HAOJUE VR 150 - Manual de Serviço

VR150
VR150
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
99500H7C2AAH000
Prepared by Haojue Holding
Aug, 2019
Printed in China
维修说明书
FOREWORD GROUP INDEX
This manual contains an introductory description on the
VR150 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
AUG, 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 Collar
3 Oil seal
4 Roller bearing
5 Front brake disc
6 Valve
7 Front tire
8 Front rim
9 Spacer
A Brake disc bolt
B Front axle nut
ITEM N•m Kgf•m
A 18-28 1.8-2.8
B 48-58 4.8-5.8
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 90-97 octane (Research Method).
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.
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 1910 mm
Overall width 720 mm
Overall height 1120mm
Wheelbase 1330 mm
Ground clearance 124 mm
Curb weight 120 kg
ENGINE
Type Single cylinder, horizontal , air-cooled, four stroke
Number of cylinders 1
Bore 57 mm
Stroke 58.6 mm
Piston displacement 1 50 ml
Compression ratio 9.6: 1
Fuel supply Fuel injection
Air cleaner Oiled paper filter
Starter system Electric starter/Kick starter
Lubrication system Wet sump
TRANSMISSION
Clutch Dry shoe, automatic, centrifugal type
Transmission Automatic
Primary reduction ratio 0.798-2.644
Final reduction ratio 7 .566
Drive system V-belt drive
1-4
GENERAL INFORMATION
ELECTRIC
Ignition type Electronic Ignition
Spark plug CR6E
Battery 12V 6Ah
Fuse 10 A 15A 20A
Headlight 12V,35W / 35W
Tail light/brake light LED
Turn signal light 12V,10W
Position light 12V,5W
Rear license plate light 12V,5W
CHASSIS
Front absorber Telescopic, coil spring, oil damped
Rear absorber Swing arm, oil dampened spring 5-way adjustable
Front brake Disc brake/Brake lever
Rear brake Drum brake/Brake lever/Brake pedal
Front tire size 100/80-12 56J
Rear tire size 100/90-10 56J
Front absorber stroke 80 m m
CAPACITIES
Fuel tank 5.9 L
Engine oil, Change 950 ml
Change oil and filter 1000 ml
Final gearbox oil 90 ml
Front fork oil(single) 100 ml
1-4
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 2-6
VALVE CLEARANCE 2-6
SPARK PLUG 2-7
ENGINE OIL 2-8
ENGINE OIL FILTER 2-8
OIL STRAINER 2-9
FINAL GEAR OIL 2-9
DRIVE BELT 2-9
CLUTCH SHOE 2-10
CLUTCH ROLLER 2-10
THROTTLE BODY 2-10
EVAPORATIVE EMISSION CONTROL SYSTEM 2-10
FUEL HOSE 2-11
FUEL PUMP FILTER 2-11
BRAKES 2-11
TIRES 2-12
STEERING 2-15
FRONT AND REAR SHOCK ABSORBERS 2-15
LIGHTING AND SIGNAL 2-16
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-16
COMPRESSION PRESSURE INSPECTION 2-18
ENGINE OIL PRESSURE INSPECTION 2-19
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.
CAUTION
More frequent servicing may be performed on motorcycles that are used under extreme 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
Clean Clean 2-4
Air cleaner paper filter
Replace 6000 km (Replace as necessary)
Muffler bolts and nuts Tighten Tighten 2-6
Valve clearance(when cold) Inspect Inspect 2-6
Inspect Inspect
Spark plug 2-7
Replace every 10 000 km
Engine oil Replace initial 500 and 1 000 km, replace every 2 000-3 000 km 2-8
Oil filter Replace initial 1 000 km, replace every 2 000-3 000 km 2-8
Oil strainer Clean Clean 2-9
Final gear oil Replace 2-9
Drive belt Inspect every 6 000km, replace every 24 000 km 2-9
Clutch shoe Inspect 2-10
Clutch roller Inspect 2-10
Throttle body Inspect 2-10
Throttle cable Inspect Inspect 2-10
Evaporative emission Inspect 2-11

control system Replace rubber hose every 4 years or every 80 000 km
Fuel hose Inspect Inspect 2-11
Replace every 10 years
Fuel pump filter Inspect 2-11
Inspect every 6 000 km, replace every 50 000 km
Brake Inspect Inspect 2-12
Brake Inspect Inspect

Brake
fluid hose Replace every 4 years
Brake fluid Inspect every 3 000 km, replace every two years.
Tires Inspect Inspect 2-15
Steering Inspect Inspect 2-15
Front and rear Inspect
2-1 6
shock absorbers
Lighting and signal Inspect Inspect 2-16
Chassis bolts and nuts Inspect Inspect 2-1 6
2-1
LUBRICATION CHART
Interval Km Initial and Every 6 000km Every 12 000 km
Item Month 6 12
Throttle cable Engine oil
Rear brake lever screw/pivot
(Brake lever)
Lever seat and balancer upper Grease
and lower contacting surface.
Balancer cable 2 installation
holes
Rear brake cable Engine oil
Rear brake camshaft Grease
Main stand and spring hook Grease
Side stand and spring hook Grease
Front brake lever screw/pivot
/lever, lever head, brake fluid Grease
master cylinder upper and
lower contacting surface.
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 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
The battery is located below the foot pedal cushion. The
battery is a sealed type battery and requires no maintenance.
The battery should be recharged if the voltage falls below
12.5V. To remove the battery, follow the procedure below:
Confirm the ignition switch is at off position, then remove the

foot step cushion.
● Remove the screw and battery cover .
● First remove the lead terminal, then remove the lead
terminal.
● Take off the battery.
Install the battery in the reverse order of removal.
CAUTION
When installing the battery lead wires, fix the lead
terminal first and lead terminal last.
FUSE
Fuse box is beside the battery. There are a 10A fuse, a 15A fuse
and a 20A fuse, as well as spare fuses for 20A, 15A and 10A .
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
Clean initial 1 000 km and every 3 000 km, replace
every 6 000km. (Replace as necessary)
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.
Check and clean the filter in the following manner.

Open the seat, remove the air cleaner protection cover .
Loosen the screw, remove the air cleaner intake ripple

pipe lower end and pull it out.
Carefully use air hose to blow the dust from the intake
ripple hose. Clean the dust around the intake hole below
the saddle.
Remove the air cleaner cover by removing the mounting

screws.
Remove the sponge element from air cleaner cover.
Fill a washing pan of a proper size with nonflammable

cleaning solvent. Immerse the element in the cleaning
solvent and wash it clean. A Non- B
Squeeze the cleaning solvent out of the washed element by flammable
pressing it between the palms of both hands. Cleaning
Immerse the filter in engine oil, and squeeze the oil out of Solvent
the element leaving it slightly wet with oil.

D C
Engine oil
CAUTION
Do not twist or wiring the element because it will tear or
the individua cells of the element will be damaged.
2-4
● Remove the mounting screws, remove the air cleaner

paper filter .
● Check the paper filter , if too much dust is found, power
output decreases and fuel consumption increases, replace
the filter.
Clean the air cleaner cover and air filter chamber.

Check to see if the seal on the air cleaner is intact.
Install the new or clean air cleaner in the reverse order of

removal. Make sure the air cleaner is fitted securely at the
specified position and sealed properly.
CAUTION
If driving under dusty condition, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to use the engine without the element or
to use a ruptured element. Make sure that the air cleaner
is in good condition at all times.
OIL DRAIN PLUG

When performing the maintenance of the air cleaner, check
the front and rear oil deposit pipe of the air cleaner, if oil is
found in the oil deposit pipe, drain the oil in time.
2-5
MUFFLER MOUNTING NUTS AND BOLTS

Tighten initial 1 000 km and every 3 000 km
Tighten the muffler mounting bolt to the specified torque.
Muffler mounting bolt : 18~28 N•m
Tighten the muffler mounting bolt .
Muffler mounting bolt : 40-60 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.
Remove the maintenance lid. (Refer to page 6-2)
Disconnect the spark plug cap , remove the spark
plug.
Remove the ignition coil .
Remove the engine breather hose and cylinder cover bolts

and cylinder cover .
2-6
To turn the cooling fan with a wrench in the normal running direction until
the “TDC” line on the rotor is aligned with the valve timing mark on the
crankcase in order to set the piston at (TDC) of the compression stroke. 上止点
Valve clearance (when cold)

Standard: IN.: 0.05-0.10 mm
EX.: 0.10-0.15 mm
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.
If clearance is off the specification, bring it into the

specified range by using the special tool.
TOOL 09900-20803: Thickness gauge

11F14-019: Tappet adjust driver TOOL
Install the spark plug.

Reinstall the cylinder head cover.(Refer to page 3-15)
Install the maintenance lib.(Refer to page 6-6)
SPARK PLUG
Inspect at initial 1 000 km and every 3 000 km,
replace every 10 000 km.
Remove the maintenance lid. (Refer to page 6-2)

Remove the spark plug.
Remove the carbon deposits with a wire of pin and adjust the
spark plug gap to 0.6 - 0.8 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
coder one.
Spark plug gap: 0.6-0.8 mm
09900-20803: Thickness gauge
Type NGK
Hot CR5E
Standard CR6E
Cold CR7E
CAUTION
Confirm the thread size and reach when replacing the 0.7-0.8 mm
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine
damage may result.
2-7
ENGINE OIL AND ENGINE FILTER

Engine oil：
Change initial 5 00 km and 1 000 km and every
2 000-3 000 km
Oil filter:
Clean initial 1 000 km and every 2000-3000 km
The oil should be changed with engine hot. According to the

maintenance interval, replace the oil filter and engine oil at the
same time.
Support the motorcycle by center stand.
Drain the oil by removing the drain plug and filler cap/filler
gauge .
Remove the oil filter cap bolt and filter cap .
Remove the oil filter .
Install new O-ring and new oil filter.

Before assembling, apply a small quantity of the engine oil to
oil filter cover o-ring .
CAUTION
Before putting on the oil filter cap, check to be sure that
the new O-ring ( and ) and spring 7 is installed
correctly.
Tighten the oil drain plug , add 1 100ml of fresh engine oil
into the engine. Use 10w-40 viscosity of oil under API
classifiction of SG.
Oil drain plug: 15-20 N•m
NECESSARY AMOUNT OF ENGINE OIL:

Oil change: 950 ml
Oil and oil strainer change: 1 000 ml
Install the filler cap/filler gauge .

Start up the engine, and allow it to run for several seconds at
idling speed.
Remove the filler cap/filler gauge. clean up ,and insert it into Upper mark
engine then draw out to check the engine oil level, it should be Oil gauge
between the “upper” line and “lower”line.
Lower mark
2-8
OIL STRAINER
Clean initial 1 000km and every 6 000km
Remove the oil strainer cover mounting bolts .

Remove the oil strainer cover and gasket .
Remove the oil strainer and clean.

After cleaning the oil strainer , reinstall it and pay
attention to the direction of oil strainer.
Install the new gasket , oil strainer cover , bracket
and bolt .
FINAL GEAR OIL

Replace every 6 000km.
Remove the kick starter lever and clutch cover.

(Refer to page 3-21).
Drain the gear oil by removing the filler plug and drain plug
Tighten the drain plug to specified torque, add the fresh
gear oil through the filler plug until the oil flows out of filler
plug.
Gearbox drain plug: 8-12 N•m
Gearbox oil viscosity and class: SAE 80w-90m, APL:GL-5
● Tighten the filler plug 1 to the specified torque.

Filler plug: 9-15 N•m
Final gear oil: 90 ml
DRIVE BELT
Inspect every 6 000km, replace every 24 000km.
● Remove the drive belt. (Refer to page 3-22)

● Check the drive belt for crack, departure and excessive worn.
● Measure the drive belt width.
09900-20101: Vernier Caliper
Drive belt width: Service limit: 18.9 mm
Install the drive belt. (Refer to page 3-29)
2-9
CLUTCH SHOE
Inspect every 6 000 km
Remove the clutch shoe. (Refer to page 3-23) 2mm
Inspect the linings for crack, uneven wear or bushing.
Measure the lining thickness with a vernier calipers, If any
defects are found or measurement exceeds the limit, replace
09900-20101: Vernier calipers
Clutch shoe thickness: Service limit ：2 mm
Install the clutch shoe. (Refer to page 3-28)
CLUTCH ROLLER
Inspect every 6 000km
● Remove the clutch rollers. (Refer to page 3-23)

● Inspect each roller and its sliding surface for abnormal wear
or damage. If any defects are found, replace the rollers as a
set.
● Install the clutch rollers. (Refer to page 3-28)
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)
THROTTLE CABLE PLAY
Use the th adjuster below the throttle grip to adjust the throttle
cable free play.
Loosen the lock nut .
Turn the adjuster so that the throttle cable play has 0.5 - 0.5-1.0 mm
1.0 mm play.
Tighten the lock nut after adjustment..
WARNING
After adjustment is completed, checked that handlebar

movement does not raise engine idle speed and that the
throttle grip returns smoothly and automatically.
2-10
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.
Front brake
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
over from the last servicing or stored for a long period.
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.
2-12
EVAPORATION EMISSION CONTROL SYSTEM

Inspect every 3 000 km
This motorcycle is equipped with evaporation emission

control 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, tilt-over valve and EVAP canister to
see whether they are clogged, clean or replace the clogged
part as necessary.
Repalce the hose in EVAP system every 4 year or 80
000km.
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.
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, replace every 50 000 km.
If the fuel pump is dirty with sediment, fuel will not flow
smoothly and loss in engine power may result, replace the fuel
pump filter with a new one.
Fuel pump filter inspection and replacement. (Refer to page
5-5)
2-11
AIR BLEEDING THE BRAKE FLUID CIRCUIT Upper line

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.
2-13
REAR BRAKE
REAR BRAKE LEVER FREE TRAVEL
Rear break lever free travel is the distance from the lever
free position to the brake starts to take affect by grasping the
lever.
Full open the rear brake lever, loosen the rear brake combined
lock nut , adjust the rear brake adjuster , set the clearance
to 0.5 mm between the rear combiner brake combiner end and
pin shaft .
Adjust by turning the adjusting nut , clockwise to turn big,

anticlockwise to turn small, set the play to be 20-30 mm
for brake lever,
Rear brake lever free play : 20-30 mm
BRAKE LINING WEAR LIMIT

The motorcycle is equipped with brake lining wear limit
indicators on rear brakes. To check wear of the break lining,
follow the steps below.
First check if the brake system is properly adjusted.
While operating the brake, check to see that the extension
line from the index mark is within the range on the
brake panel as shown in the illustration at right, or else the
brake shoe assembly should be replaced to ensure safe
operation.
REAR BRAKE SWITCH

Operate the rear brake lever to check the brake light switch,
inspect, adjust and replace the switch if abnormity is found.
2-14
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 175 1.75 175 1.75
REAR 225 2.25 225 2.25
CAUTION
Proper tire pressure and condition affect vehicle
performance. Please check the tire pressure and
surface condition periodically.
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 6-22 of this manual.
2-15
FRONT AND REAR SHOCK ABSORBERS

Inspect every 6 000 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 7-14)
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.
No ITEM N•m Kg•m
Front alxe nut 48 - 58 4.8-5.8
Front brake caliper bolt 18-28 1 . 8-2 . 8
Front brake disc bolt 18-28 1.8-2.8
Brake hose bolt 20-25 2 . 0-2 . 5
Bleeder valve 7-10 0 . 7-1 . 0
Handlebar clamp bolt 40-60 4 . 0-6 . 0
Steering stem lock nut 25-35 2 . 5-3 . 5
Lower bracket clamp bolt 18-28 1.8-2.8
Rear axle nut 102-138 10. 2-13. 8
Rear shock absorber upper bolt 25-35 2.5-3. 5
Rear shock absorber lower bolt 25-35 2.5-3.5
Rear brake cam lever bolt 6-8 0.6-0.8
Exhaust pipe nut 11 - 15 1.1-1.5
Muffler mounting nut 4 0-60 4.0-6.0
Engine mounting nut 7 0-100 7.0-10.0
Rear swing arm shaft nut 70-100 7.0-10.0
2-16
2-17
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.
2-18
OIL PRESSURE CHECK

Check periodically the oil pressure in the engine to judge roughly the condition of the moving parts.
OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.
Remove the oil gallery plug .
Install the oil pressure gauge into the oil gallery.
● Warm up the engine as follows:
Summer: 10 min at 2 000 r/min
Winter: 20 min at 2 000 r/min
● After warming up, increase the engine speed to 3 000
r/min, (observe the tachometer), and read the oil pressure
gauge.
09900-26006:Tachomenter
11F14-023: Oil pressure gauge
● Install the oil gallery plug.
OIL PRESSURE SPECIFICATION
15-35kPa (0.15-0.35kgf/cm 2) at 3 000 r/min，Oil temp at 60 .
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE

Clogged oil filter
Oil leakage from the oil passage
Damaged O-ring
Defective oil pump
Combination of the above items
HIGH OIL PRESSURE

Engine oil viscosity is too high.
Clogged oil passage
Combination of the above items
2-19
ENGINE
CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLACE 3-1
ENGINE REMOVAL AND REMOUNTING 3-2
CYLINDER HEAD AND VALVE 3-7 3
CYLINDER, PISTON AND PISTON RING 3-17
AUTOMATIC CLUTCH ASSEMBLY 3-21
GEARBOX 3-30
GENERATOR AND STARTER CLUTCH 3-35
OIL PUMP 3-39
CRANKSHAFT AND CRANKCASE 3-40
ENGINE
REMOVING ENGINE PARTS WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the
page listed in each section for removal and reinstallation instructions.
ENGINE PARTS
Throttle body 3-5
Intake pipe 3-5
Engine temperature sensor 3-7
Cylinder head cover 3-7
Camshaft sprocket 3-8
Camshaft 3-8
ENGINE LEFT SIDE PARTS

Clutch outer cover 3-21
Clutch cover 3-21
Fixed drive face 3-21
Clutch shoe 3-23
Movable driven face 3-22
Drive belt 3-22
Movable drive face 3-22
Gear box cover 3-30
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:
Drain the engine oil.
Remove the saddle, helmet case and center cover.
( Refer to page 6-3)
Remove the front left and right side covers.
(Refer to page 6-4)
Remove the battery cover.

Remove the battery - lead wire.
Remove the rear brake cable adjuster nut .
Loosen the rear brake cable mounting clamp bolt, remove

the rear brake cable .
Loosen the clutch breather hose clamp screw, remove the
clutch breather hose .
Disconnect the spark plug cap , disconnect the wire

clamp .
Disconnect the fuel injector coupler , ISC valve coupler
, high pressure fuel hose 7 and engine temp, sensor 8
coupler 9 .
3-2
ENGINE
Remove the cylinder head cover breather hose 10 .

Remove the high pressure fuel hose clamp mounting bolt
11 , 3 in 1 sensor coupler 12 and throttle cable 13 .
Remove the PVC jacket .

Disconnect the generator coupler .
Loosen the 6 wire clamps.
Disconnect the oxygen sensor coupler .
Remove the starter motor wire and engine ground wire .
3-3
ENGINE
Remove the wire clamp .
Remove the muffler mounting bolt/nut, take off the muffler
Loosen the throttle body clamp screw, remove the hose

from the throttle body.
Remove the air cleaner intake hose .

Move the PVC jacket, disconnect the speed sensor
coupler 23 .
Remove the rear fender mounting screw/nut.
3-4
ENGINE
Remove the air cleaner mounting bolts, take24off the air

cleaner 24 .
Remove the throttle cable mounting screw 25 .

Remove the rear shock absorber lower mounting bolts
26 .
Remove the engine mounting nut 27 , draw out the engine

mounting bolts, move the frame assembly.
Remove the throttle-intake hose assembly 28 .
Remove the rear axle nut, take off the rear wheel 29 .
Remvoe the rear brake shoe 30 .

Remove the spring and main stand 31 .
3-5
ENGINE
REASSEMBLY
Reassemble the engine in the reverse order of removal, tighten
the bolts to the specified torque. A
B
Specified torque:
Rear axle nut A 102-138 N•m
Engine mounting bolt B 70-100 N•m
Rear absorber lower mounting bolt C 22-35 N•m
Exhaust pipe mounting bolt D 11-15 N•m
Muffler mounting bolt E 40-60 N•m
CAUTION
When installing the battery lead wires, fix the lead first
and lead last.
C
After remounting the engine, route wiring harness, cables and

hoses properly by referring to the sections, for wire routing,
cable routing and hose routing. (Refer to page 8-19)
Adjust the following items to the specification.
* Throttle cable play (Refer to page 2-10)

* Rear brake cable play (Refer to page 2-14)
After assembly and adjustment, add the engine oil.

(Refer to page 2-8)
Check the engine oil level. (Refer to page 2-7)
3-6
ENGINE
CYLINDER HEAD AND VALVE

REMOVAL
ET SENSOR
Remove the ET sensor .
FAN COVER
● Remove the fan cover screws.
● Remove the fan right cover and left cover .
CAMSHAFT CHAIN TENSIONER

Remove the sponge and cam shaft chain tensioner .
CYLINDER HEAD COVER

Remove the cylinder head cover bolts, take off the cylinder
head cover and gasket.
CAM SPROCKET
Turn the cooling fan with the wrench to bring the index mark
on the cooling fan to the index mark on the crankcase to set
the piston at TDC of the compression stroke.
3-7
ENGINE
Remove the cam shaft sprocket mounting bracket bolt, take

off the mounting bracket .
Remove the C-ring .

Remove the camshaft chain, take off the camshaft assembly
.
CAUTION
Do not drop camshaft chain into the crankcase.
CYLINDER HEAD ASSEMBLY

Remove the cylinder head side bolt and the cylinder side
bolt .
● Remove the cylinder head nut and cooper washer.

● Remove the cylinder head assembly .
CAUTION
Do not drop camshaft chain into the crankcase.
Remove the cylinder head gasket and dowel pin.
3-8
ENGINE
DISASSEMBLY
Draw out the rocker arm shaft .
Remove the rocker arm .
Remove the camshaft chain tensioner guide rod.

Remove the valve cotters with the special tool.
TOOL 11F14-018: Valve remover
Take out the valve cotter , valve spring retainer , outer

spring and inner spring .
Draw out the exhaust and intake valve 7 from the other
side.
Take out the valve oil seal 8 and valve spring retainer 9 .
CAUTION
Mark all the removed parts or place them orderly to make

sure install correctly.
3-9
ENGINE
INSPECTION
ROCKER ARM SHAFT
Measure the rocker arm shaft O.D.
Rocker arm shaft O.D (IN. and EX.)
Standard: 11.977-11.995 mm
09900-20205: Micrometer (0-25mm)
ROCKER ARM
Measure the rocker arm I.D., and inspect the wear of the
camshaft contacting surface.
Rocker arm I.D.(IN. and EX.):

Standard: 12.000-12.018mm
09900-20605: Caliper gauge
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 H , which is to be measured with a micrometer. H
Replace camshafts if found it worn down to the limit.
CAM HEIGHT
Camshaft height H :
Limit (Intake): 32.50 mm
(Exhaust): 32.67 mm
09900-20202 : Micrometer (25~50 mm)
CYLINDER HEAD
Decarbon the combustion chamber, and clean the gasketed
surface of cylinder head.
Check the spark plug hole and valve of combustion chamber
part for crack.
Check the gasketed surface of the cylinder head for distortion
with a straightedge and thickness gauge.
TOOL 09900-20803:Thickness gauge
Cylinder head distortion:

Limit: 0.05 mm
3-10
ENGINE
VALVE SPRING
Measure valve spring free length.
Valve spring free length (IN and EX):
IN: 29.67 mm
EX: 29.57 mm
09900-20101 : Vernier calipers
Insert the valve into the valve guide, check the valve for
smooth movement of up and down.
Check the valve stem for bending or abnormal wear, measure
the valve stem O.D.
TOOL 09900-20205: Micrometer (0-25mm)
Valve stem O.D.(IN.): 4.975-4.99 mm

(EX.): 4.955-4.97 mm
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
runout with a dial gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem runout:
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 runout. If it measures more
the limit, replace the valve .
Valve head radial runout:
Limit: 0.03 mm
09900-20606:Dial gauge (1/100 mm)
09900-21304:V-block (100 mm)
3-11
ENGINE
VALVE SEAL
Oil each seal, and drive them into the position.
CAUTION
Always use new oil seal.
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 valve 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
Valve seat width:

standard: 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
进气门
angles to present three bevels. The valve seat contact
surface is 45°.
INTAKE 排气门
ANGLE 30°, 45° 15°, 45°
WIDTH 0.9-1.1mm
DIAMETER 25.5 mm 22.5 mm
VALVE GUIDE I.D. 5.000-5.012mm
09916-21110: Valve cutter set

排气门
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 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.
3-12
ENGINE
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.
CYLINDER HEAD ASSEMBLY

● 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 gasket, spring,
valve spring retainer.
99000-25140 : Moly paste
CAUTION
When inserting each valve, take care not to damage the
lip of the stem seal.
Install the valve spring, making sure that the close-pitch end of
each spring goes in first to rest on the head.
Install the valve seat spring.
朝
缸头
Install the valve cotters with the special tool.
11F14-018: Valve remover and installer tool
3-13
ENGINE
Apply engine oil on the turning part of rocker arm and rocker
arm shaft.
Install the rocker arm and rock arm shaft to the rocler arm
base.
CAUTION
When installing the rocker arm shaft, align the notch to

the intallation hole.
Install the cam chain tensioner guide rod and bolt.
Turn the tensioner all the way in with blade screw driver.
Install the dowel pin and gasket .
Install the cylinder head, clean the copper washer, cylinder

head nut and stud bolt with gasoline, tighten the cylinder head
nut in 2-3 steps diagnose to the specified torque.
Cylinder head nut: 23-27 N•m
3-14
ENGINE
Install the cylinder, cylinder head side nuts to the spcified

torque.
Cylinder head side nut: 8-12 N•m
Rotate the cooling fan until the index mark on the rotor is
aligned with index mark on the crankcase to bring the
piston to the TDC.
CAUTION
Rotate the crankshaft clockwise only.
Engage the chain on the cam sprocket,,install the camshaft

assembly.
Install the C-ring properly.
CAUTION
When installing the cam chain, the carve line 7 on the
camshaft sprocket should be parallel with cylinder head
surface.
CAUTION
When installing the cam chain, do not drop the
C-ring into the crankcase.
Install the camshaft sprocket fixer assembly 8 , tighten the

bolts to the specified torque.
Cylinder head side nut: 8-12 N•m
Install a new seal ring to the cylinder head groove and apply
the BOND “1207B” on the half-circle block, install the cylinder
head cover on the cylinder head.
99000-31140: Bond “1207B”
3-15
ENGINE
Install the cyinder head cover 9 , tighten the cylinder head

cover bolt to the specified torque.
Cylinder head cover bolt : 12-16 N•m
Install the cam chain tensioner, tighten the bolt to the specified
torque.
Cam chain tensioner: 8-12 N•m
Install the protective cover, tighten the screws.
Install the engine temp,sensor, tighten it to the specified

torque.
Engine temp.sensor: 13-16 N•m
3-16
ENGINE
CYLINDER, PISTON AND PISTON RING

REMOVAL
Remove the cylinder head. (Refer to page 3-7)
Remove cam chain guide rod .
Remove the cylinder .
Remove the dowel pin and gasket .

Remove the remaining gasket on cylinder base.
CAUTION
When cleaning the cylinder base, place a clean rag over the
cylinder base to prevent dirt or impurity into crankcase
Place a clean rag over the cylinder base to prevent piston pin
circlip from dropping into crankcase.
Remove the piston pin circlip.
Remove the piston pin and piston with the special tool.
TOOL 09910-34510: Piston pin remover
INSPECTION
CYLINDER
Check the cylinder bore inner wall for scratches or wear.
Measure the cylinder bore diameter at six places.
Cylinder bore diameter:

Limit: 57.135 mm
09900-20508: Cylinder gauge set
Remove the remaining gasket on the cylinder surface.

Inspect the cylinder for distortion.
Cylinder distortion:
Limit: 0.05 mm
3-17
ENGINE
PISTON
● Removing the piston rings one by one by expanding the gap
symmetrically.
Do not expand the piston ring excessively since it is

apt to be broken down. When installing the piston ring,
be careful not to damage the piston.
Decarbonize the piston.
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 .
Measure the piston outside diameter at the place 12mm

from the skirt end as show in Fig.
Piston outside diameter:

Limit: 12 mm from the skirt end, 56.835 mm
09900-20203: Micrometer(50~75 mm)
● Calculate piston-cylinder clearance. 12毫米
Piston-cylidner clearance: Limit: 0.12 mm
PISTON RING-GROOVE CLEARANCE

Temporarily fit the piston ring on the suitable position with
the marked side to the top.
Measure the piston ring-groove clearance.
Piston ring-groove clearance:

Limit(1st):0.18 mm
(2nd):0.15 mm
Piston ring groove width:

Standard (1st): 1.01-1.03 mm
(2nd): 1.03-1.03 mm
3-18
ENGINE
PISTON RING THICKNESS
Piston ring groove width:

Standard (1st): 0.97-0.99 mm
(2nd): 0.97-0.99 mm
TOOL 09900-20205: Mircometer (0-25mm)
Fit the ring in the cylinder, and measure each ring end gap
using a thickness gauge at the 10mm from the cylinder
bottom.
Piston ring end gap:
Limit (1st): 0.5 mm
(2nd): 0.5 mm
Using a caliper gauge, measure the piston pin bore. inside

diameter.
Piston pin bore inside diameter: Limit: 15.03 mm
Using a micrometer measure the piston pin outside

diameter.
Piston pin O.D.: Limit: 14.98 mm
Measure the conrod small end I.D.
Conrod small end I.D.: Limit: 15.04 mm
3-19
ENGINE
REASSEMBLY
Reassemble piston and cylinder in the reverse order of
removal, pay attention to the following points:
Clean the piston top, skirt and groove. 120 o

1st ring
o
CAUTION 120 120

o
2nd ring
Spacer
Fit the piston rings in the groove correctly, turn the
piston ring in the groove to make sure it is fitted with Side rail
20mm
piston circumference freely. or more
20mm
or more
Be sure to bring the marked side to the top when fitting the
piston rings to the piston.
CAUTION 1st ring
Take care not to damage the piston ring and piston 2nd ring
when installing the piston ring.
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 piston rings in the order of oil ring, 2nd ring
and 1st ring. Do not align the gap of oil ring with
expander ring.
Piston ring should turn smoothly in the piston groove after
Apply Moly paste on 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
Only use new circlip.
Do not align the opening of the piston circlip with the
piston pin hole.
When fitting the piston, turn arrow mark on the piston head
to the exhaust side.
Install the new gasket and dowel pin.
CAUTION
Apply the Bond “1207B” on the crankcase mating
surface before installing the gasket.
99000-31140: Bond "1207B”
Install the cylinder.

● Install the cylinder head. (Refer to page 3-15)
3-20
ENGINE
AUTOMATIC CLUTCH ASSEMBLY

REMOVAL
Remove the bolts, take off the clutch outer cover .
Remove the bolts, take off the clutch cover .
Remove the gasket and dowel pins.
Hold the fixed drive face with the special tool, remove the fixed
drive face nut.
TOOL 09930-40113: Rotor holder
Remove the bushing and fixed drive face .
3-21
ENGINE
Hold the clutch house with the special tool, take off the clutch
house nut.
Remove the gasket and clutch house 7 .
Remove the movable driven face assembly 8 and drive belt 9 .
Remove the spacer 10 and movable drive face assembly 11 .
DISASSEMBLY Cushion
Movable drive face
● Disassemble the movable drive face assembly.
Spacer
Movable
Roller
drive face
3-22
ENGINE
Loosen the clutch shoe nut with the special tool.
CAUTION
Do not remove the clutch shoe nut at this time.

TOOL
Remove the clutch shoe nut while holding down the clutch
shoe assembly by hand.
WARNING
危险
Gradually back off the clutch shoe assembly pressed
down by hand to reduce the clutch spring load.
Releasing the hand suddenly may cause the parts to
fly apart.
Remove the clutch shoe nut , clutch shoe assembly and

spring .
CAUTION
Do not attempt to disassemble the clutch shoe assembly.
Remove the movable driven face seat with a thin brade

screwdriver.
Remove the three pins and movable driven face 7 from

the fixed driven face .
3-23
ENGINE
Remove the oil seals 8 and O-rings 9 .
Remove the spacer 10 .
TOOL 09900-06108: Snap ring pliers
Remove the bearing 11 along with the spacer 12 with a

proper tool.
CAUTION
If abnormal noise does not occur, it is not
necessary to remove the bearing.
Remove the needle bearing 13 with the special tool.

TOOL 09923-73210: Bearing remover
09930-30102: Sliding shaft
CAUTION
If abnormal noise does not occur, it is not necessary to
remove the bearing.
TOOL
CAUTION
The removed bearings, 11 and 13 , should be replaced
with new ones.
3-24
ENGINE
INSPECTION
ROLLER
Inspect each roller for wear or damage.
SPACER
Inspect the spacer for wear or damage.
CLUTCH SHOE INSPECTION

Inspect the linings A for crack, uneven wear or
bushing.
A
Measure the lining thickness with a vernier calipers.
If any defects are found or measurement exceeds
the limit, replace the clutch shoe assembly with a
new one.
Clutch shoe thickness: Service limit: 2.0 mm
TOOL 09900-20101: Vernier calipers
CLUTCH HOUSING INSPECTOR

Inspect the inner surface of clutch housing for deep scratches
or discoloration caused by burning.
Measure the clutch housing inside diameter with an inside
calipers. If any defects are found or measurement exceeds
the limit, replace the clutch housing with a new one.
Clutch housing I.D.:

Service limit: 125.5 mm
TOOL 09900-20101:Vernier calipers
3-25
ENGINE
DRIVE BELT INSPECTION

● Inspect the drive belt for crack, separation, abnormal wear or
contamination with oil.
● Measure the belt width with a vernier calipers.
If any defects are found or width is less than the service limit,
replace the drive belt with a new one.
Drive belt I.D.: Service limit: 18.9 mm
CAUTION
If drive belt is contaminated with grease or oil, clean it
with neutral detergent. TOOL
2
REASSEMBLY
Reassemble the automatic clutch in the reverse order of removal
and disassembly, pay attention to the following points:
Install the needle bearing into the fixed driven face with 1
the special tool.
TOOL 09943-88211: Bearing installer
Apply Super grease “A” to the needle bearing.

A 99000-25010: Super grease "A”
Install the spacer . 3
CAUTION
Be sure to face the small bore side of the spacer to the
inside.
Install the bearing with the special tool.

TOOL
4
TOOL 09941-34513: Bearing installer 4
Install the circlip with a snap ring pliers.
TOOL 09900-06108: Snap ring pilers 5
CAUTION
Be sure to face the sharp edge of the circlip to the outside.
3-26
ENGINE
Install the new oil seals ( and 7 ) to both sides of the

movable driven face 8 with the special tool. TOOL
TOOL 09913-76010: Bearing installer 8
Apply Super grease ”A” to the lip of both oil seals ( and 7 ) 6
and groove A . 7
A
A 99000-25010: Super grease ”A”
Install the movable driven face to the fixed driven face.
CAUTION
When installing the movable driven face, insert it while
using a 0.1 mm thickness gauge as a guide to prevent
the damage of the oil seal lip.
Install the three pins 9 and the new O-rings 10 .

Apply Super grease ”A” to the pin groove B and O-rings 10 .
A 99000-25010: Super grease ”A”
Install the movable driven face seat 11 . .
3-27
ENGINE
Install the spring and clutch shoe assembly 12 .

Install the clutch shoe nut 13 while pressing down the clutch
shoe assembly,
Tighten the clutch shoe nut to the specified torque with the
special tool.
Clutch shoe nut: 50-70 N•m
Install the rollers and dampers.
CAUTION
The covered side of roller must face right as shown in the

right illustration.
Install the fixed drive face assembly.
CAUTION
Wipe the movable drive face with cloth contains alcohol.
Install the movable driven face and drive belt.

Install the clutch house, gasket and nut.
3-28
ENGINE
Hold the clutch house with the special tool, tighten the clutch
house nut to the specified torque.
Clutch house nut:65-85 N•m
Install the fixed drive face.

Hold the fixed drive face with the special tool, tighten the fix
drive face nut to the specified torque.
Fixed drive face nut: 40-60 N•m
Install the gasket and dowel pins.
CAUTION
Always use new gasket.
Install the clutch cover, tighten the clutch cover mounting bolt
to the specified torque.
Clutch cover mounting bolt: 8-12 N•m
CAUTION
Make sure the clamp is fitted at the right location.
● Install the clutch outer cover.
3-29
ENGINE
GEARBOX
REMOVAL
Drain the gearbox oil. (Refer to page 2-9)
Remove the rear wheel and rear brake. (Refer to page 6-30)
Remove the automatic clutch assembly. (Refer to page 3-21)
Remove the clamp, take off the speed sensor cover 1 .
Remove the speed sensor .
Remove the gearbox cover .
Remove the dowel pin and gasket .
Remove the idle gear shaft assembly 8 .

Remove the final driven gear circlip 6 and final driven gear
7.
TOOL 09930-06107: Snap ring pliers (opening type)
3-30
ENGINE
Remove the rear axle 9 from the crankcase.
Remove the drive shaft 10 from the gearbox cover 11 .
CAUTION
Do not damage the gearbox, bearing and drive shaft.
Remove the driveshaft oil seal 12 .
INSPECTION
Inspect the bearings on the gearbox cover for wear or
damage.
Rotate the inner race by hand to inspect for an abnormal noise
and a smooth rotation. Inspect whether the outer race is fitted
in the gearbox cover firmly.
Replace the bearing if there is something unusual.
Inspect the bearings of left gearbox for wear or damage.

Rotate the inner race by hand to inspect for an abnormal noise
and a smooth rotation. Inspect whether the outer race is fitted
in the gearbox cover firmly.
3-31
ENGINE
Inspect the rear axle and final driven gear for wear, damage or
smooth rotation.
Replace the rear axle and final driven gear if there is
something unusual.
Inspect the idle gears for wear, damage or corrosion, replace

the idle gears if there is something unusual.
Inspect the rear axle for wear, damage or corrode, replace the
rear axle if there is something unusual.
BEARING REPLACEMENT
Remove the idle gear shaft bearing , drive shaft bearing
and rear wheel shaft bearing with the special tool.
TOOL
09921-20240:Bearing remover
Remove the drive shaft bearing , idle gear shaft bearing ,

oil seal and rear axle shaft bearing 7 from the gearbox with
the special tool.
TOOL 09921-20240:Bearing remover
09913-50121: Oil seal remover
CAUTION
Do not damage the gearbox and gearbox cover contacting

face.
3-32
ENGINE
Apply super grease “A” to the new oil seal lip.

Install the new oil seal with the special tool.
99000-25010: Super grease ”A”
TOOL 09913-70210: Bearing installer set
Apply engine oil to the bearing turning part.

Install the new bearing with special tool.
TOOL 09913-70210: Bearing installer set
INSTALLATION
Install the drive shaft on the gearbox cover.
Apply the engine oil on the new oil seal surrounding and lip, fit
the oil seal in the gearbox cover with the special tool.
TOOL 09925-98221: Oil seal installer
Install the rear axle to the gear box.
Apply the gear oil to the gear teeth and bearing.

Install the idle shaft assembly and driven gear into the
gearbox.
TOOL 09900-06107: Snap ring pliers(Opening type)
3-33
ENGINE
Install the dowel pin and new gasket.
Install the gear box cover, tighten the bolt to the specified
torque.
Gear box cover bolt: 8-12 N•m
Install the speed sensor.
CAUTION
Always use new seal ring.
Install the speed sensor cover.

Clamp the wiring harness.
CAUTION
Use new wire clamp and cut the surplus after clamping.
Install the automatic clutch assembly. (Refer to page 3-28)

Add the gear oil to the gear box. (Refer to page 2-9)
Install the rear wheel and rear brake. (Refer to page 6-32)
3-34
ENGINE
GENERATOR AND STARTER CLUTCH

REMOVAL
Remove the bolts and clamp, take off the starter motor .
Remove the cooling fan .
Remove the cooling fan fixer nuts with the special tool.
TOOL 09930-40113：Sprocket holder
Remove the washer and cooling fan fixer .
Remove the wire clamp bracket
Remove the crankcase right cover .
3-35
ENGINE
Remove the generator stator mounting bolt, pick-up coil

mounting bolt and grommet , take off the generator stator
and pick-up coil 7 .
Remove the rotor nut with the special tool.
TOOL 11F14-001: Rotor holder
Remove the gasket 8 and dowel pins
Remove the starter idle gear shaft 9 and idle gear 10 .
Remove the rotor and starter clutch assembly 11 with the

special tool.
TOOL 09930-30102: Rotor remover slide shaft
09930-34980: Attachement
3-36
ENGINE
INSPECTION
Install the starter clutch gear to the starting clutch, check to
see if the starer clutch gear only turn anti-clockwise, or
replace the starter clutch assembly .
● Inspect the starter idle gear for wear or damage, if any defects
are found, replace the starter idle gear for a new one.
INSTALLATION
Install the generator in the reverse order of removal. Pay
attention to the following points:
Before Installing the generator stator, apply bond in the rubber

plug groove and apply Thread lock on the stator mounting
bolts and tighten them to the specified torque.
99000-31140: Bond “1207B”

13 4 2 99000-32050: Thread lock “1342"
Apply a small quantity of Moly paste on the contacting surface

of starter clutch gear and crankshaft as well as the inside of
starter idle gear shaft hole.
Install the key .
3-37
ENGINE
Tighten the generator rotor nut to the specified torque while

holding the generator rotor with the special tool.
Generator rotor nut: 110-130 N•m
TOOL 11F14-001: Rotor holder
Install the starter idle gear and idle gear shaft .
Install the crankcase right cover , tighten the bolts to the

specified torque.
Crankcase bolt: 8-12 N•m
Install the cooling fan fixer , apply the Thread lock to inside
of the nut, tighten the nut to the specified torque.
1342 99000-32050: Thread lock “1342"
Cooling fan nut: 25-30 N•m
TOOL
09930-40113: Sprocket holder
Install the cooling fan 7 , apply the thread lock on the bolt and
tighten.
13 4 2 99000-32050: Thread lock “1342"
Install the starter motor 8 , tighten the starter moto bolts to the
specified torque.
Starter motor bolt: 8-12 N•m
3-38
ENGINE
OIL PUMP
REMOVAL
Remove the generator and starter clutch.(Refer to page 3-38)
Remove the oil pump sprocket cover .
Remove the oil pump mounting bolts, take off the oil pump
and cam chain .
INSTALLATION
Install the oil pump in the reverse order of disassemble, pay
Apply clean engine oil on the oil pump drive chain and gear.
Install the oil pump sprocket, apply the Thread lock “1342" on
the threaded part of sprocket nut and tighten it to the specified
torque.
13 4 2 99000-32050: Thread lock "1342”
Sprocket nut: 7-10 N•m
Install the oil pump sprocket cover.

Install the generator and starting clutch.(Refer to page 3-40)
3-39
ENGINE
CRANKCASE AND CRANKSHAFT

REMOVAL
Remove the cylinder head and cylinder. (Refer to page 3-7
and 3-17)
Remove the automatic clutch assembly. (Refer to page 3-22)
Remove the generator assembly, starter clutch and oil pump.
(Refer to page 3-39 and page 3-41)
Remove the crankcase bolt .
Place the crankcase horizontally, remove the right crankcase.
TOOL 09920-13120: Crankcase separator
Remove the crankshaft from the left crankcase with the

special tool.
TOOL
09920-13120: Crankcase separator
INSPECTION
Inspect the bushing for wear or damage.
Inspect the oil seal for damage and crack, if defect is found,
replace the oil seal with a new one.
3-40
ENGINE
Inspect the play of crankcase bearing inner race by hand while

fixing it in the case.
Rotate the inner race by hand to inspect for abnormal noise
and a smooth rotation.
Replace the bearing if there is some-thing unusual.
Measure the conrod big end side clearance.
Conrod big end side clearance: Limit: 1.0 mm
TOOL 09900-20803: Thickness gauge
Wear on the big end of the conrod can be estimated by checkng the
movement of the small end of the rod. This method can also check the
extent of wear on the parts of the conrod’s big end.
Conrod small end runout:Limit: 3 mm
09900-20606:Dial gauge
09900-21304:V-block
Support the crankshaft with "V" blocks as shown, with the two
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

TOOL 09900-20606:Dial gauge
09900-21304:V-block
OIL SEAL REPLACEMENT
Remove the oil seal, install the new oil seal with the special
tool.
TOOL
09913-70210: Bearing installer
3-41
ENGINE
CRANKCASE BUSHING
Remove the crankcase bushing, install the new bushing into
the crankcase with the special tool.
TOOL
BEARING REPLACEMENT
Remove the crankshaft bearing with the special tool.
TOOL
09921-20240:Bearing remover
Install the new crankshaft bearing with the special tool.
TOOL
INSTALLATION
Install the crankcase in the reverse order or removal, pay
attention to the follow points:
Install the crankshaft on the crankcase.
TOOL
09910-32812: Crankshaft installer
● Apply the bond evenly on the contacting surface of right

crankcase.
CAUTION
Make sure the bond is correct, evenly and continuous.
Install the right crankcase, and tighten the bolt to the specified
torque.
Crankcase bolt: 8-12 N•m
Install the generator, starter clutch and oil pump.(Refer to

page 3-39 and 3-41)
Install the automatic clutch assembly. (Refer to page 3-26)
Install the cylinder head and cylinder.(Refer to page 3-20 and
3-13)
3-42
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
4-8
COMPENSATION OF INJECTION TIME (VOLUME)
INJECTION STOP CONTROL
FI SYSTEM PARTS LOCATION
4-8
4-9
4
FI SYSTEM WIRING DIAGRAM 4-10
ECM TERMINAL 4-11
SELF-DIAGNOSIS FUNCTION 4-12
CURRENT DTC / PAST DTC 4-12
MALFUNCTION INDICATION LIGHT FLASHING MODE 4-12
MALFUNCTION INDICATION LIGHT CHECK 4-13
PASS DTC DELETING 4-13
DTC TABLE 4-14
DIAGNOSIS DEVICE 4-15
FI SYSTEM TROUBLESHOOTING 4-17
INSPECTION PRIOR TO DIAGNOSIS 4-17
FI SYSTEM FAULT ANALYSIS 4-17
DTC “12” CKP SENSOR CIRCUIT MALFUNCTION 4-18
DTC “13” IAP SENSOR CIRCUIT MALFUNCTION 4-21
DTC “14" TP SENSOR MALFUNCTION 4-24
DTC "15" ET SENSOR CIRCUIT MALFUNCTION 4-28
DTC "21" IAT SENSOR CIRCUIT MALFUNCTION 4-31
DTC "24" IGNITION COIL CIRCUIT MALFUNCTION 4-34
DTC "32" FUEL INJECTOR CIRCUIT MALFUNCTIO 4-37
DTC "40" IDLE SOLENOID VALVE CIRCUIT MALFUNCTION 4-40
DTC "41" FUEL PUMP CIRCUIT MALFUNCTION 4-44
DTC "42" POWER CHECK MALFUNCTION 4-47
DTC "44" OXYGEN SENSOR CIRCUIT MALFUNCTION 4-49
DTC "99" BATTERY VOLTAGE MALFUNCTION 4-51
SENSORS 4-52
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. .
① Coupler
② Probe
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.
① Coupler
② Probe
③ Where male terminal fits
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 错误
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
电喷系统诊断
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..
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 intake air pressure, 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
INTAKE AIR PRESSURE INTAKE AIR PRESSURE SIGNAL

SENSOR (IAP SENSOR)
ENGINE SPEED SIGNAL Basic fuel
CRANKSHAFT POSITION
injection
SENSOR (CKP SENSOR)
time
THROTTLE OPENING SIGNAL
TP SENSOR
OTHER SENSORS Various signal Corrective

variables
Definitive
Injection signal
Injector fuel
injection
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 10 000 r/min, this circuit cuts off fuel at the
fuel injectors.
4-8
FI SYSTEM DIAGNOSIS
FI SYSTEM PARTS LOCATION
D
C
K H
L
M
A ECM D ISC valve G Combination meter K Fuel pump

B Fuse box E 3 in 1 sensor H Ignition coil L CKP sensor
C Fuel injector F ET sensor J EVAP valve L Oxygen sensor
4-9
FI SYSTEM DIAGNOSIS
FI SYSTEM WIRING
+B1
10A
Ignition coil
15A +B2 IG
C Ignition coil
output coil
3.7Ω
IG GND
Fuel pump
Fuel pump
FP M
output coil
3.01kΩ
±0. 5 % GND
Power check
AT
±0.5 %
coil
619Ω
Sensor ground
20A
Starter switch
Starter
motor M 5V
Battery 10K
VCC 51Ω 51Ω
TACO CPU
Test switch 5.1 kΩ Meter
TS Test switch output coil
input coil
Meter
GND Ground Ground Ground
Rectifier
Alarm
GND
GND
CKP sensor
CPS + Wave coil CPU ISA
ISC motor ISA-
SG output coil ISB
VCC ISB- M
VCC
TPS Th rottle ISC motor
TPS p ressure.
220kΩ input coil
IAPS VCC Injector 30kΩ±0 . 5%
SG power voltage
SG
150kΩ input coil 10kΩ±
Intake
IAPS p ressure. 0.5%
input coil
VCC VB +B1
VCC +B
SG 2.7kΩ ±0 .5%
IATS Intake temp. Power supply
IATS coil +B
input coil 100 0 V
VCC
SG
1.21kΩ ±0.5%
ETS Engine Fuel injector
ETS temp. output coil INJ
V C C input coil 12Ω
1MΩ
SG 330kΩ +B2
Oxygen MIL output
O2 10kΩ MIL
sensor coil
OX
input coil VB
56kΩ
GND
SG SG
110kΩ
Meter input/
33Ω
DIAG
output coil
GND
SG
SG
4-10
FI SYSTEM DIAGNOSIS
ECU TERMINALS
NO. Circuit NO. Circuit

1 IG I gnition coil 19 IATS IAT sensor
2 MIL Malfunction indicator light 20 OX Oxygen sensor
3 FP Fuel pump 21 TPS T P sensor
4 22 ETS E T sensor
5 GND G r o u nd 23 ISA I sc stepper motor A
6 SG Sensor ground 24 ISA- I sc stepper motor A-
7 + B Battery 25 IG GND Ignition coil ground
8 CPS+ CKP sensor 26 T ACO Tachometer
9 V CC Sensor voltage 27
10 TS T est switch 28
11 ISB- Isc stepper motor B- 29
12 ISB Isc stepper motor B+ 30
13 INJ Injector 31
14 32
15 33 IAPS IAP sensor

16 AT Power check 34 DIAG Diagnose tool
17 35
18 36
4-11
电喷系统诊断
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 too low, ECM no longer perform self-
diagnois.
● 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
remains lit, 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.
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 mode select coupler and switch
it to ON.
● Turn on the ignition switch, after self-diagnosis is
completed, malfunction indication light starts output DTC.
● After the defect is removed, start the engine 3 times,
malfunction indication light turns off.
PAST DTC
Connect the test switch, turn the mode select switch ON.
Open the throttle fully.
● Turn on the ignition switch, after malfunction indication
light being off for 3s,malfunction indication starts flashing
to output past DTC.
When the motorcycle preheating cycle reaches 40 times,
the past DTC will be deleted.
11F14-033: Test switch
NOTE:
Start the motorcycle repeatedly: Turn on the ignition
switch, start the engine and run for 3s, then turn off the
ignition switch. Repeat the process 3 times.
Engine preheating cycle: After the engine is running, the
engine temperature rises more than 22.5 oC and excesses
71 oC, it means DTC exists.it means DTC exists. counts as
4-12
FI SYSTEM DIAGNOSIS
UNDERSTANDING THE DTC (Diagnostic Trouble Code)

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(Example) 12 23 12
0.3s 0.3s 0.3s 0.3s 0.3s 0.3s
ON
3s 3s
OFF 1s 1s 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
Past DTC (Diagnostic Trouble Code) Deleting

To delete to past DTC:
Turn on the test switch, open the throttle fully.
Turn on the ignition switch.
After Malfunction indicaiton light being off for 3s, malfunction indication light starts blinking to output
DTCs, close the throttle.
Switch the test switch from off to on 3 times, each time leaving it at on for more than 0.1s and off for
more than 1s, past DTCs are deleted.
CAUTION
Step must be completed in 30s.
ON ②Ignition
Ignition
switch switch ON
OFF ④ Switch it from
OFF to ON
ON ①Test
Test switch ON
switch OFF
Full open ① Full

Throttle
open
opening
Full close
ON ③DTC
Malfunction being output
indication OFF
light
4-13
FI SYSTEM DIAGNOSIS
TABLE OF DIAGNOSTIC TROUBLE CODE (DTC)

Malfunction
Starting and
DTC Malfunction part indication
DTC Malfunction descriptions light running ability
Open circuit/ Starting No

12 P0335 CKP sensor (CPS) Turns on Running No
short circuit to VCC
Open circuit/
P0105 short circuit to VCC Starting Yes
13 IAP sensor (IAPS) Turns on
P0107 Short circuit to GND Running Yes
Open circuit/
14 TP sensor (TPS) Turns on
Open circuit/
15 ET sensor (ETS) Turns on
Open circuit/
21 IAT sensor(IATS) Turns on
Open circuit/
P1502 short circuit to VCC Starting No
23 Tip-over sensor Turns on Running No
P1503 Short circuit to GND
24 P0350 Ignition coil short circuit to GND Turns on Running No

32 P0200 Fuel injector Turns on Running No
short circuit to GND

40 Starting Yes
Idle speed control valve Open circuit/ Turns on
Running Yes
P0507 short circuit to +B
ISC valve is fixed.
41 P0230 Fuel pump Turns on Running No
short circuit to GND
Starting No
42 P1501 Power check Open circuit/lower voltage Turns on
Running No

Starting Yes
44 P0132 Oxygen sensor Short circuit to VCC Turns on Running Yes
Starting Yes
99 P0560 Battey(high voltage) Defective rectifier Turns on Running Yes
Note: POXXX DTC would only be read by the diagnosis device.
4-14
FI SYSTEM DIAGNOSIS
DIAGNOSIS DEVICE
INSTRUCTION
Brand plate
Grip
Touch
screen
Diagnosis port USB update port

Power
Dc12v power input Data port SM card slot
USE THE DIAGNOSIS DEVICE

Turn off the ignition switch.
Connect the diagnosis device coupler.
● Turn on the ignition switch.

Turn on the defect diagnose device.
4-15
FI SYSTEM DIAGNOSIS
Click “D system”, enter the model selection page.
Cleck " Haojue Special China III,IV,EURO IV”, enter the defect
diagnosis page.
● Click “Check Failure”.
● Enter the defect diagnosis page, display the defect

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

After the history DTC is displayed, click”Clean faults”.
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.
4-16
FI SYSTEM DIAGNOSIS
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.
4-17
FI SYSTEM DIAGNOSIS
DTC "12": CKP SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
EC M
CKP sensor
G/W G/W 6 SG
Bl/Y Bl/W Bl/W 8 CPS+
To rectifier
Generator rotor
ECM coupler(Harness side)
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:
After repairing the trouble, clear the DTC. (Refer to page 4-14)
Step 1
CKP sensor signal circuit check
1) Turn off the ignition switch.
2) Remove the seat and helmet case.
(Refer to page 6-3)
3) Disconnect the CKP sensor coupler and ECM couplers .
4-18
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the CKP 1

sensor coupler and ECM couplers.
5) If connections are OK, check the following points.
* Resistance

6
Tester Knob Indication: Resistance 8
Between G/W wire and Bl/W wire: Less than 1Ω
Between the G/W wire or Bl/W wire and ground: infinity 1
Between the G/W wire and Bl/W wire: infinity 1
* Voltage 1
Tester knob indication: Voltage
Between G/W wire or Bl/W wire: approx. 0 V

(When the ignition switch is turned ON.)
Is check result ok ?
YES Go to step 2.
NO Repair or replace the defective wire harness.
4-19
FI SYSTEM DIAGNOSIS
Step 2 2
CKP sensor check
1) Measure the CKP sensor resistance.
Tester knob indication: resistance
CKP Sensor Resistence:190 Ω
2) Check the continuity between each terminal and ground. 2

CKP sensor continuity: ∞ Ω (Infinity)
(G-Ground)
(Bl-Ground)
YES Go to step 3.
NO Replace the CKP sensor with a new one.
Step 3
CKP sensor and rotor signal check
1) Remove the generator cover. (Refer to page 3-39）

2) Check that end face of the CKP sensor and generator
teeth are free from any metal particles and damage.
YES Go to step 4.
NO Clear or replace defective parts.
Step 4 4
ECM INSPECTION
1) Re-connect a new ECM.
YES Replace the ECM with a new one.
NO Replace the CKP sensor with a new one
(Refer to page 3-36)
4-20
FI SYSTEM DIAGNOSIS
DTC”13”: IAP SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
3 in 1 sensor ECM
R/BL 33 IAPS
G/W 6 SG
R 9
ECM coupler (Harness side)
TROUBLESHOOTING
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler
with a needle-point tester probe to prevent terminal damage.
NOTE:
After repairing the trouble, clear the DTC (Refer to page 4-14).
Step 1
IAP sensor power supply circuit check

(Refer to page 6-3)
3) Disconnect the 3 in 1 sensor coupler .
4-21
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the IAP 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
IAP sensor power supply voltage:

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

IAP sensor power supply voltage:

4.5 – 5.5 V (+ terminal: R – - terminal: G/W)
2) Check for proper terminal connection to the ground.
YES Repair or replace G/W wire.
NO Repair or replace red wire.
Step 3 3
IAP Sensor Signal Circuit Check
2) Remove the front windshield. (Refer to page 6-2)
3) Disconnect the ECM coupler .
4-22
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the ECM couplers.

* Resistance


33
Between R/Bl wire of IAP sensor coupler and ECM coupler:
less than:1Ω
Between R/Bl wire and ground: infinity
Between R/Bl wire or G/W wire: infinity
* Voltage
Tester knob indication: voltage
Between R/Bl wire and ground: approx. 0 V

Turn the ignition switch ON.
YES Go to step 4
NO Repair or replace the R/Bl wire.
4
Step 4
ECM Check
1) Replace the ECM with a new one.
YES Replace the ECM
NO Replace the throttle body with new one
4-23
FI SYSTEM DIAGNOSIS
DTC”14” : TP SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
TP sensor
G/W 6 SG
G/B 21 TPS
R 9
TROUBLESHOOTING
NOTE:
Step 1
TP sensor power circuit check

(Refer to page 6-2)
3) Disconnect the 3 in 1 sensor 1 .
4-24
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.
TP sensor power supply voltage:

4.5 - 5.5 V ( + terminal: R – - terminal: G/W)
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 - 5.5 V ( + terminal: R – - terminal: G/W)
2) Check the continuity between each terminal and 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 front lower legsield. (Refer to page 6-2).
4-25
FI SYSTEM DIAGNOSIS

*Resistance

Tester knob indication: Resistance 21
Between G/B wire of TP sensor coupler and ECM

coupler: Less than 1 Ω .
Between G/B wire and ground: Infinity.
Between G/B wire terminal and R wire terminal and G/W

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

(When the ignition switch is turned on.)
YES Go to step 4 .
NO Repair or replace G/B wire.
4-26
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: 0.65-0.75V

Full open: 3.8-4.0V
( + 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.
4-27
FI SYSTEM DIAGNOSIS
DTC “15”: ET SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ET sensor ECM
Y/R ETS
G/W 6 SG
TROUBLESHOOTING
NOTE:
Step 1
ET sensor input voltage check

2) Remove the seat and helmet case. (Refer to page 6-3)
2) Disconnect the ET sensor coupler .
4-28
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the ET sensor

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

ET sensor input voltage: 4.5-5.5V
( + 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 front lower legshield..
(Refer to page 6-2)

*Resistance

6
Tester knob indication: Resistance
Between Y/R or G/W wire of ET coupler and ECM coupler:

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

Between Y/R wire, G/W wire and ground: approx. 0 V
Replace the ECM with a known good one, and

YES inspect it again.
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.
4-30
FI SYSTEM DIAGNOSIS
DTC "21": IAT SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
IAT sensor ECM
BR 19 IATS
G/W 6 SG
TROUBLESHOOTING
NOTE:
Step 1
IAT sensor power circuit check
2) Remove the seat and helmet case. (Refer to page 6-3)
3) Disconnect the 3 in 1 sensor coupler .
4-31
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the IAT sensor

coupler.
5) Measure the input voltage between the Br wire and ground.
6) If OK, measure the input voltage between the Br wire and
G/W wire.
YES Go to step 3.
NO Go to step 2.
Step 2
IAT sensor circuit check
2) Remove the front lower legshield.

5) If connections are OK, check the following points. .
*Resistance


19
Between Br wire and G/W wire: Less than 1Ω
Between Br wire or G/W wire and ground: Infinity.
4-32
FI SYSTEM DIAGNOSIS
Between the BR 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.
4-33
FI SYSTEM DIAGNOSIS
DTC “24”: IGNITION COIL CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Ignition coil
B/G IG
O/G 7 +B
TROUBLESHOOTING
NOTE:
Step 1
Ignition coil circuit check

2) Remove the front lower legshield and maintenance cover.
(Refer to page 6-2)
3) Disconnect the ignition coil coupler and ECM coupler .
4-34
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the ignition coil 1

and ECM couplers.
*Resistance
09900-25009: Needle-point probe set 1
7
Between O/G wire and B/G wire: Less than 1 Ω.
Between O/G or B/R wire and ground: infinity 1
Between O/G wire and B/G wire: Infinity 1
*Voltage 1
Between O/G wire, B/G wire and ground: approx. 0 V

YES Go to step 2
4-35
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:

3.2-4.3 Ω (Terminal-terminal)
Ignition coil secondary resistance:
28.8-38.0 kΩ (Terminal-spark plug cap)
2
2) Check for proper terminal connection to each terminals

Ignition coil continuity:∞Ω（Infinity）
（O/G wire-Ground）
（B/G wire-Ground）
YES Go to step 3.
NO Replace the ignition coil with a new one.
3
Step 3
ECM Check
1) Re-connect a new ECM.
NO Replace the ignition coil with a new one.
4-36
FI SYSTEM DIAGNOSIS
DTC ”32": FUEL INJECTOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
FUEL INJECTOR
13 V
7 O/G
TROUBLESHOOTING
When using the multi circuit tester, do not strongly touch the terminal of the ECM coupler with a
NOTE:
Step 1
Injector power supply circuit check

2) Re.move the seat and helmet case. (Refer to page 6-3)
3) Disconnect the injector coupler
4-37
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the fuel injector

coupler.
6) Measure the voltage between the V wire and ground
wire.
After the ignition switch is turned on,

The injector voltage self-diagnoses for 3 seconds.
Injector power
supply voltage: Battery voltage
( + terminal to V wire- - terminal to ground wire)
YES Go to step 2.
NO Repair or replace v wire.
Step 2
Injector driver circuit check

2) Remove the front lower leg shield. )Refer to page 6-2)

* resistance

Tester knob indication: resistance 13 7
Between the V wire and O/G wire : Less than 1 Ω.
Between the V wire or O/G wire and ground wire: Infinity.
4-38
FI SYSTEM DIAGNOSIS
Between the V wire and O/G wire: infinity.
* Voltage
Between the V wire and O/G wire: Approx 0V.

YES Go to step 3.
NO Repair or replace defective wire.
Step 3
Injector resistance check

2) Measure the resistance between the injector terminals.
Injector resistance:12Ωat 20 oC
(Terminal- Terminal）
3) If resistance is OK, check for proper terminal connection to

the terminals and ground.
Injector continuity: ∞ Infinity
Replace the fuel injectror with a new one.

NO
4-39
FI SYSTEM DIAGNOSIS
DTC "40": ISC VALVE CIRCUIT MALFUNCTION

WIRING DIAGRAM
ISC VALVE ECM

Bl/B 23 ISA
Br/W 24 ISA-
W/R 12 ISB
W/G 11 ISB-
TROUBLESHOOTING
NOTE:
4-40
FI SYSTEM DIAGNOSIS
Step1
ISC valve drive circuit check

2) Remove the front lower leg shield, seat and helmet case.
(Refer to page 6-2 and 6-3)
3) Disconnect the ISC valve coupler and ECM coupler .
4) Check for proper terminal connection to the ISC valve

coupler and ECM coupler.
* Resistance

12
Tester knob indication: resistance 23
Between Bl/B wire, Br/W wire, W/R wire and W/G wire:
Less then 1 Ω.
11
24
Between the Bl/B wire, Br/W wire, W/R wire, W/G wire and
ground: infinity.
4-41
FI SYSTEM DIAGNOSIS
Between the Bl/B wire and ISC valve coupler terminals:

infinity.
Between the Br/W wire and ISC valve coupler terminals:

infinity.
Between the W/R wire and ISC valve coupler terminals:

infinity.
Between the W/G wire and ISC valve coupler terminals:

infinity.
4-42
FI SYSTEM DIAGNOSIS
* voltage
Between Bl/B wire or Br/W wire or W/R wire and W/G wire:
Approx 0V. (When the ignition switch is turned on).
YES Go to step 2.
Step 2
ISC valve check
1) Remove the ISC valve. (Refer to page 5-13)
2) Check for proper terminal connection to the ISC valve
coupler and ground.

ISC valve continuity: ∞ Ω ( Infinity )( Terminal-Ground)
3）If OK, measure the resistance (between the W/R wire

terminal A and W/G wire terminal B ) and (between the
Bl/B wire terminal C and Br/W wire terminal D ).
ISC valve resistance: 20Ω at 20℃

(Terminal A -Terminal B )
(Terminal C -Terminal D )
YES Replace the ECM with a new one and check again.
NO Replace the ISC valve with a new one,
4-43
FI SYSTEM DIAGNOSIS
DTC ”41”: FUEL PUMP CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
7 O/G
3 Bl/G
Y/B
B/W
Fuel level gauge
TROUBLESHOOTING
NOTE:
Step 1
Fuel pump power supply circuit check

2) Remove the rear cover plate. (Refer to page 6-3)
3) Disconnect the fuel pump coupler
4-44
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the fuel pump

coupler.
6) Check if the voltage between O/G wire and ground
wire matchs the battery voltage.
Fuel relay power supply voltage:

Battery voltage
( + terminal to O/G wire- - terminal to ground wire）
YES Go to step 2.
NO Repair or replace the defective wire.
Step 2
Fuel pump check
Check 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) Remove the front lower leg shield.(Refer to page 6-2)
2) Disconnect ECM coupler ① .
* Resistance
3
Tester knob indication: resistance 7
Between the O/G and Bl/G wire: Less than 1Ω

4-45
FI SYSTEM DIAGNOSIS
Between the O/G wire or Bl/G wire and ground wire:

Infinity.
* voltage

Between O/G wire and Bl/G wire: Approx 0V
When the ignition switch is turned on.
YES Replace the ECM with a new one and check again.
4-46
FI SYSTEM DIAGNOSIS
DTC “42”: POWER CHECK CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Ignition switch
16 O/G
NOTE:
Step 1
Ignition switch power supply circuit check

2) Remove the cowling and headlight assembly .
(Refer to page 6-2)
3) Disconnect the ignition switch coupler .
4-47
FI SYSTEM DIAGNOSIS
4) Turn on the ignition switch, measure the voltage

between each of O/G and ground.
Power check voltage: Battery voltage

( + terminal: O/G wire – - terminal; Ground)
YES Go to step 2 .
NO Repair or replace O/G wire.
Step 2
Power check circuit check
2) Remove the front lower leg shield.
(Refer to page 6-2)
3) Disconnect the ECM coupler 1 .
4) Check for proper terminal connection to the ECM

couplers.
* Resistance

16
Between O/G wire of ignition switch and ECM coupler:less

than 1 Ω .
Between O/G wire and ground: infinity
* Voltage

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

inspect it again.
4-48
FI SYSTEM DIAGNOSIS
DTC”44”: OXYGEN SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
Oxygen sensor
20 B/BR
6 G/W
TROUBLESHOOTING
NOTE:
Step1
Oxygen sensor power supply circuit check

2) Remove the seat and helmet case.(Refer to page 6-3)
3) Disconnect the oxygne sensor coupler .
4-49
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: 4.5-5.5V

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

2) Remove the front lower leg shield.
(Refer to page 6-2)

*Resistance

6
20
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
4-50
FI SYSTEM DIAGNOSIS
Between G/W and B/Br wire of fuel pump coupler: infinity.
*Voltage
Between G/W wire or B/Br wire and ground: approx. 0 V

YES Go to step 3 .
Step 3 3
ECM check
1) Reconnect a new ECM.
YES Replace the ECM.
NO Replace the oxygen sensor.
DTC “99”: BATTERY HIGH VOLTAGE MALFUNCTION

If DTC "99" exists, replace the rectifier with a new one.
4-51
FI SYSTEM DIAGNOSIS
SENSORS
CRANK SHAFT POSITION SENSOR
REMOVAL, INPSECTION AND REASSEBLY
Remove the CKP sensor (Pick-up coil).
Fix the signal rotor on the generator rotor and CKP
sensor in the generator cover.
Install the CKP sensor in the reverse order of removal.
ISC VALVE
( Refer to page 5-12 )
ET SENSOR
Remove the ET sensor. (Refer page 3-7)
Install the ET sensor in the reverse order of removal.
4-52
FI SYSTEM DIAGNOSIS
OXYGEN SENSORS
REMOVAL
Remove the seat and helmet case. (Refer to page 6-3)
Open the PVC jacket , disconnect the oxygen coupler ,
loosen wire clamp and clamp .
Remove the oxygen sensor from the muffler.
WARNING
Do not remove the oxygen sensor when the muffler is
hot.
CAUTION
* Do not hit the oxygen sensor outer part.

* Do not use the impact pliers or like tools during the
removal and assembly.
* Do not twist or damage the sensor wire.
INSTALLATION
Install the oxygen sensor in the reverse order of removal,pay
attendtion to the following points.
CAUTION
Do not leave the oil or metal item in the sensor air hole.
Install the oxygen sensor, tighten oxygen sensor to the

specified torque.
Oxygen sensor: 20-30 N • m
4-53
FUEL SYSTEM & THROTTLE BODY
CONTENT
FUEL SYSTEM 5-1 5-1
FUEL TANK REMOVAL 5-1 5-1
FUEL TANK REASSEMBLY 5-1 5-1
5-2
FUEL PRESSURE INSPECTION 5-2
5-2
FUEL PUMP INSPECTIO 5-2
5-3
FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL 5-3
5-4
FUEL PUMP DISASSEMBLY 5-4 5-5
FUEL STAINER INSPECTION AND CLEANING 5-5 5-5
FUEL PUMP AND FUEL LEVEL GAUGE REASSEMBLY 5-5 5-7
THROTTLE BODY 5-7 5-7
THROTTLE BODY REMOVAL 5-7 5-8
THROTTLE BODY CLEANING
INSPECTION
5-8
5-9
5-9
5-9 5
5-10
THROTTLE BODY REASSEMBLY 5-9
5-10
FUEL INJECTOR REMOVAL 5-10 5-10
FUEL INJECTOR INSPECTION 5-10 5-10
FUEL INJECTOR REASSEMBLY 5-10 5-11
ISC VALVE REMOVAL 5-10 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 AND THROTTLE BODY
FUEL SYSTEM
FUEL TANK REMOVAL
Remove the left and right side covers and tail
cover. (Refer to page 6-4)
Remove the front fender .
DANGER
* Far away from fire or spark.

* Wipe up the overflow gasoline.
* Keep the area you work in is well-ventilated.
● Remove the fuel tank high preesure fuel hose and sensor
coupler , hose , overflow hose .
● Remove the stop valve .

Loosen the clamp 7 .
Remove the rear connect bracket 8 .
● Take off the fuel tank 10 by removing the fuel tank

mounting bolt 9 .
CAUTION
Hold the fuel tank to prevent falling when removing the

fuel tank mounting bolts.
FUEL TANK REASSEMBLY

Reassemble the fuel take 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 seat and helmet case. (Refer to page 6-3)
Place a cloth under the fuel hose, remove the fuel hose 1 .
Install the special tool to the fuel pump nozzle and fuel
hose.
11F14-023: Pressure inspection tool
Turn the ignition switch on, 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
DANGER
Before removing the special tool, turn the ignition off

and release the pressure slowly.
A To fuel injector nozzle

B To fuel hose
FUEL PUMP INSPECTION

Turn ignition switch on, 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
1 Fuel level gauge 5 Seal ring
2 Fuel pump fixing plate 6 O-ring ITEM N•m Kgf•m

3 Fuel pump 7 Fuel hose A 8-12 0.8-1.2
4 Fuel pump filter A Nut
5-3
REMOVAL
Remove the left and right side covers and tail cover
assembly.(Refer to page 6-4)
Disconnect the fuel pump coupler and high pressure fuel
hose .
DANGER
* Far away from fire or spark.
* Wipe up the overflow gasoline.
* Keep the area you work in is well-ventilated
Remove the rear connect bracket .
Remove the fuel pump mounting nuts, take off the fuel
pump fixing plate , wire clamp and fuel pump assembly
.
FUEL LEVEL GAUGE INSPECTION

FUEL PUMP DISASSEMBLY

Remove the fuel pump strainer .
Remove the fuel level sensor wire coupler and fuel pump
wire coupler .
5-4
Remove the fuel pump .
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:
Reassemble the fuel pump and wire.
CAUTION
When reinstall the fuel pump, do not forget to

install the white jacket.
Replace the O-ring with a new one.
Replace the O-ring and dust cover , install the fuel

pump assembly .
5-5
CAUTION
When installing the fuel pump, the boss position of
fuel pump should be as shown in the illustration.
Install the fuel pump fixing plate, tighten the fuel pump
mounting nut to the specified torque.
Fuel pump mounting nut: 8-12 N•m
CAUTION
安装燃油泵安装板时，线夹的安装位置如右图所示。
5-6
THROTTLE BODY
THROTTLE BODY REMOVAL
Remove the saddle and helmet case. (Refer to page 6-3)
Remove the high pressure fuel hose and injector coupler
, ISC valve coupler and intake hose jacket .
Remove the high pressure fuel hose mounting bolt and

3 in 1 sensor coupler .
Loosen the wire clamp 7 .
Loosen the throttle cable adjuster nut 8 , remove the

throttle cable 9 .
Remove the intake hose mounting screw.
Remove the clamp screw, take off the intake hose-throttle

assembly 10 .
5-7
● Remove the canister absorber hose 11 .
Remove the throttle mounting bolts, take off the throttle

body 12 from the 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 passage-
ways.
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.
5-8
INSPECTION
Check following items for any damage or clogging.
Replace the damaged part if necessary.
* O-ring
* Throttle valves
* Purge hoses
* Fuel hose
THROTTLE BODY REASSEMBLY

Reassemble the throttle body in the reverse order of removal.
pay attention to the following points:
Replace the O-ring before the installing the engine intake

hose.
● When installing the throttle body intake hose, fit the boss
1 of throttle body to the air filter intake hose groove 2 . .
● Adjust the throttle cable play. (Refer to page 2-9)
5-9
FUEL INJECTOR REMOVAL

Remove the fuel inject protective cover.
Remove the fuel injector from engine intake pipe.
FUEL INJECTOR INSPECTION

Inspect the fuel injector filter if dust or dirt exists, if any
defects are found, clean the filter, check the fuel hose and fuel
tank.
FUEL INJECTOR REASSEMBLY

Reassemble the fuel injector in the reverse order
of removal.
ISC VALVE REMOVAL

CAUTION
When only removing the ISC valve, remove throttle

body from the engine is not necessary.
Remove the ISC valve holder mounting screw.
Remove the ISC valve.
5-10
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,
pay attention to the following points:
Apply a small quantity of engine oil to the new 0-ring 1 .
Install the ISC control valve retainer plate and fixing plate.
CAUTION
Make sure the retainer plate and fixing plate is fitted

correctly.
5-11
CHASSIS
CONTENTS
EXTERIOR PARTS REMOVAL/REMOUNTING 6-1

FRONT WHEEL 6-5
HANDLEBAR 6-10
FRONT SHOCK ABSORBER 6-13
STEERING 6-19
FRONT BRAKE 6-23
REAR WHEEL/REAR BREAK 6-29
TIRE AND WHEEL 6-32
6
CHASSIS
EXTERIOR PARTS REMOVAL/

REMOUNTING
Handlebar front cover
Remove the rearview mirror .
Remove the handlebar front cover mounting screw. .
Disconnect the left and right front turn signal light coupler .
Remove the handlebar front cover .
METER COVER
Remove the meter coupler , left and right handlebar
switches couplers and .
Remove the meter cover mounting screws, take off the
meter cover .
6-1
CHASSIS
FRONT LEG SHIELD

● Remove the front leg shield screws, remove the front leg
shield.
FRONT LOWER LEG SHIELD ASSEMBLY

● Remove the front lower leg shield assembly mounting
screws.
Disconnect the headlamp/position light coupler and

remove the front lower leg shield assembly .
MAINTENANCE COVER
● Remove the maintenance cover screws, take off the
maintenance cover .
6-2
CHASSIS
SEAT AND HELMET CASE

Unlock the seat lock, open seat.
Remove the air cleaner intake hose dust cover .
Remove the rear cover plate .
● Remove the seat/helmet case assembly .
CENTER COVER
● Remove the center cover side mounting screws.
CAUTION
The left and right side mounting screw of center cover

is symmetrical.
Remove the center cover mounting screws.

Remove the center cover .
6-3
CHASSIS
FRONT LEFT AND RIGHT SIDE COVERS

● Remove the 3 mounting screws on upper side and rear
lower side of the front side cover, take off the front left nad
right side covers and .
REAR CARRIER AND TAIL CASE

● Remove the rear carrier mounting bolts, take off the rear
carrier and tail case.
LEFT AND RIGHT SIDE COVERS AND TAIL COVER
Remove the fastener .
Disconnect the tail light/brake light coupler and license

light coupler , remove the left and right side cover and
tial cover .
6-4
CHASSIS
REAR FOOTREST ASSEMBLY

Loosen the rear footrest mounting bolt, take off the rear
footrest assembly .
CAUTION
The left and right rear footrest assemblies
have same structure, so removal procedure is same.
FOOT PEDAL
Remove the foot pedal mounting bolts.
Draw out the battery positive and negative lead wire, fuse
box and diagnosis coupler, take off the footrest.
FRONT CASE
Loosen the horn wire clamp .
Disconnect the alarm coupler and ECM coupler .
Remove the front case body mounting nut , take off

the front case body .
INSTALLATION
Install the exterior parts in the reversor order of removal.
6-5
CHASSIS
HANDLEBAR
CONSTRUCTION
1 Rear mirror 6 Left grip

2 Handlebar 7 Throttle case
ITEM N•m kgf•m
3 Throttle cable 8 Throttle grip
A 40-60 4.0-6.0
4 Rear brake cable A Nut
5 Rear break lever
REMOVAL
Remove the handlebar front cover and meter cover. (Refer
to page 6-1)
Open the throttle case assembly , remove the throttle
cable .
6-6
CHASSIS
● Remove the rear brake cable adjuster nut , loosen the

rear brake cable.
● Remove the rear brake cable from rear brake lever .
Loosen the rear brake combined lock nut , turn the rear
brake combined adjuster to the end, then remove the rear
brake combined cable from the combiner 7 .
Remove the front brake fluid reservoir tank mounting bolts,

take off the front brake fluid reservoir tank 8 .
Remove the wire clamp 9 .
Remove the handlebaqr mounting bolt/nut, take off the

handlebar 10 .
6-7
CHASSIS
ASSEMBLY
Reassemble the handlebar in the reverse order of removal. Pay
Install the handlebar pipe.
Install the handlebar mounting bolt/nut , tighten the nut to
the specified torque.
Handlebar clamp bolt/nut: 40-60 N•m
Install the master cylinder assembly 2 , tighten the mounting

bolt to the specified torque.
Front master cylinder: 8-12 N•m
CAUTION
Be sure to face the ”up” mark on the holder ⑧ to the up-
side. Before installing the front brake lever, apply a small
quantity of SUPER GREASE “A” to the front brake lever
pivot.
Install the rear brake combined cable 4 to combiner

5 .
Install the rear brake cable 6 , adjust the rear brake combined
adjuster to suitable position, then set the rear brake cable free
play to 10-25mm.(Refer to page 2-16)
CAUTION A
Apply a small quantity grease "A" to the rear brake

lever pivot.
Install the throttle cable 7 .
Connect the throttle cable end to the throttle cable
8 , install the throttle cable case assembly
9 ,tighten the screws.
CAUTION
Apply a small quantity of super grease “A”to the throttle
cable end.

WARNING
After the throttle case screw is tighten, make sure the
throttle turns smoothly.
Install the meter cover and handlebar front cover.(Refer to

page 6-6)
6-8
CHASSIS
FRONT WHEEL
1 Front axle 7 Valve

ITEM N•m Kgf•m
2 Spacer 8 Front rim
3 Oil seal 9 Spacer A 18-28 1.8-2.8
4 Roller bearing A Brake disc bolt B 48-58 4.8-5.8

5 Front brake disc B Front axle nut
6 Front tire
6-9
CHASSIS
REMOVAL
Raise the front wheel off the ground and Support the
motorcycle with a jack or a wooden block.
Remove the front axle nut , take off the front wheel .
Do not operate the front brake lever when removing the

front wheel.
Remove the front axle spacer .
Remove the brake disc bolts, take off the brake disc .
INSPECTION
AXLE SHAFT
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
Axle shaft runout:

Limit: 0.25 mm
WHEEL RIM
Inspect the wheel runout.Excessive runout is usually due to
worn or loosen wheel bearings and can be reduced by
replacing the bearings. If bearing replacement fails to reduce
the runout, replace the wheel.
Wheel runout: Limit: 2.0 mm
6-10
CHASSIS
OIL SEAL
Check the oil seal for wear or damage. Replace the oil seal
with a new one if any damage is found.
BEARING
Insect the play of wheel bearings inner race by hand while
fixing it in the wheel hub.
Rotate the inner race by hand to inspect whether abnormal
noise occurs or rotating smoothly.
REPLACEMENT
Remove the oil seal on both side with the special tool.
Remove the bearings on the both side, take off the spacer.
09921-20240: Bearing remover set
Apply super grease “A” to the bearings before installing.
6-11
CHASSIS
First install the left wheel bearing , then install the

spacer and right wheel bearing using the special tool
and removed wheel bearings .
09924-84510: Bearing installer set
The seal side of the bearing should be faced to outside.

Remove the removed bearing .
Removed wheel bearing Spacer A Left side a Clearance

Left bearing Right bearing B Right side
Lightly apply super grease “A” to the oil seal.

Install the new oil seal using the special tool.

09913-70210: Bearing installer set (10-75Φ)
REASSEMBLY
Reassemble the front wheel in the reverse order of removal.
Pay attention to the following point:
BRAKE DISC
● Make sure that the brake disc is clean and free of any
greasy matter.
Apply Thread lock “1360" to the disc mounting bolts and
tighten them to the specified torque.
1360 99000-32130: Thread lock “1360"
Front brake disc bolt: 18-28 N•m

6-12
CHASSIS
Install the front hweel, insert the front axle, tighten the front
axle nut to the specified torque.
Front axle nut: 48-58 N•m
WARNING
After installing the front wheel, pump the brake lever

until the pistons push the pads correctly.
6-13
CHASSIS
FRONT SHOCK ABSORBER

CONSTRUCTION
1 O-ring 8 Stopper ring

2 Spring 9 Oil seal
ITEM N•m kgf•m
3 Pistion rod 10 Oil seal circlip
A 15-30 1.5-3.0
4 Spring 11 Spacer B 20-26 2.0-2.6
5 Oil lock piece 12 Outer tube
6 Inner tube A Front absorber cap
7 Dust seal B Damper rod bolt
6-14
CHASSIS
REMOVAL AND DISASSEMBLY

Remove the front wheel. (Refer to page 6-10)
Remove the two bolts, take off the front brake caliper .
Remove the front fender left mounting boltt, loosen the
brake fluid hose clamp .
Remove the front fender right side mounting bolt, take off
the front fender .
Loosen the lower bracket clamp bolt and , remove the

front shock absorbers.
● Remove the front shock absorber cap 6 .
Remove the front absorber cap 7 , O-ring 8 and front absorber

spring I 9 , washer, spring II.
6-15
CHASSIS
Invert the absorber and stroke it several times to drain out

absorber oil.
Remove the dust seal 9 and stopper ring 10 .
Remove the damper rod bolt with the special tools.

Remove the inner tube from the outer tube.
TOOL 11F14-010: Front absorber tools
● Remove the damper rod 11 and oil lock piece 12 from the
inner tube.
WARNING
The removed oil seal should be replaced with a new

one.
Remove the oil seal with the special tool.
6-16
CHASSIS
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 surfaces for any
scuffing or flaws.
FRONT ABSORBER SPRING

Measure the absorber spring free length. If it is shorter
than the service limit, replace it.
Front absorber spring I: Service limit：126.4 mm

Front absorber spring II: Service limit：119.1 mm
* Cleaning: Clean all the removed parts and blow dry.
REASSEMBLY AND REMOUNTING

Reassemble and remount the front absorber in the reverse order
of removal and disassembly. Pay attention to the following points:
CAUTION
Wash each metal part with cleaning solvent before

reassembly.
Never re-use absorber oil left over from the last
servicing.
Replace the oil seal and dust seal with new ones when
reassembly.
6-17
CHASSIS
DAMPER ROD BOLT

Apply thread lock to the damper rod bolt and tighten it to
the specified torque with the special tools.
99000-32040: Thread lock “1303"
11F14-010: Front absorber tools

Thread lock Seal ring
Damper rod: 20~26 N•m
CAUTION
The removed oil seal should be replaced with a new one.
OIL SEAL
● Install the oil seal to the outer tube by using the special tool
as shown.
09940-50112: Front absorber oil seal installer set
CAUTION
Before installing the oil seal, apply a small quantity of
SUPER GREASE “A” to the lip of oil seal.
FRONT ABSORBER OIL
Pour specified absorber oil into the inner tube.
Capacity (each leg): 100±2 ml
Absorber oil type: Special oil
ABSORBER SPRING
Up side
When installing the front absorber spring, the close pitch
end should position upside.
Down side
6-18
CHASSIS
REASSEMBLY
Reassembly and install the front abosrber in the reverse order of
removal and disassembly. Pay attention to the following points:
Apply a small quantity of absorber oil on the O-ring of

front absorber cap.
Absorber oil type: Special oil
Tighten the front absorber cap to the specified torque.
Front absorber cap: 15-30 N•m
Install the front absorber to the lower bracket, tighten the

front absorber lower bracket clamping bolt to the
specified torque.
Lower bracket clamping bolt: 18-28 N•m
Install the front fender .
Install the brake hose clamp and the front brake caliper
, and tighten the mounting bolt to the specified torque..
Brake caliper mounting bolt: 18-28 N•m
Install the front wheel. (Refer to page 6-12)
6-19
CHASSIS
STEERING STEM
CONSTRUCTION
1 Lower bracket assembly 9 Upper steering inner race

2 Lock washer 10 Lower steering inner race ITEM N•m kgf•m
3 Steering stem lock nut 11 Lower ball ring A 25-35 2. 5-3.5
4 Washer 12 Lower steering outer race B 18-28 1.8-2.8
5 Steering stem nut 13 Steering stem lower seal ring
6 Dust cover A Steering stem lock nut
7 Lower steering outer race B Lower bracket clamp bolt
8 Upper ball ring
6-20
CHASSIS
REMOVAL
● Remove the handlebar. (Refer to page 6-6)
Remove the front wheel. (Refer to page 6-10)
Remove the front shock absorber. (Refer to page 6-15)
Remove the steering stem lock nut 1 .
09940-14911: Steer stem nut sleeve
● Remove the lock washer and steering stem lock nut .
Remove the rubber washer .
Remove the steering stem nut and dust cover with the
spcial tool.
11F14-047 : 6 claws sleeve 37-6x6
CAUTION
Hold the steering stem by hand to prevent from falling.
● Remove the upper steering outer reace 7 .
6-21
CHASSIS
Remove the lower bracket assembly 7 and lower ball ring

and upper steel ball ring 9 .
Remove the outer lower race and lower seal ring with a thin
chisel.
CAUTION
The outer lower race is pressed to the steering stem. If the
lower race is removed, replace it with a new one. It is not
necessary to remove the outer lower race if corrosion,
dents or damage on the race have not occurred.
Draw out the steering stem races, upper 10 and lower 11 ,

with a suitable bar .
INSPECTION
Inspect and check the removal parts for the following
Race wear and brineling.

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: TOOL
INNER RACES
● Press in the upper and lower inner races using the
special
09941-34513: Steering race installer
6-22
CHASSIS
OUTER RACE
Apply grease to the new lower oil seal.
Press in the new lower outer race by using the special tool.
99000-25010 : Super grease “A”
09941-74910: Steering bearing installer
REMOUNTING
Reassemble the steering in the reverse order of the removal.
STEEL BALL
● Apply grease to the upper and lower inner races when
installing the steel balls.
99000-25010: Super grease "A”
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, turn back the
stem nut by 1/4-1/2 turn.
11F14-047 : 6 claws sleeve 37-6x6
Steering stem nut: 35~45 N•m
Check to be sure that the steering stem moves freely from

left to right with its own weight. If play or stiffness is
noticeable, re-adjust the steering stem nut.
CAUTION
The adjustment will vary from motorcycle to another
one.
● Tighten the steering stem head bolt to the specified torque.
11F14-039 : Steering stem nut sleeve A
Steering stem lock nut: 25~35 N•m

Install the front shock absorber. (Refer to page 6-19)
Install the handlebar assembly. (Refer to page 6-8)
Install the front wheel. (Refer to page 6-12)
6-23
CHASSIS
FRONT BRAKE
CONSTRUCTION
A
B
1 Brake lever 5 Brake pad ITEM N•m kgf • m

2 Brake caliper piston A Master cylinder mounting bolt A 8-12 0.8-1.2
3 Brake light switch B Brake hose union bolt B 20-25 2.0-2.5
C 18-28 1.8-2.8
4 Brake hose C Brake caliper mounting bolt
6-24
车体
WARNING
The brake system of this motorcycle is filled with a Haojue brake fluid. Do not use or mix
different types of fluid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will 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.
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 .
Remove the brake pads .
CAUTION
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
Reassemble the new brake pads and brake caliper in the

reverse order of removal.
Tighten the brake caliper mounting bolt to the specified
torque.
Brake caliper mounting bolt: 18~28 N•m
CAUTION
Push the pistons all the way into brake caliper.
6-25
CHASSIS
CALIPER REMOVAL AND DISASSEMBLY

Disconnect the brake hose 1 from the caliper and catch
the brake fluid in a suitable receptacle.
Remove the brake caliper mounting bolts 2 , take off the
brake caliper.
CAUTION
Never re-use the brake fluid left over from the last
servicing and stored for long periods. Do not operate the
brake lever while dismounting the brake pad.
Remove the brake caliper pads.

Remove the brake caliper spring washer .
Remove the brake caliper bracket .
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.
CAUTION
Do not reuse the removed piston seal to prevent leaking.
INSPECTION
CALIPER CYLINDER
Inspect the cylinder bore wall for nick, scratch or other damage.
6-26
车体
PISTON
Inspect the piston surface for scratches or other damage.
RUBBER PARTS
Inspect the rubber parts for cracks and damage. If any defects
are found, replace the affected parts.
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 thickness:
Measure runout of the brake disc with a dial gauge.
09900-20606: Dial gauge(1/100 mm)

09900-20701: Magnetic stand
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.
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.
6-27
CHASSIS
Tighten the brake caliper mounting bolt 1 and brake hose

union bolt 2 to the specific torque.
Brake hose union bolt: 20~25 N•m

Brake caliper mounting bolt:18~28 N•m
Bleed air from the brake fluid circuit after reassembling mater
cylinder. (Refer to page 2-12)
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 before riding.
MASTER CYLINDER REMOVAL

Remove the front handlebar’s cover and meter cover. (Refer
to page 5-1)
Remove the front brake switch coupler ① .
Drain the brake fluid, remove the brake hose union bolt ② .
Remove Brake caliper mounting bolt ③ .
● Remove the brake lever spring 4 and brake lever
mounting bolt/nut.
The fluid reacts chemically with paint, plastics and rubber

materials, etc. and will damage them severely.
● Remove the reservoir cap 7 diaphragm plate 8 ,and

diaphragm 9 .
● Remove the dust seal 10 .

● Remove the circlip 11 by using the special tool.
TOOL 09900-06108: Snap ring pliers
● Remove the piston/cup and return spring .
6-28
CHASSIS
INSPECTION
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scratches or other
damage.
Inspect the piston surface for any scratches or other damage.
Inspect the piston cup and dust seal for wear or damage.
BF
MASTER CYLINDER REASSEMBLY

AND REMOUNTING
Reassemble and remount the master cylinder in the reverse
orders of disassembly and removal, and also carry out the
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
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.
Reassemble the brake lever and rear brake combiner,

apply a small quantity of super grease “A”to the pviot and
brake lever and combiner inner surface.
99000-25010 : Super grease“A”

Upper side
When remounting the master cylinder on the handlebar, align Upper
theBmaster cylinder holder’s mating surface A with punched clamp
mark B on the handlebar and tighten the upper clamp bolt first Handlebar
bolt
as shown.
"UP"
Tightening torque: 8~12 N•m mark Master
cylinder
CAUTION B
A Clearance
Be sure to face the "UP" mark on the holder to the up-side.
Connect the brake hose, tighten the union bolt to the

specified torque
Brake hose union bolt: 20~25 N•m
● Install the combiner spring and cable to combiner.

● Adjust the rear brake lever free play.(Refer to 2-14)
● Bleed air from brake system after installing the brake
caliper. (Refer to page 2-13)
6-29
CHASSIS
REAR WHEEL AND REAR BRAKE

CONSTRUCTION
1 Rear rim 5 Rear brake cam lever

2 Brake shoe 6 Rear wheel tubeless tire N•m kgf•m
ITEM
3 Break cam A Rear wheel nut A 102-138 10.2-13.8
4 Rear brake indicator B Brake cam lever nut B 8-12 0 . 8-1.2
REMOVAL
Support the motorcycle with the main stand.
Remove the muffler .
6-30
CHASSIS
Squeeze the rear brake lever, remove the rear axle shaft nut
Remove the rear brake adjuster nut , pin and spring .

Remove the rear wheel .
Remove the brake shoe 7 .
INSPECTION
REAR WHEEL
( Refer to page 6-6)
WHEEL HUB
● Measure wheel hub I.D and ascertain its wear extent. In case
wear exceeds wear limit, replace the wheel hub.
Wheel hub I.D.: Service limit: 120.7
6-31
CHASSIS
BRAKE SHOE
Replace the brake shoe as a set, otherwise braking
Brake shoe thickness: service limit: 1.5 mm
CAUTION
Replace the brake shoe as a set, otherwise braking
REASSEMBLY
Reassemble and remount the rear wheel and brake in the
reverse order of removal and disassembly. Pay attention to the
following points.
Turn the punched mark on the camshaft to the rear axle
shaft side.
Install the protrusion of indicator plate to the groove of

camshaft.
When installing the brake cam lever, align the groove of

camshaft with slit on cam lever.
Brake cam lever nut: 8~12 N•m
● Apply grease to the camshaft lever and pin before installing

the brake shoes.
A 99000-25010: SUPER GREASE ”A”
CAUTION
Be careful not to apply too much grease to the camshaft
and pin. If grease gets on the lining, brake effectiveness
will be lost.
● Install the brake shoe.

6-32
CHASSIS
Install the rear wheel .

Install the rear brake spring 7 , pin 8 and adjuster nut 9 .
Install the rear axle nut 10 , tighten it the specified torque.

Rear axle nut:102-138 N•m
Install the muffler, tighten the muffler mounting bolt/nut to the

specified torque
Exhaust pipe mounting bolt: 11-15 N•m

Muffler mounting bolt: 40-60 N•m
6-33
CHASSIS
TIRE AND WHEEL

TIRE REMOVAL
● Remove the valve core from the valve stem, and deflate the
tire completely.
Mark the tire with chalk to note the position of the tire
on the rim and rotational direction of the tire.
Remove the tire with the tire changer.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following point:
Distortion and crack

Any flaws and scratches at the bead seating area.
Wheel runout
TIRE
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 5 (punctures or fractures) on the tire
surface visually. As surface damage may impede driving
stability, such tires should be replaced.
When repairing a flat tire, follow the repair instructions

and use only recommended repairing materials.
VALVE INSPECTION
Inspect the valve after the tire is removed from the rim. Replace
the valve with a new one if the seal rubber is peeling or has 气门嘴
damage.
6-34
CHASSIS
If the seal has abnormal deformation, replace the valve with a

new one.
Seal
VALVE INSTALLATION
Any dust or rust around the valve hole must be cleaned off,
then install the new valve in the rim.
Valve hole
To properly install the valve into the valve hole, apply a

special tire lubricant or neutral soapy liquid to the valve.
Wheel
Be careful not to damage the lip of valve.
Valve lip Valve
TIRE INSTALLATION
Apply tire lubricant or neutral soapy to the tire bead.
Never use oil, grease or gasoline.
When installing the tire, the arrow on the side wall should
point to the direction of wheel rotation.
Valve
6-35
CHASSIS
● Install the tire.
CAUTION
Align the chalk mark put on the tire at the time of removal
with the valve position.
Inflate the tire.
WARNING
危险
Do not inflate the tire to more than 400 kpa (4.0 kgf/cm ,
57 psi). The tire should burst with sufficient force to
cause severe injury. Never stand directly over the tire
while inflating it.
In this condition, check the “rim line” cast on the tire side
walls. The line must be equidistant from the wheel rim all 轮辋线
around. If the distance between the rim line and wheel rim
varies, this indicates that the bead is not properly seated.
If this Is the case, deflate the tire completely and unseat
the bead for both sides. Coat the bead with lubricant and
fit the tire again.
After tire is properly seated to the wheel rim, adjust the air-
pressure to the recommended pressure.
Do not run with a repaired tire more than 50 km/h within

24hours after tire repairing. since the patch may not be
completely cured.
TIRE PRESSURE
Solo riding Dual riding
2 2
kPa kg/cm kPa kg/cm
Front wheel 175 1.75 175 1.75
Rear wheel 200 2.00 225 225
6-36
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
CAUTIONS IN SERVICING
CONNECTOR
“卡嗒”
When connecting a connector, be sure to push it in until a
click is felt.
Inspect the connector for corrosion, contamination and
breakage in its cover.
COUPLER “卡嗒”
With a lock type coupler, be sure to release the lock when
disconnecting, and push in fully to engage the lock when
connecting.
When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
Inspect each terminal on the coupler for being loose or bent.
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
terminals must be clean and free of any foreign material
which could impede proper terminal contact.
正确不正确
CLAMP
Clamp the wire harness at such positions as indicated in “
WIRING HARNESS ROUTING”.
Bend the clamp properly so that the wire harness is clamped
securely.
In clamping the wire harness, use care not to allow it to hang
down.
Do not use wire or any other substitute for the band type
clamp.
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.
SEMI-CONDUCTOR EQUIPPED PART

不正确
Be careful not to drop the part with a semi-conductor built in
such as a CDI unit and regulator/rectifier.
When inspecting this part, follow inspection instruction
strictly. Neglecting proper procedure may cause damage to
this part.
7-1
ELECTRICAL
BATTERY
The MF battery used in this motorcycle does not require
maintenance (e.g., electrolyte level inspection, distilled
water replenishment).
During normal charging, no hydrogen gas is produced.
However, if the battery is overcharged, hydrogen gas may
be produced. Therefore, be sure there are no fire or spark
sources (e.g., short circuit) nearby when charging the
battery. Be sure to recharge the battery in a well-ventilated
and open area.
Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.
CONNECTING THE BATTERY

When disconnecting terminals from the battery for
disassembly or servicing, be sure to disconnect the
battery lead wire first.
When connecting the battery lead wires, be sure to connect
the battery lead wire first.
If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to
the battery terminals.
Install the cover over the battery terminal.
USING THE MULTI CIRCUIT TESTER

Properly use the multi circuit tester and probes.
Improper use can cause damage to the motorcycle and
tester.
If the voltage and current values are not known, begin
measuring in the highest range.
When measuring the resistance, make sure that no voltage
is applied. If voltage is applied, the tester will be damaged.
After using the tester, be sure to turn the switch OFF.
7-2
ELECTRICAL
STARTER SYSTEM
Starter relay
Brake switch Fuse

(15A) Ignition switch
Starter button
Fuse
(20A)
Generator
TROUBLESHOOTING Inspection: One of the front and rear brake light

switches is ON position.
Battery is full-charged.
Starter motor will not run Fuse is not blown before the diagnosis.
Check whether to run the starter

Check whether to hear the click noise motor when connect the starter
from the starter relay when the starter Clicks motor + terminal to the battery
button is pushed. terminal directly. (Do not use thin
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 Loose or disconnected starter motor lead
the starter relay connectors (between
Y/G + and W/B - ) when the starter No voltage Faulty ignition switch
button is pushed. Faulty front brake light switch
Faulty rear brake light switch
Faulty starter button
Poor contact of connector
Voltage measured Open circuit in wiring harness
Check the starter relay

Incorrect Faulty starter relay
(Refer to page 7-7)
Starter motor runs, Poor contact of connector or

but does not start engine. open circuit in wiring harness
Fault CDI
Fault ignition coil
Fault generator
7-3 Fault starter clutch
ELECTRICAL
STARTER MOTOR REMOVAL

● Remove the starter motor wire .
● Remove the starter motor mounting bolt, take off the starter
motor .
STARTER MOTOR REMOVAL AND DISASSEBMLY

● Disassemble the starter motor as shown.
1 Housing end(outside) 4 Spring 7 Motor body 10 Housing end(inside)

2 Bracket 5 Amature shaft 8 Washer 11 O- ring
3 Amature shaft 6 Seal ring 9 Oil seal
7-4
ELECTRICAL
STARTING MOTOR INSPECTION

CARBON BRUSHES
When the brushes are worn, the motor will be unable to
produce sufficient torque, and the engine will be difficult to
turn over. To prevent this, periodically, inspect the length of
the brushes, replacing them when they are too short or
chipping.
COMMUTATOR
Inspect the commutator surface for abnormal wear or
undercut A . 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 with a saw blade.
ARMATUR COIL
● Check for continuity between each segment.
Check for continuity between each segment and the armature
shaft.
If there is no continuity between the segments or there
is continuity between the segments and shaft, replace the
armature with a new one.
09900-25008: Pocket tester
Test scale: Continuity
OIL SEAL AND BEARING

Inspect the oil seal lip for damage or leakage.
Inspect the bearing for abnormal noise and smooth
movement.
If any defects are found, replace the housing end (inside).
BUSHING
Inspect the bushing for wear and damage.
If any defects are found, replace the housing end (outside).
7-5
ELECTRICAL
STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of
disassembly. Pay attention to the following points:
● Apply SUPER GREASE ”A” to the lip of the oil seal.
99000-25010: SUPER GREASE ”A”
● Apply a small quantity of Moly paste to the armature shaft.
99000-25140: Moly paste
Install the washer to the house end as shown.
When reassemble the starter motor, align the protrusion A

onf the starter motor body to the notch B on the housing
end
● Install the house end to the starter motor body and align the
mark,
7-6
ELECTRICAL
Apply a small quantity grease to the O-ring .
99000-25010: SUPER GREASE ”A”
Install the starter motor .

Install the starter motor wire .
STARTER RELAY INSPECTION

Remove the seat/helmet case and center cover.
(Refer to page 6-3)
Remove the starter relay.
Apply 12 volts to and terminals, inspect the continuity

between the terminals, positive and negative. If the starter
relay is in sound condition, continuity is found.
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.
Check the coil for ”open”, “ground” and ohmic resistance.

The coil is in good condition if the resistance is as follows.
Test range: Resistence
Starter relay resistence: 3-6Ω
7-7
ELECTRICAL
IGNITION SYSTEM
CKP SENSOR
10A Fuse
ECM Ignition switch
20A Fuse
Battery
TPS ECT
SENSOR SENSOR
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 12.5V Recharge the battery or
replace the battery
12.5V
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 trigger
coil (Bl/W and G/W) Incorrect Faulty trigger coil
Correct
Faulty ECM
Faulty ignition coil
Faulty high-tension cord
7-8
ELECTRICAL
IGNITION COIL
Remove the seat/helmet case and center cover.
(Refer to page 6-3)
Remove the spark plug cap .
● Measure the ignition coil resistence with the pocket tester.

Tap

Test range: resistence Ω
kΩ
Primary: 3.2~4.3 Ω (tap-tap)
Secondary: 28.5~38.5 KΩ (tap- Plug cap)
Tap
PICK-UP COIL
Using the multi-circuit tester set, measure the coil
resistance between the lead wires.
Test range: resistence
Pick-up coil resistance: 190 Ω

(Blue/White-Green/White)
SPARK PLUG
(Refer to page 2-6)
IGNITOR UNIT
If the ignition system is defective and no problem is found in.
the inspection above, replace the ignitor.
7-9
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
Fuse
(20A)
Generator
Load
Battery
Regulator/rectifier
TROUBLESHOOTING
Battery runs down quickly
Check accessories which

mounted Remove accessories
excessively waste electric power.
Not installed
Inspect battery leak current leakage Shorted circuit of wire

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

between battery terminals.
Abnormal driving condition
Incorrect
(To next page)
7-10
ELECTRICAL
Faulty generator coils or discon- not conductive Faulty generator coils or

nected lead wires disconnected lead wire.
Correct
Inspect generator no-load voltage incorrect Faulty generator rotor
Correct
Inspect regulator/rectifier incorrect Faulty regulator/rectifier
Correct
Inspect wirings incorrect Shorted circuit of wire.

Poor contact of couplers.
Correct
Faulty battery
Others
Faulty regulator/rectifier
Battery overcharge
Faulty battery
Poor contact of generator
lead wire coupler
7-11
ELECTRICAL
INSPECTION
BATTERY LEAK CURRENT INSPECTION
Remove the battery maintenance lid 1 .
Turn the ignition switch to the OFF position.
Disconnect the battery lead wire.
Measure voltage between the battery terminal and the
ground cable terminal.If the reading exceeds the specified
value,then leakage is present.
Battery leakage: Less than 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 the ignition switch to the ON position when
measuring current.
CHARGING OUTPUT INSPECTION

Remove the battery box cover.
Start the engine, keep it running at 5 000 r/min, with lighting
switch turned on and dimmer switch turned HI position.
Measure the DC voltage between the battery terminal and with
a pocket tester. If the tester reads under the specified value,
inspect the generator coil and regulator/rectifier.
CAUTION
When making this test, be sure that the battery is
fully-chaged condition. 蓄电池

Teat scale: Voltage
（直流电压）
Charging output 万用表
Standard: 14.0-15.0V at 5 000 r/min
GENERATOR COIL INSPECTION

Open the saddle,remove the helmet box. (Refer to page 5-1)
Disconnect generator coupler 1 .
Measure the resistence between the lead wires, if the
resistence is incorrect, replace the generator coil.
1

Teat scale: Resistance
Generator coil resistance: 0.55 Ω (Y-Y )
7-12
ELECTRICAL
GENERATOR COIL NO-LOAD

PERFORMANCE CHECK
Disconnect the generator coupler. (Refer to page 7-4)
Start engine and keep it running at 5,000 rpm.
Measure voltage between generator terminal and ground by
using the pocket tester. If the reading is below standard values,
replace with a new generator coil.(Refer to page 3-39)
CAUTION
It is not necessary to remove the engine from the

chassis during the removal the generator coil.

Teat scale: Voltage
Generator no-load performance:

117-122V/5000 r/min
(When engine is cold)
REGULATOR/RECTIFIER INSPECTION
If the resistance checked is incorrect, replace the regulator
/rectifier with a new one.
7-13
ELECTRICAL
FUEL LEVER GAUGE

INSPECTION
Remove the fuel lever gauge. (Refer to page 5-4)
Check the resistance of each float position with a multi-circuit
tester.
If the resistance measured is incorrect, replace the fuel
gauge assembly with a new one.
The relation between the position of the fuel gauge float and
resistance is shown in the following table.
Float position F 5→4 4→3 3→2 2→1 E F

5
Resistence(Ω) )7 30 47 64 85 100
4
Torlerance(Ω) ±2 ±2 ±2 ±2 ±2 ±2
3
2
1
TOOL 09900-25008: Multi-circuit tester
E
Ω
Tester knob indication: x 1Ω range
CAUTION
When inspecting the gauge resistance, be sure to
disconnect the battery lead wire, or a pocket tester
may be damaged.
FUEL LEVEL INDICATOR

Disconnect the fuel level gauge coupler.
To test the fuel level indicator two different checks may be
used.
The first, connect a jumper wire between B/W and Y/B wires
coming from the main wiring harness. With the ignition switch
turned on, the fuel meter should indicted “F”.
● The second test will check the accuracy of the indicator in the
full and empty positions. fuel level indicator is normal if its
pointer indicates the E (empty) position when the 100 ohms
resistance is applied to the circuit and if its pointer indicates
the F(full) position when the resistor is changed to 7 ohms. If
either one or both indications are abnormal, replace the fuel
meter with a new one.
Y/B R
Resistance 7Ω 100 Ω B/W
Float position F E B/W
7-14
ELECTRICAL
COMBINATION METER
Combination Meter System
This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
The LCD indicates speedometer, tachometer, Odometer / Trip A/ Trip B / Clock/ maintenance / low battery
voltage indicator and fuel level indicator respectively.
LED (Light Emitting Diode)

LED is used for the instrument panel light and each indicator light.LED is maintenance free.
LED is less power consuming and more resistant to vibration compared to the bulb.
1 LED (Left turn signal light） 7 ADJ button

2 LED (Malfunction indicator light） 8 SEL button
3 LED (Speedometer) 9 LED (High beam indicator light)
4 LED (Low battery voltage indicator light） 10 LCD (Fuel level indicator）
5 LED (Right turn signal light） 11 LCD (Clock)
6 LED (Oil change indicator light） 12 LCD (Odomenter and Tripmeter）
REMOVAL AND DISASSEMBLY

Remove the meter cover. (Refer to page 6-1).
Remove the screws, take off the meter .
7-15
ELECTRICAL
Disassemble the combination meter assembly as follows.

CAUTION
Do not disassemble the meter panel 5 .
Meter upper case Meter panel Meter panel Seal ring Meter lower case
INSPECTION
LED (Light Emitting Diode)
Check that the LEDs (Malfunction indicator light,low battery voltage indicator light and oil change indicator
light) immediately light up when the ignition switch is turned on. Check that other LEDs (Hi beam indicator
light and turn signal light) light up/go off by operating the turn signal and dimmer switches. If abnormal
condition is found, replace the combination meter unit with a new one after checking its wire
harness/coupler.
7-16
ELECTRICAL
OIL CHANGE INDICATOR LIGHT

The oil change indicator comes on to remind you to change
the engine oil. The indicator comes on at initial 1000km and
preset intervals thereafter. The preset interval is adjustable
between 2 000 and 3 000km. Reset the indicator after
changing the engine oil to turn off the indicator.
TO RESET THE OIL CHANGE INTERVAL

Press and hold the ADJ button and SEL button for 2
seconds until the "3 000" blinks” at the ODO meter. Press the
ADJ button or SEL button to change the interval
between“3 000" and“2 000", press the the ADJ button or
SEL button for 2 seconds, oil change indicator change light
goes off.
CAUTION
The preset interval can be adjusted after odometer
reaches 1 000 km.
Reset the display after initial engine oil replacement.
Reset the display after oil replacement even if the
display is not displayed.
FUEL LEVEL INDICATOR INSPECTION

● Remove the left and right side covers and tail cover.
● Disconnect the fuel lever gauge coupler .
● Connect the adjustable resistence to Y wire and B/W wire.
● Turn on the ignition switch.
● Check if the fuel level indicator displays right to respective
resistance. If any abnormality is found, replace the meter
assembly.
Resistence 100Ω 85Ω 64Ω 47Ω 30Ω 7Ω

Blinks Blinks
Fuel
level
indicator
Blinks On On On On On
7-17
ELECTRICAL
SPEEDOMETER AND ODOMETER

If the speedometer, odometer and trip meter don’t work
properly, check the speed sensor and coupler connection, if
no defects are found, replace the combination meter.
SPEED SENSOR
● Remove the left and right side covers and tail cover.(Refer
to page 6-4)
Disconnect the speedometer sensor coupler 1 .
Take off the speed sensor 2 .
Connect a 12v battery, a 10kΩ resis.tance and a mutil-

cicuit tester to the speed sensor as shown in the
illustration.
P
Tester knob indication:
速度传感器
● Move the blade screw driver on the speed sensor

surface as shown in the illustration, the voltage reading on
the tester should be changed accordingly (0V to 12V), if the
reading doesn’t change, replace the speed sensor with a
new one.
CAUTION
The highest voltage reading should be the same as the
battery voltage during the test.
Install the speed sensor.
ODOMETER
To change the display, push the SEL button 1 . The display
changes in the order odometer and trip meter . When the trip
meter is displayed, press and hold the SEL button for 2s to
reset the trip meter.
LOW BATTERY VOLTAGE INDICATOR LIGHT

The low battery voltage indicator light blinks when the battery
voltage is low. Shut down the high power appliance to prevent
the battery over discharge. Re-charge the battery in time.
CAUTION
The battery indication light blinks and the meter can

not display normally when the battery power wire is
disconnected or fuse blows, check the power supply
circuit.
7-18
ELECTRICAL
LIGHTS
HEADLAMP AND POSITION LIGHT
Headlamp: 35/35W 12V

Position light : 5W 12V
CAUTION
Remove the bulb when the bulb is cool.
CAUTION
If you have touched and the bulb with your bare hands, clean it with a cloth moistened with
alcohol or soapy water to maintain lens clarity.
CAUTION
Do not use bulb of other specification.
7-19
ELECTRICAL
HEADLAMP
● Remove the front wind shield and front lower leg
shield.(Refer to page 6-2)
● Disconnect the headlamp coupler 1 .
● Remove the rubber cover 2 .
● Replace the headlamp bulb.
REPLACEMENT POSITION LIGHT

Remove the front wind shield and front lower leg
shield.(Refer to page 6-2)
Remove the position light coupler .
Replace the position light bulb.
HEADLAMP LIGHT ADJUSTMENT

Open the front storage case, adjust the headlamp light by
use screw driver through the hole .
7-20
ELECTRICAL
TAIL LIGHT/BRAKE LIGHT, LICENSE LIGHT AND

LEFT AND RIGHT REAR TURN SIGNAL LIGHTS
Rear left and right turn signal lights : 10W

License light :5W
Tail light/Brake light: LED
TAIL LIGHT/BRAKE LIGHT AND LICENSE LIGHT

REPLACEMENT
Remove the left and right side cover and tail cover
assembly.(Refer to page 6-4)
Remove the rear left and right turn signal light seat ,
replace the left and right turn signal light bulb.
Disconnect the license light coupler .

Remove the license light retainer , replace the license
light bulb.
7-21
ELECTRICAL
FRONT LEFT AND RIGHT TURN SIGNAL LIGHTS
Front turn signal light ：10W 12 V
CAUTION
If you have touched and the bulb with your bare hands, clean it with a cloth moistened with
alcohol or soapy water to maintain lens clarity.
CAUTION
Do not use bulb of other specification.
TURN SIGNAL LIGHT BULB REPLACMENT

Remove the handlebar front cover.(Refer to page 6-1)
Remove the front left and right turn signal light base and
, replace the turn signal light bulb.
7-22
ELECTRICAL
SWITCHES
Inspect each switch for continuity with the multi-circuit
tester. If any abnormality is found, replace the respective
switch assemblies with new ones.

IGNITION SWITCH 1
Bl/W B/W O/R R
OFF ○ ○
ON ○ ○
○ ○
LIGHTING SWITCH 2
Gr O O Y/W
○ ○ ○
○ ○ ○
○ ○ ○ ○
STARTER BUTTON 3
B/W Y/G
○ ○
FRONT BRAKE LIGHT SWITCH 4

O/G W/B
OFF
ON ○ ○
7-23
ELECTRICAL
DIMMER SWITCH 5
Y/W W Y O
○ ○
○ ○
PASSING ○ ○ ○ ○
TURN SIGNAL LIGHT SWITCH 6

B Lbl Lg
○ ○
○ ○
HORN SWITCH 7
B/Bl G
OFF
○ ○
REAR BRAKE LIGHT SWITCH 8

O W/B
OFF
ON ○ ○
7-21
ELECTRICAL
BATTERY
SPECIFICATIONS
TYPE YTX7A-BS
Capacity 12V(6Ah)
Standard electrolyte S.G. 1.320 at 20OC
INITIAL CHARGING
Remove the aluminum tape 1 sealing the battery electrolyte
filler holes.
注入孔
Remove the caps 2 .
CAUTION
After filling the electrolyte completely, use the removed

cap as the sealed caps of battery-filler holes.
Insert the nozzles of the electrolyte container into the battery’s

electrolyte filler holes, holding the container firmly so that it
does not fall. 电解液容器
WARNING
Take precaution not to allow any of the fluid to spill. Insert in

filler holes
Make sure air bubbles are coming up each electrolyte

container, and leave in this position for about more than 20
minutes.
Air
bubbles
7-25
ELECTRICAL
CAUTION
If no air bubbles are coming up from a filler port, tap the

bottom of the two or three times. Never remove the
container from the battery.
After confirming that the electrolyte has entered that battery

completely, remove the electrolyte containers from the battery.
Wait for around 20 minutes.
Insert the caps into the filler holes, pressing in firmly so that the
top of the caps do not protrude above the upper surface of the
battery’s top cover.
CAUTION
将盖子牢牢地插入
Once install the caps to the battery; do not remove the
caps.
Using the pocket tester, measure the battery voltage. The

tester should indicate more than 12.5-12.6V (DC) as shown in
the Fig. If the battery voltage is lower than the specification,
charge the battery with a battery charger. (Refer to the
recharging operation.)
CAUTION
Initial charging for a new battery is recommended if two years have elapsed since the date of
manufacture.
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.
RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If the voltage reading is less than the 12.0V(DC),recharge
the battery with a battery charger.
CAUTION
When recharging the battery, remove the battery from the motorcycle.
Recharging time: 3A for 1 hour or 0.7A for 5 hours

CAUTION
Be careful not to permit the charging current to exceed 3A at any time.
● After recharging, wait for more than 30 minutes and check the
battery voltage with a pocket tester.
If the battery voltage is less than the 12.5V, recharge the
battery again.
If the battery voltage is still less than 12.5V, after recharging,
replace the battery with a new one.
When the motorcycle is not used for a long period, check the
battery every 1 month to prevent the battery discharge.
7-26
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 8-1
SPECIAL TOOLS 8-9
TIGHTENING TORQUE 8-11
SERVICE DATA 8-13
WIRE HARNESS, CABLE AND HOSE ROUTING 8-19
8
TROUBLESHOOTING
DEFECT CODE AND DEFECT CONDITION
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 of valves. Adjust
3. Valves mistiming. Repair or replace
4. Piston rings excessively worn. Adjust
5. Worn-down cylinder bore. Replace
6. Poor seating of spark plug. Retighten
7. Starting motor cranks but too slowly. See electrical section
Plug not sparking
1. Fouled spark plug. Clean or replace
2. Wet spark plug. Clean and dry
3. Defective CKP sensor. Replace
4. Defective ECM. Replace
5. Defective ignition coil. Replace
6. Poor contact of coupler. Repair or replace
7. Defective spark plug. Replace
8. Poor contact of spark cap. Replace
No fuel reaching the injector
1. Clogged fuel filter or fuel hose Clean or replace
2. Defective ECM Replace
3. Defective fuel pump Replace
4. Opened circuit wiring connections Check or repair
Incorrect fuel/air mixture
1.TP sensor out of adjustment. Adjust
2.Defective fuel pump. Replace
3.Defective fuel pressure adjuster. Replace
4.Defective TP sensor. Replace
5.Defective CKP sensor. Replace
6.Defective intake pressure sensor Replace
7.Defective ECM. Replace
8.Defective Intake air temp. sensor. Replace
9. ISC valve breather hose clogged Repair or replace
8-1

Engine idles poorly. 1. Valve clearance out of adjustment. Adjust
2. Poor seating of valves. Repair or replace
3. Defective valve guides. Replace
4. Worn rocker arm or arm shaft Replace
5. Defective spark plug. Adjust or replace
7. Defective crankshaft position sensor Replace
9. Defective TP sensor. Replace
10. Defective fuel pump. Replace
11. Dirty throttle valve. Clean or replace
12. Clogged or damaged absorber hose. Replace
13. Clogged or damaged ISC valve. Repair or replace
Engine stalls often Incorrect fuel/air mixture

1. Defective IAP sensor or coil Repair or replace
2. Clogged fuel filter. Clean or replace
3. Defective fuel pump. Replace
4. Defective fuel pressure adjuster. Replace
5. Defective IAT sensor. Replace
6. Cracked or damaged absorb hose Replace
7. Defective or clogged ISC valve Repair or replace
8. Defective ET sensor Replace
Defective fuel injector

1. Defective fuel injector. Replace
2. No injection signal from ECM. Replace or repair
3. Opened or shorted circuit wiring connection. Replace or repair
4. Defective battery or low battery voltage. Charge or repair
Control circuit or sensor improperly operating

2. Defective Fuel Pressure adjuster. Replace
4. Defective IAP sensor. Replace
6. Defective ISC valve. Replace
7. Defective engine temp. Sensor Replace
Defective engine parts

1. Fouled spark plug. Clean
2. Defective CKP sensor or ECM. Replace
3. Clogged fuel pipe. Clean
4. Valve clearance out of adjustment Adjust
8-2
Noisy engine. Excessive valve chatter

1. Valve clearance too large. 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 piston or cylinder. Replace
2. Fouled with carbon combustion chamber. Clean
3. Worn piston pin or piston pin bore. Replace
4. Worn piston rings or ring grooves. Replace
5. Worn conrod small end. Replace
Noise seems to come from cam chain

1. Cam chain is too long. Replace
2. Worn sprocket Replace
3. Defective chain tensioner. Repair or replace
Noise seems to come from the clutch

1. Worn or slipping drive belt. Replace
2. Worn rollers in the movable drive face. Replace
Noise seems to come from crankshaft

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

1. Damaged or worn gear Replace
2. Worn or damaged gear shaft Replace
3. Damaged bearing Replace
8-3
Complaint Symptom and possible caused Remedy
Engine lacks power Defective internal parts of engine or electric system

1. Loss of valve clearance. Adjust
2. Weakened valve springs. Replace
3. Out of adjustment valve timing. Adjust
4. Worn piston rings or cylinder Replace
5. Poor seating of valves. R epair
6. Fouled spark plug. Clean or replace
7. Incorrect spark plug. Adjust or replace
8. Clogged jets in fuel injector. Replace
9. Throttle position sensor out of Adjustment. Adjust
10. Clogged air cleaner element. Clean
11.Throttle valve or vacuum hose leak. Tighten or replace
12.Too much engine oil. Drain oil
13. Defective ECM or fuel pump. Replace
14. Defective CKP sensor or ignition coil. Replace
Defective control circuit or sensors

1. Lower fuel pressure. Repair or replace
3. Defective iAT sensor. Replace
5. Defective IAP sensor. Replace
7. TP sensor out of adjustment. Adjust
8. Defective ISC valve Replace
Engine overheats. Defective engine internal parts

1.Heavy carbon deposit on piston crowns. Clean
2.No enough oil in the engine. Add engine oil
3.Defective oil pump ro clogged oil circuit. Replace or clean
4. Air leak from intake pipe. Tighten or replace
5. Use in correct engine oil. Replace
Lean fuel/air mixture

1.Shorted circuit IAP sensor/lead wire. Repair or replace
2.Shorted circuit IAT sensor/lead wire. Repair or replace
3.Sucking air from intake pipe joint. Repair or replace
4. Defective fuel injector. Replace
Other causes
1.Defective ECM Replace
8-4
Engine runs poorly Defective internal parts of engine or electric

in high speed range system
1. Weakened valve springs. Replace
2. Worn cam shaft. Replace
3. Valve timing out of adjustment. Adjust
4. Too narrow spark plug gap.
5.Ignition not advanced sufficiently due to poorly Adjust
working timing advance circuit Replace ECM
6.Defective ignition coil. Replace
7.Defective CKP sensor. Replace
8.Defective ECM. Replace
9. Clogged air filter.
10.Clogged flue hose. Clean
11. Defective fuel pump. Clean
Replace
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
Defective control circuit or sensor

1. Low fuel pressure Repair or replace
2. Defective TP sensor Replace
3. Defective IAT sensor Replace
4. Defective CKP sensor Replace
5. Defective GP sensor
6. Defective IAP sensor
Replace
8. TP sensor out of adjustment Adjust
9. Defective ISC valve Replace
Dirty or heavy 1.Too much engine oil in the engine. Drain excessive oil
exhaust smoke. 2.Worn piston rings or cylinder. Replace
3.Worn valve guides. Replace
4.Cylinder wall scored or scuffed. Replace
5.Worn valves stems. Replace
6.Defective stem seals. Replace
7.Worn oil rings. Replace
CLUTCH
Noise clutch 1.Worn bearing or damage Replace

Slipping V-belt 1.Worn V-belt Replace
2.Worn drive face Replace
Slipping clutch 1.Worn clutch shoe Replace

2.Uneven clutch rollers weight Repair or replace
3. Worn V-belt Replace
8-5
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. 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 of replace.
motor commutator Replace
4. Defective starter relay Replace
5. Defective main fuse
8-9
8-6
维修信息
BATTERY
“Sulfation”, acidic 1 .Battery case is cracked. Replace.

white powdery 2.Battery has been left in a run-down condition for Replace
substance or spots a long time. .
on surface of cell 3.Contaminated electrolyte (Foreign matter has Replace
plates. enters the battery and become mixed with the
electrolyte.)
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
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. Contaminated electrolyte (Foreign matter has Replace the battery.
enters the battery and become mixed with the
electrolyte.)
5. 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 1. Dirty container tap and sides. Clean.
too rapidly. 2.Impurities in the electrolyte or electrolyte Change the electrolyte by
S.G is too high. consulting the battery
maker’s directions.
BRAKE
Poor braking. 1. Too much play on brake lever or pedal. Adjust

(front and rear) 2. Linings worn down. Replace
Insufficient 1.Worn pads. Replace.

brake power. 2.Oil adhesion on engaging surface of pads. Clean disc and park
Brake squeaking 1.Tilted pad. Modify pad fitting.

2.Damaged wheel bearing. Replace.
3.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
4.Worn pads. Replace.
Excessive brake 1.Worn brake lever cam. Replace.
lever stroke.
8-7
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.
absorbers.
2. Distorted front absorber. 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 absorber too soft. 1. Weakened springs. Replace.

2. Not enough absorber oil. Refill.
Front absorber too stiff. 1. Absorber oil too viscous. Replace.

2. Too much absorber oil. Remove excess oil.
Noisy front absorber. 1. Not enough absorber oil. Refill.

2. Loose nuts on absorber. 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 absorber. Retighten.
Rear absorber 1. Weakened springs. Replace.

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

too stiff. 2. Warn swing arm bushings. Replace.
Noisy rear 1. Loose nuts on absorber. Retighten.

absorber 2. Worn swing arm bushings. Replace.
8-8
SERVICE INFORMATION
SPECIAL TOOLS
09900-06107 09900-06108 09900-20101 09900-20202 09900-20202

Snap ring pliers Snap ring pliers Vernier calipers Micrometer Micrometer
(opening type) (closing type) (1/50mm,150mm) (1/100mm, 25~50 mm) (1/100mm, 50~75 mm)
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
09900-21304
09900-20803 V-block (set) 09900-25008 09900-26006 09910-32812
Thickness gauge (100mm) Multi-circuit tester Tachometer Crankshaft installer
09913-70210
09910-34510 09913-50121 Bearing installer 09913-76010 09916-10911
Piston pin puller Oil seal remover ( Bearing installer Valve lapper set
(10~75)
09920-13120 09923-73210
09916-21110 11F14-027 09921-20240 Bearing remover 09924-84510
Valve cutter tool set Crankcase separator Bearing remover tool (15-17mm) Bearing installer set
09930-34980
09925-98221 09930-30102 11F14-006 09930-40113 09940-14911
Bearing installer Slide shaft Rotor removal tool(M33) Sprocket holder Steering stem nut sleeve
8-9
SERVICE INFORMATION
09940-50112 09941-34513 09941-74910 09943-88211 11F14-001

Front fork oil seal installer Steering race installer Steering race installer Bearing installer Rotor holder
11F14-018
11F14-009 11F14-010 11F14-019 11F14-023
Valve remover and
Diagnosis device Front absorber tools installer “T” type valve adjuster Pressure inspection tool
11F14-033 11F14-039
6 pins test switch Steering stem nut sleeve A
8-10
SERVICE INFORMATION
TIGHTEN TORQUE
ENGINE
ITEM N•m Kg•m
Left crankcase oil inspection bolt 9-15 0.9-1.5

Rear brake rocker arm bolt 8-12 0.8-1.2
Oil filter cover bolt 8-12 0.8-1.2
Crankcase bolt 8-12 0.8-1.2
Drain plug 15-20 1.5-2.0
Cylinder head nut 23-27 2.3-2.7
Camshaft sprocket bolt 10-12 1.0-1.2
Gearbox cover bolt 8-12 0.8-1.2
Gearbox oil plug 9-15 0.9-1.5
Oil filter cover bolt 8-12 0.8-1.2
Oil filter inspection plug 9-15 0.9-1.5
Fuel pump screw 7-10 0.7-1.0
Generator rotor mounting nut 110-130 11.0-13.0
Right crankcase cover bolt 8-12 0.8-1.2
Cooling fan mounting nut 30-35 3.0-3.5
Cooling fan bolt 8-12 0.8-1.2
Cylinder head side nut 8-12 0.8-1.2
Cylinder head cover bolt 12-16 1.2-1.6
Spark plug 10-12 1.0-1.2
Clutch cover intake air plate bolt 8-12 0.8-1.2
Fix drive face nut 40-60 4.0-6.0
Cylinder ventilate cover screw 7-10 0.7-1.0
Clutch housing nut 65-85 6.5-8.5
Clutch cover bolt 8-12 0.8-1.2
Kick starter lever bolt 23-28 2.3-2.8
8-11
SERVICE INFORMATION
CHASSIS
ITEM N•m Kg•m
Handlebar bolt/nut 40 - 60 4.0-6.0
Lower bracket clamp bolt 18-28 1.8-2.8
Front shock absorber cap 15-30 1.5-3.0
Steering stem lock nut 25-35 2.5-3.5
Front axle nut 48-58 4.8-5.8
Brake disc bolt 18-28 1.8-2.8
Brake caliper air bleeder valve 7-10 0.7-1.0
Brake caliper mounting bolt 18-28 1.8-2.8
Brake hose mounting bolt 20-25 2.0-2.5
Mastery cylinder mounting bolt 8-12 0.8-1.2
Rear swing arm bolt/Nut(Front/rear) 70-100 7.0-10.0
Rear shock absorber upper mounting bolt 22-35 2.2-3.5
Rear shock absorber lower mounting bolt 22-35 2.2-3.5
Rear axle nut 102-138 10.2-13.8
Engine mounting bolt 70-100 7.0-10.0
Exhaust pipe nut 11-15 1.1-1.5
Muffler mounting bolt 40-60 4.0-6.0
TIGHTENING TORQUE CHART

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

A (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
8-12
SERVICE INFORMATION
SERVICE DATA
VALVE + GUIDE Unit: mm
ITEM STANDARD LIMIT
Valve diam. IN. 25.5
EX. 22.5
Valve clearance(wehn cold) IN. 0.05-0.10
EX. 0.10-0.15
Valve stem I.D. IN. 5.000-5.012
EX. 5.000-5.012
Valve stem O.D. IN. 4.975-4.990
EX. 4.955-4.970
Valve stem deflection IN.& EX. 0.3 5
Valve stem runout IN.& EX. 0.0 5
Valve head thickness IN.& EX. 0.5
Valve seat width IN.& EX. 0.9-1.1
Valve head radial runout IN.& EX. 0.03
Valve spring free length IN. 29. 67

(IN. & EX.)
EX. 29.57
CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMIT
Cam height IN. 32.80-32.84 32.50
EX. 32.97-33.01 32.67
Camshaft runout 0.10
Rocker arm I.D. IN.& EX. 12.000-12.018
Rocker arm shaft O.D. IN.& EX. 11.977-11.995
Cylinder head distortion 0.05
Cylinder head cover distortion 0.05
8-13
SERVICE INFORMATION
CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400 kPa 800 kPa
Piston to cylinder clearance 0.03-0.05 0.12
Cylinder bore 57.000-57.015 57.135
Piston diam. 56.955-56.970 at 12mm from skirt 56.835
Cylinder distortion 0.05
Piston ring end gap 1st 0.10-0.25 0.5
2nd 0.20-0.35 0.5
Piston ring free end gap 1st Approx 6 . 8 5.4
2nd Approx 6.8 5.4
Piston ring to groove clearance 1st 0.18
2nd 0.15
Piston ring groove width 1st 1.01-1.03
2nd 1.01-1.03
Oil 2.01-2.03
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 15.002-15.008 15.03
Piston pin O.D. 14.996-15.000 14.98
CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 15.006-15.014 15.04
Conrod big end side clearance 0.10-0.45 1.0
Conrod big end width 15.95-16.00
Crankshaft runout 0.05
Crank web to web width 55.9-56.1
OIL PUMP
ITEM STANDARD LIMIT
Oil pressure(at 60 ) 10-30 kPa (0.15-0.35 kgf/cm²) at 3 000 r/min.
8-14
SERVICE INFORMATION
CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch wheel I.D. 125.0-125.2 125.5
Clutch shoe thickness 2
TRANSMISSION Unit: mm
ITEM STANDARD LIMIT
Reduction ratio 0.798-2.644
Final reduction radio 7.566
Drive belt width 18.9
Clutch spring free length . 99.75
FI SENSORS
ITEM STANDARD NOTE
CKP sensor resistance Approx. 190Ω
IAP sensor input voltage 4.5-5.5V
TP sensor input voltage 4.5-5.5V
TP sensor output voltage Idling 0.65-0.75V
Full open 3.8-4.0V
ET sensor input voltage 4.5-5.5V
ET sensor resistance at 20℃, Approx 2.645Ω
IAT sensor input voltage 4.5-5.5V
Injector voltage Battery voltage
ISC valve resistence Approx 20Ω at 20℃
8-15
SERVICE INFORMATION
INJECTOR, FUEL PUMP AND FUEL PRESSURE ADJUSTER

ITEM STANDARD NOTE
Injector resistence at 20℃, 12Ω
Fuel pressure adjuster Approx.300kPa
opening pressure
Idle 1 700±100r/min
Throttle cable play 0.5-1.0mm
ELECTRICAL
ITEM STANDARD NOTE
Type NGK CR6E

Spark plug
Gap 0.7 mm-0.8 mm
Primary 3.2 Ω-4.3 Ω W-P
Ignition coil resistance
Secondary 28.8 KΩ-38.0 KΩ Spark plug cap-P
Pick-up Approx 190 Ω Bl/Y-ground
Generator coil resistance
Charge Approx 0.55 Ω Y-Y
Generator no-load voltage Above 117-122 V at 5000r/min
Regulated voltage 14 V-15 V at 5000r/min
Type designation YTX7A-BS
Battery capacity 12V 6Ah
Standard
1.28 ± 0.01 (20℃)
electrolyte S.G.
Fuse size 10A,15 A,20A
8-16
SERVICE INFORMATION
LIGHTING
ITEM STANDARD ITEM STANDARD
HI 35 W Licence light 5W
Headlight
LO 35 W Malfunction indicator light LED
Tail light/brake light LED High beam indicator light
Turn signal light 10 W Turn signal indicator light LED
Position light 5W
TIRE PRESSURE
ITEM STANDARD Limit
Cold inflation tire pressure (Solo) Front 175 kPa(1.75 kgf/cm²)
Rear 225 kPa(2.00 kgf/cm²)
Cold inflation tire pressure (Dual) Front 175 kPa(1.75 kgf/cm²)
Rear 225 kPa(2.25 kgf/cm²)
Tire specification Front 100/80-12 56 J
Rear 100/90-10 56J
BRAKE AND RIM Unit: mm

ITEM STANDARD Limit
Rear break lever play Hand brake 20-30
Brake disc thickness. Front 3.8-4.2 3.5
Brake disc runout. 0.3
Brake fluid type Haojue brake fluid
Brake drum I.D. 120.7
Brake lining thickness. 1.5
Wheel rim runout Front 2.0
Rear 2.0
Wheel axle runout Front 0.25
Rear 0.25
8-17
SERVICE INFORMATION
SUSPENSION Unit: mm
ITEM SPECIFICATION LIMIT
Front fork stroke 80
No.1 129 126.4
Front fork spring free length
No.2 121.5 119.1
Front fork oil grade SPECIAL OIL
Front fork oil capacity (each leg) 100±2
Swing arm pivot shaft runout 0.6
FUEL + OIL
ITEM STANDARD NOTE
Fuel type Use only unleaded gasoline of at least 89# octane
Fuel tank capacity 5.9 L
Engine oil type SAE 10W/40, API SF or SG
Change 950 ml
Engine oil capacity
Filter change 1 000 ml
Final gearbox oil type SAE90 or SAE 85W/90, API: GL-5
Change 90 ml
Final gearbox oil capacity
Overhaul 100 ml
8-18
SERVICE INFORMATION
WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING HARNESS ROUTING
Clamp
Wiring harness
Welded clamp Welded clamp Do not pinch

Slacken after assembly Welded guide ring
Left and right handlebar Left and right the right handlebar
branch wire Front brake hose
handlebar branch
Front brake switch (Rear brake cable)
Rear brake switch branch(hand brake)
branch Wiring harness
Welded guide ring

Throttle cable
(Rear brake cable)
Wiring harness
Welded clamp
Wiring harness
(Grommet)
Welded clamp
Throttle cable
(Rear brake cable)
Wiring harness
Clamp Clamp Clamp

Headlamp
Wiring harness Wiring harness Wiring harness
coupler
(White mark)
Clamp(Cut from root)

Starter motor wire(White mark) A
Ground wire(White mark) Clamp
Wiring harness Wiring harness
Generator(2 points)
Jacket(Do face the strap upper)

Inside jacket:
Generator coupler
(Do not stack it
above or below
the wiring harness)
Oxygen wire
Wiring harness A Battery + terminal
Starter motor wire A
Frame ground
Fuel pump test coupler
coupling after test
Test socket
Fuse box
Clamp Clamp Clamp

High tension cord (Cut from the root) Oxygen sensor coupler
Clamp Wiring harness (wire harness end) insert
Starter motor wire A Oxygen sensor the hanging pin.
Ground wire
8-19
SERVICE INFORMATION
Welded
Guide ring Welded
Clamp Guide ring
(Cut from the root Wiring harness Clamp Welded Wiring
Guide ring Guide ring harness Wiring
after tightening) clamp ( Cut from root) Clamp
Clamp Wiring harness2 Wiring Wiring Throttle harness
Wiring
Generator harness2 cable(root Throttle
harness2 harness2
below the cable
guide ring)
Neaten the wiring Welded clamp

Clamp Clamp harness as forward Clamp Welded clamp Clamp Welded clamp Welded clamp Welded clamp Welded clamp
Wiring harness
Wiring harness Wiring harness as possible. Wiring harness Wiring harness Wiring Wiring harness Wiring harnessWiring harnessWiring harness
(Grommet)
Seat cable Seat cable harness2 Generator branch Seat cable Ground wire branch
Seat cable
Clamp(Cut from the root)

Rear brake switch
(foot brake)
About 110mm
Clamp Clamp
Clamp Clamp
Wiring harness Wiring harness Clamp
Jacket (head) Jacket (middle)
Speed sensor
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
The lead wire between during the routing.
Clamp 4 the battery + terminal
to starter relay.
8-20
SERVICE INFORMATION
FRONT BRAKE HOSE ROUTING

Combined brake cable
adjuster nut
Front brake fluid 2 Non-metalic washers tightening torque:5-8N • m
reservoir tank Union bolt
Combined brake cable
Throttle cable Rear brake cable

Front brake hose Wiring harness
Front brake hose
Wiring harnes
Front brake hose
guide clamp
Flanged bolt
Brake hose clamp

Flanged bolt
Front brake hose

guide clamp
Flange bolt
2 Non-metallic washers
Union bolt
Front brake caliper
2 Flanged bolts
View B
Throttle cable Rear brake cable
(Hand brake only)
Throttle cable
Front brake hose
Brake house guide clamp
Front brake hose
When install the spring to
Wiring harness prevent the edge of spring
from trapping in the groove
Rear brake cable and hole.
(Hand brake only)
(After the brake hose

lower union has contacted
CBS assembly and adjustment note: the stoppers, tighten
1.Open the rear brake lever to maximum extent, the union bolt.)
adjust combined brake cable adjust nut to set
the gap between the two end surface as shown to
-0.5-0.5mm.Confirm after adjustment, Do not
push the cylinder piston which should be keeped
(After the brake hose at the initial position.
upper union has contacted 2. Fill the brake fluid.(Step2 and step3 are interchangeable).
the stoppers, tighten 3.Adjust rear brake cable adjust nut to set the rear brake lever
the union bolt.) end free play to 10-25mm, after adjustment, make sure the
front and rear brake works properly.
8-21
Canister breather hose
Rear brake cable
(Hand brake only)
Front brake hose
guide clamp View M
Flanged bolt Throttle cable Rear brake cable
Rear brake cable (Only hand brake)
(Foot brake only)
Front brake hose
Throttle cable guide ring
Flanged bolt
Throttle cable
View N
Rear brake pedal Throttle cable
Canister (Foot brake only)
breather hose
Canister hoes clamp II
Cross screw
SERVICE INFORMATION
Rear brake cable Seat lockclamp

(Foot brake only) Canister hose clamp II
Rear brake cable Canister absorber hose
guide clamp
Flanged bolt
Rear brake cable bracket
8-22
(Foot brake only)
Flanged bolt A-A
(Foot brake only)
Rear brake cable
(Hand brake) Throttle cable
Rear brake cable Rear brake cable
or rear brake cable Throttle cable
(Foot brake only) center clamp
(Foot brake) Rear brake cable(Hand brake)
or rear brake cable (Foot brake) Flanged bolt Front brake hose
Rear brake cable stopper guide clamp
Flanged bolt
Front brake hose
Throttle cable Cable guide clamp Wiring harness
Flanged bolt
Rear brake cable Rear brake cable
(Foot brake only) Only hand brake
Throttle cable
B-B
Throttle cable
Throttle cable guide ring
Frame
CABLE ROUTING
Wiring harness
Rear brake cable
(Hand brake only)
Rear brake cable
(Hand brake only)
or rear brake cable
(Foot brake only)
Rear brake lever
(Hand brake only)
SERVICE INFORMATION
8-23
WIRING DIAGRAM Combination meter
Left handlebar Right handlebar
Dimmer Turn signal Starter
Horn Front brake switch Lights switch
Rear brake switch switch light switch Horn switch switch Turn relay Speed sensor
ON ON
OFF OFF PASS
O W/B
B/W
O
黑/白
Br/Bl
W/R
P
B/R
B/W
B/W
Y/W
Gr
G
Y/G
Y/B
B/Bl
Gr
R
O
O
B
Lg
Bl/R
Y
Y/W
G
W
O
O
Y
Lbl
B
Lg
B/W
W/B
B/R
O
O/G
B/W
P
Y/W
O
ECM
Lbl
G
O
B
Lg
Y/W
B/W
Gr
Y/G
O
W/B
O/G
IG GND 25
TACO 26
DIAG 34
IAPS 33
IATS 19
CPS+ 8
SPD 32
ISA- 24
TPS 21
ISB- 11
ETS 2 2
GND 5
ISB 12
ISA 23
VCC 9
INJ 13
TS 10
OX 2 0
AT 16
MIL 2
FP 3
+B 7
SG 6
IG 1
Br/W
Br/Bl
Bl/W
G/W
B/Br
W/G
W/R
W/R
R/Bl
R/Bl
B/W
Bl/B
O/G
O/G
G/B
B/G
Br
Y/R
W
B/Y
G
R
Diode
V
P
Bl/B
W/G
W/R ISC valve
Bl/R
Lbl
Br/W
O/G
W
B /Y
G
V
Test socket O/G Fuel injector
B/G
O/G Ignition coil
Bl/G
O/G
B/W Fuel pump
Y/B
Front right Lg Lg
turn signal B/W B/W
light
Rear right turn
IAPS
Lg
R/Bl
B/W signal light R
TPS
G/B
Lg G/W
3 in 1 sensor
Y Y W/B W/B Tail light Br
IATS
Headlamp B/W B/W B/W B/W
Position light
Gr
W
Gr
W
Gr
B
Gr
Tail light/brake light
9
B/W Rear left turn
B signal light
Front left B B
Gr
turn signal light B/W B/W B/W License light
Y/R
G/W ET sensor
B/Br
G/W Oxygen sensor
O/G
O
15A 10A
O/R
O/R
B/W
B/W
B/Y
Ground
Bl/W
B/W
O
R
Lg
B
R
B/Y
W/B
Y/G
Bl/W
R
G/W
R
Y
R
Bl/W
O/R
B/W
R
Y
B/W
Y
R
R
Y
Y
Bl/Y
20A 12V 6Ah Alarm

Bl/W
B/W
Battery Starter motor

LOCK Starer relay
R
OFF
ON Fuse box
Ignition switch Rectifier
Generator

HAOJUE VR 150 - Manual de Serviço

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HAOJUE VR 150 - Manual de Serviço

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VR150

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"

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

PERIODIC MAINTENANCE 2-1

PERIODIC MAINTENANCE CHART

Evaporative emission Inspect 2-11

Brake Inspect Inspect

Confirm the ignition switch is at off position, then remove the

Install the battery in the reverse order of removal.

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

Check and clean the filter in the following manner.

Loosen the screw, remove the air cleaner intake ripple

Remove the air cleaner cover by removing the mounting

Remove the sponge element from air cleaner cover.

Fill a washing pan of a proper size with nonflammable

the element leaving it slightly wet with oil.

● Remove the mounting screws, remove the air cleaner

Clean the air cleaner cover and air filter chamber.

Install the new or clean air cleaner in the reverse order of

OIL DRAIN PLUG

MUFFLER MOUNTING NUTS AND BOLTS

Tighten the muffler mounting bolt to the specified torque.

Muffler mounting bolt : 18~28 N•m

Tighten the muffler mounting bolt .

Muffler mounting bolt : 40-60 N•m

Excessive valve clearance results in valve noise and

Remove the engine breather hose and cylinder cover bolts

Valve clearance (when cold)

If clearance is off the specification, bring it into the

TOOL 09900-20803: Thickness gauge

Install the spark plug.

Remove the maintenance lid. (Refer to page 6-2)

ENGINE OIL AND ENGINE FILTER

The oil should be changed with engine hot. According to the

Install new O-ring and new oil filter.

Oil drain plug: 15-20 N•m

NECESSARY AMOUNT OF ENGINE OIL:

Install the filler cap/filler gauge .

Remove the oil strainer cover mounting bolts .

Remove the oil strainer and clean.

FINAL GEAR OIL

Remove the kick starter lever and clutch cover.

● Tighten the filler plug 1 to the specified torque.

Final gear oil: 90 ml

● Remove the drive belt. (Refer to page 3-22)

Install the drive belt. (Refer to page 3-29)

● Remove the clutch rollers. (Refer to page 3-23)