DAELIM A-FOUR - Service Manual Download

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1-21

SERVICE INFORMATION

WINKER REALY, ASS’Y

WIRE HARNESS CLIP

SEAT LOCK CABLE

COMB. & LOCK SW.

HEAD LIGHT ASS’Y

FR. BRAKE HOSE

RR. BRAKE CABLE

THROTTLE CABLE

HORN COMP.

PILOT BOX CORD COUPLER

STARTER REALY, ASS’Y

AUTO BY STARTER COUPLER

SPEEDOMETER ASS,Y

LIGHTING START SW. CORD

ACG. CORD COUPLER

LIGHTING START SW.

FR. WINKER CORD

FR. BRAKE HOSE

SPEEDOMETER CABLE

HEAD LIGHT COUPLER

WINKER REALY, ASS’Y

RESISTOR

HEAD LIGHT ASS’Y

FR. BRAKE HOSE

SPEEDOMETER CABLE

RESISTOR
AUTO BY STARTER 5W 6.7

SPEEDOMETER CORD

PILOT BOX

WIRE HARNESS

RR. BRAKE CABLE

FR. WINKER CORD

CABLE CLIP

SPEEDO METER CORD

LIGHTING SW. CORD
PILOT BOX CORD
COUPLER

RR. STIOP SW. CORD

SECONDARY
AIR FILTER ASS’Y

IG COIL

HIGH TENSION CORD

OIL TANK

FUEL VENT TUBE

LICENSE LAMP

FUEL TANK

FUEL UNIT

FUEL VENT TUBE

FUEL STRAINER

SEAT LOCK CABLE

OIL STRAINER JOINT

OIL TUBE

THERMOSTAT SW. CORD

AUTO BY STARTER CORD
FUEL TUBE

THROTTLE CABLE
AIR VENT TUBE

OIL PUMP CABLE

OIL PASS CABLE

SIDE STAND SW.

BATTERY ASS,Y

THROTTLE CABLE

SEAT LOCK CABLE

RR. BRAKE CABLE

FR. BRAKE HOSE

FR. BRAKE CALIPER

THROTTLE CABLE JUNCTION

RR. BRAKE CABLE

SPARK PLUG CAP ASS’Y

FUEL AUTO COCK ASS’Y

CDI UNIT, ASS’Y

THERMOSTAT SW.

OIL LEVEL S/W

LIGHTING SW. CORD

RR. STOP SW. CORD

SPEEDO METER CORD

FR. WINKER CORD

WIRE FRONT WIRING DETAIL

Summary of Contents for A-FOUR -

Page 1: ......

Page 2: ...oting guide If you cannot find the cause of trouble refer to Section 18 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be reproduced without written permission of DAELIM Motor Co Ltd CONTENTS SERVICE INFORMATION INSPECTIONS ADJUSTMENTS EXTERNAL PARTS LUBRICATION SYSTEM FUEL SYS...

Page 3: ...ned and always put on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must performed in the place free of the open fire or electric spark 5 When more than two person are working always pay attention to other worker s action and alway have safety in mind 6 The skin exposed to used engine oil can be a major reason o...

Page 4: ...he bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air Apply oil to seal face during installation 6 Check necessary place and measure necessary data during installation When installing return to the state before removing 3 Store the parts of each s...

Page 5: ...rection in case of the single sided sealed ball bearing Install the open direction or double sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle 15 When blowing the ball bearing with compressed air after cleaning keep the race from rotating High speed rotation of the race may damage the bearing Prior to installation apply oil or grease to...

Page 6: ...all the oil seal so that the manufacturer marked surface directs outer surface direction not covered with oil Pay attention not to bend or damage the lip Apply the grease to the lip 20 Connect the tube until the tube fully inserted in the joint Install the clip if it is supplied Replace the tube having slacked end 23 Pay attention not to bend the cable excessively Transformed or damaged cable may ...

Page 7: ...ler in case of water proof coupler Recheck the condition of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After connecting the terminal apply the grease to the terminal When disconnecting the battery the minus terminal must be disconnected first Make sure that the tool such as spanner do not contact with the fra...

Page 8: ...e following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler Pay attention not to damage the vinyl cover of the coupler Check to see if there is bended terminal and secure it to avoid disc...

Page 9: ...ing T start broaden the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start from the frame replace it with the new one In case of the weld clamp do not clamp in the welded part When clamping the wire harness make sure that the harness is not contacted with the shaft or rotating...

Page 10: ...ness not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please read the manual care fully and understand the contents When testing the resistance of the tester the zero adjustment must be performed before testing Do not drop or throw the parts especially semiconduct...

Page 11: ...1 9 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION KMYSE7ADS5C003019 ...

Page 12: ...X OUTPUT MAX TORQUE PRIMARYSPEEDREDUCTIONRATIO SECONDARYSPEED REDUCTIONRATIO TRANSMISSION UNDER BONE 8 0m 30km h VELOCITY 1 800mm AIR COOLED STARTER MOTOR KICK 2 CYCLE 1 CYLINDER TRANSVERSE READVALVE PISTONVALVECOMBINATION 39 0X41 4mm 6 8 1 5 1PS 7 000rpm 0 42kgf m 7 500rpm 4 083 3 615 GEARLESS TRANSMISSION 0 76 2 41 DRY WEIGHT GROSSWEIGHT ITEM STANDARD LUBRICATION SYSTEM ENGINE OIL TANK CAPACITY ...

Page 13: ...E DIAMETER OUTSIDE DIAMETER ID MARK A ID MARK B NO ID MARK CYLINDER AND PISTON CLEARANCE PISTON PIN HOLE INSIDE DIAMETER PISTON PIN OUTSIDE DIAMETER PISTON AND PISTON PIN CLEARANCE PISTON RING GAP TOP SECOND RING MARK CONNECTING ROD SMALL END PORTION DIAMETER 6ℓ Urethane Foam PB11P ր16mm 1 1 4 Rotation 8 0mm 1 800 100rpm 4 65 38 2 6mm Auto Control Auto Control 81 5 BBDC 81 5 ABDC 56 5 BBDC 56 5 AB...

Page 14: ...YLINDER INSIDE DIAMETER MASTER PISTON OUTSIDE DIAMETER CALIPER CYLINDER INSIDE DIAMETER CALIPER PISTON OUTSIDE DIAMETER REAR BRAKE LEVER FREE PLAY DRUM INSIDE DIAMETER LINING THICKNESS SUSPENSION FRONT FRONT CUSHION FREE LENGTH REAR REAR CUSHION FREE LENGTH Automatic Centrifugal Continuously Variable Transmission 107 0 107 2mm 3 0mm 17 5mm 20 035 20 085mm 20 011 20 025mm 15 920 16 080mm 98 1mm 33 ...

Page 15: ...E EXCITE COIL PULSE GENERATOR IGNITION COIL RESISTANCE VALUES 20 PRIMARY COIL SECONDARY COIL PLUGCAPCONNECTION SECONDARY COIL PLUGCAPDISCONNECTION EXCITE COIL RESISTANCE VALUE 20 PLUSE GENERATOR RESISTANCE VALUE 20 CHARGING SYSTEM AC GENERATOR AC GENERATOR TYPE OUTPUT CHARGING COIL RESISTANCE VALUE 20 LIGHTING COIL RESISTANCE VALUE 20 REGULATOR RECTIFIER TYPE CONTROL VOLTAGE LAMP SIDE CHARGINGSIDE...

Page 16: ...OLT NUT TWIST TORQUE 0 4 f m 0 9 f m 1 2 f m 2 7 f m 4 0 f m TWIST PART FLY WHEEL NUT DRIVE FACE NUT CYLINDER HEAD BOLT SPARK PLUG DRIVEN FACE NUT CLUTCH OUTER NUT OIL LEVEL CHECK BOLT EXHAUST PIPE JOINT NUT MUFFLER BRACKET BOLT CRANK CASE BOLT NUMBER 1 1 4 1 1 1 1 2 2 6 TWIST TORQUE 4 0 f m 5 5 f m 1 0 f m 1 4 f m 5 5 f m 4 0 f m 1 3 f m 1 2 f m 3 3 f m 1 0 f m REFERENCE SCREW DIAMETER mm 10 12 6...

Page 17: ...RONT AXLE NUT REAR AXLE NUT SPEEDOMETER CABLE SETTING SCREW REAR BRAKE ARM BOLT FRONT BRAKE DISK BOLT REAR CUSHION UPPER BOLT REAR CUSHION LOWER BOLT ENGINE HANGER BRACKET NUT EXHAUST PIPE JOINT NUT MUFFLER BRACKET BOLT EXHAUST PIPE PROTECTOR SCREW NUMBER 1 1 1 1 1 1 2 2 2 2 1 2 1 1 4 1 1 1 1 3 1 1 2 3 2 4 TWIST TORQUE 7 0 f m 5 0 f m 1 0 f m 1 0 f m 0 3 f m 0 4 f m 1 2 f m 0 2 f m 3 5 f m 2 7 f m...

Page 18: ...700 07960 KM10000 0723 03900 07724 0050001 07725 0030000 0740 00001 0749 0010000 07746 0010200 07746 0040400 0755 00001 0751 00003 0740 00001 07746 0010400 07746 0040500 07749 0010000 0740 00001 07916 1870101 07916 KM10000 07946 GA70000 07746 0010300 07749 0010000 07GM 0010000 079GME 0010100 07967 GA70102 07JME GW20100 07725 0030000 0750 00006 USAGE CarburetorOilLevelMeasurement ChangeofDrivenFace...

Page 19: ... Cycle Oil Separation Lubrication Use SAE 80W 90 Multi Purpose Grease Molybdenum Grease FRAME PARTS APPLICATION AREAS FRONT WHEEL DUST SEAL EDGES FRONT PIVOT ARM BUSH FRICTION FACE FRONT PIVOT ARM SEAL EDGES REAR BRAKE CAM AXLE PART CAM PART WHOLE AREA OF REAR BRAKE CAM DUST SEAL REAR BRAKE ANCHOR PIN AXLE PART FRONT BRAKE OIL SEAL EDGES FRONT BRAKE CAM AXLE PART CAM PART WHOLE AREA OF FRONT BRAKE...

Page 20: ... made by mixing molybdenum grease with engine oil at a 1 1 ratio Indicates needed application of a multi purpose grease NLG 1 2 using a lithium soap base Example brand Shell Albania EP 2 Fire proof Shell Oil Indicates needed application of molybdenum grease containing over 3 of emulsified molybdenum NCG 1 2 Indicates needed application of molybdenum paste containing over 40 of emulsified molybdenu...

Page 21: ... HOSE SPEEDOMETER CABLE SPEEDOMETER ASS Y SPEEDOMETER CORD FR WINKER LIGHT CORD RR BRAKE CABLE RR STOP SW CORD WINKER SW CORD WINKER SW ASS Y FR WINKER ASS Y HORN COMP INNER COVER CLIP CLAMPER RESISTOR FR BRAKE HOSE FR BRAKE HOSE FR WINKER LIGHT CORD LIGHTING START SW CORD FR STOP SW LIGHTING START SW THROTTLE CABLE GREASE HEADLIGHT COUPLER SEAT LOCK CABLE COMB LOCK SW FRAME EARTH REGULATE RECTIFI...

Page 22: ...ENSE LAMP COUPLER FUEL UNIT COUPLER CDI UNIT THERMOSTAT SW STARTER REALY ASS Y IG COIL ACG CORD COUPLER SECODARY AIR FILTER ASS Y HIGH TENSION CORD SIDE STAND SW COUPLER SPARK PLUG CAP ASS Y BATTERY ASS Y SPEEDOMETER CABLE TAIL STOP RR WINKER R L COUPLER FR BRAKE HOSE OIL TUBE OIL PASS TUBE THROTTLE CABLE OIL PUMP CABLE COMB LOCK SW WIRE HARNESS HEAD LIGHT ASS Y WINKER REALY ASS Y WIRE HARNESS COU...

Page 23: ...BRAKE CABLE FR WINKER CORD CABLE CLIP SPEEDO METER CORD LIGHTING SW CORD PILOT BOX CORD COUPLER RR STIOP SW CORD SECONDARY AIR FILTER ASS Y IG COIL HIGH TENSION CORD OIL TANK FUEL VENT TUBE LICENSE LAMP FUEL TANK FUEL UNIT FUEL VENT TUBE FUEL STRAINER SEAT LOCK CABLE OIL STRAINER JOINT OIL TUBE THERMOSTAT SW CORD AUTO BY STARTER CORD FUEL TUBE THROTTLE CABLE AIR VENT TUBE OIL PUMP CABLE OIL PASS C...

Page 24: ...RD SEAT LOCK CABLE THROTTLE CABLE RR BRAKE CABLE SIDE STAND SW OIL PUMP CABLE THROTTLE CABLE OIL PASS TUBE FUEL TUBE OIL TUBE THERMOSTAT SW CORD AUTO BY STARTER CORD SEAT LOCK CABLE FUEL AUTO COCK ASS Y FUEL UNIT FUEL VENT TUBE THROTTLE CABLE JUNCTION IG COIL ACG CORD COUPLER STARTER REALY ASS Y THERMOSTAT SW OIL LEVEL S W CDI UNIT FUEL UNIT COUPLER LICENSE LAMP COUPLER LICENSE LAMP TAIL STOP RR W...

Page 25: ... CLOGGING 2 3 THROTTLE GRIP OPERATION 2 3 AIR CLEANER 2 4 SPARK PLUG 2 5 CYLINDERCOMPRESSIONPRESSURE 2 5 CARBURETOR IDLING 2 6 AIR SCREW ADJUSTMENT 2 6 BRAKE FLUID 2 6 BRAKE PAD SHOE 2 7 BRAKE SYSTEM 2 7 HEADLIGHT ADJUSTMENT 2 8 SIDE STAND 2 8 SUSPENSION 2 9 BOLTS NUTS FASTENERS 2 9 WHEELS TIRES 2 9 STEERING HEAD BEARING 2 10 BATTERY 2 10 ITEM STANDARD VALUE REFERANCE THROTTLE GRIP FREE PLAY 2 6mm...

Page 26: ... center NOTE 1 After the odometer reading exceeds 12 000km repeat maintenance service at intervals indicated in the table 2 After riding in areas with high humidity or pollution carry out maintenance service more frequently 3 Replace every 2 years Proper technology is required for this job FUEL LINE FUEL TUBE THROTTLE GRIP OPERATION OIL PUMP OIL LINE AIR CLEANER SPARK PLUG CARBON REMOVAL CARBURETO...

Page 27: ...able If the throttle grip does not operate properly check the throttle cable for aging damage or kinking Check the throttle grip free play FREE PLAY 2 6mm 2 3 INSPECTIONS ADJUSTMENTS Inner walls get contaiminated making visual i n s p e c t i o n difficult FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUTO COCK FUEL AUT...

Page 28: ...before applying oil Otherwise the oil will be diluted by the and the filtering ability of the filter will be much less effective Spread clean 80 90 gear oil on the element rubbing inthoroughly over the surface with both hands and then squeeze out any excess oil Using air filter oil when riding in extremely dusty conditions prevents premature engine wear due to dust dirt drawn into the engine Apply...

Page 29: ...ore using a wrench to tighten to the specified torque torque 14kgf m Do not overtighten the spark plug CYLINDERCOMPRESSIONPRESSURE Start and warm up the engine Remove the plug maintenance cover Stop engine and remove the spark plug cap and spark plug Install a compression gauge Open the throttle completely and crank the engine with the starter motor until the gauge reading rising The maximum readi...

Page 30: ...ve the brake fluid cover Check the oil level inside the front brake reservoir If the oil level is near the lower limit line remove the reservoir diaphragm and fill DOT 3 and DOT 4 brake fluid to the top limit line If the brake fluid reaches the lower limit line check the entire brake system for leaks Brake fluid will damage painted plastic or rubber parts Mixing incompatible fluids can impair brak...

Page 31: ...ately Check the brake rod for looseness or damage and replace it if necessary BRAKE LEVER FREE PLAY Check the free play after pulling the lever FRONT 10 20mm REAR 10 20mm 2 7 INSPECTIONS ADJUSTMENTS RED MARK MARK FREE PLAY BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE B...

Page 32: ...and see if it moves freely If the side stand does not move smoothly apply grease to the pivot area If the side stand moves too freely check the side stand spring Check the axial movement of the side stand Check the side stand ignition cut off switch Put the side stand up Start the engine Lower the side stand The engine should stop as you put the side stand down If there is a problem with the syste...

Page 33: ... the operating conditions Check the rear fork for oil leakage parts damage or looseness BOLTS NUTS FASTENERS Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value Check all pins clips hose clamps and cable stays WHEELS TIRES Check the tire pressure when the tires have been cooled off Check the tread the part making contact with the r...

Page 34: ...st the steering head bearing BATTERY Remove a tapping screw securing the battery cover from the floor panel Check if the terminal is loose If the terminal is loose check and clean the contacting surface and then tighten it Apply grease thinly after tightening If the terminal is rusted remove the battery pour warm water and clean with the wire brush FULL CHARGING VOLTAGE 13 0 13 2V LOW CHARGING VOL...

Page 35: ...ervice it immediately after the engine is stopped 3 SERVICE INFORMATION 3 1 MAINTENANCE PRECEDURE 3 2 LUGGAGE BOX 3 3 PLUG MAINTENANCE COVER CENTER COVER 3 3 REAR CARRIER 3 3 BODY COVER 3 3 TAILLIGHT BASE 3 4 FLOOR SIDE COVER 3 4 FLOOR PANEL 3 4 ENGINEHANGERSIDECOVER 3 5 FRONT COVER 3 5 FRONT FENDER 3 5 INNER COVER 3 5 FRONT UNDER COVER 3 6 MUFFLER 3 6 REAR FENDER 3 7 REAR WHEEL MUD GUARD 3 8 UNDE...

Page 36: ... OF FRAME COVERS This chart shows arrows connected in the order of disassembling covers LUGGAGE BOX PLUGMAINTENANCE COVER CENTER COVER REAR CARRIER BODY COVER TAILLIGHT BASE FLOORSIDECOVER FLOOR PANEL ENGINE HANGER SIDE COVER FRONT COVER FRONT FENDER INNER BOX FRONT UNDER COVER ...

Page 37: ...er of removal FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAINTENANCE COVER PLUG MAIN...

Page 38: ...e the floor side cover Remove the floor panel cap A and B Loosen the 4 washer bolts securing the floor panel Remove the floor panel from the connecting groove of the inner box by lifting the rear part of the panel slightly Draw the floor panel moving it to the right and left to remove it Install in the reverse order of removal WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT...

Page 39: ...int part of the front under cover and remove the inner box Install in the reverse order of removal SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCR...

Page 40: ...ffler and the EX pipe Install the 2 flange bolts on the rear wheel mud guard Tighten the muffler securing 2 flange bolts to install the R crankcase Tightening torque of the R crankcase TORQUE 3 3kgf m When installing the gasket replace it with the new one Check to see if there is any evacuation after installing the muffler FLANGE NUT CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP...

Page 41: ...lt securing the air cleaner Loosen the flange bolt securing the inlet pipe Remove the rear wheel mud guard Install in the reverse order of removal Never perform the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot UNDER COVER Remove the floor side cover 3 4 Remove the engine hanger side cover 3 5 Loosen the 2 R L setting screws securing the frame Rem...

Page 42: ...RICATION SYSTEM LUBRICATION POINTS THROTTLE GRIP STEERING BEARING WHEEL BEARING SPEEDOMETER GEAR BOX SIDE STAND PIVOT WHEEL BEARING THROTTLE SPEEDOMETER BRAKE HOSE GREASE GREASE GREASE GREASE GREASE GREASE OIL ...

Page 43: ...SHOOTING Overheating or engine clogging Faulty adjustment of oil pump insufficient amount pumped Bad quality of engine oil Engine oil not being injected or blocked bent strainer screen or oil tube Entering of air in oil tube system Faulty oil pump Engine oil not being supplied from oil tank Blocked oil tank cap air hole Blocked oil strainer screen Excess exhaust smoke accumulation of carbon on spa...

Page 44: ...4 2 LUBRICATION SYSTEM OIL SYSTEM DRAWING ...

Page 45: ...oil tube by cleaning around the oil pump If the air enters into the oil line it may cause faulty lubrication or engine sticking Always remove the air in the oil line after maintenance Pay attention not to damage the O ring when assembling the oil pump OILPUMPINSPECTION ADJUSTMENT Remove the oil pump Rotate the shaft and check for proper rotation Check the gear for wear damage and leak of each seal...

Page 46: ...tly When the oil pump lever is excessively opened Emitting of white exhaust gas or starting problems When the oil pump lever is insufficiently opened Clogging of engine If the oil pump cable stay bolt is removed apply the screw locking compound to the bolt thread OIL PUMP BLEEDING Air infiltration in the oil pass may cause the engine sticking Always remove the air in the oil pass after maintenance...

Page 47: ... connected In this state locate the oil pump in the level lower than the oil tank and drain the oil to bleed the air Install the oil pump shaft in the oil pump after completing the bleeding Install the oil pump in the crankcase OIL PASS TUBE INSPECTION Bend the oil pass tube in the U shape keep the two ends parallel with each other and fill the oil pass tube with the oil 4 5 LUBRICATION SYSTEM OIL...

Page 48: ...ed Connect the oil control cable Adjust the oil pump if the adjustment nut of the oil comtrol lever is loose ENGINE OIL LEVEL INSPECTION Check the engine oil level if the pilot lamp blinks when the main switch is turned on LOW OIL WARNING LIGHT BLINKING LEVEL 0 3 4 6 LUBRICATION SYSTEM CONTROL LEVER OIL PASS TUBE OIL WARNING LIGHT OIL WARNING LIGHT OIL WARNING LIGHT OIL WARNING LIGHT OIL WARNING L...

Page 49: ...ne component for any leak Remove the oil check bolt and check to see if the oil overflows from the oil check hole If only the small amount of oil overflows fill the recommended transmission oil through the oil filler hole gradually Oil level inspection must be performed in the flat ground with the vehicle being straight by raising the main stand RECOMMENDED OIL SAE 80W 90 Tighten the oil level che...

Page 50: ... Make sure that the oil tube is connected properly Drain the oil in the clean container Install the oil strainer after cleaning it 4 8 LUBRICATION SYSTEM OIL LEVEL SWITCH FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT OIL LEVEL SWI...

Page 51: ...MEMO ...

Page 52: ...FUEL SYSTEM 5 0 FUEL GAUGE FUEL TANK FUEL AUTO COCK STRAINER CARBURETOR ...

Page 53: ...period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits and idling may become unstable SPECIFICATIONS FUEL TANK CAPACITY 5 8ℓ RESERVE FUEL CAPACITY 1 7ℓ CARBURETOR TOOL FLOAT LEVEL GAUGE 5 1 5 FUEL SYSTEM 5 SERVICE INFORMATION 5 1 TROUBLESHOOTING 5 2 FUEL TANK 5 3 AIR CLEA...

Page 54: ...operly Air screw is adjusted improperly Compression pressure is low Air Fuel mixture is either too lean or rich Carburetor is blocked Mis firing occurs when driving at high speeds Ignition system is damaged Mixture is too lean Back firing Ignition system is damaged Mixture is too lean Insufficient power and high fuel consumption Air cleaner is blocked Ignition system is damaged Mixture is too rich...

Page 55: ...move the rear fender 3 7 Loosen the 2 flange bolts and remove the seat catch Loosen the 2 flange bolts and remove the fuel tank support stay Loosen the 2 flange bolts and remove the fuel tank INSTALLATION Install in the reverse order of removal Check for gasoline leakage Gasoline mark is on the fuel tank cap Check this mark when filling gasoline FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLAN...

Page 56: ... 3 3 Air cleaner 5 4 Wiring coupler of the auto by starter Oil pass tube Throttle valve set 2 flange bolts securing the inlet pipe Carburetor insulator Carburetor Install in the reverse order of removal Install the carburetor after aligning the throttle valve cutaway and the throttle stop screw Tighten the top set correctly so that it is not released CARBURETOR INSULATOR CARBURETOR INSULATOR CARBU...

Page 57: ...y starter set plate Remove the auto by starter Remove the auto by starter O ring Assemble in the reverse order of disassembly Install the auto by starter in the carburetor body after applying grease to the starter O ring and then tighten firmly with set plate piece FLOAT CHAMBER FLOAT JET DISASSEMBLY ASSEMBLY Loosen the 2 float chamber screws CHECK Float valves and seats for cracks or damage Float...

Page 58: ... adjustment is necessary Do not fasten it strongly otherwise the face of seat get damaged CARBURETOR INSPECTION Connect an ohmmeter to the auto bystarter wire connector terminals and measure the resistance If the resistance is greatly out of specification it indicates a faulty PTC in the auto bystarter Replace the auto bystarter RESISTANCE 4 0Ω 1Ω 20 C The auto by starter might be normal if the re...

Page 59: ...cuit to close too soon and starting will be difficult THROTTLE VALVE REMOVE Throttle valve Throttle cable Throttle valve spring Needle clip Seal cap Clip Jet needle ASSEMBLY Install the jet needle into the throttle valve and be sure to fixes the needle clip Route the throttle cable through the spring and compress the spring fully Attach the throttle cable end to the bottom of the throttle valve an...

Page 60: ...il damage the diaphragms or may force them off the aluminum link Disconnect the fuel line and place it in a clean container as shown Place a clean container under the fuel tube Connect the fuel auto valve vacuum tube to the vacuum pump and apply vacuum Be sure that the fuel flows out smoothly If the vacuum does not remain steady it indicates the diaphragm is incorrectly installed or damaged If the...

Page 61: ...t pipe Reed valve Install in the reverse order of removal Do not remove the reed valve and replace the assembly if necessary Keep the foreign material from entering into the engine by cleaning around the needle valve INSPECTION Check the reed valve for fatigue or damage and replace the reed valve assembly if necessary Check the reed valve seat for cracks damage and clearance from the reed and repl...

Page 62: ...ENGINE REMOVAL INSTALLATION 6 0 ...

Page 63: ...llowing works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 9 A C GENERATOR SECTION 13 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION SECTION 7 CYLINDER HEAD CYLINDER PISTON SECTION 8 CARBURETOR SECTION 5 OIL PUMP SECTION 4 Items to be worked after removing engine CRANKSHAFT CRANKSHAFT BEARING CRANK CASE BEARING TORQUE VALUES ENGINE HANGER BOLT ENGINE 5...

Page 64: ...l the clip in the oil tube Take precautions not to damage the engine when removing the engine from the chasis REMOVE Muffler 3 7 Rear wheel 11 3 Install in the reverse order of removal Pay attention not to damage wiring and cable and not to damage the threded part of bolts Arrange the cable tubes and wiring in the right positions BODY COVER CLIP BODY COVER CLIP BODY COVER CLIP BODY COVER CLIP BODY...

Page 65: ...E REMOVAL INSTALLATION Check the following after the engine is assembled Electric systems Adjust of the rear brake free play Inspection of the throttle cable operation Inspection of the oil pump cable operation ...

Page 66: ...FACE GUIDE PIN DRIVEN FACE RAMP PLATE WEIGHT ROLLER MOVABLE DRIVE FACE DRIVE FACE BOSS DRIVE FACE KICK STARTER SPINDLE KICK DRIVEN GEAR KICK STARTER RETURN SPRING KICK SPINDLE BUSH DRIVE BELT MOVABLE DRIVEN FACE SPRING SHOE SPRING CLUTCH SHOE DRIVE PLATE CLUTCH OUTER ...

Page 67: ... FACE BOSS OUTER DIAMETER 20 011 20 025mm 19 97mm DRIVE BELT WIDTH 17 5mm 16 50mm WEIGHT ROLLER OUTER DIAMETER 15 920 16 080mm 15 40mm CLUTCH OUTER AND INNER DIAMETER 107 0 107 2mm 107 50mm DRIVEN FACE SPRING PLAY 98 1mm 92 8mm DRIVEN FACE OUTER DIAMETER 33 965 33 985mm 33 94mm DRIVEN FACE INNER DIAMETER 34 000 34 025mm 34 06mm TROUBLESHOOTING Engine starts but motorcycle does not work Drive belt ...

Page 68: ...ver 7 2 Kick starter ratchet and the thrust washer while rotating the kick starter arm Loosen the flange bolt securing the kick starter arm remve the kick starter arm Remove 14mm external circlip Kick spindle washer Kick starter spindle Kick spindle spring bush INSPECTION Wear and damage of the kick starter spindle and gear portion Damage to return spring Defects and damage of the kick starter spi...

Page 69: ...he kick starter arm draw the spindle to the L side cover and assemble the kick starter ratchet When installing the 14mm external circlip keep holding the spindle manually and install the circlip in the groove correctly Apply the grease to the kick starter ratchet groove and gear Check the kick starter ratchet and the kick starter spindle for smooth operation after installation 7 3 KICKSTARTER CONT...

Page 70: ...nal reduction system Squeeze the drive belt into the pulley groove as shown so that it slackens enough to remove the driven pulley from the drive shaft Loosen the drive face setting nut 12mm with the clutch center holder TOOL CLUTCH CENTER HOLDER REMOVE Driven pulley clutch with the drive belt in place Drive belt from the driven pulley groove and drive pulley groove 7 4 KICKSTARTER CONTINUOUSLYVAR...

Page 71: ...orarily install the driven pulley clutch assembly on the drive shaft Turn the pulley clockwise and spread the faces apart while installing the drive belt Remove the pulley assembly once with the drive belt installed Hold the pulley faces apart preventing them from closing Put the drive belt over the drive pulley Reinstall the driven pulley on the drive shaft with the drive belt attached Install th...

Page 72: ... side of the crankshaft and hold the flywheel with the universal holder TOOL UNIVERSAL HOLDER MOVABLE DRIVE FACE DISASSEMBLY Remove Dirve face Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 6 Drive belt Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 4 Movable drive face Remove the ramp plate and weight rollers from the...

Page 73: ...service limit is exceeded Measure the I D of the drive face Replace it if the service limit is exceeded Movable drive face boss outer diameter SERVICE LIMIT 19 97mm Movable drive face inner diameter SERVICE LIMIT 20 6mm MOVABLEDRIVEFACEASSEMBLY INSTALLATION Install the weight roller on the movable drive face Install the ramp plate Pack the inside of the movable drive face with the specified amount...

Page 74: ... when assembling If the universal holder cannot be used remove the cooling fan and hold the flywheel with the universal holder Install the L side cover CLUTCH DRIVEN PULLEY DISASSEMBLY Remove L side cover Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 2 Drive face Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 9 Hold t...

Page 75: ...ace form the clutch spring compressor TOOL CLUTCH SPRING COMPRESSOR SOCKET WRENCH 39 41mm Assembly is done in the reverse order of disassembly REMOVE Seal collar from the driven pulley Guide pins and guide pin rollers and the movable driven pulley face Some guide pin can be separated to the roller and the pin Remove the O ring and oil seals from the movable driven face INSPECTION Clutch outer Meas...

Page 76: ...easure the O D of the driven face and the I D of the movable driven face Replace either part if the service limit is exceeded Drivenfaceouterdiameterservicelimit 33 94mm Movabledrivenfaceinnerdiameterservicelimit 34 06mm Driven Face Bearing Inspection Check the inner bearing oil seal if installed for damage replace as necessary Check the needle bearing for damage or excessive play and replace as n...

Page 77: ...ge or deformation replace as necessary Apply a small amount of grease on the pivot pins Install new clutch shoes on the pivot pins and push them into place Use a small amount of grease on the pivot pin and keep grease off of the brake shoes Replace the brake shoes if there is any grease on them Grease or oil damages clutch shoes and can lead to a loss of engaging ability Use pliers to hook the spr...

Page 78: ...hen drive out the outer bearing toward the inner bearing side Drive a new outer bearing into place with the sealed end toward the outside Install the snap ring securely Apply the specified amount of specified grease as shown GREASE APPLICATION 5 0 5 5g Install in a new inner bearing Install the bearing with the sealed side facing out Install the needle bearing using a hydraulic press Install the b...

Page 79: ...ll the seal collar Assemble the driven pulley spring and clutch in the clutch spring compressor Compress the assembly by turning the tool handle until the lock nut can be installed Clamp the clutch spring compressor in a vise and tighten the lock nut to the specified torque using the lock nut wrench TORQUE VALUE 4 0kgf m Remove the spring compressor Install the clutch driven pulley and drive belt ...

Page 80: ...8 0 CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD BOLT CYLINDER HEAD CYLINDER HEAD GASKET TOP RING SECOND RING EXPANDER STOPPER PIN PISTON PIN NEEDLE BEARING CYLINDER GASKET PISTON CLIP CYLINDER ...

Page 81: ...ston Improper installation of piston rings Scored or scratched piston or cylinder wall Overheating Excessive carbon build up on the piston combustion Incorrect spark plug Knocking or abnormal noise Worn piston and cylinder Excessive carbon build up Low octane fuel 8 SERVICES INFORMATION 8 1 TROUBLESHOOTING 8 1 FAN COVER SHROUD REMOVAL 8 2 CYLINDER HEAD CYLINDER PISTON 8 3 ITEM CYLINDER PISTON PIST...

Page 82: ...cover comp washer screws Remove the fan cover element B Remove the fan cover rubber Loosen the 2 fan cover flange bolts Remove the fan cover toward the floor panel Loosen the 2 left shroud flange bolts Remove the left shroud Pay attention not to damage certain part when removing Remove according to the working precedure Install in the reverse order of removal BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOL...

Page 83: ... panel 3 4 Exhaust muffler assembly 3 7 Fan cover shroud 3 2 Cylinder Head Loosen the 4 cylinder head bolts Bolts are loosened by rotating 2 3 times and alternating to a diagonal bolt Remove Cylinder head Cylinder head gasket Cylinder Remove the cylinder Piston Piston Ring Remove Piston pin clip Piston pin Be careful not to bend pins Be careful not to damage the cylinder and crankcase gasket face ...

Page 84: ...cle engine than 4 cycle engine because the engine oil is burnt in the 2 cycle engine Excessive carbon deposit may cause self ignition by the overheating of the carbon in the combustion chamber and the piston head and may damage the engine Carbon deposit in the exhaust gas port disturbs exhaust gas flow and causes decrease of the output Remove the carbon deposit periodically Pay attention not to da...

Page 85: ...Measure the piston O D SERVICE LIMIT 39 05mm Calculate the piston to cylinder clearance Take the maximum reading to detemine the clearance Piston Outer Diameter Inspection Measure and record the piston O D 90 to the piston pin bore and at the point specified in the Model Spectific manual near the bottom of the piston skirt Replace the piston if the service limit is exceeded SERVICE LIMIT 38 90mm C...

Page 86: ...iston rings and ring grooves with clean 2 stroke oil Install the piston rings on the piston with the marks facing up Do not confuse the top and second rings Be sure to install them in the proper grooves Some 2 stroke engines use an expander ring behind the second ring In 2 stroke engines theh piston has stopper pins that hold the piston rings away from the intake and exhaust ports Align the piston...

Page 87: ...t is stamped on the piston head should be facing the correct direction IN MARK TO INTAKE SIDE EX or MARK TO EXHAUST SIDE Install new piston pin clips Always use new piston pin clips Reinstalling used piston pin clips may lead to serious engine damage Take care not to drop the piston pin clip into the crankcase Set the piston pin clip in the groove properly Do not align the clip s end gap with the ...

Page 88: ...9 0 TRANSMISSION CRANKSHAFT CRANKCASE R CRANK CASE CRANKSHAFT L CRANK CASE FINAL GEAR MISSION COVER COUNTER GEAR COUNTER SHAFT DRIVE SHAFT ...

Page 89: ...al procedure specified in each section TRANSMISSION SECTION 9 REAR BRAKE SECTION 12 To assemble the crank case and crankshaft set the special tool to the inner race of the crankshaft bearing and push and assemble Remove the bearing from the crankshaft during disassembling work and insert a new bearing in the case Install the oil seal after the case is assembled SPECIFICATIONS TROUBLESHOOTING Engin...

Page 90: ...sion cover guide ruber Drive shaft from the transmission cover by using a hydraulic press Take precautions not to damage the cover joints Remove the oil seal of the drive shaft REMOVE Final shaft gear Thrust washer Countershaft Counter shaft gear Side washer INSPECTION Inspect the drive shaft for wear or damage 9 2 TRANSMISSION CRANKSHAFT CRANKCASE MISSION COVER 6202 BEARING 6203 BEARING MISSION C...

Page 91: ...is accurately installed in the case Replace the bearing if necessary Install the bearing with the carved mark directing to the outside Use special tools to push in the bearing into the case TOOLS DRIVER HANDLE A OUTER DRIVER 52X55mm DRIVER PILOT 20mm Check the L crank case oil seal for wear or damage 9 3 TRANSMISSION CRANKSHAFT CRANKCASE FINAL GEAR COUNTER GEAR COUNTER SHAFT 6203 BEARING 6202 BEAR...

Page 92: ...n cover Tighten the transmission cover with the flange bolts Tighten bolts diagonally and alternately and tighten with specified torque in the end Remove the oil check bolt release the transmission oil filler ACG cap or the L crankcase until the oil overflow through oil hole and fill the recommended oil slowly Install the oil check bolt and the cap RECOMMENDED OIL SAE 80 90 TRANSMISSION OIL AMOUNT...

Page 93: ...ing disassembly Do not force to disassemble by pounding on the crankshaft TOOL CRANKCASE PULLER 0751 00003 Remove the oil seal from the R and L crankcases Remove the dowel pin CRANKSHAFT BEARING REMOVAL If the radial ball bearing is left on the crankshaft remove the bearings out of the crankshaft using a bearing puller TOOL UNIVERSAL BEARING PULLER 0755 00001 CRANKSHAFT INSPECTION Place the cranks...

Page 94: ...he bearing inner race to see if it rotates smoothly Check the outer race to see if it is accurately pressed into the case If the outer race is excessively loose or is loosely pressed into the case remove in and replace with a new one REPLACEMENT L Crankcase Use special tools to remove the drive shaft bearing TOOLS BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD Remove the final gear bearing and oil...

Page 95: ...R DRIVER 52x55mm DRIVER PILOT 20mm Clean the crankcase using cleaning oil and check for rack and damage to each area After removing the liquid gasket from the joining face of the crankcase amend the scratched areas using oil ston Apply 2 cycle oil to the radial ball bearings and the connecting rod large end portion Install the crankshaft to the L crankcase Install not to interfere with the case wi...

Page 96: ...Make sure that the crankshaft is rotated smoothly after installation prior to oil seal installation If the smooth rotation is not acquired tap the crankshaft bearing part of crankcase with plastic hammer to ensure proper installation without mismatch Install a new L oil seal in the crankcase end portion at 1 0mm depth Install a new R oil seal in the crankcase end portion at 5 0mm depth 9 8 TRANSMI...

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Page 98: ...10 0 FRONT WHEEL FRONT FORK STEERING STEERING HANDLE STEERING STEM FRONT FORK FRONT BRAKE DISK FRONT CASTING WHEEL FRONT TIRE ...

Page 99: ...ain front wheels front fork and steering system For information on the front brake system refer to section 10 Place a jack underneath the engine to support the 2 wheeled vehicle SPECIFICATIONS TORQUE VALUES STEERING STEM LOCK NUT 7 0 m BRAKE DISK BOLT 3 9 f m FRONT AXLE NUT 6 0 f m 10 SERVICE INFORMATION 10 1 TROUBLESHOOTING 10 2 STEERING HANDLE 10 3 FRONT WHEEL 10 5 FRONT AXLE DEFLECTION 0 2mm FR...

Page 100: ...nt wheel wobbling Bent rim Worn front wheel bearings Faulty tire Axle nut not tightened properly Wheel out of balance Soft suspension Weak fork springs Insufficient fluid in front forks Hard suspension Incorrect fluid weight in front forks Front fork air pressure incorrect Bent fork tubes Clogged fluid passage Clogged anti dive orifice Front suspension noise Worn slider or guide bushings Insuffici...

Page 101: ...INDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE BRACKET HANDLE ...

Page 102: ...der facing upwards or front and tighten the rear or front first Check to see if the cylinder is passing each cable and wire harness directly and make sure that there is any interference by rotating the handle to the right and left INSTALL Rear handle cover Front handle cover Front cover THROTTLE HOUSING MASTER CYLINDER PUNCH MARK STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEE...

Page 103: ... SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX SPEEDOMETTER GEAR BOX FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRO...

Page 104: ...uter race is accurately fitted into the wheel hub and replace worn ones Replace bearings in pairs left and right set FRONT WHEEL DISASSEMBLY Remove Speedometer gear box Dust seal Speedometer gear retainer Remove the front brake collar A Remove te dust seal and brake disc Check the disc for defects SPEEDOMETER GEAR BOX FRONT BRAKE COLLAR A FRONT BRAKE DISK ...

Page 105: ...ing Insert accurately Upon assembling the distance collar insert the left bearing with its seal surface facing outside TOOLS DRIVER ATTACHMENT 32x35mm PILOT 15mm The bearing inserted in the last must be inserted until it contacts with the distance collar Excessively inserted bearing can cause damage the opposite side bearing SPEEDOMETER GEAR REPLACEMENT Remove the speedometer gear and washer from ...

Page 106: ...Install disk bolts TORUE VALUE 3 9kgf m Install the front brake collar A Align the wheel hub tangs with the slots of the speedometer gear retainer and assemble the speedometer gear box seal BRAKE DISK FRONT BRAKE COLLAR A SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX RADIAL BEARING DISTANCE COLLAR RADIAL BEARING AXLE BRAKE DISK RIM TIRE R SIDE COLLAR OIL SEAL NUT ...

Page 107: ... other disk facing up Remove the valve cap and bleed air by pressing the valve core Remove the valve core after bleeding air completely Remove the valve stem nut and push the valve stem lightly If a bead stopper is installed loosen the lock nut and push the bead stopper down Collapse in the bead with a tire bead breaker If no tire bead breaker is available step on the side wall to collapse the bea...

Page 108: ...rim when using the tire lever always use rim protectors Be sure to use motorcycle tire levers Do not apply the mild detergent solution to the rim and tire mating surfaces of low pressure tire Apply water only Insert another tire lever at 30 50mm from the first tire lever and remove the tire from the rim little by little Do not try to remove the bead too much at one time Do not pry against or scrat...

Page 109: ...explosive force to cause serious injury or death Always change rims which have been bent or have cracks as they may cause air leakage Always change the rim if there are any flaws over 0 5mm in depth and 1 0mm in width on the surface touching the bead Check the tire for overall condition and use a mild detergent solution on the bead TUBELESS TIRE INSTALLATION Use only water as a lubricant when remo...

Page 110: ...r easy assembly apply a mild detergent solution to the tire and rim mating surfaces Do not use the detergent solution on the tire and rim mating surfaces of the low pressure tires Use water only Install the other side of the bead while holding the assembled portion of the bead with your knee to prevent it from coming off Before using the levers be sure that the bead on the opposite side is positio...

Page 111: ...nt solution to the bead again Use only water as a lubricant when removing or mounting tires Soap or other tire lubricants may leave a slippery residue which can cause the tire to shift on the rim Tap on the tire tread surface with a rubber hammer so that the tire and rim fit evenly around the circumference Be sure that the tire center and rim center are aligned Inflate the tire to 1 5 times the st...

Page 112: ...ront axle into the speedometer gear box and the wheel hub Install the axle nut Assemble the speedometer cable and tighten with screws Place the front wheel on the ground and tighten the axle nut to the prescribed torque TORQUE VALUE 6 0kgf m FRONT FORK REMOVAL Remove Front cover 3 5 Front fender 3 5 Front brake caliper 12 7 Front wheel 10 5 Loosen the front brake hose stay bolt remove the L fork S...

Page 113: ...by the force fo the spring Take due precautions Remove the fork spring and expand and release the fork pipe several times to drain fork oil Wrap the bottom case with a piece of cloth and remove the socket bolt FORK BOLT SPRING FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANG...

Page 114: ...ring and the fork tube cap bolt first Hold the bottom case firmly with a vise taking precautions not to distort or damage it Remove the dust seal Remove the oil seal stopper ring Remove the oil seal Take precautions not to damage the interior and exterion rim of the bottom case DUST SEAL OIL SEAL STOPPER RING OIL SEAL ...

Page 115: ...ents for damage or abnormal wear Replace defective parts with new ones SERVICE LIMIT 243mm Place the fork tube on a V block and measure deflection with a dial gauge SERVICE LIMIT Replace if the deflection is greater than 0 2mm Check the slider bush contact face If the slider bush is extensively damaged replace the bottom case FRONT FORK ASSEMBLY Wash parts with clean oil prior to assembling Assemb...

Page 116: ...f but insert the bracket Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed TOOLS FORK SEAL DRIVER FORK SEAL DRIVER BODY Install the set ring Accurately assemble the set ring to the bottom case Install the dust seal Fill a prescribed amount of automatic transmission fluid ATF...

Page 117: ...rake caliper 12 7 Front fender 3 5 Front cover 3 5 FREE LENGTH FORK SPRING FORK BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM S...

Page 118: ...nd front brake hose from the steering stem bracket Loosen the steering top cone race Remove the steering stem Place steel ball in a pan to prevent from being lost Check the steel ball cone race and ball race for wear or damage Replace worn or damaged ones Remove the steering steel ball upper steering ball race steering bottom cone race STEERING LOCK NUT SOCKET STEERING TOP CONE RACE SOCKET STEEL B...

Page 119: ...r and replace as necessary If the vehicle has been involved in a collision the steering stem may be damaged STEERING STEM INSTALLATION Insert the upper under ball race into the steering head pipe Using a steering stem driver drive the steering stem bottom cone race into the steering stem Insert the ball race after applying grease thereto BALL RACE DRIVER BOTTOM CONE RACE ...

Page 120: ... the front fork Install the following parts Steering handle 10 3 Front wheel 10 5 Front handle cover rear handle cover 3 6 Front fender 3 5 Front brake caliper 12 7 Check the cables and wiring for interference Install the front cover STEERING LOCK NUT SOCKET SETTING BOLT CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER ...

Page 121: ... Use a brake cleaner designed to minimize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES AXLE SHAFT RUN OUT 10 0 12 0 f m REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION LOWER BOLT 3 5 4 5 f m 11 SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 2 REAR WHEEL 11 3 ITEM STANDARD VALUE SERVICE LIMIT AXLE SHAFT RUN OUT 0 2 mm REAR WHEEL RIM RUNOUT 2 0 mm 2 0 mm REAR BRAKE DRUM I...

Page 122: ...t rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorber rod Suspension noise Loose fasteners Worn shock 11 2 REAR WHEEL BRAKE SUSPENSION ...

Page 123: ...B Remove Muffler 3 7 Rear wheel mud guard Loosen the rear wheel U nut Remove Washer Rear wheel INSPECTION Turn the wheel and check the rim for wobbles SERVICE LIMIT Radical 2 0mm Axial 2 0mm INSTALLATION Insert the rear wheel over the final shaft 11 3 REAR WHEEL BRAKE SUSPENSION ADJUST NUT BRAKE ARM JOINT B REAR WHEEL U NUT DIAL GUAGE FINAL SHAFT ...

Page 124: ...Rear brake rod adjusting nut Rear wheel mud guard Muffler REAR BRAKE Remove the rear wheel 11 3 INSPECTION Measure the brake drum of inner diameter SERVICE LIMIT 111mm Measure the thickness of the brake lining SERVICE LIMIT 2 0mm 11 4 REAR WHEEL BRAKE SUSPENSION U NUT ADJUST NUT REAR WHEEL X Y BRAKE LINING THICKNESS ...

Page 125: ...mount of grease to the brake cam Install the brake cam Install the rear brake dust seal indicator rear brake arm Align the punch marks of the brake arm and the brake cam before assembly Remove the excessive grease after assembling the shoe INSTALL Brake shoe and spring Rear brake shoe to the rear brake cam Rear wheel Washer and U nut Check the brake for smooth operation 11 5 REAR WHEEL BRAKE SUSPE...

Page 126: ...own in the figure Install the cushion on the cushion compressor and compress the spring TOOLS COMPRESSOR ATTACHMENT REAR COMPRESSOR Fix the bottom metal and loosen the lock nut Remove the bottom metal Remove the stopper rubber spring from the damper component INSPECTION Measure the rear cushion spring free length Check the damper rod for deflection or damage SERVICE LIMIT 228 0mm 11 6 REAR WHEEL B...

Page 127: ...ock nut and install the rear cushion compressor attachment on the damper rod Fix the upper joint and tighten the lock nut TORQUE VALUE 4 0kgf m TOOLS REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT Install the rear cushion Tighten the top and bottom of the cushion with bolt TORQUE VALUE UPPER SIDE 3 5kgf m LOWER SIDE 3 5kgf m 11 7 REAR WHEEL BRAKE SUSPENSION REAR CUSHION ...

Page 128: ...BRAKE SYSTEM 12 0 ...

Page 129: ...eized or worn Brake lever bent Brake drag Brake pad and disk contaminated Improper wheel alignment Lopsided wear of brake pad and disk Disk bent or distorted Unsatisfactory caliper sliding part operation Hydraulic system contaminated with dust SERVICE INFORMATION GENERAL SAFETY Do not allow foreign material to enter the system when replenishing brake fluid To prevent chemical changes do not mix di...

Page 130: ... drum Worn brake shoes at cam contact areas Improper engagement between brake arm and camshaft serrations Brake lever hard or slow to return Worn broken return spring Improperly adjusted brake Sticking brake drum due to contamination Worn brake shoes at cam contact areas Brake cable sticking needs lubrication Worn brake cam Improperly installed brake linings Brake squeaks Worn brake linings Worn b...

Page 131: ...mbling or using the brake bleeder Protect the bleeder valve with tape to prevent air from entering the bleeder valve Repeat the above operation until there is no air flowing out of the bleeder hose Squeeze the bleeder valve and operate the brake lever to check the ingress of air Add brake fluid BLEEDER VALVE MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYL...

Page 132: ...rake fluid up to upper level Install diaphragm and mater cylinder cap TORQUE VALUE 1 0kgf m BRAKE PAD REPLACEMENT When replacing brake pads replace whole set Do not remove the brake hose when replacing brake pads Loosen the hanger pin MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTE...

Page 133: ...PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN...

Page 134: ...t is less then the specified service limit Check the brake disk for bent and twist SERVICE LIMIT 0 4mm Replace the brake disk if the disk for damage or cracks FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT HANGER PIN HANGER PIN HAN...

Page 135: ...face of the caliper Clean the piston and the inside of the caliper and remove the oil from the seal groove OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL B...

Page 136: ...R ASSEMBLY INSTALLATION Clean the piston seal and the dust seal with the brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad Make sure that each part is free from dust or dirt before reassembly Replace the dust seals and piston seals as a set whenever they are removed When cleaning with the brake fluid use the specified br...

Page 137: ...SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWIT...

Page 138: ...e side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Check the master cylinder for scores scratches or nicks and replace if necessary Measure the master cylinder I D in X and Y axis at several points SERVICE LIMIT 11 08 mm MASTER CYLINDER ASSEMBLY INSTALLATION Replace the piston spring cups and snap ring as a set Be sure ...

Page 139: ...6 Install the front handle cover 3 6 Install the back mirror MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MAS...

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Page 141: ... years of noromal use and although it will re charge its load is reduced leading to a loss in battery strength It is possible for the battery to become overcharged from battery body load If a battery cell becomes short circuited and if a state develops where voltage is not created between the terminals the regulator will not operate and excessive voltage will develops where voltage is not created ...

Page 142: ... IG COIL ACG CORD COUPLER A C GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS Y BATTERY ASS Y COMB LOCK SW WIRE HARNESS WHITE YELLOW GREEN GREEN BATTERY LIGHTING SWITCH REGULATOR RECTIFIER BROWN BROWN GREEN BLACK RESISTER 5W 6 7 RESISTER 30W 5 9 HEADLIGHT 12V 35 35W METERLIGHT 12V 1 7W TAIL LIGHT 12V 5W AUTO BYSTARTER WHITE BLUE PINK DIMMER SWITCH RED 7A FUSE A C GENERATOR ...

Page 143: ...coil Damaged regulator rectifier darkened headlight Damaged headlight register Damaged regulator rectifier Damaged Battery Check charge level Check the voltage of the regulator rectifier battery lines and the ground line Check the changing coil with the regulator rectifier coupler charging coil Check the lighting coil at the regulator rectifier coupler lighting coil line Check the headlight lighti...

Page 144: ...ER CHARGING SYSTEM INSPECTION LEAK TEST Trun off the main switch and remove the earth cable from the battery Connect an ampere meter between the battery terminal and the earth cable and check current when the main switch is turned off Use an ampere meter while sequentially changing its measuring range from large to small If the current level greater than the measuring limit is measured the ampere ...

Page 145: ...terminals Never open the sealed filler cap The battery generates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery easpecially while charging it Turn power ON OFF at the charger not at the battery terminals If the cable is disconnected or connected at the battery terminal during charging spark may jump and ignite the flammable gas Always remove the ...

Page 146: ...egulator rectifier coupler for faulty connection and measure the resistance between the terminals of the regulator rectifier 13 6 CHARGING SYSTEM A C GENERATOR REGULATOR RECTIFIER COUPLER ITEM BATTERYWIRE CHARGING COIL LIGHTING COIL Voltage between red and green Resistance between white wire and earth wires Disconnect the starter Resistance between yellow wire and earth wires Disconnect dimmer swi...

Page 147: ...r on the wire harness or starter motor Remove the ground wires Loosen the 2 pulse generator fixing flange bolts remove the pulse generator Loosen the 2 stator fixing flange bolts Remove the grommet from the crankcase cover Remove the stator Insert the puller shaft and remove the flywheel after inserting the ACG rotor puller and securing it with spanner The flywheel may easily removed if you rotate...

Page 148: ...e in the crankshaft Set the flywheel groove to the woodruff key and install the flywheel on the crankshaft Tighten the flywheel bolt or nut with your fingers Before installing the flywheel check that no nuts or bolts are magnetically attached to the flywheel Installing the flywheel with anything attached to it could damage the stator coil Hold the flywheel rotor with a holder and tighten the bolt ...

Page 149: ...e yellow wire and ground STANDARD RESISTANCE 20 BETWEEN WHITE WIRE AND GROUND 0 3 1 2Ω BETWEEN YELLOW WIRE AND GROUND 0 1 1 0Ω RESISTER INSPECTION Remove the front cover 3 5 Measure the resistance between the register lead wire and ground STANDARD VALUE 20 RESISTER 6 7Ω 5W GREEN BLACK BODY GROUND 6 3 7 1Ω RESISTER 5 9Ω 30W PINK BODY GROUND 5 6 6 5Ω Problems with the resister are caused by operatio...

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Page 151: ...ten appear to be malfuctioning when the couplers or connectors are disconnected Check these connections before working on Use recommended spark plug Using incorrect spark plug may make the engine run badly or damage the engine This manual gives explanations on inspections to receive peak voltage As inspections for coil resistance values are also included it may be difficult to make a correct deter...

Page 152: ...REGULATOR RECTIFIER CDI UNIT STARTER REALY ASS Y IG COIL ACG CORD COUPLER A C GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS Y BATTERY ASS Y COMB LOCK SW WIRE HARNESS BLUE YELLOW PULSE GENERATOR AC GENERATOR MAIN SWITCH SIDE STAND SWITCH IGNITION COIL SPARK PLUG BLACK YELLOW BLACK WHITE BLACK RED GREEN CDI UNIT ...

Page 153: ...s emitted from spark plug 1 Damage to spark plug or leakage of ignition coil secondary current 2 Damaged ignition coil 1 Using a tester with a low internal resistance 2 Cranking speed is too low Battery is insufficiently charged or kick power is weak 3 Influence of tester sampling time normal state if measured a number of times and shows over the set voltage 4 Excite coil is damaged when 1 3 is ok...

Page 154: ...ow and ground on vehicle body Turn the main swtich ON operate the starter motor and measure the ignition coil initial side peak voltage CONTACT POINTS BLACK YELLOWTERMINAL BODYEARTH PEAK VOLTAGE OVER 120V When measuring voltage do not touch the metal part of the handle rod as there is the danger of receiving an electric shock EXCITE COIL Assemble the spark pug to the cylinder head inspect in a sta...

Page 155: ...d peak voltage in the CDI unit coupler portion is abnormal Disconnect the AC generator cord coupler and connect the adaptor In the same manner as with the unit coupler side measure peak voltage and compare with the first peak voltage When the measured value in the unit side is abnormal and normal in the pulse generator side the problem is either incorrect coupler connection or disconnection of the...

Page 156: ...e high tension code and green code terminals RESISTANCE VALUE 2 6 1 25 20 EXCITE COIL INSPECTION Assembly the spark plug to the cylinder head and inspect in an state having compression pressure Remove the luggage box 3 3 Remove the connection of the AC Generator wire connector black red measure the resistance between the terminal of AC generator and body earth STANDARD VALUE 500Ω 20 20 PULSE GENER...

Page 157: ...e CDI unit and check the ignition system circuits from the wiring coupler side TESTING BY CDI TESTER Check the CDI unit spark performance by using a CDI tester Read tester manual carefully prior to using the tester INSPECTION ITEM PULSE GENERATOR IGNITION COIL PRIMARYCOIL SECONDARY COIL BLUE YELLOWANDGREEN BLACK YELLOWANDGREEN GREENANDHIGH TENSIONCORD ATTACHTHEPLUGCAP DETACHTHEPLUG CAP 100Ω 20 20 ...

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Page 159: ...in switch is not turned to OFF First check connection with battery and battery charge level before beginning maintenance on the starter motor It is possible for the starter motor coil to become damaged if the starter is operated when the engine does not turn over 15 SERVICE INFORMATION 15 1 STARTING DEVICES LOCATION 15 2 TROUBLESHOOTING 15 3 STARTER MOTOR 15 4 STARTER RELAY INSPECTION 15 7 STARTER...

Page 160: ...TIFIER CDI UNIT STARTER REALY ASS Y IG COIL ACG CORD COUPLER A C GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS Y BATTERY ASS Y COMB LOCK SW WIRE HARNESS RED WHITE YELLOW RED GREEN YELLOW GREEN YELLOW BATTERY FRONT STOP SWITCH STARTER RELAY MAIN SWITCH RED GREEN GREEN BLACK FUSE REAR STOP SWITCH STARTER SWITCH STARTER MOTOR ...

Page 161: ...n in starter switch wire Loose or poor contact at starter relay switch connector Faulty starter relay switch Remove the coupler from the starter replay and inspect the relay coil ground wire Check the starter relay voltage in the starter relay coupler with the coupler connected Check the operation of the starter relay CLICKS NO CLICK ROTATES DOES NOT ROTATE CONTINUITY VOLTAGE MEASURED NO CONTINUIT...

Page 162: ...er is connected the starter motor may be activated and damaged DISASSEMBLY Remove the starter motor screws and remove the motor cover Record the order so the parts can be installed correctly later INSPECTION Check for continuity of the starter motor case Between cord terminal and bracket normal if no continuity Between cord terminal and brush black wire normal if there is continuity If abnormal re...

Page 163: ...een individual commutator bars and the armature shaft There should be no continuity Check the bearings Do not rotate smoothly Replace with a new one Loose bearing Replace with a new one STARTER MOTOR ASSEMBLY Carefully insert the armature shaft into the front bracket Align the front bracket notch with the brush The sliding surcfaces of the brushes can be damaged if they are not installed properly ...

Page 164: ...t does not lean in the holder Apply grease to both ends of the armature shaft Install the starter motor cover The coil may be damaged if the magnet pulls the armature against the case Align the front bracket with the cover Tighten the washer screw 15 6 STARTING SYSTEM BRUSH HOLDER GREASE STARTER MOTOR COVER WASHER SCREW ...

Page 165: ...guished by the corresponding wire color of the wire harness connector STARTERPINIONGEARINSPECTION REMOVE L side cover 7 2 Drive face 7 6 Starter pinion gear Install in the reverse order of removal INSPECTION Wear or damage to the pinion reduction gears Replace with a new one Worn journals Replace with a new one Check if the pinion gear moves smoothly along the axis Pinion gear does not move smooth...

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Page 167: ...el switch damaged Loose connector Harness disconnection Oil indicator does not turn off when oil is out Oil level switch damaged Green red wire joined SERVICE INFORMATION GENERAL SAFETY Refer to tester owner s manuals when performing continuity inspections Refer to wiring diagram chapter 17 for switch continuity After inspecting and or performing maintenance work make sure the wires and cables are...

Page 168: ... fuel unit Install it aligning the part of the fuel unit with the loop part of fuel tank Check the fuel leakage 16 2 LIGHTS METER SWITCHES FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT SET CAP FUEL UNIT SET CAP FUEL UNIT SET CAP FUEL UNIT SET CAP FUEL UNIT...

Page 169: ... It s normal state if there is no continuity when the float is up but continuity when it is down MAIN SWITCH REMOVAL INSTALLATION Remove the front cover 3 5 Remove the inner box 3 5 Disconnect the main switch coupler Remove the seat lock cable Loosen the 2 screws and remove the main switch Install in the reverse order of removal INSPECTION Inspect continuity of each terminal 16 3 LIGHTS METER SWIT...

Page 170: ...H STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH DIMME...

Page 171: ...GHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT BULB HEADLIGHT BULB HEADLIGH...

Page 172: ...peedometer wiring from the steering handle cable guide Remove the speedometer and the gear handle cover assemblied from the steering handle 16 6 LIGHTS METER SWITCHES TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGH...

Page 173: ...ty for any abnormalities 16 7 LIGHTS METER SWITCHES HORN FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE S...

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Page 175: ...17 1 17 WIRING DIAGRAM 17 ...

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Page 177: ...head cracked 4 Crank case air leaks 5 Cylinder head gasket damaged 1 Manifold air leaks 2 Inadequate ignition timing 1 Carburetor flooded 2 Faulty control box 3 Throttle valve excessively opened 1 Open the drain screw and check fuel flow to the carburetor 2 Check spark plugs 3 Test cylinder pressure 4 Start engine in the following procedure 5 Remove spark plugs Fuel not supplied to the carburetor ...

Page 178: ...ure 3 Poor quality fuel used 4 Carbon deposit inside the combustion chamber excessive 5 Ignition timing incorrect 1 Carbon deposit inside the combustion chamber excessive 2 Poor quality fuel used 3 Lean fuel mixture 1 Gently accelerate engine 2 Check ignition timing 3 Press the kick starter pedal to check the cylinder pressure 4 Check the carburetor for clogging 5 Remove spark plugs 6 Check for en...

Page 179: ...aulty A C generator 5 Faulty main switch 1 Check ignition timing 2 Check the carburetor air screw 3 Check the area around the manifold for air leakage 4 Check sparks Abnormal Incorrect Leaking Weak or intermittent sparks Normal Sparks normal Correct No leak POOR PERFORMANCE AT HIGH SPEED CAUSE OF TROUBLE 1 Faulty CDI unit 2 Faulty A C generator 1 Fuel tank empty 2 Fuel tube or fuel filter clogged ...

Page 180: ...ve pulley bearing worn 1 Oil or grease spilled on the drive belt and inside pulley 2 Drive belt worn 3 Weak drive face spring 4 Driven pulley bearing worn or seized Check tire pressure CAUSE OF TROUBLE 1 Steering head adjuster excessively tightened 2 Steering cone race or steel ball damaged 1 Excessive wheel bearing play 2 Rim bent 3 Axle nut loose 1 Front wheel and rear wheel not aligned 2 Front ...

Page 181: ...Clay or moisture inside the brake drum 4 Brake lining contaminated by grease or oil 1 If the arrow were mark and the brake panel mark match with each other 2 Brake noise 3 Poor braking POOR BRAKE PERFORMANCE Check brake adjustment CAUSE OF TROUBLE 1 Cushion spring weak 2 Overloaded 3 Damper oil leaks 1 Fork pipe or cushion rod bent 1 Sliders stuck 2 Cushion stopper rubber damaged 1 Suspension exce...

Page 182: ...torily Check Needle not moving Needle not moving CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Ignition switch damaged or shorted 4 Terminal loose of faulty connection 5 Wire harness damaged 1 Faulty fuel level sensor connection 1 Damper oil inside the meter insufficient 1 Faulty connection between the sliding arm and the resistance 1 Terminal connection loose or faulty connec...

Page 183: ...ck operation Light not activated Light not activated Signal continuously operates dim or does not operate at all Unsatisfactory Starter does not turn Light is activated Signal operates satisfactorily 60 120 signaling second Satisfactory Starter turns CAUSE OF TROUBLE 1 Battery totally discharged 1 Connector terminal loose 2 Faulty starter relay connector 1 Engine seized 1 Faulty connection between...

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Page 185: ...SERVICE MANUAL 2005 6 PRINTED 2005 6 PUBLICATION NO COPY ...

Page 186: ... 01E HEAD OFFICE FACTORY 58 SUNG SAN DONG CHANGWON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7524 OVERSEAS SALES OFFICE 13 5 SUNG SOO 1DONG 1GA SUNG DONG GU SEOUL KOREA TEL 82 2 498 6465 FAX 82 2 467 9997 ...

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