Haojue TR 150 en Ingles

TR150ES
HAOJUE HOLDING CO.,LTD.

Add:No.5 Jiandabei Road, Jiangmen City, Guangdong Province, P.R China
Tel :(0750) 3288999 Fax:(0750) 3288333 Postcode:529000
TR150ES
S E R V I C E
M A N U A L
维修说明书
99500H373E1H000
Prepared by Haojue Holding
Feb, 2021
Printed in China
维修说明书
维修说明书
FOREWORD GROUP INDEX
This manual contains an introductory description on the
HAOJUE TR150ES(HJ150-16E) and procedures for its
inspection service and overhaul of its main components.
GENERAL INFORMATION 1
Other information considered as generally known is not
included.
Read the GENERAL INFORMATION section to familia-
rize yourself with the motorcycle and its maintenance.
PERICDIC MAINTENANCE 2
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
ENGINE 3
service.
8
This manual has been prepared on the basis of the
latest specifications at the time of publication. If
FI SYSTEM DIAGNOSIS 4
modifications have been made since then, differ-
FUEL SYSTEM AND
ences may exist between the content of this manual
and the actual motorcycle.
Illustrations in this manual are used to show the
THROTTLE BODY 5
basic principles of operation and work procedures.
They may not represent the actual motorcycle
exactly in detail.
CHASSIS 6
This manual is written for persons who have enough
knowledge, skills and tools, including special tools,
for servicing Haojue motorcycles. If you do not have
the proper knowledge and tools, ask your authorized
ELECTRICAL SYSTEM 7
HAOJUE motorcycle dealer to help you.
电路图 INFORMATION
SERVICING 8
WARNING
Improper repair may result in injury to the

mechanic and may render the motorcycle unsafe
WIRING DIAGRAM 9
for the rider and passenger.
CAUTION
Inexperienced mechanics or mechanics without

proper tools, not to able to properly perform the
services described in this manual.
HAOJUE HOLDING CO.,LTD

FEB, 2021
(The 1st Edition)
HAOJUE HOLDING CO., LTD . 2021
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 wheel axle

2 Bush
3 Dustproof cover
4 Oil seal
5 Roller bearing
6 Bush
7 Front wheel rim
8 Front tire
9 Brake disc
10 Bush
A Front brake disc bolt
B Front axle nut
ITEM N•m Kgf•m
A 18-28 1.8-2.8
B 36-52 3.6-5.2
SYMBOL
The following symbols are instructions and necessary information for maintenance.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Data beside it indicates specified Apply or use the absorber oil
torque.
Apply oil. Use engine oil unless

OIL
Apply or use the brake fluid

otherwise specified.
Apply grease
Measure in voltage
99000-25010
Apply Moly paste

Measure in resistance
99000-25140
Apply BOND“1207B"
99000-31140 Measure in continuity test range
Apply THREAD LOCK “1342"

Use special tool
99000-32050
Apply THREAD LOCK “1303" The data of maintenance

99000-32030
Apply THREAD LOCK “1360"

99000-32130
ABBREVIATIONS USED IN THIS MANUAL
AATS: Ambient Air Temperature Sensor ODO: Odometer
ABS: Anti-lock Brake System O.D: Outer Diameter
AC: Alternating Current PAIR: Pulsed Secondary Air Supply
ADJ: Adjust PCV: Positive Crankcase Ventilation
API: American Petroleum Institute RH: Right head
B+: Battery Positive RON: Research Octane Number
CKPS: Crankshaft Position Sensor RPM: Revolution Per Minute
CPU: Center Processing Unit SAE: Society of Automotive Engineers
DC: Direct Current SEL: Select
DTC: Diagnostic Trouble Code SOHC: Single Over Head camshaft
ECM: Engine Control Module STD: Standard
ECTS: Engine Coolant Temperature Sensor TACO: Tach (tachometer)
EVAP: Evaporative Emission TDC: Top Dead Center
EX: Exhaust TOS: Tilt Over Sensor
FI: Fuel Injector TOV: Tilt Over Valve
FP: Fuel pump TPS: Throttle Position Sensor
FWD: Forward TS: Test Switch
GND: Ground
GP: Gear Position
HI: High
HOXS: Heated Oxygen Sensor
HU: Hydraulic Unit
IAPS: Intake Air Pressure Sensor
IATS: Intake Air Temperature Sensor
I.D: Inner Diameter
IG: Ignition
IN: Intake
ISCV: Idle Speed Control Valve
JASO: Japanese Automobile StandardS
Organization
LCD: Liquid Crystal Display
LED: Light Emitting Diode
LH: Left Hand
LO: Low Light
Max: Maximum
MIL: Malfunction Indication Light
Min: Minimum
NT: Natural
Wire Color Symbols
Symbol Wire color Symbol Wire color
B Black Lg Light green
Bl Blue O Orange
Br Brown P Pink
Dbr Dark brown R Red
Dg Dark green V Violet

G Green W White
Gr Gray Y Yellow
Lbl Lbl
There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is
dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses two color
symbols (i.e. G/Y).
The first symbol represents the base color of the wire and the second symbol represents the color of
the stripe.
1
1. G (Base color) 3. G (Base Color)

2.Y (Stripe color)
GENERAL INFORMATION
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 1-3
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 Haojue 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, bond 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.
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS

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

FUEL
Use unleaded gasoline with an octane rating of 89-97 RON.
Use non-unleaded gasoline will shorten the life of spark plug and muffler accelerant. Dirty fuel
will block the fuel passage result in abnormal engine working condition.
Do not overfill the fuel.
ENGINE OIL
Select Haojue motorcycle engine oil of API SG or
higher and its viscosity rating is SAE 10W-40 Engine oil
(JASO T903 MA). If SAE10W-40 engine oil is not
available, select an alternative according to the
right chart.
SG or higher
BREAK-IN PROCEDURE
The correct ”BREAK-IN” extends the engine life and maximums the engine performance. The general
rules are as follows:
The throttle must not be opened to the full during the new motorcycle's break-in period. Throttle opening
should be limited to less than 3/4 of its maximum, while violent acceleration should be avoided.
Do not maintain constant engine gear and speed for an extended time period during any portion of the
break-in. Try to vary the throttle position. During the period of break-in, increase the throttle opening
properly to enable break-in fully.
When engine is running at constant low speed (low load), parts will wear rapidly leads to bad brake-in.
1-2
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 2100 mm
Overall width 780 mm
Overall height 1100 mm
Wheelbase 1390 mm
Ground clearance 150 mm
Curb weight 146 kg
ENGINE
Type Single cylinder, vertical, air-cooled, four stroke
Number of cylinders 1
Bore 57.3 mm
Stroke 57.8 mm
Piston displacement 149 ml
Compression ratio 9.3:1
Fuel supply Fuel injection
Air cleaner Paper filter
Starter system Electric starter/Kick starter
Lubrication system Wet sump
TRANSMISSION
Clutch Wet multi-plate type
Transmission 1-down,4-up
Primary reduction ratio 3.333
Final reduction ratio 2.928
Gear ratios, Low 3.083
2nd 1.941
3rd 1.450
4th 1.174
Top 0.960
Drive chain KMC 428H 126links
1-3
GENERAL INFORMATION
ELECTRIC
Ignition type Electronic ignition
Ignition timing 13° B.T.D.C at 1 500r/min
Spark plug DR8EA
Battery 12V 6Ah
Fuse 20A/15A/10A
Headlight 12V,35W/35W
Tail light/Brake light 12V,5W/21W
Turn signal light 12V,10W
Position light 12V,5W
CHASSIS
Front absorber Telescopic, coil spring, oil damped
Rear absorber Swingarm type, 5 level adjustable coil spring oil damped
Steering angle 40°
Caster 30°
Trail 117.5 mm
Turning diameter 4947mm
Front brake Disc type/Hand brake
Rear brake Drum type/Foot brake
Front tire size 90/90-18 51R
Rear tire size 100/90-16 59P
Front absorber stroke 115.6mm
CAPACITIES
Fuel tank 11.5 L
Reserve 2.1 L
Engine oil, oil change 1 000 ml
Overhaul 1 200 ml
Front absorber(Single) 317 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
CYLINDER HEAD NUTS 2-6
VALVE CLEARANCE 2-6
SPARK PLUG 2-8
ENGINE OIL 2-8
ENGINE OIL FILTER 2-9
ENGINE OIL CENTRIFUGAL FILTER 2-9
CLUTCH CABLE PLAY 2-9
THROTTLE BODY 2-10
THROTTLE CABLE 2-10
FUEL HOSE 2-10
DRIVE CHAIN 2-10
BRAKES 2-12
TIRES 2-16
STEERING 2-16
FRONT AND REAR ABSORBERS 2-17
LIGHTING AND SIGNAL 2-17
EVAPORATIVE EMISSION CONTROL SYSTEM 2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-18
COMPRESSION 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.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

Interval Km Initial 1 000 Every 3 000 Every 6 000
Page
Item Month 3 6 12
Battery / Fuse Inspect Inspect 2-3
1
Clean 2-4
Air cleaner element 1
Clean every 18 months or 12 000 km 2-4
Exhaust pipe bolts and Inspect Inspect 2-5

muffler bolts
Cylinder head and cylinder nuts Inspect Inspect 2-5
Valve clearance (when cold) Inspect Inspect 2-6
Inspect Inspect
Spark plug 2-7
Replace every 10 000 km
Engine oil Replace Replace 1 2-8
Oil sump filter Clean every 18 months or 12 000 km 2-8
Engine oil centrifugal filter Clean every 18 months or 12 000 km 2-8
Clutch cable play Inspect Inspect 2-9
Throttle body Clean 2-9
Idle speed Inspect Inspect 2-9
Throttle cable play Inspect Inspect 2-9
Inspect Inspect
Fuel hose 2-10
Replace every 10 years
EVAP system Inspect Inspect 2-17
Drive chain Inspect, clean, lubricate every 1 000 km 2-10
Brake Inspect Inspect
Brake Inspect Inspect

Brakes 2-12
hose Replace every 4 years
Brake fluid Inspect every 3 000 km, replace every 2 years
Tire Inspect Inspect 2-16
Steering Inspect Inspect 2-16
Front and rear absorbers Inspect 2-17
Lights and signals Inspect Inspect 2-17
Chassis bolts and nuts Inspect Inspect 2-18
Note 1: The interval for replacement or inspection, cleaning should be adjusted according the
driving condition.
2-1
LUBRICATION CHART
Interval Km Initial and Every 6 000km Every 12 000 km
Item Month 6 12
Clutch cable Engine oil
Throttle grip Grease
Clutch cable Engine oil
Drive chain Engine oil, every 1 000 km
Brake lever pivot Engine oil
Brake pedal pivot Grease or engine oil
Brake cam Grease
Steering
Grease every 2 years or 20 000 km.
Swing arm bearings
WARNING
Be careful not to apply too much grease to the brake cam. If grease gets on the linings, break
slippage will result.
CAUTION
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean
off any rusty spots and wipe off any grease, oil dirt or grime.
2-2
MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of the Periodic Maintenance requirements.
BATTERY/FUSE
Inspect initial 1 000 km and every 3 000 km
BATTERY
The battery is fixed inside the right side cover. This battery is a
sealed type battery, and reuquires no maintenance. However,
re-charging is required once the voltage falls below 12.4V.
First confirm the ignition switch is off.

Remove the frame right side cover .
Remove the battery brace .

Remove the - lead wire first, then remove + lead wire .
Take off the battery.
CAUTION
When install the battery lead wires, fix the lead first and
the lead last.
Install the battery in the reverse order of the disassembly.
FUSE
The fuse box locates on the battery bracer. If engine is shut
down suddenly during the driving or circuit is open, please
check the fuse.
WARNING
Do not use a fuse of a different specification , or it will incur
negative effect to electric, fire and power loss of engine
which is very dangerous.
CAUTION
Do not use aluminum, iron wire or any other substitute for
the fuse. If the fuse blows frequently, it indicates the
electric system may has problem. Always investigate the
cause, correct it and then replace the fuse.
2-3
AIR CLEANER
Clean every 3 000 km and repalce every 12 000 km.
NOTE:
If driving under dusty conditions, clean the air cleaner more
frequently.
Clean the air cleaner in the following manner.

Remove the right side cover. (Refer to page 6-1)
Remove the right rear decoration cover .
Remove the right small cover .
Remove the air cleaner cover .
Remove the air cleaner .
2-4
The air cleaner element is made by oiled paper, do not clean

the element with water or solvent or blow it with compressed
air, or apply any grease on it. If the element is too dirty or
worn result in poor engine starting and insufficient power,
replace the cleaner.
Remove the fireproof plate .
Wipe up the dust on the inner wall of air cleaner case.
Reinstall the air cleaner in the reverse order of removal.
CAUTION
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to operate the engine without the element
or to use a torn element. Make sure that the air cleaner is
in good condition at all times. The life of the engine
depends largely on this component.
DRAIN PLUG
Remove the air cleaner drain plug and drain water and oil at
the moment checking air cleaner.
CAUTION
After cleaning, make sure the drain plug is fitted
properly.
2-5
EXHAUST PIPE BOLTS

。3 000km
Inspect initial 1 000km and every
Tighten the exhaust pipe bolt to the specified torque.
Exhaust pipe bolt: 11-15 N•m
CYLINDER HEAD NUTS
。3 000km
Inspect initial 1 000km and every
When the engine is cold, tighten the engine cylinder head

cover cap nut .
Cylinder head cover cap nut: 25-35 N•m
VALVE CLEARANCE
Inspect initial 1 000km and every 3 000km
Excessive valve clearance results in valve noise and

insufficient valve clearance results in valve damage and
reduced power. At the distances indicated above, check and
adjust the clearance to the following specification. The
procedure for adjusting the valve clearance is as follows:
Remove the seat and left and right side covers.
(Refer to page 6-1)
Remove the fuel tank left and right side covers and .
Remove the wire couplers PVC boot .
Disconnect the fuel pump coupler and meter coupler .
Remove the fuel tank mounting bolt .
2-6
Lift the fuel tank from the left side, disconnect the high
pressure fuel hose 7 , absorber hose 8 and overflow hose
9.
Remove the fuel tank.
Remove the intake and exhaust valve inspection caps 10 .

Remove the valve timing inspection plug 11 and generator
cover cap 12 .
Rotate the generator rotor counter clockwise until the T line

on the rotor is aligned with center (mark line) of hole on
the crankcase to set the piston at the top dead center of the
compression stroke.
NOTE：
Valve clearance is to be checked when the engine iscold.
Both the intake and exhaust valves must be checked and
adjusted when the piston is at Top-Dead-Center(TDC) of
the compression stroke.
Hook the rocker arm with the special tool, check the intake
and exhaust valve clearance.
09900-20803: Thickness gauge

11F14-017: Valve spring hook
Valve clearance specification

Valve clearance (When cold)
Standard: IN: 0.04-0.06mm
EX: 0.09-0.11mm
If the valve clearances is out of specification, bring it

into the specified range by using the special tool.

11F14-017: Valve spring hook
11F14-019: Valve adjust wrench (T shape)
Install the removed parts in the reverse order of

removal.
2-7
SPARK PLUG
Inspect Initial 1 000 km and every 3 000 km.
Replace it every 10 000 km.
Remove the carbon deposits with a wire of pin and adjust
the spark plug gap A to 0.8-0.9 mm, measuring with a
thickness gauge.
When removing carbon deposits, be sure to observe the
appearance of the plug, noting the color of the carbon
deposits. The color observed indicates whether the standard
plug is suitable or not, if the standard plug is apt to get wet, a
hotter plug should be used. If the standard plug is apt to
overheat (porcelain is whitish in appearance), replace with a
cooler one.
Spark plug gap A :0.6-0.7 mm
09900-20803: thickness gauge
Type NGK
A
Hot DR7EA
Standard DR8EA
Cold DR9EA
ENGINE OIL
Replace initial 1 000km and replace every 3 000km thereafter.
The oil should be changed when the engine is warm. The

procedure is as follows:
Stop the engine, support the motorcycle on flat ground
with the main stand.
Remove the oil drain plug and oil filler cap/oil level
gauge , drain the oil.
Tighten the oil drain plug and pour new oil through the
oil filler. The engine will hold about 1000 ml of oil(1200 ml
for overhaul). Use of SG or above in API standard with an
oil viscosity of SAW 10W-40.
Required amount of engine oil:

Oil change: 1 000 ml
Engine overhual:1 200 ml
Start the engine and allow it to run for several minutes at
idling speed.
Turn off the engine, wait about several minutes, take off
the filler gauge, wipe off the oil on it. Insert the filler gauge
and take off it, Check the oil level on the filler gauge. The
oil level should be between the lower line and upper line of
the filler gauge. If the oil level is below lower line, fill the oil
to the upper line. If oil level exceeds upper line, drain some
oil until it below upper line.
Upper
Lower
Tighten the filler gauge.
2-8
OIL SUMP FILTER

Clean every 18 months and every 12 000 km
Drain the engine oil.

Remove the filter cover , take out the spring and oil
sump filter .
Clean the oil sump filter, replace the oil sump filter if it is
damaged.
Reinstall the oil sump filter , spring and oil sump filter
cover .
CAUTION
Replace the O-ring with a new one.
ENGINE OIL CENTRIFUGAL FILTER
Clean every 18 months or 12 000 km
Remove the clutch cover. (Refer to page 3-21)

Remove the engine oil centrifugal filter cover .
Clean the engine oil centrifugal filter rotor and cover with a
clean cloth.
Reinstall the engine oil centrifugal filter cover after
cleaning.
CLUTCH CABLE PLAY

Inspect initial 1 000 km and every 3 000 km.
Clutch play should be 4 mm as measured at the clutch lever

holder before the clutch begins to disengage. If the play in the
clutch is incorrect, adjust it in the following way:
Remove the jacket, loose the lock nut , screw the 4mm
adjuster nut on the clutch lever holder all the way in.
Loose clutch cable adjuster lock nut .
Turn the clutch cable adjuster in or out to acquire the
specified play.
Use adjuster nut for minor adjustment.
Tighten the lock nut and while holding the adjuster in
position.
CAUTION
Excessive clutch cable play may cause clutch

dragging and clutch and gear shifting mechanism
wear and damage.
2-9
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 fluctuant, clean as
necessary. (Refer to page 5-8)
THROTTLE CABLE PLAY

Adjust the throttle cable play as follows.

Loosen the adjuster lock nut .
Turn the adjuster so that the throttle cable play has
0.5 -1.0 mm play.
Tighten the lock nut after adjustment. 0.5-1.0 mm
WARNING
After the adjustment is completed, check that handlebar

movement does not raise the engine idle speed and that the
throttle grip returns smoothly and automatically.
FUEL HOSE
Inspect initial 1 000 km and every 3 000 km, replace
every 10 years.
Check the fuel hose 1 for leakage, cracks, wear and damage.
If any defects are found, replace the fuel hose with a new one.
2-10
DRIVE CHAIN
Inspect, clean & lubricate for every 1 000 km
DRIVE CHAIN/SPROCKET
When inspecting the drive chain, look for the following:
1. Loose pins 2. Damage rollers
3. Rusted links 4. Twisted or seized links
5. Excessive wear
If any defects are found, the drive chain must be placed.
Damage to the drive chain means that the sprockets may also
be damaged. Inspect the sprockets for the following:
1.Excessively worn teeth
2.Broken or damaged teeth
3.Loose sprocket mounting nuts
Cleaning and Lubrication

Good Worn
After throughly washing the drive chain with detergent liquid
and allowing it to dry, lubricate the drive chain with chain lube
or new engine oil.
Drive Chain Adjustment
Adjust the drive chain slack to the proper specification. The
drive chain may require more frequent adjustment than
periodic maintenance schedule depending upon your riding
conditions.
WARNING
Too much chain slack can cause the chain to come off the
sprockets, resulting in an accident or serious damage to the
motorcycle. Inspect and adjust the drive chain slack as
follows:
Place the motorcycle on center stand.

Loosen the rear axle nut .
Loose or tighten both chain adjuster nuts till there is
10-20mm of chain slack.
Make sure the mark on both chain adjusters and rear
swing arm 5 must be at the same position on the scale to
ensure that front and rear wheels are correctly aligned.
After adjusting the drive chain, tighten rear wheel axle nut
to the specified torque, then tighten the nut , confirm
10-20mm
the chain slack again.
Check the rear brake pedal travel. (Refer to page 2-15)
Rear axle nut: 50-80 N•m
DRIVE CHAIN 123 20 21 22
Count out 21 pins of the chain and measure the distance

between. If the distance exceeds 259.1 mm, the chain must be 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
replaced. 0 1 2 3 4 5 6 7 8
Drive chain 20 pitch length:

Service limit: 259.4 mm
09900-20103 : Vernier caliper
2-11
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 fluid level

Support the motorcycle body on the center stand, and
place the handlebars straight.
Check the brake fluid level in the front brake fluid reservoir LOWER
tank and rear brake linked brake fluid reservoir tank .
If the level is lower than the lower limit, replenish with brake
fluid that meets the following specification.
Haojue Brake fluid: DOT4
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 LOWER
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. 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
AIR BLEEDING THE FRONT BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in the
following manner:
Fill up the master cylinder reservoir to the upper line.
Install the reservoir cap to prevent dirt from entering.
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 上刻线
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, install the reservoir cap.
CAUTION
Handle the brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials, etc.
FRONT BRAKE SWITCH

Operate the front brake lever to check to see if the brake light
switch works , if any defects are found, inspect, adjust or
replace the switch as necessary.
2-13
REAR BRAKE
Loosen the lock nut , turn the adjuster nut until the break
pedal height is 5-15mm above the upper surface of front
footrest. Tighten the lock nut securely .
Rear brake pedal height A : 5-15 mm
Rear brake pedal travel is the distance from the free

position to the position that the rear brake starts taking
effect.
Rotate the adjuster nut to adjust the rear brake pedal
free travel to 15-25 mm.
Rear brake pedal free travel : 15-25 mm
REAR BRAKE LINING WEAR LIMIT

This motorcycle is equipped with brake lining wear limit
indicators on rear brake. To check wear of the break lining,
follow the steps below.
Check if the brake system is properly adjusted first.
While operating the brake, check to see the extension line
from the index mark is within the range on the brake
panel as shown in the right illustration.
If the index mark is outside the range, the brake shoe
assembly should be replaced to ensure safe operation.
2-15
AIR BLEEDING THE REAR BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in the
following manner:
Fill up the master cylinder reservoir to the upper level.
Install the reservoir cap to prevent dirt from entering.
Attach a hose to the air bleeder valve and insert the free
end of the hose into a receptacle.
Depress and release the brake pedal several times in rapid
succession and depress the pedal fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn
so that the brake fluid runs into the receptacle. Then, close
the air bleeder valve, release and depress the pedal, and
open the valve. Repeat this process until fluid flowing into
the receptacle contains no air bubbles.
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 hose. Fill the Upper line
reservoir with brake fluid to the upper line, install the
reservoir cap.
CAUTION
Handle the brake fluid with care: the fluid reacts

REAR BRAKE LIGHT SWITCH

Operate the rear brake pedal to inspect the brake light switch.
If the brake light switch works abnormally, it should be
inspected, adjusted or replaced.
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 200 2.00 225 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
The steering s hould b e a djusted p roperly f or s mooth t urning

o f the handlebars a nd s afe r unning . O vertighten s teering
p revents smooth turning o f t he h andlebars a nd t oo l oose
s teering w ill cause poor s tability . C heck t hat t here i s n o p lay
i n t he f ront absorber. Support the m otorcycle s o t hat t he f ront
w heel i s o ff t he g round . With the w heel f acing s traight a head ,
g rasp t he l ower f ork t ubes near the a xle a nd p ull f orward . I f
p lay i s f ound , r eadjust t he steering . (Refer to page 6-22)
2-16
FRONT AND REAR ABSORBERS

Inspect every 6 000 km.
FRONT ABSORBER
Grasp the front brake lever, squeeze the front
absorber to check if it moves smoothly.
Check for leaks or damage.
REAR ABSORBER
Depress the rear seat, move the rear shock absorber up
and down four or five times to check for the noise and
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 7-18)
EVAPORATION EMISSION CONTROL SYSTEM

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

system. Inspect the following items periodically.
Inspect the connection of each hose. (Refer to page 8-27)

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

required to be inspected and servicing, we strongly
recommend you do this job in a qualified service
shop.
2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

Inspect Initial 1 000 km and every 3 000 km
The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be
re-tightened, as necessary, to the specified torque with a torque wrench.
ITEM N•m Kg•m
1 Front axle nut 36-52 3.6-5.2
2 Brake caliper mounting bolt 18-28 1.8-2.8
3 Brake hose union bolt 20-25 2.0-2.5
4 Brake disc mounting bolt 18-28 1.8-2.8
5 Handlebar holder clamp bolt 12-20 1.2-2.0
6 Steering stem lock bolt 40-60 4.0-6.0
7 Upper bracket bracket clamp bolt 18-28 1.8-2.8
8 Lower bracket bracket clamp bolt 25-40 2.5-4.0
9 Rear absorber mounting bolt 22-35 2.2-3.5
10 Rear axle nut 50-80 5.0-8.0
11 Brake cam lever nut 8-12 0.8-1.2
12 Upper 33-39 3.3-3.9
13 Engine mounting nut Front 33-39 3.3-3.9
14 Rear 50-60 5.0-6.0
15 Rear swing arm pivot shaft nut 50-80 5.0-8.0
16 Exhaust pipe bolt 11-15 1.1-1.5
17 Front footrest mounting bolt 18-28 1.8-2.8
2-18
2-19
COMPRESSION PRESSURE
The cylinder compression is an indicator of its inner state. The necessity of repair depends on the result of
the inspecton. 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 2-7)
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.
11F14-023: Pressure test tool
Compression pressure
Standard Limit
1 000-1 400 kPa 800 kPa

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

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

following malfunctions:
Excessively worn cylinder wall.

Worn piston or piston rings.
Piston rings stuck in the grooves.
Poor seating contact of the valves.
Defective the cylinder head gasket.
2-20
ENGINE
CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLAC 3-1

ENGINE REMOVAL AND REMOUNTING 3-2 3
CYLINDER HEAD AND VALVE 3-8
CYLINDER AND PISTON 3-18
CLUTCH 3-22
OIL PUMP 3-27
GEAR SHIFTING MECHANISM 3-28
GENERATOR AND STARTER CLUTCH 3-29
CRANKSHAFT, TRANSMISSION AND KICK STARTER 3-32
发动机维修
REMOVING ENGINE PARTS WITH ENGINE IN PLACE
UPPER SIDE OF ENGINE

Starter motor 3-8
Engine temp. sensor 3-8
Cam chain tensioner 3-8
Cam sprocket 3-9
Camshaft 3-9
Valve rocker arm 3-10
RIGHT SIDE OF ENGINE

Kick starter lever 3-22
Clutch cover 3-22
Oil filter rotor 3-22
Clutch 3-23
Oil pump 3-27
Gear shifting lever 3-28
LEFT SIDE OF ENGINE

Sprocket cover 3-29
Starter reduction gear 3-29
Generator cover 3-29
Starter motor idle gear 3-29
Generator rotor 3-30
Starter clutch 3-30
Generator stator 3-30
Trigger coil 3-30
3-1
ENGINE
ENGINE REMOVAL AND

REASSEMBLY
ENGINE REMOVAL
Before taking the engine out of the chassis, wash the engine
The procedure of engine removal is sequentially explained in
the following steps:
Remove the saddle and left and right side covers.
(Refer to page 6-1)
Remove the battery - lead wire .
Remove the fuel tank and throttle body.

(Refer to page 5-1 and 5-7)
Disconnect the engine temp. sensor coupler .
Disconnect the spark plug cap .
Loose the clutch cable lock nut and adjuster nut,

remove the clutch cable .
Disconnect crankcase breather hose .

Remove the starter motor wire .
Loosse the starter motor mounting bolts, take off
the engine ground wire 7 .
3-2
ENGINE
Disconnect the oxygen sensor coupler 8 .
Remove the PVC jacket 9 .
Loose the clamp 10 , disconnect the speed sensor

coupler 11 , gear position switch coupler 12 and
generator coupler 13 .
Remove the gear shifting lever lock bolt, take off the
gear shifting lever .
Remove the engine sprocket cover .
3-3
ENGINE
Remove the muffler heat insluation brace .
Remove the cowling. (Refer to page 6-3)

Remove the front right footrest assembly .
Remove the front left footrest assembly .
Remove the muffler/exhaust pipe mounting bolts,

take off the muffler/exhaust pipe .
Remove the speed sensor rotor .
3-4
ENGINE
Remove the engine sprocket mounting bolts, take off the

engine sprocket retainer , engine sprocket and drive
chain 23 .
Remove the front bumper 24 .
Remove the cotter pin and washer, pull out the pin
25 , remove the rear brake pedal 26 .
Remove the engine front hanging mounting bolt 27 and

engine front mounting bolt 28 , take off the engine front
hanging brace 29 .
Remove the engine rear mounting bolt/nut 30 .
3-5
ENGINE
Hold the engine assembly, remove the engine upper

mounting bolt/nut 31 ,take off the engine.
NOTE:
The engine mounting nuts are self-lock nuts. Once the nut has
been removed, it is no longer of any use. Be sure to use new
nuts and tighten them to the specified torque.
ENGINE REMOUNTING
The engine can be mounted in the reverse order
of removal.
Before inserting the engine mounting bolts, pre-tighten
engine hanging brace.
Tightening torque for engine mounting bolts:
Engine upper mounting nut A : 33-39 N•m

Engine front hanging nut B : 22-33 N•m
Engine front mounting bolt C : 33-39 N•m
Engine rear mounting bolt D : 50-60 N•m
Exhaust pipe bolt E : 11-15 N•m
Front footrest mounting bolt: F 18-28 N•m
D
E
F
F
3-6
ENGINE
Install the engine sprocket bolt, apply the Thread Lock

“1303" to the thread portion of mounting bolt, then tighten
engine sprocket mounting bolt.
99000-32030: Thread lock "1303"
Install the speed sensor rotor, tighten the rotor mounting

bolt to the specified torque.
Speed sensor rotor mounting bolt: 18-28N • m
Install the gear shifting lever, tighten the gear shifting lever
mounting bolt to the specified torque.
Gear shifting lever mounting bolt: 8-12 N•m
After assembling the engine, add the engine oil.

(Refer to page 2-8)
Inspect the engine oil level. (Refer to page 2-8)
Route the wiring harness .(Refer to page 8-21)
After remounting the engine, following adjustments are

necessary.
* Clutch cable (Refer to page 2-9)
* Throttle cable (Refer to page 2-9)
* Drive chain (Refer to page 2-11)
3-7
ENGINE
CYLINDER HEAD AND VALVE

REMOVAL
Drain the engine oil, remove the engine.
(Refer to page 3-2)
Remove the spark plug and Engine temp. sensor .
Remove the starter motor mounting bolts, take off the

starter motor .
Remove the cam chain tensioner adjuster cap .

Remove the camshaft chain tensioner .
Remove the generator cover cap and time

inspection hole cap 7 .
Remove the valve inspection cap 8 .
3-8
ENGINE
Remove the cylinder head right cover 9 .
Bring the piston the top dead center.
CAUTION
When taking off the cylinder head cover, the piston
must be at the TDC of compression stroke.
Align the mark A on the camshaft sprocket and the mark B

on the cylinder head. B
Remove the camshaft sprocket mounting bolt 10 , take off

the camshaft sprocket.
A
CAUTION
Do not drop the sprocket, cam chain or bolt into
the crankcase.
Remove the cylinder head mounting nut 11 and bolt 12 ,

remove the cylinder head and washer.
CAUTION
Remove the bolt 12 first.
CAUTION
If it is difficult to remove the cylinder head, gently

pry it off while tapping the finless portion of the
cylinder head with a plastic hammer. Be careful not to
break the fins.
Remove the cylinder head gasket and dowel pins.
3-9
ENGINE
DISASSEMBLY
Remove the cam chain tensioner rod .
Remove the rocker arm shaft retainer .
Remove the camshaft .
Pull out the rocker arm shaft , remove the rocker

arm and spring .
3-10
ENGINE
Take off the valve cotters from the valve stem with the
special tool.
11F14-018 : Valve installer and remover
Take out the valve spring retainer, inner spring and outer spring.
Pull out the valve from the other side.
Remove the oil seal.
CAUTION
Always use new oil seal.
Take off the spring lower seat.
INSPECTION
ROCKER ARM SHAFT
Measure diameter of rocker arm shaft.
Rocker arm shaft O.D. (IN and EX.):

Standard: 11.966-11.994mm
09900-20205: Micrometer (0~25 mm)
ROCKER ARM
When checking the valve rocker arm, the inside diameter of
the valve rocker arm and wear of the camshaft contacting
surface should be checked.
Rocker arm I.D (IN and EX.):
Standard: 12.0-12.018 mm
09900-20605 : Caliper gauge
3-11
ENGINE
VALVE SPRING
Measure the valve spring free length.
Valve spring free length (IN and EX):

Limit (IN) : 37.44 mm
(EX): 40.13 mm
09900-20103: Vernier calipers
CAMSHAFT
The camshaft should be checked for run-out and also for wear
of cams and journals if the engine has been noted to produce
abnormal noise or vibration or a lack of output power. Any of
these mal-conditions could be caused by a worn camshaft. H
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 term of cam height H which is to be measured by a
micrometer. Replace the camshafts if found it worn down to
limit.
CAM HEIGHT
CAM HEIGHT H ：
Service Limit: (IN.): 31.036 mm
(EX.): 30.941 mm
09900-20202: Micrometer (25~50 mm)
CYLINDER HEAD
Visual inspect the spark plug hole and valve seat for
scratch or wear.
Check the gasketed surface of the cylinder head for
distortion with a straightedge and thickness gauge.
Cylinder head distortion

Service limit : 0.05 mm
09900-20803 : Thickness gauge
3-12
ENGINE
VALVE
Inspect the valve for pitting, scratch or wear.
Measure the valve stem outer diameter.
Valve stem O.D.:

Standard (IN): 4.975-4.99 mm
(EX): 4.955-4.97 mm
09900-20205 : Micrometer (0~25 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)
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 head runout:

Limit: 0.03 mm
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block (100 mm)
OIL SEAL
Oil each seal, and drive them into the position.
CAUTION
Always use new oil seal.
3-13
ENGINE
VALVE SEAT WIDTH

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

Intake: 1.0-1.1 mm
Exhaust: 1.1-1.3 mm
If either requirement is not met, correct the seat by servicing it

as follows.
VALVE SEAT SERVICING 进气门

The valve seats for both intake and exhaust valves are
angles to present three bevels. The valve seat contact
surface is 45°.
INTAKE EXHAUST
Valve seat angle 3 0°, 4 5 ° 3 0 °, 45°
Valve seat width 1.0-1.2 mm 1.1-1.3 mm
Valve diameter 29.0 mm 25.0 mm
Valve guide I.D. 5.000-5.012 mm
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.
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.
Take extreme care when handling with gasoline.
3-14
ENGINE
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
Install valve springs, making sure that the close-

pitch end of each spring goes in first to rest on the
head.
Turn the valve slowly while installing the valve oil seal
to prevent the valve oil seal from damage.
Install the valve cotters with the special tool.
11F14-018: Valve remover and installer tool
3-15
ENGINE
Oil the rocker arm shaft.

Mount the rocker arm, rocker arm spring and rocker arm shaft to
the cylinder head.
Apply a small quantity of moly paste to the camshaft journal

and place camshaft on the cylinder head.
Install the rocker arm retainer plate and tighten the bolts.
99000-25140 : Moly paste
Apply the Bond “1207B” to cam chain tensioner mounting

bolt, then install the cam chain tensioner.
99000-31140: Bond “1207B”
INSTALLATION
Install the cylinder head in the reverse order of removal.
Pay attention to the following points.
Remove the gasket material on the cylinder head
contacting surface.
CAUTION
Do not let the dirt and dust get into the engine.
Install the chain guide, dowel pin and cylinder head gasket
3-16
ENGINE
Install the four cap nuts and washer, tighten the nut to the
specified torque.
Cylinder head cover nut :25-35 N•m
Install the camshaft, cam sprocket and cam chain.

B
CAUTION
When installing the camshaft and sprocket,, bring the
piston to the TDC and align the mark A on the cam A
sprocket with mark B on the cylinder head. Apply the
Thread lock to the bolt and tighten it.
99000-32030: Thread Lock "1303"
Install the cylinder head left cover and gasket.
CAUTION
Always use new gasket
Install the valve timing inspection hole and O-ring.

CAUTION
Always use new seal ring.
Install the cam chain tensioner.

Check the valve clearance. (Refer to page 2-5)
3-17
ENGINE
CYLINDER AND PISTON

CYLINDER REMOVAL
Remove the cylinder head. (Refer to page 3-8)
Remove the gasket, dowel pins and guide rod.
Remove the cylinder.
INSPECTION
Remove the remaining gasket on the cylinder surface.
Inspect the gasketed surface of cylinder head for
distortion
Cylinder distortion:
Limit: 0.05 mm
Check the cylinder bore inner wall for scratches or

wear.
Measure the cylinder bore diameter at six places. If
any one of measurements exceeds the limit,
overhaul the cylinder and replace the piston with an
oversize, or replace the cylinder.
Cylinder bore diameter: Limit: 57.43 mm
09900-20508: Cylinder gauge set
PISTON REMOVAL AND INSPECTION

REMOVAL
CAUTION
Place a clean rag over the cylinder base to prevent
piston pin circlip from dropping into crankcase.
Remove the piston pin circlip.

Remove the piston pin and piston with the special tool.
09910-34510: Piston pin remover
CAUTION
Hold the piston stably when taking out the piston pin to
prevent the damage to conrod big end bearing.
Removing the piston rings one by one by expanding the
gap symmetrically.
CAUTION
Do not expand the piston ring excessively since it is
apt to be broken down.
3-18
ENGINE
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.
INSPECTION
Temporarily fit the piston ring on the suitable position with
the marked side to the top.
Measure the piston ring-groove clearance with thickness
gauge.
Piston ring-groove clearance:

Limit: (1st): 0.180 mm
(2nd):0.150 mm
Measure the piston outside diameter at the place

7mm from the skirt end.
Piston outside diameter:

Limit: 7 mm from the skirt end, 57.145 mm
7mm
09900-20205: Micrometer (50-75 mm)
Using a caliper gauge, measure the piston pin bore

inside diameter.
Piston pin bore inside diameter:
Limit: 14.03 mm
09900-20605: Caliper gauge
Using a micrometer measure the piston pin outside

diameter.
Piston pin O.D.: Limit: 13.98 mm
09900-20205: Micrometer (0-25)
3-19
ENGINE
Measure the conrod small end I. D.
Conrod small end I.D.: Limit: 14.04 mmmm
09900-20605: Caliper gauge
Fit the rings in the cylinder and measure each ring end gap
using a thickness gauge. If any ring has an excess end gap,
replace the ring.
Piston ring end gap: Limit(1st): 0.50 mm
(2nd):0.50 mm
CAUTION
Make sure fit the piston ring into the cylinder evenly
with the piston head.
INSTALLATION
Install the piston and cylinder in the reverse order of
removal, pay attention to the following points:
Clean the piston top, skirt and groove.
CAUTION
Fit the piston rings in the groove correctly, rotate the
piston ring by hand to see if it turns smoothly.
Install the piston ring carefully with marked side to the top.
120°
12
0° 0°
12
Be careful not to damage the piston ring and piston

during the installing the piston ring. Pay attention to
the angle between the 1st ring and 2nd ring.
The gaps of two piston rings should be staggered at 120°.
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

assembly.
3-20
ENGINE
Apply engine oil to piston pin.
Place a clean rag over the cylinder base to prevent piston

pin circlip from dropping into crankcase, and then fit the
piston pin circlip with long-nose pliers.
CAUTION
Use a new piston pin circlip.
End gap of the circlip should not be aligned with the
cutaway in the piston pin bore.
When fitting the piston, turn the ”IN” on the piston head to
intake side.
Apply engine oil to the conrod big end, small end, and piston
sliding part before reassembling cylinder.
Apply bond to the contacting surface between crankcase and
cylinder, install the dowel pins and gasket.
99000-31110: Bond “1215"
CAUTION
Always use new gasket to prevent leaking.
Turn the opening of piston ring to the suitable position,

apply the engine oil to the piston surface and then fit the
piston in the cylinder, make sure the piston is fitted in the
CAUTION
When mounting the cylinder, keep the cam chain 2
taut, or the chain 2 will be caught between crankcase
and cam drive sprocket.
There are the guide holder for the bottom end of cam
chain guide cast in the crankcase. Be sure that the cam
chain guide are inserted properly.
Install the cylinder head. (Refer to page 3-16)
3-21
ENGINE
CLUTCH
REMOVAL
Drain the engine oil.
Remove the clutch adjust bolt, disconnect the clutch cable
.
Remove the kick starter lever .

Remove the oil gauge .
Remove the front right footrest assembly .
Remove the exhaust pipe bolt, loose the muffler mounting

bolt, move the muffler downward.
Remove the clutch cover screws diagonally, take off the

clutch cover .
Remove the gasket and dowel pins.

Remove the oil filter rotor cover 7 .
Remove the clutch push rod 8 and bearing 9 .
CAUTION
Always use new gasket.
3-22
ENGINE
Hold the crankshaft with the special tool, remove the oil
filter rotor lock nut.
11F14-036: Gear stopper

11F14-011: Four claws sleeve
Remove the washer and oil filter rotor 10 .
Hold the clutch with the special tool, remove the clutch
sleeve hub lock nut.
09930-40113: Sprocket holder
11F14-011: Four claws sleeve
Remove the washer and clutch sleeve hub 11 .
Remove the clutch washer and primary driven gear

assembly 12 .
3-23
ENGINE
Disassembly the clutch sleeve hub assembly, take off the

clutch pressure plate, spring and clutch drive and driven
plates.
INSPECTION
Measure the thickness and claw width of each drive plate
with vernier calipers. Replace drive plates found to have
worn down to the limit.
Drive plate thickness:

Limit: 2.6 mm Checking thickness
Drive plate claw width:
Limit: 15.0 mm
Checking claw width
Measure each driven plate for distortion with a thickness

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

Limit: 36.2 mm
CAUTION
Replace all the springs if any spring is not within the
limit.
3-24
ENGINE
Inspect the clutch release bearing for any abnormality,

particularly cracks, to decide whether it can be reused or
should be replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
Inspect clutch outer disk notch for flaws or dents

caused by drive plates, replace as necessary.
Inspect the clutch driven hub for notches or abnormal

wear caused by driven plates, replace as necessary.
REASSEMBLY
Apply the engine oil to clutch drive and driven plates,
reassemble the clutch driven hub assembly, clutch springs,
pressure plate and bolts.
CAUTION
The top and bottom clutch drive plates have different
color of the middle 3 clutch drive plate. Do not install
the drive plate wrongly. When installing the clutch
drive plates, the top one should be installed to the
shallow indentation of clutch sleeve hub.
REASSEMBLY
Install the clutch in the reverser order of removal, Pay
attention to the following points:
Hold the clutch sleeve hub with the special tool, tighten the
clutch lock nut the specified torque.

11F14-011: 4 claws sleeve
Clutch lock nut: 40-45 N•m
3-25
ENGINE
Install the oil filter rotor and washer, tighten the filter rotor
lock nut to the specified torque.

11F14-011: 4 claws sleeve
Oil filter rotor lock nut: 40-45 N•m
Install the engine oil filter rotor cover, apply the Bond “1342"
to the bolt.
99000-32050: Bond "1342"
CAUTION
Install the dowel pin and new gasket.
CAUTION
Install the clutch cover, tighten clutch cover bolts to the

specified torque.
Clutch cover bolt: 10-15 N•m
Re-adjust the clutch cable clearance. (Refer to page 2-9).
3-26
ENGINE
OIL PUMP
REMOVAL AND INSPECTION
Remove the clutch cover.
Remove the oil pump driven spring .
Remove the oil pump driven gear .
Remove the oil pump .
Check the O-ring for damage or missing installation, replace

it with a new one.
Check the oil pump for smooth running, replace the oil pump
if any abnormality is found.
INSTALLATION
Install the oil pump in the reverse order of removal. Pay
Apply a small quantity of engine oil to the inside of oil pump
before installing the oil pump.
Apply the Thread Lock ”1342" to the oil pump mounting bolt,
and tighten the screw.
99000-32050: Thread Lock "1342"
3-27
发动机维修
GEAR SHIFTING MECHANISM

REMOVAL
Remove gear shifting lever .
Remove the clutch. (Refer to page 3-21).
Remove the gear shifting shaft assembly .
Remove the gear shifting cam and dowel pin.

Remove the gear shifting fixing pin assembly .
INSPECTION
Inspect the gear shifting shaft for wear or bend.
INSTALLATION
Install the gear shifting mechanism, pay attention to the
following points.
Apply the Thread Lock “1342" to the threaded part of
gear shifting fixing pin bolt and cam bolt, install the gear
shifting fixing pin and cam.
99000-32050: Thread Lock"1342”
3-28
ENGINE
GENERATOR AND STARTER CLUTCH

REMOVAL
Disconnect the generator coupler and speed sensor
coupler .
.
Remove the gear shifting lever bolt and gear shifting lever
.
Remove the engine sprocket cover .

Remove the left front footrest .
Remove the reduction gear cover .

Remove the reduction gear shaft 7 and reduction
gear 8 .
Remove the generator wire retainer plate bolt and retainer plate 9 .
Remove the bolt, take off the generator cover 10 .
Remove the gasket and dowel pin.
CAUTION
Loose the generator cover bolts diagonally.
There are magnetic force between the generator
cover(stator installed) and rotor, so be careful for
removal.
Remove the starter motor idle gear 11 and shaft.
3-29
ENGINE
INSTALLATION
Install the generator cover in the reverse order of removal.
Pay attention to the following points:
Apply the Bond “1207B” to the generator stator grommet ,
then install it to the generator cover.
99000-31140 : Bond 1207B”

Install the stator, apply the Thread Lock ”1342" to the bolt
and tighten it.
Install the trigger coil, apply the Thread Lock ”1342" to the
bolt 3 then tighten it.
99000-32050: Thread Lock "1342"
Install the key to the crankshaft key slot.

Degrease to the rotor cone surface and crankshaft cone
surface, make sure the surface is clean and dry without oil
or grease.
Do not damage the key slot and crankshaft when

installing the key.
Align the key slot on the rotor with the key on the
crankshaft, install the rotor.
Apply the Thread Lock to the threaded part of bolt, tighten
the bolt to the specified torque.
99000-32050: Thread Lock "1342"
Generator bolt: 45-50 N•m
11F14-001: Rotor holder
Install the gasket and dowel pin.

Install the generator cover.
Replace the gasket with a new one to prevent leakage.
3-31
ENGINE
Hold the rotor with the special tool, remove the generator
rotor bolts.
11F14-001 : Rotor holder
Remove the generator rotor and key with the special tool.
Remove the primary driven gear assembly and washer.
11F14-001: Generator rotor holder

11F14-002: Generator rotor remover
CAUTION
removing the key.
Remove the generator stator bolt, take off the generator

stator 12 .
Remove the trigger coil screw, take off the trigger coil 13 .
INSPECTION
Rotate the starter clutch gear by hand in the direction as
shown. The rotation should be smooth and continuous.
Check gear engagement in the opposite direction. If rotation
is difficult or noise occurs, check starter clutch gear wear.
Replace as necessary.
Inspect the starter driven gear spacer for damage,

replace the spacer if there is something unusual.
3-30
ENGINE
INSTALLATION
Install the generator cover in the reverse order of removal.
Apply the Bond “1207B” to the generator stator grommet ,
then install it to the generator cover.
99000-31140 : Bond 1207B”

Install the stator, apply the Thread Lock ”1342" to the bolt
and tighten it.
Install the trigger coil, apply the Thread Lock ”1342" to the
bolt 3 then tighten it.
99000-32050: Thread Lock "1342"
Install the key to the crankshaft key slot.

Degrease to the rotor cone surface and crankshaft cone
surface, make sure the surface is clean and dry without oil
or grease.

installing the key.
Align the key slot on the rotor with the key on the
crankshaft, install the rotor.
Apply the Thread Lock to the threaded part of bolt, tighten
the bolt to the specified torque.
99000-32050: Thread Lock "1342"
Generator bolt: 45-50 N•m
11F14-001: Rotor holder
Install the gasket and dowel pin.

Install the generator cover.
Replace the gasket with a new one to prevent leakage.
3-31
ENGINE
Remove the key and crankcase mounting bolts.
Remove the right crankcase with the special tool.

Fit the crankcase separating tool, so that the tool plate is
parallel with the end face of the crankcase.
11F14-027: Crankcase separating tool
CAUTION
When separating the crankcase, remove the right
crankcase or else the gear shifting mechanism will be
damaged.
Remove the gear shifting fork shaft, take off the forks.
Remove the gear shifting hub.
Remove the transmission assembly.
3-33
ENGINE
CRANKSHAFT, TRANSMISSION AND KICK STARTER

REMOVAL
Remove the engine and drain the engine oil.
(Refer to page 3-2)
Remove the cylinder head and cylinder.
Remove the clutch. (Refer to page 3-22 and 3-28)
Remove the generator rotor and starter clutch.
Remove the cam chain .

Remove the gear position switch mounting screws,
take off the gear position switch and pin, spring.
Remove the crankshaft pin retainer plate bolt, pressure
plate, spring and pin.
Remove the circlp and oil pump driven gear .

Remove the washer, primary drive gear and
balancer shaft drive gear and two keys.
Hold the balancer shaft with special tool, remove the

balancer shaft nut.
Remove the adjuster washer and flexuous washer.
11F14-030: Balancer shaft holder 8
Remove the circlip, washer, balancer driven gear assembly

and bush.
09900-06107: Snap ring pliers(opening type)
3-32
ENGINE
Remove the crankshaft with the special tool.
11F14-027: Crankcase separating tool
Remove the balancer shaft.
Remove the kick starter assembly.
INSPECTION
Measure the big end of conrod side clearance with a
thickness gauge.
Conrod big end side clearance:

Limit: 0.6 mm
Support the crankshaft with “V” blocks as shown, with the

two end journals resting on the blocks. Measure the
crankshaft runout with the dial gauge.
Crankshaft runout:
Limit: 0.05 mm
09900-20606: Dial gauge (1/100 mm)

09900-21304: V-block (100 mm)
Wear on the big end of the conrod can be estimated by

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

Limit: 3.0 mm
09900-20606: Dial gauge (1/100 mm)
09900-21304: V-block (100 mm)
3-34
ENGINE
Using a thickness gauge, check the shift fork clearance in

the groove of its gear. If the clearance limit is exceeded by
any of the three gears, determine whether the gear of the
gear shift fork should be replaced by measuring the
thickness and groove width.
Shifting fork to groove clearance: 0.45 mm

Checking clearance
Measure the thickness of gear shift fork.
Gear shift fork thickness: 4.93-5.0 mm
Checking thickness
Measure the gear shift fork groove width.
The gear shift fork groove width: 5.1-5.18 mm
Checking claw width
Inspect the gear shifting cam guide slot for damage.

Replace the gear shifting cam if the damage is found.
Check if abnormal wear or poor lubrication exist on each

bush, inner race of gear and gear teeth surface.
3-35
ENGINE
Inspect the kick starter shaft, kick starter, compressive

spring, twist spring and spring bush for wear or damage.
if any defect is found, replace the defective part.
Rotate the inner races of bearings with finger,

bearing rotation should be smooth and silent.
Simultaneously inspect if the bearing outer race rotates in
crankcase.
In case of difficult rotation of the bearing inner or outer
race, replace the bearing with a new one.
BEARING REMOVAL
Remove the left and right crankcase bearing retainer plates.
Remove the crankshaft bearing, counter shaft bearing and
drive shaft bearing from the left and right crankcases.
09921-20240: Bearing removing tool
3-36
ENGINE
INSTALLATION
Install the crankshaft in ther reverse order of removal. Pay
BEARING
Install the bearings on the left and right crankcases
with the special tool.
09913-70210: Bearing installer tool
Apply the Thread Lock ”1342" to the bearing retainer plate

bolt and tighten it.
99000-32050: Thread Lock”1342”
CRANKSHAFT
Decide the width between the webs referring to the figure

below when rebeuilding the crankshaft.
Width between webs：
Standard: 55±0.1 mm
55±0.1 mm
3-37
ENGINE
When mounting the crankshaft in the crankcase, it is

necessary to pull its left end into the crankcase.
09910-32812: Crankshaft installer

09910-20116: Conrod holder
09910-32812-02: Crankshaft installer attachment
CAUTION
Never fit the crankcase into the crankcase by striking it

with a plastic hammer. Always use the special tool,
otherwise crankshaft alignment accuracy will be
affected.
TRANSMISSION
3-38
ENGINE
CAUTION
Never reuse a circlip. After a circlip has been removed

from a shaft, it should be discrarded and a new circlip
must be installed. When installing a new circlip, care
must be taken not to expand the end gap large than
required to slip the circlip over the shaft. After
installing a circlip, always insure that it is completely
seated in its groove and securely fitted.
Press-fit 2nd drive gear onto the counter shaft. Before

reassembling, coat the internal face of the 2nd drive gear
with Thread Lock "1303" and install it so that the length A
as shown in Fig.
Countershaft length A ：
Stardard: 96.2-96.5 mm
A
99000-32030: Thread Lock "1303"
CAUTION
This procedure may be performed only twice
GEARING SHIFTING CAM AND FORK
3-39
ENGINE
Install the gear shifting cam to the crankcase, fit the gear
shifting forks from bottom to top as per the order of “L, C, R”.
CAUTION
The forks resemble each other very closely in external
appearance and configuration, install the fork with
mark ”JBL, JBC, JBR”.
Check if driven shaft and counter shaft rotate
smoothly after forks are installed. Adust as
neceassary.
Install the kick starter shaft assembly, tighten the stopper

bolt to the specified torque.
Stopper bolt: 25-30 N•m
Install the dowel pins and gasket.
CAUTION
Install the right crankcase to the left crankcase, tighten the

left and right crankcases mounting bolts.
CAUTION
Tighten the bolts in 2-3 steps.
3-40
FI SYSTEM DIAGNOSIS
CONTENTS
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
4-8
4
INJECTION TIME (INJECTION VOLUME)
COMPENSATION OF INJECTION TIME (VOLUME) 4-8
INJECTION STOP CONTROL 4-8
FI SYSTEM PARTS LOCATION 4-9
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 "23" TO SENSOR CIRCUIT MALFUNCTION 4-34
DTC "24" IGNITION COIL CIRCUIT MALFUNCTION 4-37
DTC "32" FUEL INJECTOR CIRCUIT MALFUNCTION 4-38
DTC "40" IDLE SOLENOID VALVE CIRCUIT MALFUNCTION 4-40
DTC "41" FUEL PUMP CIRCUIT MALFUNCTION 4-45
DTC "42" POWER CHECK MALFUNCTION 4-48
DTC "44" OX SENSOR CIRCUIT MALFUNCTION 4-50
DTC "99" BATTERY VOLTAGE MALFUNCTION 4-52
SENSORS 4-53
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 咔哒
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 咔哒

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.
Coupler
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.
Coupler
Probe
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

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

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

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

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

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

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

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

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

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

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

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

applied to the circuit being checked, measure voltage
between each terminal and body ground.
If measurements were taken as shown in the figure at the

right and results are as listed below, it means that the
circuit is open between terminals A and B .
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

(WIRE HARNESS TO GROUND) *1
Disconnect the negative - cable from the battery.

Disconnect the connectors/couplers at both ends of the
circuit to be checked.
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 TECHNICAL FEATURES

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 angle, 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)
Basic
Crankshaft Position Engine speed signal fuel
Sensor (CKP Sensor) injection
time
Throttle Position Throttle Opening signal

Sensor (TP Sensor)
Various Sensors Various signal Corrective

variables
Definitive
Injection signal
Injector fuel
injection
time
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
ET SENSOR SIGNAL When engine temperature is low, injection time
(volume) is increased.
IAT SENSOR SIGNAL
Air/fuel ratio is compensated to the theoretical ratio from
OX SENSOR SIGNAL 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.
IAP SENSOR SIGNAL Determine the fuel injection time (volume) by calculating the intake air
volume in accordance with the engine intake air pressure
ENGINE SPEED SIGNAL At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during
STARTING SIGNAL cranking engine.
During acceleration, the fuel injection time (volume) is increased in
ACCELERATION SIGNAL/
accordance with the throttle opening speed and engine rpm. During
DECELERATION SIGNAL
deceleration, the fuel injection time (volume) is decreased.
ATMOSPHERIC PRESSURE SIGNAL When the altitude is increased, the air density is decreased, the fuel
injection time (volume) is decreased.
INJECTION STOP CONTROL

Signal Description
OVER-REV. LIMITER SIGNAL The fuel injectors stop operation when engine rpm reaches rev. limit
rpm.The fuel cut-off circuit is incorporated in this ECM in order to prevent
over-running of engine. 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
A B C D E
H G F
J K
L M N
A Test coupler(6P) D Fuel injector G Ignition coil K 3 in 1 sensor

B ECM E Meter H ET sensor L CKP sensor
C Fuel pump F OX sensor J ISC valve M Speed sensor
N Fuse box
4-9
FI SYSTEM DIAGNOSIS
FI SYSTEM WIRING DIAGRAM
+B1
10A
Engine stop switch
Dimmer light switch
Pass switch
Light switch
OFF Ignition coil
+B2 POS
ON
C 400V IG
15A HLS
Dimmer light
3.7Ω
switch input coil Ignition coil
Dimmer 3.3kΩ output coil
Signal light IG GND
Position light Ground Fuel pump
FP M
Neutral indication light Fuel pump
Ignition switch output coil
3.01k Ω±0.5%
Power check coil Ground
AT
619±0.5%Ω
Ground
+B
20A 10kΩ
Neutral switch
NT input coil
Starter relay Ground

VCC
5.1kΩ
Clutch switch
CLS input coil
600V
Starter motor Starter switch
M
Clutch switch Engine stop switch 51Ω 51Ω
Battery TACO
400V Engine stop switch
STPS Meter ouput
input coil coil
3.3kΩ
Ground Ground Ground Ground

VCC
Test switch 5.1kΩ
Test switch
TS input coil
Rectifier Ground VCC

5.1kΩ
GP switch
GPS1 input coil
400V CPU
C ISA
Ground
ISA-
ISC valve
ISB
Motor output coil M
Neutral The 3rd position ISB-
GP switch ISC valve motor

GND
Ground
CKP sensor Coil emission
CPS+ signal Injector power 30kΩ±0.5%
input coil
10kΩ±0.5%
Ground
VCC VCC +B +B1
VB
VCC
TPS TP Power supply +B
TPS input coil coil 400V
VCC 220kΩ Injector 12Ω
Fuel injector INJ
Ground output coil
IAPS Ground 150kΩ
IAP
IAPS input coil
VCC
+B2
2.7k Ω± 0.5%
Ground
IATS IAT
IATS input coil MIL MIL
VCC output coil
Ground 1.21k Ω± 0.5%

ETS Engine temp. Ground
ETS input coil
VCC
1MΩ
Ground 330kΩ
OX 10kΩ OX sensor VB
OX input coil Diagnosis tool
56kΩ 110kΩ
Ground Meter input/ DIAG
Ground 33Ω
output coil
Alarm tool
TO valve Ground
TO sensor
DON input coil
220kΩ
Ground
Ground
SG
Ground
4-10
FI SYSTEM DIAGNOSIS
ECM TERMINALS
Terminal Circuit Terminal Circuit

1 IG Ignition coil 19 IATS Intake air temperature sensor
2 MIL Malfunction indication light 20 OX Oxygen sensor
3 FP Fuel pump 21 TPS Throttle position sensor
4 NT Neutral switch 22 ETS Engine temperature sensor
5 GND Ground 23 ISA Idle speed motor A
6 SG Sensor ground 24 ISA- Idle speed motor A-
7 +B Battery 25 IG GND Ignition coil ground
8 CPS+ Crankshaft position sensor+ 26 TACO Tachometer
9 VCC Sensor voltage 27
10 TS Test switch 28
11 ISB- Idle speed motor B- 29 STPS Engine stop switch

12 ISB Idle speed motor B+ 30
13 INJ Fuel injector 31 HLS Headlamp switch

14 32 GPS1 Gear position switch 1
15 33 IAPS IAP sensor
16 AT Power check 34 DIAG Diagnosis tool
17 35
18 DON Tilt over sensor 36 CLS Clutch switch
4-11
FI SYSTEM DIAGNOSIS
SELF-DIAGNOSIS
The self-diagnosis function is incorporated in the ECM. When
the FI system has fault, ECM will turn on the Malfunction
indication light and save the DTC to erasable memory. When
the voltage is lower than 8V, ECM no longer perform self-
diagnois. After turning off the ignition switch, the diagnosis
result will be reset.
Turn on the ignition switch, after self-diagnosis,

malfunction indication light turns on, then start the engine,
the light turns off, it means no ECM defect is detected.
If after engine is started, malfunction indication light
staying on, it means the DTC or past DTC exists.
Push the start button several times but staring is no
successful, the malfunction indication light is staying on, it
means DTC exists.
A two-digit DTC is shown through the flashing pattern of
the malfunction indicator light and also can be read by a
defect diagnose device.
MALFUNCTION INDICATION LIGHT

INSPECTION
When turning 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 turn on the test switch.
Turn on the ignition switch, after self-diagnosis is
completed, malfunction indication light starts flashing to
output DTC.
After the defect is removed, check if past DTC exists,
delete the past DTC if it exists.
PAST DTC
Connect the test switch coupler, turn on the test switch.
Open the throttle fully.
Turn on the ignition switch, after malfunction indication
light being off for 3s,malfunction indication starts flashing
to output past DTC.
After checking the past DTC, delete the past DTC with
test switch.(Refer to page 4-13)
09930-82720: Test switch
4-12
FI SYSTEMDIAGNOSIS
UNDERSTANDING THE DTC (Diagnostic Trouble Code)

A two-digit DTC is shown through the flashing pattern of the malfunction indicator light.For current DTC, a
number between 1 and 9 is represented by the number of times that the malfunction indicator light lights up
in interval of 0.3 seconds and the separation between the tens and ones are indicated by the light staying
off for 1 seconds. In addition, the separation between the start code and the 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 0.5 seconds. In addition, the separation between the start
code and the 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 0.3s
ON
3s 3s
OFF 1s 1s 1s
0.3s 0.3s 0.3s 0.3s
PAST DTC(Example)
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 DELETING

1 Turn on the test switch, open the throttle fully.
2 Turn on the ignition switch.
3 After malfunction indication light being off for 3s, malfunction indication light starts to output
DTC, close the throttle.
4 Switch the test switch from off to on 3 times, each time leaving it
at on for more than 1.5s and off for more than 1.5s, the past DTC is deleted.
The operation step 4 must be completed in 30s.
ON Ignition
Ignition switch on
switch OFF
④模式开关
连续ON、OFF
Test ON ①Test
switch switch on
OFF
Throttle Full
①Full open
opening
scale Close
Malfunction on ③DTC
indication output starts
light off
4-13
FI SYSTEM DIAGNOSIS
TABLE OF DIAGNOSTIC TROUBLE CODE (DTC)

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

12 P0335 Turns on
sensor(CPS) Short circuit to VCC Running No
Open circuit /
P0105 Intake pressure Short circuit to VCC Starting Yes
13 Turns on
P0107 sensor (IAPS) Short circuit to GND Running Yes
Open circuit /
P0123 Throttle position Short circuit to VCC Starting Yes
14 Turns on
P0120 sensor (TPS) Short circuit to GND Running Yes
Open circuit /
P0115 Engine temp. sensor Short circuit to VCC Starting Yes
15 Turns on
P0117 (ETS) Short circuit to GND Running Yes
Open circuit /
P0110 Intake air temp. sensor Short circuit to VCC Starting Yes
21 Turns on
P0112 (IATS) Short circuit to GND Running Yes
Open circuit /
P1502 Short circuit to VCC Starting No
23 TO sensor Turns on
P1503 Short circuit to GND Running No
Open circuit / Starting No

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

32 P0200 Fuel injector Turns on
P0505 Short circuit to GND Starting Yes

40 ISC valve Open circuit/short circuit to +B
Turns on
P0507 Running Yes
ISC valve is fixed.

41 P0230 Fuel pump Turns on
Starting No
42 P1501 Power check Open circuit / lower voltage Turns on
Running No
P0130 Short circuit to GND
Starting Yes
44 P0132 OX sensor Short circuit to VCC Turns on
Running Yes
P0131 Short circuit to GND
Starting Yes
99 P0560 Battery(High voltage) Fault regualtor/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
Handle
Touch
screen
Diagnose port USB update port

Power
DC12V power input Data port SM card slot
USE THE DIAGNOSE DEVICE

Turn off the ignition switch.
Connect the diagnosis device to battery, then connect the
diagnose device coupler.
Turn on the ignition switch.

Turn on the diagnosis device.
4-15
FI SYSTEM DIAGNOSIS
Click “Cross bike”, enter the model selection page, or click

“D system”, enter the system selection page.
Click the ”HJ150-16C/D”, or click the “Haojue special China

III, IV, Euro IV” to enter the defect diagnose page.
Click " Check Failure”.
Enter the diagnose page where displays the defect

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

After the DTCs are deleted, click”Refresh”, check if the
defect is removed again.
After confirming defect is removed, exit the diagnose
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.
Working condition of MIL Connection of plugs and sockets Throttle cable
Engine oil volume and oil leakage Cracking, damaging or loosening Fuel volume and leakage
Battery condition of vacuum throat Air filter blockage
Melted fuse
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.
For example: Faults in the central relay, relay fuse, sensor power supply or sensor wiring.
PROCESS PROCEDURE:
Check all the Check the bus wiring based Follow the steps mentioned above to solve faults
related fuses. on the fault pattern. 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
ECM
CKP sensor
G/W G/W G/W 6 SG
Bl/W Bl/W Bl/W 8 CPS+
To the regulator/rectifier
Generator rotor
ECM coupler (Harness side)
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
CKP sensor signal circuit check
1) Turn off the ignition switch.

2) Remove the left side cover and saddle.
(Refer to page 6-1)
3) Disconnect the CKP sensor coupler and ECM
coupler .
4-18
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the CKP sensor 1

coupler and ECM couplers.
5) If connections are OK, check the following points.
* Resistance
09900-25008: Multi-circuit tester set

09900-25009: Needle-point probe set 6
Tester knob indication: Resistance 8
Between G/W and Bl/W wire: Less than 1Ω
Between G/W wire or Bl/W wire and ground: Infinity. 1
Between the G/W wire or Bl/W wire: infinity 1
* Voltage 1
Tester knob indication: Voltage
Between G/W w ire or Bl/W w ire : a pprox . 0V (When the

ignition switch is turned on).
Is check result ok ?
YES Go to step 2 .
NO Repair or replace the defective wire.
4-19
FI SYSTEM DIAGNOSIS
Step 2 2
CKP sensor check
1) Measure the CKP sensor resistance.
Tester knob indication: resistance
CKP sensor resistance: 115-155 Ω
2) Check the continuity between each terminal and ground. 2

CKP sensor continuity: ∞Ω (Infinity)

(G/W wire-ground)
(Bl/W wire-ground)
Is check result OK?
YES Go to step 3
NO Replace CKP sensor.
Step 3
CKP sensor and rotor signal check
1) Remove the generator cover. ( Refer to page 3-29)
2) Check that end face of the CKP sensor and generator
teeth are free from any metal particles and damage.
Is check result OK ?
YES Go to step 4
NO Clear or replace defective parts.
Step 4 4
ECM check
1) Reconnect a new ECM.
YES Replace ECM.
NO Replace CKP sensor. (Refer to page 3-30)
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
TROUBLESHOOTING
NOTE:
After repairing the trouble, clear the DTC. (Refer to page 4-
Step 1
IAP sensor power supply circuit check

2) Remove the saddle and left side cover.
(Refer to page 6-1)
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 on the ignition switch.
6) Measure the voltage between the R wire and G/W wire.
Tester knob indication: voltage
IAP sensor power supply voltage: 4.5-5.5V

(+ 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.
Tester knob indication: voltage
IAP sensor power supply voltage: 4.5-5.5V

( + terminal: R – - terminal: Ground)
YES Repair or replace G/W wire.
NO Repair or replace R wire.
Step 3 3
IAP sensor signal wire check
2) Remove the saddle. (Refer to page 6-1)
3) Disconnect the ECM coupler .
4-22
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the ECM

couplers.
* Resistance
Tester knob indication: 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 terminal and R wire and G /W wire

terminal at IAP sensor connector: infinity
*Voltage

Between R/Bl wire and ground: approx. 0 V
(When the ignition switch is turned on)
YES Go to step 4 .
NO Repair or replace R/Bl wire.
4
Step 4
ECM check
1) Reconnect the a new ECM.
YES Replace ECM.
NO Replace throttle body
4-23
FI SYSTEM DIAGNOSIS
DTC “14”: TP SENSOR CIRCUIT MALFUNCTION

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

2) Remove the saddle and frame left side cover.
(Refer to page 6-1)
4-24
FI SYSTEM DIAGNOSIS
4) Check for proper terminal connection to the TP sensor

coupler.
5) If connection is OK, turn on the ignition switch.
6) Measure the voltage between the R wire and G/W wire.
TP sensor power supply voltage: 4.5-5.5V

( + terminal: R – - terminal: G/W)
YES Go to step 3 .
NO Go to step 2 .
Step 2
TP sensor ground circuit check

TP sensor power supply voltage: 4.5-5.5V

( + terminal: R wire – - terminal: Ground)
YES Repair or replace the G/W wire.
NO Repair or replace the R wire.
Step 3 3
TP sensor signal wire check
2) Remove the saddle. (Refer to page 6-1).
4-25
FI SYSTEM DIAGNOSIS

couplers.
*Resistance

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

coupler: Less than 1 Ω .
Between B/G wire of TP sensor coupler and ground: infinity .
Between the B/G wire, Red or Bl/W wire: infinity
*Voltage
Between B/G wire and ground: approx. 0V (When the

ignition switch is turned on).
YES Go to step 4 .
NO Repair or replace B/G wire.
4-26
FI SYSTEM DIAGNOSIS
Step 4
TP sensor check
2) Connect the ECM coupler 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 fully.

TP sensor output voltage: Full close: 0.65-0.75V

Full open: 3.8-4.0V
( + terminal: B/G wire – - terminal: G/W wire)
Replace the ECM with a known good one, and
YES
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) Disconnect the ET sensor coupler .
4-28
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the ET sensor

coupler.
5) Measure the input voltage between the Y/R wire 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 saddle.(Refer to page 6-1)
4) Check for proper terminal connection to the ECM couplers.

5) If connection is OK, check the following points.
*Resistance

6
Between Y/R or G/B wire of injector coupler and ECM

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 or G/B wire and ground: approx. 0 V
(When the ignition switch is turned on.)
YES Replace the ECM with a known good one, and
inspect it again.
NO Repair or replace the defective wire harness.
Step 3
ET sensor check
2) Disconnect the ET sensor coupler , remove the ET
sensor .
3) Measure the ET sensor resistence.
ET sensor resistence:
Approx. 2.645kΩ, at 20℃( Terminal- Terminal)

inspect it again.
4-28
NO Replace the ET sensor .
4) Install the ET sensor.
4-30
FI SYSTEM DIAGNOSIS
DTC "21": IAT SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
IAT sensor ECM
Br 19 IATS
G/W 6 SG
TROUBLESHOOTING
When using the multi-circuit tester, do not strongly touch the terminal of the ECU coupler with a
needle-point tester probe to prevent terminal damage.
NOTE:
Step 1
IAT sensor power circuit check
2) Remove the seat and left side cover. (Refer to page 6-1)
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.
IAT sensor input voltage: 4.5-5.5V

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

2) Remove the saddle. (Refer to page 6-1).

*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

Between Br wire or G/W wire and ground: Approx 0V.
YES
inspect it again.
NO Replace the defective wiring harness.
4-33
FI SYSTEM DIAGNOSIS
DTC”23”: TO SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
TO sensor
R 9 VCC
O/Bl 18 DON
G/W 6 SG
ECU coupler (Harness side)
TROUBLESHOOTING
When using the multi-circuit tester, do not strongly touch the terminal of the ECU coupler with a
NOTE:
Step 1
TO sensor power supply circuit check
3) Remove the TO sensor and disconnect the TO
sensor coupler .
4-34
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the TO sensor

coupler.
5) Measure the input voltage between the R wire and G/W
wire.
TO sensor input voltage: 4.5-5.5V

( + terminal: R wire – - terminal: G/W wire)
YES Go to step 3 .
NO Go to step 2 .
Step 2
TO sensor ground circuit check
TO sensor input voltage: 4.5-5.5V

( + terminal: R wire – - terminal: Ground)
YES Repair or replace G/W wire.
NO Repair or replace red wire.
4-35
FI SYSTEM DIAGNOSIS
Step 3 3
TO sensor circuit check


couplers.
*Resistance

Between O/Bl wire of TO sensor coupler and ECM coupler:

Less than 1 Ω .
\
Between O/Bl wire and ground: Infinity
Between O/Bl wire or B/Br wire and ground: approx. 0

V
*Voltage
09900-25008: Multi-circuit tester

Between O/Bl wire and ground: Approx 0V.
YES Go to step 4 .
NO Repair or replace O/Bl wire.
4-36
FI SYSTEM DIAGNOSIS
Step 4
TO sensor check
2) Connect the ECM couplers and TO sensor coupler.
3) Insert the needle-point probes to the lead wire coupler.
4) Turn on the ignition switch.
5) Measure the TO sensor voltage between the O/Bl wire
and G/W wire.

TP sensor voltage(Normal): 0.4-1.4V

( + terminal: O/Bl wire – - terminal: G/W wire)
6) Measure the voltage when it is leaned 45° and more, left

and right, from the horizontal level.

TP sensor voltage(leaned): 3.7-4.4V

( + terminal: O/Bl wire – - terminal: G/W wire)
YES
inspect it again.
NO Replace the TO sensor with a new one.
7) Install the TO sensor.
DTC”24”: IGNITION SYSTEM CIRCUIT MALFUNCTION

(Refer to page 7-9)
4-37
FI SYSTEM DIAGNOSIS
DTC”32”: INJECTOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
Fuel Injector
Engine stop switch 10A Ignition switch
ECM
20A
INJ 13 V
STPS 29 O/W
Battery
Starter relay
M
Starter motor
Starter switch Clutch switch
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) Remove the fuel tank. (Refer to page 5-1)
3) Remove the protective cap , disconnect the
fuel injector coupler .
4-38
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the injector

coupler.
5) Measure the voltage between V wire and ground.
NOTE:
Voltage can be detected only for 3 seconds after ignition switch
is turned on.
Injector power supply voltage: Battery voltage

( + terminal: V wire – - terminal: G round )
YES Go to step 2 .
NO Repair or replace the V wire.
Step 2
Injector drive circuit check


couplers.
*Resistance

Tester knob indication: Resistance 13 7
Between V or O/W wire of injector coupler and ECM

Between V or O/W wire and ground: infinity
4-39
FI SYSTEM DIAGNOSIS
Between V and O/W wire terminals of injector coupler:

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

YES Go to step 3
Step 3
Injector resistence check

2) Measure the injector resistance between terminals.
Injector resistance: 12 Ω at 20℃

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

ground.
Injector continuity: ∞ (Infinity)
YES
inspect it again.
Replace the injector with a new one.
NO (Refer to page 5-8)
4-40
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:
4-41
FI SYSTEM DIAGNOSIS
Step 1
ISC valve drive circuit check

2) Remove the saddle and left side cover. (Refer to page 6-1)
3) Disconnect the ISC valve coupler and ECM coupler .
4) Check for proper terminal connection to the ISC valve

coupler and ECM couplers.
*Resistance

12
Tester knob indication: Resistance 23
Between the Bl/B wire, Br/W wire, W/R wire and W/G wire
of ISC valve coupler and ECM coupler: less than 1 Ω .
11
之间 :
24
Between the Bl/B wire, Br/W wire, W/R wire and W/G wire
of ISC valve coupler and ground: infinity
4-42
FI SYSTEM DIAGNOSIS
Between the Bl/B wire of ISC valve coupler and

other terminals: infinity
:
Between the Br/W wire of ISC valve coupler and
Between the W/R wire of ISC valve coupler and

Between the W/G wire of ISC valve coupler and other

terminals: infinity
4-43
FI SYSTEM DIAGNOSIS
: 大
*Voltage
Between Bl/B wire, Br/W wire, W/R wire and W/G wire and
ground: approx. 0 V
YES Go to step 2.
NO Repair or replace defective wire.
Step 2
ISC valve check
1) Remove the ISC valve. (Refer to page 5-11)
2) Check the continuity between each ISC valve terminal and
ground.
ISC valve continuity ∞ (Terminal-Ground)
4) If OK, measure the resistance (between the W/R wire

terminal A and W/G wire terminal B ) and (between the B/Bl
wire terminal C and Lbl wire terminal D ).
09900-25008: Multi-circuit tester()
ISC valve :resistence: 20Ω at 20-30℃

(Terminal A - Terminal B ）
(Terminal C - Terminal D )
inspect it again.
NO Replace the ISC valve with a new one.
4-44
FI SYSTEM DIAGNOSIS
DTC “41”: FUEL PUMP CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
STPS 29 O/W
FP 3 Bl/G
Y/B
B/W
Fuel level gauge
TROUBLESHOOTING
NOTE:
Step 1
Fuel pump power supply circuit check

2) Remove the fuel tank decoration cover.
(Refer to page 6-1) .
3) Remove the fuel tank wiring harness jacket .
4) Disconnect the fuel pump coupler .
4-45
FI SYSTEM DIAGNOSIS
5) Check for proper terminal connection to the fuel pump

coupler. 。
7) Check the voltage between O/W wire and ground is
battery voltage.
Fuel pump power supply voltage: Battery voltage

( + terminal: W/G wire – - terminal; G round )
YES Go to step 2 .
Step 2
Fuel pump check
Inspect the fuel pump. (Refer to page 5-4)
YES Go to step 3.
NO Replace the fuel pump.
Step 3
Fuel pump circuit check
3) Disconnect the ECM .
4) Check for proper terminal connection to the ECM coupler.

*Resistance
3
7
Between O/W wire and Bl/G wire of fuel pump coupler and
ECM coupler: less than 1 Ω.
4-46
FI SYSTEM DIAGNOSIS
Between O/W wire or Bl/G wire and ground: infinity
* Voltage

Between O/W wire or Bl/G wire and ground: approx. 0V
inspect it again.
4-47
FI SYSTEM DIAGNOSIS
DTC “42”: POWER CHECK MALFUNCTION

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

2) Remove the headlamp assembly.(Refer to page 6-11)
3) Disconnect the ignition switch coupler .
4-48
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; G round )
YES Go to step 2 .
NO Repair or replace O/G wire.
Step 2
Power check circuit check
3) Disconnect the ECM coupler 1 .

*Resistance


16
Between G/W or B/Br wire of injector coupler and ECM

coupler: less than 1 Ω .
Between O/G wire and ground: Infinity
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.
4-49
FI SYSTEM DIAGNOSIS
DTC “44”: OX SENSOR CIRCUIT MALFUNCTION

WIRING DIAGRAM
ECM
OX sensor
20 B/Br
6 G/W
TROUBLESHOOTING
NOTE:
Step 1
OX sensor power supply circuit check

2) Remove the fuel tank decoration cover.(Refer to page 6-1)
3) Disconnect the OX sensor coupler .
4-50
FI SYSTEM DIAGNOSIS
3) Check for proper terminal connection to the OX

sensor coupler.
5) Measure the voltage between BlBr wire and ground.
OX 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
OX sensor circuit check

4) Check for proper terminal connection to the ECM coupler.

*Resistance

6
20
Between G/B or B/Br wire of OX sensor coupler and

ECM coupler: less than 1 Ω .
Between G/B wire or B/Br wire and ground: Infinity
4-51
FI SYSTEM DIAGNOSIS
Between G/W and B/Br wire: infinity.
*Voltage
Between G/W wire or B/Br wire and ground: approx. 0 V

YES Go to step 3 .
NO Repair or replace defective wire.
Step 3 3
ECM check
1) Reconnect a new ECM.
YES Replace the ECM.
NO Replace the OX sensor.
DTC “99”: BATTERY HIGH VOLTAGE MALFUNCTION

If DTC "99" exists, replace the rectifier with a new one.
4-52
FI SYSTEM DIAGNOSIS
SENSORS
CKP SENSOR
REMOVAL, INSPECTION AND INSTALLATION
Remove the CKP sensor (Trigger coil).

The signal rotor is mounted on the generator rotor 1 and
CKP sensor 2 is installed at the inside of the generator
cover.
Install the CKP sensor in the reverse order of removal.
ISC VALVE
ET SENSOR
Remove the ET sensor . (Refer to page 3-7)
Install the ET sensor in the reverse order of removal.
4-53
FI SYSTEM DIAGNOSIS
OX SENSOR
REMOVAL
Disconnect the OX sensor coupler .
Remove the OX sensor from the muffler.
WARNING
Do not remove the oxygen sensor when the muffler is
hot.
* Be careful not to expose the OX sensor to

excessive shock.
* Do not use an impact wrench when removing or
installing the OX sensor.
* Be careful not to twist or damage the sensor lead
wires.
INSTALLATION
Install the OX sensor is in the reverse order of removal.
Do not apply oil or other materials to the sensor air

hole.
Tighten the OX sensor to the specified torque.
OX sensor: 20-30 N•m
TO SENSOR
REMOVAL, INSPECTION AND INSTALLATION
Remove the TO sensor , disconnect the TO sensor

coupler .
Inspect the TO sensor.(Refer to page 4-34)
Install the TO sensor in the reverse order of removal.
4-54
FUEL SYSTEM AND THROTTLE BODY
CONTENT
FUEL SYSTEM 5-1
FUEL TANK REMOVAL 5-1
FUEL TANK REASSEMBLY 5-1
FUEL PRESSURE INSPECTION 5-2
FUEL PUMP INSPECTION 5-2
FUEL PUMP AND FUEL LEVEL GAUGE REMOVAL 5-3
FUEL PUMP DISASSEMBLY 5-4
FUEL STAINER INSPECTION AND CLEANING
FUEL PUMP AND FUEL LEVEL GAUGE
5-5
5-5
5
THROTTLE BODY 5-7
THROTTLE BODY REMOVAL 5-7
THROTTLE BODY CLEANING 5-8
INSPECTION 5-9
THROTTLE BODY REASSEMBLY 5-9
FUEL INJECTOR REMOVAL 5-10
FUEL INJECTOR INSPECTION 5-10
FUEL INJECTOR REASSEMBLY 5-10
ISC VALVE REMOVAL 5-11
ISC VALVE INSPECTION 5-11
ISC VALVE REASSEMBLY 5-11
DANGER CAUTION
* Far away from fire or spark. * Do not remove part blindly to prevent the
* Take care to the overflow gasoline impurities getting into fuel system.
during the disassembly. * After the throttle body is removed, use adhesive
* Wipe up the overflow gasoline tape to seal the cylinder intake hole to prevent
* Keep the area you work in is the dust from getting into the cylinder.
well-ventilated
燃油系统和节气门体
FUEL SYSTEM
FUEL TANK REMOVAL
Drain the gasoline in the fuel tank.
Remove the saddle and left and right side covers.
(Refer to page 6-1)
Remove the fuel tank left and right decoration covers
and .
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 wiring harness PVC jacket .
Disconnect the fuel pump coupler and fuel meter
coupler .
Remove the fuel tank mounting bolts .
Remove the high pressure fuel hose 7 .

Disconnect the fuel tank overflow hose 8 and
canister absorber hose 9 , remove the fuel
tank.
FUEL TANK INSTALLATION

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

Remove the left and right side covers and fuel tank left and
right side covers. (Refer to page 6-1)
Remove the fuel tank mounting bolts, lift the fuel tank,
disconnect the high pressure fuel hose from the fuel
pump.
Install the special tool to the fuel pump nozzle and fuel
hose.
11F14-023: Pressure inspection tool
Turn on the ignition switch, check the fuel pressure.
Fuel pressure: Approx 300kPa (3.0kgf/cm²)

A low compression pressure may indicate any of following
malfunctions:
* Fuel hose leakage
* Fuel strainer clogged
* Pressure adjuster
* Fuel pump
If the fuel pressure is higher than the limit may indicate any
of following malfunctions:
* Fuel pump
* Pressure adjuster A To fuel pump
B To high pressure
fuel hose
DANGER
Before removing the special tool, turn off the ignition

switch and release the pressure slowly.
FUEL PUMP INSPECTION

Turn on the ignition switch, check if the fuel pump has working
sound, If the working 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 pump seal ring 5 Fuel level gauge sensor
2 Dust-proof ring 6 High pressure fuel hose Item N•m kgf•m

3 Fuel pump assembly A Fuel pump mounting nut A 8-12 0.8-1.2
4 Fuel pump retainer plate
5-3
REMOVAL
Remove the fuel tank. (Refer to page 5-1)
Turn over the fuel tank, disconnect the fuel pump coupler
, remove the fuel pump mounting nut, take off the fuel
pump installation plate .
DANGER
* Far away from fire or spark.
* Wipe up the overflow gasoline.
* Keep the area you work in is well-ventilated
Lift the fuel pump assembly , loose the fuel lever

sensor fixing clamp , remove the fuel pump.
FUEL PUMP DISASSEMBLY

Disconnect fuel level sensor coupler, remove the fuel level
sensor .
Disconnect the fuel pump coupler .
Open the four fasteners, remove the fuel pump and fuel
strainer assembly .
CAUTION
5-4
Remove the fuel pump .
CAUTION
FUEL LEVEL GAUGE INSPECTION

FUEL STAINER INSPECTION AND CLEANING

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

REASSEMBLY
Reassemble the fuel pump in the reverse order of removal,
pay attention to the following point:
Reinstall the fuel pump and fuel strainer .
CAUTION
Replace the O-ring when installing the fuel pump.
Install the fuel pump to the fuel pump seat.
CAUTION
Replace the seal ring if deformation or damage is
found.
5-5
Fit the wires in the clamp orderly, connect the fuel pump
coupler .
Install the new fuel pump seal ring and dust-proof ring 7 .
Install the fuel level sensor 8 , connect the fuel level

sensor coupler.
As shown in the right photo, fit the fuel level sensor clip
in the fuel tank bracket 9 , then install the fuel pump
assembly.
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
Align the fuel pump boss 10 with the hole on the fuel
pump fixing plate hole.
5-6
THROTTLE BODY
THROTTLE BODY REMOVAL
Loose the clamp , remove the cover ,disconnect the
fuel injector coupler.
Loose the throttle lock nut, remove the throttle cable .
Remove the canister absorber hose .
Remove the high pressure fuel hose .
Disconnect the ISC valve coupler and 3 in 1 sensor

coupler 7 .
Loose the throttle intake hose clamp screw 8 .
5-7
Remove the intake hose mounting bolts, take off the

throttle-intake hose assembly 9 from the right side.
Remove the fuel injector cover 10 and intake hose

mounting bolt 11 .
Remove the throttle body mounting bolt, take off the
throttle body 12 from the throttle-intake hose assembly.
THROTTLE BODY CLEANING

DANGER
Some 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 cleaner solvent) to clean the

passageways, and then dry the cleaned surfaces with
compressed air.
CAUTION
Do not apply cleaning chemicals to the

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

Reassemble the throttle body in the reverse order of removal.
pay attention to the following points:
When installing the throttle body to the intake hose, use
new seal ring .
Before installing the fuel injector cover , first install the

intake hose mounting bolt to the throttle-intake hose
assembly.
Before installing the engine intake hose, replace

the O-ring and with new ones.
When installing the throttle-intake hose assembly,

make sure air filter exhaust hose is fitted in the
throttle body groove fully.
Install the throttle cable 7 .

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

Remove the mounting bolts, remove the fuel injector
assembly .
FUEL INJECTOR INSPECTION

Inspect the fuel injector and injector seat .If dust or dirt
exists, clean the injector, check the fuel hose and fuel tank.
Inspect the fuel injector rubber seat for damage or aging, if
any defects are found, replace the rubber seat.
FUEL INJECTOR REASSEMBLY

Reassemble the fuel injector in the reverse order of removal.
When install the fuel injector seat, make sure the injector
oil seal is fitted properly.
5-10
ISC VALVE REMOVAL

CAUTION
When only remove the ISC valve, remove throttle
body from the engine is not necessary.
Remove the ISC valve bracket screw and stopper plate

and holder .
Remove the ISC valve .
ISC VALVE INSPETCTION

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 4-34)
ISC VALVE INSTALLATION

Install the ISC valve in the reverse order of removal,
pay attention to the following points:
Apply a small quantity engine oil to the new O-ring .
Install the ISC valve retainer plate, holder and mounting

screw.
CAUTION
The holder installation position should be correct.
5-11
CHASSIS
CONTENTS
EXTERIOR PARTS 6-1

FRONT WHEEL 6-4
HANDLEBAR 6-9
FRONT ABSORBER 6-15 6
STEERING STEM 6-20
REAR WHEEL/REAR BRAKE 6-26
REAR SWING ARM 6-32
FRONT BRAKE 6-32
REAR COMBINED BRAKE SYSTEM 6-32
TIRE AND WHEEL 6-32
CHASSIS
EXTERIOR PARTS
REMOVAL
SADDLE
Open the saddle lock, take off the rear saddle .
Remove the front saddle mounting bolts, take off the front
saddle .
LEFT AND RIGHT SIDE COVERS

Remove the mounting screws, remove the left side cover
and right side cover .
FUEL TANK DECORATION COVER

Remove the fuel tank left and right decoration covers
and .
6-1
CHASSIS
TAIL COVER LEFT AND RIGHT DECORATTION COVERS

Open the left and right side cases, remove the tail cover
left and right decoration covers 7 and 8 .
TAIL RIGHT SMALL COVER

Remove the tail right small cover 9 .
LEFT AND RIGHT SIDE CASES

Remove the side case bolts, take off 11
the left and right side
cases 10 and 11 .
REAR CARRIER
Remove the rear carrier 12 .
6-2
CHASSIS
TAIL COVER
Remove the tail cover mounting screws.
Remove the clamp 13 , disconnect the rear turn

signal light and tail light coupler .
Disconnect the license light coupler , take off the tail

cover assembly .
Remove the tail light assembly and left and right

turn signal light assembly.
6-3
CHASSIS
REFT AND RIGHT SIDE CASE BRACES
Remove the side case mounting brace bolt, take

off the left and right side case braces and .
LOWER COWLING COVER

Remove the lower cowling mounting bolts, take off
the lower cowling by pulling it forward.
INSTALLATION
Install the exterior parts in the reverse order of
removal.
6-4
CHASSIS
FRONT WHEEL
CONSTRUCTION
Front axle Front wheel rim

Bush Front tire Item N•m kgf•m
Dust proof cover Brake disc A 18-28 1.8-2.8
Oil seal Bush B 36-52 3.6-5.2
Roller bearing A Brake disc bolt
Bush B Front axle nut
6-5
CHASSIS
REMOVAL AND DISASSEMBLY

Raise the front wheel off the ground and support the
motorcycle with a jack or a wooden block.
Remove the front axle nut .
Draw out the front axle shaft, take off the front wheel .
Remove the front axle left collar and dust proof cover .
CAUTION
Do not operate the front brake lever when
removing the front wheel.
Remove the front axle left collar and dust proof cover.
.
Take off the brake disc by removing the brake disc

bolts.
INSPECTION AND DISASSEMBLY

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

Using the special tools, check the axle shaft for runout
and replace it if the runout exceeds the limit.
09900-20606 : Dial gauge (1/100)
09900-20701 : Magnetic stand
09900-21304 : V-block (100mm)
Wheel axle runout:
WHEEL RIM
Make sure that the wheel runout checked as shown does
not exceed the service limit. An excessive runout is usually
due to worn or loosened wheel bearings and can be
reduced by replacing the bearings. If bearing replacement
fails to reduce the runout, replace the wheel.
Wheel rim runout:

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

take off the spacer.
09921-20240:Bearing remover tool
6-7
CHASSIS
REASSEMBLY
Reassemble and remount the front wheel in reverse
order of removal. Pay special attention to the following
points.
WHEEL BEARING
Apply super grease ”A” to bearings before reassembly.
99000-25010: Super grease "A"
Install the right wheel bearing first, then install the

spacer and left wheel bearing using the special
tool
09913H70210: Bearing installer
Right bearing Left bearing A LH a Clearance

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

09913-70210 : Bearing installing set
6-8
CHASSIS
BRAKE DISC
Make sure that the brake disc is clean and free of any
greasy matter. 1360 ”
Install the brake disc, apply the Thread Lock “1360"
to the thread portion of brake disc bolt, tighten to the
brake disc bolts to the specified torque.
99000-32130: Thread lock ”1360”
Front brake disc bolt: 18~28 N•m
FRONT AXLE SHAFT

Install the front wheel and front axle shaft, tighten
the front axle nut to the specified torque.
Front axle nut: 36-52 N•m
WARNING
After installing the front wheel, pump the brake lever

until the pistons push the pads correctly.
6-9
CHASSIS
HANDLEBAR
CONSTRUCTION
A
B C
B
D
1 Handlebar holder 14 Clutch lever

2 Washer 15 Clutch lever cover
ITEM N•m kgf•m
3 Cushion 16 Clutch lever holder
4 Upper bracket
A 12-20 1.2-2.0
17 Clutch adjuster
B 18-28 1.8-2.8
5 Bush 18 Clutch switch
C 40-60 4.0-6.0
6 Rearview mirror 19 Left handlebar switch
D 40-50 4.0-5.0
7 Upper bracket decoration cover 20 Right handlebar switch assembly
E 8-12 0.8-1.2
8 Handlebar balancer 21 Throttle grip
9 Handlebar A Handlebar clamp bolt
10 Throttle cable assembly I B Upper bracket clamp bolt
11 Throttle cable assembly II C Steering stem lock nut
12 Clutch cable D Handlebar holder mounting nut
13 Left grip E Clutch lever holder mounting bolt
6-10
CHASSIS

Remove the rearview mirror.
Remove the headlamp assembly mounting bolts.
Disconnect the headlamp coupler , take off the

headamp assemby .
Remove the headlamp case wire clamp ,

disconnect the headlamp case coupler.
Remove the headlamp case mounting bolts, take off the

headlamp case assembly .
Disconnect the front brake switch coupler .

Remove the front brake master cylinder mounting bolts,
take off the front brake master cylinder assembly .
6-11
CHASSIS
Loose the right handlebar switch assembly

mounting screws, disassemble the right handlebar
switch assembly, take off the throttle cable assembly
8 .
Disconnect the clutch switch coupler 9 , remove the

clutch lever holder mounting bolts, take off the clutch
lever assembly 10 .
Remove the handlebar holder bolt cap 11 .

Remove the steering stem decoration cover bolts,
take off the steering stem decoration cover 12 .
Remove the handlebar holder bolts, take off the

handlebar assembly 13 .
Remove the right handlebar balancer and throttle

lever from the handlebar assembly.
6-12
CHASSIS
Loose the left handlebar switch assembly mounting

screws, remove the left handlebar switch assembly
.
INSTALLATION
Install the handlebar in the reverse order of removal.
Apply a handle grip bond onto the handlebar before
installing the handlebar grip.
Bond Handlebar grip bond (General)
When installing the left handlebar switch assembly,

fit the left handlebar switch assembly screw head
to the handlebar hole .
When installing the handlebar, place the striped part of

handlebar on the holder concave.
Install the handlebar holder, tighten the handlebar holder

clamp bolt to the specified torque.
Handlebar holder clamp bolt: 12-20N•m
CAUTION
When installing the handlebar upper holder, set the

mark on the handlebar upper holder forward.
6-13
CHASSIS
Install the throttle cable to the throttle grip.

When installing the right handlebar switch assembly,
insert the screw head into the hole 7 of handlebar.
When installing the clutch lever, first tighten upper

clamp bolt, then tighten the lower clamp then tighten
the clamp bolt to the specified torque.
Clutch lever clamp bolt: 8~12 N•m
CAUTION
When installing the clutch lever, align the holder slit

8 to mark 9 of handlebar.
When installing the front brake master cylinder, first

tighten upper clamp bolt, then tighten the lower Master cylinder
clamp then tighten the clamp bolt to the specified
torque.
Up
Front brake master cylinder mounting bolt: 8~12 N•m
CAUTION Handlebar
Clearance
When installing the front brake master cylinder, the
slit of holder should be aligned with the mark on the
handlebar.
Install the headlamp case assembly, re-route the wiring

harness.(Refer to page 8-21)
Install the headlamp assembly.
Adjust the headlamp light.
6-14
CHASSIS
FRONT ABSORBER
CONSTRUCTION
1 Washer 5 Left front absorber

2 Dust-proof cover 6 ITEM N•m kgf•m
Reflector
A 35-55 3.5-5.5
3 Stopper ring A Cap bolt
B 20-26 2.0-2.6
4 Oil seal B Bolt
6-15
CHASSIS

Remove the front wheel. (Refer to page 6-6)
Remove the two bolts, take off the front brake caliper .
Remove the front fender mounting bolts and brake hose
clamp .
Remove the front fender mounting bolts, take off the front
fender .
Remove the upper and lower bracket clamp bolt caps.

Loose the upper and lower bracket clamp bolts, take off
the front absorber .
Remove the cap bolt and draw out the spacer,

washer and absorber spring.
Invert the absorber and stroke it several times to

remove the oil.
6-16
CHASSIS
Remove the damper rod bolt by using the special tools and
hexagon wrench.
11F14-010: Front absorber remover and installer
Remove the oil lock piece and damper rod with

rebound spring.
Separate the inner tube from the outer tube.
Remove the stopper ring.
Remove the oil seal with the special tool.
WARNING
The oil seal removed should be replaced with a new

one.
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
6-17
CHASSIS
INNER TUBE AND OUTER TUBE

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

* Cleaning: clean the parts with solvent and blow dry.
REMOUNTING
Remounting the front absorber in the reverse order of
removal, pay attention to the following points：
DAMPER ROD BOLT

Apply Thread Lock to the damper rod bolt and tighten the
bolt by using the hexagon wrench and special tools.
99000-32040: Thread lock “1303" Thread lock O-ring (copper)
11F14-010: Front absorber remover and installer
Damper rod bolt: 20~26 N•m
CAUTION
Do not reuse the removed O-ring.
OIL SEAL
Install the oil seal to the outer tube by using the
special tool as shown.
09940-50112: Absorber oil seal installer
CAUTION
Apply Super Grease lightly on the oil seal lip.
6-18
CHASSIS
ABSORBER OIL
Pour the specified fork oil into the inner tube.
Front absorber oil capacity (each leg): 317±2 ml
Absorber oil type: #34
REASSEMBLY
Reassemble the front absorber in the reverse order of
removal, pay attention to the following points：
Install the front absorbers, tighten the front absorber
upper and lower bracket clamp bolts to specified
Upper bracket clamp bolt:18-28 N•m

Lower bracket clamp bolt: 25-40 N•m
Install the front fender.
CAUTION
When installing the front fender, pay attention to the
installation direction of front brake hose.
Install the front brake caliper, tighten the mounting bolt to

the specified torque.
Front brake caliper mounting bolt: 18-28 N·m
Install the front wheel.(Refer to page 6-9)
6-19
CHASSIS
STEERING STEM
CONSTRUCTION
1 Handlebar holder 11 Lower steering inner race

2 Upper bracket 12 Lower ball ring ITEM N•m kgf•m
3 Spacer 13 Lower steering outer race A 12-20 1.2-2.0
4 Headlamp bracket 14 Lower oil seal B 40-60 4.0-6.0
5 Lower bracket A Handlebar clamp bolt C 18-28 1.8-2.8
6 Steering stem nut B Steering stem lock bolt D 25-40 2.5-4.0
E 40-50 4.0-5.0
7 Dust-proof cover C Upper bracket clamp bolt
8 Upper steering outer race D Lower bracket clamp bolt
9 Upper ball ring E Handlebar clamp bolt
10 Upper steering inner race
6-20
CHASSIS
REMOVAL
Remove the front wheel. (Refer to page 6-6)
Remove the handlebar. (Refer to page 6-11)
Remove the front absorber. (Refer to page 6-16)
Remove the meter .
Remove the steering stem lock bolt , take off the upper
bracket assembly .
Remove the headlamp brace .

Remove the wiring harness fix clamp .
Remove the front brake hose fix brace .
Remove the steering stem nut 7 and lower bracket.
09940-14911: Steering stem nut wrench
CAUTION
Hold the lower bracket with hand to prevent falling.
6-21
CHASSIS
Remove the upper dust-proof cover 8 and steering stem

outer race 9 .
Take off the upper and lower ball rings.
Remove the outer race fitted on the steering stem. This

can be down with a chisel.
Draw out the two inner races fitted to the top and
bottom ends of the head pipe with the special tool.
09941-54911: Bearing remover set

09941-74910: Steering bearing installer
INSPECTION
Inspect and check the removed parts for the following
abnormalities.
Race wear and brinelling.
Ball wear or damage.
Steering stem distortion.
6-22
CHASSIS
REASSEMBLY
Reassemble and install the steering in the reverse order of
removal and disassembly. Pay attention to the following
points:
INNER RACES
Press in the upper and lower inner races using the
special tool.
09924H84510: Bearing installer set
OUTER RACE
Apply the grease to the lower outer race.
Press in the lower outer race with the special tool.
09941-74911: Steering bearing installer
REASSEMBLY
Reassemble and remount the steering stem in the reverse
order of disassembly and removal. and also carry out the
following steps:
STEEL BALL
Apply grease to the upper and lower inner races when
installing the steel balls.
STEERING STEM NUT

Turn the steering stem bracket about five or six times to
the left and right so that the steel balls will be seated
properly.
Tighten the steering stem nut with the special tool.
09940-14911: Steering nut socket wrench
Steering stem head nut: 30-40 N•m
Turn back the steering stem nut by 1/4-1/2 turn with

Turn back 1/4-1/2 circle
the special tool.
09940-14911: Steering nut socket wrench
Steering stem nut: 4-6 N•m
CAUTION
The adjustment will vary from motorcycle to motorcycle.
6-23
CHASSIS
Install the lower bracket, tighten the steering stem lock nut
to the specified torque.
Steering stem lock nut:40-60 N•m
Install the meter.
Route the cables and wires.

Install the front absorbetr. (Refer to page 6-19)
Install the handlebar(Refer to page 6-13)
Install the front wheel.(Refer ti page 6-9)
After performing the adjustment and installing the

steering stem upper bracket, “rock” the front
wheel assembly forward and backward to ensure that
there is no play and that the procedure was
accomplished correctly. Finally 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.
6-24
CHASSIS
REAR WHEEL AND REAR BRAKE

CONSTRUCTION
1 Rear axle 14 Brake shoe

2 Chain adjuster 15 Rear wheel rim
3 Rear sprocket 16 ITEM N•m kgf•m
Rear brake panel
A 50-80 5.0-8.0
4 Right spacer 17 Spacer
B 8-12 0.8-1.2
5 Oil seal 18 Rear brake cam lever
C 30-37 3.0-3.7
6 Ball bearing 19 Brake cable nut
7 Rear sprocket drum retainer 20 Pin
8 Rear sprocket drum 21 Spring
9 Cushion 22 Rear brake rod
10 Roller bearing A Rear axle nut
11 Spacer B Nut
12 Rear tire C Rear sprocket nut
13 Rear brake cam
6-25
CHASSIS

Support the motorcyle with the main stand.
Loose the chain adjuster lock nut and rear wheel axe
nut .
Remove the rear brake adjuster nut , take off the rear
brake rod .
Draw out the cotter pin, remove the rear torque link nut ,
take off the rear torque link.
Remove the rear axle nut, draw off the rear axle, take off
the collar and rear wheel assembly.
Remove the rear brake drum from the rear wheel

assembly.
Remove the rear sprocket 7 from the rear wheel

assembly.
Remove the four bolts/nuts of mounting sprocket.

Remove the rear sprocket 8 from the rear sprokcet drum.
Remove the oil seal with the special tool 9 .
6-26
CHASSIS
Remove the bearing and bush from the rear sprocket

drum.
09921-20240: Bearing remover
Take off the cushions.
Remove the right and left side wheel bearings.
09921-20240: Bearing remover tool
REAR BRAKE
Remove the brake shoe.
Remove the brake cam lever nut and bolt.
6-27
CHASSIS
Remove the brake cam, washer, O-ring and cam lever.
INSPECTION
WHEEL BEARING
Inspect the wheel bearings for play by hand. Rotate the inner
race by hand to inspect whether abnormal noise occurs and it
rotates smoothly. Replace the bearing if there are any defects.
AXLE SHAFT
Using the special tools, check the axle shaft for
runout and replace it if the runout exceeds the limit.
Axle shaft runout: Limit: 0.25 mm
09900-20606: Dial gauge(1/100)

09900-21304: V-block
SPROCKET
Inspect the sprocket teeth for wear. If they are worn
as illustrated, replace the sprocket and drive chain.
Normal wear Excessive wear
REAR BREAK DRUM

Measure the brake drum I.D to determine the extent of
wear and, if the limit is exceeded by the wear noted,
replace the drum. The value of this limit is indicated inside
the drum.
Break drum I.D. limit：130.7 mm
6-28
CHASSIS
BRAKE SHOE
Check the brake shoes and decide whether is should
be replaced or not from the thickness of the brake shoe linings.
Brake shoe lining thickness limit: 1.5 mm
WARNING
Replace the brake shoes as a set, otherwise braking

performance will adversely affected.
CUSHION
Inspect the cushion for wear and damage.
REASSEMBLY
Reassemble and remount the rear wheel and rear
brake in the reverse order of disassembly and
removal, and also carry out the following steps.
WHEEL BEARING
Apply grease to the bearings before installing.
99000-25010: Super grease “A”
Install the rear wheel bearings by using the special tool.
CAUTION
Install the right bearing first.
REAR SPROCKET DRUM

Install the bearing with the special tool.
6-29
CHASSIS
Apply super grease to the rear sprocket drum.
99000-25010: Super grease ”A”
SPROCKET
Tighten the four nuts to specified torque, bend the
lock washer to the bolt.
Sprocket lock nut: 30~37 N•m
CAUTION
Do not reuse the removed nuts, replace the nuts with

new ones for safe riding.
BRAKE CAM
Apply grease to the brake cam.
BRAKE CAM LEVER

Install the brake cam lever and tighten the cam lever nut
with specified torque.
Cam lever bolt: 8~12 N•m
REAR WHEEL
Install the rear wheel, tighten the rear wheel axle nut to and
rear torque link nut to the specified torque.
Rear axle nut:50-80 N•m

Rear torque link nut: 10-16 N•m
6-30
CHASSIS
REAR ABSORBER / REAR SWING ARM

CONSTRUCTION
B
C
D
D
A
B
1 Rear swing arm shaft 10 Chain case

2 Bush 11 Washer
ITEM N·m kgf·m
3 Rear swing arm 12 Rear absorber A 50-80 5.0-8.0
4 Washer 13 Washer B 10-16 1.0-1.6
5 Bolt A Nut C 22-35 2.2-3.5
6 Washer B Nut D 22-35 2.2-3.5
7 Cotter pin C Nut
8 Rear torque link D Nut
9 Chain touch defense buffer
6-31
CHASSIS

Remove the rear wheel. (Refer to page 6-26)
Remove the side box and side box bracket.
Remove the rear brake rod spring .
Loose the exhaust pipe/muffler mounting bolt/nut,

move the muffler outward.
Remove the rear absorber bolt/nut, take off the rear

absorber .
Remove the rear swing arm pivot shaft nut , take

off the rear swing arm pivot shaft.
Remove the chain case mounting screws, take off

the chain case .
Remove the rear swing arm .
6-32
CHASSIS
Remove the fastener, take off the chain touch defense

buffer 7 .
Remove the cotter pin, take off the bolt and nut.
Remove the rear torque link 8 .
Remove the swing arm shaft bush 9 .
INSPECTION
REAR SWING ARM PIVOT SHAFT
Using a dial gauge, check the pivot shaft for runout and
replace it if the runout exceeds the limit.
Pivot shaft runout: Service limit: 0.6 mm
09900-20606: Dial gauge(1/100)

09900-21304: V-block
REASSEMBLY
Reassemble and remount the swing arm in the reverse
order of disassembly and removal, and also carry out
the following steps:
Install the rear swing arm shaft bush with the special tool.
09913-70210: Bearing installer set
6-33
CHASSIS
Installl the rear torque link, tighten the rear torque link nut
to the specified torque.
Rear torque link nut: 10~16 N•m
As shown in the right photo, pass the rear swing arm

into the drive chain, fit the chain case tongue into the
concave of rear swing arm.
Install the rear sprocket case.
Pass the rear swing arm pivot shaft from the left
side, tighten the rear swing arm pivot shaft nut to
the specified torque.
Rear swing arm pivot shaft nut: 50~80 N•m
Install the rear absorber lower bolt, tighten the bolt to

specified torque.
Rear absorber lower bolt: 22~35 N•m
Install the exhaust pipe/muffler.(Refer to page 3-6)

Install the side case braces and side case.
(Refer to page 6-4)
Install the rear wheel and side case.
6-34
CHASSIS
FRONT BRAKE
CONSTRUCTION
B
C
1 Front brake lever 12 Front brake caliper

ITEM N•m kgf • m
2 Piston 13 Bleed valve A 8-12 0.8-1.2
3 Front brake reservoir tank cap 14 Brake caliper brace B 20-25 2.0-2.5
4 Front brake master cylinder holder 15 Brake caliper piston C 18-28 1.8-2.8
5 Front brake master cylinder 16 Spring pad
6 Front brake light switch 17 Brake pads mounting pin
7 Rear brake hose 18 Brake pad
8 Front brake hose A Bolt
9 Brake hose brace B Bolt
10 Brake hose clamp C Bolt
11 Washer
6-35
CHASSIS
WARNING
The brake system of this motorcycle is filled with a Suzuki brake fluid. Do not use or mix
different types of fuid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will be caused.
Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the
brake fluid left over from the last servicing and stored for long periods.
When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
CAUTION
Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The
brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage
them severely.
Brake Pad Replacement

Loosen brake caliper mounting bolts .
Loosen brake pads mounting bolts .
Draw out the brake pad mount bolt , take off the brake
pads and replace them with new ones.
CAUTION
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
Reassemble the brake pads and brake caliper in the

reverse order of removal.
Tighten the brake caliper mounting bolts to the specified
torque.
Brake caliper mounting bolt: 18~28 N•m
CAUTION
Push the pistons all the way into brake caliper.
6-36
CHASSIS
BRAKE CALIPER DISASSEMBLY

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

Remove brake pads mounting pin , take off the brake
caliper pads and brake caplier bracket .
Remove the brake spring pad .
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.
6-37
CHASSIS
INSPECTION
BRAKE CALIPER CYLINDER
Inspect the brake caliper cylinder wall for nicks,
scratches and other damage. If any damage is found,
replace the caliper with a new one.
BRAKE CALIPER PISTON

Inspect the brake caliper piston surface for any scratches
and other damage. If any damage is found, replace the
pistons with a new set.
BRAKE CALIPER SLIDING PIN

Inspect the brake caliper sliding pins for wear and other
damage. If any damage is found, replace it with a new
one.
RUBBER PARTS
Inspect the rubber parts for cracks and damage. If
any defects are found, replace the affected parts.
PAD SPRING
Inspect the pad spring for damage and excessive bend. If

any defects are found, replace it with a new one.
BRAKE DISC
Visually inspect brake disc for cracks or damage, and
measure brake disc thickness with a micrometer.
09900-20205: Micrometer (0-25 mm)
Brake disc thickness limit: 3.5 mm
6-38
CHASSIS
Measure the brake disc surface runout with a dial gauge.
09900-20606: Dial gauge (1/100 mm)

Brake disc runout limit : 0.3 mm
INSTALLATION
Install the brake caliper in the reverse order of removal. Pay
WARNING
Wash the master cylinder components with fresh brake
fluid before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all internal parts
before inserting into the bore.
Apply super grease ”A” to sliding pin.

Connect the brake hose, tighten the union bolt and brake
caliper mounting bolt to the specified torque.
Brake hose union bolt: 20~25 N•m
Brake caliper mounting bolt:18~28 N•m
Refill the brake fluid after installing the brake caliper, and
perform the air bleeding. (Refer to page 2-13)
WARNING
Brake fluid, if it leaks, will interfere with safe running and

immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joint for
leakage before riding.
6-39
CHASSIS
MASTER CYLINDER
Drain the brake fluid in the brake fluid master cylinder.
Place a clean rag underneath the union bolt on the brake
caliper to catch any split brake fluid.
Remove the brake hose from the caliper by removing the union
bolt and catch the brake fluid in a suitable
receptacle.
Disconnect the front brake switch coupler .
Remove the master cylinder holder bolt, take off the mastery
cylinder assembly .
CAUTION
Immediately and completely wipe off any brake fluid
contacting any part of the motorcycle. The fluid reacts
and will damage them severely.
Remove the front brake lever and front brake switch .
Remove the dust-proof cover .

Remove the circlip 7 , piston 8 by using the special
tool.
09900-06108: Snap ring pliers
INSPECTION
Inspect the master cylinder bore for any scratches or other
damage.
Inspect the piston surface for scratches or other damage.
Inspect the primary cup, secondary cup and dust seal boot
for wear or damage.
6-40
CHASSIS
REASSEMBLY
Reassemble and install the master cylinder in the reverse
order of removal and disassembly. Pay attention to the
following points:
Wash the master cylinder components with fresh brake
fluid before reassembly.
Brake fluid specification: Haojue brake fluid DOT4
CAUTION
When washing the components, use the specified
brake fluid. Never use different types of fluid or Master cylinder
cleaning solvents such as gasoline, kerosine, etc. Mark
Do not wipe the brake fluid off after washing the
components.
Apply brake fluid to the cylinder bore and all internal Up
parts before inserting into the bore.
Handlebar
When installing the master cylinder onto the handlebar, align
the master cylinder holder's mating surface with the punch Clearance
mark on the handlebar.
Tighten the front brake master cylinder mounting blot to the
specified torque.
Front brake master cylinder

mounting bolt:20-25 N•m
Connect the brake hose, tighten the union bolt to the
specified torque.
Bleed air from brake system after installing the brake

caliper. (Refer to page 2-13)
6-41
CHASSIS
REAR BRAKE MASTER CYLINDER AND

REAR BRAKE RESERVOIR TANK
REMOVAL AND INSTALLATION
REMOVAL
Remove the rear brake master cylinder cap , seal plate
and diaphragm.
Connect the special tool to the front brake caliper rear
bleeder valve , loose the front brake caliper rear bleeder
valve , draw the brake fluid with the special tool.
11F14-035: Pneumatic liquid drawer
Remove the rear brake reservoir tank mounting bolt .

Place a cloth below the rear brake hose union bolt, remove
the rear brake hose union bolt and washer.
Remove the rear brake linkage rod cotter pin and washer,
draw out the pin .
Remove the rear brake master cylinder mounting bolt,

take off the rear brake master cylinder and reservoir tank
assembly .
Remove the front brake hose union bolt 7 , loose the

clamp 8 and brake hose guide clamp 9 .
Remove the brake hose clamp mounting bolt 10 and brake
hose mounting bolt 11 , loose the bundy hose joint nut 12 ,
take off the front brake hose I .
Loose the clamp and bundy hose joint nut 12 , take off the
bundy hose 13 .
Remove the bundy hose I mounting bolt .
6-43
CHASSIS
REAR COMBINED BRAKE SYSTEM

CONSTRUCTION
D
C
1 Rear brake reservoir tank cover 11 Circlip

ITEM N•m kgf•m
2 Rear brake reservoir tank cap 12 Dust-proof rubber sleeve
A 8-12 0.8-1.2
3 Rear brake reservoir tank diaphragm 13 Rear brake master cylinder rocker arm
B 20-25 2.0-2.5
4 Rear brake reservoir tank 14 Rear brake master cylinder connect hose
C 18-28 1.8-2.8
5 Rear brake hose 15 Combined linkage lever D 12-17 1.2-1.7
6 Bundy tube I 16 Combined linkage plate
7 Bundy tube II A Rear brake reservoir tank mounting bolt
8 Rear brake master cylinder B Brake hose union bolt
9 Spring set C Rear brake master cylinder mounting bolt
10 Piston D Bundy hose connection nut
6-42
CHASSIS
Loose the clamp, remove the bundy hose .
Remove the rear brake master cylinder from the

rear brake master cylinder/reservoir tank assembly.
REAR BRAKE MASTER CYLINDER DISASSEMBLY

Loose the lock nut , remove the rear brake master
cylinder connector .
Remove the rear brake master cylinder rubber cup .
Remove the rear brake master cylinder circle circlip .

Remove the rear brake master cylinder piston and
spring set .
09900-06108: Snap ring pliers (closing type)
Remove the rear brake master cylinder connection hose 7

and O-ring 8 .
6-44
CHASSIS
REASSEMBLY
Install the rear brake master cylinder in the reverser order of
removal. Pay attention to the following points:
When installing the rear brake master cylinder connect

rod, replace the O-ring with a new one.
Install the rear brake master cylinder circlip .
09900-06108: Snap ring pliers (closing type)
INSTALLATION
Install the rear brake system in the reverse order of removal.
Pay attention to the following ponits:
CBS INSTALLATION AND HOSE ROUTING, refer to
” Front brake hose routing” (Page 8-23)
Install the bundy hose, tighten the the bundy hose union
nut to the specified torque.
Bundy hose union nut: 12-17 N•m
Install the rear brake master cylinder and reservoir tank

assembly, tighten the mounting bolt to the specified
torque
Rear brake master cylinder mounting bolt: 8-12 N•m
Rear brake reservoir tank mounting bolt: 18-28 N•m
When installing the brake hose union bolt, set the

washer to both sides of brake hose, the coarse side
of washer should face brake fluid hose side.
6-45
将制动液管连接螺栓拧紧至规定扭矩。
CHASSIS
When installing the rear brake hose union bolt,

setting the b rake h ose u nion t o t he s topper as
shown.
Tighten the brake hose union bolt to the specified torque.
REFILL THE BRAKE FLUID
Refill the brake fluid in the brake fluid reservoir tank.
Attach the special tool hose to the brake caliper bleeder

valve, start the special tool to draw out the brake fluid in
brake system and fill the brake fluid in the brake fluid
reservoir tank until fluid flows out from the special tool
hose connected to brake caliper.
11F14-035: Pneumatic fluid drawer
Bleed air from the brake system after filling the brake fluid.
6-46
CHASSIS
TIRE AND WHEEL

TIRE REMOVAL
The most critical factor of tubeless tire is the seal
between the wheel rim and the tire bead.
CAUTION
For operating procedures, refer to the instructions
supplied by the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection,
mark the tire with a chalk to indicate the tire position relative to
the valve position.
Even though the tire is refitted to the original position after
repairing puncture, the tire may have to be balanced again
since such a repair can cause imbalance.
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. (Refer to page 6-7)
TIRE
Tire must be checked for the following points:
Nick and rupture on side wall

Tire tread depth
Tread separation
Abnormal, uneven wear on tread
Surface damage on bead
Localized tread wear due to skidding (Flat spot)
Abnormal condition of inner liner
6-47
CHASSIS
VALVE
Inspect the valve after the tire is removed from the rim.
Replace the valve with a new one if the seal A rubber is
peeling or has damage.
NOTE:
If the external appearance of the valve shows no
abnormal condition, removing of the valve is not
necessary.
If the seal has abnormal deformation, replace the valve
with a new one.
Any dust or rust around the valve hole B must be

cleaned off.
Then install the new valve in the rim.
NOTE:
To properly install the valve into the valve hole, apply a
special tire lubricant or neutral soapy liquid to the valve.
Be careful n ot t o d amage t he l ip C of v alve .
6-48
CHASSIS
TIRE INSTALLATION
Apply tire lubricant or neutral soapy to the tire bead.
CAUTION
Never use oil, grease or gasoline.
When installing the tire onto the wheel, observe thefollowing

points:
When installing the tire, the arrow on the side wall should
point to the direction of wheel rotation.
Align the chalk mark put on the tire at the time of removal
with the valve position.
For installation procedure of tire onto the wheel, follow the

instructions given by the tire changer manufacturer.
Bounce the tire several times while rotating. This makes
the tire bead expand outward to contact the wheel,
thereby facilitating air inflation.
Inflate the tire.
WARNING
Do not inflate the tire to more than 400 kPa (4.0

kgf/ cm² ). If inflated beyond this limit, the tire
can burst and possibly cause injury. Do not stand
directly over the tire while inflating.
In the case of preset pressure air inflator, pay
special care for the set pressure adjustment.
In this condition, check the “rim line” B cast on the tire

side walls. The line must be equidistant from the wheel rim
all 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.
When the bead has been fitted properly, adjust the
pressure to specification.
As necessary, adjust the tire balance.
WARNING
Do not run with a repaired tire at a high speed.
Cold inflation tire pressure
Solo riding Dual riding
Kpa kg/cm 2 kpa Kg/cm 2

Front 175 1.75 175 1.75
wheel
Rear 200 2.00 225 2.25
wheel
6-49
ELECTRICAL SYSTEM
CONTENTS
CAUTIONS IN SERVICING 7-1

STARTER SYSTEM 7-3
IGNITION SYSTEM 7-8
CHARGING SYSTEM 7-10
FUEL LEVER SENSOR 7-13
COMBINATION METER 7-14
LIGHTS 7-18
SWITCHES 7-21
BATTERY 7-23
7
ELECTRICAL
CAUTIONS IN SERVICING
CONNECTOR
”Click”
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 ”Click”
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.
Right Wrong
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

Wrong
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
Kill switch
Ignition switch
Starter button
Fuse 10A Fuse 20A
Starter motor
Clutch switch
TROUBLESHOOTING * Make sure that the fuses are not blown and the
battery is fully-charged before diagnosing.
Starter motor will not run
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
the starter relay connectors starer motor lead wire
(between O and Y/G ) when the No voltage * Faulty ignition switch
starter button is pushed. * Faulty front brake light switch
* Faulty rear brake light switch
* Faulty starter button
Voltage measured * Poor contact of connector
* Open circuit in wiring harness
Check the starter relay

(Refer to page 7-7) Incorrect * Faulty starter relay
*Open circuit in wiring harness

Starter motor runs, *Poor contact of connector
but does not start engine. *Faulty ECM.
*Faulty ignition coil
*Faulty generator
*Faulty starter clutch
7-3
ELECTRICAL
STARTER MOTOR DISASSEMBLY

Remove the starter motor.
Disassemble the start motor as shown.
1 O-ring 4 Starter motor body 7 Housing end(outside)

2 Housing end(inside) 5 Amature shaft
3 Oil seal 6 Carbon brush
STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If either carbon brush is defective, replace the brush with a new
one.
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.
7-4
ELECTRICAL
ARMATURE 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: Multi circuit tester
Tester knob indication: Continuity test
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).
BUSH
Inspect the bush for wear and damage.
If any defects are found, replace the housing end (outside).
STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of removal.
Apply little grease to the oil seal lip and bearing.
99000-25010 : Super grease “A”
Apply little moly paste to motor Amature shaft.
99000-25140: Moly paste
7-5
ELECTRICAL
Install the washer on the house end(inside).
Align the starter motor body protrusion A with the groove

of house end (outside) B during the assembly.
Install the house end(inside) to the starter motor body and

align the mark.
Apply little grease to the O-ring .
99000-25010 : Super grease “A”
Tighten the starter motor mounting bolt and

battery negative wire .
Tighten the starter motor wire mounting bolt .
7-6
ELECTRICAL
STARTER RELAY INSPECTION

Remove the right side cover.(Refer to page 6-1)
Disconect the starter relay coupler , remove the starter
relay wire securing bolt . 1
Remove the starter relay mounting bolt , take off the

starter relay .
Apply 12 volts to A and B terminals, inspect the continuity

between the terminals, positive and negative. If the starter
relay is in sound condition, continuity is found.
A B
Measure the relay coil resistance between the terminals

using the multi circuit tester. If the resistance is not
within the specified value, replace the starter relay with a
new one.
09900-25008: Multi circuit tester
Tester knob indication: Resistance (Ω)
Starter relay resistance: 3-6 Ω
7-7
ELECTRICAL
IGNITION SYSTEM
O/W O/W O/W 10A fuse
Ignition switch
O/G O
O/W O/W Kill switch
Trigger coil
Starter switch
Ignition coil
R
G/W
20A fuse
Generator
Bl/W
ECM Y/G
Starter relay
B/R
Spark plug
R
Battery
Bl/R
Bl/R W/R B/Y
Clutch switch
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 12.4V * Recharge the battery or
replace the battery
12.4V
Check the ECM coupler Looseness

for poor contact * Poor contact of couplers
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
Incorrect * Faulty trigger coil
coil (Bl/W and G/W)
Correct
* Faulty ECM
* Faulty ignition coil
* Faulty high-voltage cord
7-8
ELECTRICAL
IGNITION COIL
Remove the spark plug cap .
Measure the ignition coil resistence with the

Tap
multi-circuit tester.
Test range: resistence Ω
kΩ
Primary: 3.15~4.26 Ω (tap-tap)

Secondary: 28.8~38.2 K Ω (tap - Plug cap)
Tap
TRIGGER COIL
Using the multi-circuit tester set, measure the coil
resistance between the lead wires.
Test range: resistence
Trigger coil resistance: 115-155 Ω
(Green/White-Blue/White)
Spark plug
(Refer to page 2-8)n
7-9
ELECTRICAL
CHARGING SYSTEM
DESCRIPTION
Ignition switch
Battery
Load
Regulator/rectifier
AC generator
TROUBLESHOOTING
Battery runs down quickly
Check accessories which

excessively waste electric power. Installed * Remove accessories
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
Inspect continuity of generator coils not conductive * F aulty generator coils or

disconnected lead wires.
Correct
Inspect generator no-load voltage incorrect * Faulty generator rotor

Correct
(To next page)
7-10
ELECTRICAL
Inspect regulator/rectifier incorrect * Faulty regulator/rectifier
Correct
Inspect wirings incorrect * Shorted circuit of wire.

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

* Faulty battery
* Poor contact of generator
lead wire coupler
INSPECTION
BATTERY LEAK CURRENT INSPECTION
Remove the left side cover.(Refer to page 6-1).
Turn off the ignition switch.
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 ( --- , 2mA) mA
CAUTION
Because the leak current might be large, turn the
tester to high range first when connecting an
ammeter.
Do not turn on the ignition switch when measuring
current.
GENERATOR COIL INSPECTION

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

Tes t scale: Resistance
Generator coil resistance: 0.5-1.3 Ω (B-B )
7-11
ELECTRICAL
CHARGING OUTPUT INSPECTION

Remove the left side cover.(Refer to page 6-1)
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 multi-circuit tester set. 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.
Battery
Teat scale: Voltage
Charging output
Standard: 14.0-15.0V at 5 000 r/min DC voltage
Tester
GENERATOR COIL INSPECTION

Disconnect the generator coupler.
Start engine and keep it running at 5,000 rpm.
Measure voltage between generator terminal and ground
by using the multi-circuit tester. If the reading is below
standard values, replace with3-31
a new 页） generator coil.
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:
100V-115V /5000 RPM
(When engine is cold)
REGULATOR/RECTIFIER INSPECTION
If the resistance checked is incorrect, replace the
regulator /rectifier with a new one.
7-12
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 Resistence

A Full 5-9Ω A
B Empty 98-102Ω
B
TOOL 09900-25008: Multi-circuit tester set
Ω
Tester knob indication: x 1Ω range
CAUTION
When inspecting the gauge resistance, be sure to
disconnect the battery lead wire, or a multi-circuit 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 5-9 ohms.
If either one or both indications are abnormal, replace the fuel
level indicator with a new one. B/W R
Y/B
Resistance 5-9 Ω 98-102 Ω
Float position F E B/W
7-13
ELECTRICAL
COMBINATION METER
Combination Meter System Description
This combination meter mainly consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
The LCD indicates speedometer, tachometer, ODO / Trip A/ Trip B / Clock / GP indicator / 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 indicator light） 8 LCD (Trip A, Trip B) ）

2 LED (Netrual indicator light） 9 LCD (Tachometer)
3 LCD (Gear position indicator light） 10 ADJ button
4 LED (High beam indicator light) 11 LCD (Oil change indicator light）
5 LED (Right turn signal indicator light） 12 LCD (Low battery voltage indicator light）
6 Speedometer 13 LCD(Malfunction indication light)
7 LCD (Fuel level indicator） 14 SEL button

Remove the steering stem decoration cover.
Remove the meter mounting screw, take off the meter
(speedometer) .
7-14
ELECTRICAL

Loose the clamp and wiring harness fix clamp .
Remove the fuel tank filler cap ,remove the

meter(fuel gauge)mounting screws, take off the
meter(Fuel gauge) .
Disassemble the meter assembly as shown.

CAUTION
Do not disassemble the meter unit 7 and 12 .
6 Speedometer shell 7 Speedometer body 8 Seal ring 9 Speedometer bottom case

10 Fuel meter shell 11 Fuel gauge case 12 Fuel meter panel 13 Fuel meter bottom case
7-15
ELECTRICAL
INSPECTION
After turning on the ignition switch, perform operation to each switches, inspect the LED lights
(neutral indication light, Hi and low beam indication light and turn signal light indication light and self-
dignosis of meter.
If any defect is found, replace the meter.
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

The fuel level indicator displays 5 portions, when 5 portions
are solid when means the fuel is full,when only 1 portion or
low fuel level indicator light blinks together, it means the
remaining fuel is about 2.1L, please add the fuel as soon as
possible.
CAUTION
When the fuel level indicator display portions come on

and go off one by one. it means fuel level sensor wire
open circuit or short circuit.
Turn on and off the ignition switch repeatedly,
accelerate or decelerate quickly, lean motorcycle,
or go uphill or downhill will lead to the change of fuel
level indicator which is normal.
7-16
ELECTRICAL
SPEEDOMETER AND ODOMETER

If the speedometer, ODO meter 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 side cover. (Refer to page 6-1)
Remove the engine sprocket cover.(Refer to page 3-3)
Disconnect the speedometer sensor coupler 1 .
Take off the speed sensor 2 .
Connect a 12v battery, a 10kΩ resistance and a mutil-cicuit
tester to the speed sensor as shown in the illustration.

Speed sensor
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 ODO, Trip A and Trip B . When the Trip
A/B 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.
7-17
ELECTRICAL
TAIL LIGHT/BRAKE LIGHT AND LICENSE LIGHT
Tail light/brake light: LED

License light bulb ：12V 5W
TAIL LIGHT/BRAKE LIGHT AND

LICENSE LIGHT REPLACMENT
Remove the tail cover assembly. (Refer to page 6-3)
Remove the tail light/brake light from tail cover assembly.
Remove the license light mounting screws , replace the

license light bulb.
Install the lights in the reverse order of removal.
7-19
ELECTRICAL
LIGHTS
HEADLIGHT AND POSITION LIGHT
HEADLAMP BULB : 12V 35W/35W

POSITION LIGHT BULB : 12V 5W
HEADLAMP
Remove the headlamp assembly.(Refer to page 6-11)
Replace the headlamp bulb and position light bulb.
Install the headlamp and position light in the reverse order

of removal.
HEADLAMP LIGHT BEAM ADJUSTMENT

Turn the adjuster screw , adjust the light beam vertically.
7-18
ELECTRICAL
FRONT AND REAR TURN SIGNAL LIGHTS
Turn signal light light bulb :12V 10W
FORNT TURN SIGNAL LIGHT

BULB REPLACEMENT
Remove the turn signal light case mounting screws 2
,replace the turn signal light bulb.
Install the lights in the reverse order of removal.
7-20
ELECTRICAL
SWITCHES INSPECTION
Inspect each switch for continuity with a tester. If any
abnormality is found, replace the respective switch
assemblies with new ones.

Tester knob indication: Continuity test
IGNITION SWITCH 1
R O B/W Bl/W
ON ○ ○
OFF ○ ○
LOCK ○ ○
KILL SWITCH 2
O/B O/W
○ ○
○ ○
LIGHTS SWITCH 3
Gr O Y/W
○ ○
○ ○ ○
STARTER SWITCH 4
B/R Y/G
○ ○
FRONT BRAKE LIGHT SWITCH 5

B B
OFF
ON ○ ○
7-21
ELECTRICAL
CLUTCH SWITCH
B/Y B/R
OFF
ON ○ ○
PASS SWITCH 7
Y O
PUSH ○ ○
DIMMER SWITCH 8
Y/W W Y
○ ○
○ ○
TURN SIGNAL LIGHT SWITCH 9

B Lbl Lg
○ ○
○ ○
HORN SWITCH 10
B/Bl B/W
○ ○
REAR BREAK LIGHT SWITCH 11
O W/B
OFF
ON ○ ○
GEAR POSITION INDICATION LIGHT SWITCH 12

Ground Bl W/Y R/B G/Bl Y/Bl Br/R
○ ○
Neutral
○ ○
Low
○ ○
2nd
○ ○
3rd
○ ○
4th
○ ○
Top
7-22
ELECTRICAL
BATTERY
MF BATTERY
SPECIFICATIONS
Type YTX7L-BS
Capacity 12V(6Ah)
Standard electrolyte S.G. 1.320 at 20OC
INITIAL CHARGING
Remove the aluminum tape sealing the battery
electrolyte filler holes.
注入孔
Remove the caps .
CAUTION
After filling the electrolyte completely, use the removed

cap 2 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. Electroyte
containers
WARNING
危险
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
7-23
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
Once install the caps to the battery; do not remove Fit the cap firmly
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
Do not remove the cap during charging.
Recharging time: 3A for 1 hour or 0.6A 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.
7-24
ELECTRICAL
SEALED BATTERY
START USING BATTERY
CAUTION
The battery is placed inside the left side cover of frame.
Remove the battery. (Refer to page 2-3)

Using the multi circuit tester, check the battery voltage. If the
voltage reading is less than 12.8 V, recharge the battery with a
battery charger.
INSPECTION
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, clean the battery terminals with sandpaper.
RECHARGING OPERATION (V)
13
Check the battery voltage. If the voltage reading is the less
5℃(41℉)
than 12.4 V(DC), recharge the battery as follows.
12.4 25℃(77℉)
12 40℃(104℉)
CAUTION
11
60℃(140℉)
For charging the battery, make sure to use the charger
specially designed for sealed battery. Charge the 0 2 3 4 5 6 (months)
battery in a well-ventilated area and keep away from Time
fire is forbidden.
Pay attention to the following points during the charging. (V)

Charging time
Stop charging
18
After recharging, wait for more than 30 minutes and check the 17
battery voltage with a mutil-circuit tester. 16
If the battery voltage is less than the 12.4V, recharge the 15
14
battery again. 13
If the battery voltage is still less than 12.4V, after 12
recharging, replace the battery with a new one.
When the motorcycle is not used for a long period, check 0 10 20 30 40 50 60
the battery every 1 month to prevent the battery discharge. Time (minutes)
Charge method: Current 0.6A, voltage 14.4V-14.8V, 5-8 hours.
7-25
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 8-1
SPECIAL TOOLS 8-7
TIGHTENING TORQUE 8-9
SERVICE DATA 8-11
WIRING HARNESS, CABLE AND HOSE ROUTING 8-21
INTAKE SYSTEM ASSEMBLY ILLUSTRATION 8-25
FUEL SYSTEM INSTALLATION 8-26
EVAPORATION EMISSION SYSTEM INSTALLATION 8-27 8
BRAKE PEDAL ASSEMBLY 8-28
COWLING INSTALLATION 8-29
GEAR SHIFTING LEVER INSTALLATION 8-30
WIRING DIAGRAM 8-31

SERVICE INFORMATION
TROUBLESHOOTING
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION
(Refer to page 4-14 to -17)
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low

or is hard to start 1. Valve clearance out of adjustment Adjust.
2. Worn valve guides or poor seating 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. Starter motor cranks but too slowly. Consult "electrical
complaints"
Plug not sparking

1. Fouled spark plug. Clean or replace
2. Wet spark plug. Clean or dry
3. Defective CKP sensor Replace
4. Defective ECM Replace
5. Defective ignition coils Replace
6. Open or short in high-tension cords Replace
7. Open-circuited wiring connections Repair or replace
No fuel reaching the injector
1. Clogged fuel filter or fuel hose Clean or replace
2. Defective fuel pump. Replace
3. Defective fuel pressure adjuster Replace
4. Defective fuel injector Replace
5. Defective fuel pump relay Replace
7. Open-circuited wiring connections Repair or replace
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 IAP sensor Replace
8. Defective ET sensor Replace
9. Defective IAT sensor Replace
10.Clogged ISC valve air passage way Repair or replace
8-1
SERVICE INFORMATION

Engine idles poorly 1. Valve clearance out of adjustment Adjust.
2. Poor seating of valves Replace or repair.
3. Defective valve guides Replace.
4. Worn down camshaft Replace.
5. Too wide spark plug gaps Adjust or replace.
6. Defective ignition coils Replace.
7. Defective CKP sensor Replace.
8. Defective ECM Replace.
9. Defective TP sensor Replace.
10. Defective fuel pump Replace.
11.Imbalance throttle valve Adjust
12. Damaged or cracked vacuum hose Replace.
13. Damaged or clogged ISC valve Repair or replace.
14. ISC bad learning Reset learned value.
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 ET sensor Replace.
6.Defective IAT sensor Replace.
7. Damaged or cracked vacuum hose Replace.
8. Damaged or clogged ISC valve Repair or replace.
Fuel injector i mproperly o perating

1. Defective fuel injectors Replace.
2. No injection signal from ECM Repair or replace.
3. Open or short circuited wiring connection Repair or replace.
4. Defective battery or low battery voltage Charge or replace.
Control circuit or sensor improperly
operating
2.Defective fuel pressure adjuster Replace.
3.Defective TP sensor Replace.
4. Defective IAT sensor Replace.
6. Defective ET sensor Replace.
7. Defective fuel pump relay Replace.
8. Defective ISC valve Replace.
9. ISC bad learning Reset the learn value
Engine internal p arts i mproperly o perating

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

1. Too large valve clearance Adjust
2. Weakened or broken valve springs Replace
3. Worn rocker arm or cam surface Replace
4. Worn and burnt camshaft journal. Replace
Noise seems to come from piston
1. Worn down pistons or cylinder Replace
2. Carbon combustion chambers fouled with Clean
carbon
3. Worn piston pins or piston pin bore Replace
4. Worn piston rings or ring grooves Replace
Noise seems t o c ome f rom t iming c hain
1. Stretched chain Replace
2. Worn sprockets Replace
3. Tension adjuster not working Repair or replace
Noise seems t o c ome f rom c lutch
1. Worn splines of countershaft or hub Replace
2. Worn teeth of clutch plates Replace
3. Distorted clutch plates, driven and drive Replace
4. Worn clutch release bearing Replace
Noise seems t o c ome f rom c rankshaft

1. Rattling bearings due to wear Replace
2. Worn and burnt big-end bearings Replace
3. Worn and burnt journal bearings Replace
4. Too large thrust clearance Replace thrust bearing
Noise seems t o c ome f rom balancer shaft

1. Worn and burnt journal bearings Replace
Noise seems t o c ome f rom t ransmission
1. Worn or rubbing gears Replace
2. Worn splines Replace
3. Worn or rubbing primary gears Replace
4. Worn bearings Replace
8-3
SERVICE INFORMATION
Engine runs poorly Defective engine internal/electrical parts

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

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

1.Low fuel pressure Repair or replace
3. Defective IAT sensor Replace
5. Defective GP sensor Replace
6.Defective IAP sensor Replace
9.Defective ISC valve Replace
8-4
SERVICE INFORMATION
Engine lacks power Defective engine internal/electrical parts

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

1.Low fuel pressure Repair or replace
2.Defective TP sensor Replace
3.Defective IAT sensor Replace
5. Defective IAP sensor Replace
8.Defective ISC valve Replace
Engine overheats Defective engine internal parts

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

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

Dirty or heavy 1. Too much engine oil in the engine Drain excess oil
exhaust smoke 2. Worn piston rings or cylinders Replace
3. Worn valve guides Replace
4. Scored or scuffed cylinder walls Replace
5. Worn valves stems Replace
6. Defective stem oil seal Replace
Dragging clutch 1. Clutch release screw out of adjustment Adjust

2. Some clutch spring weakened while others Replace
are not
3. Distorted pressure plate or clutch plates Replace
Slipping clutch 1. Clutch release screw out of adjustment Adjust

2. Weakened clutch springs Replace
3. Distorted pressure plate or clutch plates Replace
Transmission will 1. Broken gearshift cam Replace

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

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

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

heavy or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Steering oscillation. 1. Loss of balance between right and left front Replace.
suspensions.
2. Distorted front fork. Repair or replace
3. Distorted front axle or crooked tire. Replace.
Wobbly front wheel. 1.Distorted wheel rim. Replace.
2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.
Front suspension 1. Weakened springs. Replace.

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

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

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

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

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

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

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

power system
2. Worn pads Replace.
3. Friction surfaces of pad are dirty oil or dust Clean disc/pads or replace.
4. Worn disc Replace.
5. Air in hydraulic system Bleed air.
6. Not enough brake fluid in the reservoir Replenish.
Brake squeaking 1. Carbon adhesion on pad surface
2. Tilted pad
3. Damaged wheel bearing

4. Loosen front wheel axle or rear wheel axle
5. Worn pads
6. Foreign material in brake fluid
7. Clogged return port of master cylinder
Excessive brake 1. Air in hydraulic system Bleed air.

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

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

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

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

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

become fouled 2. Worn piston or cylinder Replace.
too soon. 3. Excessive clearance of valve stems in valve Replace.
4. Worn stem oil seal Replace.
Spark plug 1. Too hot spark plug Replace with cold type plug.
electrodes 2. Overheated the engine Tune up.
overheat or burn. 3. Loose spark plug Retighten.
4. Too lean mixture Inspect FI system
Generator does 1. Open- or short-circuited lead wires, or loose Repair or replace or retighten.
not charge. lead connections
2. Short-circuited, grounded or open generator coil. Replace.
3. Short-circuited or punctured rectifier. Replace.
Generator charge, 1. Lead wires tend to get shorted or open- Repair or retighten.
but charging rate circuited or loosely connected at terminals
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.
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 1. Lead wire insulation frayed due to vibration, Repair or replace.
charging. resulting in intermittent short-circuiting
2. Internally shorted generator Replace.
3. Defective regulator/rectifier Replace.
Starter button is not 1.Batttery run down. Charge or replace.

effective. 2.Defective switch contacts. Replace.
3.Brusnes not seating properly on commutator Repair or replace.
in starter motor.
4.Defective start relay. Replace
5.Defective main fuse Replace
8-9
SERVICE INFORMATION
BATTERY
Battery runs 1. The charging method is not correct. Check the generator,
down quickly. regulator/rectifier and
circuitconnections and make
necessary adjustments to
obtain specified charging
operation.
2. Cell plates have lost much of their active Replace the battery and
material as result of over-charging. correct the charging system.
3.Internal short-circuit in the battery Replace
4.Poor contact of generator coupler Inspect and repair
5.Battery is too old. Replace
Generator 1.Damaged or defective regulator/rectifier Replace battery and rectifier.

overcharges 2. Internal short-circuit in the battery Replace battery.
3. Charging current is too large or charging Replace battery and reset
time is too long. the charging current and
charging time
“Sulfation”, acidic 1. Cracked battery case Replace.

white powdery 2. Battery has been left in a run-down Replace.
substance or spots condition for a long time
on surface of cell
plates.
8-10
SERVICE INFORMATION
SPECIAL TOOLS
09900-06107
09900-06108 09900-20103 09900-20202 09900-20203
Snap ring pliers Snap ring pliers Vernier calipers Micrometer Micrometer
(open type) (closing type) (1/50mm, 300mm) (1/100mm, 25~50mm) (1/100mm, 50~75mm)
09900-20205 09900-20508 09900-20605 09900-20606

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

09910-32812
Thickness gauge V-block (set) (100mm) Multi-circuit tester Crankshaft installer Piston pin puller
09913-70210
09913-50121 Bearing installer set 09916-10911 09916-21110 09920-13120
Oil seal remover (Φ10-75) Valve seat cutter set Valve cutter set Crankcase separator
09921-20240 09924H84510 09930-30104 09930-40113 09940-50112

Bearing remover tool Bearing installer set Slide shaft Sprocket holder Fork oil seal installer
09940-14911
09940-53311 Steering stem nut 09941-54911 09941-74910 11F14-001
Bearing installer socket wrench Bearing remover Steering bearing installer Rotor holder
8-11
SERVICE INFORMATION
11F14-006 11F14-009 11F14-019

National IV diagnosis 11F14-011 11F14-018
Rotor remover M33 device 4 claws nut remover Valve remover and installer T adjuster wrench
11F14-023 11F14-030 11F14-033 11F14-035 11F14-036

Pressure inspection tool Balancer holder 8 Test switch(6 pins) Pneumatic liuid drawer Gear stopper
11J14-001
Balancer shaft
nut wrench 19
8-12
SERVICE INFORMATION
TIGHTENING TORQUE
ENGINE
ITEM N•m Kg•m
Crankcase bolt 10-15 1.0-1.5
Oil filter cover 20-28 2.0-2.8
Crankshaft bearing pin retainer bolt 8-12 0.8-1.2
Engine sprocket bolt 10-15 1.0-1.5
Cam stopper bolt 10-15 1.0-1.5
Fixing cam pin bolt 10-15 1.0-1.5
Balancer shaft nut 25-35 2.5-3.5
Oil pump mounting screw 8-12 0.8-1.2
Oil drain bolt 25-30 2.5-3.0
Rocker arm shaft retainer plate screw 8-12 0.8-1.2
Generator stator bolt 5-8 0.5-0.8
Trigger coil bolt 3-6 0.3-0.6
Clutch lock nut 40-45 4.0-4.5
Oil filter rotor lock nut 40-45 4.0-5.0
Oil filter rotor cover screw 3-6 0.3-0.6
Clutch cover bolt 10-15 1.0-1.5
Cylinder head nut 25-35 2.5-3.5
Cam shaft sprocket bolt 10-15 1.0-1.5
Speedometer rotor bolt 18-28 1.8-2.8
Generator rotor bolt 45-50 4.5-5.0
Generator cover bolt 10-15 1.0-1.5
Spark plug 15-20 1.5-2.0
Upper 33-39 3.3-3.9
Front 33-39 3.3-3.9
Engine mounting bolt
Rear upper 50-60 5.0-6.0
Rear lower 50-60 5.0-6.0
Upper 22-33 2.2-3.3
Engine hanging mounting bolt
Front 22-33 2.2-3.3
8-13
SERVICE INFORMATION
CHASSIS
ITEM Kg • m N•m
Front axle nut 3.6-5.2 36-52
Left 1.8-2.8 18-28
Upper bracket bolt Right 1.8-2.8 18-28
Middle 4.0-6.0 40-60
Lower bracket bolt 2.5-4.0 25-40
Handlebar clamp bolt 1.2-2.0 12-20
Exhaust pipe bolt 1.1-1.5 11-15
Engine hanging bolt/nut(upper & front) 2.2-3.3 22-33
Front footrest mounting bolt 1.8-2.8 18-28
Rear shock absorber nut(upper & lower) 2.2-3.5 22-35
Rear torque link bolt (Front and rear) 1.0-1.6 10-16
Rear axle nut 5.0-8.0 50-80
Brake cam rocker arm bolt/nut 0.8-1.2 8-12
Rear sprocket nut 3.0-3.7 30-37
Rear swing arm shaft bolt/nut 5.0-8.0 50-80
Brake disc bolt 1.8-2.8 18-28
Brake caliper bleeder valve 0.7-1.0 7-10
Brake caliper mounting bolt 1.8-2.8 18-28
Brake hose mounting bolt 2.0-2.5 20-25
Master cylinder mounting bolt 0.8-1.2 8-12
TIGHTENING TORQUE CHART

Conventional or "4" marked bolt "7" marked bolt
Bolt Diameter(mm)
Kg • m N•m Kg • m N•m
4 0.1-0.2 1.0-2.0 0.15-0.3 1.5-3.0
5 0.2-0.4 2.0-4.0 0.3-0.6 3.0-6.0
6 0.4-0.7 4.0-7.0 0.8-1.2 8.0-12
8 1.0-1.6 10-16 1.8-2.8 18-28
10 2.2-3.5 22-35 4.0-6.0 40-60
12 3.5-5.5 35-55 7.0-10 70-100
14 5.0-8.0 50-80 11-16 110-160
16 8.0-13 80-130 18-25 170-250
18 13-19 130-190 20-28 200-280
8-14
SERVICE INFORMATION
SERVICE DATA
CYLINDER HEAD + VALVE Unit: mm
ITEM STANDARD LIMIT

Valve diam. IN. 29
EX. 25
Valve clearance (when cold) IN. 0.04-0.06
EX. 0.09-0.11
Valve guide 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 deflection IN. & EX. 0.35
Valve stem runout IN.& EX. 0.05
Valve head thickness IN. & EX. 0.5
Valve seat width IN. 1.0-1.2
EX. 1.1-1.3
Valve head radial runout IN.& EX. 0.03
Valve spring Inner 37.44

free length (IN.& EX.)
Outer 40.13
Cylinder head distortion 0.05

Cylinder head cover distortion 0.05
CAM + ROCKER Unit: mm

ITEM STANDARD LIMIT
Cam height IN. 31.336 31.036
EX. 31.241 30.941
Rocker arm I.D 12.000-12.018
Rocker arm shaft O.D 11.986-11.994
8-15
SERVICE INFORMATION
CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400kPa 800kPa
Piston to cylinder clearance 0.025-0.045 0.120
Cylinder bore 57.30-57.31 57.43
Piston diam. 57.270-57.275

57.145
Measure at 7 mm from the skirt end
Cylinder distortion 0.05
Piston ring free end gap 1st Approx 5.3 4.24
2nd Approx 6.2 4.96
Piston ring end gap 1st 0.10-0.25 0.50
2nd 0.15-0.30 0.50
Piston ring to groove clearance 1st 0.180
2nd 0.150
Piston ring groove width 1st 1.01-1.03
2nd 1.01-1.03
Oil 1.505-1.525
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 14.002-14.008 14.030
Piston pin O.D. 13.996-14.000 13.980
CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I. D. 14.01-14.017 14.040
Conrod big end side clearance 0.1-0.3 1.0
Conrod big end width 15.95-16.00
Conrod deflection 3.0
Crankshaft web to web width 55.0-55.05
Crankshaft runout 0.05
8-16
SERVICE INFORMATION
CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch cable play 4
Drive plate thickness 2.92-3.08 2.6
Drive plate claw width 15.75-15.85 15.0
Driven plate distortion 0.10
Clutch spring free length 38.1 36.2
TRANSMISSION + DRIVE CHAIN

ITEM STANDARD LIMIT
Primary reduction ratio 3.333(70/21)
Final reduction ratio 2.928(41/14)
Gear ratios Low 3.083(37/12)

2nd 1.941(33/17)
3rd 1.450(29/20)
4th 1.174(27/23)
Top 0.960(24/25)
Shift fork to groove clearance 0.10-0.25 mm 0.45 mm
Shift fork groove width 5.10-5.18 mm
Shift fork thickness 4.93-5.00 mm
Drive chain Type KMC 428H
Links 126
20 pitch length 259.08 mm
Drive chain slack 10-20 mm
INJECTOR, FUEL PUMP AND FUEL PRESSURE REGULATOR

ITEM STANDARD Note
Injector resistence 11.4-12.6Ω at 20℃
Fuel pressure regulator Approx 294kPa
operating set pressure
8-17
SERVICE INFORMATION
FI SENSORS
ITEM STANDARD NOTE
CKP sensor resistence 115-155 Ω
CKP sensor peak voltage 1.5V or higher When crankshaft turns
IAP sensor input voltage 4.5-5.5V

IAP sensor output voltage Approx 2.6V at idle
TP sensor input voltage 4.5-5.5V
TP sensor output voltage Idle 0.65-0.75 V
Open 3.8-4.0 V
ET sensor input voltage 4.5-5.5V
ET sensor resistence Approx 2.645KΩ at 20℃
IAT sensor input voltage 4.5-5.5V
IAT sensor resistence Approx 2.645KΩ at 20℃
TO sensor resistance 25.0-26.0KΩ
TO sensor voltage Normal 0.4-1.4V
Tilt 3.7-4.4V Tilt 65º
Injector voltage Battery voltage
OX sensor supply voltage 0.4V or less at idle
0.6V or higher at 5 000r/min
ISC valve resistence 20Ω, at 20℃
THROTTLE BODY
ITEM STANDARD
I.D. NO D24
Idle 1 500±100r/min
Throttle cable play 2.0-4.0mm
8-18
SERVICE INFORMATION
ELECTRICAL
ITEM SPECIFICATION NOTE
13° B. T. D. C. Below 1 500 r/min

Ignition timing
Type NGK:DR8EA
Spark plug
Gap NGK: 0.6-0.7 mm
Primary 3.15-4.26Ω Terminal-Terminal

Ignition coil resistance
Secondary 28.8-38.2 KΩ Plug cap-Terminal
Trigger 115-155 Ω G/W-Bl/W
Generator coil resistance
Charge 0.5-1.3 Ω B-B
Generator no-load voltage at 5 000r/min,110-115 V(AC)
Rectifier voltage at 5 000r/min,14.4-15.6 V
Model YTX7L-BS
Battery
Capacity 12V 6 Ah
Fuse specification 15 A
LIGHT
ITEM SPECIFICATION ITEM SPECIFICATION
HI 35 W Neutral indicator light LED

Headlamp
LO 35 W Meter light LED
Tail/Brake light 5/21 W Hi beam indicator light LED
Turn signal light 10 W Turn signal indicator light LED
Position light 5W License light 5W
TIRE
ITEM SPECIFICATION LIMIT
Cold inflation tire pressure FRONT 175 kPa(1.75 kgf/cm)
(Solo riding) REAR 200 kPa(2.00 kgf/cm)
Cold inflation tire pressure FRONT 175 kPa(1.75 kgf/cm)
(Dual riding)
REAR 225 kPa(2.25 kgf/cm)
Tire size FRONT 90/90-18 51P
REAR 100/90-16 59P
8-19
SERVICE INFORMATION
BRAKE + WHEEL
ITEM STANDARD NOTE
Rear brake pedal height 5-15
Rear brake pedal free travel 15-25
Brake disc thickness Front 3.8-4.2 3.5
Brake disc runout 0.30
Brake fluid type Special Haojue brake fluid
Brake drum I.D 130.7
Brake shoe thickness 1.5
Wheel rim runout Front 2.0
Rear 2.0
Wheel axle runout Front 0.25
Rear 0.25
SUSPENSION Unit: mm
ITEM STANDARD LIMIT
Front absorber stroke 115.6
Front absorber spring free length 363 355.7
Fork absorber oil type 34#
Front absorber oil capacity(each leg) 317±2 ml
Rear absorber spring adjustment The 2nd position
Rear swing arm pivot shaft runout 0.6
FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Fuel used should be unleaded
graded 89-97 octane.
Fuel tank capacity Include reserved 11.5 L
Reserved 2.1 L
Engine oil type and grade SAE 10W-40, API SG or higher
Engine oil Oil change 1 000 ml
capacity
Overhaul 1 200 ml
8-20
SERVICE INFORMATION
WIRING HARNESS, CABLE AND HOSE ROUTING

WIRING ROUTING High handlebar model left and right
switches wire clamping detail
Ignition switch wire Meter wire
Left handlebar switch wire Turn relay
Right handlebar switch wire

Clutch cable
Right handlebar Left handlebar switch wire
Front right turn signal light wire Front left turn (要求：绑后尾端朝内
switch wire
signal light wire Throttle cable
并剪尾，留3-5扣)
Front brake hose
Face the tip inward
Clamp the tip
after clamping
Clamp end faces rearward Meter(White mark) leaving 3-5knobs.
Right handlebar switch Clamp the tip
Left handlebar switch Low handlebar model left and right
Front right turn signal light after clamping switches wire clamping detail
Ignition switch leaving 3-5knobs.
Brake hose clamp

Wiring harness left branch
Brace
(Comes with frame) Clamp the tip
Front brake hose after clamping
leaving 3-5knobs. Clutch cable
Right handlebar switch wire Left handlebar switch wire
Throttle cable Clamp the tip
Front brake hose
Clamp the tip and face it inside
Oxygen sensor branch Wiring harness branch Wiring harness branch
and face it inside after clamping
Refer to Detail D after clamping
Clamp the tip Note: Clamp it near the leaving 3-5knobs.
leaving 3-5knobs.
Brace(Comes with frame) after clamping for area circle marked. handlebar.Face the clamp
Oxygen sensor leaving 3-5knobs. Detail A
tip downward after clamping Welded clamp
Fuel tank meter wire
ISC valve branch A Battery + terminal
Fuse case
branch A
A Battery + Welded clamp Fuel pump coupler

wire branch Fuel pump wire
Gear position A Battery + wire branch

Rectifier branch switch coupler (Note:Clamp at the
and coupler Speed sensor coupler upper steel wire and A Fuse box Clamp(comes with fuse box branch) Detail C
Battery - coupler face the tip rearward) Battery holder Battery brace hole
upper insert Fuel tank
Generator coupler A Speed sensor
Fuel pump test coupler Generator wire meter wire
3 in 1 sensor branch Gear position switch wire
Note: After test fit Battery - wire(to engine)
the test coupler in
the wire jacket
Clamp (comes with
wiring harness) Welded guide ring Welded brace
Refer to Detail A for routing Wiring harness Fuel tank meter wire
Frame hole
Fuel pump meter wire Wiring harness horn branch Fuel pump wire
Fuel pump wire Fuel pump wire
(Requirement: Fuel pump
wire is below the fuel tank
meter wire.
Clamp the tip and face it
downward after clamping
Neaten the coupler leaving 3-5knobs.
end wire by depressing
Detail D
Short wire
Long wire
Fuel tank meter coupler

Fuel pump coupler
Welded clamp Note: The side of

large diameter of
Fuel tank meter and washer should be
fuel pump joint branch contacted to the nut
Clamp (comes with Welded clamp
high voltage wire) Oxygen sensor wire
Upper hanging mounting plate
8-21
SERVICE INFORMATION
Tail light assembly

ECM branch
Guide ring (Note: Face the tip downward
Tail light assembly coupler Tail light wire
Wirng harness Anti-theft
Wiring harness after clamping leaving ECM branch Anti-theft
(Note: Clamp the tip
3-5knobs.)
alarm coupler alarm branch
and face it inside
after clamping
leaving 3-5knobs.)
Wiring harness
(Note:Clamp the tip
and face it inside
after clamping
leaving 3-5knobs.)
Wiring harness Test coupler

branch Note: Fit the jacket to the
A Fuse box branch
Wiring harness branch TO sensor coupler and branch fender vertical pin
TO sensor branch Below the frame tube
(Note: Face clamp tip
(Note: Face clamp tip
Wiring harness branch downward after clamping)
downward after clamping)
(Do not clamp battery + branch, Air filter front wire routing detail
face the clamp tip to inside of
Canister motorcycle)
absorber Fuel tank overflow hose
hose
Routing the wire
shown in the circle
area to inside of the
canister absorber hose
A Battery + branch
Welded steel wire
Rear brake swith A Battery + branch
and ET sensor Fuel tank overflow hose
joint branch
(Note: Fix it at the Frame tube
canister absorber
hose clamp. Face
the tip rearward
and cut the tip
leaving 3-5knobs)
Starter relay branch A Starter motor wire Welded guide ring

ET sensor coupler Battery - wire
A Starter relay terminal Anti-theft alarm assembly drawing
ET sensor branch
Fit the anti-theft alarm antenna (blue)
Anti-theft alarm coupler below the alarm wire branch
Rear brake switch Wiring harness Note: Do not pinch wire here
branch(wire jacket) A Starter motor terminal (alarm branch)
ET sensor branch Antenna
Rear brake switch wire Paste the anti-theft alarm body
A Starter motor wire to the rear fender upper surface.
Do not contact anti-theft alarm
boby to left and right frame braces.
A Starter motor wire
Inside the PVC jacket: ET sensor branch(Blue mark)
Rear brake switch coupler Battery - wire
Detail B ET sensor branch
Align the left side of anti-theft alarm

with the outside of the reinforce
rid of rear fender as shown.
A Starter motor wire Battery - wire
Note: Avoid the tighten wire Anti-theft alarm + wire(Red) Align the front of anti-theft alarm
between the coupler and clamp. Place the bullet head terminal as shown. with the boss edge of band of the
Make sure the distance is more tool bag of rear fender as shown.
than 10mm,face the clamp tip
upward leaving 5-10mm.
CBS MODEL HORN BRANCH WIRING ROUTING
Rear left turn signal light Horn branch

Rear right turn signal light Route in the front of clamp bend shape.
Couple with Tail light Couple with license light Do not pass it inside the clamp.
wiring harness (Note:Cut the tip
after clamping
leaving 3-5knobs.)
Tail light wiring routing
A Routing location Control item Requirement
The clearance
Battery + terminal between the
1 Starter relay terminal and Above 8mm
Starter motor other metal
terminal parts. Horn branch
Battery + terminal Burr and sharp edge are not allowed. Note: Do not contact
2 to fuse the branch to the horn.
Do not route the wiring harness at the
movable position.
Face the clamp head
Battery + terminal Routing area
forward and clamp tip Short wire Long wire
3 to starter relay Clamp must be used for fixing the wire to right side.
at the specified position.
Starter relay to Do not contact the wire to other parts.
4 starter motor
Generator trigger Fit the male and female terminal

Coupling
5 coil
method as per the wire color. Install the
jacket properly after coupling. 8-22
SERVICE INFORMATION
CABLE ROUTING
Brake hose A-A

A
Throttle cable assembly 右组合开关线束Right switch wire
Throttle cable assembly I Left handlebar switch wire
Throttle cable assembly II Clutch cable assembly Throttle cable assembly

A Clutch cable assembly
Left handlebar switch wire
Throttle cable assembly
Front brake hose
Front brake hose
Cable left guide ring Clamp
Right guide ring Clutch cable assembly
Throttle cable
Front brake hose
Note: When bumper is assembled, pass the

clutch cable should be in front of bumper.
Brake hose
Right guide ring

Left guide ring Throttle cable
Clutch cable Front brake hose
I Detail Welded guide ring

II Detail
Guide ring Throttle cable
Clutch cable Welded guide ring
Flanged bolt Throttle cable
Throttle cable I
Welded guide ring Throttle cable II

Clutch cable
B
A
Clutch cable
Welded guide ring

Clutch cable
II Detail Clutch cable brace

Throttle cable II Clutch cable assembly Torque:4-5N·m
The gap between the adjuster
Throttle cable I Torque:4-5N·m nut and lock nut should be less
than a pitch.
I Detail
Front brake hose
Clutch cable assembly
Right guide ring

Left guide ring
Cross screw
A B Cross screw
Throttle cable I
Throttle cable II
Clutch cable assembly
8-23
SERVICE INFORMATION
BRAKE HOSE ROUTING

A Hexagon flanged bolt
After the brake hose union has

contacted the stopper, tighten
the union bolt. Right handlebar switch wire
Front brake hose I

Brake hose clamp
Front brake hose II

Brake hose clamp
Throttle cable
Front brake hose II Hexagon flanged bolt

Front brake hose I Hexagon flanged bolt
Wiring harness
Headlamp bracket C
E
G F Bundy hose
Bundy hose I
Front brake hose

Pass the front brake hose
After the brake hose union
neck has been fitted in the J F
between the headlamp caliper, tighten the union bolt.
brace and rear case.
D Pin G
Flat washer(Back) Bundy hose I
Cotter pin(Back)
Wiring harness Bundy hose Saddle cable clamp
Flat washer
Cotter pin Front brake fluid

reservoir tank Nonmetal washer
Washer
H J Union bolt
Cotter pin
CBS linkage rod Washer
Cotter pin E
Cotter pin(Back) The clamp tip leaves
3-6mm and cut others.
Flat washer(Back) the clamp installation
CBS linkage rod direction as shown. B
Throttle cable assembly
Pin Clamp
Bundy hose I Flanged bolt
Clamp
A
H
Front brake hose I
Rear brake fluid
reservoir tank
Flanged bolt
Flanged bolt Bundy hose
Rear brake hose Front brake hose II
Union bolt Brake hose guide clamp Flanged bolt
Nonmetal washer Nonmetal washer

Flanged bolt D
Rear brake fluid The fixing clamp
master cylinder C Union bolt (Fit the clamp in
the center of hose
boot)
Nonmetal washer
8-24
SERVICE INFORMATION
INTAKE SYSTEM ASSEMBLY ILLUSTRATION
Exhaust hose clamp assembly requirement:

1.Exhaust hose clamp head faces upward and screw head faces to left side.
2.Torque range: 0.8-1.5N·m; 1 2 5 6
3.After clamp screw is tighten,
minimum clearance 1mm.(Measure from the screw center)
The clamp handle The clamp handle

I faces rearward 3
faces downward The white mark faces upward
3 4
I (explosive drawing)
12
11
The slit faces the right lower side of motorcycle.
8 7 9 10
7
1 Air filter assembly 7 O-ring

2 Hexagon flanged bolt 8 Insulation plate
3 Clamp 9 Hexagon flanged bolt
4 Breather hose 10 Intake hose assembly
5 Hexagon flanged bolt 11 Throttle body
6 Shoulder bolt 12 Hexagon flanged bolt
8-25
SERVICE INFORMATION
FUEL SYSTEM INSTALLATION

Insert the Item2 end with white mark to item4
Welded guide ring

A
Pass the item11 through the

Battery brace guide ring guide ring on the battery brace
Frame welded guide ring
The white mark of Item11

should be leveled with frame
guide ring(less than ±5mm)
Cushion edge to
fuel tank edge
B Cushion edge to
TO valve brace
Pass the item 7 below the Item 2 .

5-10mm
Fuel tank symmetrical center line

The white mark on the Item 7
should be vertical to fuel tank
symmetrical center line .
1 Fuel tank assembly 8 Canister clamp
2 Fuel tank to TO valve hose 9 Cushion
3 Clamp 10 Clamp
4 Fuel tank TO valve 11 Fuel tank overflow hose II
5 Fuel tank to TO valve sleeve 12 Hose connector Cushion edge level to this edge
6 TO valve to canister hose 13 Cushion

7 Fuel tank overflow hose I
Cushion edge to fuel tank edge
8-26
SERVICE INFORMATION
EVAPORATION EMISSION SYSTEM INSTALLATION

1 2 3 4 5 6 7 8 9 10
Fit the item 5

in the guide clamp.
11 12
View A Detail
Pass the water drain hose through the

Pass the breather hose The assembly mark guide hole and guide ring
through the frame faces downward.
1 Clamp 7 Canister absorber hose
2 Canister assembly 8 Clamp
3 Clamp 9 Clamp
4 Canister breather hose 10 Canister water drain hose
5 Absorber hose 11 Canister bracket
6 Absorber one way valve assembly 12 Hexagon flanged bolt
8-27
l
da n
Hook faces inside pe o
Spring installation directioin is as shown Frame ke diti
Bra e con
Rear swing arm Install it as shwon.
The hook faces outward, do not install assembly
assembly it revesrsely
fre
l
da
pe l
Hook faces inside Rear brake ke e
switch spring Bra e trav
fre
Front right
footrest assebmly
Rear brake
rod assembly
Hexagon nut
Spring assembly
Brake pedal adjuster bolt
SERVICE INFORMATION
Brake pedal assembly
8-28
Oil seal
installtion
direction Cotter pin
Flat washer Flat washer
Cotter pin
BRAKE PEDAL ASSEMBLY
Oil seal Oil seal

Frame brake
Circlip pedal shaft Circlip
Washer Washer
Apply grease evenly Apply grease evenly
10
8 4
COWLING INSTALLATION
7 5
8-29
6
3 2
SERVICE INFORMATION
1
1 Lower bracket 6 Headlamp case
2 Upper bracket 7 Headlamp case left cover
3 Headlamp brace 8 Front left turn signal ligth

4 Front right turn signal ligth 9 Headlamp upper cover
5 Headlamp case right cover 10 Headlamp
M6 Bolt Torque: 8-12N·m
Front left footrest Gear shifting rocker arm

rubber sleeve
When installing the clutch
release arm, align the
groove of clutch release
arm with the slit of clutch
release camshaft.
Gearshifting shaft
GEAR SHIFTING LEVER INSTALLATION
8-30
The thread length
exposed should be
Circlip same .
Flat washer
SERVICE INFORMATION
Apply grease
Gear shifting lever shaft
Torque: 40±5N·m
Front left footrest mounting brace

Thread lock 1271 or equivalent
(Wipe off engine oil, grease or foreign matter
etc before applying.)
WIRING DIAGRAM
Combination
Fuel sensor meter II Speed sensor Combination meter I
Right handlebar switch Ignitior Ignition coil Rectifier Rear brake switch
Spark plug
Lights switch Starter buttion
ON
Turn relay
OFF
B/W
Front brake
Y/B
W/B
switch
O
ON
B/W
Y/B
OFF
Bl/W
G/W
B/W
B/W
O/Y
W
B/W
W
B/W
W/B
O
B
B/W
B/R
Lbl
Gr
O
R
P
O
O
R
B
B
Br/R
B/W
G/Bl
Y/Bl
Y/W
W/Y
B/R
R
P
Y/G
B/Y
R/B
O
Lg
Gr
Gr
Bl
O
B
B/W
Gr
O
R
P
Br/R
G/Bl
B/W
W/Y
W/B
Y/W
Y/G
Y/Bl
R
P
R/B
B/R
B/Y
Lg
Gr
Gr
Bl
O
O
B
Front right
turn signal light Rear right turn
signal light
Lg Lg
B/W B/W Lg
B/W
Headlamp Lg Lg Tail light/brake light

W W W/B W/B
B/W B/W B/W B/W
Y Y
Gr Gr Gr
B/W B B
Gr Gr
B/W
Position light License light
B/W B/W
Front left turn

B B B/W
B 8
signal light Rear left turn
signal light
R
O/Y
O
R
B/W
Y/G
Bl/W
B/W
O
Lg
O
R
B
Bl/W
G/W
O/Y
B
B
O
R
Anti-theft
Y/W
B/W
B/Bl
B/Bl
B/Y
B/W
Lbl
Lock
Lg
alarm coupler
W
Y
OFF
R
Bl/W
ON
Br/R
G/Bl
G/W
W/Y
Y/Bl Starter relay

R/B
Bl
B
B
B/W
B/Bl
Y/W
B/Y
Lbl
Lg
W
Ignition swtich
Y
Br/R
G/Bl
W/Y
Y/Bl
R/B
Starter motor
Bl
OFF
Clutch switch ON Battery
Horn
Engine ground
Generator
Y/W
Dimmer switch Pass switch Horn button Turn signal

light switch
Left handlebar switch
Gear position switch
8-31

Haojue TR 150 en Ingles

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Haojue TR 150 en Ingles

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TR150ES

HAOJUE HOLDING CO.,LTD.

Improper repair may result in injury to the

Inexperienced mechanics or mechanics without

HAOJUE HOLDING CO.,LTD

COMPONENT PARTS AND WORK TO BE DONE

EX: Front wheel

1 Front wheel axle

ITEM N•m Kgf•m

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply oil. Use engine oil unless

Apply or use the brake fluid

Apply Moly paste

Apply THREAD LOCK “1342"

Apply THREAD LOCK “1303" The data of maintenance

Apply THREAD LOCK “1360"

Dbr Dark brown R Red

Dg Dark green V Violet

1. G (Base color) 3. G (Base Color)

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 CHART

Exhaust pipe bolts and Inspect Inspect 2-5

Brake Inspect Inspect

MAINTENANCE AND TUNE-UP PROCEDURES

First confirm the ignition switch is off.

Remove the battery brace .

Install the battery in the reverse order of the disassembly.

Clean the air cleaner in the following manner.

Remove the right small cover .

Remove the air cleaner cover .

Remove the air cleaner .

The air cleaner element is made by oiled paper, do not clean

Remove the fireproof plate .

Wipe up the dust on the inner wall of air cleaner case.

Reinstall the air cleaner in the reverse order of removal.

EXHAUST PIPE BOLTS

Tighten the exhaust pipe bolt to the specified torque.

Exhaust pipe bolt: 11-15 N•m

CYLINDER HEAD NUTS

When the engine is cold, tighten the engine cylinder head

Excessive valve clearance results in valve noise and

Remove the fuel tank mounting bolt .

Remove the intake and exhaust valve inspection caps 10 .

Rotate the generator rotor counter clockwise until the T line

09900-20803: Thickness gauge

Valve clearance specification

If the valve clearances is out of specification, bring it

09900-20803: Thickness gauge

Install the removed parts in the reverse order of

Spark plug gap A :0.6-0.7 mm

09900-20803: thickness gauge

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

Required amount of engine oil:

Tighten the filler gauge.

OIL SUMP FILTER

Drain the engine oil.

ENGINE OIL CENTRIFUGAL FILTER

Clean every 18 months or 12 000 km

Remove the clutch cover. (Refer to page 3-21)