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DAELIM BESDI 125 - SERVICE, Service Manual

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4-6

EXTERNAL PARTS

FLOOR SIDE COVER

Loosen the floor panel fixing bolt.
Loosen the 2 screws and pull the floor side cover back
ward to remove it.
Install in the reverse order of removal.

FLOOR PANEL

Remove.

-Floor side cover
-4 washer bolts
-Pull the floor panel backward to remove it

Install in the reverse order of removal.

UNDER COVER

Remove the floor side cover.
Loosen the 4 bolts and remove the under cover.
Install in the reverse order of removal.

FLANGE BOLT

EX. MUFFLER

CAP NUT

FLANGE BOLT

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Summary of Contents for BESDI 125 - SERVICE

Page 1: ......

Page 2: ...shooting guide If you cannot find the cause of trouble refer to Section 20 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehi...

Page 3: ...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 sp...

Page 4: ...e 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 compresse...

Page 5: ...ection 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 a...

Page 6: ...ll 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...

Page 7: ...er 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 co...

Page 8: ...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 t...

Page 9: ...ng 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 fro...

Page 10: ...ess 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...

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

Page 12: ...TDC 0 05 mm 0 05 mm OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION STROKE REAR SUSPENSION STROKE FRONT TIRE SIZE TYPE...

Page 13: ...V LED 12V1 7W 1 12V1 7W 2 12V 3 4W 2 12V 5W TYPE VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITI...

Page 14: ...OVER CHECK BOLT COOLING FAN BOLT STARTING CLUTCH NUT STARTER MOTOR FLANGE BOLT TORQUE VALUES ENGINE ITEM REFERENCE TORQUE VALUE THREAD DIA mm Q TY 7 0 kgf m 0 25 kgf m 6 0 kgf m 6 0 kgf m 3 1 kgf m 1...

Page 15: ...2 2 kgf m 3 5 kgf m 5 5 kgf m 0 4 kgf m 0 9 kgf m 1 2 kgf m 2 7 kgf m 4 0 kgf m 5mm BOLT NUT 6mm BOLT NUT 8mm BOLT NUT 10mm BOLT NUT 12mm BOLT NUT 5mm SCREW 6mm SCREW 6mm FLANGE BOLT NUT 8mm FLANGE B...

Page 16: ...ing oil change or parts MEANING Add oil If there is no specific oil indicated use the designated or recommended engine oil Apply grease Indicates reference page example Refer to page 3 1 MEANING Indic...

Page 17: ...1 15 SERVICE INFORMATION WIRING DIAGRAM FR WINKER FUEL TANK FUEL STRAINER COMP FUEL TANK SAI PIPE C D I UNIT MUFFLER FUEL PUMP AIR CLEANER ENGINE KICK KEY SET IGNITION COIL COMP...

Page 18: ...INFORMATION SPEEDOMETER CABLE FR BRAKE HOSE CARBURETOR INSULATOR START MAGNETIC SWITCH C D I UNIT COMP IGNITION COIL COMP SAI PIPE COMP GAS RATIO CONTROLLER WINKER RELAY HEADLIGHT CONTROLLER KEY SET R...

Page 19: ...ENGINE OIL TRANSMISSION OIL TORQUE VALUES OIL FILTER SCREEN CAP 1 5 f m OIL PUMP BOLT 1 1 f m OIL DRAIN PLUG BOLT 2 5 f m SERVICE INFORMATION 2 1 TROUBLE SHOOTING 2 2 ENGINE OIL LEVEL INSPECTION 2 3 E...

Page 20: ...rally External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed often enough Faulty head gasket Worn piston rings L...

Page 21: ...N It is extremely important to replace oil filter or clean the oil filter screen at the first maintenance interval after 1 000Km Clean the oil filter screen every 4 000Km Clean the filter screen with...

Page 22: ...fan 8 2 A C generator 8 4 RH crankcase cover 8 4 Starter driven gear 8 6 Reduction gear 8 5 Starting clutch assembly 8 6 Remove the oil separator Remove the oil pump drive gear nut Remove the oil pum...

Page 23: ...eaning oil INSPECTION Assemble the inner and outer rotors to the oil pump body correctly Measure the clearance between the pump body and outer roter SERVICE LIMIT 0 23mm TOOL FEELER GAUGE Measure the...

Page 24: ...he pump body Tighten the pan screw NOTE After installing check the oil pump to operate smoothly INSTALLATION Install the oil pump to the RH crankcase Install the following parts Oil pump drive gear an...

Page 25: ...eck hole If only the small amount of oil overflows fill the recommended transmission oil through the oil filler hole gradually OIL CAPACITY 0 11 FULL 0 09 CHANGE NOTE Oil level inspection must be perf...

Page 26: ...general grease to lubricate the lubrication points For sliding parts not shown here add oil or grease CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable and apply oil...

Page 27: ...BRAKE FLUID 3 6 BRAKE PAD SHOE 3 7 SIDE STAND 3 7 SUSPENSION 3 8 BOLTS NUTS FASTENERS 3 8 WHEELS TIRES 3 8 STEERING HEAD BEARING 3 9 BATTERY 3 9 THROTTLE GRIP PLAY 2 6mm SPARK PLUG P Z9HC SPARK PLUG...

Page 28: ...TORQUE VALUES SPARK PLUG 1 2kgf m CYLINDER HEAD COVER BOLTS 0 9kgf m VALVE ADJUSTING NUTS 1 1kgf m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE 3 2 INSPECTIONS ADJUSTMENTS...

Page 29: ...s are based on the assumption that the motorcycle will be used exclusively for its designed purpose Sustained high speed operation or operation in unusually wet or dusty conditions will require more f...

Page 30: ...ing Check the throttle grip free play FREE PLAY 2 6mm For adjustment loosen the lock nut and turn adjuster After adjusting tighten lock nut After adjustment is completed recheck the throttle grip free...

Page 31: ...er Center cover Loosen the 4 cylinder head cover bolts NOTE Inspect and adjust the valve clearance when the engine is cool under 35 C 95 F Remove the cooling fan cover Turn the flywheel counterclockwi...

Page 32: ...Turn the main key left release the seat lock Remove the luggage box Adjust the throttle stop screw with screw driver NOTE Erect the motorcycle on the main stand Verify all engine adjustments satisfy...

Page 33: ...f the wear limit aligns with the mark when the parking brake lever is tightly depressed it indicates the brake lining has reached the service limit Replace the brake shoes Check the front brake hose f...

Page 34: ...to check the operating conditions Check the rear fork for oil leakage parts damage or looseness BOLTS NUTS TIGHTENER Check all nuts and bolts of the frame during the regular maintenance to check if th...

Page 35: ...ric cord interferes with the handle If the handle moves satisfactorily adjust the steering head bearing BATTERY Remove the battery cover Check to see if the terminal has loosed If the terminal is loos...

Page 36: ...3 10 MEMO...

Page 37: ...A muffler is hot Do not service it immediately after the engine is stopped SERVICE INFORMATION 4 1 MAINTENANCE PRECEDURE 4 2 FRONT FENDER 4 3 REAR WHEEL MUD GUARD 4 3 MUFFLER 4 3 INNER COVER 4 4 METE...

Page 38: ...TS MAINTENANCE PROCEDURE NAME OF COVERS This chart shows arrows connected in the order of disassembling covers LUGGAGE BOX REAR CARRIER BODY COVER CENTER COVER FLOORSIDECOVER FRONT COVER UPPER UNDER I...

Page 39: ...e mud guard securing the muffler Remove the rear wheel mud guard Install in the reverse order of removal MUFFLER Loosen the 2 cap nuts securing the cylinder head Loosen the muffler flange bolt securin...

Page 40: ...side cover screw Back holder Front cover Floor side cover Floor panel Inner cover Install in the reverse order of removal METER COVER Remove Head light Upper handle cover Speedometer cable Coupler and...

Page 41: ...under handle cover Upper handle cover Install in the reverse order of removal FRONT COVER Loosen the 1 special screw of front cover Loosen the 8 tapping screws securing the inner cover Loosen the 4 ta...

Page 42: ...Install in the reverse order of removal FLOOR PANEL Remove Floor side cover 4 washer bolts Pull the floor panel backward to remove it Install in the reverse order of removal UNDER COVER Remove the fl...

Page 43: ...al CENTER COVER Remove the body cover Loosen the floor planel fixing bolt Loosen the washer screw Open the fuel lid with the key and remove the center cover Install in the reverse order of removal REA...

Page 44: ...remove the seat Install in the reverse order of removal LUGGAGE BOX Release the seat Loosen the 3 flange bolts and the 2 cap nuts Remove the luggage box Install in the reverse order of removal REAR C...

Page 45: ...MEMO...

Page 46: ...MEMO...

Page 47: ...n of O ring Replace with new ones when disassembled If it is desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float c...

Page 48: ...perly 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 da...

Page 49: ...oor side cover Floor panel The fuel unit wire coupler The fuel tube from the fuel tank Fuel paper tube Fuel tank Install in the reverse order of removal NOTE After removing the fuel tank be sure to cl...

Page 50: ...in screw and drain the gasoline Remove the drain tube and air band hose Loosen the 4 diaphragm cover setting screws Remove the diaphragm cover Remove the diaphragm spring diaphragm assembly Remove the...

Page 51: ...m check it thronghly FLOAT CHAMBER FLOAT JET DISASSEMBLY Loosen the 4 screws securing the float body Remove the float pin float and float value NOTE Handle with care kind of carburetor jet because it...

Page 52: ...NOTE Turn in the pilot jet and record the number of turns it takes before it seats lightly Do not force the pilot screw against its seat the seat will be damaged CLEANING CAUTION Cleaning the air and...

Page 53: ...table floats must be replaced NOTE Be sure to keep the float level at the specified height If the float level is low high fuel mixture becomes lean rich Install the float body assembly install the bra...

Page 54: ...screw securing the carburetor and set plate Install the fuel tube to the carburetor Install the wiring coupler of the auto bystarter Install the throttle cable to the carburetor Install the air clean...

Page 55: ...g the pilot screw check the following items Fuel system electrical system for troubling Spark plug for cleaning and gap adjusting Valve clearance for adjusting CAUTION Be sure of tightening the pilot...

Page 56: ...outlet vacuum tuble in the fuel pump Loosen the 2 securing fuel pump and remove the fuel pump Removal Loosen the 4 body screw Remove the fuel pump Check the fuel pump diaphram A and B for damage Chec...

Page 57: ...5 11 FUEL SYSTEM Check the section valce out valve and relief valve for damage and crack Install in the reverse order of removal...

Page 58: ...MEMO...

Page 59: ...owing works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 11 STARTING CLUTCH SECTION 8 OIL PUMP SECTION 2 A C GENERATOR SECTION 8 STARTER MOTOR SECTION 17 K...

Page 60: ...connector wiring connected to the A C generator disconnect the starter motor wiring cable Remove the battery earth cable from the cooling fan cover clamp Disconnect the high tension cord from the eng...

Page 61: ...m the engine ENGINE INSTALLATION Install in the reverse order of removal NOTE Take precautions not to damage wiring and cable Take precautions not to damage the threaded part of bolts Arrange the cabl...

Page 62: ...7 0 LH CRANKCASECOVER KICKSTARTER CONTINUOUSLYVARIABLE TRANSMISSION...

Page 63: ...06mm DRIVE FACE BOSS OUTER DIAMETER 23 960 23 974mm 23 94mm DRIVE BELT WIDTH 20 0mm 19 0mm WEIGHT ROLLER OUTER DIAMETER 18 0 18 10mm 17 9mm CLUTCH OUTER INNER DIAMETER 125 0 125 2mm 120 50mm DRIVEN FA...

Page 64: ...LH crankcase cover LH crankcase cover Remove the gasket and dowel pin INSTALLATION Install the new gasket and dowel pin after removing the gasket of the crankcase surface NOTE Tighten the bolts diagon...

Page 65: ...sen the return spring stop plate securing bolt Remove the return spring Remove the starting shaft Remove the starting idle gear Put the tool pipe etc over the starting drive gear and remove it beating...

Page 66: ...for defects or damage Check the starting idle gear for wear or damage INSTALLATION INSTALL Driven gear Starting idle gear as arrow direction Return spring stop plate Install the movable drive face dri...

Page 67: ...Install the LH crankcase cover 7 5 LH CRANKCASECOVER KICKSTARTER CONTINUOUSLYVARIABLE TRANSMISSION...

Page 68: ...he final 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 with the...

Page 69: ...Clean off any grease or oil before reinstalling DRIVE BELT INSTALLATION Install the driven pulley sub assembly on the drive shaft Turn the pulley clockwise and spread the faces apart while installing...

Page 70: ...l holder tighten the nut to the speciried torque Tighten the nut to the specified torgue using the drive face holder TORQUE 4 0 kgf m TOOL UNIVERSAL HOLDER MOVABLE DRIVE FACE REMOVAL Remove the LH cra...

Page 71: ...e 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 23 94mm Movable drive face inner diameter...

Page 72: ...e using the drive face holder TORQUE VALUE 4 0 kgf m TOOL DRIVE FACE HOLDER NOTE Tighten the drive face nut to the specified torque Correctly match the drive face and crank shaft serration when assemb...

Page 73: ...ove the clutch outer TOOLS UNIVERSAL HOLDER DRIVE FACE HOLDER Remove the driven pulley sub assembly from the drive shaft Remove the drive belt DISASSEMBLY Remove the special nut TOOLS CLUTCH SPRING CO...

Page 74: ...pulley Remove the guide pins and guide pin rollers and the movable driven face Remove the O ring and oil seals from the movable driven face Remove the movable driven face 7 12 LH CRANKCASECOVER KICKST...

Page 75: ...fits securely Replace the bearing if necessary Movable Driven Face Spring Inspection Measure the free length of the driven pulley spring and replace if the service limit is exceeded SERVICE LIMIT 163...

Page 76: ...s used on the inside remove the snap ring first then remove the bearing Remove the snap ring then drive out the outer bearing toward the inner bearing side Drive a new outer bearing into place with th...

Page 77: ...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 an...

Page 78: ...e Install the drive face and install the drive pulley nut temperarily Tighten to the specified torque using the face TORQUE 4 0 kgf m TOOLS DRIVE FACE HOLDER Install the cluch outer into the driven pu...

Page 79: ...MEMO...

Page 80: ...8 0 A C GENERATOR STARTER CLUTCH...

Page 81: ...e engine SPECIFICATIONS TORQUE VALUES FLY WHEEL BOLT 5 5 kgf m STARTER CLUTCH LOCK NUT 5 5 kgf m RH CRANKCASE COVER BOLT 1 1 kgf m TOOLS SPECIAL SOCKET 12 7 x 28 x 120 A C G ROTOR PULLER SERVICE INFOR...

Page 82: ...e to remove the upper hood and low hood when disassemble the engine A C GENERATOR REMOVAL Remove the cooling fan cover Loosen the 4 cooling fan bolts Remove the A C G wiring coupler and connector conn...

Page 83: ...otor puller and securing it with spanner The flywheel may easily removed if you rotate the puller while tapping the roller shaft with metal hammer Always use a holder and a puller to remove the flywhe...

Page 84: ...l nut with the specified torque TORQUE VALUE 5 0 6 0 kgf m TOOL UNIVERSAL HOLDER If the universal holder cannot be used remove the LH crankcase cover and hold the drive face with the drive face holder...

Page 85: ...lace with a new one as necessary STARTER REDUCTION GEAR REMOVAL Remove the RH crankcase cover Remove the startting clutch Remove the starter reduction gear and shaft INSPECTION Check the reduction gea...

Page 86: ...sket and dowel pin Tighten the RH crankcase cover with setting bolts Install the following parts A C Generator Cooling fan Cooling fan cover EX muffler STARTER CLUTCH REMOVAL Remove the following part...

Page 87: ...LUTCH INSPECTION Remove the starter driven gear needle bearing and starter oneway clutch set from the starter clutch assembly Measure the outer diameter of the start clutch oneway set SERVICE LIMIT 29...

Page 88: ...clutch match it with the groove accurately Install the thrust washer Temporarily install the starter clutch lock nut Hold the drive face with the drive face holder Tighten the starter clutch lock nut...

Page 89: ...MEMO...

Page 90: ...9 0 CYLINDER HEAD VALVES...

Page 91: ...0 kgf m SPARK PLUG 1 2 kgf m CAMSHAFT HOLDER 8mm NUT 2 9 kgf m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m CYLINDER HEAD COVER BOLT 0 9 kgf m CYLINDER HEAD...

Page 92: ...urned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 10 Excessiv...

Page 93: ...mark of the RH crankcase cover Verify that the piston is located at the top dead center Make all camshaft lobes face downward If all camshaft lobes face upward rotate the crankshaft to the left for 1...

Page 94: ...Remove the other side rocker arm shaft and rocker arm in the same sequence CAMSHAFT INSPECTION Check the rocker arm and rocker arm shaft for wear or damage Measure the inner diameter of the rocker ar...

Page 95: ...heck the valve clearance CYLINDER HEAD REMOVAL Luggage box Body cover Engine from the frame Carburetor Cylinder head cover Shroud comp upper under Cam shaft SAI pipe Cylinder head The cylinder head ga...

Page 96: ...k plug assembling hole and the valve seat for cracks Using a square and a feeler gauge check the cylinder head distortion SERVICE LIMIT 0 05 mm VALVE SPRINGS Measure the free length of the inner and o...

Page 97: ...mm Measure the guide to stem clearance with a dial indicator while rocking the stem in the direction of normal thrust SERVICE LIMIT IN 0 080 mm EX 0 100 mm Measure the inner diameter of the new valve...

Page 98: ...Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed Use cutting oil on th...

Page 99: ...operly the valve must be replaced Measure the valve seat width STANDARD VALUE 0 8 1 0 mm SERVICE LIMIT 1 4 mm VALVE SEAT REFACING Reface the worn valve seat by using valve seat cutters and grinders NO...

Page 100: ...too high on the valve the seat must be lowered using a 37 degree flat cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too low on the valve the seat m...

Page 101: ...Install new stem seals NOTE Replace the stem seals with new ones whenever a stem seal is removed Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide CA...

Page 102: ...ssary precautions not to damage the valve Install the spark plug TORQUE 1 2 kgf m CYLINDER HEAD ASSEMBLY Cleananygasketmaterialfromthecylindermatingsurface Install the cam chain guide to the cylinder...

Page 103: ...e of the rocker arm shaft Check the camshaft assembly for abnormal condition and place it on the cylinder head Put the cam chain on the cam sprocket Slowly rotate the crankshaft counterclockwise and a...

Page 104: ...rocker arm shaft fit section must be in alignment Of IN and EX the shorter rocker arm should be installed on the IN side Apply engine oil to the threaded part install the camshaft holder nut and bolt...

Page 105: ...semble the O ring and pan screws to the tensioner lifter TORQUE VALUE 0 4 kgf m Fill clean engine oil into the operating parts of the cylinder head Adjust the valve clearance Remove oil from the cylin...

Page 106: ...10 0 CYLINDER PISTON...

Page 107: ...Damaged piston ring Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston SERVICE INFORMATION 10 1 TROUBLE SHOOTING 10 1 CYLINDER 10 2 PISTON PISTON RING 10 3 CYLINDE...

Page 108: ...ylinder inner diameter at three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 52 50 mm Measure the piston outer diameter Calculate the piston to...

Page 109: ...ve the piston pin clip using a pair of pliers Press the piston pin out of the piston NOTE Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the clip fall int...

Page 110: ...30 mm PISTON PIN INSPECTION Measure the piston pin bore inner diameter in an X and Y axis Take the maximum reading to determine the inner diameter Replace the piston if the inner diameter is over the...

Page 111: ...nd rings Space the ring end gaps 120 degrees apart Space the side rail gaps 40mm or more apart as shown After installing the rings they should rotate freely without sticking PISTON INSTALLATION NOTE P...

Page 112: ...rom the cylinder head mating surface Do not scratch the surface Install a new cylinder gasket and dowel pins NOTE Take care not to damage the cylinder mating surface Coat the cylinder wall with clean...

Page 113: ...MEMO...

Page 114: ...11 0 TRANSMISSION CRANKSHAFT CRANK CASE...

Page 115: ...EN PULLEY SECTION 7 The following parts must be removed prior to changing the LH crank case Follow the removal procedure specified in each section TRANSMISSION SECTION 11 BRAKE SECTION 14 To assemble...

Page 116: ...SSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission damage Transmission seized Noise during op...

Page 117: ...4 3 Remove the rear wheel 13 3 Loosen the transmission cover bolts Remove the transmission cover Remove the gasket and dowel pin Remove the drive shaft from the transmission cover by using a hydraulic...

Page 118: ...ft and the counter shaft comp TRANSMISSION INSPECTION Check the drive shaft for wear or damage Check the final shaft for wear or damage Check the counter shaft for wear or damage 11 4 TRANSMISSION CRA...

Page 119: ...Install the bearing to the case with special tools TOOLS DRIVE HANDLE A OUTER DRIVER DRIVER PILOT Check the LH crankcase oil seal for wear or damage TRANSMISSION ASSEMBLY Install the drive shaft on th...

Page 120: ...e transmission LH crank case cover Remove the oil check bolt and fill the recommended oil slowly RECOMMENDED OIL SAE 80W 90 TRANSMISSION OIL AMOUNT 0 11 CRANK CASE REMOVAL Remove the engine from the f...

Page 121: ...e with a plastic hammer NOTE Be careful not to distort the mating surface of the crank case during removal Remove the dowel pin and gasket CRANK SHAFT REMOVAL Remove the crankshaft If the bearing is l...

Page 122: ...L FEELER GAUGE SERVICE LIMIT 0 05 mm Measure the connecting rod radial clearance in both X and Y directions Replace the crankshaft if the service limit is exceeded SERVICE LIMIT 0 05 mm TRANSMISSION B...

Page 123: ...bearing and oil seal Remove the counter gear bearing Apply clean engine oil to a new bearing and assemble it to the crankcase TOOLS DRIVER HANDLE A DRIVER PILOT OUTER DRIVER Install a new final shaft...

Page 124: ...in in order to check to see if the crankshaft hasembled or not Install the RH crankcase to the LH crankcase NOTE Make sure that the gasket is completely attached without any clearance Install refer to...

Page 125: ...MEMO...

Page 126: ...MEMO...

Page 127: ...e a jack underneath the engine to support the 2 wheeled vehicle SPECIFICATIONS TORQUE VALUES STEERING STEM NUT 7 0 m STEERING TOP THREAD 0 25 m BRAKE CALIPER BOLT 3 1 m FRONT CUSHION BOLT 2 25 f m FRO...

Page 128: ...axle wheel installed incorrectly Front 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...

Page 129: ...from the speedometer Loosen the front master cylinder holder bolts remove the front master cylinder Loosen the throttle housing fixing screw remove the RH LH housing Remove the throttle cable from the...

Page 130: ...all the steering handle to the steering stem Insert the flange bolt and tighten with locknut TORQUE VALUE 3 92 4 9 kgf m NOTE Check that the throttle grip moves smoothly Adjust the throttle grip free...

Page 131: ...after the front wheel is removed FRONT WHEEL INSPECTION Check the front axle for deflection Place the front axle on a V block and measure deflection with a dial gauge SERVICE LIMIT 0 2mm Place the fro...

Page 132: ...h its seal surface facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left bearing with its seal surface facing outside TOOLS DRIVER HANDLE A DRIVE...

Page 133: ...the dust seal rim Install the dust seal and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box FRONT WHEEL INSTALLATION Insert the front wheel b...

Page 134: ...UE 5 0 7 0 kgf m FRONT FORK REMOVAL Remove the following parts Front fender Front caliper Loosen the upper under fixing bolts and remove the front cushion NOTE Support the vehicle securely under the e...

Page 135: ...ce and measure the free length SERVICE LIMIT 215mm Set the fork pipe on a V blocks and measure fork pipe deflection by rotating with a dial gauge SERVICE LIMIT Replace if the deflection is greater tha...

Page 136: ...tem nut socket Remove the steering top thread nut using the steering stem socket Remove the front fork Check to see if there is the damage or wear in the steel ball con race ball race if necessary rep...

Page 137: ...mount TOOL STEERING STEM DRIVER Install the steering bottom and top ball races into the head pipe Insert the front fork into the head pipe Install the steering upper ball assembly Retighten the top th...

Page 138: ...MEMO...

Page 139: ...eaner designed to minimize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION LOWER BOLT 3 5 4 5 f m REAR CUSHION ROD LOCK NUT...

Page 140: ...ose 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 absorb...

Page 141: ...the rear wheel fixing u nut Remove the rear wheel REAR WHEEL INSPECTION Check the rim for wobbles by rotating the wheel SERVICE LIMIT Radical 2 0mm Axial 2 0mm TOOL DIAL GAUGE REAR WHEEL INSTALLATION...

Page 142: ...l mudguard 4 11 NOTE After installing the parking brake be sure to adjust the parking brake free play REAR BRAKE REMOVAL Remove the rear wheel INSPECTION Measure the brake drum for inner diameter SERV...

Page 143: ...e cam Install the rear brake arm NOTE Align the punch marks of the brake arm and the brake cam before assembly Remove the excessive grease after assembling the shoe Install the brake shoe and spring I...

Page 144: ...he cushion on the cushion compressor and compress the spring TOOLS REAR CHUSION COMPRESSOR ATTACHMENT REAR CHUSION COMPRESSOR Fix the upper metal and loosen the hex nut Remove the upper metal Remove t...

Page 145: ...hment on the damper rod Fix the upper metal and tighten the hex nut TORQUE VALUE 4 0kgf m TOOLS REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT Install the rear cushion Tighten the top and...

Page 146: ...MEMO...

Page 147: ...ad disk Misaligned wheel Clogged restricted brake hose Warped deformed brake disk Caliper not sliding properly Clogged restricted brake hose joint Brakes drag Contaminated brake pad disk Misaligned wh...

Page 148: ...ng the brake lever AIR BLEEDING When the brake bleeder is available Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level CAUTION To prevent chemical changed do not use different types...

Page 149: ...ir from being pumped into the system Release the brake lever slowly and wait several seconds after it reaches the end of its travel Repeat the above steps and until bubbles cease to appear in the flui...

Page 150: ...order to avoid dust from adhering DISASSEMBLY Remove the slide pin caliper bracket pad spring the boot from the caliper If there is any wear or damage in the boot replace it with a new one Wind the c...

Page 151: ...he brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad NOTE Make sure that each part is free from dust or dirt before reasse...

Page 152: ...he front brake switch wire Brake tube bolt Master cylinder holder bolt Master cylinder CAUTION Brake fluid causes damage to the painted plastic or rubber parts Do not spill fluid on these parts If con...

Page 153: ...te the side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Check the master cylinder for scores scratches or nicks and repla...

Page 154: ...n the groove properly INSTALLATION Install the front rear master cylinder to the handle bar NOTE Install the holder with its UP mark facing upwards and align the holder joint with the punch mark on th...

Page 155: ...MEMO...

Page 156: ...repeatedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important...

Page 157: ...CHARGING DEVICE LOCATION 15 2 BATTERY CHARGING SYSTEM A CGENERATOR C D I UNIT REGULATOR RECTIFIER KEY SET IGNITION UNIT...

Page 158: ...Loose broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Batte...

Page 159: ...minal contacts the frame The spark could ignite or damage the battery To prevent shorting always connect the positive cable first BATTERY OPEN CIRCUITVOLTAGE INSPECTION Remove the battery cable Measur...

Page 160: ...w may change abruptly if not sufficiently charged Use a battery whose voltage between its terminals is 13 0 13 2V When the engine is started using the starter motor a large amount of current may flow...

Page 161: ...alues are much larger than the specified value or if there is continuity between terminals and earth terminals replace the stator with a new one Install in the reverse order of removal REGULATOR RECTI...

Page 162: ...t the same color couplers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive pe...

Page 163: ...16 2 IGNITION SYSTEM IGNITION DEVICES LOCATION A CGENERATOR C D I UNIT BATTRY REGULATOR RECTIFIER KEY SET IGNITION UNIT...

Page 164: ...nnected CDI unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty ignition system control circuit such as side stand switch 6 Faulty peak voltage adaptor 7 Faulty CD...

Page 165: ...luggage box Disconnect the A C generator 4P coupler and the blue yellow wire connector Measuretheresistancebetweenthegreenandblue yellow STANDARD VALUE 50 200 PVA MEASUREMENT DisconnecttheA C generat...

Page 166: ...asure the resistance between the primary coil terminal and the spark plug cap If the resistance value is within the specified range then the coil is good If the resistance is open wire disconnect the...

Page 167: ...MEMO...

Page 168: ...to turn the starter motor quickly enough or supply adequate ignition current The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over The engine may not b...

Page 169: ...17 2 STARTER SYSTEM STARTER DEVICES LOCATION A CGENERATOR C D I UNIT BATTRY REGULATOR RECTIFIER KEY SET IGNITION UNIT...

Page 170: ...t at starter magnetic switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 7 Connect the starter magnetic...

Page 171: ...arth cable DISASSEMBLY Remove the starter motor cable Before disassembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later Loosen the starter...

Page 172: ...r abnormal wear Replace with a new one Discoloration of the commutator bar Replace with a new one Metallic debris between commutator bars Clean it off Check for continuity between pairs of commutator...

Page 173: ...d install the case Insert the thrust washer 0 5t thrust washer 0 2t slip washer and thrust support CAUTION The sliding surfaces of the brushes can be damaged if they are not installed properly When in...

Page 174: ...Check if the starter magnetic switch clicks when it is turned ON Clicks Poorly connected battery terminal and motor terminal of the switch Check the starter magnetic switch No clicks No starter magnet...

Page 175: ...witch wire connector Apply battery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there...

Page 176: ...n be locked Remove these locks prior to disassembling and insert these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The con...

Page 177: ...create hot spots that cause a bulb to break Be sure to install the dust cover after replacing the bulb WARNING Headlight bulbs become very hot while the headlight is ON and remain hot for a while afte...

Page 178: ...mirror Remove the wind screen 4 10 Remove the front handle cover 4 10 Disconnect the RH LH winker wire Disconnect the handle bar switch connector and coupler check for continuity between the terminal...

Page 179: ...RONT REAR STOP SWITCH INSPECTION Remove the wind screen 4 10 Remove the front handle cover 4 10 Check for continuity between the black and green yellow wire terminals inside the speedometer assembly W...

Page 180: ...emove the floor panel NOTE Be careful not to damage the wire Be careful not to damage the float arm Check the base packing for damage Measure the resistance between the upper and lower of fuel unit FL...

Page 181: ...MEMO...

Page 182: ...e speed misadjusted Faulty ignition timing Clogged air cleaner Lean fuel mixture Flooded carburetor Throttle valve excessively opened Contaminated or clogged air cleaner Rich fuel mixture Recheck the...

Page 183: ...r O ring Faulty insulator band tightening Faultyinsulator Lean fuel mixture Rich fuel mixture Slow circuit clogged Open the drain screw and check fuel flow to the carburetor Check the spark plug Inser...

Page 184: ...k plug with an incorrect heat range Lean mixture Worn cylinder or piston Lean fuel mixture Poor quality fuel being used Excessive carbon build up on combustion chamber Incorrect ignition timing Damage...

Page 185: ...seized driven pulley bearing Steering top thread too tight Insufficient tire pressure Damaged steering bearing Damaged ball race Faulty tire Insufficient tire pressure Worn or faulty tire Faulty wheel...

Page 186: ...TROUBLE Weak cushion spring Overloaded Oil leakage from damper unit Bent fork pipe or cushion rod Worn slider Damaged cushion stopper rubber Soft suspension Hard suspension Suspension noisy POOR FRON...

Page 187: ...MEMO...

Page 188: ...G Gr B G O Lb Lb I GNI TI ON SWI TCH I GNI TI ON SWI T CH FUEL UNI T G O ENGI NE STOP SWI T CH COMBI MERER ASS Y PASS...

Page 189: ...MEMO...

Page 190: ...MEMO...

Page 191: ...MEMO...

Page 192: ...SERVICEMANUAL 2007 09 PRINTED 2007 09 PUBLICATION...

Page 193: ......

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