorber oil (single) 61 ml
These specifications are subject to change without notice.
1-5
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE 2-1
MAINTENANCE PROCEDURES 2-3 2
BATTERY/FUSE 2-3
AIR FILTER 2-4
EXHAUST PIPE BOLTS AND MUFFLER BOLTS 2-5
CYLINDER HEAD NUTS 2-5
VALVE CLEARANCE 2-5
SPARK PLUG 2-6
ENGINE OIL 2-7
OIL SUMP FILTER 2-8
ENGINE OIL CENTRIFUGAL FILTER 2-8
CLUTCH CABLE PLAY 2-8
THROTTLE BODY 2-8
IDLE 2-9
THROTTLE CABLE 2-9
EVAPORATIVE EMISSION CONTROL SYSTEM 2-9
FUEL HOSE 2-10
FUEL PUMP FILTER 2-10
DRIVE CHAIN 2-10
BRAKES 2-13
TIRES 2-16
STEERING 2-17
FRONT AND REAR SHOCK ABSORBERS 2-17
LIGHTING AND SIGNAL 2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-18
COMPRESSION PRESSURE INSPECTION 2-20
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

Interval Km Initial 1 000 Every 3 000 Every 6 000
Page
Item Month 3 6 12
Battery / Fuse Inspect Inspect 2-3
Air filter Inspect Replace 2-4
Muffler bolts Inspect Inspect 2-5
Cylinder head nut Inspect Inspect 2-5
Valve clearance(when cold) Inspect Inspect 2-5
Inspect Inspect
Spark plug 2-6
Replace every 10 000 km
Engine oil Replace Replace 2-7
Oil sump filter Clean every 18 months or 12 000 km 2-8
Engine oil centrifugal filter Clean every 18 months or 12 000 km 2-8
Clutch cable Adjust every 12 000 km 2-8
Throttle body Inspect Inspect 2-8
Idle speed Inspect Inspect 2-8
Throttle cable Inspect Inspect 2-9
Evaporative emission
Inspect 2-9
control system
Inspect Inspect
Fuel hose 2-9
Replace every 10 years
Inspect 2-9
Fuel pump filter
Replace every 50 000 km 2-10
Drive chain Inspect, clean & lubricate for every 1,000 km 2-10
Brakes Inspect Inspect
Inspect Inspect
Brakes Brake hose 2-12
Replace every 4 years
Brake fluid Inspect every 3 000 km, replace every 2 years
Tire Inspect Inspect 2-14
Steering Inspect Inspect 2-14
Front and rear shock absorbers Inspect 2-15
Lights and signals Inspect Inspect 2-15
Chassis bolts and nuts Inspect Inspect 2-16
2-1
LUBRICATION CHART
Interval Km Every 6 000km Every 12 000km

Item Month 6 12
Throttle cable Engine oil
Throttle grip Grease
Clutch cable Engine oil
Speedometer cable Grease
Speedometer gear box Grease
Drive chain Engine oil, every 1 000 km
Break lever pivot Engine oil
Break pedal pivot Grease or engine oil
Steering stem bearings
Grease every 2 years or 20 000 km.
Swing arm bearings
WARNING
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the
linings, break slippage will result.
CAUTION
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean
off any rusty spots and wipe off any grease, oil dirt or grime.
2-2
MAINTENANCE AND TUNE-UP

PROCEDURES
This section describes the servicing procedures for each item
of the Periodic Maintenance requirements.
BATTERY/FUSE
Inspect initial 1 000 km and every 3 000 km
BATTERY
● Inspect the electrolyte's level and specific gravity, the
battery must be removed.
● Remove the right side cover and battery holder .
● Dismount the negative pole of the battery .
● Dismount the positive pole of the battery .
Take off the battery from the battery holder.
Inspect the electrolyte level. If necessary, repour some
distilled water to make the electrolyte level higher than the
“LOWER LEVEL” and lower than the “UPPER LEVEL”
. Use a hydrometer to inspect the electrolyte's specific
gravity to see the charging situation of the battery. If the
data is below 1.28 (20oC), it means that the battery should
be charged now. During charge, the battery should be
dismounted and charged with a charger. If not, the rectifier
may be damaged.
Standard specific gravity: 1.28± 0.01 20 oC
09900-28403: Hydrometer
● Install the battery in the reverse order of the disassembly.

CAUTION
When installing the battery lead wires, fix the lead wire
first and lead wire last.
FUSE
The fuse box is located on the battery holder. If engine is shut
down suddenly during the driving or circuit is open, please
check the fuse.
WARNING
Do not use a fuse of a different specification , or it will incur
negative effect to electric, fire and power loss of engine
which is very dangerous.
CAUTION
Do not use aluminum, iron wire or any other substitute for
the fuse. If the fuse blows frequently, it indicates the
electric system may has problem. Always investigate the
cause, correct it and then replace the fuse.
2-3
AIR CLEANER
Replace every 6 000 km, inspect every 3 000km
If the air cleaner is clogged with dust, intake resistance will be

increased with a resultant decrease in power output and an
increase in fuel consumption.
Clean the air filter element in the following manner.
Open the air filter cover fastener .
Remove the air filter cover screws, take off the air filter
cover
Take out the air filter and check for the dirt or damage,
replace it as necessary.
Clean the air filter case and cover.
Reinstall the air cleaner in the reverse order of removal.

Make sure the air filter is fitted and sealed property at.
specified position.
CAUTION
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to operate the engine without the element
or to use a torn element. Make sure that the air cleaner is
in good condition at all times. The life of the engine
depends largely on this component.
Clean the drain plug of air filter water and dirt from air filter
drain hose every time at maintenance for air filter.
2-4
EXHAUST PIPE BOLTS AND MUFFLER BOLTS

Inspect initial 1 000km and every 3 000km
Tighten the exhaust pipe bolt to the specified torque.
Exhaust pipe mounting bolt : 11-15 N•m
● Tighten the muffler mounting bolt to the specified torque.
Muffler mounting bolt : 35-45 N•m
CYLINDER HEAD NUTS
Tighten the cylinder head cover cap nut to the specified

torque when engine is cool.
Cylinder head nut: 17-20 N•m
VALVE CLEARANCE

Excessive valve clearance results in valve noise and
insufficient valve clearance results in valve damage and
reduced power. At the distances indicated above, check and
adjust the clearance to the following specification. The
procedure for adjusting the valve clearance is as follows:
Remove the cylinder head cover and spark plug .
Remove the valve timing inspection plug and generator

cover cap .
2-5
Rotate the generator rotor counter clockwise until the “III”

line on the rotor is aligned with center (mark line) of hole on
the crankcase to set the piston at the top dead center of the
compression stroke.
Insert the thickness gauge between the valve stem end and
adjuster screw of rocker arm.
09900-20803: thickness gauge
Valve clearance specifiecations

Valve clearance(When cold)
Standard: IN: 0.08-0.12mm
EX: 0.08-0.12mm
If the valve clearances is out of specification, bring it into

the specified range by using the special tool.
11F14-019: Valve adjust wrench
Reinstall the generator cover cap,
CAUTION
Valve clearance is to be checked when the engine is

cold. Both the intake and exhaust valves must be
checked and adjusted when the piston is at Top-Dead-
Center(TDC) of the compression stroke.
SPARK PLUG
Inspect Initial 1 000 km and every 3 000 km.
Replace it every 10 000 km.
Remove the spark plug cap .
Remove the spark plug with spark plug sleeve .
2-6
Remove the carbon deposits with a wire of pin and adjust

the spark plug gap to 0.8-0.9 mm, measuring with a
thickness gauge.
When removing carbon deposits, be sure to observe the
appearance of the plug, noting the color of the carbon
deposits. The color observed indicates whether the standard
plug is suitable or not. if the standard plug is apt to get wet, a
hotter plug should be used. If the standard plug is apt to
overheat (porcelain is whitish in appearance), replace with a
cooler one.
Spark plug gap: 0.8-0.9 mm

09900-20803: thickness gauge
TYPE NGK
Hot type C PR5EA-9
Standard C PR6EA-9
0.8～0.9 mm
Cold type C PR7EA-9
ENGINE OIL
Change initial 1 000 km and every 3 000 km
The oil should be changed when the engine is warm. The

procedure is as follows:.
● Support the motorcycle by the main stand.
● Drain the oil by removing the drain plug and oil filler
cap/gauge .
● Tighten the drain plug and pour new oil through the oil
filler. The engine will hold about 750 ml of oil (1200ml for
overhaul). Use of SF or SG in API with an oil viscosity of
SAW 10W-40.
Required amount of engine oil:
Oil change: 750 ml
Overhaul: 900 ml
CAUTION
Do not remove the cam chain tensioner plug during
the removal of oil drain plug .
● Start up the engine and allow it to run for several
seconds at idling speed.
● Shut down the engine and wait about 1 minutes. Remove
the oil filler cap/oil level gauge, wipe the tip of the oil level
gauge with clean cloth.
Keep the motorcycle on level ground and hold it vertically.
Close the oil filler cap/oil level gauge of the oil filler without
tightening the cap.
● Remove the oil filler cap/oil level gauge and inspect the oil
level. The oil level should be between the lower line and Upper limit lower limit
upper line of the oil level gauge. If the oil level is below
lower line, fill with oil to the upper line. If oil level exceeds
upper line, drain some oil until below upper line.
2-7
OIL SUMP FILTER

Clean every 18 months and every 12 000 km
Inspect the oil sump filter after removing the right crankcase
cover. Replace the filter as necessary.
CAUTION
Whether or not to replace oil sump filter should be
judged by qualified mechanic.
ENGINE OIL CENTRIFUGAL FILTER

Clean every 18 months or 12 000 km
● Remove the clutch cover and the engine oil centrifugal

filter cover. (Refer to page 3-19)
● Clean the engine oil centrifugal filter rotor and cover with a
clean cloth.
● Reinstall the engine oil centrifugal filter cover after
cleaning.
CLUTCH CABLE PLAY

Inspect and adjust every 12 000 km.
Loosen the clutch lock nut .

Turn clutch adjuster screw a circle clockwise,
then anti-clockwise turn the screw until a slight resistance
is felt, start from here, turn clockwise the screw 1/18-
1/12, (20°-30°), tighten the lock nut .
Start the engine after adjustment, check the clutch
performance and smooth gear shifting.
THROTTLE BODY
Clean every 6 000 km.
The throttle position screw is set precisely at factory. Do

not make adjustment to it. Check the idle speed of
motorcycle, if the idle speed is not stable, clean as
necessary. (Refer to page 5-8)
2-8
IDLE
Warm up the motorcycle engine, then remove the adjuster
screw cap , turn the adjuster screw by using a cross
driver to adjust the idel speed.
WARNING
Do not turn the adjust idle air screw over 90° .After
adjustment to idle air screw, wait 10s, confirm if the idle
speed meets the requirement. Do not adjust throttle
adjuster screw at any time.
THROTTLE CABLE PLAY

Throttle cable play adjuster is below the throttle grip. To adjust
the throttle cable play:
● Loosen the lock nut , turn the adjuster so that the throttle
cable play has 0.5 -1.0 mm play.
● Tighten the lock nut after adjustment..
WARNING 0.5-1.0mm
After adjustment is completed, checked that handlebar

movement does not raise engine idle speed and that the
throttle grip returns smoothly and automatically.
EVAPORATION EMISSION CONTROL SYSTEM

Inspect every 3 000 km
This motorcycle is equipped with fuel evaporation prevent

system. Inspect the following items periodically.
Inspect the connection of each hose.

Inspect each hose and EVAP canister bodies for
damage, if any defects are found, replace the hose and
EVAP canister with a new one.
Check each hose, EVAP canister to see whether they are
clogged, clean or replace the clogged part as necessary.
WARNING
If fuel evaporation emission control system is required

to be inspected and servicing, we strongly recommend
you do this job in a qualified service shop.
2-9
FUEL HOSE
Inspect initial 1 000 km and every 3 000 km, replace
every 10 years.
Check the fuel hose for damage or leakage. If it is worn or

damaged, replace the fuel hose with a new one.
FUEL PUMP FILTER

Inspect every 6 000 km and replace every 50 000 km.
Fuel pump filter inspection and replacement.

(Refer to page 5-4)
DRIVE CHAIN
Clean & lubricate for every 1 000 km
Drive Chain Adjustment

WARNING
Do not check and inspect drive chain when the engine is
running,
Stop the engine, support the motorcycle with main stand,

set the gear to neutral position.
Remove the inspection hole cap on the chain case.
● Check the chain sag through the inspection hole.
Chain sag: 10-20 mm
WARNING
Too much chain slack can cause the chain to come off the 10-20mm
sprockets, resulting in an accident or serious damage to the
motorcycle. Inspect and adjust the drive chain slack before
each use.
2-10
CHAIN SAG ADJUSTMENT

Loosen the rear axle nut
Loosen the lock nut and adjuster nut .
Loosen or tighten the adjuster nut to obtain the correct

chain sag.
Confirm the scale on the both adjusters is at same
position.
Tighten the rear axle nut to specified torque.

Tighten the two lock nuts .
Check the chain sag and if the rear wheel rotates freely .
Inspect the rear brake pedal free travel.(Refeer to page 2-1),
adjust as necessary.
Rear axle nut: 48-58 N•m
Cleaning, Inspection and Lubrication Bolt
Remove the bolt and lower chain case. Upper case
Lower case
If the drive chain is too dirty, remove the drivan chain, clean
it with clean solvent before lubrication.
Remove the chain clip with pliers carefully, remove the
union plate and chain.
Use non-flamable solvent to clean drive chain and wipe dry.
Wipe out the excessive gear oil.
Apply gear oil 80-90# to chain after chain is dry
2-11
Check the drive chain for damage or worn

If the chain links damage,pins loose or unrepairable, replace 123 20 21 22
the drive chain.
Count out 21 pins on the chain and measure the distance
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
0 1 2 3 4 5 6 7 8
Drive chain 20 pitch length:

Service limit: 259.0 mm
09900-20103 : Vernier caliper
SPROCKET INSPECTION
Install the new drive chain ot the old sprocket will
accelerate the worn of drain chain.
Check sprocket teeth for worn or damage. Replace it as
necessary. Do not install new drive chain on the worn
sprocket.
Inspect if the engine sprocket and rear sprocket mounting Good Worn
nuts are loose, tighten the nut if found.
Install the chain clip, the clip opening should face oppostive to Travel
direction
Union
plate
the moving direction. Chain clip
Install the drive chian on the sprocket, union plate and chain
plate.
Install the chain cover, tighten the chain cover bolts.
Clip
Chain plate
2-12
BRAKES
BRAKE:
Inspect initially at 1 000 km and every 3 000 km thereafter.
BRAKE HOSE:
Inspect initially at 1 000 km and every 3 000 km thereafter. Replace every 4 years.
BRAKE FLUID
Inspect every 3 000km. Replace every 2 years.
Brake fluid level

Support the motorcycle body on the center stand, and
place the handlebars straight.
Check the brake fluid level in the brake fluid reservoir.
If the level is very low, replenish with brake fluid that meets
the following specification.
Haojue Brake fluid
CAUTION
The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or pertroieum-
based. Do not use any brake fluid taken from old, used
or unsealed containers. Never re-use brake fluid left 上刻线
over from the last servicing or stored for a long period.
下刻线
WARNING
Brake fluid is harmful or fatal if swallowed, and harmful
if it comes in contact with skin or eyes. If brake fluid is
swallowed, immediately contact a poison control
center or a physician. If brake fluid gets in eyes, flush
eyes with water and seek medical attention. Do not
wash the master cylinder with high pressure water.
BRAKE DISCS AND BRAKE PADS

Check the thickness of brake disc, replace the brake disc
with new one if the thickness is less than 3.5mm.
The extent of brake pad wear can be checked by observing
the grooved limit line on the pad. When the wear exceeds
the grooved limit line, replace the pads with new ones.
WARNING
Do not drive the motorcycle immediately after the

replacement of the new brake disc or brake pads.
Squeeze and release the brake lever several times to
make the mating of brake disc and brake pads
completely and circulation of brake fluid stably. The
brake distance is longer than the original distance after
the replacement of new brake disc or brake pads. After
300 km of driving, the motorcycle will get the best
break performance. Before that , Keeping enough brake
distance is necessary during the driving.
2-13
AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in the
following manner:
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any fluid when filling the brake fluid
reservoir. Wipe spilled fluid up immediately.
FRONT BRAKE
Fill up the master cylinder reservoir to the upper line.
Attach a hose to the air bleeder valve and insert the free end
of the hose into a receptacle.
Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle. This will remove
the tension of the brake lever causing it to touch the handlebar
grip. Then, close the air bleeder valve, pump and squeeze
the lever, and open the valve. Repeat this process until fluid
flowing into the receptacle contains no air bubbles.
CAUTION
While bleeding the brake system, replenish the brake fluid in
thereservoir as necessary. Make sure that there is always
some fluid visible in the reservoir.
Close the bleeder valve, and disconnect the pipe. Fill the
reservoir to the "UPPER” level line, replace the reservoir cap.
CAUTION
Handle the brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials, etc.
FRONT BRAKE SWITCH

When operating the front brake lever to check the brake light
switch if works , if any defects are found, inspect, adjust or
replace the switch as necessary.
2-14
REAR BRAKE AND CBS SYSTEM

Fill the rear master cylinder reservoir to the upper level.
Attach a hose to the front brake caliper rear air bleeder valve
and insert the free end of the hose into a receptacle.
Depress and release the brake pedal several times in rapid

succession and depress the pedal fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle. Then, close the air
bleeder valve, release and depress the pedal, and open the
valve. Repeat this process until fluid flowing into the receptacle
contains no air bubbles.
Replenish the brake fluid reservoir as necessary while bleeding
the brake system. Make sure that there is always some fluid
visible in the reservoir.
Close the air bleeder valve, and disconnect the pipe. Fill the
reservoir to the "UPPER” level line, replace the reservoir cap.
REAR BRAKE
REAR BRAKE PEDAL FREE TRAVEL
Rear brake pedal travel is the distance from the free
position to the position that the brake starts taking effect.
Turn the adjuster nut to adjust the rear brake pedal free
travel to 20-30 mm.
Rear brake pedal free travel : 20-30 mm
2-15
BRAKE LINING WEAR LIMIT

This motorcycle is equipped with brake lining wear limit
indicators on front brake. To check wear of the break lining,
follow the steps below.
Check if the brake system is properly adjusted first.
While operating the brake, check to see the extension line
from the index mark is within the range on the brake
panel as shown in the illustration at right.
If the index mark is outside the range, the brake shoe
assembly should be replaced to ensure safe operation.
REAR BRAKE LIGHT SWITCH

Step on the rear brake pedal to inspect the brake light switch.
If the brake light switch doesn’t work well, it should be
Inspected, adjusted by turning the adjusting nut of the brake
switch or replaced as necessary.
TIRES
Check the tire pressure and surface during the maintenance.

There are serial marks (tire wear indicator) in the edge of
the tire. Check the block of T.W.I. in the tread near the
mark. If the tire wears off to reach the boss, the tire should be
replaced.
Check the damage (punctures or fractures) on the tire
surface visually. As surface damage may impede driving
stability, such tires should be replaced.
COLD SOLO RIDING DUAL RIDING

INFLATION
TIRE
PRESSURE Kpa kg/cm 2 kpa Kg/cm 2
FRONT 200 2.00 225 2.25
REAR 225 2.25 280 2.80
CAUTION
Proper tire pressure and condition affect vehicle
performance. Please check the tire pressure and
surface condition periodically.
2-16
STEERING
Inspect Initial 1 000 Km and every 3 000 Km
Steering stem bearings should be adjusted properly for

smooth turning of the handlebars and safe running.
Steering which is too stiff prevents smooth movement of
handlebars.
Steering which is too loose will cause vibration and damage to
the steering bearing. Check to see that there is no play in the
front fork attachment.
If the play is found, perform the steering bearing adjustment
as described in page 5-23 of this manual.
FRONT AND REAR SHOCK ABSORBERS

Inspect every 3 000 km.
FRONT SHOCK ABSORBER

● Grasp the front brake, squeeze the front shock absorber to
check if it moves smoothly.
● Check for leaks or damage.
REAR SHOCK ABSORBER

● Depress the rear carrier, move the rear shock absorber up
and down four or five times to check for the noise or smooth
movement.
● Inspect the rear absorber spring for damage, deformation
or oil leakage.
LIGHTING AND SIGNAL

Inspect the headlight, left and right turn signal lights, tail
light/brake light and combination meter signal light, replace
the light with new one if there is something unusual. (Refer to
page 6-10)
2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

Inspect Initial 1 000 km and every 3 000 km
The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be
re-tightened, as necessary, to the specified torque with a torque wrench.
ITEM N•m Kg•m
1 Handlebar clamp bolt/nut 45-55 4.5-5.5

2 Lower bracket bolt 35-55 3.5-5.5
3 Front axle nut 40-48 4.0-4.8
4 Brake disc mounting bolt 18-28 1.8-2.8
5 Brake caliper mounting bolt 18-28 1.8-2.8
6 Bleeder valve 7-10 0.7-1.0
7 Brake hose union bolt 20-25 2.0-2.5
8 Master cylinder mounting bolt 8-12 0.8-1.2
9 Front footrest mounting bolt 18-28 1.8-2.8
10 Engine mounting bolt/nut 60-80 6.0-8.0
11 Rear swing arm pivot shaft nut 60-80 6.0-8.0
12 Rear shock absorber mounting bolt/nut 22-35 2.2-3.5
13 Rear footrest mounting bolt 22-35 2.2-3.5
14 Rear axle nut 48-58 4.8-5.8
15 Brake cam lever bolt/nut 7-10 0.7-1.0
16 Rear torque link bolt/nut 10-16 1.0-1.6
17 Exhaust pipe mounting bolt 11-15 1.1-1.5

18 Muffler mounting bolt 18-28 1.8-2.8
2-18
2-19
COMPRESSION PRESSURE
The cylinder compression is an indicator of its inner state. The necessity of repair depends on the result of
the inspection. The record of your authorized dealer should include the compression pressure readings
obtained in every maintenance.
NOTE:
Before testing the engine for compression pressure, make sure that the cylinder head nuts and bolts are
tightened to specified torque values and valves clearance are properly adjusted.
Have the engine warmed up by idling before testing it.
Ensure that the battery is fully charged.
Remove the related parts and inspect the compression pressure
in the following process:
Warm up the engine.

● Remove the spark plug. (Refer to page 2-6)
Fit the pressure gauge and adapter to the spark plug
hole, paying attention to the connector tightening;
Turn the throttle to full opening;
Electrically start the motorcycle, take the maximum
reading in the recording as the cylinder compression
pressure.
09915-64510 : Compression gauge
Compression pressure
Standard Limit
1 000-1 400 kPa 800 kPa

10-14 kgf/cm 2 8 kgf/cm 2
When the compression pressure noted is down to or below

the limit indicated above, the engine must be disassembled,
inspected and repaired as required.
A low compression pressure may indicate any of the

following malfunctions:
Excessively worn cylinder wall.

Worn piston or piston rings.
Piston rings stuck in the grooves.
Poor seating contact of the valves.
Defective the cylinder head gasket.
2-20
ENGINE
CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLACE 3-1
ENGINE REMOVAL AND REMOUNTING 3-2
CYLINDER HEAD AND VALVE 3-7
CYLINDER AND PISTON 3-16
CLUTCH 3-20
OIL PUMP 3-25
GEAR SHIFTING MECHANISM 3-26
GENERATOR, STARTER CLUTCH AND GEARSHIFT SWITCH 3-27 3

CRANKSHAFT AND TRANSMISSION 3-30
ENGINE
REMOVING ENGINE PARTS WITH ENGINE INPLACE
UPPER SIDE OF ENGINE
Starter motor 3-6

Cylinder head cover 3-7
Cam sprocket 3-7
Cylinder head 3-7
Camshaft 3-8
Rocker arm 3-8
Cylinder 3-15
Piston 3-15
RIGHT SIDE OF ENGINE
Kick starter lever 3-6

Clutch cover 3-19
Primary clutch assembly 3-20
Clutch assembly 3-20
Oil pump 3-25
Gearshift shaft 3-26
LEFT SIDE OF ENGINE

Generator cover 3-27
Generator rotor 3-27
Starter clutch 3-27
Generator stator 3-28
Cam chain tensioner 3-28
3-1
ENGINE
ENGINE REMOVAL AND REASSEMBLY

ENGINE REMOVAL
Before taking the engine out of the chassis, wash the engine
with a steam cleaner. The procedure of engine removal is
sequentially explained in the following steps:
● Support the motorcycle with the main stand.

● Drain the engine oil.
● Open the saddle, remove the battery cover , take off the
battery .
● Remove the frame exterior parts.

(Refet to page 6-1 and 6-4)
● Loosen the fastener, disconnect the generator coupler
and gear shifting switch coupler .
Disconnect the oxygen sensor coupler , engine temp.

sensor and spark plug cap 7 .
Remove the oxygen sensor coupler bracket 8
Remove the gear shifting lever 9 .
3-2
ENGINE
Remove the engine sprocket cover 10 .
Remove the chain case 11 .
Remove the starter motor wire 12 and engine ground wire 13.
Remove the crankcase breather hose .
Loosen the rear axle nut and chain tenisoner adjuster

nut .
Remove the sprocket mounting bolts, take off the chain

retainer and sprocket .
3-3
ENGINE
Remove the engine intake hose mounting bolt .
● Remove the kick starter lever .

● Remove the exhaust pipe mounting bolts.
● 21shaft nut,
Remove the muffler mounting bolt and rocker arm
take off the muffler .
Remove the rear brake switch and spring 23 .

Remove the cotter pin, draw out the rear brake combined
rocker arm shaft 24 .
Remove the engine mounting nut 25 , draw out the engine

mounting bolts, take off the engine.
3-4
ENGINE
ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal.
CAUTION
The engine mounting nuts are self-lock nuts. Once the

nut has been removed, it is no longer of any use.
Tightening torque for engine mounting bolts

Engine mounting nut A : 60-80 N•m
Exhaust pipe mounting bolt B : 11-15 N•m
Muffler mounting bolt/nut C : 22-28 N•m
Swing arm shaft nut D : 60-80 N•m
Install sprocket and lock piece, apply a small quantity of

Thread Lock on the screwed part of sprocket bolt .
99000-32050: Thread Lock “1303"
After remounting the engine, add the oil. (Refer to page 2-7).
● After remounting the engine, following adjustments are

necessary,
Engine oil level (Refer to page 2-7)
Idling speed (Refer to page 2-9)
Throttle cable (Page 4-10)
Drive chain (Refer to page 2-12)
3-5
ENGINE
CYLINDER HEAD AND VALVE

REMOVAL
INSTALLATION BRACKET
Remove the installation bracket .
FRONT FOOTREST AND SIDE STAND

Remove the front footrest and side stand assembly .
ENGINE TEMP. SENSOR

Remove the engine temp. sensor
STARTER MOTOR
Remove the starter motor .
CAM CHAIN TENSIONER

● Remove the cam chain tensioner bolt , take off the spring
and push rod.
3-6
ENGINE
CYLINDER HEAD COVER

Remove the cylinder head cover bolts, take off the cylinder
head cover
CAM SPROCKET
Remove the generator cover cap 7 and inspection plug 8
Bring the piston to TDC.

CAUTION
When removing cylinder head cover, piston must be

at TDC (top dead center) on the compression stroke.
Align the carved line with groove on the generator
cover, the line on the cam sprocket should be paralleled
with the cylinder head end surface.
Remove the cam sprocket 9 .
CAUTION
Pass a metal wire into the cam chain to prevent the
cam chain from dropping into thecrankcase.
CYLINDER HEAD ASSEMBLY

Remove the cylinder head mounting nuts and cylinder head
side bolts, take off the cylinder head assembly 10 .
3-7
ENGINE
CYLINDER HEAD DISASSEMBLY

Remove the camshaft retainer bolt and retainer, take off
the cam shaft .
Remove the valve rocker arm mounting bolts
Draw out the valve rocker arm with a M8 bolt, take off the
wave washer and valve rocker arm .
Remove the valve cotters with the special tool.
11F14-018: Valve remover and installer
Take out the valve spring retainer, inner spring and outer
spring.
Pull out the valve from the other side.
3-8
ENGINE
Remove the oil seal.
CAUTION
Always use new oil seal.
● Remove the spring lower gasket.
INSPECTION
ROCKER ARM
When checking the valve rocker arm, the inside diameter of
the valve rocker arm and wear of the camshaft contacting
surface should be checked.
Rocker arm I.D (IN and EX.):

Standard: 10.0-10.015 mm
09900-20605 : Caliper gauge
ROCKER ARM SHAFT

Measure diameter of rocker arm shaft.
Rocker arm shaft O.D. (IN and EX.):
Standard: 9.972-9.987 mm
09900-20205: Micrometer (0~25 mm)
CAMSHAFT BEARING
Inspect the play of cam shaft bearing outer race by hand,
Rotate the outer race by hand to inspect for an abnormal noise
and a smooth rotation. Replace the bearing if there is
something unusual.
3-9
ENGINE
CAMSHAFT
The camshaft should be checked for runout and also for
wear of cams and journals if the engine has been noted
to produce abnormal noise or vibration or a lack of output
power. Any of these malconditions could be caused by a worn H
camshaft.
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power. The limit of cam
wear is specified for both intake and exhaust cams in terms of
cam height, which is to be measured with a micrometer.
Replace camshafts if found it worn down to the limit.
CAMSHAFT
Camshaft height :
Limit (Intake): 32.014 mm
(Exhaust): 31.81 mm
09900-20202 : Micrometer (25~50 mm)
VALVE SPRING
● Measure valve spring free length.
Valve spring free length (IN and EX):

Limit: 24.38 mm
09900-20103 : Vernier calipers
CYLINDER HEAD
Inspect the spark plug hole and valve seat for scratch.
Check the cylinder head for distortion with a straightedge
and thickness gauge.
Cylinder distortion:
Limit: 0.03 mm
09900-20803 : Thickness gauge
VALVE
Inspect the valve for pitting, scratch or wear.
Measure the valve stem O.D.
Valve stem O.D.

Standard (IN.) : 4.970-4.99 mm
(EX.): 4.955-4.97 mm
09900-20205 : Micrometer (0-25 mm)
3-10
ENGINE
● Measure the thickness , and if the thickness is found to

have been reduced to the limit, replace the valve.
Valve face thickness:

Limit: 0.5 mm
CAUTION
Visually inspect each valve for wear of its seating
face. Replace any valve with an abnormally worn face.
● Support the valve with “V” blocks, as shown, and check its
run-out with a dial gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem run-out:
Limit: 0.05 mm
09900-20606: Dial gauge (1/100 mm)
09900-20701: Magnetic stand
09900-21304: V-block ( 100 mm)
● Place the dial gauge at right angles to the valve head, and
measure the valve head radial run-out.If it measures more
than the limit, replace the valve.
Valve head run-out:

Limit: 0.03 mm
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block ( 100 mm)
VALVE OIL SEAL

Oil each seal, and drive them into the position.
CAUTION
3-11
ENGINE
VALVE SEAT WIDTH

Coat the valve seat with prussian blue uniformly. Fit the valve
and tap the coated seat with the valve face in a rotating
manner, in order to obtain a clear impression of the seating
contact. The ring-like dye impression left on the vale face
must be continuous-without any break. In addition, the width
of the dye ring, which is the visualized seat “width”, must be
within the specification.
09916-10911: Valve lapper set
Valve seat width W ：Standard：

Intake ：0.9-1.1 mm
Exhaust : 0.9-1.1 mm
If either requirement is not met, correct the seat by servicing it
as follows.
VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves are
angles to present three bevels. The valve seat contact
surface is 45°.
进气门
INTAKE EXHAUST
Valve seat angle 20°,45° 3 0°, 45°
20°
Valve seat width 0.9-1.1 mm
Valve diameter 25.5 mm 21.0 mm
CAUTION
The valve seat contact area must be inspected after

each cut. Do not use lapping compound after the
final cut is made. The finished valve seat should
have a velvety smooth finish and not a highly 排气门
polished or shiny finish. The will provide a soft
surface for the final seating of the valve which will
occur during the first few seconds of engine
operation.
CAUTION
Be sure to adjust the valve clearance after

reassembling the engine.
Clean the cylinder head with the detergent, check the

intake and exhaust valve for leakage with gasoline.
If leakage is found, check the valve seat and valve surface
for burr.
WARNING
Take extreme care when handling with gasoline.
3-12
ENGINE
CYLINDER HEAD ASSEMBLY

Reinstall the cylinder head in the reverse order or removal.
Pay attention to the following points:
● Clean the cylinder head with the detergent,clean all the oil
passages with compressed air.
Clean each valve with Moly paste.
Insert the valves into valve guide and Install the valve spring
washer, spring, valve spring retainer.
99000-25140: Moly paste
CAUTION
Install each valve spring with the small-pitch portion

facing cylinder head.
Turn the valve slowly while installing the valve oil seal to 朝
prevent the valve oil seal from damage.
缸头
Install the valve cotters with special tool.
11F14-018: Valve remover and installer
Install the rocker arm, wave washer, and rocker arm shaft, tighten the bolt to fix
the rocker arm shaft.
CAUTION
When installing the rocker arm, face the threaded end
outward.
Install the cam shaft and retainer, apply the Thread Lock to the camshaft
mounting bolt then tighten it to the specified torque.
99000-32030 : Thread lock“1303”
Cam shaft mounting bolt: 8-12 N•m
3-13
ENGINE
REASSEMBLY
Reassemble the cylinder head in the reverse order of removal.
Pay attention to the following points.
Install the cylinder head, washer, and tighten the cylinder
head nut to the specified torque.
Cylinder head nut: 16-20 N•m
Install the cylinder head side bolts, tighten the bolt to the
specified torque.
Cylinder head side bolt: 8-14 N•m
● Install the cam chain and cam sprocket.

● Install the cam sprocket bolts, apply a small quantity of
Thread lock to the cam sprocket bolt before tightening the
bolt.
99000-32030 : THREAD LOCK “1303”
Cam sprocket bolt: 18-28 N•m
CAUTION
When installing the cam sprocket, bring the piston ot
TDC.The mark on the cam sprocket should be parallet
with the cylinder head surface.
● Apply the Bond to the cylinder head margin.
99000-311400 : Bond “1207B”
Install the cylinder head cover, tighten the cylinder head

cover bolt to the specified torque.
Cylinder head cover bolt: 8-12 N•m
Install the push rod, spring and cam chain tensioner bolt,
tighten the bolt to the specified torque.
Cam chain tensioner bolt: 17-28 N•m
3-14
ENGINE
CYLINDER AND PISTON

CYLINDER REMOVAL
Remove the cylinder head. (Refer to page 3-6)
Remove the gasket and dowel pins.
● Remove the cam chain guide wheel bolt。
● Remove the cylinder.
Remove the dowel pin and gasket.
CYLINDER INSPECTION
● Clean the gasket surface of cylinder.
● Check the cylinder for distortion with a straight edge and
thickness gauge.
Cylinder distortion:
Limit: 0.05 mm
Check the cylinder bore for wear or damage.

Measure the cylinder bore diameter at six places. If any one
of the measurements exceeds the limit, overhaul the cylinder
and replace the piston with an oversize or replace the
cylinder.
Cylinder bore diameter:
Limit: 51.135 mm
09900-20508 : Cylinder gauge set
PISTON REMOVAL AND INSPECTION

REMOVAL
CAUTION
Place a clean rag over the cylinder base to prevent
piston pin circlip or other parts from dropping into
crankcase
● Remove the piston pin circlip.
3-15
ENGINE
● Remove the piston pin and piston with the special tool.
09910-34510: Piston pin puller
CAUTION
Hold the piston stably when taking out the piston
pin to prevent the damage to conrod big end bearing.
Removing the piston rings one by one by expanding the

gap symmetrically.
CAUTION
Do not expand the piston ring excessively since it is
apt to be broken down.
Decarbonize the piston.

CAUTION
Using a soft-metal scrapper or discarded piston ring
to decarbon the ring grooves of the piston. Do not
use the steel brush or the piston will be scratched.
INSPECTION
● Temporarily fit the piston ring on the suitable position with
the marked side to the top.
● Measure the piston ring-groove clearance with thickness
gauge.
Piston ring-groove clearance:
Limit: (1st): 0.180 mm
(2nd):0.150 mm
09900-20803: Thickness gauge
Measure the piston outside diameter at the place 5mm from

the skirt end.
Piston outside diameter:
Limit: 6 mm from the skirt end, 50.86 mm
6mm
09900-20203: Micrometer (50-75 mm)
3-16
ENGINE
Using a caliper gauge, measure the piston pin bore inside

diameter.
Piston pin bore inside diameter: Limit: 13.03 mm
09900-20605: Caliper gauge
Using a micrometer measure the piston pin outside

diameter.
Piston pin O.D.: Limit: 12.98 mm
09900-20205: Micrometer (0-25)
Measure the conrod small end I.D.
Conrod small end I.D.: Limit: 13.04 mm
09900-20605: Caliper gauge
● Fit the ring in the cylinder, and measure each ring end gap
using a thickness gauge. If any ring has an excess end gap,
replace the ring.
Piston ring end gap:
Limit(1st): 0.5 mm
(2nd):0.5 mm
NOTE:
Make sure fit the piston ring into the cylinder evenly with
the piston head.
3-17
ENGINE
REASSEMBLY
Reassemble the piston and cylinder in the reverse order of
removal, pay attention to the following points:
● Clean the piston top, skirt and groove. Top ring
120°
CAUTION
120 0°
Fit the piston rings in the groove correctly, rotate ° 12
the piston ring by hand to see if it turns smoothly.
Install the piston ring carefully with marked side to the top. 2nd ring
CAUTION Oil ring

Take care not to damage the piston ring and piston
when installing the piston ring. Side rail
Before inserting piston into cylinder, confirm that the
gaps are located as required.
The gaps of two piston rings should be staggered at 120°.
CAUTION
Install the spacer into the bottom ring groove first
then the install both side rails. Do not align the
opening of with the opening of expander ring.
Piston ring should turn smoothly in the piston groove.

Lightly apply Moly Paste to the piston pin outer surface.
99000-25140 : Moly Paste
Place a clean rag over the cylinder base to prevent piston pin
circlip from dropping into crankcase, and then fit the piston pin
circlip with long-nose pliers.
CAUTION
Use a new piston pin circlip.
Do not align the end gap of the circlip with the cutaway
of the piston pin bore.
● When fitting the piston, turn “IN”mark on th piston head to the

intake side.
● Before mounting the cylinder, oil the big end and small end of
the conrod and also the sliding surface of the piston. Apply the
Bond “1207B” to the area marked with black line.
● Fit the dowel pins to crankcase and then fit the gasket.
99000-31140 : Bond “1207B”
CAUTION
Use a new cylinder head gasket to prevent oil leakage.
Do not use the old gasket.
Apply a small quantity of engine oil to piston outer surface,
piston ring groove and cylinder inner wall.
Compress the piston rings, install the cylinder.
Apply a small quantity of engine oil to cam chain guide wheel
Install the cam chain guide wheel, new washer and guide
pin bolt.
Install the cylinder head.(Refer to page 3-14)
3-18
ENGINE
CLUTCH
REMOVAL
Remove the kick starter lever bolt, take off the kick start
lever .
Remove the clutch cover by removing the clutch cover

screws.
Remove the gasket and dowel pin .

Remove the clutch control arm and cam plate .
● Remove the primary clutch cover .

● Remove the clutch bearing .
Remove the oil pan mounting bolts, remove the primary

clutch thrust washer 7 .
3-19
ENGINE
● Hold the primary clutch shoe assembly 8 with the special

tool, and remove the primary clutch lock nut , disc washer,
thrust washer with the special tool.
11F14-011 : Four claw wrench

11F14-008 : Sprocket holder
● Hold the clutch 9 with the special tool, and remove the
clutch lock nut and washer with special tool.
11F14-011 : Four claw remover

Remove the primary clutch shoe assembly 8 .
Remove the clutch sleeve hub, clutch assembly and oil pan
as a whole.
Remove the washer from the crankshaft.

Remove the spacer and washer from the counter shaft.
3-20
ENGINE
DISASSEMBLY AND INSPECTION

PRIMARY CLUTCH HOUSING ASSEMBLY
Fit the clutch shoe in the clutch housing temporarily. Turn the
drive disc and inspect the one way clutch work condition.
Check to insure that the drive disc only turns clockwise.
Remove the circlip and retainer plate.
09900-06108 : Snap ring pliers(closing type)
Remove the primary clutch rollers and springs.
Inspect the primary clutch rollers and springs for wear or

damage. Replace the defective parts as necessary.
Inspect the clutch inner parts for wear or damage. Replace

it as necessary.
3-21
ENGINE
Inspect the primary clutch housing slide surface for wear or

damage. Replace the primary clutch as necessary.
● Measure the primary clutch housing I.D. if the measurements
is more than the limits, replace the primary clutch.
Primary clutch housing I.D. :

Limit: 104.3 mm
PRIMARY CLUTCH SHOE ASSEMBLY

● Measure the thickness of each primary clutch shoe.
Primary clutch shoe thickness(each): Limit: 1.0 mm
● Remove the circlip and gasket.

● Remove the primary clutch shoe and spring.
CAUTION
Remove the primary clutch shoe as a whole set.
● Reassemble the clutch shoe in the reverse order of

removal.
SECONDARY CLUTCH ASSEMBLY

Remove the 4 bolts, push plate and spring.
CAUTION
Remove the clutch push plate bolts diagonally.
Remove the pressure plate, drive plates and driven plates Drive plate
and driven hub.
Driven hub
Pressure plate
Driven plate
3-22
ENGINE
INSPECTION
Measure the thickness and claw width of each drive plate
with vernier calipers. Replace drive plates found to have
worn down to the limit.
09900-20103: Vernier calipers
Drive plate thickness:

Limit: 2.6 mm Checking thickness
Drive plate claw width:
Limit: 15.3 mm
Checking claw width
Measure each driven plate for distortion with a thickness

gauge. Replace driven plates which exceed the limit.
Driven plate distortion: Limit: 0.1 mm
Replace the drive and drive plates as a whole set which Checking distortion
exceed the limit.
Measure the clutch spring free length.

Clutch spring free length:
Limit: 24.7 mm
Replace all the springs if any spring is not within the

limit.
Inspect the clutch release bearing for any abnormality,

particularly cracks, to decide whether it can be reused or
should be replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
3-23
ENGINE
Reassemble the clutch assembly and apply a small quantity of

oil on the drive plates and driven plates.
If the internal damper wears, play is generated between gear

and housing, causing abnormal noise. If the play is extreme,
replace the primary driven gear assembly with a new one.
INSTALLATION
Reassemble the clutch in the reverse order of removal, pay
attention to the follow points:
Before install the bush, apply a small quantity of oil on the

bush and driven shaft.
● Install the primary clutch, clutch and oil pan as a whole.

● Install the gasket, apply Thread Lock on the threaded part
of clutch lock nut and tighten the clutch lock nut to the
specified torque.
99000-32050: Thread lock “1342"
Clutch lock nut: 40-45 N•m

● Install the disc washer. thrust washer and primary clutch

lock nut, and tighten the lock nut to the specified torque.
● Remove the thrust washer with a chisel, fit one end of the
lock nut into the groove of lock nut.
Primary clutch lock nut: 40-60 N•m

Install the dowel pin and new gasket, tighten the clutch
cover bolt to the spectified torque.
Clutch cover bolt: 8-16 N•m
3-24
ENGINE
Install the kick starter lever, tighten the kick starter level
Kick starter lever bolt: 18-28 N•m
Oil PUMP
REMOVAL AND INSPECTION
● Remove the oil pump by removing the oil pump mounting
bolts.
Disassemble the oil pump by removing the fuel pump
screws
Rotate the oil pump by hand to inspect for abnormal noise
and a smooth rotation. Replace the oil pump if there is
something unusual.
ASSEMBLY
Apply a small quantity of oil inside the oil pump before
installing the oil pump.
Install the oil pump and tighten the screws.
Oil pump bolt: 8-12 N•m
3-25
ENGINE
GEAR SHIFTING MECHANISM

REMOVAL
Remove the gear shifting lever.
Remove the clutch. (Refer to page 3-20)
Remove the bolt, take off the gear shifting cam stopper
mechanism assembly and spring.
Remove the bolt, take off the fixing cam pin and pin.
Remove the gear shifting shaft assembly .
INSPECTION
Inspect the removed parts for damage and the gear shifting
shaft for wear and bend.
ASSEMBLY
Reassemble the gear shifting mechanism in the reverse order of
removal. Pay attention to the following points:
Install the fixing cam pin and stopper cam and apply the
Thread Lock "1342" on the threaded part of lock bolt.
99000-32050: Thread Lock "1342”
3-26
ENGINE
GENERATOR, STARTER CLUTCH

AND GEAR SHIFTING SWITCH
REMOVAL
GENERATOR COVER
Remove the gear shifting switch 1 .
Take off the generator cover by removing the
generator cover bolts.
CAUTION
Be careful to the magnetic force when you remove
the generator cover.
● Remove the gasket and dowel pins.

● Remove the starter motor idle gear and idle gear shaft
GENERATOR ROTOR
Hold the generator rotor with the special tool, remove the
generator rotor nut.
11F14-001: Rotor holder
Remove the generator rotor and key with the special tool.
11F14-001 : Rotor holder

11F14-005 : Generator rotor remover
11F14-003 : M16 screw
STARTER CLUTCH
Remove the roller bearing and starter clutch gear
3-27
ENGINE
Remove the rollers , pins and springs .
Hold the rotor with the special tool, remove the starting clutch
bolts.
11F14-001: Rotor holder
CAUTION
Do not remove the starting clutch unless inspection is

necessary.
GENERATOR STATOR
Remove the generator stator bolt, take off the generator
stator .
Remove the pick-up coil screws, take off the pick-up coil .
CAM CHAIN TENSIONER

Remove the cam chain tensioner plug , washer and tensioner
spring and tensioner rod .
Remove tensioner arm bolt , tensioner arm and

tensioner wheel 7 .
3-28
ENGINE
INSPECTION
Install the starter clutch gear temporarily,
Check to see if the starter clutch gear turns only in one
direction. Replace it if defect is found.
Inspect the starter clutch outer cover for wear or damage.
Inspect the cam chain tensioner spring for damage or

deformation.Replace the spring if any unusual is found.
Inspect the tensioner rod for damage or deformation.
Replace the rod if any unusual is found.
INSTALLATION
Reassemble the tensioner in the reverser order of removal,
pay attention to the following points:
CAM CHAIN TENSIONER

● Install the tensioner rod, spring and washer, tighten the
tensioner bolt to the specified torque.
Tensioner bolt: 17-28 N•m
GENERATOR STATOR
Install the generator stator on the generator cover, route
the wire. Apply the Bond “1207B” to the groove on the
generator cover, then insert the grommet in the groove on
the generator cover.
Apply Thread Lock “1342" on the generator stator mounting
bolt and tighten the bolt.
99000-31140 : Bond ”1207B”

99000-32050 : Thread lock ”1342”
3-29
ENGINE
STARTER CLUTCH
● Clean the starter clutch, apply oil on the rim, mounting the
starter clutch on the rotor.
● Apply Thread Lock in the starter clutch bolt and tighten with
the specified torque.
Starter clutch bolt: 28-35 N•m
99000-32030: Thread Lock “1303"

GENERATOR ROTOR
● Fit the key into the crankshaft key slot.
CAUTION
Do not damage the key slot and crankshaft.
Align the rotor key slot with the key on the crankshaft,
install the rotor.
Apply a small quantity of Thread Lock to the threaded part
of generator nut, fit the generator nut and tighten to the
specified torque.
99000-32030: Thread lock ”1303”
Generator nut: 45-60N•m
Install the dowel pin and new gasket

Install the generator cover, tighten the generator cover bolt
to the specified torque.
Generator cover bolt: 8-16 N•m
3-30
ENGINE
CRANK,TRANSMISSION AND KICK STARTER

CRANKSHAFT
Remove the cylinder head and cylinder.
(Refer to page 3-6 and 3-15).
Remove the clutch and gear shifting mechanism.
(Refer to page 3-27).
Remove the generator rotor and starter clutch.
● Remove the circlip from the kick starter shaft.

● Remove the kick starter shaft return block
09900-06107 : Snap ring pliers(Opening type)
Remove the bolt and gear shifting switch .
● Remove the crankshaft mounting bolts diagonally.
Remove the left crankcase and dowel pins with the special
tool.
11F14-027 : Crankcase separator
CAUTION
Fit the crankcase separating tool, so that the tool
plate is parallel with the end face of the crankcase.
3-31
ENGINE
Remove the kick starter shaft and spring.
Remove the drive shaft, counter shaft and gear shifting

cam as a whole.
● Remove the crankshaft from the right crankcase with the

special tool.
11F14-027: Crankcase separator
Remove the oil pump sprocket shaft and oil pump sprocket
if necessary.
Disassemble the drive shaft, counter shaft and gear

shifting cam.
3-32
ENGINE
Remove the timing gear with the special tool,

replace the crankshaft bearing with a new one.
11F14-040: Timing gear remover
Remove the guide pin clip.

Remove the guide pin, take off the forks.
INSPECTION
● Measure the conrod big end side clearance.
Conrod big end side clearance:

Limit: 0.5 mm
Wear on the big end of the conrod can be estimated by

checking the movement of the small end of the rod. This
method can also check the extend of wear on the parts of
the conrod’s big end.
Conrod small end deflection:

Limit: 3.0 mm
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block (100 mm)
Support the crankshaft with "V" blocks as shown, with the two
end journals resting on the blocks. Position the dial gauge, as
shown, and rotate the crankshaft slowly to read the runout.
Crankshaft runout:
Limit: 0.05 mm
09900-20606 : Dial gauge (1/100 mm)
09900-20701 : Magnetic stand
09900-21304 : V-block (100 mm)
3-33
ENGINE
Using a thickness gauge, check the shifting fork clearance

in the groove of its gear. If the clearance limit is exceeded
by any of the three gears ,determine whether the gear or
the gear shifting fork should be replaced by measuring the
thickness and groove width.
Shifting fork to groove clearance: 2.275 mm

Checking clearance
● Measure the thickness of gear shift fork.
No.1 3.0-3.5 mm
Standard
No.2 3.0-3.5 mm
Measure the gear shift fork groove width.
The gear shift fork groove width：

Standard (No.1): 5.0-5.075 mm
(No.2): 5.0-5.075 mm
Checking groove width
Inspect the each bush, gear inner surface, gear teeth

surface for abnormal wear or poor lubrication.
Inspect the gear shifting guide slot for damage.

Replace the gear shifting guide slot if the damage is found.
3-34
ENGINE
Inspect the key starter shaft for straightness

Inspect the spring for fatigue.
Inspect the each part for wear or damage, replace as
necessary.
Inspect the play of crankcase bearing inner race by hand

while fixing ti in the case. Rotate the inner race by hand to
inspect for an abnormal noise and a smooth rotation.
Replace the bearing if there is something unusual.
BEARING REPLACEMENT
● Remove the driven shaft oil seal.
09913-50121 : Oil seal remover
Remove the left and right crankcase bearings with the

special tool.
09921-20240 : Bearing remover
Install the new bearing with the special tool.
09913-70210 : Bearing installer
3-35
ENGINE
REASSEMBLY
Reassemble the transmission in the reverse order of removal. Pay attention to the follow points:
TRANSMISSION
CAUTION
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded
and a new circlip must be installed. When installing a new circlip, care must be taken not to
expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip,
always insure that is is completely seated in its groove and securely fitted.
Gear shifting cam and forks
Fork
Clip
Pin
Gear shifting cam
3-36
ENGINE
Assemble the drive shaft, driven shaft and gear shifting

cam as per the right photo.
CRANKSHAFT
Apply a small quanitity of oil on the inner surface of conrod big
end and crankshaft bearing, install the crankshaft into the left
crankcase.
09910-32812 : Crankshaft installer

09910-32812-004: Attachment
Install the drive shaft, counter shaft and gear shifting cam
as a whole into the crankcase. Check if driveshaft and
counter shaft rotate smoothly.
Align the spring with the crankcase groove, install the kick
starter mechanism.
● Apply the Super Grease ”A” to the oil seal lip.

Clean the gasketed surface and degrease throughly to left
and right crankcases.
Apply the Bond “1207B” to contacting surface of
crankcase, install the left crankcase.
A 99000-25010: Super grease “A”
99000-31140: Bond ”1207B”
3-37
ENGINE
Apply super grease to the new drive shaft oil seal. Install
the drive shaft oil seal with the special tool.
A 99000-25010 : Super grease “A”
09913-70210 : Bearing installer tool
Install the spring and pin, install the gear shifting switch
and tighten the bolt.
Install the generator and starter clutch.

(Refer to page 3-29)
Install the clutch and gear shifting mechanism.
(Refer to page 3-24 and 3-26)
Install the cylinder head and cylinder.
3-38
FI SYSTEM DIAGNOSIS
CONTENT
PRECAUTIONS IN SERVICING 4-1

ELECTRICAL PARTS 4-1
FUSE 4-2
SWITCH 4-2
ECM / VARIOUS SENSORS 4-3
BATTERY 4-3
ELECTRICAL CIRCUIT INSPECTION PROCEDURE 4-4
USING THE MULTI CIRCUIT TESTER 4-7
FI SYSTEM TECHNICAL FEATURES 4-8
INJECTION TIME (INJECTION VOLUME) 4-8
4-9
COMPENSATION OF INJECTION TIME (VOLUME)
INJECTION STOP CONTROL
FI SYSTEM PARTS LOCATION
4-9
4-10
4
FI SYSTEM WIRING DIAGRAM 4-11
ECM TERMINAL 4-12
SELF-DIAGNOSIS FUNCTION 4-13
MALFUNCTION INDICATION LIGHT INSPECTION 4-13
CURRENT DTC / PAST DTC 4-13
MALFUNCTION INDICATION LIGHT FLASHING MODE 4-14
PASS DTC DELETING 4-15
INITIALIZE VALUES IN ECM 4-15
PLATEAU MODE SETTING 4-16
DTC TABLE 4-17
DIAGNOSIS DEVICE 4-18
FI SYSTEM TROUBLESHOOTING 4-17
INSPECTION PRIOR TO DIAGNOSIS 4-20
FI SYSTEM FAULT ANALYSIS 4-20
DTC “14” TP SENSOR CIRCUIT MALFUNCTION 4-21
DTC “15” ET SENSOR CIRCUIT MALFUNCTION 4-25
DTC “21" IAT SENSOR MALFUNCTION 4-28
DTC "24" IGNITION COIL CIRCUIT MALFUNCTION 4-31
DTC "32" FUEL INJECTOR CIRCUIT MALFUNCTION 4-34
DTC "40" IDLE SOLENOID VALVE CIRCUIT MALFUNCTION 4-36
DTC "41" FUEL PUMP CIRCUIT MALFUNCTION 4-40
DTC "44" OXYGEN SENSOR CIRCUIT MALFUNCTION 4-43
SENSORS 4-46
TP SENSOR REMOVAL AND INSTALLAITON 4-46
IAP SENSOR REMOVAL AND INSTALLAITON 4-46
ET SENSOR REMOVAL AND INSTALLATION 4-46
OXYGEN SENSOR REMOVAL AND INSTALLATION 4-46
FI SYSTEM DIAGNOSIS
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the FI system,
observe the following points for the safety of the system.
ELECTRICAL PARTS
CONNECTOR/COUPLER
Faulty FI system is often related to poor electrical contact Click
of connector/coupler. Before servicing individual electronic
part, check electrical contact of connector/coupler.
When connecting a connector, be sure to push it in until a
click is felt.
With a lock type coupler, be sure to release the lock when Click
disconnecting, and push in fully to engage the lock when
connecting.
When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires.
Inspect each terminal on the connector/coupler for
looseness or bending. Push in the coupler straightly. An
angled or skewed insertion may cause the terminal to be
deformed, possibly resulting in poor electrical contact.
Inspect each terminal for corrosion and contamination.
The termnals must be clean and free of any foreign
material which could impede proper terminal contact.
Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may possibly
come off the position during disconnecting work and if the
coupler is refitted with the seal rubber improperly
positioned, it may result in poor water sealing.
Inspect each lead wire circuit for poor connection by

shaking it by hand lightly. If any abnormal condition is
found, repair or replace.
4-1
FI SYSTEM DIAGNOSIS
When taking measurements at electrical connectors using

a tester probe, be sure to insert the probe from the wire
harness side (rear) of the connector/coupler.
When connecting meter probe from the terminal side of the

coupler (where connection from harness side not being
possible), use extra care not to force and cause the male
terminal to bend or the female terminal to open.
Connect the probe as shown to avoid opening of female
terminal.
Never push in the probe where male terminal is supposed
to fit.
Check the male connector for bend and female connector
for excessive opening. Also check the coupler for locking
(looseness), corrosion, dust, etc.
Avoid applying grease or other similar material to

connector/coupler terminals to prevent electric trouble.
FUSE
When a fuse blows, always investigate the cause to correct
it and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use wire or any other substitute for the fuse.
SWITCH
Never apply grease material to switch contact points to
prevent damage.
4-2
FI SYSTEM DIAGNOSIS
ECM / VARIOUS SENSORS

INCORRECT
Since each component is a high-precision part, great care

should be taken not to apply any severe impacts during
removal and installation.
Be careful not to touch the electrical terminals of the

electronic parts (ECM, etc.). The static electricity from your
body may damage them.
When disconnecting and connecting the coupler, make

sure to turn off the ignition switch, or electronic parts may
get damaged.
BATTERY Wrong
Battery connection in reverse polarity is strictly prohibited.

Such a wrong connection will damage the components of
the FI system instantly when reverse power is applied.
Removing any battery terminal of a running engine is

strictly prohibited.
The moment such removal is made, damaging counter
electromotive force will be applied to the electronic unit
which may result in serious damage.
4-3
FI SYSTEM DIAGNOSIS
Before measuring voltage at each terminal, check to make

sure that battery voltage is 11 V or higher. Terminal voltage
check with a low voltage battery will lead to erroneous
diagnosis.
Never connect any tester (voltmeter, ohmmeter, or

whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit may
result.
Never connect an ohmmeter to the electronic unit with its
coupler connected. If attempted, damage to ECM or
sensors may result.
Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained and personal
injury may result.
ELECTRICAL CIRCUIT INSPECTION

While there are various methods for electrical circuit
inspection, described here is a general method to check for
open and short circuit using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK

Possible causes for the open circuits are as follows. As the
cause can exist in the connector/coupler or terminal, they
need to be checked carefully.
Loose connection of connector/coupler.

Poor contact of terminal (due to dirt, corrosion or rust,
poor contact tension, entry of foreign object etc.).
Wiring harness being open.
Poor terminal-to-wire connection
When checking system circuits including an electronic control

unit such as ECM, etc., it is important to perform careful
check, starting with items which are easier to check.
Disconnect the negative cable from the battery.

Check each connector/coupler at both ends of the circuit
being checked for loose connection. Also check for
condition of the coupler lock if equipped.
① Sensor
② ECM
*1 Check for loose connection.
4-4
FI SYSTEM DIAGNOSIS
Using a test male terminal, check the female terminals

of the circuit being checked for contact tension.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust, entry of foreign object,
etc.). At the same time, check to make sure that each
terminal is fully inserted in the coupler and locked.
If contact tension is not enough, rectify the contact to
increase tension or replace.
The terminals must be clean and free of any foreign
material which could impede proper terminal contact.
*1 Check contact tension by

inserting and removing.
*2 Check each terminal for
bend and proper alignment.
Using continuity inspect or voltage check procedure as

described below, inspect the wire harness terminals for
open circuit and poor connection. Locate abnormality, if
any.
A Looseness of crimping
B Open
C Thin wire (a few strands left)
Continuity check
Measure resistance across coupler B (between A and
C in the figure).
If no continuity is indicated (infinity or over limit), the
circuit is open between terminals A and C .
① ECM
Disconnect the coupler B and measure resistance

between couplers A and B .
If no continuity is indicated, the circuit is open between
couplers A and B . If continuity is indicated, there is an
open circuit between couplers B ’and C or an
abnormality in coupler B ’or coupler C .
① ECM
4-5
FI SYSTEM DIAGNOSIS
VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
With all connectors/couplers connected and voltage

applied to the circuit being checked, measure voltage
between each terminal land body ground.
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V
A and body ground: 0 V
Also, if measured values are as listed below, a resistance

(abnormality) exists which causes the voltage drop in the
circuit between terminals A and B .
Voltage Between:
C and body ground: Approx. 5 V
B and body ground: Approx. 5 V 2 V voltage drop

A and body ground: 3 V
SHORT CIRCUIT CHECK

*1
● Disconnect the battery - lead wire.
Pull out the coupler for circuit check.
NOTE:
If the circuit to be checked branches to other parts 1 as
shown, disconnect all connectors/couplers of those
parts. Otherwise, diagnosis will be misled.
Measure resistance between terminal at one end of

circuit ( A terminal in figure) and body ground. If 5V
continuity is indicated, there is a short circuit to ground
between terminals A and C .
1 Other parts
*1 To other parts
4-6
FI SYSTEM DIAGNOSIS
Disconnect the connector/coupler included in circuit

(coupler B) and measure resistance between terminal A
*1
and body ground.
If continuity is indicated, the circuit is shorted to the
ground between terminals A and B .
USING THE MULTI CIRCUIT TESTER

Use the multi circuit tester set.
Use well-charged batteries in the tester.
Be sure to set the tester to the correct testing range.
09900-25008: Multi circuit tester set
USING THE TESTER

Incorrectly connecting the + and - probes may cause the
inside of the tester to burnout.
If the voltage and current are not known, make
measurements using the highest range.
When measuring the resistance with the multi circuit tester 1
, will be shown as 10.00 M and “1” flashes in the display.
Check that no voltage is applied before making the
measurement. If voltage is applied the tester may be
damaged.
After using the tester, turn the power off.
09900-25008: Multi circuit tester set
NOTE:
When connecting the multi circuit tester, use the needle-point
probe to the back side of the lead wire coupler and connect the
probes of tester to them.
Use the needle-point probe to prevent the rubber of the water
proof coupler from damage.
When using the multi circuit tester, do not strongly touch the
terminal of the ECM coupler with a needle-point tester probe to
prevent the terminal damage.
09900-25009: Needle-point probe set
4-7
FI SYSTEM DIAGNOSIS
FI SYSTEM
INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the
basis of engine speed and throttle opening angel, and various compensations. These
compensations are determined according to the signals from various sensors that detect the engine and
driving conditions.
ECM
Crankshaft Position Engine speed signal Basic fuel

Sensor (CKP Sensor) injection
time
Throttle Position Throttle Opening signal
Sensor (TP Sensor)
Various Sensors Various signal Corrective

variables
Injection signal Definitive

Injector fuel
injection
4-8
FI SYSTEM DIAGNOSIS
COMPENSATION OF INJECTION TIME (VOLUME)

The following different signals are output from the respective sensors for compensation of the fuel
injection time (volume).
SIGNAL DESCRIPTION
ENGINE TEMPERATURE SENSOR SIGNAL When engine temperature is low, injection time
(volume) is increased.
INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature is low, injection time
(volume) is increased.
OXYGEN SENSOR SIGNAL Air/fuel ratio is compensated to the theoretical ratio
from density of oxygen in exhaust gas. The
compensation occurs in such a way that more fuel is
supplied if detected air/fuel ratio is lean and less fuel
is supplied if it is rich.
BATTERY VOLTAGE SIGNAL ECM operates on the battery voltage and at
the same time, it monitors the voltage signal for
compensation of the fuel injection time (volume).
A longer injection time is needed to adjust injection
volume in the case of low voltage.
ENGINE SPEED SIGNAL At high speed, the injection time (volume) is

increased.
STARTING SIGNAL When starting engine, additional fuel is injected
during cranking engine.
ACCELERATION SIGNAL/ During acceleration, the fuel injection time (volume) is
DECELERATION SIGNAL increased in accordance with the throttle opening
speed and engine rpm. During deceleration, the fuel
injection time (volume) is decreased.
INJECTION STOP CONTROL

Signal Description
OVER-REV. LIMITER SIGNAL The fuel injectors stop operation when engine speed
reaches 9700 r/min, this circuit cuts off fuel at the
fuel injectors.
4-9
FI SYSTEM DIAGNOSIS
FI SYSTEM PARTS LOCATION
IAT sensor Fuel injector Battery

Fuse box Diagnosis coupler ECM
Fuel pump CKP sensor Meter

Ignition coil Idle solenoid valve CKP sensor
ET sensor Oxygen sensor
4-10
FI SYSTEM DIAGNOSIS
FI SYSTEM WIRING DIAGRAM
Brake light and horn.
Generator
Rectifier
D Ignition switch E B
10A Fuse
D 20A Fuse
10A Fuse Starter relay Starter switch
A A
- + D
C D Battery M
B D
Headlamp
switch
HLS 29
1 VB
Headlamp
D 8 FP Fuel pump
16 INJ Fuel injector
TP sensor TPS
VCC
TPS
6
5
ECM
11 IG Ignition coil
SG 4
IAT sensor
IATS 14 22 MIL
IATS
Malfunction
indication light
ET sensor ETS
ETS 24 28 ISC Idle solenoid valve
OX 3
Oxygen sensor OX
30 DIAG
15 TS
E
C
D
CPS+ 12
CPS- 23
CKP sensor
2 9 10
LG PG1 PG2
C D
4-11
FI SYSTEM DIAGNOSIS
ECM TERMINALS
NO. Circuit NO. Circuit

1 VB Battery 18
2 LG Logic ground 19
3 OX Oxygen ground 20
4 SG Sensor ground 21
5 TPS TP sensor 22 MIL Malfunction indication light

6 VCC Sensor voltage 23 CPS- CKP sensor-
7 24 ETS ET sensor
8 FP Fuel pump 25
9 PG1 Sensor ground 1 26
10 PG2 Sensor ground 2 27
11 IG Ignition coil 28 ISC Idle solenoid valve

12 CPS+ CKP sensor+ 29 HLS Headlamp switch
13 30 DIAG Diagnosis tool
14 IATS IAT sensor+ 31
15 TS Test switch 32
16 INJ Injector 33
17
4-12
FI SYSTEM DIAGNOSIS
SELF-DIAGNOSIS
The self-diagnosis function is incorporated in the ECM. When
the FI system has fault, ECM will turn on the Malfunction
indication light and save the DTC to erasable memory. When
the voltage is lower than 8V, ECM no longer perform self-
diagnois. After turn off the ignition switch, the diagnosis result
will be reset.
Turn on the ignition switch, after self-diagnosis,
malfunction indication light turns on, then start the engine,
the light turns off, it means no ECM defect is detected.
If after engine is started, malfunction indication light
staying on, it means the DTC or past DTC exists.
Push the start button several times but staring is no
successful, the malfunction indication light is staying on, it
means DTC exists.
A two-digit DTC is shown through the flashing pattern of
the malfunction indicator light and also can be read by a
defect diagnose device.
CAUTION
When the past DTCs exist, the malfunction

indication light stays on after engine is started.
MALFUNCTION INDICATION LIGHT

INSPECTION
When turn on the ignition switch, if the malfunction indication
light doesn’t perform self-diagnose, check if the ignition
switch circuit 15A fuse burnt or malfunction indication light
open circuit.
CURRENT DTC / PAST DTC

There are two kinds of DTC:
CURRENT DTC
● Connect the test switch to test coupler and turn on it.
Turn on the ignition switch, after self-diagnosis is
completed, malfunction indication light starts blinking to
output DTC.
PAST DTC
Connect the test switch coupler, turn on the test switch.
Open the throttle fully.
Turn on the ignition switch, after malfunction indication
light being off for 3s,malfunction indication starts blinking
to outputs past DTC.
09930-82720: Test switch
4-13
FI SYSTEM DIAGNOSIS
Understanding the DTC (Diagnostic Trouble Code)

A two-digit DTC is shown through the flashing pattern of the malfunction indicator light. For current DTC, a
number between 1 and 9 is represented by the number of times that the malfunction indicator light lights
up in interval of 0.3 seconds and the separation between the tens and ones are indicated by the light
staying off for 1 seconds. The separation between each DTC is indicated by the light being off for 3
seconds.
For past DTC, a number between 1 and 9 is represented by the number of times that the malfunction
indicator light lights up in interval of 0.5 seconds and the separation between the tens and ones are
indicated by the light staying off for 1.6 seconds. The separation between each DTC is indicated by the light
being off for 5 seconds.
Current DTC
12 23 12
0.3S 0.3S 0.3S 0.3S 0.3S 0.3S 0.3S
ON
OFF 1S 3S 1S 3S 1S
0.3S 0.3S 0.3S 0.3S
Past DTC
12 23
0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S

ON
OFF
1.6S 0.5S 5.0S 0.5S 1.6S 0.5S 0.5S
4-14
FI SYSTEM DIAGNOSIS
Past DTC (Diagnostic Trouble Code) Deleting

To delete to past DTC:
1 Turn on the test switch, open the throttle fully.
2 Turn on the ignition switch.
3 After Malfunction indicaiton light being off for 3s, malfunction indication light starts blinking to
output DTCs, close the throttle.
4 Turn off switch for more than1.5s, and turn on switch for more than 1.5s, switch it
from off to on three times, past DTCs are deleted.
Step must be completed in 30s.
Ignition ON ②Ignition
switch switch ON
OFF
④ Switch it from
OFF to ON
Test ON ①Test
switch switch ON
OFF
Full open
Throttle ①Full
opening open
Full close
Malfunction ON
③DTC
indication
being output
light OFF
Initialize values in ECM

When replacing the FI system related parts(ECM and throttle body,etc) or maintenance(Clean throttle and air
filter). In order to avoid the abnormality running of motorcycle due to the values in the ECM, initialise the ECM
is necessary. To initialise the ECM:
1 Connect the test switch, turn on the ignition switch.
2 Turn on the ignition switch, after 2.5s, turn on the test switch.
3 Within 5s when the test switch is on, start the following operation: wide open
throttle more than 1s and closed throttle more than 0.1s, three times of continue operation.
4 The malfunction indication light blinks 2 times means ECM initializing is finish.
CAUTION
After turning on the ignitiion switch,step 2 and step 3 must be completed in 32.5s.
ON
Ignition ②Ignition
switch switch ON
OFF
ON
Test ②Test
switch switch ON
OFF
Full open
③Full
Throttle
open
opening
Full close
Malfunction ON ④Malfunction
indication indication
light light blinks
OFF
2 times.
4-15
FI SYSTEM DIAGNOSIS
PlATEAU MODE SETTING

This system is not equipped with IAP sensor, w hen the vehicle is transported to a plateau or from a
plateau to a plain, the altitude cannot be identified automatically. To ensure the normal use of the vehicle, it
is necessary to set the plateau mode manually .
Mode change conditon：1.Do not start the engine; 2. TP sensor is good.
1 Connect the test switch, open the throttle fully.
2 Turn on the ignition switch.
3 Turn on the Ignition switch for 2.5s, turn on test switch.
4 After the ignition switch is on for 10s, enter the plateau mode for selection: the fault indicator
blinks, and the flash mode is changed every 10s, blinks 1 time (mode 1) → blinks 2 times
(mode 2) →blinks 3 times (mode 3)→ blinks 4 times (mode 4)→blinks 1 time (mode 1)
→......(See the table of plateau mode for details);
5 In the require plateau mode (number of flashing lights), full close throttle;
6 After mode setting is successful, malfunciton indication light blinks the times of mode set
i n a cyclic manner.
7 Turn off the ignition switch, pleteau mode setting is complete.
Full open ①Throttle

Throttle ⑤Throttle
opening full open full close
Full close
ON ② Ignition
Ignition
switch switch ON
OFF
ON
③Test switch
Test ON
switch OFF
ON
Malfunction ④P lateau
indication OFF mode
light selection Mode 1 Mode 2 Mode 3 Mode 4 Mode 1 Mode 2 Mode 2
Table of plateau mode
Altitude H Plateau mode Air adjust screw

Mode 1
0 m H 1000 m Pre-set in factory
(Pre-set in factory)
Turn halfway anticlockwise
1000 m H 2500 m Mode 2 based on the pre-set condition.
Mode 3 Turn a circle anticlockwise
2500 m H 3500 m
based on the pre-set condition.
3500 m H 4500 m Mode 4 Turn a circle and a half anticlockwise
based on the pre-set condition.
CAUTION
If the idle speed still fails to meet the setting requirements after setting according to the table of
plateau mode, the idle speed can be adjusted according to the idle speed adjustment method.
4-16
FI SYSTEM DIAGNOSIS
TABLE OF DIAGNOSTIC TROUBLE CODE (DTC)

Malfunction
Starting and
DTC DTC Malfunction part Malfunction descriptions indication
running ability
light
Open circuit/
P0123 short circuit to VCC Starting Yes
14 TP sensor Turns on
P0120 Short circuit to GND Running Yes
Open circuit/
P0115 short circuit to VCC Starting Yes
15 ET sensor Turns on
Open circuit/
P0110 short circuit to VCC
Starting Yes
21 IAT sensor Turns on
Open circuit/ Starting No

24 P0350 Ignition coil short circuit to GND Turns on
Running No

32 P0200 Fuel injector Turns on
short circuit to GND Running No
Short circuit to GND
Open circuit/ Starting Yes
40 P0505 Idle solenoid valve Turns on
short circuit to + B Running Yes
ISC valve is fixed.
41 P0230 Fuel pump Turns on
short circuit to GND Running No
P0130 Short circuit to GND
Starting Yes
44 P0132 Oxygen sensor Short circuit to VCC Turns on Running Yes
P0131 Short circuit to GND
Note: POXXX DTC would only be read by the diagnosis device.
4-17
FI SYSTEM DIAGNOSIS
DIAGNOSIS DEVICE
INSTRUCTION
Brand
Handrail
Touch
screen
Diagnose port USB update port

Power switch
DC12V power input SM card slot

Data port
USE THE DIAGNOSE DEVICE

● Turn off the ignition switch.
● Connect the diagnosis device to battery, then connect the
diagnose device coupler.
4-18
FI SYSTEM DIAGNOSIS
Turn on the ignition switch.

Press down the diagnosis device switch.
Click ”Motorcycle Diagnostic” on the homepage.
Click “Cub”,or click “K system” enter the model selection

page.
Click ”NEX115” on the model selection page.
Enter the defect diagnosis page, display the defect

content.
After the defect is removed, click” Delete DTC”.

After the DTCs are deleted, click”Refresh”, check if the
defect is removed again.After confirming defect is
removed, exit the diagnosis system, turn off the ignition
switch.
4-19
DCP-FI AND FUEL
FI SYSTEM TROUBLESHOOTING
INSPECTION PRIOR TO DIAGNOSIS
Prior to diagnosis, perform the following visual inspections. The reason for visual inspection is that
mechanical failures( such as oil leakage) cannot be displayed on the screen.
● Engine oil volume and oil leakage ● Melted fuse

● Fuel volume and leakage ● Working condition of the malfunction
● Air filter blockage indication light
● Battery condition ● Working condition of the speedometer
● Clearance of air throttle cable ● Exhaust leakage
● Cracking, damaging or loosening of vacuum throat ● Connection of plugs and sockets
FI SYSTEM FAULT ANALYSIS

Fault with specific DTC: System faults that have specific fault codes corresponding to it.
Features: Malfunction indication light displays a single DTC.
Causes: Short or broken circuits in the signal circuit or control circuit of electronic control components;
short or broken circuits in the electronic control components; Short or broken circuits in the ECM.
For example: defective ET sensor and its wire
PROCESS PROCEDURE:
Follow the instructions Check the connection of
in the malfunction the plugs and sockets. Check the terminals of the plugs and sockets.
indication light
Faults in electronic control Check the connection

components or the ECM of wiring.
Faults without specific DTC: The actual fault is not the one indicated by the MaIfunction
indication light or the diagnosis device.
Features: Malfunction indication light shows several DTC at the same time.
Causes: Short or broken circuits in the bus wiring.
PROCESS PROCEDURE:
Check all the Check the bus wiring based Follow the steps mentioned above to
related fuses. on the fault pattern. solve faults in bus wiring.
The motorcycle tests 'normal' using a diagnosis device but will not start or will not work normally after
starting.
Features: The malfunction indication light doesn't display any DTC.
Causes: Non-electrical faults or inaccurate signals in the electrical controlled components.
4-20
FI SYSTEM DIAGNOSIS
DTC “14” : IAP SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
TP Sensor
G/W 4 SG
LG 5 TPS
R 6
ECM coupler (Harness side)
TROUBLESHOOTING
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler
NOTE:
After repairing the trouble, clear the DTC (Refer to page 4-14).
Step 1
TP sensor power supply circuit check
1) Turn off the ignition switch.

2) Remove the left and right windshields.
(Refer to page 6-1)
3) Disconnect the TP sensor coupler .
4-21
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the TP sensor

coupler.
5) If connections are OK, turn the ignition switch ON.
6) Measure the voltage between the R wire and G/W
wire.
09900-25008: Multi-circuit tester set
Tester knob indication: Voltage
TP sensor power supply voltage: 4.5-5.5V

( + terminal: R – - terminal: G/W)
Is check result ok ?
YES Go to step 3 .
NO Go to step 2 .
Step 2
TP sensor ground circuit check
1) Measure the voltage between the R wire and ground.
TP sensor power supply voltage: 4.5-5.5V

( + terminal: R wire – - terminal: Ground)
YES Repair or replace the G/W wire.
NO Repair or replace the R wire.
Step 3 3
TP sensor signal wire check

2) Remove the seat/storage case. (Refer to page 6-1).
3) Disconnect the ECM coupler .
4-22
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the ECM

couplers.
5) If connections are OK, check the following points.
*Resistance
5
Tester knob indication: Resistance
Between Dg wire of TP sensor coupler and ECM

coupler: Infinity .
Between B/G wire of TP sensor coupler and ground:

Less than 1 Ω .
Between Dg wire terminal and R wire terminal and G/W

wire at TP sensor coupler: infinity
*Voltage
Between B/G wire and ground: approx. 0 V

(When the ignition switch is turned on.)
YES Go to step 4 .
NO Repair or replace Dg wire.
4-23
FI SYSTEM DIAGNOSIS
Step 4
TP sensor check
2) Connect the ECM couplers and TP sensor coupler.
3) Insert the needle-point probes to the lead wire
coupler.
4) Turn on the ignition switch.
5) Measure the TP sensor output voltage between the
B/G wire terminal + and G/W wire terminal - with
turning the throttle grip open and close.

TP sensor output voltage: Full close: 0.29-0.71V

Full open: 4.13-4.76V
( + terminal: B/G wire – - terminal: G/W wire)
YES Replace the ECM with a known good one, and
inspect it again.
NO Replace the throttle body with a new one.
4-24
FI SYSTEM DIAGNOSIS
DTC “15”: ET SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ET sensor ECM
Y/R 24 ETS
G/W 4 SG
TROUBLESHOOTING
with a needle-point tester probe to prevent terminal damage.
NOTE:
Step 1
ET sensor input voltage check
(Refer to page6-3)
2) Disconnect the ET sensor coupler .
4-25
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the ET sensor

coupler.
5) If connections are OK, turn the ignition switch ON.
6) Measure the input voltage between the Y/R wire and
and G/W wire.

ET sensor input voltage: 4.9-5.1V
( + terminal: Y/R wire – - terminal: Ground)
( + terminal: Y/R wire – - terminal: G/W wire)
YES Go to step 3 .
NO Go to step 2 .
Step 2
ET sensor circuit check
2) Remove the seat and storage caseI.
(Refer to page 6-1)
4) Check for proper terminal connection to the ECM couplers.

*Resistance

4
24
Between Y/R or G/W wire of injector coupler and ECM
coupler: Less than 1 Ω .
Between Y/R wire or G/W wire and ground: Infinity
4-26
FI SYSTEM DIAGNOSIS
Between Y/R wire or G/Wbr wire: Infinity
*Voltage

Between G/W wire and ground: approx. 0 V

inspect it again.
NO Repair or replace the defective wire harness.
Step 3
ET sensor check
2) Disconnect the ET sensor coupler , remove the
ET sensor .
3) Measure the ET sensor resistence.
ET sensor resistence:
Approx.2.645kΩ. at 20℃ (Terminal-Terminal)

inspect it again.
4-28
NO Replace the ET sensor .
4) Install the ET sensor.
4-27
FI SYSTEM DIAGNOSIS
DTC "21": IAT SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
IAT sensor ECM
R/Y 14 IATS
G/W 4 SG
TROUBLESHOOTING
When using the multi circuit tester, do not strongly touch the terminal of the ECU coupler with a
needle-point tester probe to prevent terminal damage.
NOTE:
Step 1
IAT sensor power circuit check

(Refer to page6-3)
3) Disconnect the IAT sensor coupler .
4-28
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the IAT sensor

coupler.
4) If connections are OK, turn on the ignition switch.
5) Measure the input voltage between the R/Y wire and ground.
6) If OK, measure the input voltage between the R/Y wire and
G/W wire.
IAT sensor input voltage: 4.9-5.1V

( + terminal: R/Y wire – - terminal: Ground)
( + terminal: R/Y wire – - terminal: G/W wire)
YES Go to step 3.
NO Go to step 2.
Step 2
IAT sensor circuit check

2) Remove the seat/storege case. (Refer to page 6-1).

*Resistance
14
Between G/Y wire and G/W wire: Less than 1Ω
Between G/Y wire or G/W wire and ground: Infinity.
4-29
FI SYSTEM DIAGNOSIS
Between the R/W wire and G/W wire: Infinity
* Voltage

Br wire and G/W wire: Approx 0V
(When the ignition switch is turned on)
YES Replace ECM
NO Repair or replace the defective wire.
Step 3
IAT sensor check

2) Disconnect the IAT sensor coupler , take off the IAT
sensor .
3) Measure the IAT sensor resisance
IAT sensor resistence:

1.044-1.276kΩ, at 40℃ ( Terminal-Terminal)
YES Replace the ECM.
NO Replace the IAT sensor.
4) Install the IAT sensor.
4-30
FI SYSTEM DIAGNOSIS
DTC “24”: IGNITION COIL CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Ignition coil
O/G VB
B/G 11 IG
TROUBLESHOOTING
NOTE:
Step 1
Ignition coil circuit check

2) Remove the left and right windshields. (Refer to page 6-3)
3) Disconnect the ignition coil coupler and injector coupler
4-31
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the ignition coil 1

and ECM couplers.
*Resistance

1
7
Between B/G or O/G wire and ground: Less than 1 Ω

1
Between O/G or B/R wire and ground: infinity
Between B/G or O/G wire of injector coupler: infinity. 1
*Voltage 1
Between B/G wire and ground: approx. 0 V

YES Go to step 2
4-32
FI SYSTEM DIAGNOSIS
Step 2 2
Ignition coil check
1) Measure the ignition coil resistance.
09900-25008: Multi-circuit tester
Tester knob indication: Resistance()
Ignition coil primary resistance:

3.15-4.26 Ω (Terminal-terminal)
Ignition coil secondary resistance:
23.8-33.2 kΩ (Terminal-spark plug cap)
2
3) Check the continuity between each terminal and ground.

Ignition coil continuity: ∞Ω( Infinity )
( O/G-ground )
( B/G-ground )
YES Go to step 3 .
NO Replace the ignition coil. 3
Step 3
ECM check
1) Reconnect a new ECM.
NO Replace the ignition coil
4-33
FI SYSTEM DIAGNOSIS
DTC”32”: INJECTOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Fuel injector
INJ 16 V
VB 1 O/G
TROUBLESHOOTING
NOTE:
Step 1
Injector power supply circuit check

(Refer to page 6-3)
3) Disconnect the injector coupler .
4-34
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the injector

coupler.
6) Measure the voltage between O/G wire and ground.
NOTE:
Voltage can be detected only for 3 seconds after ignition switch
is turned on.

Injector power supply voltage: Battery voltage
( + terminal: O/G wire – - terminal; Ground)
YES Go to step 2 .
NO Repair or replace the O/G wire.
Step 2
Injector drive circuit check

4) Check for proper terminal connection to the ECM

couplers.
*Resistance

1
Tester knob indication: Resistance 16
Between V or O/W wire of injector coupler and ECM

coupler: Less than 1 Ω .
Between V or O/W wire and ground: infinity
4-35
FI SYSTEM DIAGNOSIS
DTC “40”: IDLE SOLENOID VALVE CIRCUIT MALFUNCTION

WIRING DIAGRAM
ISC Valve ECM

O/G 1 VB
W/R 28 ISC
TROUBLESHOOTING
NOTE:
4-36
FI SYSTEM DIAGNOSIS
Between V or O/G wire of injector coupler and other

terminal at injector coupler: infinity.
*Voltage
Between V or O/W wire and ground: approx. 0 V

YES Go to step 3
Step 3
Injector resistence check

2) Measure the injector resistance between terminals.
Injector resistance: 11.4-12.6 Ω at 24℃

(Terminal – Terminal)
3) If OK, check the continuity between each terminal and

ground.
Injector continuity: (Infinity)
Replace the ECM with a known good one, and
YES
inspect it again.
Replace the injector with a new one.
NO
4-37
FI SYSTEM DIAGNOSIS
Step 1
Idle solenoid valve drive circuit check
2) Remove the seat and left side cover. (Refer to page 6-1)
3) Disconnect the Idle solenoid valve coupler and ECM
coupler .
4) Check for proper terminal connection to the Idle

solenoid valve coupler and ECM couplers.
*Resistance

1
Between W/R wire terminal and O/G wire terminal at Idle

solenoid valve coupler: infinity
Between W/R wire terminal and O/G wire terminal at Idle

solenoid valve coupler: infinity
4-38
FI SYSTEM DIAGNOSIS
* Voltage
Between W/R or O/G wire and ground: Battery voltage

YES Go to step 2.
NO Repair or replace defective wire.
Step 2
Idle solenoid valve check
1) Remove the idle solenoid valve. (Refer to page 5-11)

2) Check the continuity between each ISC valve terminal
and ground.
Idle solenoid valve continuity ∞ (Terminal-Ground)
3) If OK, check the idle solenoid valve resistance.
Idle solenoid valve resistence: Approx.30Ω at 20℃
NO Replace the idle solenoid valve.
4-39
FI SYSTEM DIAGNOSIS
DTC “41”: FUEL PUMP CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
FP 8 BL/G
VB 1 O/G
Y/B
B/W
FUEL LEVEL GAUGE
NOTE:
Step 1
Fuel pump power supply circuit check

2) Remove the seat/storage case. (Refer to page 6-1)
3) Remove the fuel pump protection cover , disconnect the
fuel pump coupler .
4-40
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the fuel pump

coupler.
6) Check the voltage between O/R wire and ground is
battery voltage.
Fuel relay power supply voltage: Battery voltage

( + terminal: O/G wire – - terminal; G round )
YES Go to step 2 .
Step 2
Fuel pump check
Inspect the fuel pump. (Refer to page 5-4)
YES Go to step 3 .
NO Replace the fuel pump.
Step 3
Fuel pump circuit check

2) Disconnect the ECM .

* Resistance

8
Between O/G wire and Bl/G wire of fuel pump coupler and
ECM coupler: less than 1 Ω.
4-41
FI SYSTEM DIAGNOSIS
Between O/G wire or O/W wire and ground: infinity
* Voltage
Between Bl/G wire and ground: approx. 0 V

inspect it again.
4-42
FI SYSTEM DIAGNOSIS
DTC “44”: OXYGEN SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Oxygen sensor
OX 3 B/BR
SG 4 G/W
NOTE:
Step 1
Oxygen sensor power supply circuit check

2) Remove the left and right windshields. (Refer to page 6-3)
3) Disconnect the oxygen sensor coupler .
4-43
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the HO2 sensor

coupler.
6) Measure the voltage between B/Br wire and ground.
Oxygen sensor power supply voltage: 0.24-0.31V

( + terminal: B/Br wire – - terminal; Ground)
YES Go to step 2 .
NO Repair or replace B/Br wire.
Step 2
Oxygen sensor circuit check

2) Remove the seat/storage case.
(Refer to page 6-1)

*Resistance


4
Between G/W or B/Br wire of injector coupler and ECM

coupler: less than 1 Ω .
Between G/W wire or B/Br wire and ground: Infinity
4-44
FI SYSTEM DIAGNOSIS
Between G/W and B/Br wire of fuel pump coupler: infinity.
*Voltage
Between G/W wire and ground: approx. 0 V

YES Go to step 3 .
NO Repair or replace defective wire.
Step 3
ECM check
1) Reconnect a new ECM.
NO Replace the oxygen sensor.
4-45
FI SYSTEM DIAGNOSIS
SENSORS
TP SENSOR REMOVAL AND INSTALLATION
(Refer to page 5-7 and page 5-9)
IAT SENSOR REMOVAL AND INSTALLATION

Remove the left and right windshields.
(Refer to page 6-3)
Disconnect the IAT sensor coupler , take off the IAT
sensor .
Install the IAT sensor in the reverse order of removal.
ET SENSOR REMOVAL AND

INSTALLATION
(Refer to page 6-3)
Disconnect the ET sensor coupler , take off the IAT
sensor .
Install the ET sensor in the reverse order of removal.
OXYGEN SENSOR REMOVAL AND

INSTALLATION
(Refer to page 6-3)
Disconnect the oxygen sensor coupler , take off the
oxygen sensor wire from the clamp .
Remove the protection cover bracket mounting bolts, take

off the protective cover bracket
Remove the oxygen sensor.
Oxygen sensor: 20-30 N•m
Install the oxygen sensor in the reverse order of removal.
4-46
FUEL SYSTEM AND THROTTLE BODY
CONTENT
FUEL SYSTEM 5-1
FUEL TANK REMOVAL 5-1
FUEL TANK REASSEMBLY 5-1
FUEL PRESSURE INSPECTION 5-2
FUEL PUMP INSPECTION 5-2
FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL 5-3
FUEL PUMP DISASSEMBLY 5-4
FUEL STAINER INSPECTION AND CLEANING 5-5
5
FUEL PUMP AND FUEL LEVEL GAUGE THROTTLE 5-5
BODY 5-7
THROTTLE BODY REMOVAL 5-7
THROTTLE BODY CLEANING 5-8
INSPECTION 5-9
THROTTLE BODY REASSEMBLY 5-9
FUEL INJECTOR REMOVAL 5-10
FUEL INJECTOR INSPECTION 5-10
FUEL INJECTOR REASSEMBLY 5-10
ISC VALVE REMOVAL 5-11
ISC VALVE INSPECTION 5-11
ISC VALVE REASSEMBLY 5-11
DANGER CAUTION
* Far away from fire or spark. * Do not remove part blindly to prevent the
* Take care to the overflow gasoline impurities getting into fuel system.
during the disassembly. * After the throttle body is removed, use adhesive
* Wipe up the overflow gasoline tape to seal the cylinder intake hole to prevent
* Keep the area you work in is the dust from getting into the cylinder.
well-ventilated.
FUEL SYSTEM
FUEL TANK REMOVAL
Drain the gasoline in the fuel tank.
Remove the left and right side covers and tail
cover. (Refer to page 6-3)
Remove the fuel pump
DANGER
* Far away from fire or spark.

* Wipe up the overflow gasoline.
* Keep the area you work in is well-ventilated.
Disconnect the fuel pump coupler and high pressure

fuel hose .
Remove the fuel tank cover belt .

Remove the alarm case mounting screws, take off the
alarm case .
Disconnect the canister absorber hose .
Remove the fuel pump mounting bolts, take off the fuel
tank 7 .
FUEL TANK REASSEMBLY

Reassemble the fuel tank in the reverser order of removal.
CAUTION
Connect the fuel hose to the fuel pump, lock the safe
lock.
5-1
FUEL PRESSURE INSPECTION

Remove the main pipe cover, left and right windshields.
Place a cloth below the high pressure fuel hose , loosen
the fastener, remove the high pressure fuel hose .
Install the special tool to the fuel pump nozzle and fuel
hose.
11F14-023: Pressure inspection tool
● Turn on the ignition switch, check the fuel pressure.
Fuel pressure: Approx 300kPa (3.0kgf/cm²)

A low compression pressure may indicate any of following
malfunctions:
* Fuel hose leakage
* Fuel strainer clogged
* Pressure adjuster
* Fuel pump
If the fuel pressure is higher than the limit may indicate any
of following malfunctions:
* Fuel pump
* Pressure adjuster A To fuel injector nozzle
B To fuel hose
DANGER
Before removing the special tool, turn off the ignition
switch and release the pressure slowly.
FUEL PUMP INSPECTION

Turn on the ignition switch, check if the fuel pump has opening
sound, If the opening sound is not heard, check the
connection for fuel pump coupler. If connection is Ok, the fuel
pump may have defect, replace it with a new one.
5-2
FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL

CONSTRUCTION
Nut Fixing plate Fuel level sensor
Fuel pump High pressure fuel hose Hose clamp
Bolt Seal ring O-ring
Fuel pump cover Cushion
5-3
REMOVAL
Remove the fuel pump cover .
DANGER
* Far away from fire or spark.
* Wipe up the overflow gasoline.
* Keep the area you work in is well-ventilated
Disconnect the fuel pump coupler and high pressure fuel

hose .
Remove the fuel pump mounting nuts, remove the fuel

pump fixing plate and fuel pump .
FUEL PUMP DISASSEMBLY

Remove the fuel stainer .
Disconnect the fuel level sensor coupler, remove the fuel

level and fuel pump o-ring and fuel pump seal ring .
CAUTION
Replace the O-ring with a new one.
5-4
Remove the fuel level gauge sensor wire from the clamp,
disconnect the fuel pump wire coupler .
Remove 4 fasteners, take off the fuel pump .
CAUTION
Replace the O-ring 7 with a new one.
FUEL LEVEL GAUGE INSPECTION

FUEL STAINER INSPECTION AND CLEANING

If the fuel strainer is dirty with sediment, fuel will not flow
smoothly and loss in engine power may result.
CAUTION
Replace the fuel strainer as necessary.
FUEL PUMP AND FUEL LEVEL SENSOR

REASSEMBLY
Reassemble the fuel pump in the reverse order of removal,
pay attention to the following point:
Install the fuel pump to the fuel pump seat.
CAUTION
Replace the O-ring when reassemble the fuel pump.
5-5
Reinstall the fuel pump wire and fuel level sensor wire into
the groove in the reverse order of removal.
Install the new seal ring , O-ring and fuel level sensor
, connect the fuel level sensor coupler properly.
● Install the fuel strainer to the fuel pump, turn the fuel
strainer to fit its hook into fuel pump groove.
Install the fuel pump assembly 7 into the fuel tank slowly as
shown.
CAUTION
Always use new o-ring.
Install the fuel pump installation plate 8 and fuel pump

mounting nuts, insert the fuel pump coupler 9 and high
pressure fuel hose 10 .
Install the fuel pump cover.
5-6
THROTTLE BODY
THROTTLE BODY REMOVAL
Disconnect the idle solenoid valve coupler , throttle
sensor coupler and ET sensor coupler .
Remove the throttle cable , fuel injector coupler and

high pressure fuel hose .
Remove the intake hose mounting bolts 7 .
Loosen the air filter-throttle body clamp bolt 8 .
Disconnect the absorber hose 9

Remove the intake hose-throttle body assembly 10 .
5-7
Remove the throttle body mounting bolts, take off the

throttle body from throttle body-intake hose assembly.
THROTTLE BODY CLEANING

DANGER
Some carburetor cleaning chemicals, especially

dip-type soaking solutions, are very corrosive and
must be handled carefully. Always follow the
chemical manufacturer’s instructions on proper
use, handling and storage.
Use a swab moistened with a carburetor cleaner

(petroleum solvent) to clean the passageways, throttle
valve, and main bore and then dry the cleaned surfaces
with compressed air.
Warning
Do not apply carburetor cleaning chemicals to the

throttle body inner and rubber and plastic products.
Do not use wire or compressed air to clean
passageways.
Do not use a dip-type cleaning solution and do not
allow them to soak.
use cleaning solvent contains chlorine or ketone
element is prohibited.
INSPECTION
Check following items for any damage or clogging.
Replace the damaged part if necessary.
* O-ring
* Throttle valves
* Absorber hose
* Fuel hose
5-8
THROTTLE BODY REASSEMBLY

Reassemble the throttle body in the reverse order of removal.
Replace the O-ring before the installing the throttle body
to engine intake hose.
Install the absorber valve hose, then install the throttle

body-intake hose assembly, use new O-ring and .
Install the intake hose mounting bolt and air filter-throttle

body clamp bolt.
Install the throttle cable .

Adjust the throttle cable play.(Refer to page 2-9)
5-9
FUEL INJECTOR REMOVAL

Remove the fuel injector assembly .
FUEL INJECTOR INSPECTION

Inspect the fuel injector and injector seat if dust or dirt
exists, if any defects are found, clean the filter, check the fuel
hose and fuel tank.
Inspect the fuel injector rubber seal for damage or aging, if

any unusual is found, replace the rubber seal.
FUEL INJECTOR REASSEMBLY

● Reassemble the fuel injector in the reverse order of
removal.
5-10
ISC VALVE REMOVAL

CAUTION
Remove the throttle body from the engine is not

necessary when only removing the ISC valve.
Remove the ISC valve
ISC VALVE INSPECTION

● Check the ISC valve if carbon deposits exists, if it exists,
clean the ISC valve. Replace the throttle body as
necessary.
* ISC valve inspection.(Refer to page 4-43)
ISC VALVE REASSEMBLY

Reassemble the ISC valve in the reverse order of removal,
● Apply a small quantity engine oil to the new O-ring .
● Install the ISC valve.
5-11
CHASSIS
CONTENTS
EXTERIOR PARTS 6-1

HANDLEBAR 6-7
FRONT WHEEL 6-8
FRONT SHOCK ABSORBER 6-13
STEERING STEM 6-18
REAR WHEEL AND REAR BRAKE 6-22
REAR SHOCK ABSORBER/REAR SWING ARM 6-27 6
FRONT BRAKE 6-30
REAR COMBINED BRAKE SYSTEM 6-37
CHASSIS
EXTERIOR PARTS REMOVAL

REMOVAL
SEAT/STORAGE CASE
Open the seat lock, remove the battery cover and battery.
CAUTION
First remove the lead at the battery terminal.
● Remover the seat/storage case.
LEFT AND RIGHT LOWER SIDE COVERS

Remove the left and right lower side covers by removing
the screws.
LEFT AND RIGHT SIDE COVERS

Remove the left and right lower side covers by removing
the screws.
6-1
CHASSIS
FRAME HEAD COVER

Take off the frame head cover by removing the mounting
scerws.
MAIN PIPE COVER

Take off the main pipe cover by removing the mounting
screws.
6-2
CHASSIS
LEFT AND RIGHT WINDSHIELDS ASSEMBLY

Disconnect the left and right front turn signal light
couplers 7 .
● Remove the mounting screws, take off the left and
right windshields assembly .
CENTER COVER
Take off the center cover 8 by removing the mounting
screws.
REAR CARRIER
Take off the rear carrier 9 by removing the rear carrier
mounting bolt.
LEFT AND RIGHT SIDE COVERS AND TAIL COVER

ASSEMBLY
Disconnect the tail light and rear turn signal light coupler 10
6-3
CHASSIS
Remove the left and right side covers and tail cover
assembly mounting screws.
Remove the seat cable, take off the left and right side
covers and tail cover.
HANDLEBAR FRONT COVER

Remove the handlebar front cover mounting screws.
Disconnect the headlamp coupler, remove the handlebar

front cover 13 .
6-4
CHASSIS
METER COVER
Remove the meter cover mounting screws.
Disconnect the speedometer cable .
Disconnect the couplers inside the meter cover assembly.
FRONT FENDER FRONT PART

Remove the front fender front part by removing the front
fender mounting bolts.
6-5
CHASSIS
FRONT FENDER REAR PART

Remove the front fender rear part .
REAR FENDER
● Remove the rear fender mounting bolts.
Disconnect the rear turn signal light coupler .
Remove the rear fender and rear trun signal light
assembly .
INSTALLATION
Install the side cover in the reverse order of removal.
6-6
CHASSIS
HANDLEBAR
REMOVAL
● Remove the handlebar front cover and meter cover.(Refer
to page 6-4)
Remove the wiring harness clamp .
Remove the front brake switch coupler , remove the
wiring harness away.
Remove the master cylinder .

Remove the throttle grip assembly and throttle cable
Remove the handlebar mounting nut, take off the

handlebar .
INSTALLATION
Install the handlebar in the reverse order of romoval. Pay
attedtion to the following points:
Tighten the handlebar mounting nut to the specified torque.
Handlebar mounting nut: 45-55 N•m
When installing the master cylinder, align the master

cylinder holder right side of slit with the mark on the
handlebar, tighen the master cylinder mounting bolt to the
specified torque.
Master cylinder mounting bolt: 8-12 N•m
6-7
CHASSIS
FRONT WHEEL
CONSTRUCTION
Front axle Gearbox Oil seal
Roller bearing Spacer Front tire
Front inner tire Front wheel rim Dust seal Item N•m kgf•m
Front brake disc 11 Collar A Front axle A 40-48 4.0-4.8

B Brake disc bolt B 18-28 1.8-2.8
6-8
CHASSIS
REMOVAL AND DISASSEMBLY

Support the motorcycle with assistant tool.
Remove the front axle nut , draw out the front axle shaft,
remove the front wheel .
Do not operate the front brake lever when removing the

front wheel.
Remove the speedometer gearbox .
Remove the front axle right collar .
Remove the brake disc bolts, take off the brake disc .
INSPECTION AND DISASSEMBLY

OIL SEAL
Inspect the oil seal for wear or damage. Replace the oil seal if
there is something unusual.
6-9
CHASSIS
Remove the oil seal with the special tool.
09913-50121: Oil seal remover
FRONT WHEEL AXLE

Using the special tools, check the axle shaft for runout and
replace it if the runout exceeds the limit.
09900-20606 : Dial gauge (1/100)
09900-20701 : Magnetic stand
09900-21304 : V-block (100mm)
Wheel axle runout:
WHEEL RIM
Make sure that the wheel rim runout does not exceed the
service limit when checked as shown. An excessive amount of
runout is usually due to loose spokes or a bent wheel rim. If
properly tightening the spokes will not correct the runout,
replace the wheel rim.
Wheel rim runout:

WHEEL BEARING
Inspect the wheel bearings for play by hand. Rotate the inner
race by hand to inspect whether abnormal noise occurs and it
rotate smoothly. Replace the bearing if there are any defects.
Remove the bearings on both side with the special tool,

take off the spacer.
09921-20240:Bearing remover tool
6-10
CHASSIS
REASSEMBLY
Reassemble and remount the front wheel in reverse order of
removal. Pay special attention to the following points.
WHEEL BEARING
Apply super grease ”A” to bearings before reassembly.
99000-25010: Super grease "A”
Install left wheel bearing first, then install the spacer

and right wheel bearing using the special tool and
removed wheel bearings .
09924-84510: Bearing installer
The sealed cover of the bearing must face outside.
Remove the removed wheel bearing .
1 Left bearing 3 Right bearing A LH a Clearance

2 Spacer 4 Removed wheel bearing B RH
OIL SEAL
Apply the Super grease ”A” to the dust seal lips.
Install the new dust seals using the special tool.
99000-25010 : Super grease ”A”

09913-70210 : Bearing installing set
6-11
CHASSIS
BRAKE DISC
Make sure that the brake disc is clean and free of any
greasy matter.
Install the brake disc, apply the Thread Lock to the thread
, tighten the brake disc bolts to the specified torque,
99000-32130 : Thread Lock ”1360”
Front brake disc bolt: 18~28 N•m
SPEEDOMETER GEARBOX
Before installing the speedometer gearbox, grease it and
align groove on the speedometer drive gear box with the
boss on the front shock absorber.
FRONT AXLE SHAFT

Install the front wheel right collar and front wheel, tighten
the front axle nut to the specified torque.
Front axle nut: 40-48 N•m
CAUTION
After installing the front wheel, pump the brake lever
until the pistons push the pads correctly.
6-12
CHASSIS
FRONT SHOCK ABSORBER

CONSTRUCTION
1 O-ring 4 Oil seal ITEM N•m kgf•m

2 Dust cover A Cap bolt A 15-30 1.5-3.0
3 Snap ring B Bolt B 15-25 1.5-2.5
6-13
CHASSIS

● Remove the front wheel. (Refer to page 6-8)
Remove the front fender front and rear part.
(Refer to page 6-6)
Lossen the lower bracket mounting bolts, take off the front
shock absorber .
Remove the cap bolt and draw out the spacer, spring seat and
fork spring.
● Invert the absorber and stroke it several times to remove

the oil.
Remove the damper rod bolt by using the special tools

and 8mm inner hexagon wrench.
11F14-010: Front absorber remover and installer
● Remove the oil lock piece and damper rod with rebound
spring.
Separate the inner tube from the outer tube.
6-14
CHASSIS
● Remove the stopper ring.
● Remove the oil seal by using the special tool.
WARNING
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE

Inspect the inner tube and outer tube sliding surface for
any scuffing or flaws.
ABSORBER SPRING
Measure the fork spring free length. If it is shorter than the
service limit, replace it.
Fork spring free length:

* Cleaning: clean the parts with solvent and blow dry.
6-15
CHASSIS
REASSEMBLY
Reassemble the front shock absorber in the reverse order of
disassembly. Pay attention to the following points.:
DAMPER ROD BOLT

Apply Thread lock to the damper rod bolt and tighten the
bolt by using the 8mm hexagon wrench and special tools. T hread lock cement Seal ring
(Copper)
99000-32030: Thread lock "1303"
11F14-010 ：
Front shock absorber remover and installer
Damper rod bolt: 15-25N•m
CAUTION
Always use new seal ring.
OIL SEAL
● install the oil seal with the special tool.
09940-50112: Absorber oil seal installer
CAUTION
Apply a small quantitty of Super grease to the oil seal
lip before assembly.
FRONT FORK OIL

● Pour the specified fork oil into the inner tube.
Front absorber oil capacity (each leg): 61±1 ml
Absorber oil type: MX34 # or equivalent
FRONT SHOCK ABSORBER SPRING

Upside
When installing the front shock absorber spring,
The close-pitch end of spring should position
downside.
Downside
6-16
CHASSIS
INSTALLATION
Install the front shock absorber in the reverse order or
removal. Pay attention to the following points:
Tighten the front shock absorber cap bolt to the specified

torque.
Upper cap bolt: 16-30 N•m
Tighten the lower bracket clamp bolts 2 to the specified

torque.
Lower bracket clamp bolt: 25~35 N•m
6-17
CHASSIS
STEERING STEM
CONSTRUCTION
1 Lock washer 8 Lower steering outer race

2 Steering stem nut 9 Seal ring ITEM N•m kgf•m
3 Upper steering outer race 10 Washer A 25-30 2.5-3.0
4 Upper ball ring 11 Lower bracket B 35-55 3.5-5.5
5 Upper steering inner race A Steer stem lock nut
6 Lower steering inner race B Clamp bolt
7 Lower ball ring
6-18
CHASSIS
REMOVAL
Remove the handlebar. (Refer to page 6-6).
Remove the front wheel.(Refer to page 6-8)
Remove the front shock absorber.(Refer to page 6-14
Remove the steering stem lock nut with the special tool.
11F14-026: Octagonal nut sleeve-32
Remove the lock washer

● Remove the steering stem nut assembly 3 with the spcial
tool.
11F14-029: Single head 4 claws sleeve 42-4x5
CAUTION
Hold the steering stem by hand to prevent from
falling.
Remove the upper steering outer race and lower bracket
Remove the upper and lower steering ball rings.
Remove the outer race fitted on the steering stem. This can
be down with a chisel.
6-19
CHASSIS
Draw out the two inner races fitted to the top and bottom
ends of the head pipe with the special tool.
09941-54911: Bearing remover

09941-74910: Steering bearing installer
INSPECTION
Inspect and check the removed parts for the following
abnormalities.
Race wear and brinelling.
Worn or damaged steel balls.
Distortion of steering stem.
REASSEMBLY
Reassemble and remount the steering stem in the reverse
order of disassembly and removal, and also carry out the
following steps:
INNER RACES
Press in the upper and lower inner races using the special
tool.
09941-34513: Steering race installer
OUTER RACE
Apply grease on the new lower oil seal.
Press in the lower outer race by using the special tool.
09941-74910: Steering bearing installer
STEEL BALL
● Apply grease to the upper and lower inner races when
installing the steel balls.
6-20
CHASSIS
STEERING STEM NUT

Tighten the steering stem nut with the special tool.
Turn the steering stem right and left, lock-to-lock, five or
six times to “seat” the steel ball bearings.
Tighten the steering stem nut to the specified torque with

the special tool.
Steering stem nut: 25-30 N•m
Turn back the stem nut by 1/8-1/4 turn, tigthen the steering Turn back 1/8 -1/4
stem nut to the specified torque.
Steering stem nut: 10N•m

CAUTION
The adjustment will vary from motorcycle to motorcycle.
Tighten the steering stem lock nut to the specified torque.
11F14-026: Octagon nut sleeve-32
Steering stem lock nutL 25-30N • m
6-21
CHASSIS
REAR WHEEL AND REAR BRAKE

CONSTRUCTION
1 Rear axle shaft 14 Rear tire

2 Chain adjuster 15 Rear wheel rim
3 Spacer 16 Brake shoe
4 Rear sprocket 17 Rear brake cam ITEM N•m kgf•m
5 Stud bolt 18 Rear brake anchor panel A 48-58 4.8-5.8
6 Oil seal 19 Spacer B 18-28 1.8-2.8
C 7 - 10 0.7-1.0
7 Roller bearing 20 Rear brake cam lever
8 Rear sprocket drum 21 Adjuster assembly
9 Rear sprocket drum retainer 2 2 Rear brake rod
10 Damper A Nut
11 O-ring B Nut
12 Roller bearing C Nut
13 Spacer
6-22
CHASSIS

● Support the motorcycle with the main stand.
● Remove the chain case nuts, take off the upper and
lower sprocket cases.
Remove the chain adjuster lock nut , adjuster not and

rear axle nut .
Remove the rear brake adjuster nut , take off the rear
brake rod .
Draw out the cotter pin, remove the rear torque link
nut, take off the rear torque link .
Remove the rear axle nut, draw out the rear axle, take off
the spacer, rear brake drum, rear shwel and rear sprocket.
Remove the rear brake drum assembly 7 .
Remove the 4 nuts from the sprocket.

Remove the rear sprocket drum and rear sprocket.
6-23
CHASSIS
Remove the oil seal with the special tool.
Remove the bearing and retainer from rear sprocket drum.
Remove the cushions and spacer.
Remove the left and right side wheel bearings.
09921-20240: Bearing remover
CAUTION
It is easier to remove the left bearing.
REAR BRAKE
(Refer to page 6-8 FRONT BRAKE)
● Install the rear wheel bearing with the special tool.
CAUTION
Remove the right bearing first
09913-70210: Bearing installer set
6-24
CHASSIS
INSPECTION Play
间隙
WHEEL BEARING
Play
间隙
Inspection the wheel bearing for play by hand. Rotate the inner
race by hand to inspect whether abnormal noise occurs and it
rotates smoothly. Replace the bearing if there are any defects.
AXLE SHAFT
Using the special tools, check the axle shaft for runout and
Axle shaft runout: Limit: 0.25 mm
09900-20606: Dial gauge (1/100)

09900-21304: V-block
SPROCKET
Inspect the sprocket teeth for wear. If they are worn as
illustrated, replace the sprocket and drive chain.
Normal wear Excessive wear
CUSHION
● Inspect the cushions for wear and damage.
Replace the cushions if there is anything unusual.
REASSEMBLY
Reassemble and remount the rear wheel and rear brake in
the reverse order of disassemble and removal.
WHEEL BEARING
Apply grease to the bearings before installing.
99000-25010: Super grease ”A”
6-25
CHASSIS
REAR SPROCKET DRUM

Insert the bearing by using the special tool.
Apply grease to the rear sprocket drum as shown, install

the rear sprocket drum retainer.
99000-25010: Super grease”A”
REAR SPROCKET
Apply the Thread lock to threaded part of nut, tighten the
rear sprocket mounting nut to the specified torque.
99000-32130: Thread lock ”1360"
Rear sprocket lock nut: 18-28 N • m
Install the rear wheel and rear sprocket drum.

Tighten the rear torque link nut to the specified torque,
install the cotter pin.
Adjust the chain sag. (Refer to page 2-10)
Rear torque link nut: 10-16 N•m
Tighten the rear sprocket nut to the specified torque.
Rear spocket lock nut: 48-58N·m
6-26
CHASSIS
REAR SHOCK ABSORBER AND REAR SWING ARM

CONSTRUCTION
C
B
1 Rear swing arm shaft 11 Rear torque link

2 Spacer 12 Inspection cover
3 Washer 13 Lower chain case
4 Chain buffer 14 Upper chain case
ITEM N•m kgf•m
5 Spacer 15 Flat washer A 60-80 6.0-8.0
6 Rear swing pivot arm 16 Rear shock absorber B 10-16 1 . 0-1 . 6
7 Cotter pin A Nut C 22-35 2.2-3.5
8 Flat washer B Nut D 22-35 2.2-3.5
9 Spring washer C Nut
10 Bolt D Bolt
6-27
CHASSIS

Remove the tail cover, left and right side cover and
rear carrier. (Refer to page 6-3)
Remove the rear wheel.(Refer to page 6-24)
Remove the rear shock absorber nut, take off the rear
shock absorber
Remove the kick starter lever .
Remove the rear swing arm shaft nut , draw out the rear
swing arm shaft,
Take off the rear swing arm .
Draw out the cotter pin, remove the bolt and nut.
Remove the rear torque link .
Remove the chain buffer .
6-28
CHASSIS
INSPECTION
BUSHING
Inspect the bushing for wear and damage.
ROCKER ARM PIVOT SHAFT

Using a dial gauge, check the pivot shaft for runout and
Pivot shaft runout: Service limit: 0.6 mm
09900-20606: Dial gauge (1/100)

09900-21304: V-block
REASSEMBLY
Reassemble and remount the swing arm in the reverse order
of disassembly and removal, and also carry out the following
steps:
Force-fit he bushings into the swing arm by using the
special tool.
Install the rear torque link, tighten the nut to specified

torque.
Rear torque link nut: 10-16 N•m
Apply grease to the bush of rear swing arm.

Insert the rear rocker arm shaft from the left side, tighten
the rear rocker arm shaft nut to the specified torque.
Tighten the rear shock absorber nut/bolt to the specified
torque.
Rear swing pivot shaft nut: 60-80 N•m

Rear shock absorber bolt/nut:22-35 N•m
6-29
CHASSIS
FRONT BRAKE
CONSTRUCTION
B B
1 Front brake lever 12 Front brake caliper

ITEM N•m kgf • m
2 Piston 13 Air bleeder valve A 8-12 0.8-1.2
3 Reservoir tank cover 14 Brake caliper bracket B 20-25 2.0-2.5
4 Front master cylinder holer 15 Brake caliper pin C 18-28 1.8-2.8
5 Front master cylinder 16 Spring pad
6 Front brake light switch 17 Pin
7 Front brake hose 18 Brake pads
8 Rear brake hose A Bolt
9 Brake hose clamp B Union bolt
10 Brake hose clamp C Bolt
11 Brake hose washer
6-30
CHASSIS
WARNING
The brake system of this motorcycle is filled with a Suzuki brake fluid. Do not use or mix
different types of fuid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will be caused.
Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the
brake fluid left over from the last servicing and stored for long periods.
When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
CAUTION
Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The
brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage
them severely.
Brake Pad Replacement

Loosen brake caliper mounting bolts .
Loosen brake pads mounting bolts .
Remove the brake pads 3 by removing the brake pad

mounting bolt .
Replace brake pads as a set otherwise braking

performance will be adversely affected.
Reinstall the brake pads and brake caliper in the reverse

order of removal.
Tighten the brake caliper mounting bolt to the specified
torque.
Brake caliper mounting bolts: 18~28 N•m
While installing the brake caliper, push the pistons all

the way into the brake caliper.
6-31
CHASSIS
BRAKE FLUID REPLACEMENT

Support the motorcycle with the main stand,
keep the steering straight.
Remove the master cylinder cover and diaphragm.
Draw the brake fluid as mush as possible.
Add new brake fluid to the reservoir tank..
Attach the special tool hose to the brake caliper air

bleeder valve.
Loosen the brake caliper bleed valve nut, starter the
special tool, draw out the brake fluid in the brake system,
and add new brake fluid in the master cylinder as
necessary.
11F14-035: Pneumatic fluid drawer
Tighten the brake caliper bleed valve, take off the special
tool.
Add the new brake fluid to the reservoir tank to the upper
level.
Check the brake performance, if the brake force is
insufficient, apply air bleeding to the brake system.
CALIPER REMOVAL AND DISASSEMBLY

Place a clean rag underneath the union bolt on the brake
caliper to catch any split brake fluid.
Remove the brake hose from the caliper by removing the
union bolt and catch the brake fluid in a suitable
receptacle.
Remove the brake caliper mounting bolt , take off the
brake caliper.
CAUTION
Never re-use the brake fluid left over from the last
servicing and stored for long periods.
BRAKE CALIPER DISASSEMBLY

Remove the sliding pin , brake pads and bracket .
6-32
CHASSIS
Remove the pad spring .
Place a clean rag over the pistons to prevent it from

popping out and then force out the pistons using
compressed air.
CAUTION
Do not use high pressure air to prevent piston damage.
● Remove the piston, piston boot and piston seal.
INSPECTION
CALIPER CYLINDER
Inspect the brake caliper cylinder wall for nicks, scratches
and other damage. If any damage is found, replace the
caliper with a new one.
PISTON
Inspect the brake caliper piston surface for any scratches
and other damage. If any damage is found, replace the
piston with a new one.
BRAKE CALIPER SLIDING PIN

Inspect the brake caliper sliding pin for wear and other damage.
If any damage is found, replace it with a new one.
6-33
CHASSIS
RUBBER PARTS
Inspect the rubber parts for cracks and damage. If any
defects are found, replace the affected parts.
PAD SPRING
Inspect the pad spring for damage and excessive bend. If
any defects are found, replace it with a new one.
BRAKE DISC
Visually inspect brake disc for cracks or damage, and
measure brake disc thickness with a micrometer.
09900-20205: Micrometer (0-25 mm)

Brake disc runout:
Measure runout of the brake disc with a dial gauge.
09900-20606: Dial gauge (1/100 mm)

Brake disc runout:

R E A S S E M B LY
Reassemble and remount the brake caliper in the reverse
orders of disassembly and removal, and also carry out the
following steps.
WARNING
Wash the master cylinder components with fresh brake
fluid before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all internal parts
before inserting into the bore.
6-34
CHASSIS
Apply the super grease to sliding pin.
● Tighten the brake caliper mounting bolt and brake hose
Brake hose union bolt: 20~25 N•m

Brake caliper mounting bolt:18~28 N•m
Refill the brake fluid after reassembling brake caliper. (Refer to
page 6-38)
WARNING
Brake fluid, if it leaks, will interfere with safe running

and immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joint for
leakage
MASTER CYLINDER
R E M O VA L A N D D I S A S S E M B LY
Drain the brake fluid from the master cylinder.
Place a clean rag underneath the union bolt on the master
cylinder to catch any split brake fluid, unscrew the union bolt
and disconnect the brake hose from the master cylinder joint..
Disconnect the front brake switch coupler .
Remove the two clamp boltws and take off the master
cylinder.
Immediately and completely wipe off any brake fluid

contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics, rubber materials, etc. and
will damage them severely.
Remove the brake lever and front brake switch .
6-35
CHASSIS
Remove the dust seal boot .

Remove the circlip 7 and piston 8 by using the special
tool.
09900-06108: Snap ring pliers
INSPECTION
Inspect the master cylinder bore for any scratches or other
damage.
Inspect the piston surface for scratches or other damage.
Inspect the primary cup, secondary cup and dust seal boot
for wear or damage.
R E A S S E M B LY
Reassemble and remount the master cylinder in the reverse
following steps:
Wash the master cylinder components with fresh brake
fluid before reassembly.
Brake fluid specification: Haojue brake fluid
CAUTION
When washing the components, use the specified
brake fluid. Never use different types of fluid or
Mark Master cylinder
cleaning solvents such as gasoline, kerosine, etc.
Do not wipe the brake fluid off after washing the
components.
Apply brake fluid to the cylinder bore and all internal
parts before inserting into the bore. Up
When remounting the master cylinder on the handlebars, first Handlebar

tighten the clamp bolt for upside as shown. Align the mark on the
handlebar with the mating slit. Clearance
Connect the brake hose, tighten the union bolt to the

specified torque.
Brake hose union bolt: 20~25 N•m
Refill the brake fluid after installing the master cylinder.

6-36
CHASSIS
REAR COMBINED BRAKE SYSTEM

CONSTRUCTION
1 Rear reservoir tank cover 11 Piston

ITEM N·m k g f·m
2 Rear master cylinder cover 12 Dust cap
A 8-12 0.8-1.2
3 Rear reservoir tank diam 13 CBS transmission bar
Rear brake linked
B 20-25 2 . 0 -2.5
4 Rear reservoir tank 14 rocker arm shaft C 18-28 1 . 8 -2.8
5 Bundy pipe clamp 15 Washer
6 Bundy pipe 16 Cotter pin
Rear master cylinder
7 Rear brake hose A mounting bolt
8 Rear master cylinder B Union bolt
Rear reservoir tank
9 Rear master cylinder bracket C mounting bolt
10 Rear master cylinder bracket connect hose
6-37
CHASSIS
REAR BRAKE MASTER CYLINDER

A N D R E S E RV O I R TA N K R E M O VA L
A N D D I A S S E M B LY
REMOVAL
Remove the rear brake fluid reservoir tank cap , seal
plate and diaphragm.
● Attach the special tool hose to the brake caliper air
bleeder valve , loosen the brake caliper bleed valve 2,
starter the special tool, draw out the brake fluid in the brake
system,.

Remove the kick starter lever .
Place a cloth around the brake hose, remove the rear

brake hose union bolt .
Remove the rear brake mastery cylinder and reservoir
tank .
Remove the bundy hose 7 .
6-38
CHASSIS
REASSEMBLY
Reassemble and remount the rear brake system in the reverse
following steps:
When installing the bundy hose, first tighten the bundy hose nut
with hand, then tighten the bundy hose nut to the specified
torque.
Bundy hose nut:12-17 N•m
Install the rear brake master cylinder and reservoir tank ,

tighten the mounting bolt to the specified torque.
Rear brake master cylinder mounting bolt: 8-12 N•m

Rear brake reservoir tank mounting bolt: 18-28 N•m
When installing the washer, the coarse side faces to brake

hose side.
Tighten the brake fluid hose union bolt 3 to the specified
torque.
Brake hose union bolt:20-25 N•m
REFILL THE BRAKE FLUID

Refill the brake fluid to rear reservoir tank.
Attach the special tool hose to the brake caliper rear bleeder
valve , start the special tool draw out the brake fluid slowly,
add the brake fluid into the reservoir tank as the same time until
the brake fluid flows out of hose.
After filling the brake fluid to the rear brake reservoir tank,
apply the air bleeding to the brake fluid circuit.
6-39
E L E C T R I C A L
CONTENTS
CHARGING SYSTEM 7-1

STARTER SYSTEM 7-4
IGNITION SYSTEM 7-7
COMBINATION METER 7-9
LIGHTS 7-10
SWITCHES 7-11
BATTERY 7-13
7
ELECTRICAL
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in the figure, which is composed of an AC generator,
regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current, then is
charges the battery.
Ignition switch
Battery
Load
Regulator/rectifier
Generator
TROUBLESHOOTING
Battery runs down quickly
Check accessories which excessively

Installed Remove accessories
waste electric power
Not installed
Inspect battery leak current Leak Short circuit of wiring harness.

Loose or disconnected wires.
No leak Faulty battery.
Inspect charging voltage

between battery terminals. Correct Faulty battery.
Abnormal driving condition.
Incorrect
Inspect continuity of generator coils No continuity Faulty generator coils or

disconnected lead wires.
Correct
Inspect generator no-load voltage Incorrect Faulty generator rotor.
Correct
(to next page ) 7-1

ELECTRICAL
(Continue the last page)
Inspect regulator/rectifier. Incorrect Faulty regulator/rectifier
Correct
Inspect wirings Incorrect Short circuit of wiring harness.

Poor contact of couplers
Correct
Faulty battery
Others
Battery overcharge Faulty regulator/rectifier

Faulty battery
Poor contact of generator
wire coupler.
INSPECTION
BATTERY LEAK CURRENT INSPECTION
Open the seat, Remove the battery case 1 .
Turn off the ignition switch..
Disconnect the battery - lead wire.
Measure voltage between the battery - terminal and the
specified ground cable terminal. If the reading exceeds the
specified value, then leakage is present.

Battery leakage: Less than 0.1mA
Test scale: Current ( --- , 20mA) mA
CAUTION
* Because the leak current might be large, turn the
tester to high range first when connecting an
ammeter.
* Do not turn on the ignition switch when measuring
current.
7-2
ELECTRICAL
CHARGING OUTPUT INSPECTION

● Remove the battery case cover
● Start the engine, keep it running at 5 000 r/min, with
● lighting switch turned ON and dimmer switch turned HI
position.
CAUTION
When making this test, be sure that the battery is

fully-charged condition.

Ignition switch
Charging output Rectifier
Standard: 14.0-15.0V at 5 000 r/min
Battery
GENERATOR COIL INSPECTION

Remove the helmet case. (Refer to page 6-1)
Disconnect generator coupler .
Measure the resistence between the lead wires, if the
resistence is incorrect, replace the generator coil.

Generator coil resistance: 0.4-1.2 Ω (Y-Y)
REGULATOR / RECTIFIER INSPECTION

If the inspections above are normal, replace the rectifier
with a new one.
7-3
ELECTRICAL
STARTER SYSTEM
The starter system is shown in the diagram below: namely, the starter motor, starter relay, starter button,
clutch switch, ignition switch and battery.
Depressing the starter switch (on the right handlebar switch box) energizes the relay, causing the contact points
to close which connects the starter motor to the battery. The motor draws about 70 amperes to start the engine.
Starter relay
Starter button Ignition switch on
Fuse
Starter motor
Clutch switch
* Inspection:
TROUBLESHOOTING Battery is fully-charged.
Fuse is not blown before the diagnosis.
Starter motor will not run
Check whether to run the starter

motor when connect the starter
Check whether to hear the click noise
Clicks motor terminal to the battery
from the starter relay when the starter
terminal directly. (Do not use thin
button is pushed.
wire, because a large amount
of current flows.)
No click
Run Not run
● Faulty starter relay ● Faulty starter motor
Measure the starter relay voltage at the ● Loose or disconnected starter
starter relay connectors (between O motor lead wire
and Y/G ) when the starter button is Not voltage ● Faulty ignition switch
pushed. ● Faulty front brake light switch
● Faulty rear brake light switch
● Faulty starter button
Voltage measured ● Poor contact of connector
● Open circuit in wiring harness
Check the starter relay

Incorrect ● Faulty starter relay
(Refer to page 6-9)
Starter motor runs, ● Open circuit in wiring harness

but does not start engine. ● Poor contact of connector
● Faulty CDI unit
● Faulty ignition coil
● Faulty generator
● Faulty starter clutch
7-4
ELECTRICAL
STARTER MOTOR REMOVAL AND DISASSEBMLY

Disassemble the starter motor as shown.
STARTER MOTOR REMOVAL AND DISASSEMBLY

● Remove the starter motor. (Refer to page 3-6)
● Remove the starter motor mounting screws, disassemble
the starter body,
● Remove the starter motor screws, take off the following parts:
* Starter motor case
* Armature shaft
* Housing end(Inside)
STARTER MOTOR INSPECTION

CARBON BRUSHES
Inspect carbon brush for cracks or abnormal wear. If any

defects are found, replace with a new carbon brush assembly.
7-5
ELECTRICAL
COMMUTATOR
If the commutator surface shows abnormal wear, replace with
a commutator.
If the commutator surface is worn unevenly, polish with
no,.400 sand paper and wiped with a clean dry cloth.
If there is no undercut, scrape out insulator 1 with a saw
blade.
ARMATUR COIL
Inspect for continuity between each segment and between
each segment and the armature shaft using the multi circuit
tester.
If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
armature with a new one.

Tester knob indication : Continuity test
STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of
disassembly. Pay attention to the following points:
STARTER RELAY INSPECTION

Apply 12 volts to terminals A and B , inspect the
continuity between the terminals, positive and negative.
If the starter relay clicks and continuity is found, the
relay is OK.

Test scale: continuity
CAUTION
Do not apply a battery voltage more than 5 seconds to
the starter relay as It may overheat and cause damage
to the relay coil.
Disconnect the starter relay coupler, measure the relay

coil resistance between the terminals using the multi
circuit tester. If the resistance is not within the specified
value, replace the starter relay with a new one.

Test range: Resistence
Starter relay resistence: 90-110 Ω

7-6
ELECTRICAL
IGNITION SYSTEM
DESCRIPTION
In the capacitor discharged ignition system, the electrical energy generated by the generator charges the
capacitor. The energy is released in a signal surge at the specified ignition timing, and current flows
through the primary side of the ignition coil. A high voltage current is induced in the secondary windings of
the ignition coil resulting in strong spark between the spark plug gap.
Ignition switch
O
W Fuse
Pick-up coil
Bl/W
Igniter Ignition coil
G/W 火花塞
蓄电池
Generator
黑/白
TROUBLESHOOTING
No spark at plug * Check the ignition switch is ” ” position.
Inspect
that the fuse is not blown before the diagnosis.
Inspect the battery voltage Less than 12V Recharge the battery or
replace the battery
12V
Check the CDI unit couplers

Looseness Poor contact of couplers
for poor contact
Correct
Inspect the ignition system

compoents and couplers. Incorrect Faulty ignition switch
Broken wire harness or poor
Correct contact of related circuit
connectors
Inspect the resistance of pick-up Incorrect Faulty pick-up coil
coil (Bl/W and G/W)
Correct
Faulty igniter
Faulty ignition coil
Faulty high-tension cord
7-7
ELECTRICAL
INSPECTION
IGNITION COIL
Measure the ignition coil resistence with the multi-circuit
tester.
Tester knob indication : resistence
Primary: 3.15~4.26 Ω (tap-tap)

Secondary: 23.8~33.2 K Ω (tap - Plug cap)
PICK-UP COIL RESISTANCE

Measure resistance between lead wires using multi-circuit
tester. If resistance is out of specified values, replace with
new pick up coil.
Tester knob indication : Resistence
Pick up coil resistance: 100-140 Ω (G/W-Bl/W)
SPARK PLUG
用金属丝或针清除火花塞积炭，调整火花塞间隙至0. 8 -
0.9mm，用塞尺测量。
当清除积炭时，注意火花塞陶瓷及电极颜色。通过观察颜
色，可判断出标准火花塞是否合适。如果标准火花塞易于潮
湿，则应改为热型火花塞，如果标准火花塞易过热（陶瓷变
白），则应更换冷型火花塞。
火花塞标准间隙: 0 .8- 0 . 9 m m
0 9 900-20803 : 塞尺
种类 NGK
热型 CPR5EA
0.8～0.9 mm
标准型 CPR6EA
冷型 CPR7EA
IGNITER
If ignition system has defect and no problem is found through
the inspections above, replace the igniter.
7-8
ELECTRICAL
COMBINATION METER
Remove the combination meter.(Refer to page5-5)
Disassemble the combination meter as shown.
Meter top case Meter bottom case Meter wire

Meter panel Speedometer cable Gear position indicator coupler.
Meter unit Bulb
INSPECTION
Combination meter
Using the pocket tester, check the continuity between lead Lights 1
Gear switch
2 3 4
Fuel
wires. N FI
gauge
+ -
If the continuity measured is incorrect, replace the
respective part.
Lg/B
B/W
Y/B
G/Bl
W/Y
Y/Bl
Gr
Bl
Lg
R/B
O
O
B
Y
Test range selection: Continuity

Meter
CAUTION
When making this test, it is not necessary to remove
the dashboard.
7-9
ELECTRICAL
LIGHTS
HEADLAMP TURN SIGNAL LIGHT
TAIL LIGHT/BRAKE LIGHT
REMOVAL
Remove the handlebar front cover.(Refer to page5-4)
Remove the headlamp bulb and position light bulb,

(Refer to page 5-3)
Remove the front turn signal light bulb.
7-10
ELECTRICAL
Remove the rear turn signal light lens, replace the rear turn
signal light bulb.
● Remove the left and right side cover and tail

cover. (Refer to page 5-3)
● Replace the tail light bulb.
SWITCHES
Inspect each switch for continuity with the pocket tester. If
any abnormality is found, replace the respective switch
assemblies with new ones.
Test scale: Continuity
IGNITION SWITCH
Bl/Y B/W R O/R
○ ○
OFF ○ ○
ON ○ ○
LIGHT SWITCH 1
Y/W O O Gr
○ ○ ○ ○
○ ○
STARTER SWITCH 2
B/W Y/G
OFF
○ ○
7-11
ELECTRICAL
FRONT BRAKE LIGHT SWITCH 3

O W/B
OFF
ON ○ ○
DIMMER SWITCH 4
Y/W W Y
○ ○
○ ○
TURN SIGNAL LIGHT SWITCH 5

B Lbl Lg
○ ○
○ ○
HORN SWITCH 6
O G
OFF
○ ○
REAR BREAK LIGHT SWITCH 7

O W/B
OFF
ON ○ ○
GEAR POSTITION INDICATOR LIGHT SWITCH 8

Ground Bl W/Y R/B G/Bl Y/Bl
○ ○
Neutral
○ ○
1st
○ ○
2nd
○ ○
3rd
○ ○
4th
7-12
ELECTRICAL
BATTERY
SPECIFICATIONS
Type YB5L-A2
Capacity 5 Ah
Standard electrolyte S.G. 1.28 ± 0.01 20OC
In fitting the battery to the motorcycle, connect the breather

tube to the battery vent.
INITIAL CHARGING
Remove short sealed tube before filling electrolyte. Fill
battery with electrolyte (dilute sulfuric acid solution with acid
concentration of 35% by weight, having a specific gravity of
1.28 at 20 OC/86 OF) up to indicate UPPER LEVEL. Filling
electrolyte should be always cooled below 20 OC/86 OF before
filling into battery. Leave battery standing for half an hour
after filling. Add additional electrolyte if necessary.
Standard Charging current 0.5 A
CHARGING TIME
The charging time for a new battery is determined by the
number of months that elapsed since the date of manufacture.
Near the end of the charging period, adjust the specific gravity
of electrolyte level to the UPPER LEVEL with DISTILLED
WATER.
Months after 6-12 Over 12
manufacturing
Necessary
5 8
charging hours
Servicing
Visually inspect the surface of the battery container. If any
signs of cracking or electrolyte leakage from the sides of
the battery have occurred, replace the battery with a new
one.
● If the battery terminals are found to be coated with rust or
an acidic white powdery substance, then this can be
cleaned away with sandpaper.
7-13
ELECTRICAL
Check the electrolyte level and add distilled water, as

necessary, to raise the electrolyte to each cell’s upper level.
Check the battery for proper charge by taking an electrolyte
S.G. reading. If the reading is 1.22 or less, as corrected to
20 it means that the battery is still in a run-down condition
and needs recharging.
CAUTION
Disconnect the lead wire first.
BASED ON S.G. READING
Specific gravity
Normal
RECHARGING OPERATION Recharge
To read the S.G. on the hydrometer, bring the electrolyte in the

Recharge or Replace
hydrometer to eye level and read the graduations on the float
scale bordering on the meniscus (curved-up portion of
electroylte) as shown in figure. Temperature
Check the reading (as corrected to 20 ) with chart to
determine the recharging time in hours by constant-current
charging at a charging rate of 0.7A,
Be careful not to permit the electrolyte temperature to exceed
45 , at any time during the recharging operation. Interrupt the
operation, as necessary, to let the electrolyte cool down.
Recharge the battery to the specification.
Hydrometer
09900-28403 : Hydrometer
Electrolyte specific gravity: 1.28 ± 0.01 20 c
CAUTION
Before charging a battery, remove the seal cap from each
cell.
Specific gravity
Keep fire and sparks away from a battery being charged.

When removing a battery from the motorcycle, be sure to
remove the terminal first.
CAUTION
Constant-voltage charging, otherwise called “quick”

charging, is not recommendable for it could shorten the life
of the battery.
CAUTION
When a battery is left for a long term without using, it is apt

to be subject to sulfation. When the motorcycle is not used
for more than 1 month (especially during the winter season),
recharge the battery once a month at least.
7-14
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 8-1
SPECIAL TOOLS 8-11
TIGHTENING TORQUE 8-13
SERVICE DATA 8-15
WIRE HARNESS, CABLE AND HOSE ROUTING 8-20
EMISSION EVAPORATION CONTROL SYSTEM 8-22
FRONT BRAKE HOSE INSTALLATION 8-23
REAR BRAKE PEDAL INSTALLATION 8-24
8
SERVICE INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
(Refer to page 4-14 to 4-17)
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low

or is hard to start 1. Valve clearance out of adjustment. Adjust
2. Worn valve guides or poor seating Repair or replace
3. Mistiming valves Adjust
4. Excessively worn piston rings Replace
5. Worn-down cylinder bores Replace
6. Too slowly starter motor cranks See electrical section
7. Poor seating of spark plugs Retighten
Plug not sparking

1. Fouled spark plugs Clean or replace
2. Wet spark plugs Clean or dry
3. Defective ignition coils Replace
4. Defective CKP sensor Replace
5. Defective ECM Replace
6. Open-circuited wiring connections Replace
7. Open or short in high-tension cords Repair or replace
No fuel reaching the injector

1. Clogged fuel filter or fuel hose Clean or Replace
2. Defective fuel pump Replace
3. Defective fuel pressure regulator Replace
4. Defective fuel injector Replace
5. Defective fuel pump relay Replace
7. Open-circuited wiring connections Inspect and repair
Incorrect fuel/air mixture

1. TP sensor out of adjustment Adjust
4. Defective TP sensor Replace
6. Defective IAP sensor Replace
8. Defective ECT sensor Replace
9. Defective IAT sensor Replace
10. Clogged ISC valve air passage way Repair or replace
8-1
SERVICE INFORMATION

Engine idles poorly 1. Valve clearance out of adjustment Adjust.
2. Poor seating of valves Replace or repair.
3. Defective valve guides Replace.
4. Worn down camshaft Replace.
5. Too wide spark plug gaps Adjust or replace.
6. Defective ignition coils Replace.
7. Defective CKP sensor Replace.
8. Defective ECM Replace.
9. Defective TP sensor Replace.
10. Defective fuel pump Replace.
11. Imbalanced throttle valve Adjust.
12. Damaged or cracked vacuum hose Replace.
13. Damaged or clogged ISC valve Replace or repair.
14. ISC bad learning Reset learned value.
Engine stalls often Incorrect fuel/air mixture

1. Defective IAP sensor or circuit Repair or replace.
2. Clogged fuel filter Clean or replace.
3. Defective fuel pump Replace.
4. Defective fuel pressure regulator Replace.
5. Defective ET sensor Replace.
6. Defective thermostat Replace.
7. Defective IAT sensor Replace.
8. Damaged or cracked vacuum hose Replace.
9. Damaged or clogged ISC valve Replace or repair.
Fuel injector improperly operating

1. Defective fuel injectors Replace.
2. No injection signal from ECM Repair or replace.
3. Open or short circuited wiring connection
4. Defective battery or low battery voltage Repair or replace.
Replace or recharge..
Control circuit or sensor improperly
operating
6. Defective ECT sensor Replace
7. Defective fuel pump relay Replace
8. Defective ISC valve Replace
9. ISC bad learning Reset the learn value
Engine internal parts improperly operating

1. Fouled spark plugs Clean
2. Defective CKP sensor or ECM Replace
3. Clogged fuel hose Clean
4. Out of adjustment valve clearance Adjust
8-2
SERVICE INFORMATION
Noisy engine Excessive valve chatter

1. Too large valve clearance
Adjust
2. Weakened or broken valve springs
Replace
3. Worn rocker arm or cam surface
Replace
4. Worn and burnt camshaft journal.
Replace
Noise seems to come from piston
1. Worn down pistons or cylinders Replace
2. Carbon combustion chambers fouled with Clean
carbon
3. Worn piston pins or piston pin bore Replace
4. Worn piston rings or ring grooves Replace
Noise seems to come from timing chain

1. Stretched chain Replace
2. Worn sprockets Replace
3. Tension adjuster not working Repair or replace
Noise seems to come from clutch

1. Worn splines of countershaft or hub Replace
2. Worn teeth of clutch plates Replace
3. Distorted clutch plates, driven and drive Replace
4. Worn clutch release bearing Replace
Noise seems to come from crankshaft

1. Rattling bearings due to wear Replace
2. Worn and burnt big-end bearings Replace
3. Worn and burnt journal bearings Replace
4. Too large thrust clearance Replace thrust bearing
Noise seems to come from balancer

1. Worn and burnt journal bearings Replace
Noise seems to come from transmission

1. Worn or rubbing gears Replace
2. Worn splines Replace
3. Worn or rubbing primary gears Replace
4. Worn bearings Replace
8-3
SERVICE INFORMATION
Engine runs poorly Defective engine internal/electrical parts

in high speed range 1. Weakened valve springs Replace
2. Worn camshaft Replace
3. Valve timing out of adjustment Adjust
4. Too narrow spark plug gaps Adjust
5. Ignition not advanced sufficiently due to Replace ECM
poorly working timing advance circuit
6. Defective ignition coils Replace
9. Clogged air cleaner element Clean
10. Clogged fuel hose, resulting in inadequate Clean
fuel supply to injector
Defective air flow system

1. Clogged air cleaner element Replace
2. Defective throttle valve Adjust or replace
3. Sucking air from throttle body joint Repair or replace
5. Imbalanced throttle valve synchronization Adjust
Defective control circuit or sensor

1. Low fuel pressure Repair or replace
5. Defective GP switch Replace
8-4
SERVICE INFORMATION
Engine lacks power Defective engine internal/electrical parts

1. Loss of valve clearance Adjust
2. Weakened valve springs Replace
3. Valve timing out of adjustment Adjust
4. Worn piston rings or cylinders Replace
5. Poor seating of valves Repair
6. Fouled spark plugs Clean or replace
7. Incorrect spark plugs Adjust or replace
8. Clogged fuel injectors Replace
10. Clogged air cleaner element Clean
11. Sucking air from throttle valve or vacuum Tighten or replace
hose
12. Too much engine oil Drain excess oil
13. Defective fuel pump or ECM Replace
14. Defective CKP sensor and ignition coils Replace
Defective control circuit or sensor
1. Low fuel pressure Repair or replace
4. Defective CKP switch Replace
Engine overheats Defective engine internal parts

1. Heavy carbon deposit on piston crowns Clean
2. Not enough oil in the engine Add oil
3. Defective oil pump or clogged oil circuit Replace or clean
4. Sucking air from intake pipes Tighten or replace
5. Use incorrect engine oil Replace
Lean fuel/air mixture

1. Short-circuited IAP sensor/lead wire Repair or replace
2. Short-circuited IAT sensor/lead wire Repair or replace
3. Sucking air from intake pipe joint Repair or replace
4. Defective fuel injectors replace
5. Defective ET sensor replace
Other factors
1. Ignition timing is too advanced due to Replace
defective timing advance system (ET
sensor, CKP sensor and ECM)
2. Drive chain is too tight Adjust
3. ISC bad learning Reset the learned value
8-5
SERVICE INFORMATION

Dirty or heavy 1. Too much engine oil in the engine Drain excess oil
exhaust smoke 2. Worn piston rings or cylinders Replace
3. Worn valve guides Replace
4. Scored or scuffed cylinder walls Replace
5. Worn valves stems Replace
6. Defective stem oil seal Replace
Slipping clutch 1. Weakened clutch springs Replace

2. Worn or distorted pressure plate Replace
3. Distorted clutch plates Replace
4. Clutch release screw out of adjustment Adjust
Dragging clutch 1. Some clutch spring weakened while Replace

others are not
2. Distorted pressure plate or clutch plates Replace
3. Clutch release screw out of adjustment Adjust
Transmission will 1. Broken gearshift cam Replace

not shift 2. Distorted gearshift forks Replace
3. Worn gearshift pawl Replace
Transmission will 1. Broken return spring on shift shaft Replace

not shift back 2. Rubbing or stickily shift shaft Repair
3. Distorted or worn gearshift forks Replace
Transmission jumps 1. Worn shifting gears on driveshaft or Replace

out of gear countershaft
2. Distorted or worn gearshift forks Replace
3. Weakened stopper spring on gearshift Replace
stopper
4. Worn gearshift cam stopper plate Replace
8-6
SERVICE INFORMATION
CHASSIS
Steering feels too 1. Steering stem nut overtightened. Adjust.

heavy or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Steering oscillation. 1. Loss of balance between right and left front Replace.
suspensions.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobbly front wheel. 1.Distorted wheel rim. Replace.

2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.
Front suspension 1. Weakened springs. Replace.

too soft. 2. Not enough fork oil. Refill.
Front suspension 1. Fork oil too viscous. Replace.

too stiff. 2. Too much fork oil. Remove excess oil.
Noisy front 1. Not enough fork oil. Refill.

suspension. 2. Loose nuts on suspension. Retighten.
Wobbly rear wheel. 1. Distorted wheel rim. Remedy

2. Worn-down rear wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushings. Replace.
6. Loosen nuts on the rear shock. Retighten.
Rear suspension 1. Weakened springs. Replace.

too soft. 2. Rear suspension adjuster improperly set. Adjust.
Rear suspension 1. Rear suspension adjuster improperly set. Adjust.

too stiff. 2. Worn swing arm bushings. Replace.
Noisy rear 1. Loose nuts on suspension. Retighten.

suspension 2. Worn swing arm bushings. Replace.
8-7
SERVICE INFORMATION
BRAKE
Insufficient brake 1. Leakage of brake fluid from hydraulic Repair or replace.

power system
2. Worn pads Replace.
3. Friction surfaces of pad are dirty oil or dust Clean disc/pads or replace.
4. Worn disc Replace.
5. Air in hydraulic system Bleed air.
6. Not enough brake fluid in the reservoir. Replenish.
Brake squeaking 1. Carbon adhesion on pad surface Repair surface with
sandpaper.
2. Tilted pad Correct pad fitting or
replace.
3. Damaged wheel bearing Replace.
4. Loosen front wheel axle or rear wheel axle Tighten to specified
torque.
5. Worn pads Replace.
6. Foreign material in brake fluid Replace brake fluid.
7. Clogged return port of master cylinder Disassemble and
clean master cylinder.
Excessive brake 1. Air in hydraulic system Bleed air.

lever stroke 2. Insufficient brake fluid Replenish fluid to specified
level; bleed air.
3. Improper quality of brake fluid Replace with correct fluid.
Leakage of brake 1. Insufficient tightening of connection joints Tighten to specified torque.

fluid 2. Cracked hose Replace.
3. Worn piston and/or cup Replace piston and/or cup.
Brake drags 1. Rusty part Clean and lubricate.

2. Insufficient brake lever or brake pedal Lubricate.
pivot lubrication
8-8
SERVICE INFORMATION
ELECTRICAL
No sparking or 1. Defective ignition coils Replace.

poor sparking. 2. Defective spark plugs Replace.
3. Defective CKP sensor Replace.
4. Defective ECM Replace.
5. Defective TO sensor Replace.
6. Open-circuited wiring connections Check and repair.
Premature carbon 1. Mixture too rich Inspect FI system.

buildup on spark plug 2. Excessively high idling speed Inspect FI system.
3. Incorrect gasoline Change.
4. Dirty air cleaner element Replace.
5. Too cold spark plugs Replace with hot type plug.
Spark plug become 1. Worn piston rings Replace.

fouled too soon. 2. Worn piston or cylinders Replace.
3. Excessive clearance of valve stems in valve Replace.
guides
4. Worn stem oil seal Replace.
Spark plug electrodes 1. Too hot spark plugs Replace with cold type
overheat or burn plugs.
2. Overheated the engine Tune up.
3. Loose spark plugs Retighten.
4. Too lean mixture Inspect FI system.
Generator does not 1. Open- or short-circuited lead wires, or loose Repair or replace or
charge lead connections retighten.
2. Short-circuited, grounded or open generator Replace.
coil
3. Short-circuited or punctured rectifier. Replace.
Generator does 1. Lead wires tend to get shorted or open- Repair or retighten.
charge, but charging circuited or loosely connected at terminals
rate is below the 2. Grounded or open-circuited generator coil Replace.
specification 3. Defective regulator/rectifier Replace.
4. Defective cell plates in the battery Replace the battery.
Generator 1. Internal short-circuit in the battery Replace the battery.

overcharges 2. Damaged or defective regulator/rectifier Replace.
3. Poorly grounded regulator/rectifier Clean and tighten ground
connection.
Unstable charging 1. Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent short-circuiting
2. Internally shorted generator Replace.
3. Defective regulator/rectifier Replace.
Starter button is not 1. Run down battery Charge or Replace.

effective. 2. Defective switch contacts Replace.
3. Brushes not seating properly on starter Repair or Replace.
motor commutator
4. Defective starter relay Replace.
5. Defective main fuse Replace.
8-9
SERVICE INFORMATION
BATTERY
“Sulfation”, acidic 1. Not enough electrolyte. Pour distilled water or electrolyte

white powdery 2.Battery case is cracked. Replace.
substance or spots 3.Battery has been left in a run-down Replace
on surface of cell condition for a long time. .
plates. If "sulfation" has not advanced
4.Contaminated electrolyte (Foreign matter too far, try to restore the battery
has enters the battery and become mixed by replacing the electrolyte,
with the electrolyte.) recharging it fully and then
adjust the electrolyte S.G.
Battery runs 1. The charging method is not correct. Check the generator,
down quickly. regulator/rectifier and
circuitconnections and make
necessary adjustments to
obtain specified charging
operation.
2. Cell plates have lost much of their active material Replace the battery and
as result of over-charging. correct the charging system.
3.A shorted circuit condition exists within the Replace the battery.
battery due to excessive accumulation of
sediments caused by the high electrolyte S.G.
4.Battery is too old. Replace the battery.
Reversed battery The battery has been connected the wrong way Replace the battery and be
polarity. round in the system, so that it is being charged sure to connect the battery
in the reverse direction. properly.
Battery “sulfation” 1. Incorrect charging rate (When not in use Replace the battery.
batteries should be east once a month to
avoid sulfation).
2. The battery was left unused in a cold climate Replace the battery if badly
for too long. sulfated.
Battery discharges
too rapidly. 1. Dirty container tap and sides. Clean.
8-10
维修信息
Special tool
09900-06107 09900-06108 09900-20103 09900-20202 09900-20203

Snap ring pliers Snap ring pliers Vernier calipers Micrometer Micrometer
(open type) (closing type) (1/50mm, 300mm) (1/100mm, 25~50mm) (1/100mm, 50~75mm)
09900-20205 09900-20508 09900-20605 09900-20606

Micrometer Cylinder bore gauge kit Dial calipers Dial meter 09900-20701
(1/100mm,0~25mm) (1/100mm,40~80mm) (1/100mm,10~34mm) (1/100mm,10mm) Magnetic bracket
09900-20803 09900-21304 09900-25008 09910-34510 09913-50121

Thickness gauge V-block (set) (100mm) Multi-circuit tester Piston pin puller Oil seal remover
09913-70210 09920-13120
Bearing installer set 09916-10911 09916-21110 Crankcase separating 09921-20240
(Ø10-75) Valve seat cutter set Valve cutter set tool Bearing remover set
09930-40113
09924-84510 (11F14-008) 09940-50112 09940-53311 09941-34513
Bearing installer set Sprocket holder Fork oil seal installer Bearing installer Steering racer installer
11F14-004
09941-54911 09941-74910 11F14-001 11F14-003 Generator rotor remover
Bearing remover Steering bearing installer Rotor holder M16 screw M28
8-11
SERVICE INFORMATION
11F14-010
11F14-009 Front shock absorber 11F14-018 11F14-019 11F14-023
Diagnosis device remover and installer Valve remover and installer Tappet adjust driver Pressure test tool
11F14-026 11F14-029 11F14-030 11F14-033

Octagon nut sleeve-32 4 claws sleeve 42-4x5 Gear stopper 6 pins test switch
8-12
SERVICE INFORMATION
TIGHTENING TORQUE
ENGINE
ITEM Kg•m N•m
Engine oil drain plug 2.5-4.0 25-40
Gearshifting return fixing shaft 1.0-2.6 10-26
Tensioner arm bolt 1.0-2.6 10-26
Crankcase bolt 0.8-1.6 8-16
Cam stopper 0.8-1.6 8-16
Fixing cam pin bolt 0.8-1.6 8-16
Gear shift display mounting screw 0.8-1.4 8-14
Crankshaft push pin bolt 0.8-1.4 8-14
Drive sprocket bolt 1.0-1.8 10-18
Spark plug 1.3-2.5 13-25
Primary clutch mounting nut 4.0-6.0 40-60
Secondary clutch mounting nut 4.0-6.0 40-60
Clutch cover bolt 0.8-1.6 8-16
Clutch lock nut 1.5-2.5 15-25
Cylinder head nut 1.6-2.0 16-20
Cam sprocket bolt 1.8-2.8 18-28
Generator rotor nut 4.0-6.0 40-60
Camchain tensioner plug 1.7-2.8 17-28
Cylinder connect bolt 0.8-1.4 8-14
Guide wheel bolt 1.5-2.5 15-25
Valve adjuster lock nut 0.8-1.1 8-11
Generator cover bolt 0.8-1.6 8-16
CHASSIS
ITEM Kg•m N•m
Handlebar holder clamp bolt/nut 4.5-5.5 45-55
Lower bracket bolt 3.5-5.5 35-55
Steering stem lock nut 2.5-3.5 25-35
Front axle nut 4.0-4.8 40-48
Front footrest bolt 1.8-2.8 18-28
Engine mounting bolt/nut 6.0-8.0 60-80
8-13
SERVICE INFORMATION
ITEM Kg•m N•m

Brake disc bolt 1.8-2.8 18-28
Brake caliper mounting bolt 1.8-2.8 18-28
Bleeder valve 0.7-1.0 7-10
Bundy hose mounting nut 1.2-1.7 12-17
Master cylinder mounting bolt 0.8-1.2 8-12
Brake hose union bolt 2.0-2.5 20-25
Rear swing arm shaft nut 6.0-8.0 60-80
Rear shock absorber bolt/nut 2.2-3.5 22-35
Rear footrest bolt 2.2-3.5 22-35
Rear axle nut 4.8-5.8 48-58
Front 0.6-0.8 6-8
Rear brake cam lever bolt/nut
Rear 0.7-1.0 7-10
Rear torque link bolt/nut 1.0-1.6 10-16
Rear sprocket nut 1.8-2.8 18-28
Muffler mounting bolt 1.8-2.8 18-28
TIGHTENING TORQUE CHART

For other bolt and nuts who’s torque is not listed, refer to this chart.
Bolt Diameter A Conventional or "4" marked bolt "7" marked bolt

(mm) N •m Kg•m N •m Kg•m
4 1.5 0.15 2 0.2
5 3 0.3 5 0.5
6 6 0.6 10 1.0
8 13 1.3 23 2.3
10 29 2.9 50 5.0
12 45 4.5 85 8.5
14 65 6.5 135 13.5
16 105 10.5 210 21.0
18 160 16.0 240 24.0
Conventional bolt "4" marked bolt “7" marked bolt
8-14
SERVICE INFORMATION
SERVICE DATA
VALVE Unit: mm
ITEM STANDARD LIMIT

Valve diam. IN. 25.5
EX. 21
Valve clearance (when cold) IN. 0.08-0.12
EX. 0.08-0.12
Valve stem O.D. IN. 4.975-4.990
EX. 4.955-4.970
Valve deflection IN.& EX. 0.35
Valve stem runout IN.& EX. 0.05
Valve head thickness IN.& EX. 0.5
Valve seat width IN.& EX. 0.9-1.1
Valve head radial runout IN.& EX. 0.03
IN. 28.96
Valve spring free length (IN.& EX.)
EX. 28.96
CAM + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMIT
Cam height IN. 32.314 32.014
EX. 32.110 31.810
Camshaft runout 0.10
Rocker arm I.D IN.& EX. 10.0-10.015
Rocker arm shaft O.D IN.& EX. 9.972-9.987
Cylinder head distortion 0.05
Cylinder head cover distortion 0.05
8-15
SERVICE INFORMATION
CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400kPa 800kPa
Piston to cylinder clearance 0.005-0.035 0.12
Cylinder bore 51.000-51.015 51.135
Piston diam. Measure at 9mm from the skirt end 50.980-50.995 50.860
Cylinder distortion 0.05
Piston ring free end gap 1st Approx 5.6 4.6
2nd Approx 5.4 4.6
Piston ring end gap 1st 0.08-0.20 0.5
2nd 0.18-0.30 0.5
Piston ring to groove clearance 1st 0.18
2nd 0.15
Piston ring groove width 1st 0.805-0.820
2nd 0.805-0.820
Oil 2.005-2.020
Piston ring thickness 1st 0.77-0.79
2nd 0.77-0.79
Piston pin bore 13.002-13.008 13.03
Piston pin O.D. 12.994-13.0 12.98
CONROD AND CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 13.006-13.017 13.04
Conrod big end side clearance 0.10-0.35 1.0
Conrod big end width 13.95-14.05
Crankshaft web to web width 40.15-40.20
Crankshaft runout 0.05
CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch adjuster screw Turn left to the end, then turn right 25-45 º
Drive plate thickness 2.9-3.1 2.6
Drive plate claw width 1 5.75-15.85 15.3
Driven plate distortion 0.1
P r i mary cl u t c h o ut I.D 1 04-104.2 104.3
Clutch spring free length 27.14 25.8
8-16
SERVICE INFORMATION
TRANSMISSION + DRIVE CHAIN

ITEM STANDARD 极限值
Primary reduction ratio 4.059(69/17)
Final reduction ratio 2.571(36/14)
Gear ratios Low 2.615(34/13)

2nd 1.556(28/18)
3rd 1.136(25/22)
4th 0.917(22/24)
Shift fork to groove clearance 0.05-0.22 mm 2.275 mm
Shift fork groove width No. 1 5.0-5.07 mm
No. 2 5.0-5.07 mm
Shift fork thickness No. 1 4.85-4.95 mm
No. 2 4.85-4.95 mm
Drive chain Type KMC 420SB
Links 120 links
20 pitch length 259.0 mm
Drive chain slack 10-20 mm
FI SENSORS
ITEM STANDARD NOTE
CKP sensor input voltage 4.5-5.5V
CKP sensor output voltage Idle 0.29-0.71V
Open 4. 13- 7.76V
ET sensor input voltage 4.5-5.5V
ET sensor resistence 在20℃ 时，大约2.645kΩ
Injector voltage Battery voltage
IAT sensor input voltage 4.5-5.5V
IAT sensor resistence 1.044-1.276kΩ at 40℃
Oxygen sensor input voltage 4.5-5.5V
Idle solenoid valve resistence 28Ω at 20℃
INJECTOR, FUEL PUMP AND FUEL PRESSURE REGULATOR

ITEM STANDARD Note
Injector resistence 11.4-12.6k at 24℃
Fuel pump discharge amount at 20L/h, 294kPa
Fuel pressure regulator operating Approx 300kPa
set pressure
8-17
SERVICE INFORMATION
ELECTRICAL
ITEM SPECIFICATION NOTE
转速为1 50 0 r/min时，上止点前10°

Ignition timing
Type NGK CPR6EA-9

Spark plug
Gap 0.8mm-0.9mm
Primary 3.15-4.26 Ω Terminal-Terminal
Ignition coil resistance
Secondary 23.8-33.2 KΩ Plug cap-Terminal
Pick-up 100-140 Ω Bl/Y-G/W
Generator coil resistance
Charging 0.4-1.2 Ω B-B
Rectifier voltage at 5 000r/min, 14.0V-15.0V
Starter relay resistance 90-110 Ω
Model YB5L-A2
Battery
Capacity 5Ah
Fuse 10A, 15A, 20A
LIGHT
ITEM SPECIFICATION ITEM SPECIFICATION
HI 35W Neutral indicator light 2W

Headlamp
LO 35W Meter illumination light 2W
Tail/Brake light 5/21W High beam indicator light 2W
Turn signal light 10W Turn signal indicator light 2W
Position light 5W Malfunction indicator light 2W
TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 200 kPa(2.00 kgf/cm²)
(Solo riding)
Rear 225 kPa(2.25 kgf/cm²)
Cold inflation tire pressure Front 225 kPa(2.25 kgf/cm²)
(Dual riding)
Rear 280 kPa(2.80 kgf/cm²)
Tire size Front 70/90-17 38P
Rear 80/90-17 50P
8-18
SERVICE INFORMATION
BRAKE + WHEEL Unit: mm

ITEM STANDARD LIMIT
Brake disc thickness Front 3.3-3.7 3.0
Brake disc runout 0.3
Brake fluid type Special Haojue brake fluid
Brake drum I.D Front
Rear 11 1
Brake shoe thickness 1.5
Wheel rim runout Front 2.0
Rear 2.0
Wheel axle runout Front 0.25
Rear 0.25
SUSPENSION
ITEM STANDARD LIMIT
Front fork stroke 90 mm
Front fork spring free length 291 mm 285.2 mm
Fork fork oil type 34#
Front fork oil capacity(each leg) 61 ± 1 ml
Rear shock absorber spring adjustment The 2nd position
Rear swing arm shaft runout 0.3 mm
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Unleaded graded 90-97 or higher octane
Fuel tank capacity 4.1 L
Engine oil type and grade SAE 10W-40, API SG or higher
Engine oil capacity Oil change 800 mL
Overhaul 1 000 mL
8-19
SERVICE INFORMATION
WIRING HARNESS, CABLE AND HOSE ROUTING
Pass the front brake switch coupler

Clamp inside the handlebar
Clamp
5 switches wire branch 5 switches wire branch
Front brake switch Front brake cable
wire branch Front right turn
Ignition switch signal light wire branch
lock coupler Ignition switch lock
Front right turn
signal light coupler
Clamp
Gear shift display Headlamp coupler Meter coupler
Wiring harness
coupler Turn relay
Meter wire branch Front left turn signal Clamp
Throttle cable Speedometer light branch Wire harness
cable Horn branch
Welded guide ring
Front brake hose
Wiring harness(outward) Ignition switch lock
Speedometer cable wire branch detail
Front brake hose
View C- Turn relay Front left turn Speedometer cable

View B Drum brake signal light
coupler
Ignition switch
Starter relay Air filter stopper Horn

Front brake hose Wiring harness
Main swithc
lock coupler
Oxygen sensor
Front right turn coupler Clamp
signal light coupler Wiring harness
Starter motor
Clamp Meter coupler
Wiring harness
Turn relay Tail light coupler
Front left turn Clamp
signal light branch Wiring harness
Horn branch
Welded guide ring
Wiring harness(outside)
Speedometer cable
Front brake cable
TPS,PDP,Injector
View C-
Disc brake Turn relay Front left turn Speedometer cable Rectifier Clamp Clamp Ignition Face the ET sensor
signal light Oxygen coil high-tension
coupler sensor clamp cord rear downward.
Rear brake switch Generator wire Gear postion switch

wire branch branch wire branch
Left windshield Front left turn signal
IAT sensor Clamp outer part light assembly
Starter motor
+ lead wire branch
Front left turn

signal light coupler Starter motor
- lead wire branch
Wiring harness
fixing plate
Screw
IAT sensor Injector coupler

branch Front left turn signal light
assembly detail
Wiring harness fixing plate
assembly detail
8-20
SERVICE INFORMATION
Note: Fit the starter

Fuel level White mark motor + lead wire
Alarm wire branch branch to inside of
installation position sensor coupler position Fuse case Battery harness when
Wiring harness
(Without alarm) installing the clamp.
Starter motor
+ and - wire branch
Oxygen sensor
wire branch
Cut the surplus after
tightening.
Alarm Clamp Test coupler Clamp Clamp

Wiring harness Wiring harness Wire branch of
wiring harness
starter motor + lead wire,
Gear position switch
generator, rear brake switch
Cut the surplus after tightening.
Clamp
Battery breather hose
Fender guide hose
Welded hook
Pass the brattery breather hose
Clamp Battery breather hose from inside to outside.
Clamp
Wiring harness Wiring harness assembly detail
Rear turn signal light

wire assembly detail
Cross screw Cross screw
(Starter motor + terminal) (Starter motor - terminal)
Routing part Control item Requirement
Battery + terminal The gap

1 Starter relay terminal between the More than 8mm
Starter motor rerminal terminal and
other metal parts.
The lead wire between

2 the battery + terminal
and fuse. Free of burr and sharp edge.
Do not pass the lead wire over
The lead wire between movable part. Fix the lead wire
3 the start relay and Routing with the clamp at the specified
starter motor area position.Lead wire interferes
other parts is not allowed
Starter motor The lead wire between during the routing.
4 the battery + terminal
to starter relay.
Starter motor assembly detail
8-21
SERVICE INFORMATION
8-22
EVAPORATION EMISSION CONTROLSYSTEM
Canister
Absorber hose between
the canister and PVC valve
Canister breather hose
Canister fix belt
Canister water drain hose
Clamp
Clamp
SERVICE INFORMATION
FRONT BRAKE HOSE INSTALLATION
8-23
SERVICE INFORMATION
REAR BRAKE PEDAL INSTALLATION
8-24
SERVICE INFORMATION
8-25
WIRING DIAGRAM
Combination meter
Gear position light

Meter lights Fuel level Gear position Engine ground
gauge
1 2 3 4 Lights switch switch ECM
Rear brake Rectifier
switch Starter relay
12 CPS+
DIAG
23 CPS-
DON
6 VCC
14 IAPS
PG1
ETS
PG2
29 HLS
5 TPS
22 MIL
28 ISC
OX
VB
INJ
LG
4 SG
TS
FP
IG
Starter
24
30
26
11
10
15
16
1
9
2
3
8
switch
Y/W
Gr
O
O
Front brake
G/Bl
Y/Bl
W/Y
R/B
Bl
switch
W/B
O
W/R
G/W
Bl/G
B/Br
Br/Y
Y/W
B/W
B/W
Bl/Y
O/G
G/B
B/G
Y/R
R/Y
W
B/Y
G
R
Lg
V
Br/Bl
G/Bl
Bl
W/Y
Y/Bl
R/W
O/G
Y/G
B/W
R/B
Gr
B/W
Y/B
R
O
Y
B
R
Lg
B
B
B
W/R
G/Bl
Y/Bl
W/Y
Idle solenoid valve
R/B
Bl
Combination
W/B
Gear position light
O
O/R
meter
W/B
O
Br/Bl
G/Bl
W/Y
Y/Bl
B/W
R/B
Gr
O
Y/B
Bl
O
Y
B
Lg
B/W
Y/G
O/G
W/B
O
B/G Ignition coil
Y/B
B/W
O/G
Fuel pump
Bl/G
Front left W
turn signal B/Y
light G Test coupler
O/G
B B
B /W B /W
R/Y
IAT sensor
G/W
Headlamp Gr Gr
Y Y B/W W/B
B /W B /W B/W B/W
Tail lights
W W Gr Gr
Rear left
B B
turn signal
Position light B/W B/W light
Lg
B/W
Lg
Rear right
turn signal
9
light
B /W B /W
Lg Lg
Front right
turn signal
light O/G
R
O
G/W
Y/R
10A P OWER
20A Main
DC
B/Br
15A
G/W
O/G
V
Fuse case
G/W
B/W
Bl/Y
Dg
R
R
Lg
O
B
ET sensor
G/B
Bl/Y
B/W
O/R
O/R
B
B
B
B
R
R/W
B
B/W
Bl/Y
O/R
TP sensor
R
G/W
Bl/Y
B/W
B
B
B
Y /W
LBl
Lbl
G
W
G
O
Lg
B
Y
Oxygen Injector
sensor Alarm
Dimmer switch Turn relay Horn switch Horn Battery

Turn signal Ignition switch
Starter Generator
light switch
motor

NEX 115 Manual de Serviços (Ingles) UH110S PDF

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NEX 115 Manual de Serviços (Ingles) UH110S PDF

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NEX115

Improper repair may result in injury to the

COMPONENT PARTS AND WORK TO BE DONE

EX: Front wheel

ITEM N•m Kgf•m

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply oil. Use engine oil unless

otherwise specified. Apply or use the absorber oil

Apply SUPER GREASE “A”

Apply MOLY PASTE

Apply sealant “1215”

Apply sealant “1207B”

Apply THREAD LOCK “1342"

Apply THREAD LOCK “1303"

FUEL AND OIL RECOMMENDATION 1-2

BREAK-IN PROCEDURE 1-2

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.

SERIAL NUMBER LOCATIONS

FUEL AND OIL RECOMMENDATIONS

These specifications are subject to change without notice.

PERIODIC MAINTENANCE CHART

Interval Km Every 6 000km Every 12 000km

MAINTENANCE AND TUNE-UP

● Install the battery in the reverse order of the disassembly.

If the air cleaner is clogged with dust, intake resistance will be

Clean the air filter case and cover.

Reinstall the air cleaner in the reverse order of removal.

EXHAUST PIPE BOLTS AND MUFFLER BOLTS

Tighten the exhaust pipe bolt to the specified torque.

Exhaust pipe mounting bolt : 11-15 N•m

● Tighten the muffler mounting bolt to the specified torque.

Muffler mounting bolt : 35-45 N•m

CYLINDER HEAD NUTS

Inspect initial 1 000km and every 3 000km

Tighten the cylinder head cover cap nut to the specified

Cylinder head nut: 17-20 N•m

Inspect initial 1 000km and every 3 000km

Remove the cylinder head cover and spark plug .

Remove the valve timing inspection plug and generator

Rotate the generator rotor counter clockwise until the “III”

09900-20803: thickness gauge

Valve clearance specifiecations

If the valve clearances is out of specification, bring it into

Valve clearance is to be checked when the engine is

Remove the spark plug cap .

Remove the spark plug with spark plug sleeve .

Remove the carbon deposits with a wire of pin and adjust

Spark plug gap: 0.8-0.9 mm

Change initial 1 000 km and every 3 000 km

The oil should be changed when the engine is warm. The

OIL SUMP FILTER

ENGINE OIL CENTRIFUGAL FILTER

● Remove the clutch cover and the engine oil centrifugal

CLUTCH CABLE PLAY

Loosen the clutch lock nut .

The throttle position screw is set precisely at factory. Do

THROTTLE CABLE PLAY

After adjustment is completed, checked that handlebar

EVAPORATION EMISSION CONTROL SYSTEM

This motorcycle is equipped with fuel evaporation prevent

Inspect the connection of each hose.